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May 12, 2023How effective lubrication of conveyor chain can impact process efficiency even at high temperatures?
Chains in drives and conveyors are highly stressed components in production lines as they typically endure harsh operating conditions like high temperatures, high load, dusty environments etc. High friction is encountered during the force introduction and force transmission in the direction of transmission. Lubrication plays a critical role in the efficient working as well as long life of chains. Failure of the lubricant to form a parting film to reduce friction can cause premature wear of the pins and bushings and adversely affect chain life. Additional problems due to poor lubrication include chains jumping off the sprockets, undesired noise, corrosion, chain failure and ultimately affecting production schedules.
Optimum and timely lubrication schedule results in better performance and can ensure long-lasting life for these critical power transmission equipments.
However, quality of the lubricant and its application procedure also has an impact on the service life of the chains. Lubricating oils with optimum viscosity and excellent penetrating property, efficiently lubricates the pins and bushings of chains, providing sufficient lubrication to reduce friction and wear. Detergency properties in the chain oil helps to flush out wear debris and contaminants helping in smooth engagement of the chain with sprocket. Hence, effective chain lubrication is the key to keep chains of drives and conveyors operational ensuring production reliability without extensive maintenance effort.
Below is a case study to illustrate how effective lubrication can enhance operational reliability of conveyor chains operating at high temperatures.
Customer: A leading manufacturer of aluminium containers with two production facilities located in South India. The particular unit and production lines are dedicated to produce aluminium cans for packaging segments of soft drinks, perfumes, cosmetics, pesticide industries etc.
Customer was using (mineral / synthetic) chain oil of brand ‘X’ having viscosity of 100 cst at 40˚C and high consumption rate.
Issues Faced:
- Excessive fume formation as the existing chain oil reacted with lacquer dust at high process temperatures
- Slippery workplace as the existing chain oil was prone to dripping and sling off on the frame and floor, causing slip hazard
- Seemingly high oil consumption : Frequent relubrication exercise due to spillage of oil resulted in higher consumption, (approx. 90 litres per month).
- Poor lubrication film on frictional partners of the chain.
Process Details:
The roller chain was used in the lacquer drying oven application, which is attached to a wire belt that travelled through hot paint ensuring that aluminum cans travelled from the paint dispenser through the drying process without sinking to the bottom of the paint trough.
- Application: Lacquer drying oven
- Oven length: 90 metre
- Chain set up: Single loop chain both LH & RH
- Chain movement: Both horizontally & vertically
- Operating Temperature (avg) : 163 ˚C (Oven entry)
Avg : 194 ˚C (Oven exit)
- Re-Lubrication frequency: Approx. 3 litres per day.
Operating Conditions:
- Availability of drip lubrication pump on the top of both the chains
- Chain oil should not react with lacquer and produce fumes while operating at high temperature
- Lubricating oil must not drip from the chain while operating in vertical position
- Presence of lacquer dust
Closely monitoring the operational parameters, BECHEM’s engineering team recommended synthetic chain oil Berusynth CU 250 with high load carrying capacity specially developed to ensure seamless operations of conveyor chains in drying ovens.
Trial observation:
- Drastic reduction in fume generation even operating at higher temperatures improving the air quality and safety for operators
- Long term lubrication with Bechem’s Berusynth CU 250.
- Overall consumption of chain oil was reduced to 25 litres approx. on a monthly basis
- Cleaner workstation since there is no spillage of oil after application and during regular operation
Why Berusynth CU 250?
- Excellent penetration properties of Berusynth CU 250 enables to creep into the friction partners like pin and bush of the roller chain for high performance lubrication.
- Due to polar properties Berusynth CU 250 is highly adhesive in nature, hence, prevents dripping while running even in upright position. It ensures cleaner and safer workplace.
- Having a low evaporation rate, Berusynth CU 250 generates lesser fumes when exposed to high temperature 220 °C and above resulting in better work environment.
- Bechem’s synthetic chain oil Berusynth CU 250 ensures extended lubrication intervals as the lubricating film is retained on chains for longer duration.
- It results in reduced consumption and operational cost
- Anti-wear additive package of Berusynth CU 250 ensures longer chain life due to improved wear protection. Thus, frequent downtime can be avoided
- Additionally, the level of machine cleanliness also improved
Having observed performance of Berusynth CU 250 in optimizing production process efficiency and reducing maintenance costs, the customer switched over to the BECHEM’s synthetic chain oil without any hesitation. Further, Berusynth CU 250 was also introduced in their other unit as well.
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