Around 60 to 80 percent of bearing failures are lubricant-related. One of the most effective ways to prevent these issues is to ensure lubrication is applied properly. While under-lubricating a machine component can cause overheating, excessive wear and premature bearing failure, over-lubrication can be just as damaging. Getting the balance right, and applying the right quantity of lubricant at the correct interval, is essential for the correct functioning and longevity of mechanical equipment.
“Many people don’t know that over-lubricating is problematic, as it causes grease churning and overheating, which can eventually damage a machine’s motor coils or windings,” says Gavin Ford, National Marketing Manager at Lubrication Engineers (LE) South Africa. LE advises customers to use the minimum quantity lubrication (MQL) approach, applied at the correct interval, to protect equipment and minimise costs.
Getting the volume and timing of lubrication also affects a plant’s environmental footprint. Over-greasing wastes product and increases the amount of lubricant that is flung off from moving components onto the surrounding floor and equipment. In contrast, using the correctly calculated application volumes reduces both waste and contamination risk.
Reducing the risk of cross-contamination
LE supplies a range of products and solutions to make correct application easier and reduce the risk of lubrication cross-contamination. The Xport™ battery-powered grease gun is especially useful for lubricating hard-to-reach areas or equipment that needs frequent or large-scale lubrication.
“When the wrong grease is applied to a piece of equipment, the resulting issues can be expensive and time-consuming to fix,” says Ford. The grease gun has a clear grease tube, which allows maintenance teams to easily and accurately see what they are doing, and it eliminates cross-contamination.
The Xport™ has a 19.2-volt rechargeable battery, so it can provide powerful, efficient grease delivery, and its extra-long whip hose conveniently extends into hard-to-reach areas. The tubes are made of high-impact, fracture-resistant polycarbonate, capable of withstanding heavy use and high temperatures, and they fit many standard grease guns – making it easy and cost-effective to upgrade existing equipment.
Single-point systems for larger-scale applications
For larger-scale applications, Ford recommends single-point lubrication systems. Single-point lubricators remove the uncertainty around greasing intervals and product volumes for each bearing, and ensure no lubrication point is missed during inspection. This makes it easier to catch bearing problems early, reduces unplanned maintenance and lowers overall maintenance costs, while also cutting down on the wasted lubricant and mess that come with manual over-application.
LE has a range of single-point lubricators that help maintenance teams simplify and improve their processes. “Our range of Xport™ Perma® single-point applicators are essentially micro-computer lubricators. They provide automated, precise and timed lubrication to be applied where needed, rather than maintenance teams having to do time-consuming manual lubricant application,” says Ford. The built-in RFID system helps customers to track, monitor and fix lubrication-related issues during routine inspections and the exact greasing quantity and re-greasing intervals for each bearing can be easily calculated and managed by the MQL schedule.
The Xport™ single-point lubricators run on battery or mains power and can be installed at any location. This makes them ideal for equipment located in isolated or dangerous areas and help to eliminate potential human errors and improve employee safety, says Ford. “They can be used with LE’s complete line of high-performance industrial greases, from electric motors to food-grade, high-temperature and all-purpose lubricants.”
