Manufacturing of paper and pulp-based utensils used in packaging and read to eat industry, involves liquid pulp filled into metal moulds of desired shape and cured at high temperatures. The sticky pulp with process chemicals leave residues on metal moulds typically made of steel and aluminium metallurgy. Even further, the pulp slurry clog the fine holes (dia) in the metal mesh, hindering the moulding process during continuous production runs.

Thorough and spotless cleaning is critical before reusing these moulds as it would impact finish of the final product. However, the pulp residues after the curing process are a pain to be cleaned. Also, rougher the process of cleaning, shorter the life expectancy of the moulds with intricate mesh. Abrasive cleaning methods can shorten the life of components, hence immersion cleaning with compatible cleaner is recommended.

Beruclean 3849

Beruclean 3849 is a liquid acidic cleaner specifically formulated for high-temperature environments and can effectively break down tough deposits on components and moulds. It is designed to address the unique cleaning challenges faced by paper tray manufacturers.

Best suited for manual, ultrasonic and spray cleaning methods.

Compatible with metals, ceramic glass, plastics and other acid resistant materials.

Removes organic and inorganic residues including tough lime deposits.

Result:  

Having experienced the performance of Beruclean 3849 cleaner, the customer switched to Beruclean 3849 for all machine cleaning applications.   

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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Performance Case study of special forming oil, Beruform MF 155 C in metal shaving operation and positive impact on rejection rates.

Metal shaving is a finishing operation in which burrs from the cut edges are sheared off in order to make the edges smooth and also impart dimensional accuracy. Shaving operation is typically preceded by punching, piercing or other stamping operations that further require close dimensional tolerances.

An effective lubricant will help in component finish and can also impact die life. Below case study demonstrates benefits of using a high performance lubricant over a conventional oil in an actual use case scenario.

Customer: A leading manufacturer of precision stamping parts for commercial vehicles, agricultural machinery and construction equipment. With more than 100 stamping machines of varying capacities, the company specializes in manufacturing brake part assemblies, chassis structures and blocks.

Application details:

Component         : Brake-pad body
Material               : Steel and mild steel
Thickness            : 2-7 mm
Operation            : Shaving

Customer was using a regular blanking oil with viscosity of 50 Cst at 40˚C.

Issues encountered by the operations team:

1. Frequent maintenance or dressing of the shaving tool due to accelerated wear
2. Reduction in die life, leading to increased production downtime
3. Significant increase in material rejection rates. Material rejection was also reported from end customers as well.

Key challenges presented to the Bechem team:

The Operations team listed the below aspects as ‘improvement parameters’ against which performance of any trial lubricant would be measured,

• No cracks or fractures on the component
• The occurrence of burrs sticking to the die during the shaving process must be avoided
• Reduction of excessive heat buildup on die/machine and workpiece being processed
• Reduction in ‘burr’ component edges and enhanced surface finish
• Also minimize oil consumption

After analyzing the operation parameters and considering the expectations put forward, the BECHEM team recommended the high-performance cold forming oil, Beruform MF 155C.

The team identified, two 150 ton punching presses to conduct trials, one with single shaving and the other with double shaving operation.

Based on the success of a pilot lot, a rigorous 24-hour trial was carried out to evaluate the performance parameters.

Trial observations:

• Superior surface finish of the punched components without any signs of overheating
• Zero component rejection
• No signs of stickiness on the die or punch. Punched surfaces exhibited better finish
• Approximately 40% reduction in punched components. Operators could now hold the component with ease
• Continuous stamping operation for two shifts without interruption, indicated stability and reliability that could be achieved with Beruform MF 155 C

Result:

Post witnessing the exceptional performance with Beruform MF 155 C, the customer extended the trial for the next couple of months. It was observed that die life improved by 20% in comparison to the earlier blanking oil. Additionally, reduction in rejection rates and overall positive impact on production process was witnessed during this period. Consequently, the customer established Beruform MF 155 C as their ‘go-to’ forming oil for their processes.

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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Can industrial cleaners help increase surface finish, reduce wire breakage, improve machine cleanliness and avoid blackening in copper wire drawing process.

Industrial cleaners or degreasers play an integral role in efficiently removing tough dirt, grease, grime and other process chemicals from surface of machine components and finished products coming off the production line. Regular machine cleaning as a part of routine maintenance can create better work environment and in case of annealing process in wire drawing impact reject rates.

Selection of the appropriate cleaner or degreaser is critical as it may impact the effectiveness of the cleaning process, the health safety of the user and the overall performance of the equipment. Using an incompatible cleaning agent may damage or corrode the surface of metals, plastics or rubber.

The below case study illustrates how a suitable cleaner helped the customer get over the issues of blackening in copper wires and also help keep machine appearance in top shape.

Customer: An Indian wire and cable manufacturing giant, with production facilities in multiple locations and global supplies to diverse sectors.

Process: Copper wire drawing and annealing section.

Application details:

• Component: Dies and capstan in drawing machine
• Operation: Cleaning of machines and dies
• Machine: Ultrasonic
• Material: Metals, diamond, ceramics

Customer was using liquid fuels like petrol, diesel, methanol and detergents for cleaning. However wire finishing issues plagued the operations team with increased rejection rates.

Issues encountered by the operations team :

• Deposition of copper dust on surface of the wire before annealing process leading to rough surface finish
• Frequent breakage of wires resulting in production loss impacting productivity
• The copper wires turned black in the ‘drawing’ process, resulting in increased maintenance and delays in subsequent operations.

Observation by BECHEM team on causes for wire blackening and surface roughness of copper wires

• The copper wire being annealed developed surface roughness as a result of residues or other impurities being transferred to the metal due to the lack of cleaning in the annealing system.
• Cleaning of ‘die’ and ‘capstan’ are mandatory prior to the annealing process to get better slippage on the capstan.
  • Poorly cleaned drawing section can trigger issues like wire breakage and uneven surface finish when the wire is drawn through a series of dies to produce the required form and thickness.
• Lack of cleanliness in the annealing section accelerated the rate of oxidation, leading to wire blackening

Understanding the requirement, the Bechem engineering team initiated a trial with the aqueous cleaner, Beruclean 3050.

Why Beruclean 3050?

• Heavy duty degreaser, Beruclean 3050 efficiently cleans tough greases, oils, drawing compounds and other process contaminants

• Suitable for metal surfaces like aluminium, steel, copper, bronze, ferrous etc. Beruclean 3050 can be safely used on machine surfaces with ceramic, plastic, rubber and painted materials as well

• Beruclean 3050 is effective for both traditional and modern cleaning techniques like ultrasonic washers, high pressure spray washer machine and spray washer machine, stream jet units and manual cleaning etc.

• Due to its low consumption, Beruclean 3050 is extremely cost effective

Trial observations:

• Excellent cleaning of machine components including capstan and die
• No traces of dust deposition were noted on the drawn wires. Superior surface finish of the copper wires was achieved
• No traces of corrosion or blackening observed. No lot was rejected during the trial period
• Clean equipment ensured cleaner working environment for the operations team

Observing the efficiency of the product in cleaning, the customer switched over to Beruclean 3050 fand proposed to explore other application areas and initiate the trial.

For more information on Bechem’s cleaner/degreaser, case studies and references write back to us at [email protected] or visit our website www.bechemindia.com

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

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Metal forging is the process by which metals are formed and shaped using compressive forces. Depending on temperature of the metal being worked upon, the process is classified into cold, warm and hot forging. Many automotive parts are forged due to unique advantages which include increased strength, different size/shape and mass production.

A typical forging press involves the moving vertical ram, die casts, bolster plate, ejector and frame. The vertical rams apply gradual and controlled pressure to the die holding a heated metal workpiece, causing it to take the shape of the die cavity. Due to the extreme pressure and shock loads involved in the process, the type and quality of lubricant used affects performance of these ram-based vertical presses.

Incorrect lubricant selection and inconsistent lubrication can reduce bearing life and lead to performance issues, including:

• Slow movement of the ram resulting in improper component accuracy
• Wear of the phosphor bronze bush bearings used in connecting rod, brake and clutch
• Excessive lubricant consumption due to frequent pumping
• Grease leakage from bearings resulting in fire hazard incidents
• Entry of forging dust and scale particles inside the bearings accelerating wear
• Sudden increase in operating temperatures of the bearing
• Chocking of distributors used in centralized lubrication system

The application requires special lubrication requirements. BECHEM provides best in class, special greases for forging presses with the following advantages:

• Longer life span of bearings as a result excellent wear protection with BECHEM’s range of greases. Customers have experienced bearing life of over five years with BECHEM Premium
• Resists bearing pitting: The special greases for the application create a high-pressure resistant film a result of the special additive package in the formulation.
• Strong adhesive property of the grease due to special tackiness improvers ensure a consistent lubrication film in the contact zone of eccentric shafts and phosphor bronze bearings
• Proven thickener and base oil combination for effective sealing of bearings to prevent external contamination.
• Prevent choking: Uniform and homogeneous structure of grease ensures no choking or clogging of distributors and tubing even if the machine is not in use for few days.
• Reduces grease leakage to ensure cleaner workplace as well as eliminate incidents of fire hazard.

The below case study illustrates how customized lubrication solutions for the hot forging press enhanced production efficiency at a renowned automotive component manufacturing brand.

Customer: A leading automotive components manufacturer in the world supplying a wide range of automotive components (such as distributor, gibs, connecting rod, brake and clutch journal etc), catering to both domestic and international markets.

The customer was using an extreme pressure grease of a popular brand “X” which was applied through pneumatic lubrication pump. The ‘On’ time for the pump was set 50 seconds.

Challenges experienced by the Maintenance team:

• Slow movement of ram in the mechanical system observed
• Sudden and abnormal rise of temperature in bearings.
• Severe grease leakage leading to higher grease consumption and fire hazard incidents
• During long idle hours, the issue of ‘distributor chocking’ was noticed.
• The removal of old grease from the equipment was a strenuous process.

The hot forging machine with a capacity of 2500, Tons has in-built temperature sensors, a modern grease pump and distribution system in place.

• Component name: Tripod Joint
• Number of strokes – 13 strokes/min
• Lubrication cycle- once in 100 strokes
• of strokes per Job- 3 strokes
• of stokes per Minute – 18 strokes
• Grease consumption per day – 21 Kg. /24hrs
• Monthly grease consumption: 504 Kg.

By considering the operational parameters and challenges, the BECHEM Application Engineering team recommended the high-performance grease “BECHEM Premium” for a trial.

Observations made during the trial period: 

Trial period : 60 days 

• Normal movement of the ram was noticed throughout the trial period.
• The re-lubrication cycle extended to 125 strokes in 30 Seconds.
• The issue of grease dripping was minimized.
• Operating temperature of the bearings were stable and sustained.
• Grease consumption reduced by 46.5% resulting in reduced operational costs.
• Issue of grease leakage was minimized reducing the risk of fire hazards.
• Process of degreasing was much easier.

Why ‘BECHEM Premium’?

• Developed with high quality base oil with optimum viscosity (110 Cst at 40˚ C), ‘BECHEM Premium’ ensures the formation of a high-load absorbent film.
• Fortified with special tackifier, ‘BECHEM Premium’ resists the ‘squeeze out’ phenomenon of grease from the bearings
  • The grease being highly tacky in nature helps in providing a secondary function of efficient sealing for the bearing
• The special additive package in the formulation of BECHEM Premium ensures a high-pressure-resistant film that absorbs shock loads and prevents bearing pitting
• BECHEM Premium provides strong protection against corrosion, this is validated by the EMCOR test result rating of 0/0.
• Developed with an ultra-refined base oil of higher oxidative stability, ‘BECHEM Premium’ prevents clogging or drying out in the tubes and distributors even during long idling hours of the machine
• BECHEM premium is fully compatible with phosphor bronze bearings for wear and corrosion protection as these bearings operate in high temperature and humid environments
• Readily pumpable from centralized lubrication system.

Observing the efficiency of ‘BECHEM Premium’ in optimizing production processes and minimizing maintenance costs during the trial, the customer switched over to BECHEM Premium for the rest of the presses.

*** pitting: Damage that is caused by the entry of foreign materials like dirt or other metal particles. 

** EMCOR test evaluates the effectiveness of grease in preventing corrosion in roller bearings operating in water, saline water, and sodium chloride solution.

For more details on BECHEM Premium sample of the product, write to us at [email protected]

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

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Vertical shaft impactor (VSI) crushers, widely used in the construction and mining industries, are uniquely designed for high-impact crushing. The crushers are suitable for a wide range of applications including the production of high-quality manufactured sand, well-formed aggregates, and industrial minerals.

Working Principle of Vertical Shaft Impactor (VSI) Machine

• The principle involves a fast-spinning rotor that is fed with the solid hard stones (mostly boulders or granite) by conveyor mechanism. The centrifugal forces generated by the rotor, throw the stones at high speeds against a solid stationery impact wall. The impact causes the material to shatter into smaller pieces due to their natural fault lines.
• The rotor with shaft and bearing are connected to drive pulley mechanism. Due to different size and shape of the stones being processed, the operating conditions induce impact loads and vibration in bearings of the rotor.
• Even though the sealing is effective, the abrasive nature of the dust particles can cause cracks or ruptures in seals over time, resulting in the entry of fine dust particles into the bearing and cause damage.

Common reasons for premature bearing failures in VSI Crushers:

• Contamination of lubricant inside the bearing with abrasive wear and debris
• Selection of grease with incorrect base oil viscosity and viscosity index for the application
  • Temperature and consistency behaviour of the grease
• Fretting or fretting corrosion, which typically results from a loose fit of bearing inside housing or shaft, leading to relative motion between the bearing and the shaft or housing
• Incorrect lubrication practices such as over lubricating the bearing leading to excessive heat build-up.

Operating conditions of the bearings in Vertical shaft Impactor:

• Bearing position: Vertically mounted
• Bearing number: NU 2324/QJ 2324
• Bearing type: Cylindrical roller bearings
• Bearing RPM: 1500

• Operating temperature: 110˚C
• Dust entry: M Sand dust particles
• Frequency of lubrication: Once in 8 hours

Challenges encountered by the production team:

• High operating temperatures of 80°C to ≥ 120°C resulted in rapid degradation of lubricant, leading to insufficient lubrication and frequent bearing failures.
• Frequent relubrication cycles (every 8 hours) made it difficult for continuous production
  • The maximum production output was only 2000 Tons/day
  • Frequent replenishment of lubricants results in increased operational costs
• Vertically mounted bearings caused additional challenges. Increase in centrifugal forces during operation, lead to rise in churning losses of grease in the bearing along with the influence of gravitational forces.

The customer was using a mineral oil-based grease of a reputed brand and was in search of an alternate to maximize production capacity while reducing operation costs.

Considering round-the-clock (24/7) operations, BECHEM’s engineering team recommended Beruplex LIEP 3, specially designed for vertically mounted bearings, fortified with an additive package for absorbing shock loads and vibration.

Why Beruplex LIEP 3?

• Developed on optimum -viscosity base oil, Beruplex LIEP 3 forms an effective lubrication film on the cylindrical roller bearings used in VSI machines and provides continual protection from wear.
• Beruplex LIEP 3 ensures superior adhesion on bearings due to the polar nature of the lithium-complex thickener, which is ideally suited for bearings rotating at high speeds.
• Excellent structural stability provided to Beruplex LIEP 3 for mechanisms exposed to shock loads and vibrations.
• Additive package in Beruplex LIEP 3 protects bearings from high friction zones especially during start-up and shut-down phase.
  • Also provides effective protection against corrosion
• Beruplex LIEP 3 is a NLGI 3 grade grease which provides essential stiffness in vertically mounted bearings.

Trial Observations:

• Smooth operation with minimum bearing failure during the trial period. Also, machine run-time was enhanced.
• The frequency of re-lubrication extended from 8 hours to 24 hours.
• Prolonged re-lubrication intervals reduced frequent man-machine interference.
• Better lubricity reduced grease leakage and ensured a cleaner work environment.
• Reduction in lubricating quantities with Beruplex LIEP3 benefitted the customer commercially as well.

Having observed the performance during the trial period, the customer was convinced of the reduction in grease consumption, resulting in cost saving and has since switched over to Beruplex LIEP 3.

For more details on Beruplex LIEP 3 sample of the product, write to us at [email protected]

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

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Case study on impact of high temperatures and loads on lubrication and therefore life of plummer block bearings in the drying range of a textile spinning mill.

The drying range or VDR (Vertical Drying Range) in the woven dyeing and printing segment of a textile mill enables rapid drying of fabric under high steam pressures and temperatures. The pillow or plummer block bearings play an important role in functioning of these vertical drying ranges by supporting movement of rotating shafts or rolls.

These vertically oriented plummer block bearings face unique operating conditions of high temperatures and loads, exposure to process chemicals, steam, dust and other contaminants. In the absence of effective lubrication, environmental factors can cause undue stress on the plummer block bearings, leading to premature failure and unexpected downtime in the drying section.

Selection of lubricant to endure such aggressive conditions determines the performance and life of functional elements in bearings like rollers, raceways, balls, and cages. BECHEM’s range of speciality greases for bearings operating in such harsh conditions ensure effective lubrication and also extend bearing service life.

Customer: A leading textile producer in India with a value chain extending from yarns to garments. With a production capacity of over 75,000 meters of fabric per day, the integrated textile unit has multiple facilities for the processes of bleaching, mercerizing, dyeing, printing of yarn, garment washing and finishing in the same vicinity.

The drying range is equipped with 16 vertically mounted cylinders in two rows. The customer was using a synthetic grease based on OE recommendation (brand Y) to lubricate a total of 32 bearings in each row.

Issues reported by the Maintenance Dept.

• • Excessive oil bleeding and evaporation loss due to exposure to high temperatures
    • • When exposed to hot steam, grease oxidised rapidly losing its inherent properties
  • Frequent re-lubrication
    • • In order to avoid plummer blocks going dry, re-lubrication frequency was increased. However, the process was tedious as bearings are located at different heights and in difficult-to-reach locations
  • Nevertheless, frequent bearing failures were reported leading to downtime and productivity loss

Operating conditions of ‘vertical drying range (VDR) cylinder

• • 1^st row and 2^nd row with 16 cylinders vertically mounted in each row
  • Bearing number: UC 215 bearing
  • Temperature: 150 to 180 ˚C
  • Load: 1- 1.5 Ton
  • RPM: very low
  • Re-lubrication frequency: once in 15 days
  • Bearing life: 1 year

Closely monitoring the operational parameters, BECHEM’s application team recommended the high temperature grease, Berutemp M 2 KN. A high-performance, polyurea grease developed for bearings that are exposed to high temperatures and loads, steam and water ingress.

Why Berutemp M 2 KN?

• • Based on polyurea thickener and fortified with additives, Berutemp M 2 KN offers exceptional oxidation stability ensuring long term lubrication.
    • • Extended service life of the grease avoids repetitive lubrication breaks and production loss
  • Berutemp M 2 KN forms a consistent lubrication film between rolling contact and sliding surfaces even at high temperatures
  • Berutemp M 2 KN offers excellent resistance to water and steam, thereby protects rolling elements from corrosion
  • Formulated with ultra-refined base oil, Berutemp M 2 KN exhibits excellent temperature resistance behavior with controlled oil bleed characteristics
  • Developed on comparatively higher base oil viscosity (490 Cst at 40 ˚C), Berutemp M2 KN prevents metal-to-metal contact under high load conditions

Based on the BECHEM team’s recommendation, a trial was initiated with Berutemp M2 KN to observe any change in lubrication life.

Trial Observations:

• • No issue of grease oxidation when exposed to steam was reported
  • Re- lubrication interval extended from 15 to 30 days
  • No bearing failure reported in the drier section of the plant for a span of 1 year

Having observed performance of the product in optimizing production process efficiency, the customer switched over to ‘Berutemp M 2 KN’. Usage of grease was also extended to other bearings which were exposed to high operating temperatures and similar work environments.

For more details on Berutemp M 2 KN or for sample of the product, write to us at [email protected].

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

Drilling as a machining process is often considered a challenging process due to multiple factors such as strain hardening, toughness, high plasticity, tendency to form built-up edges and difficulty in chip evacuation. The role of cutting fluid is indispensable to reduce both temperature as well as friction between chips and the drill flutes and additionally to clear off the hot chip debris. However, the conventional ‘flood lubrication’ process typically used for lubrication, cooling and chip evacuation, often trigger issues like frequent re-lubrication, abrupt tool wear, disposal of used coolant etc.

Among other lubricant application techniques, the process of spraying out limited quantity of cutting fluid as cold mist to the cutting zone has proved to be effective. With MQL, there is minimal or no need to clean the tool and workpiece regularly after every machining process. Additionally, the task of disposal of used medium gets eliminated completely.

Can the process of Minimum Quantity Lubrication (MQL) reduce operational costs in metal drilling processes?

Customer: A leading Indian manufacturer with over four decades of experience in manufacturing forged engine and drive-line components. The technology driven company with multiple production facilities caters to the automotive, earth moving, tractor and pipe fitting industries across the globe.

Machining Parameters

Application: Pin hole drilling

Machine type: Oil hole machine

Machine OE: Reputed Indian brand

Material: Steel

Existing cutting fluid type: Mineral, OE recommended

Viscosity at 40˚C: 47 mm²/S

Pressure- 3-4 bar

Customer was using OE recommended non-water miscible oil, brand “X” for over seven years. During this phase the customer with an intention to reduce operational cost had conducted multiple trials with alternate cutting fluid brands available in the market. However, none of the trials were successful due to concerns of tool life and machining performance.

Consequently, when approached by BECHEM’s Engineering team, the Customer was skeptical. Nevertheless, the team convinced the customer for a trial opportunity for its MQL product, Beruform STO 110.

Trial observation:

• Superior machining performance
• Consumption of 2 litres of Beruform STO 110 observed for a span of 10 days. No operational downtime.
• Over 40% reduction in cost per component with Beruform STO 110 when compared to the existing product

Result:

Customer was pleasantly surprised with the result of Beruform STO 110 which facilitated near-dry machining. Convinced on factors of cost saving when compared to the existing product, the customer switched over to Beruform STO 110 readily.

Why Beruform STO 110?

The next generation of Bechem MQL lubricants have been specifically formulated to solve existing problems of wet machining with performance and productivity.

• Developed from high performance synthetic base oils
• Beruform STO110 ensures less smoke and mist formation and hence ensures work friendly environment for the operator
• Beruform STO 110 as an MQL facilitates near-dry machining with superior machining results and a cleaner workplace
• Beruform STO 110 is free from heavy metal containing additives like Chlorine, Sulphur etc. and ensures a safer work environment and hassle-free disposal.

For more information on BECHEM’s mist oil range and to experience reliable and cost-effective MQL solutions, write to us at [email protected].