Improving lubrication safety and consistency in recycling plant
When a metal & waste recycling plant has more than 200 lubrication points across the site, keeping lubricated was a significant task for the maintenance team.
ACORN worked with the site to install automatic lubricators at 115 points, helping to address three connected challenges: the time required for manual lubrication, access to difficult locations and inconsistent grease application.
The challenge
time, access and inconsistent lubrication
Lubrication was scheduled every 40 running hours, but completing it manually took a technician around half a working day. Some points were difficult to reach and required a cherry picker, adding time and complexity to the task.
The schedule could also be interrupted when the technician was needed elsewhere. This made it harder to maintain a consistent routine across the site. An inspection found clear signs of both over-lubrication and bearings that had received little or no grease.
Together, these issues created avoidable maintenance demands and made it harder for the team to focus on proactive work.
The solution
115 automatic lubricators, selected for each application
ACORN’s Yorkshire branch recommended and fitted 115 Simatec automatic lubricators, ranging from 15ml to 125ml. Where possible, the lubricators were set to provide up to 12 months of grease, allowing them to be changed together as part of a planned maintenance routine.
Access and safety were considered as part of the installation. In difficult or hazardous locations, lubricators were mounted on magnets and connected with tubing. This placed them away from rotating parts and made them easier to reach and inspect, reducing the need for employees to climb onto machinery to lubricate these points.
The benefits
safer access and time for proactive maintenance
The new system provides a more controlled and consistent supply of grease to the selected bearings. This is expected to help reduce the risk of under- or over-lubrication, support bearing life and reduce the likelihood of premature failure.
Moving these lubrication points to automatic systems should also reduce the time technicians spend on routine manual lubrication, freeing up an estimated 730 hours per year, per technician, giving them more capacity for proactive maintenance. The amount of time and any reduction in bearing failures will be reviewed as the installation is monitored.
MRO Sales Specialist, Jack Burge has arranged monthly site visits to inspect the lubricators, identify any adjustments needed and discuss other opportunities to improve reliability at the plant.
Struggling with consistent lubrication and keeping up with essential maintenance? Contact your local branch to discuss automated lubrication solutions.