How to properly introduce grease into production and integrate it correctly into the application system?

The first step in introducing grease into production is… to open the grease container properly. This applies especially to medium and large containers, where the lid must be lifted. It is important to bear in mind that the lubricant container may become soiled during transport or storage, and that various contaminants may accumulate on the lid.

It is absolutely essential that the lid is carefully wiped before opening, so that no particles are introduced into the lubricant when tilting it. This seems trivial but is often overlooked. Meanwhile, it is easy to imagine the damage that can be done by, for example, metal filings or wooden particles carelessly introduced into the lubricant then applied to precision gears or bearings.

So remember to prepare the lubricant container properly before opening it. It is a simple action that can prevent serious consequences.

What to do if, when you open a lubricant container, you see a layer of oil on top? Do I make a complaint about the product? Get rid of the oil?

People involved in the introduction of lubricants into production are often confronted with the situation when, after opening a lubricant container, they see a layer of oil deposited on the lubricant. Our experience shows that this phenomenon can raise doubts about the quality and fitness for use of the lubricant. It turns out that there is absolutely no reason for concern. It is a natural phenomenon of oil separation.

At its core, a grease consists of a base oil, a thickener whose role is to hold the oil in place, and various additives that affect the final performance of the grease in question.
The highest percentage oil separation occurs within the first 24 hours after filling a dedicated package. Information on the percentage oil separation can be found in the Lubricant Data Sheet.

What should you do, then, if you find a film of oil on the grease you want to use? Absolutely do not pour it off! The precipitated oil should be pumped back into the lubricant to maintain the percentage of base oil and thickener and thus the original properties of the lubricant.

Often, the first thought in this situation is to use a mechanical stirrer. However, this method is not recommended because it alters and destroys the structure of the joints in the lubricant and causes air bubbles to be introduced into the lubricant.
Therefore, if oil separation is observed, it is advisable to use a semi-hard hand spatula and slowly inject the oil in circular motions until all the oil is reintroduced into the grease. In the case of soft grease (NLGI class 0 or 1), a concave depression (“bowl-shaped”) should be formed on the surface of the grease. Conversely, in a stiff grease (NLGI class 2 or 3), form a convex mound on the surface.

Once we know how to open the grease container correctly and remember to inject the separated oil, it is time to discuss connecting the lubricant container to the metering system.

Dosing systems vary according to the parameters:

• the size of the lubricant container,
• the number of production lines to be fed,
• the number of components to be lubricated per shift.

As the topic is very broad, we will focus on dispensing grease from a large barrel using a pressure disc.

There are a few golden rules to follow when installing a metering system:

1. Reduce the total pressure in the system as much as possible. Excessive pressure can cause oil separation, equipment damage or even system rupture.
2. Place the pump as close as possible to the metering station. Shorter connection lengths mean less pressure is required to pump the lubricant.
3. Avoid nodes and t-connectors as they impede the flow of grease and require additional pressure to pump the grease. It is best to use a flexible hose with gradual bends. This is particularly important for PTFE thickened lubricants where excessive pressure and a large number of nodes and t-connectors can cause the thickener to gradually precipitate out and clog the line.
4. Use a large diameter piping system to reduce the pressure needed to pump the grease.
5. If one pump feeds multiple dispensing stations, balance the plumbing. The distance from the pump to each direct dosing location should be relatively equal. A balanced hydraulic system reduces overall system pressure and promotes consistent dosing.
6. Attention should be paid to the pressure at the pump outlet and output. Excessive system pressure can be caused by an incorrect calculation of the pump output pressure. For example, a 20:1 ratio on the pump means that the pressure exerted on the lubricant is 20 times greater than the air inlet to the pump. Adding a pressure gauge on the output side of the pump can eliminate the need to calculate the actual pressure. It is generally recommended to use the lowest possible pumping ratio. In the meantime, it happens that in order to accelerate the flow of the lubricant, this coefficient is increased, resulting in the decomposition of the lubricant.
7. Note that the pumping ratios are averages obtained between the upward and downward movements of the pump piston. The actual pressure will increase above the specified ratio.
8. Prevent residual grease from accumulating on the pressure plate. It is recommended to add a piece of hose with a shut-off valve to the pressure plate vent valve. Grease expelled through the vent valve can then be collected in a clean container for re-use.
9. When the metering system is not in use, it is essential to release the pressure in the metering system, both in the container and in the system. This should help reduce oil separation in the lubricant during production downtime.

By sticking to the above rules, you can be assured of consistent and more efficient lubricant dispensing.