Support response: Median email response time of less than 3 hours.
Performance report of Berusynth 46 and 68 H1 as food grade hydraulic oil for manufacturing of molded pulp products
Molded pulp products are an eco-friendly, affordable and sustainable alternative to plastic and styrofoam packaging products. Typical molded pulp products are made from recycled raw materials such as paper, cardboard or other natural fibers (sugarcane, bamboo, wheat straw etc.) and are usually recycled again after active use. In case products are discarded after their service life, molded pulp products are biodegradable unlike plastic and styrofoam material, hence eco friendly.
Over the years, with significant improvement in the manufacturing technology, the final molded products have smoother surface and sophisticated look and feel. Molded pulp products now find use in variety industries like food, healthcare, pharma, cosmetics, electronics etc. Also, the growing importance of sustainability has helped make pulp packaging an attractive option that demonstrates commitment to the environmental cause.
Patented manufacturing process
Considering the factors of sustainability and market demand, a reputed Indian paper manufacturer with decades of experience has set-up a state-of-the-art manufacturing unit for producing molded fiber food packaging products. The intention, to manufacture about 2000 T of food containers, table ware, packaging products etc. in its first year of operation. The completely automated manufacturing process was set-up in technical collaboration with a global provider of advanced molded-fiber manufacturing systems. The patented design and manufacturing technologies present an automated system to replace single-use plastic with 100% compostable plant fiber-based products.
BECHEM had the unique opportunity in providing lubrication solutions for the sophisticated automated manufacturing set-up. The requirement was for a synthetic food grade oil that acted as a power transfer medium in the hydraulic arm of the ‘thermoforming press’.
Machine specifications:
Type: Pulp thermoforming press
Hot pressure – 80 tons
Daily output – 2.5 tons
No. of press – 10
Requirement for the oil:
- Food grade oil with power transmission capacity
- Viscosity of the food grade oil should be 46/68 cst as recommended by the OEM
- The food grade oil should be NSF H1 certified
BECHEM’s high performance, synthetic food grade oils are available in varying viscosities. Due to their special formulation, the Bechem synthetic oils are meant for use in multiple applications, including in hydraulic systems. They are designed to provide power transmission with lowest energy losses and corrosion protection of sensitive parts in the hydraulic system.
Why Berusynth H1?
• Fully synthetic PAO (Polyalphaolefins) base oils with proprietary additives available in varied viscosity range
• High viscosity index (VI) (140 for Berusynth 46 H1 and 145 for Beruynth 68 H1) provides superior lubrication over a wider temperature range
• NSF H1 and ISO 21469* certified for lubrication of machinery and components in food processing industries
• High oxidation and thermal stability, inhibits formation of sludge/varnish, thereby ensures longer component life and minimizes operational costs
• Fortified with anti-wear additives, Berusynth 46/68 H1 helps to reduce wear, enhances equipment reliability
• Very good oxidation stability extends oil change interval
• Superior corrosion protection properties of Berusynth H1 range inhibit rust and corrosive wear and ensures longer equipment life
Current status / Customer’s feedback
Berusynth 46 and 68 H1 range of food grade oils performed consistently as per the OEM’s expectation for over two years. The customer’s Maintenance team too vouches for the long-life performance of Berusynth 46 and 68 H1 as well as machine reliability achieved with the food grade oil.
Berusynth H1 range of food grade oils are also recommended for lubrication of gears, drive chains and as circulatory oils in compressors in food processing and allied industries. For more details of the case study, write to us as [email protected]
*ISO 21469 is global standard for food grade lubricants that verify compliance and specifies hygiene requirements for product formulation, manufacturing and packaging requirements. Additionally, ISO 21469 specifies hygiene requirements for use and handling of lubricants during manufacture and processing, that can come into incidental contact (e.g. through heat transfer, load transmission, lubrication or the corrosion protection of machinery) with products and packaging used in the food, food-processing, cosmetics, pharmaceutical, tobacco or animal-feeding-stuffs industries.
The post Hydraulic Food Grade Oil For A Sustainable Cause appeared first on Speciality Lubricants from Carl Bechem Lubricants India.
]]>Modern gear systems are characterized by enhanced power and torque transfer with smaller and lighter gears. The power to weight ratio ( Kg/ Kw) has been considerably reduced over the past decades, which has resulted in increased power density. To accommodate this factor, there have been many mechanical changes made in terms of gear materials, hardening process resulting in wear reduction, improvement in machining methods and tooth geometry. However, the conventional, mineral based lubricating gear oil which was comfortably meeting the demands earlier, becomes severely stressed with increasing power density.
Challenges for the gear oil
The stress on the gear oil is mainly with respect to its anti-scuffing, anti-wear and temperature resistance property. Due to smaller surface area available in the housing to dissipate the internally generated heat, the oxidation resistance of the lubricating oil becomes critical.
The way to reduce internally generated heat is to reduce frictional losses and ensuring a gear cooling arrangement. Frictional losses can be considerably reduced with synthetic base oils which results in reduced operating temperatures. In many cases, external cooling may not be necessary. Synthetic base oils have uniform molecular structure and are more stable than conventional mineral oils. Due to the inherent oxidation resistance of synthetic gear oils, substantial improvement in life time (typically 3 times that of mineral oils) can be achieved. Enhanced life time ensures that frequent disposal of used gear oils is avoided and machine availability is enhanced.
Effective lubrication
Reduced frictional losses, means reduction in input energy required to deliver the required output torque. Hence power saving is achieved with specially formulated synthetic gear oils.
The gear movements are classified as primarily sliding, primarily rolling and combination of sliding and rolling gears. As the sliding percentage increases (for example sliding percentage starts from 10 to 30 % for helical gears extending up to 90 % for worm gears), the shear forces on the gear oil increases. Hence synthetic oils are a product of choice for most of the gear types in industrial gear boxes.
Extend Gearbox life with Berusynth 220 H1
Analysing performance of food grade synthetic gear oil in agitator gear box on slurry line of food processing unit.
Background
Customer: A multinational consumer healthcare company leading the space of health drinks in India with state-of-the-art manufacturing facilities. The maintenance team at one of its primary plants in India currently using Berusynth 220 H1 in its agitator gear boxes had been coerced to benchmark the performance of a comparative synthetic gear oil as an alternative. The trigger for the study was the claim by a competing lubricant brand on further optimisation of gear box temperature with their gear oil, Brand R. Similar to Berusynth 220 H1, the proposed product ‘Brand R’ is also H1 certified and ‘Polyalphaolefin (PAO)’ based.
The particular unit and production lines are dedicated to produce the popular health drink synonymous in Indian households made of ground wheat, malted barley, milk and proprietary nutrients. The agitator gear box is a critical equipment in the slurry line as an interim process that ensures key ingredients mix and blend well before the next end process of drying and filling. A gear box failure would create a serious bottleneck and an undesired maintenance activity for the operations team.
Apart from installation errors, improper alignments, a common cause for gear box failure is insufficient or starved lubrication. Scoring, galling and general fatigue of gear drives are frequently a result of ineffective lubrication leading to metal-to-metal contact and elevated operating temperatures. Elevated operating temperatures in turn expedite the oxidation process, deteriorating further the lubricating and load bearing properties of the gear oil.
As a part of the benchmarking trial process, two similar agitator gear boxes were chosen of parallel lines which were running in continuous process. Both the gear boxes were thoroughly cleaned and filled in with respective oil fills of Berusynth 220 H1 and Brand R.
Gear oil fill quantity : 7.5 l
Motor : 20 Hp
Defined oil change interval : 3 months
The gearbox temperature was monitored for a period of one month on three identical positions of both the gear boxes.
Reading on Machine D2 : Brand R Gear Oil
| Date | Time | Temperature in °C | ||
| Position 1 | Position 2 | Position 3 | ||
| 20.02.2019 | 12.30 PM | 86 | 79 | 82 |
| 20.02.2019 | 14.30 PM | 78 | 75 | 74.5 |
| 20.02.2019 | 18.00 PM | 94.4 | 91 | 89.5 |
| 28.02.2019 | 12.00 PM | 88 | 85 | 80 |
| 28.02.2019 | 17.20 PM | 105 | 103 | 102 |
| 14.03.2019 | 13.00 PM | 97 | 95 | 92 |
| 19.03.2019 | 2.04 PM | 104 | 98 | 97 |
| Average | 93.2 | 89.4 | 88.1 | |
Reading on Machine E2 : Berusynth 220 H1
|
Date |
Time | Temperature in °C | ||
| Position 1 | Position 2 |
Position 3 |
||
|
20.02.2019 |
12.30 PM | 79 | 77 |
76 |
|
20.02.2019 |
14.30 PM | 78 | 74 |
73 |
|
20.02.2019 |
18.00 PM | 84 | 81.5 | 79.3 |
|
28.02.2019 |
12.00 PM | 90 | 84 | 80 |
|
28.02.2019 |
17.20 PM | 82 | 80 | 78 |
| 14.03.2019 | 13.00 PM | 85 | 82 |
78 |
| 19.03.2019 | 2.04 PM | 94 | 92 |
90 |
| Average | 84.6 | 81.5 |
79.2 |
|
|
Avg. temperature difference between Berusynth 220 H1 and Brand R Gear Oil |
8.6 | 7.9 |
9 |
|
Trial conclusion
-
It was observed that there was a noticeable temperature difference of about 10% between the gear boxes filled with Berusynth 220 H1 and Brand R gear oil
Lower temperature in the gear box with Berusynth 220 H1 can be attributed to effective lubrication resulting in reduction of frictional heat generated
-
No leakage of oil was observed
-
While Brand R gear oil was also based on Polyalphaolefin (PAO), the formulation, additives and manufacturing process are proprietary for respective brands and play an important role in enhancing the lubrication effectiveness, life and load bearing abilities of Berusynth 220 H1
-
After a period of 1 month, Brand R oil on Machine D2 was replaced with Berusynth 220 H1 as the trend with Brand R oil showed incremental temperature rise consistently
The Maintenance team was satisfied with the benchmarking exercise and continues to use Berusynth 220 H1 and has subsequently recommended the same for other plants.
Berusynth 220 H1 is a high-performance synthetic gear oil that provides superior wear resistance to contacting surfaces. The NSF H1 certified food grade oil has high viscosity index and demonstrates consistent oil film thickness at elevated temperatures. Developed with high quality synthetic base oil and the special additive package, Berusynth H1 grade oils have scored a rating of > 14 stages on FZG load test, proving the scuffing wear resistance of the oil
The post Why recommend synthetic gear oil for industrial gear boxes ? appeared first on Speciality Lubricants from Carl Bechem Lubricants India.
]]>