1Lubrication is our world
JOURNAL E D I T I O N 1 / 2 0 0 7
Focus on:Plastics andlubricants
Further topics:High performance underextreme conditions
Reliability at sub-zerotemperatures in refrigera-tion compressors
Tailor-made package for food-processing industry
The chemistry has to be rightSpeciality oils for extruder gears help savecosts and increase operational reliability
Save costs – increase performance – solve problemsBonded coatings improve friction and wear behaviorof plastic components
Lube & Seal, a combination ensuring reliable functionin power transmission technology
Lubricant and radial shaft seal from a single source
High performance under extreme conditionsFaster, higher, further – PFPE lubricants push performance limits
Hot stuffHigh-temperature grease offers new performance range
Reliability at sub-zero temperaturesNew generation of refrigeration compressor oils enableslower operating costs throughout the refrigeration cycle
Exhibitions: Platforms for contacts
Tailor-madeProduct and service packagefor the food-processing in industry
Reader Service
New brochures
Professional tips and hintsCustomer training made by Klüber
Fit for the futureLonger automotive component life attainedwith new special grease
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Contents
PLASTICS
HIGH-PERFORMANCEGREASES
COMPRESSORS
NEWS, SERVICE
2 T R I B O J O U R N A L 1 / 2 0 0 7
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Innovation is today more in demand thanever. It is generally regarded as the pre-requisite for the competitiveness and long-term success of a company in ever morecontested and internationalized markets.On the other hand, the term ‘innovation’appears to be somewhat overused, it hasoften become a mere buzzword andleaves much space for interpretation. Solet’s have a closer look to get it clear whatwe’re talking about.
Klüber Lubrications offers its customers in-novation – and has done so even beforethe word was on everyone’s lips. Alreadythe company founder Theodor Klüber hadsolutions to very specific problems of cus-tomers in mind. In the early 1950ies, hebegan with the development of specialitylubricants – although his existing businesswith mineral oil products and petrol wasflourishing – because he was foresightedenough to realize the industry’s oncomingdemand for such products. And there aremany more examples of creative ideas andpioneering products to be found in the 77years of our company’s history. The trendylabel ‘innovation’, however, has not beenattached to each and every item.So not every innovation is recognized assuch at first glance!
Dear reader,The range of innovations we offer you –even without that label – and, even moreimportant, what these novelties fromKlüber Lubrication can contribute to yoursuccess, is outlined in this edition of Tribo-journal. There is, for example, our Lube &Seal concept, a development partnershipfor power transmission applications aim-ing at optimized service lives and tightnessof seals. Or take KLASS, the Klüber Lubri-cation Asset Support Service helping allkinds of industrial operations to attain prof-itability and quality goals in all kinds of in-dustrial operations, the food-processingindustry being the example referred to inthis edition.
I wish you interesting reading!
Claus Langgartner
Claus LanggartnerSpeaker of the Board,Klüber Lubrication München KG
4 T R I B O J O U R N A L 1 / 2 0 0 7
Speciality oils for extruder gears help save costs and increase operational reliability
Extruder output is steadily being ma -ximised in extrusion and compounding.At the same time, operators are tryingto minimise their investments onprocess technology and operation.Technological advances in recent yearsin screws and drives have doubled thethroughput performance of extruders.As a result, the requirements on the en-tire power train are changing. On onehand, the gears are becoming morecompact and less expensive. On theother, the torque, temperature andloads in extruder gears have increasedas efficiency has improved.
As designs have become more com-pact, the quantity of oil in the gears hasdecreased. Nevertheless, the bestpossible build-up of lubricating filmmust be guaranteed for every drive op-erating mode. While in the past thegears were actually over-dimensionedfor operation, the new generation ofextruder gears frequently work non-stop under full load. Such conditionspush mineral oils to the limit of theirperformance.
When so-called high-torque andhigh-speed extruder gears are beingdesigned, choosing the right oil hasbecome a major factor that influencesadded value and long-term operationalstability. Synthetic oil grades offer manyadvantages here.
Unique features of extruder gears
Extruder gears come particularlyunder strain at the last pair of gearsand on the thrust bearings on accountof high torque and longitudinal thrust.Twin screw extruders additionally haveless design space on account of thesmall distances between the axes ofthe screws. As a result, there are limitsimposed on the design of the last gear
The chemistry has to be right
The requirements to be met by extruder
gears have risen continuously, and thegear oil plays a major
role in terms of performance and
equipment dimensions.Mineral gear oils are in
many ways inferior to synthetic oils. Whenswitching to a better
oil, power loss andwear can be reducedas well as oil change
intervals extended.Service life and
operational reliability of the equipment are
increased while operating costs are
reduced.train and the splitting of forces between the individualscrews. Synthetic oils afford a means of designing wear pre-vention into the drives as they are being developed.
At high longitudinal screw pressure, high forces act on thethrust bearings. Twin-screw extruders are for this reason fittedwith tandem bearings arranged in line. A circulating lubri catingsystem lubricates these bearings with oil. The viscosity of thelubricating oil has to be determined on the basis of the ex-pected operating conditions at the last pair of gears and onthe thrust bearing assembly. The most common viscosityclasses for extruder gears are ISO VG 220, ISO VG 320 andISO VG 460. In a cold start, the oil must be soft enough tobe pumpable and at the same time viscous enough to forma lubricating film. Synthetic oils offer the necessary perform-ance spectrum.
5
Evaluation reveals a substantial reduction in power loss inthe case of synthetic specialty oils.
In a multi-stage extruder gear, this seemingly low im-provement leads to a measurable decrease in power con-sumption. For example, an extruder drive lubricated withpolyglycol oil has a power loss of around 13,500 kW at a rat-ing of 150 kW and an annual operating time of 6000 hours.By comparison, the power loss for a drive operated with min-eral oil is around 18,000 kW. This difference translates intosubstantial savings potential on energy costs.
Longer lifetime
The better frictional performance of the synthetic oilscauses less frictional heat to be generated in the contactzone and hence the lubricating film. At the same time, theseoils have a higher thermal stability. For these two reasons,they age more slowly than mineral oils. Also, less stress isplaced on existing oil cooling systems. Oil life can be ex-tended up to five-fold. In practice, the oil-change interval for
Good selection matters
Mineral oils are mixtures of hydrocarbons of different molecular structure. These structures influence their physicalcharacteristics. For this reason, performance characteristicswithin the group of mineral oils differ, too. Synthetic oils arederived from polyglycol, polyalphaolefin and esters. The tribo logical advantages of synthetic oils over mineral oils include
❚ high thermal and oxidation stability
❚ less change in viscosity over the temperature profile
❚ lower friction values at the gear teeth
❚ high wear protection in bearings and gears
❚ good load carrying capacity in bearings and gears,and
❚ low residue formation.
From the diversity of synthetic base oils and with an in-depth know-how of chemical additives, it is possible to de-velop synthetic oils that offer technical advantages for specificrequirements. In this regard, it is important that the chem-istry of the oils be taken into account when the gears arebeing designed. By using synthetic oils, the extruder opera-tor can save energy in the power transmission and enhancethe operational reliability of the extruder while requiring lessoil changes. All in all, costs will be reduced and the availabil-ity of the plant may be increased.
Saving energy
In recent years, extruder manufacturers have paid in-creasing attention to the reduction of energy losses in powertransmission. This is a further argument speaking in favour ofsynthetic oils with their higher efficiency.
Gear efficiency can be substantially improved by using oilsbased on polyalfaolefins, esters and polyglycols. Tribologicalstudies have shown that different friction coefficients are at-tained at identical operating conditions:
Mineral oils: 0.039 µ Polyalphaolefins, ester oils: 0.022 µ Polyglycol oils: 0.011 µ
These friction values and the results of efficiency studieswere used to establish the power loss occurring with the var-ious oils:
Mineral oils: approx. 2% Polyalphaolefins, ester oils: approx. 1.6% to 1.7%Polyglycol oils: approx. 1.45%
Fig. 1: Compared friction coefficients attained with mineral oil and polyglycol oil (FZG test)
Fig. 2: Compared power losses attained with mineral oil and polyglycol oil (FZG test)
Speed (rpm)
Speed (rpm)
Mineral oil (ISO VG 150)
Polyglycol oil (ISO VG 150)
Mineral oil (ISO VG 150)
Polyglycol oil (ISO VG 150)
Fri
ctio
n co
effic
ient
µ (–
)P
ow
er lo
ss (k
W)
6 T R I B O J O U R N A L 1 / 2 0 0 7
mineral oils is 10,000 operating hours in a standard extruderdrive with an operating temperature of 70 °C. Synthetic oilshave service lives of up to 40,000 operating hours, and insome cases the values are even higher. Analysing used oil of-fers additional security when oil-change intervals are beingdetermined. As a result, numerous oil changes can be dis-pensed with, along with the associated outlay. To an extentdepending on the maintenance intervals for the whole unit,this can also translate to higher availability of the extrusionequipment.
Wear reduction
Gear manufacturers instruct operators on the oil viscositiesto be used. The right oil viscosity ensures that a lubricatingfilm forms also under load. However, viscosity changes withtemperature to a stronger or lesser degree, which is de-scribed by the viscosity index. This change is more pro-nounced in mineral oils than in synthetic oils. The higher theviscosity index, the lower is the change in viscosity acrossthe temperature range for the drive. When the temperaturein the gear changes, the oil viscosity and the conditions forcontinuous build-up of lubricating film also change. In thelong-term, therefore, a high viscosity index equates to lowerwear.
Viscosity indexes of different base oils
Mineral oils: 80 to 100Polyalphaolefins: 130 to 150Ester oils: 140 to 175Polyglycol oils: 150 to 270
Besides the higher load-carrying capacity of synthetic oils,their lesser tendency towards residue formation plays also a major role. Mineral oils that are operated continuously at their limits generate solid ageing residues that increasewear.
Compatibility
Synthetic oils need to be chemically compatible with ra-dial shaft seals, sight glasses, and interior coatings if leaksare to be avoided. The synthetic oils approved by gear man-ufacturers have frequently been tested for their interactionswith the corresponding plastics and coatings.
In extruder gears, the fitted radial shaft seals are primarilymade of the elastomers NBR and FKM. Synthetic hydrocar-bons (polyalfaolefins) are usually compatible with these typesof seals. In the meanwhile, intensive fundamental research
Fig. 3: A common experience – longer service life
Gear data
Input power 750 kW
Revolutions 1500 min–1
With mineral oil, pitting and tooth fracture after 6000 hours,oil sump temperature 70 °C,defective drive
With polyglycol oil after 9500 hours,oil sump temperature 55 °C,functioning drive
7
conducted in conjunction with producers of radial shaft sealshas also led to the approval of ester and polyglycol oils. Thecompatibility is tested both statically and dynamically in orderthat a harmonised system of lubricating oil and elastomerseals may be offered. This makes it much easier to decide to switch from mineral oils to synthetic oils. In cases ofdoubt, individual studies by the oil manufacturer can providesecurity for the customer.
The Lube & Seal cooperation between Klüber Lubricationand Simrit offers the additional benefit of increasing the seallife. (Read also the article on page 15.)
Maintenance – living values
Synthetic oils, and polyglycols in particular, help operatorsworking in a 24/7 production mode with their long-termmaintenance strategies:
❚ safeguarding plant availability
❚ initiating preventive maintenance measures
❚ increasing operational reliability
❚ increasing productivity
❚ increasing machine life
Cost/benefit ratio
The pure purchase costs per litre of synthetic oil, espe-cially for specialties, may be higher than those of mineral oil.However, when viewed over the entire lifetime of the equip-ment, the operating costs are much lower on account of theaforementioned technical advantages of synthetic specialtyoils over mineral oils. Costs for oil change and oil disposalare reduced due to the longer oil change intervals. Further -more, the right synthetic oil can help to save energy costsand reduce wear in the machinery. Klüber Lubrication will bepleased to conduct detailed cost-benefit analyses togetherwith the customer.
Your benefit:
❚ Less wear
❚ Higher efficiency
❚ Higher drive torque
leading to
❚ longer oil change intervals
❚ less maintenance and repairs
❚ energy savings
❚ lower operating costs
Fig. 4: Possible oil change intervals
Dipl. Ing (FH) Sebastian Homborg
Industrial Group Manager
Rubber and Plastics Industry
Klüber Lubrication München KG
Operating life of oil (hours)
Mineral oil
Polyglycol oil
PolyalphaolefinO
il su
mp
tem
per
atur
e (°
C)
8 T R I B O J O U R N A L 1 / 2 0 0 7
Together with two major OEMs from the plastics industry, Klüber Lubrication has conducted extensivefield tests. They showed that large extruder gears lubri-cated with the polyglycol special oil Klübersynth GH 6-220 run longer at lower cost than with the previously used mineral oil.
Companies involved:Thielenhaus Technologies GmbH, Wuppertal; Business Unit Köllmann Gear, a leading German manufacturer of single-worm extruder gears
Kiefel Extrusion GmbH, Worms, a leading German manufacturer of plastic processing technology, especiallyof blow moulding machines
Test description
❚ Seven-layer blow moulding machine with seven extruders
❚ Two extruders fitted with single type of gears, max. power 56 kW
❚ One set of gears filled with previously used mineral oil
❚ A second set of gears fitted with polyglycol-resistantmaterials (inner paint and seal), filled with KlübersynthGH 6-220 (polyglycol)
❚ Measurement of oil sump temperature at identical load onboth gears. Lower oil sump temperature indicates thatless friction heat is being generated in the gears. Bymeans of the WTPlus program of FVA (Research Associ-ation for Power Transmission Engineering), these meas-ured data can be used for calculating the gears' efficiency.In combination with the experience gained in practice, the
oil sump temperature also allowsconclusions on equipment life. Themeasurements are made with aspecifically calibrated sensor (mea-suring incertainty 0.14 °C).
❚ Oil sump temperature is comparedwith ambient temperatures of the individual gears.
Results
The oil sump temperature of the setof gears lubricated with the polyglycoloil was 2.8 °C lower at the operatingpoint than that of the gears filled withmineral oil. To enable a direct conclu-sion on the efficiency, the efficiencyunder full-load conditions was deter-mined (WTPlus program by FVA). Thecalculated efficiency attained withKlübersynth GH 6-220 was 97.168 %,i.e. 0.434 % above that of mineral oil.
Benefit: cost reduction
For mineral oils in extruder gears, anoil change is recommended every6000 operating hours. Due to the oil sump temperature measured in the test, the oil change interval can be much extended for Klübersynth GH 6-220, namely to 20,000 operat-ing hours.
For gears operating under less thanfull load, this constitutes a major bene-fit in terms of less costs for buying andstoring oil and for maintenance. Ingears operating under full load, energycosts are also reduced.
For the gears under test, for example, a yearly cost benefit of approx. 500 Euro can be generated.For the blow moulding plant as awhole, this would mean savings of upto 3,000 Euro per year, amounting toup to 15,000 Euro in five years.
From practice for practice
Squeaking noises, high friction losses and wear - if you work with plastic parts that are subject to
high loads, you know these problems all too well. But this needn't be so: our Klübertop bonded
coatings offer a clean, reliable and flexible alternative to traditional lubrication. Even in parts where
regular relubrication is either not possible or very problematic, friction can be dramatically reduced,
particle emission limited and component life significantly extended. A soft-feel effect, a modifiable
surface structure and individual coloring enable you to design your components the way you wish.
And the smooth planning and execution of your individual solution is ensured through the able as-
sistance of our experts. Just call us, and together we will prolong component life with bonded coat-
ings made by Klüber.
For more, see feature article on page 10
Longer service life with bonded coatings from Klüber
10 T R I B O J O U R N A L 1 / 2 0 0 7
ficient, though not fully utilized, alternative to the aforemen-tioned methods of minimizing friction and wear on plasticcomponents.
Minimizing friction and wear
The following table allows an evaluation by comparing theuse of bonded coatings for plastic components with incor-porated and traditional lubrication (Fig. 1).
The advantages of bonded coatings are obvious. Besidesclean and low-maintenance lubrication, the individualized
The incorporation of lubricating sub-stances in polymer materials is state-of-the-art. Besides solid lubricants likeMoS2, wax, PTFE fibers, powders orother lubricating polymer particles, oilscan also be used as fluid lubricants.Greases and oils continue to be usedfor subsequently minimizing friction,wear or noise behavior of plastic com-ponents. In this context, dry lubricationby means of bonded coatings is an ef-
Bonded coatings improve friction and wear behavior of plastic components
Save costs – increase performance –solve problems
The use of plastic components for applica-tions that are subject to
tribological stress is becoming more popular,
e.g. in the automotive industry. Thus, higher
demands are made on thefriction and wear behavior
of such materials. Oneway of optimizing the
performance of a component is to
incorporate lubricatingsubstances into the
plastic. Of course, traditional lubrication with greases or oils is also suitable for many
applications. An alternative method is
the application of wearand friction reducing
bonded coatings. The advantages and
possibilities offered bysuch bonded coatings
are explained in this article.
▲
▲
Lubrication method
1) Integrated lubrication
2) Subsequent lubricationwith grease, oil etc.
3) Dry lubrication withbonded coating
Clean-liness
++
– –
++
Mainte-nance
++
– –
++
Impairmentof
material
–
–/o
++
Functionality,lifetime
lubrication
+
+
+
Adaptabilityto
problem
+
++
++
Expendi-ture
+
++
–
Fig. 1
11
selection of the suitable product for the specific applicationcan be mentioned in this context. Especially in the case ofproblems occurring suddenly during use, like elevated wearor creaking and squeaking noises of unfavorable materialcombinations, a bonded coating can solve the problem in aquick and uncomplicated way. The use of bonded coatingsis recommended when dry lubrication at low to mediumloads is required and/or if a problem has to be solved quicklywith the currently used plastic.
Composition and functionality of bonded coatings
The performance of a bonded coating in terms of chemi-cal stability is determined by the binder. State-of-the-artbinders include physically hardening resins, highly cross-linked single or multi-component resins based on poly -urethane, acrylate or phenol/epoxide. Suitable cross-linkingagents are isocyanate, melamines or silanes. Because elas-tic components deform when exposed to mechanical load,the binder has to show adequate elasticity. Short-chain andhard binders may break under load and cause prematurewear. To achieve optimum lubricating properties, solid lubri-cants like polytetrafluoroethylene (PTFE), MoS2, graphite andwaxes are used alone or in combination.
A fluid consistency is obtained by using organic solventsor water. Due to tightened ecological regulations, in terms ofexhaust air purification for the use of lacquers and chemicalsubstances, there is an increasing trend towards water-mis-cible bonded coatings.
Selection criteria
The selection of a bonded coating is not only determinedby its functionality. When coating polymer materials, the thermal stability of the material must also be taken into consideration. Thermosensitive materials like ABS or POM,for example, can only be coated with bonded coatings whichharden at low temperatures. In the case of thermally stablepolymer materials like PPS or PEEK, a much wider range of high-performance, thermosetting bonded coatings isavailable.
Bonded coatings have a lot to offer
Bonded coatings can significantly increase the func-tionality of polymer materials. This is illustrated in the follow-ing examples:
A) Better friction behavior
Bonded coatings reduce the dispersion of friction valuesand the friction of the plastic by up to 70 % (Fig. 2), and atthe same time minimize undesired stick-slip.
At different temperatures the friction behavior of thebonded coating may change in a positive or negative way(Fig. 3). The decisive factors are the softening point of thebinder matrix, its basic hardness and the solid lubricantused.
Bonded coatings can have a positive effect on the frictionbehavior of plastics and even adjust the friction coefficientto the required standard. The decisive factors are the typeand quantity of solid lubricant used.
Fig. 2: Comparison of friction behavior of uncoated and coated plastic determined on the UTI friction and wear test rig (see Fig. 7a).Reference: PA 66 40% GF uncoated/H1/, bonded coating /H2/
Fig. 3: Frictional behavior of different bonded coatings at room temperature and 100 °C /H3/ determined on UTI friction and wear test rig; Hertz pressure (–) 186 N/mm2
PA 66 40% GF uncoated
coated with bonded coating
Coating A
Coating B
Coating C
Coating D
PA 66 40%GF
Duration of test (h)
f F
irctio
n co
eff.
f friction coeff.RT 100°C
12 T R I B O J O U R N A L 1 / 2 0 0 7
The friction behavior of a bonded coating is relatively independent of the modification of the individual type of plastic. Therefore, bonded coatings cannot only reduce fric-tion but also standardize the friction behavior of differenttypes of plastics (Fig. 4).
B) Wear on the opposing body
In the case of fiber-reinforced plastics, in particular, wearmay occur on the opposing body when subjected to friction.A bonded coating can eliminate wear (Fig. 5).
C) Longer lifetime
Under high dynamical loads the bonded coating can actas a sacrificial layer for the polymer material and thus signif-icantly delay wear on the component (Fig. 6). Decisive factors for the wear resistance of a bonded coating are the type of binder and solid lubricant used as well as the pigment volume concentration.
The UTI test rig (Fig. 7a) and the OGP test rig (Fig. 7b)serve to examine the friction and wear behavior of oscillatingsliding partners.
In both cases the flat body fixed on the running surfaceoscillates against a stationary opposing body. Unlike the UTItest rig/H5/ working with a low stroke of 5 mm and a ball asopposing body, the oscillating plate test rig OGP uses a vari-able geometry of the opposing body. Ball, line or areageometries can be used. The sliding distance is also con-siderably longer with a stroke of 50 mm.
D) Surface roughness to measure
Proper selection of the filler used for the bonded coatingallows modification of the surface structure of a plastic (Fig. 8). In this way, the bonded coating has a positive effecton the appearance and tribological behavior of a componentas well as on how it feels to the touch.
Fig. 4: Friction behavior of different plastics with and without bonded coating (reference: H4)
Fig. 5: Wear on the opposing body determined on UTI friction andwear test rig (reference: H5)
Fig. 6: Wear test on the OGP test rig (see Fig. 7b) – The bondedcoating increases wear resistance and extends the service life (reference: K1)
3. + slip coating
2. + slip coating
1. + slip coating
3. PA 66 40% CF
2. PA 66 40% GF
1. PA 66 not
reinforced
PA 66 40% GFcoated with
PTFE coating
PA 66 40% GF
Ball abrasion mm3 x 10–3
f friction coeff.RT 100°C
PPS + slip coat
PPSuncoated
test distance in meters (m)
13
Factors influencing the performance of bonded coatings
Besides the chemical composition of a bonded coatingthere are other factors which have a great effect on its performance. The surface polarity or energy of the polymermaterials plays a major role in both the wetting of the sub-strate and the adhesion of the bonded coating. The higherthe surface energy of the plastic, the better its coatability (Fig. 9).
Plasma pretreatment increases the surface energy of theplastic by embedding oxygen molecules and thus creates aconsiderably better basis for good adhesion of the bondedcoating. The higher the adhesion of the bonded coating onthe polymer material, the better the performance to be ex-pected under dynamic loads (Fig. 10).
Plastics with already improved sliding properties shouldnot be provided with an additional coating because the ad-hesion of the bonded coating will probably be insufficient.Another important parameter in achieving optimum slidingsurfaces is the method used to apply the bonded coating.State-of-the-art coating of large components is spraying bymeans of compressed air, electrostatics or HVLP (High Vol-ume Low Pressure) spray guns. For small components, ap-plication by means of spray drum or immersion centrifuge isused. The selection of the suitable application method is pri-marily determined by the requirements, the componentgeometry, the size and the economic efficiency. Coating canbe performed by contract coating companies.
Fig. 8: Different surface roughnesses (reference: K2)
PP
ABSPOM
PEEK
PBTPPS
PET
PEPC
PETP
PA
PMMA
Fig. 9: Surface energies of different plastics – the higher the surfaceenergy of a plastic, the better its coatability
Fig. 7a: UTI test rig /H5/
Fig. 7b: OGP test rig /K1/
Coating D
Coating C
Coating B
Coating A
PA 66 40% GF
Roughness RA
Coatabilityuncriticalcritical
Sur
face
ene
rgy σ
(mN
/m)
14 T R I B O J O U R N A L 1 / 2 0 0 7
Summary
Bonded coatings not only solve tribological problems –which often do not arise until series application – in a quickand clean way, but also offer new possibilities of modifyingthe surface of plastics. To achieve the optimum performanceof a bonded coating, the adhesion to the substrate as wellas the application method is of major importance in additionto functional requirements. Based on the variety of raw materials and the range of different bonded coatings offeredby Klüber Lubrication, users of plastic components canchoose a combination suitable to improve performance intheir applications. This also offers new business opportuni-ties to coating companies.
Fig. 10: Friction and wear curves of a bonded coating with and without plasma pretreatment (reference: K1)
Benefits for your application
❚ Longer component life
❚ Minimized noise through prevention of stick-slip
❚ Better process security
❚ Less maintenance
❚ Easy modification of surfaces
❚ Color or UV coding of components
Marion Karden-Ott
Product Manager Bonded Coatings for Rubber and PlasticsKlüber Lubrication München KG
References
/H1/ – /H5/ HSG-IMAT, Stuttgart, Arbeitskreis Gleitlacke/K1/ Klüber Lubrication München KG, OGP-test rig/K2/ Klüber Lubrication München KG, Internal tests
Units
f Friction coefficient[ N ] Assembly forceT Temperature °Ct Time h
No pre-treatmentABS + slip coating
Friction force curve
Distance (m)
Distance (m)
Distance (m)
Distance (m)
Test 1
Test 2
Test 3
Test 4
Test 1
Test 2
Test 3
Friction force curve
Wear curve
Wea
r d
epth
(µm
)
VW
ear
dep
th (µ
m)
µ µ
Wear 1
Wear 2
Wear 3
Wear 4
Wear 1
Wear 2
Wear 3
Wear curve
Plasma-treatedABS + slip coating
15
Freudenberg Simrit and Klüber Lubrication, worldwideleading manufacturers of radial shaft seals and speciality lubricants, respectively, have combined the know-how intheir specific fields to create the Lube & Seal concept, whichis synonomous with comprehensive technological compe-tence. With this concept, both companies offer developmentpartnerships for the power transmission industry, aiming atproviding comprehensive solutions with optimally tunedcombinations of seals and lubricants from a single source.With Lube & Seal, the reliability of machines and drive unitscan be considerably improved and their lifetime extended. Furthermore, design and R&D engineers have a single con-tact person with whom to cooperate for the development ofa tested high-end solution.
Reliable radial shaft seals (Fig. 1) are a key component inmany industrial gears and can impact service life, machineavailability, the need for maintenance, as well as the qualityand hence the image a machine supplier has with his cus-tomers. The technical requirements for the seal are clearlydefined: it is expected to reliably ensure tightness for a longtime even while subject to severe physical, tribological and
chemical stress. A decisive factor forthe durability of a seal is the reaction ofthe sealing material to the lubricantused, which has received little attentionin the design of gears and the devel-opment of gear oils.
Since 2004, DIN 51517 has beenexpanded to include the interaction ofthese two chemical worlds. The spec-ification of this DIN standard stipulatesa compatibility test between the lubri-cant and NBR 28, a reference elas-tomer. Unfortunately this test does notreflect real-life conditions and is there-fore not really helpful in seal and lubri-cant selection. The elastomers used inpractice are normally different from thereference elastomer in the standard.For this reason, gear oils that havebeen tested and approved in accor-dance with this DIN are not always suit-
Lubricant and radial shaft seal from a single source
Lube & Seal, a combination ensuring reliablefunction in power transmission technology
Sealing industrial gears by means ofSimmerring® radialshaft seals is highlycomplex under tribological aspects. Experience has shownthat lubricants can dramatically influencethe elastomer andsealing lip. The require-ments of low friction,less wear and goodcompatibility are noteasily met as the twoseparate worlds of lubrication and elas-tomers collide. Still,both lubricants andelastomers are only regarded as C com-ponents by purchasersand designers in thefield of power trans-mission technology.The reliable function of this tribo-system,however, is a vital factor for the overallperformance and service life of aggre-gates as a whole: these C components of the tribological system have, in fact, an A function!
16 T R I B O J O U R N A L 1 / 2 0 0 7
preventing abrasion and wear. However, it works only if the lubricant and the sealing lip elastomer are compatible. Ifthey are not, decomposition or hardening of the sealing lip may be the consequence, due to depolymerization or carbon build-up.
To reduce friction and wear to a minimum and maximizecomponent life, the seal and the lubricant must form a func-tional unit. At the same time, the tribological system must bedesigned with a view to preventing running-in damage to theshaft (Fig. 3 a).
The lubricant must meet several requirements: it shouldform a separating film in the bearing, the teeth, and at thesealing lip to reduce damage to the friction bodies whichmay consist of various materials. It should reduce friction andincrease the gears' efficiency, improve the dissipation of heat,and protect the components against corrosion. High-perfor-mance lubricants can meet all of these requirements andsubstantially extend the service life and efficiency of driveunits.
C components safeguard A function
The importance of looking into all aspects of the tribo-system becomes obvious through an analysis of cost dis -tribution. Both the sealing ring and the lubricant account forvery little of the manufacturing cost of a drive unit. When analyzing complaints, however, e.g. those regarding gears,it becomes apparent that inadequately designed seals causea high proportion of equipment failures. If the tribo-systemformed by seal and lubricant is not optimized for its particu-lar application, leakage or even total breakdown of a driveunit may be the consequence. In a nutshell: these classicalC components clearly serve an A function! While lifetime de-signs are the daily bread of engineers they have nothing butpersonal experience to fall back on when selecting seals. Anunlucky choice of this component can have severe conse-
able for use with the seals found inpractice. Moreover, purely static con-siderations are not sufficient; dynamictests should also be conducted. Theanswer to these needs is offered by Freudenberg with its Lube & Sealservices.
A radial shaft sealing ring (Fig. 2),simply put, works like a small pumptransporting lubricant or gas to belowthe sealing edge and back to the oilreservoir. This ensures sufficient lubri-cation between shaft and sealing lip,
Fig. 1: Lube & Seal caters for the three tribo-systems present ingears: teeth, bearings and sealing lip
Fig. 2: A radial shaft sealing ring works like a small pump transporting lubricant or gas to below the sealing edge and back to the oil reservoir. This ensures sufficient lubrication between shaft and sealing lip, preventing abrasion and wear.
+
17
quences for the user as well as for the warranty obligationsand image of the manufacturer.
Lube & Seal offers R&D and design engineers for drivetechnology as well as their purchasers the first opportunity touse an accurately tuned and tested seal-lubricant system. Ateam jointly set up by Simrit and Klüber Lubrication haspooled their combined know-how for seals and speciality lu-bricants. This Lube & Seal team supplies radial shaft sealsand lubricants from a single source and offers comprehen-sive services in all matters regarding this highly complex tri-bological system. The specialists on the team deal with thesystem as a whole, which consists of the three individualtribo-systems
❚ gear teeth – lubricant
❚ bearings – lubricant
❚ sealing lip – shaft – lubricant.
The objective of the Lube & Seal approach is to minimizethe failure rate over the unit’s lifetime to ensure that a failureoccurs only when the definite wear or age limit of the lubri-cant is reached. Lube & Seal is aimed at substantially widen-ing the ‘bathtub’ curve describing the failure rate (Fig. 4).
Tested comprehensive solution offers high reliability
The Lube & Seal team achieves this objective through in-novation: specialty lubricants from Klüber coupled with sealsof the latest design and materials by Simrit. Once a particu-lar combination of seal and lubricant has been developed, itis tested in the lab or the drive unit provided by the manu-facturer. These tests include standard tests as well as dy-namic tests specifically designed for the expected operatingtime, operating temperature and shaft speed of the driveunit. 240 h DIN tests, low-temperature tests, low-tempera-
Fig. 3b: Well tuned tribological system at sealing lip / shaft
ture torque tests, friction or tempera-ture measurements can be performeddirectly at the seal lip. Of course, theduration of long-term tests depends onthe requirements in practice, and lubri-cant condition analyses are also made.
All this ensures that the solution thatis eventually chosen has been thor-oughly tested and offers the user amaximum of reliability and durability.Since this approach looks at the sys-tem as a whole, development times arereduced, which in turn results in com-petitive edge for the manufacturer ofthe drive system. Due to their system-atic development, these solutions en-able much more accurate estimates forwarranties.
Fig. 3a: Poorly tuned tribological system at sealing lip / shaft
=
18 T R I B O J O U R N A L 1 / 2 0 0 7
Fig. 4: The objective of the Lube & Seal approach is to minimize the failure rate over the unit’s lifetime to ensure that a failure occursonly when the definite wear or age limit of the lubricant is reached.Lube & Seal is aimed at substantially widening the ‘bathtub’ curvedescribing the failure rate.
Your benefit:
❚ Reliable operation of the system as the lubricant is optimally tuned to suit the sealing ring and the drivesystems
❚ Longer component life due to low friction and wear
❚ Competitive edge and cost savings due to reduceddevelopment times
❚ Better estimates for warranties
Dipl.-Ing. (FH) Sebastian Homborg
Industry Group ManagerRubber and Plastics Industry
Klüber Lubrication München KG
Erich Prem
Product Development General Industry
Freudenberg Simrit KG,
Early failures Occasional failures Failures dueto wear / ageing
IST = today
GoalLifetime
Failure rate Practical experience
In a project conducted with a customer, the lifetime of a radial shaft seal (elastomer 75 FKM 170055) used in com -bination with Klübersynth GH 6-220 (polyglycol oil) was extended to 20,000 operating hours – a reproducible success! The unit was a worm gear unit with a drive shaftoperating at a maximum speed of 1750 rpm.
All in all, Lube & Seal means better reliability due to longerequipment life, less failure for the users of drive systems, anda higher quality for the manufacturer. This is especially truefor high-end long-life solutions operating at high rpm andhigh peripheral speeds, or under particular environmentalconditions; Lube & Seal offers the support of a developmentpartnership that makes the ambitious objectives of gearmanufacturers attainable.
19
Frequently, there is no economicallyviable alternative when long lubricantlives are required under extreme orstrongly fluctuating operating condi-tions, the influence of chemicals orchanging pressure. The longer lubri-cant life and extended maintenance in-ter vals more than compensate for thehigher material costs.
In the box on page 21, the bene-fits of PFPE lubricants are summar-ized.
Faster, higher, further –PFPE lubricants push performance limits
High performance under extreme conditions
“Only constantly in-creasing productivityand innovations ensurebusiness success andcompetitiveness in theglobal market.” Theseor similar lines intro-duce many a paperdealing with the eco-nomic framework inwhich today’s machinebuilding sector exists.For bearings andguides this means operating under higherloads and tempera-tures, at higher speedsand with longer main -tenance intervals. Consequently, the lubri-cants are expected towork under more tax-ing conditions than before. Under extremeoperating conditions,lubricants based onperfluorinated poly-ethers (PFPE) oftenoffer the best solutionsfrom both a technicaland economical aspect: they make aneffective contributionto meeting the tightening requirementsin terms of speed andproductivity. Looking ata few key parameterscan make lubricant selection much easier.
In contrast to all other fully synthetic lubricants, PFPE oils do not contain any carbonhydrogen bonds. Where these bonds are absent, most known chemical ageingprocesses are prevented, and this is exactly the reason why products based on PFPE score over other lubricants in terms chemical and thermal stability. PFPE oils can coverapplications at temperature ranges from below – 80 °C tofar above 300 °C. Extreme ambient conditions and contactwith aggressive media do not normally affect the perform-ance of PFPE lubricants. Especially at high temperatures,PFPE lubricants live significantly longer than “traditional”products in many applications.
20 T R I B O J O U R N A L 1 / 2 0 0 7
The success of PFPE productsbegan roughly four decades ago whenthe BARRIERTA® brand was intro-duced. This new product class was thefirst to enable long-term lubrication attemperatures greatly exceeding 200 °C.In some applications, e.g. in the man-ufacture of corrugated cardboard, thebenefits attained were so striking that the very design of the corrugatingroller with its complex oil circulationsystem could be changed. Today, mostcorrugating rollers operate with PFPE-greased bearings at temperatures upto 200 °C. As a recent development,PFPE lubricants with an NSF-H1 ap-proval for use in the food-processingindustry are also available. This is a fun-
damental step towards new and innovative machine designsin this branch of industry.
Which PFPE lubricant for which requirements?
The range of PFPE lubricants, especially greases, has continuously grown over the past few years. While there usedto be only a limited number of mostly standardized multi -purpose products, today OEMs and operators can choose from a vast array of PFPE greases with different properties.But what are the characteristics that help the user determine“what’s what” and compare various products? Besides manufacturers’ recommendations, there are three major criteria that may be used for the various fields of applica-tion: the type and viscosity of the oil, the type of thickener and the additives.
Influence of base oil and base oil viscosity
For the manufacture of PFPE greases, different base oil types with different viscosities and viscosity indexes are used, depending on the application. The viscosity indexdescribes to what degree the viscosity of the fluid decreaseswith rising temperature. As guidance values, Klüber Lubri-cation always states the viscosity of its greases at 40 °C and100 °C. This makes it easier for the user to compare the var-ious products. For applications at very high temperaturesthere is a rule of thumb saying that the viscosity of a greaseshould not fall below 20 mm2/s at 100 °C. Such greases willnot suffer excessive evaporation losses of the oil, which inturn safeguards a sufficient lubricant film and thus preventspremature wear. If the lubricated component is also regularlyexposed to low temperatures, or if high speeds must be al-lowed for, a lower viscosity is normally recommended,namely one not exceeding 200 m2/s at 40 °C. Klüber Lubri-cation provides specific data for each product.
Typical lifetimes of PFPE greases compared with other grease types, based on typical L10 runtimes obtained on FAG-FE9 and SKF-ROF test rigs.
Minerial oil grease
(h)
(°C
)
Ester grease PFPE grease
21
Summary
Before opting for a particular PFPEgrease, the user should check if aproduct made specifically for the purpose of the application might not offer additional value comparedwith a standardized multi-purposePFPE grease. A rough assessment of the product concept, by means ofthe mentioned criteria, as well as of the grease’s key data narrows downthe choice. It then makes sense to re-quest application-specific consultingfor product selection. Klüber Lubrica-tion offers on-site practical supportduring testing and putting into opera-tion of the lubricant. If product selec-tion is guided in this way, savings andhigher efficiency can be reached reli-ably in a short time.
A decisive factor: the thickener type
Most PFPE greases are thickened with PTFE (polytetra -fluoroethylene), which suitably complements these high-quality oils and offers good lubricating characteristics in itsown right. However, not all PTFEs are the same. Differentdegrees of grinding and different chemical chain lengths leadto a variety of product characteristics. Therefore, PFPE/PTFEgreases can have different compositions and be manu -factured in different ways to suit varying requirement pro-files; consequently, they may be found in high-speedbearings in electric motors as well as in the shut-off valves ofchemical containers. Problems of incompatibility with sealsor sensitive materials are extremely rare. Furthermore, somePFPE/PTFE greases are permitted for use in the food-pro-cessing industry.
At permanent temperatures above 260 °C, mineral thick-eners such as aerosil or inorganic solid lubricants should begiven preference since the upper temperature limit of PTFEthickeners is exceeded. PFPE greases with metal-soapthickeners are more rare, not least because of their com-paratively limited temperature hardness. However, productswith metal-soap thickeners are more easily removed fromsurfaces with the aid of conventional cleaning agents, whichmakes them more compatible with painting processes.
Additives provide corrosion protection
PFPE lubricants normally have a good load-carrying capacity. When containing a suitable additive, they can alsooffer good protection against corrosion. But not all PFPE lubricants were designed with an anticorrosive effect in mind. Users should therefore make sure to use products withsuitable additives when choosing lubricants for applicationsin corrosive environments, e.g. where humidity cannot beprevented.
Dr. Wolfgang Sammer
Product Manager for fluorinated lubricantsKlüber Lubrication München KG
Benefits of PFPE greases
Long operating times
❚ at high operating temperatures (300 °C and above)
❚ at pronounced temperature fluctuationsabove 200 °C
❚ in the presence of aggressive media
Flexible uses
❚ due to excellent compatibility with many materials
❚ due to excellent compatibility with seals
High degree of safety
❚ contain no toxic substances
❚ are not flammable
22 T R I B O J O U R N A L 2 / 2 0 0 6
Hot stuffHigh-temperature grease offers new performance range
Where there’s a baking oven, there’s heat – whether athome or in a factory. If an oven can be operated convenientlyand without problems does not least depend on lubricants,for instance those used in the ball and roller bearings or linearguides of the baking tray extension mechanism.
Klüberalfa HPX 93-1202 is a new special grease with NSF H1 approval for applications in the food-processing industry. Operating temperatures up to 300 °C pose noproblem, not even in the long term. Previously used greasesusually went along with a loss of performance due to lubri-cant starvation, while Klüberalfa HPX 93-1202 has a baseoil with a particularly low evaporation rate, ensuring lubricityover an extremely long period of time. The enduring lubricityenables guide mechanisms in ovens to run smoothly andwith good dampening for a long time, too. This marks an increase in performance which the manufacturers of house-hold or industrial ovens can market as a longer service life oftheir components and equipment.
For more information, use the reader service on page 29.
SE
RV
ICE
SAFETY
QUALITY
KLASS: The carefree,all-around cost-saving package
from Klüber Lubrication
Production processes in the food-processing industry are highly sensitive. Using high quality lubricants is the first step in protectingthose processes. But a supplier in the food and beverage industrymust offer more than high-quality lubricants – service and supportafter the sale are critical. Our Klüber Lubrication Asset Support Service program (KLASS) offers a complete review of your currentlubrication program and identifies ways to improve operational relia-bility, extend relubrication intervals, free-up maintenance hours andmore. And the results are impressive. Customers using KLASS can enjoy,for example, a downtime reduction of more than 5%, a reduction inthe number of lubricants by 40%, and a potential increase in plantavailability of 35%. The production output per day is now consider-ably higher.
If you’d like to know more about how Klüber might help you reachyour operational objectives, visit us at www.kluber.com.
We’ll design a KLASS package just for you!Just call us: +49 89 7876-404
For more, see feature article on page 28
23
The intense contact between theammonia and the lubricating oil in refrigeration compressors constitutes a great challenge. The unsaturated hydrocarbons and the sulphur com-pounds contained in mineral oils mayreact with the aggressive refrigerantammonia. Due to this chemical reac-tion the oil gradually becomes darkeruntil, eventually, it turns black. The re-action products, which are insoluble inthe oil, remain in the compressor or therefrigeration cycle (mainly in the evapo-rator and the condenser) as residues orsludge. These residues may bringdown refrigeration plant efficiency (dueto reduced heat transfer in the heat exchangers) and noticeably affect op-erational reliability. Experience showsthat blackening and acidification of theoil can be accelerated in particular bythe presence of air and water in the re-frigeration cycle (up to 3 % of water ispossible). In addition to that, abrasivewear caused by oil sludge may directlyattack various compressor compo-nents. Also, the oil filter and separatorare under increased strain and aremore susceptible to clogging. All thisleads to a reduced lifetime of the com-ponents, a drop in efficiency and in-creased operating costs.
“Cleaned” oil prevents sludgeformation
A solution can be found in the use ofhydrogenated mineral oils or syntheticlubricating oils. Klüber has taken themineral oil route with Klüber SummitRHT-68, a lubricating oil on the basis of a paraffinic, hydrogenated mineral oil developed for use in ammonia re-frigeration plants with evaporator tem-peratures down to – 35 °C. The hydro-genation of the base oil (also called“hydrotreating”) removes unsaturatedand sulphur compounds from the oil.
Reliability at sub-zero temperatures
Whether a refrigerationcompressor is used in abrewery, an ice rink orfor air conditioning: itslubrication has a majoreffect on the reliabilityand the efficiency of therefrigeration plant as awhole. The widely usednaphthene-based mineral oils do not always meet the strin-gent requirements oftoday: used in smallerquantities than previ-ously, they have to withstand higher temperatures, higherpressures and shorterrecirculation cycles. At the same time, compressor operatorscall for longer main-tenance intervals inorder to reduce costs.Especially developedrefrigeration compres-sor oils ensure the reliable operation ofammonia refrigerationcompressors and helpto reduce operatingcosts. With the aid of in-depth consulting, oil analyses and hands-on support, oil change -over can be madewithout problems.
Thus, the oil is being “cleaned” and becomes less reactivewith ammonia. Changing from a naphthenic mineral oil tothis type of oil constitutes no problem at all.
The same goes for Klüber Summit RPA-68, a fully synthetic lubricating oil on the basis of polyalphaolefin and alkylbenzene. This oil was developed especially for lowevaporator temperatures down to – 53 °C when, due to theirhigh pour point, mineral oils are no longer capable of flowing.Finally, Klüber Summit R-200, is not only suitable for use withammonia, but can also be applied in combination with CO2,propane or butane. As a fully synthetic lubricating oil on thebasis of polyalphaolefin, it is NSF registered for use in thefood processing industry and is suitable for evaporator tem-peratures down to – 50 °C.
Both synthetic products contain very chemically stablebase oils. Their high resistance to reaction with ammoniaprevents blackening of the oils, a phenomenon that is verycommon with conventional mineral oils, and undesirableresidue formation in the evaporator, thus avoiding unplanneddowntime and increasing the efficiency of the entire refriger-ation plant.
.
New generation of refrigeration compressor oils enableslower operating costs throughout the refrigeration cycle
24 T R I B O J O U R N A L 1 / 2 0 0 7
charged with 200 l of mineral oil operated for around 7,000service hours per year. The operator had to replenish around300 l of oil per year, about 1.5 times the filling quantity. Whenchanging to a hydrogenated mineral oil, the refill quantity wasreduced by up to 70 %.
Extending oil change intervals
As it is the low-molecular constituents of the mineral oilwhich evaporate the fastest in the compression chamber, oilviscosity gradually increases over a period of time. Apartfrom the viscosity increase, blackening of the oil and sludgeand residue formation may be other reasons for excessiveageing of the oil. All this inevitably leads to frequent oilchanges, which interrupt normal operation and can be verycostly.
Reducing oil consumption
The quantity of oil carried over fromthe compression chamber into the refrigeration cycle, the so-called oilcarry-over, depends, among others, onthe evaporation tendency (vapor pres-sure) of the oil at the relevant dischargetemperature (sometimes clearly above100 °C). A high oil carry-over, causedby the comparatively high evaporationrate of a naphthenic mineral oil, maylead to excessive oil consumption andincreased maintenance requirementsdue to frequent oil top-up. Both phe-nomena lead to increased operatingcosts. Here, too, hydrogenated or fullysynthetic oils offer a satisfactory solu-tion: Highly refined, chemically stablebase oils clearly reduce oil carry-overas compared to conventional mineraloils, thus contributing to a reduction inoil consumption of the compressor. Apractical example illustrates the poten-tial savings: A refrigeration compressor
Deposits can reduce refrigeration efficiency
Picture: Grasso GmbH RT, Berlin
25
Highly refined and specially formulated mineral and syn-thetic oils do not contain these volatile oil constituents.Therefore, oil viscosity remains stable over a long period oftime, permitting oil change intervals that are up to four or fivetimes longer. The operator of a refrigeration compressorwhich was lubricated with naphthenic oil (ISO VG 68) meas-ured a viscosity increase of the oil from 68 to 105 mm2/safter only 2,000 service hours. Changing over to syntheticoil en abled him to extend oil lifetime to six times that of themineral oil fill.
Oil changeover without losses
Despite the undeniable advantages offered by syntheticoils, there is still a lot of uncertainty regarding changeover tothese oils, for example regarding compatibility with seals.Naphthenic oils often cause seals to swell, while some syn-thetic oils, in particular PAOs (polyalphaolefins) have the con-trary effect and may lead to seal shrinkage. Especially inammonia refrigeration compressors where neoprene sealsare often used, leakage may occur following changeoverfrom a naphthenic lubricating oil to a PAO. In this instance,Klüber Lubrication offers a special oil, which considerablysimplifies changeover: The PAO used is mixed with alkyl-benzene, where the shrinking effect of one constituent isneutralized by the swelling effect of the other, achieving aneutral behavior towards sealing materials. Greater care hasto be taken when changing from a naphthenic oil to a purePAO with seal shrinking effect. Pure PAOs, such as the oneused for Klüber Summit R 200, may cause a seal which has
swollen in contact with the naphthenicoil to shrink, which may lead to leakageat O-rings in the housing or at face andshaft sealing rings. When changingover to Klüber Summit R 200 (one rea-son to choose this product may be itsNSF approval for the food processingindustry), operators are advised to re -new any O-rings, face seals or shaftsealing rings.
Hands-on support
Klüber Lubrication offers tailor-madelubricants for refrigeration compressorsand, on request, also provides supportfor oil changeover. The first step con-
26 T R I B O J O U R N A L 1 / 2 0 0 7
sists in a detailed analysis of the oilpresently used, which gives an indica-tion as to the current state of the re-frigeration plant and may highlight“hidden” problems. Once the best so-lution for the particular customer hasbeen determined, a service team canassist in the oil changeover on theplant. The procedure depends largelyon the degree of oil contaminationand/or the compressor. Usually it issufficient to simply drain the oil, replacefilters and oil separators and to removeany residual oil from the pipes, hous-ings and filters before filling with thenew oil. For heavily contaminatedscrew compressors, Klüber offers anoil-based cleaning concentrate whichis added to the compressor oil in a 10 %concentration 60 hours before theplanned oil change. The compressorcontinues to operate during these 60hours, and residues and deposits aredissolved by the cleaning agent. Thecompressor does not have to be dis-mantled for cleaning.
Benefits for refrigeration plant operators
❚ Low oil consumption due to special oils resistant to evaporation – reduction by 50 to 90 % comparedwith mineral oils
❚ Oil change intervals up to five times longer due to constant viscosity
❚ Reliable operation and high efficiency of the refrigera-tion compressor as no reaction with ammonia takesplace and hence residue and sludge formation is pre-vented
Dipl.-Ing. (FH) Holger Körber
Industry Group ManagerCompressors
Klüber Lubrication München KG
Also, after the changeover to new oil, Klüber Lubricationcan provide further support. Together with the customer,Klüber Lubrication’s specialists can inspect used oil samplesat regular intervals. Should any problems occur, the situationis analyzed and countermeasures can be taken immediately.Always, the objective is to reduce maintenance costs andachieve the best possible availability and reliability of a re-frigeration plant.
Summary
Changing over from naphthenic mineral oils to the newgeneration of hydrogenated mineral oils and fully syntheticlubricating oils offers many advantages. In many cases,these lubricants enable untroubled and reliable operation ofrefrigeration compressors without frequent interruptions dueto unavoidable cleaning or maintenance. Worn parts are re-placed less frequently and filter costs are reduced. Oilchange intervals, on the other hand, become up to six timeslonger and oil consumption decreases by as much as 70 %.And last but not least, due to the absence of oil-relatedresidues, the efficiency of the refrigeration plant as a wholeshould increase. A successful changeover, however, requiresa high degree of experience and know-how. Therefore,Klüber Lubrication offers the customers comprehensive con-sulting, provides tailor-made solutions and supports themduring the entire changeover period.
27
17 to 20 January 2007New Delhi, India
SAMULEGNO8 to 12 February 2007Pordenone, Italy
19 to 25 February 2007Barcelona, Spain
2 to 5 March 2007Padova, Italy
6 to 8 March 2007Rennes, France
MAINTENANCE28 to 29 March 2007Antwerp, Belgium
16 to 20 April 2007Hannover, Germany
2 to 5 May 2007Buenos Aires, Argentina
7 to 10 May 2007Milan, Italy
May 2007São Paulo, SP – Brazil
5 to 8 June 2007 Tokyo, Japan
Windpower3 to 6 June 2007Los Angeles, CA – USA
August 2007Florianópolis, SC – Brazil
September 2007Sertãozinho, SP – Brazil
ExposibramSeptember 2007Belo Horizonte, MG – Brazil
10 to 14 September 2007Arequipa, Peru
OIL & GAS22 to 25 October 2007 Buenos Aires, Argentina
13 to 20 September 2007Munich, Germany
Use these opportunities for a personal talk: We look forward to meeting you at our stand, for example at the
Exhibitions: Platforms for contacts
17 to 22 September 2007Hannover, Germany
7 to 10 October 2007Orlando, FL – USA
Process Expo15 to 17 October 2007Las Vegas, NV – USA
Worldwide Food Expo24 to 27 October 2007Chicago, IL – USA
24 to 31 October 2007Düsseldorf, Germany
TOKYO MOTOR SHOW26 October to 11 November 2007Chiba, Japan
SAENovember 2007São Paulo, SP - Brazil
SEMICON JAPAN5 to 7 December 2007Chiba, Japan
You will find a comprehensive overview of exhibitions attended by Klüber under www.klueber.com / News / Exhibitions etc. – just click and have a look!
Texmac
Fispal
FOOMA JAPAN
Expoman
Fenasucro
EXTEMIN
Graphispag
VenMec
CFIA
Hannover Fair
ARMINERA
EWEC
International Baking Industry Exposition (IBIE)
K 2007
ITMA
EMO
28 T R I B O J O U R N A L 1 / 2 0 0 7
In the food-processing industry, lubrication not only influ-ences operating costs and productivity, but the integrity ofthe food product as well. Particularly challenging for manycompanies in this field is the addition of increased food safetyprocesses which have been introduced by governments andauthorities. The international ISO standard 22000 “Manage-ment Systems for Food Safety”, for example, defines activi-ties enabling an organization to safeguard food safetythroughout all process stages until the food product reachesthe consumer. This requires staff training, audits and so-called PRP (prerequisite programmes) as well as docu-mented GMP (good manufacturing practice).
With KLASS, the Klüber Lubrication Asset Support Service, Klüber offers a comprehensive package of lubri-cants and services for companies in the food, beverages andpharmaceutical industries, supporting them in a wide varietyof tasks and requirements. For example, lubrication auditsthat include risk analyses for all critical control points(HACCP = Hazard Analysis and Critical Control Points) maybe conducted along with lubrication workshops that intro-duce staff members to the topic and heighten the aware-ness of the importance of good lubrication. Finally, KLASScan be a valuable contribution to both higher productivityand reduced energy and operating costs.
The elements of KLASS are selectedand implemented according to individ-ual requirements:
• Lubricant application consultingto select a suitable lubricant
• Support with HACCP analysis(HACCP = Hazard Analysis andCritical Control Points) for legallysound production and consumerprotection
• Friction point inspection by service engineers and tribo-logical analyses for optimised lubricant selection and relubri-cation intervals
• Support with stockkeeping anddocumentation (best practice)
• Lube point management soft-ware, Klüber Maintenance System, for effective mainte-nance planning and reporting
• On-site customised training programs and seminars
• Comprehensive range of NSF H1specialty lubricants for all kindsof applications
Product and service package for the food-processing industry
Tailor-made
A vital element of the KLASS
package: hands-onsupport by service
engineers
29
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❚❚ The chemistry has to be right
❚❚ Save costs – increase performance –
solve problems
❚❚ Lube & Seal, a combination ensuring reliable
function in power
❚❚ High performance under extreme conditions
❚❚ Hot stuff
❚❚ Reliability at sub-zero temperatures
❚❚ Product and servic package for the
food-processing industry
❚❚ Brochure “Lubrication of large gear
drives”
❚❚ Brochure “At home on the Seven Seas …”
❚❚ Training
❚❚ Fit for the future
30 T R I B O J O U R N A L 1 / 2 0 0 7
Background information with a lot of refer-ences to practice can be found in the newly edited brochure “Lubrication of large geardrives”. Besides the contents already knownfrom the previous edition, the new brochure nowalso offers comprehensive solutions for all operat-ing modes of two different lubrication concepts:that with ‘black’ products containing graphite aswell as that with transparent products without. Withits 72 pages, the brochure is a tribological guidemanual provided by Klüber Lubrication for thosewhose job is the reliable operation of large geardrives.
Lubrication solutions for maritime and off-shore industriesis the topic of the new brochure “At home on the Seven Seas ...”. Whether reduction gears on ships, winch drives,
process gas compressors or twist locks – all aggre-gates and components common to this sector are examinedunder aspects of lubrication. On 28 pages, you will learnwhich speciality lubricants your highly loaded componentsneed to operate without problems. And how you can reduceyour operating costs.
Klüber know-howshown in black onwhite
New brochures
Customer training made by Klüber
Professional tips and hints
How do I find the lubricant that’s best for my machines?Can I optimize my design by using a special lubricant? Howcan I save costs by using the right lubricant? There are
answers to questions like these: in seminars of one or two daysduration, experts from Klüber Lubrication explain everythingyou need to know in terms of lubrication; you will be shownthe latest developments and gain inside knowledge. Seminartopics range from basics of tribology to the latest trends inmaintenance or different fields of lubricant application.
Any special wishes are highly welcome – if requested,Klüber Lubrication also organizes individually tailored semi-nars at the customer’s site. This has been done, for instance,at the premises of a major lubrication equipment OEM inSeptember, where trends and developments in the lubrica-tion of large gear-rim/pinion drives were discussed. Anotherexample is a worldwide leading bearing OEM, where Klübertrained R&D engineers on various lubricant concepts as partof a Tech Day program.
Klüber’s seminars cross not only technical borders withease. They are also offered wherever there are customers ofKlüber – in other words: worldwide.
Please make use of our reader service on page 29 to ob-tain further information on our seminars.
Fit for the futureLonger automotive component life attained withnew special grease
Absolute reliability of performance is a must for any safety-related component in cars. This requirement does of courseextend to the lubricants they contain. Developing a lubricantfor future-oriented technologies, i.e. one that meets expec-tations like 20 years of service life, thermal stability up to 180 °C, with still much higher peaks, as well as an excellentpressure absorption capacity, poses quite a challenge in asector of industry where pricing is also a sensitive issue. WithKlübersynth BR 46-82, Klüber Lubrication has overcome thegap between seemingly irreconcilable objectives: a powerfullow- and high-temperature grease for drive-by-wire compo-nents in cars.
The silicone-free special grease can cope with permanenttemperatures of 180 °C, and short-term peaks up to 250 °C,while also ensuring smooth running at temperatures farbelow zero. Further characteristics of this newly developedproduct are good wear protection in steel/steel friction pair-ings, compatibility with EPDM and miscibility with brake fluids. Klübersynth BR 46-82 is therefore a first-choice prod-uct when it comes to the long-term lubrication of numerouscomponents such as ball screws, rolling bearings, verticallymounted needle bearings and gears. It allows several lubepoints of a component like the brake unit to be made fit forthe future with a single grease.
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Publisher and CopyrightKlüber Lubrication München KG Geisenhausenerstraße 7 81379 München – Deutschland phone +49 (0)89-78 76- 0 Fax +49 (0)89-78 76 333E-mail: [email protected]
Reprints, total or in part, are permittedonly prior consultation with Klüber Lubrication München KG and if sourceis indicated and voucher copy is for-warded.
The contents of these articles are basedon our general experience and knowl-edge at the time of printing. They servefor general information only and can beno substitute for expert consulting. Wetherefore do not accept liability for anydamage resulting from using informationgained from these articles. Any informa-tion given on Klüber products does notconstitute an assurance of productproperties or of a product’s suitability fora particular application. Our competentstaff will be pleased to support you byconsulting you in all matters regardinglubrication. If required and possible wewill be pleased to provide a sample fortesting.
GermanyHeadquarters:Klüber Lubrication München KGGeisenhausenerstraße 7, 81379 München� +49-89-7876-0, Fax: +49-89-7876-333www.klueber.com
GermanyKlüber Lubrication Deutschland KGGeisenhausenerstraße 7, 81379 München� +49-89-7876-0, Fax: +49-89-7876-565www.klueber.com
Sales Offices:Verkaufsregion Süd-OstGeisenhausenerstraße 7, 81379 München� +49-89-7876-0, Fax: [email protected]
Verkaufsregion NordKrendelstraße 32, 30916 Isernhagen bei Hannover� +49-511-610170-0, Fax: [email protected]
Verkaufsregion WestCarl-Sonnenschein-Straße 124, 47809 Krefeld� +49-2151-522940/522950, Fax: [email protected]
Verkaufsregion Süd-WestWeilimdorfer Straße 74/1, 70839 Gerlingen� +49-7156-9400-0, Fax: [email protected]
ArgentinaKlüber Lubrication Argentina S.A.Martin J. Haedo 4301/63, (1602) Florida, Prov. Buenos Aires� +54-11-4709-8400, Fax: [email protected]
AustraliaKlüber Lubrication Australia Pty. Ltd.1st Floor, 3 Brand Drive, P.O. Box 4, Thomastown Victoria 3074 (Melbourne)� +61-3-9464-7577, Fax: [email protected]
Sydney OfficeUnit 23, 380 Marion Street, Condell Park, NSW 2200 Sydney� +61-2-97908562, Fax: +61-2-97904760
AustriaKlüber Lubrication Austria Ges.m.b.H.Franz-Wolfram-Scherer-Straße 32, Postfach 845028 Salzburg-Kasern� +43-662-452705-0, Fax: [email protected]
BelgiumKlüber Lubrication Benelux S.A./N.V.Rue Cardinal Mercier 100, 7711 Dottignies� +32-56-483311, Fax: [email protected]
BrazilKlüber LubricationLubrificantes Especiais Ltda. & Cia.Rua São Paulo, 345, Distrito Industrial de Alphaville06465-902 Barueri - São Paulo� +55-11-4166-9005, Fax: [email protected]
ChileKlüber Lubrication Chile Ltda.Av. Edo. Frei Montalva 9950, Módulo B1, Cargo ParkQuilicura, Santiago� +56-2-7471188, Fax: [email protected]
China, People’s Rep. ofKlüber Lubrication China Ltd.Room 1012 Shatin Galleria, 18-24 Shan Mei StreetFotan, Shatin, N.T., Hong Kong� +852-26920191/26920329, Fax: [email protected]
Klüber Lubrication (Shanghai) Co. Ltd.Room 1806-1809, Tian An Center, No. 338 Nanjing Road(West), Shanghai 200003� +86-21-63720022, Fax: [email protected]
Beijing Liaison Office:Room 1805, A BuildingChina International Science & Technology Convention CenterYumin Road No.12, Chaoyang District, Beijing 100029� +86-10-82252221, Fax: [email protected]
Chengdu Liaison Office:Room 2306 Zongfu Building, No. 45 Zongfu RoadChengdu, Sichuan 610016� +86-28-8675-2970/8675-2971, Fax: [email protected]
Shenzhen Liaison Office:RM 2904, Huaneng Building, 2068 Shennanzhong Road, Futian District, Shenzhen, Guangdong 518031� +86-755-83680482, Fax: [email protected]
Czech RepublicKlüber Lubrication CZ s.r.o.Prazákova 10, 61900 Brno� +420-5-43424836/43424837, Fax: [email protected]
DenmarkKlüber Lubrication Skandinavien A/SLiterbuen 9, 2740 Skovlunde� +45-70-234277, Fax: [email protected]
FinlandKlüber Lubrication Skandinavien A/SHämeentie 3, 00530 Helsinki� +358-9-8545610, Fax: [email protected]
FranceKlüber Lubrication France S.A.S.Z.I. des Auréats, 10 à 16 Allée Ducretet26014 Valence Cedex� +33-4-75448426, Fax: [email protected]
IndiaKlüber Lubrication (India) Pvt. Ltd.Silver Jubilee Block III Floor,Mission Road III Cross,Bangalore 560 027� +91-80-5124-0201, Fax: [email protected]
ItalyKlüber Lubrication Italia S.A.S. di G. ColoriVia Monferrato 57, Sesto Ulteriano, Casella postale 438120098 San Giuliano Milanese Centro (MI)� +39-02-98213-1, Fax: [email protected]
JapanNOK Klüber Co., Ltd.1-12-15, Shibadaimon, Minato-ku, Tokyo 105-8585� +81-3-3434-1734, Fax: [email protected]
Kitaibaraki Plant955-4, Aza - Ohishi, Isohara, IsoharamachiKitaibaraki-City, Ibaraki - 319-1541� +81-293-427320/425365, Fax: [email protected]
Korea, Republic ofKlüber Lubrication Korea Ltd.Seoul Head Office:Rm. 901, Samhwan Camus Bldg. 17-3, Seoul, 150–874� +82-2-7825151, Fax: [email protected]
Factory:562 Okmyung-ri Daesong-myun, Nam-kuPohang, Gyungbuk 790-840� +82-54-278-5151, Fax: [email protected]
MalaysiaKlüber Lubrication (Malaysia) Sdn BhdNo. 17 Jalan PJU 3/49, Sunway Damansara Technology Park47810 Petaling Jaya, Selangor Darul Ehsan� +60-3-78034954, Fax: [email protected]
North Malaysia Office:No. 22A (1st Floor) Persiaran Mahsuri 1/2, Sunway Tunas11900 Penang� +60-4-6469335, Fax: [email protected]
MexicoKlüber Lubricación Mexicana, S.A. de C.V.Parque Industrial Querétaro, Avenida de la Montaña No. 109Km. 28.5 Carr. Qro.-S.L.P., Santa Rosa JáureguiQuerétaro 76220� +52-442-22957-00, Fax: [email protected]
NorwayKlüber Lubrication Skandinavien A/SIndustriveien 25, Inngang B, 2020 SkedsmokorsetPostboks 220, 2021 Skedsmokorset� +47-64837800, Fax: [email protected]
PolandKLÜBER LUBRICATION POLSKA sp.z o.o.Ul. Wierzbiecice 44a, 61-558 Poznan�
� +48-61-8700790, Fax: [email protected]
RussiaKlueber Lubrication OOOSkladochnaja ul., dom 2 A, strojenije 1, 127015 Moskau� +7-495-1011707/1011708, Fax: [email protected], [email protected]
Sankt Petersburg Office:Litejny prospekt, d. 22, of. 55, 191028 Sankt Petersburg� +7-812-2724757, Fax: [email protected]
Rostov-na-Donu Office:prospekt Semashko, d. 114, of. 310344010 Rostov-na-Donu� +7-863-2500007, Fax: [email protected]
Samara Office:ul. Uritskogo, d. 19, of. 2, etash 9, 443030 Samara� [email protected]
Kazan Office:ul. Kremljovskaja, d. 13, of. 202/B, 420111 Kazan� [email protected]
Singapore, Republic ofKlüber Lubrication South East Asia Pte Ltd25 International Business Park, # 04-54 German CentreSingapore 128384� +65-6562-9460, Fax: [email protected]
South Africa, Republic ofKlüber Lubrication (Pty) Ltd. P.O. Box 11461, Randhart / Alberton 1457� +27-11-908-2457/908-2458/908-2459, Fax: [email protected]
SpainKlüber Lubrication GmbH Ibérica S. en C.Carretera C-17, Km 15,508150 Parets del Valles (Barcelona)� +34-93-5730711/5730666/5730667, Fax: +34 [email protected]
SwedenKlüber Lubrication Skandinavien A/SBox 601, 194 26 Upplands Väsby� +46-8-59098600, Fax: [email protected]
SwitzerlandKlüber Lubrication AG (SCHWEIZ)Thurgauerstraße 39, 8050 Zürich� +41-44-3086969, Fax: [email protected]
TurkeyKlüber LubricationYAGLAMA ÜRÜNLERI SAN. VE TIC. A.S.Cerkezköy Organize Sanayi BölgesiAtatürk Cad. 10 Sok. No: 7, Cerkezköy/TekirdagPostal address:PK 56, 59500 Cerkezköy/Tekirdag� +90-282-7581530/7581710Fax: +90-282-7582935/7582936/[email protected]
United KingdomKlüber Lubrication Great Britain Ltd.Hough Mills, Northowram, Halifax, HX3 7BN� +44-1422-205115, Fax: [email protected]
United States of AmericaHeadquarters:Klüber Lubrication North America L.P.32 Industrial Drive, Londonderry, NH 03053� +1-603-647-4104, Fax: [email protected]
Midwestern Group Office512 West Burlington Avenue, Suite 208, LaGrange, IL 60525� +1-708-482-9730, Fax: +1-708-482-9407
Southeastern Group Office233 North Main Street, Suite 300 A, Greenville, SC 29601� +1-800-889-4283, Fax: +1-864-467-0740
Western Group Office572 East Green St., Suite 208, Pasadena, CA 91101-2045� +1-626-795-5455, Fax: +1-626-795-6064
Klüber Lubrication Texas, L.P.P.O. Box 131359, Tyler,TX 75713, 9010 CR 2120,Tyler, TX 75707� +1-903- 5348021, Fax: +1-903- [email protected]
Klüber Lubrication ein Unternehmen der Freudenberg-GruppeKlüber Lubrication a member of the Freudenberg groupKlüber Lubrication una empresa del grupo Freudenberg
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Klüber Lubrication une société appartenant au groupe FreudenbergKlüber Lubrication una società del gruppo FreudenbergKlüber Lubrication uma empresa do Grupo Freudenberg
