KlüberConsult – saving energy and reducing CO2

For some considerable time Klüber Lubrication has been extoling the virtues of synthetic gear oils and the energy savings that can be achieved using this advanced lubricant technology.

Recently a major insulation materials manufacturer has seen this is action. As a high energy user, the priority of reduction in energy consumption couldn’t be more

important. All aspects of their process were under review and as their lubrication partner, Klüber Lubrication proposed reviewing their gearbox lubricants.

In consultation with the site maintenance team, an SEW SA67 bevel helical gearbox on the product conveyor, from the Cooling Zone to Packaging was selected as representative for trial with Klübersynth GEM 4-220N synthetic hydrocarbon gear oil.

An energy monitor was fitted to record the power consumption during typical production. The mineral oil lubricant was then drained and replaced with Klübersynth GEM 4-220N. The power consumption was then recorded during production.

Overall, during mixed production conditions, a reduction of 7.2% power consumption was achieved. This resulted in a potential annual saving of 300kWh on this gearbox, purely due to the better lubricating properties of the Klübersynth GEM 4-220N providing higher efficiency in addition to superior wear reduction properties.

Across the site, on approximately 200 assorted gearboxes, the potential for savings is 100,000kWh per annum.

Oil drain intervals are also extended 3-fold due to the extended life of the Klübersynth GEM 4 range and their improved resistance to oxidation. Add that to the associated reduction of maintenance costs and waste disposal; and additional significant savings are achieved.

The gearboxes will benefit from extended life due to the better anti-wear properties of Klübersynth GEM 4-220N, thereby helping to reduce spares inventory.

Matching all this to the reduced energy consumption measured in reduced CO2 emissions and this insulation manufacturer is making significant headway on their costs reduction programme.