Importance of proper lubrication in industry

Where previously the "youngest employee" was sent into the factory with a grease gun, lubrication maintenance has now been elevated to a serious field. A field that also has the full attention of universities and research institutes. Lubrication maintenance can make an important contribution to the reliability and availability of machines, but also to energy efficiency. For maximum results, there are now various (maintenance) software packages available that support the user in determining the correct lubrication intervals.

Research shows that friction in machinery and equipment determines up to 20% of global energy consumption. Moreover, it accounts for 40%(!) of industrial maintenance costs. These two facts don't lie and indicate that reducing friction - through proper lubrication maintenance - can make a significant contribution to energy and cost savings. In concrete figures, using the right materials and lubricants can reduce long-term energy losses due to friction by about 25%. Other cost savings lie in higher machine availability, leading to higher output, less product rejection and lower maintenance costs.

Lowering friction

To reduce friction, the first thing the machine or plant must do is get the basics right. That means choosing the right components to match not only the forces and speeds of the application but also the environmental conditions. Proper alignment also plays a role. When this is completely in order, the lubricants can be chosen. On the one hand, it is prudent to follow the manufacturer's manual for this, but on the other hand, it is also no problem to seek advice from specialists. Sometimes a more expensive lubricant can be better and ultimately lead to a (much) lower TCO. A good lubricant creates a minimal film between the moving parts and thus minimizes friction. In addition, these products can dissipate heat and dirt. 

Features

The market has a multitude of general purpose lubricants. However, for applications that work under more extreme conditions, it is important to choose a lubricant specifically tailored to this situation. Think, for example, of extremely high pressures, high or just low temperatures, and applications that are outdoors where dirt, moisture and sometimes a salty atmosphere add to the stress. By choosing the right lubricant - composed of a good base oil and the necessary additives - it will last the longest. This leads not only to a trouble-free application but also to lower costs related to maintenance: fewer hours and fewer lubricants.

Lubricate well

Besides choosing the right lubricant, two other factors play a role in good lubrication maintenance: frequency and the amount of lubricant applied. To begin with the latter: more is NOT better. There are countless practical cases where an "overdose" of lubricant actually led to a machine jamming. When lubricant leaks out of bearings, it is certainly not a sign of "nice lubrication" but of "overkill. 

The frequency of lubrication is related to the fact that a lubricant is "used up" over time and thus must be replenished. This can be done manually but also by means of an automatic lubrication system in which the amount of lubricant to be dispensed every number of hours is preset. In locations with many lubrication points, this is a common solution to relieve the pressure on the maintenance department. It also prevents difficult-to-reach lubrication points from being easily "forgotten".

For proper planning of lubrication maintenance, both generic and specific maintenance management programs are available. These include the lubricant and frequency of lubrication for each lubrication point. Often there is also room to provide feedback on problems or add visuals.