Rethinking lubrication management

LUBRICATION MANAGEMENT is a job that’s continually ignored. But fixing it now could save your company a small fortune in the long run by reducing maintenance and unplanned downtime.

Starting small

It’s usually the small things that have the greatest effect. A regular lunchtime walk will boost your health more than a frantic weekly gym session; similarly, looking after your seals and bearings can work wonders for productivity.

These components live out of the spotlight but keep machines running smoothly, if you treat them right, with enough lubrication. Without it, metal grinds on metal, heat builds up, contamination creeps in and machines fail early, sometimes catastrophically.

This is why lubrication management is critical. Done properly, it raises reliability, efficiency and safety. A well-planned programme, with expert guidance, can extend machine life, banish unplanned downtime and cut maintenance costs. It can even support sustainability by reducing energy consumption and waste.

Expert guidance

Expert insight always helps, and that’s what we provide at Acorn Industrial Services. Just as a personal trainer helps you reach your health goals more effectively, a lubrication expert knows exactly how to solve your problems.

Using our customised approach, businesses can flip lubrication from a basic task into a strategic asset. No longer a chore, it is now the process by which machine life is extended, uptime maximised and environmental impact reduced.

Services like a lubrication survey - which assesses all machinery assets - application reviews and relubrication options go beyond simple advice into operational advantage. We manage the hidden detail: identifying lubrication points; selecting products for re-lubrication; oil reconditioning; and debris analysis. Every customer has different needs – and understanding that detail is critical when proposing a solution.

Single advantage

A good example is automatic single-point lubrication, which makes re-lubrication more regular and consistent. While under-lubrication is often seen as the main cause of machine failure, over-lubrication is a much greater problem. This is a common issue caused by manual lubrication, that can be solved by single-point systems.

This year, Acorn became a distributor for Simatec, whose Simalube product range raises the standard for compact automatic single-point lubrication. Available in five sizes, they come pre-filled, empty or custom filled with any grease up to NLGI 2. These lubricators can supply various lubrication points around the clock – for up to one year.

Its 15 ml product, the world’s smallest automatic lubricator, is ideal in confined spaces (even underwater) at ambient temperatures of -20 to +55 °C. The dispenser is supplied filled or unfilled,  and can be refilled up to three times over its lifetime. While manual lubrication typically sees a component alternate between under- and over-lubricated, an automatic system like Simalube delivers the optimum amount. Larger Simalube lubricators, up to 250ml, are used in applications with a higher grease/oil requirement.

Medical emergency

Single-point lubrication is often an important factor in fixing problems. A case in point is a medical waste recycling company that was recently plagued by recurring bearing failure. Constant equipment breakdowns had led to spiralling maintenance costs and reduced productivity. The company knew it was caused by under-lubricated bearings – but needed practical advice to solve the problem.

Acorn visited the client’s facility in Leeds to discuss exact lubrication needs and assess bearing performance. One key finding was that the lubrication issue was not isolated to this single location, but affected similar sites across the country.

On this basis, Acorn devised a strategy to fix the problem. This involved:

• installing a single-point system that delivers continuous lubrication to the bearings - maintaining optimal performance and preventing premature wear;
• supplying sealed spherical bearings that retain lubricant and reduce ingress of contaminants - which was ideal for the recycling plant’s harsh conditions;
• adding breakdown support and replacement supply, to minimise downtime; and
• adding caster upgrades to certain equipment, ensuring smoother movement and reducing stress on the bearings over time.

This plan solved the immediate bearing problems and helped prevent future disruptions across other facilities. Acorn has since optimised the lubrication system across all the customer’s sites.

This is just one example. We’ve helped many other customers to address and fix their lubrication regimes. For a food manufacturer, we recommended and supplied food-grade lubricants suited to its operations, and developed a lubrication compliance manual. Meanwhile, a mining customer found that a new excavator, with automatic lubrication system, was experiencing blockages. Our advice? Switch to a lower-consistency grease with a calcium thickener to boost water resistance and wear properties.

Jay Goodgame is product manager (lubricants, sealants and adhesives) and MRO sales specialist at Acorn Industrial Services

For more information:

www.acorn-ind.co.uk

Tel: 0800 8766 441