Lubrication is vital, but it can be a complicated business. Every piece of equipment with moving parts needs to be lubricated, yet it can quickly become overwhelming with many factors to consider. How often should a machine be lubricated? What job does the equipment perform? Is the environment wet or dry, hot or cold, clean or dirty? How fast does the equipment move? Is it involved in food processing? These questions should be answered before you select your lubricant. That is why Oilfast UK has decided to answer some key questions to help you make the right lubricant choice.
Function: What Does the Lubricant Do?
Lubricants have a wide range of functions that include controlling the following:
- Friction (lubricants reduce heat generation and energy consumption)
- Wear (lubricants can reduce mechanical and corrosive wear)
- Corrosion (quality lubricants protect surfaces from corrosive substances)
- Contamination (lubricants transport particles and other contaminants to filters and separators)
- Temperature (lubricants can absorb and transfer heat)
- Sometimes, in the case of hydraulics, lubricants also provide power transmission.
All this means is that you need to know your application’s unique challenges and choose your lubricant accordingly. For example, high pressure, low temperature and exposure to saltwater are just a few possibilities. Select lubricants that are clearly labelled to indicate how they perform and under what circumstances.
Ingredients: What’s in the lubricant?
You may not think of lubricants as having many ingredients, but there are many different additions to the base oil. These ingredients are deliberately chosen based on how the lubricant will be used. This is true of greases as well as oils. Many people are unaware that greases are oils with thickeners added. The type of thickener matters a great deal. The thickener is typically composed of fibrous particles that act like a sponge, holding the oil in place to give it a more dense quality. Each thickener type confers different advantages and disadvantages, specifically regarding shear stability, pumpability, heat resistance and water resistance.
Terminology: What Do These Things Mean?
To make correct lubrication choices, you must understand the terminology involved. Commonly used terms include the following:
Viscosity: This describes how thick or resistant to the flow of the oil or grease is. Higher viscosity means higher flow resistance.
Kinematic viscosity: A simple pour test can be used to offer a visual illustration of density. Lube technicians can demonstrate kinematic viscosity on the shop floor because it’s easy to do and takes little time.
Weight: This also relates to how viscous oil is or how easily it flows at a specific temperature.
NLGI consistency: The consistency indicates how hard or soft a grease is. The numbers range from 000 (like cooking oil) to 6 (like cheddar cheese).
Run-out: This term refers to the ability of grease or oil to resist higher temperatures, which tend to make lubricants less viscous.
Shear stability: This is an oil’s resistance to a change in viscosity caused by mechanical stress.
Metal on metal: A condition that every equipment owner should avoid, like the plague, describes a situation where no lubricant resides in a bearing or other application.
Ease of Use
Not all oils are applied the same way. The method of application will depend on your particular piece of equipment. An aerosol lubricant, such as an easy-to-reach hinge, may suffice for some situations. Grease can be applied by hand to an accessible gearbox very easily. However, an automatic dispenser that only needs to be refilled every six months can be an excellent option for hard-to-reach locations. For chains that require regular lubing, a continuous dispenser might be best. If you are purchasing lubricants from a reputable vendor, consult with one of their specialists to determine what method will be most beneficial.
Longevity
Lubricants have an optimal lifespan; once it’s over, you must replace them. Failure to do so can result in run-out, metal-on-metal contact, destroyed bearings and other issues leading to downtime. As a result, it results in higher costs and expenses. The problem is that it’s not always obvious when this is about to occur.
One meaningful way to track a lubricant’s lifespan is by monitoring the operating temperature of your equipment. Excess heat destroys lubricants. Every rise in temperature of 10 degrees C (18 degrees F) above 65 degrees C (150 degrees F) will cut the lubricant’s service life in half. So, an oil that would typically last one month at 150 degrees F will last only two weeks at 168 degrees F, one week at 186 degrees F, and just three or four days at 204 degrees F before needing to be replaced or rejuvenated. After that, it will cease to do its job, offering little or no protection even if lubricant levels appear high.
Heat tracking can be done with digital calibration tools, which can offer thermal imaging and vibration analysis. We recommend monitoring your lubrication intervals.
Finally, if you’re not familiar with predictive maintenance (PdM), it’s highly recommended that you take a few minutes to research it. This trend in maintenance schedules proves to be highly effective at saving companies money while keeping equipment functioning at optimum levels.
Cost
As with most things in life, you get what you pay for. A food-processing plant may use mineral oil on transport chains because it’s cheap and food-safe. However, plain mineral oil has several disadvantages that outweigh the low cost. For instance, this particular oil may have poor run-out characteristics and attract contaminants to form an abrasive paste or drip to create an unsafe working environment. Managers who choose this option will soon discover that their savings are wiped out by the cost of downtime resulting from using inferior-quality lubricants, not to mention the potential of workplace accidents.
To calculate the actual cost of a lubricant, don’t just look at the price tag on the container. Take that number and compare it to the cost of downtime or replacement, loss of product due to halted production or contamination, employee hours, and other factors that may be an issue for your company. If you just spent $2 million on a new production line, paying a few hundred dollars a month for a high-quality lubricant should seem like a no-brainer if it means the machine will function better and its lifespan will be increased.
In conclusion, while all production facilities depend on lubricants to continue operating, remember that not all fats are created equal. It can be a grave mistake to purchase a cheap lubricant without considering the above-mentioned factors. Breakdowns are expensive and can have a snowball effect. Innovative businesses spend as much time thinking about lubrication as they do about the types of equipment they purchase.
Tips for finding the perfect lubricant
So, what’s the best product for each surface and condition? Consider these tips for choosing the perfect lubricant:
Metal-on-Metal
Oil-based products are best for providing a lubricating film that prevents direct contact with moving metal parts. Oils can flow freely, allowing for uniform protection from friction. For long-lasting lubrication, use multi-purpose oil that further protects the surfaces and won’t break down quickly.
A penetrant can be used for parts that aren’t moving but should — like a frozen nut or bolt. Penetrants are thin, oil-based materials that quickly seep into narrow spaces like threads on bolts or screws to provide a lubricating film that helps release the stuck piece.
Greases can be used for metal-on-metal applications that require heavy-duty lubrication and protection against rust. Spray products like white lithium grease provide an even layer that sets dry for a thick, protective coating that won’t wash off, melt, freeze or run in any weather. This product is best used on parts like auto hinges, gears, sprockets and pulleys exposed to the elements.
Metal-on-Plastic
Lubricants with silicone or PTFE (polytetrafluoroethylene) are best used on plastic surfaces. PTFE is hydrophobic, meaning it repels water, so lubricants containing it are effective in damp conditions. Silicone lubricants make surfaces ultra-slippery while repelling water. They’re safe to use on rubber, plastic, wood and metal. While some lubricants can be used around painting operations, silicone-based lubricants should not so check the product’s label.
Plastic-on-Plastic
Silicone or PTFE products are suitable for plastic-to-plastic lubrication, but the silicone will form a thicker, wetter layer that may collect dust and dirt. PTFE will have a thinner yet more challenging layer that will not attract dust or absorb grime.
Metal-on-Rubber
PTFE products are best for the lubrication of rubber. They provide a thin, hard layer that protects best against the accumulation of dust and dirt.
Removing Rust
Non-acid rust remover products will safely remove rust from metal tools and equipment. They do not contain harsh acids that damage surfaces but are based on chelation chemistry. The chelates are materials that react with rust and only rust. These products may take a little longer to work but will not harm the surrounding parts, trim, gaskets or painted surfaces and are safer because they maintain a neutral pH. Once the rust is removed, you can quickly apply a film of lubricant or corrosion inhibitor.
Fast Action
It’s going to happen — tools, parts and equipment will become caked with dirt, rust and moisture on the job. But quick service is critical when clients seem to want everything done instantaneously. Maintaining rust-free equipment that operates efficiently, quickly frees up stuck parts and makes fast repairs at the job site will keep clients satisfied with your services.
Regular maintenance is challenging, but it’s easier than you think. Lubricant products fit easily into your work truck or toolbox, and taking the time to spray a piece of working equipment to maintain its condition requires much less effort than repairing it if it’s broken. You can’t afford to buy new tools just because the ones you own have been neglected. If you take care of your tools, they will take care of you.
Your reliable lubricant supplier
Oilfast UK is proud to work with distributors across the UK to offer a wide range of premium lubricants at great prices to meet your requirements.
We work alongside brands like Shell and Fuchs to provide customers with an excellent, market-leading portfolio of lubricants, oils, and greases.
Our lubricant experts are on hand to listen to your business needs and give expert advice to help find the correct lubricant for your business. We’re here to help; get in touch to discuss your lubricant options.