Industrial Lubricant - Speciality Lubricants from Carl Bechem Lubricants India https://www.bechemindia.com/category/industrial-lubricant/ High Performance Industrial Greases, Oils, Ant-Friction Coatings and Cleaners Thu, 06 Mar 2025 06:52:42 +0000 en-US hourly 1 https://wordpress.org/?v=6.7.2 https://www.bechemindia.com/wp-content/uploads/2021/08/cropped-fevicon-32x32.png Industrial Lubricant - Speciality Lubricants from Carl Bechem Lubricants India https://www.bechemindia.com/category/industrial-lubricant/ 32 32 Enhance Corrugated mill reliability with high-temperature grease solutions. https://www.bechemindia.com/enhance-corrugated-mill-reliability-with-high-temperature-grease-solutions/ Tue, 04 Mar 2025 09:27:49 +0000 https://www.bechemindia.com/?p=12666 The post Enhance Corrugated mill reliability with high-temperature grease solutions. appeared first on Speciality Lubricants from Carl Bechem Lubricants India.

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The corrugated sector, driven by e-commerce and sustainability, has experienced growing demand for containerboard as packing material.

The corrugated machine line is a versatile set-up designed to produce single, double or multiple plies of corrugated sheets with an assembly of rollers operating in tandem. Effective lubrication of roller bearings within the segments of single facers or double backer is critical for continuous operation of the line. A roller bearing failure within the segment can lead to significant equipment downtime and production loss.

The roller bearings within the segments operate under high speeds and considerable loads. Additionally, the heat roller bearings are subjected to high temperatures and steam as the rollers are pre-heated for quick drying and conditioning of the bonded liner and fluting sheets.

Effective lubrication of bearings would improve their operational reliability and productivity of the Corrugated machine. Additionally, lubricants that can provide longer service life will reduce the re-lubrication frequency and associated man-power costs.

 

4x increase in lubrication life with special poly urea grease, Berutox FH 28 EPK 2 at high temperature bearings of corrugator machine.

Customer: A renowned corrugated box manufacturer, equipped with fully automated production lines in a state-of-the-art facility. Having a monthly production capacity of more than 2500 MT supplies to FMCG sector.

Operational parameters:

Application area Corrugating and pressure rolls of a fully automatic machine
Bearing nos. NU224 and NJ334 (mounted horizontally)
Total no. of bearing 12 nos.
Operating temperature around 180°C
Bearing speed 130 RPM

 

Customer was using a lithium complex-based grease of brand ‘X’ of NLGI grade 2.

Key challenges:

Persistent grease leakage from the bearing housing, caused significant accumulation on the machine base, resulting in poor housekeeping. This required daily cleaning, increased lubricant consumption and higher maintenance costs. Additionally, the frequent need to replenish grease increased the man-machine interface affecting the safety quotient and also impacting production schedules.

 

BECHEM’s Recommendation:

High temperature grease, Berutox FH 28 EPK 2.

High performance grease formulated with poly urea thickener and synthetic base oil of high viscosity index.

 

Reason for Recommendation :

The grease offers excellent thermal ageing, shear stability and sealing properties.

It’s High viscosity index PAO base oil minimizes viscosity changes at high temperatures, ensuring a strong lubricating film.

Formulated with advanced additives Berutox FH 28 EPK 2 provides superior thermal stability, extended longevity and exceptional protection against wear and contamination in high temperature conditions.

 

Trial observations:

  • No evidence of grease bleeding or leakage from the bearing housing was observed during the trial period of 5 weeks
  • Re-greasing interval extended significantly from one week to five weeks.
  • Extended re-greasing frequency led to a substantial reduction in the quantity of grease consumption.

Condition of used Berutox FH 28 EPK 2 after a span of 3 weeks.

 

Key benefits:

  1. Bearing protection: Fortified with anti-wear additives, Berutox FH 28 EPK 2 ensures longer service life of bearings by maintaining strong lubricating film that resists high temperatures and centrifugal forces.
  2. Enhanced operational efficiency: Seamless operations without frequent re-greasing procedures leading to improved productivity.
  3. Cost effectiveness: Substantial reduction in grease consumption led to significant cost savings over time.

Result:

Following the impressive results of the trial period, the customer switched to Berutox FH 28 EPK 2  high temperature grease for the other three machines in their plant.

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]]> Effective lubrication of pellet feed mill bearings https://www.bechemindia.com/effective-lubrication-of-pellet-feed-mill-bearings/ Thu, 09 Jan 2025 05:27:21 +0000 https://www.bechemindia.com/?p=12585 The post Effective lubrication of pellet feed mill bearings appeared first on Speciality Lubricants from Carl Bechem Lubricants India.

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While the straight up grease cost is an important consideration, maintenance engineers recognize the importance of high quality lubricants and correct lubrication practices for effective plant maintenance and a reliable process. Factors such as grease consumption, replacement of spares, production downtime, manpower for re-lubrication exercise etc. can impact process parameters and reduce long-term expenses. This holistic approach not only enhances lifespan and reliability of machinery but also contributes to overall productivity and cost-effective operations.

Why consider high performance greases in animal feed pellet mills ?

The feed mill is a fully mechanized process and bearings play a key role. Besides enabling the grinding and pelleting of feed ingredients, bearings support the rotating shafts in feed mixers.  However, during pellet production these pelletizing machines operate under extreme conditions including high temperature, pressure, water vapor and contaminants, which can impact bearing performance and consequently, the process efficiency.

Also the method of grease application, amount of grease applied can affect functionality of the roller bearings. For example over lubrication bearings can result in grease leakage and risk of feed contamination.

Regular lubricants and challenges for effective lubrication of bearings in pellet presses

  • The bearing press typically operate at high temperatures (90-100˚C). Continuous exposure to such high temperatures can impact health of the grease film in bearings leading to metal-to-metal contact and wear
  • Base oil evaporation and subsequent grease loss from bearings often accelerate grease consumption
  • With regular greases, prolonged exposure to high temperatures can lead to buildup of solid residues of thickener in the bearings that can obstruct fresh grease flow and starve the friction zones.
  • In addition to high temperatures, moisture condensation during idle time can also lead to corrosion of the bearings.
  • Hence, the lubricant needs to form a protective shield against corrosion
  • Equipment downtime during peak operations negatively impacts reduces productivity

Selection of grease with an appropriate formulation for pellet presses is critical to mitigate maintenance expenses and productivity losses. Grease suitable for bearings operating in extremely dusty and moist environments must offer effective sealing in addition to lubrication.

Customer : A leading Indian manufacturer of pellet and crumble feed, with a production capacity exceeding 20 TPH, also operates poultry breeding farms and hatcheries. The fully automated, state-of-the-art facility is designed to meet extensive in-house requirements.

Operation conditions of the pellet press:

No of machine -2

Machine Type PM615XW

Application- Main drive shaft of press roller bearings

Bearing Type – Single row taper roller bearing no. 32220

Bearing Speed- 540 RPM

Operating temperature – 110˚ C

Greasing method – Single line automatic lubrication system

Grease flow time- 2 mins once for every 10 mins of idle time

Quantity of grease flow – 6.81 grams in 2 mins

Customer was using a lithium complex grease from a reputed brand “X”.

Issues faced by the customer:

  • Due to the demanding operating conditions, lifespan of pellet roller bearings decreased to a maximum of three months, with multiple instances of premature bearing failures within a single month
  • With process temperatures nearing 110˚ C approximately, cake like formation of grease was observed in bearings due to evaporation of base oil
  • In order to avoid lubricant starvation, the grease pump was operated continuously resulting in higher consumption of grease
  • With regular bearing failures, the unplanned equipment downtime to replace bearings in the rollers resulted in production loss
  • Occasional mild contamination of oozed grease from the bearings with chicken feed led to batch rejections

Having assessed the above issues, the Bechem team recommended the specially formulated polyurea thickened high temperature grease, Berutemp M2 KN, designed for superior performance of the pellet roller bearings.

Trial result :

  • 40 % reduction in grease consumption
  • No bearing failure during trial period
    • Lifespan of bearings for pellet rollers doubled
  • Eliminated grease leakage from bearings, reducing the risk of contamination and batch rejection.
  • No lump/cake formation of grease was observed at elevated process temperatures of 110˚ C
Sl.No Process details Brand ‘X’ Berutemp M 2 KN
1 Grease flow time for every 10 minutes 2 min 1 min 10 sec
2 Total quantity of grease flow for every 10 min of idle pump time. 6.81 g. 3.85 g.
3 No. of times Pump On / day 121 130
4 Total quantity of grease flow / day 824 g. 500.5 g.

Why Berutemp M 2 KN?

  • Longer service life: Inspite of exposure to process temperaures of over 110˚C, Berutemp M2 KN retained its consistency by preventing base oil oxidation and also ensured a resilient lubrication film on bearings
  • Protection for bearings – Formulated with highly structured polyurea thickener with high shear stability, Berutemp M2 KN protects bearings from friction, wear for longer duration
  • Excellent thermal stability – Based on high viscosity base oil of 490 cSt, Berutemp M2 KN remains stable and provides effective lubrication at high temperatures.
  • Prevents corrosion – Berutemp M2 KN protects bearings from corrosion and damage caused by moisture or water ingress
  • Fortified with anti-wear additives and high viscous base oil, Berutemp M2 KN maintains lubrication effectiveness, preventing metal-to-metal contact and potential damage to bearings.

After monitoring an extended two-month trial, no bearing failures were observed and substantial cost savings was achieved, the customer switched to Berutemp M2 KN.

For further details of the product, comparison chart and trial samples, write to us at [email protected]

 

 

Support response: Median email response time of less than 3 hours.

 

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]]> Food grade grease increases pellet mill bearing life by 2X https://www.bechemindia.com/food-grade-grease-increases-pellet-mill-bearing-life-by-2x/ Sat, 15 Oct 2022 07:13:21 +0000 https://www.bechemindia.com/?p=11625 The post Food grade grease increases pellet mill bearing life by 2X appeared first on Speciality Lubricants from Carl Bechem Lubricants India.

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Berulub FG H 2 SL at Pellet feed mill: Case study of impact of food grade grease on performance and life of tapered roller bearings at food pellet press mill

The customer, a reputed international brand with diverse business interests ranging from agriculture and food processing to international logistics. The case study is specific to its plant involved in manufacturing products related to animal nutrition /feed.

Application : The purpose of food pelleting is to process finely divided (pulverised), nutrient feed ingredients by using heat, moisture and mechanical pressure to form larger particles (pellets). While the fine particles are dusty and difficult to handle, the end result of larger pellets with desired taste are easier to manage and find better acceptance with domestic pets and poultry.

The pellet mill is a critical equipment in the process where the conditioned mash ( balanced assortment of grain, bran or malt feed, fibre and protein ) from the mixer is fed into circular rollers in the die chamber. The rollers, press the soft mash in a circular die. Knives placed outside the circular die cut the pellets into required lengths.

Operating conditions of the pellet mill

The temperature at the die chamber was observed around 90- 120°C due to the mash that is conditioned with vapour, heat and continuous vibration in the mixer. The closed environment in which the pellet mill works does not allow for easy dissipation of the heat generated in the system.

No. of rollers: 2
No. of bearings: 4 nos.
Bearing type: Tapered roller bearing, no. 33220
Bearing rotational speed: 200 rpm
Load on bearing: High
Bearing temperature: 110 °C (recorded during operation)
Grease type: Brand O, synthetic food grade grease
Re-greasing frequency: Once in 8 hours
Re-greasing quantity: No specific quantity. Practice to pump in fresh grease until it oozed out of the roller
Greasing method: Air gun
Bearing life with brand O grease: 4 months approx.

Pellet mill die chamber

Premature bearing failures

The unusual rate of bearing failure was a cause of concern for the customer. Further it was observed that dust accumulation on the oozed grease was a recurring phenomenon at the pellet mill.

Discussing the instances of higher bearing failure, the Bechem Application Engineering team had a chance to observe the lubrication practices at the shop floor. The team then submitted its report to the Maintenance Dept., broadly attributing the failure causes to the following,

  • Improper and inconsistent lubrication to the bearing
  • Mishandling: Improper assembly practises of new bearing

Bearing failure mode: Spalling

Analysis of failed bearings

Micro spalling was visible in the inner race of the bearings.  The spalling was not extended throughout the contact surface, indicating only a portion of the load zone was exposed to severe fatigue stresses.

This phenomenon of micro spalling are typical to bearings rotating at low RPM’s and temperatures above 90°C.  The lubricant plays a major role in avoiding such micro spalling. If the grease does not have adequate temperature resistance properties, lubricating film will rupture under low speeds, high loads and elevated temperature conditions.

Subsequently, industry best practices for lubrication and proper bearing assembly procedure was discussed with the maintenance team. BECHEM’s synthetic food grade grease, ‘Berulub FG H 2 SL’ was recommended as an effective alternative to the existing grease. Also, a calculated quantity was recommended for optimum re-lubrication of the bearings instead of the ‘continuous pump until purge’ method.

Why Berulub FG H 2 SL

Based on special Calcium Complex Soap thickener,

  • Very good structural stability to retain consistency in high load applications
  • Provides good vibration resistance
  • Excellent drop point (≥ 400°C) which results in high temperature resistance
  • Provides excellent resistance to moisture and water
  • High load bearing capacity with a four ball weld load of > 3000 N
  • Excellent corrosion protection property with an Emcor corrosion protection rating of 0 / 0

EMCOR Test: The purpose of the test is to measure the ability of a grease to protect a bearing against corrosion in the presence of water. The procedure subjects a set of new, cleaned and lubricated bearings to partial immersion in water with no applied load at a constant speed (80 revolutions per minute), in a predetermined sequence of starting and stopping for a period of approximately one week. The results are recorded according to the following table:

Rating Designation Description / Criteria
0 No corrosion No corrosion
1 Trace No more than three spots of corrosion, none with a diameter greater than 1 mm
2 Slight / light Small areas of corrosion, covering not more than 1% of the surface but more or larger corrosion sites than for rating 1
3 Moderate Areas of corrosion covering between 1 and 5% of the surface
4 Heavy / Severe Areas of corrosion covering between 5 and 10% of the surface
5 Very Severe Areas of corrosion covering more than 10% of the surface

Base oil – Synthetic PAO (Polyalphaolefin) Oil

  • Low traction co-efficient to offer least internal friction for bearing rotation
  • Fully saturated hydro carbon giving high temperature resistance
  • Hydro phobic nature to provide water and steam resistance
  • Uniform molecular structure and molecular weight providing high viscosity index (150).
  • Low volatile losses when exposed to high temperatures

Berulub FG H 2 SL is also food grade H1 certified by NSF.

Initial trial observations with Berulub FG H 2 SL

  • Re-lubrication cycle extended from 8 hours to 12 hours
  • Monthly grease consumption reduced by 50% with Berulub FG H 2 SL
    • Maintenance team was informed to re-grease with calculated quantity only
  • Bearing temperature reduced by 15 °C from 110 °C to 93-95°C
  • No grease leakage was observed from the bearings

Based on initial trial results, the customer switched over to Berulub FG H 2 SL. The maintenance team was glad with the upkeep of pellet mill as there was no sign of oozed grease that generally attracted dust.

Extended trial observation revealed no bearing failure for over 8 months at the pellet mill, doubling the bearing life with Berulub FG H 2 SL compared to that of the earlier food grade grease.

Support response: Median email response time of less than 3 hours.

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