Alemite Corporation

The leader in lubrication and oil mist technology for 80 years

Charlotte, North Carolina, USA

technology for 80 years.

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What Is Oil Mist Lubrication?A i li dAn automatic, centralized system that continuously delivers fresh, clean oil to multiple, and often widespread machine elements.

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From Liquid Oil To Mist

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Different Mist Forms forDifferent Mist Forms for Different Elements

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Different Mist FittingsDifferent Mist Fittings Create Different Mist Forms

* Mist fittings for metering input of oil* Mist fittings for metering input of oil in “mist form”

* Condensing Fittings for metering input of oil in “droplet form”in droplet form

* Spray fittings for metering input of oil spray* Spray fittings for metering input of oil sprayin “combination of mist and larger oil particles”

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For High Speed Ball Bearings

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For Plain Bearings SlidesFor Plain Bearings, Slidesand Other Sliding Motion Partsg

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For Gears Chains andFor Gears, Chains and Large Rolling Element Bearingsg g g

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Thin & Even Film Application

The way to save oil, energy &reduce bearing temperature!!!

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Advantages

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Success Story

yPaper Mill

Rewinder isRewinder is lubricatedby oil mistby oil mist.

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Success StoryPaper Mill

manufacture double coated printing papermanufacture double-coated printing paper

Problem Areas before Oil Mist Application

Elements of extreme heat and forced suction which drewoil out of the bearings, resulting in excessive consumptionof oil, as well as materially shortened bearing life. Six , y gfans served the #3 coater, four feeding hot air into it, whiletwo exhaust units pulled hot air out. Circulating fans were subjected to the highest temperatures These fans forcesubjected to the highest temperatures. These fans force 600F air to the coater. Temperature at the roller bearing of these fans was estimated at about 220F.

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Success StorySuccess StoryPaper Millp

Oil mist has greatly reduced fire hazards.

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Paper MillpBEFORE & AFTER

B E F O R E A F T E RF a n s w e r e m a n u a l l y O i l c o n s u m p t i o n r e d u c e dF a n s w e r e m a n u a l l yl u b r i c a t e d e v e r y h o u r t h a tc o n s u m e d 3 g a l l o n s o f o i ld a i l y .

O i l c o n s u m p t i o n r e d u c e do n e g a l l o n p e r d a y ; h o u r l yl a b o r w a s s a v e d .

yA v e r a g e 2 s e t s o f b e a r i n gw e r e l o s t w i t h i n a w e e k .

B e a r i n g l i f e w a s g r e a t l ye x t e n d e d .

E x c e s s i v e h e a t a n d s u c t i o n T h e c o n s t a n t d e l i v e r y o fE x c e s s i v e h e a t a n d s u c t i o nf r o m t h e f a n s d r e w t h el u b r i c a n t o u t o f t h e b e a r i n g si n t o t h e h o t a i r d u c t t h a t

T h e c o n s t a n t d e l i v e r y o ff i n e s p r a y o i l b y o i l m i s tr e d u c e d t h e f i r e h a z a r d s om u c h t h a t r e s u l t e d i n o n l y

c r e a t e d a s e r i o u s p r o b l e m -o n e f i r e e v e r y d a y w h i c hb u r n e d o u t t h e e x p e n s i v ei l t i i i d t h d k

o n e f i r e a y e a r .

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i n s u l a t i o n i n s i d e t h e d u c k .

Success StorySuccess StorySteel Mill

Problem Areas: Grease oozed out of bearings and ontothe steel being rolled - finished and ready to go to theg y gcustomer, and the spotted condition was not tolerated.

Solution: 8 lubrication points on the single-stand tempermill were served with oil mist. Problem of spotting was gonewas gone.

Additional Advantages: only 0.0003” wear on the 12” g ydiameter tapered roller bearing, after 800,000 tons of steel rolled; substantial savings in lubricant cost.

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Success StorySuccess StorySteel Mill

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Success StorySuccess StoryChemical Plant

Mississippi Chemical Corporation Mississippi Chemical Corporation

Fertilizer plants are entirely open

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and exposed to the elements.

S St Success StoryChemical PlantChemical Plant

Spare reduction gear boxes in warehouse with oil mist continuously applied to protect them from rusting

Oil mist keepsbearings runningbearings runningsmoothly for this500 HP electricmotor in the rock grinding mill.

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S St Success StoryChemical PlantChemical Plant

The benefits to Mississippi Chemical are:L b i i d i(a) Lubricating and purging equipment in operation.q p p

(b) Protecting equipment in storage.

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Success StorySuccess StoryChemical Plant

BEFORE AFTER

Dryer blowers were breaking down monthly due to bearing contamination.

Bearings were not changed for six months.

Fertilizer plant has a potash elevator whichwas frequently losing a drive chain.

Have not had an elevator drive chain breakdown in four years.

One plant used two - three 55 gallon drumsa week.

b i i

Oil consumption reduces to one drum every2-3 weeks.

After six months in storage with oil mistMany gear boxes were rusting in storagesimply from exposure to the environment.

After six months in storage with oil mist applied, the gear boxes look like new, and have a thin coating of oil on all internal surfaces.

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S St Success StoryPharmaceutical LaboratoryPharmaceutical Laboratory

Miles Laboratories

Bottle cappers, operating

Miles Laboratories

pp , p g8 - 16 hours a day, producingup to 15 million tablets duringtwo shifts, are lubricated withoil mist. Primarily on spindleshafts and bearings This unitshafts and bearings. This unitlubricates 20 separate pointson the four machines in operation.

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p

S St Success StoryPharmaceutical LaboratoryPharmaceutical Laboratory

ADVANTAGE NO. 1: SAVING 2/3 LUBRICATION COST

The secret to the benefits lies in the positive, controllabled di bl i h hi h h Al iand predictable manner with which the Alemite systems put

oil right where it is needed at the precise time it is required.

Not only is waste eliminated, but excess of lubricant is also controlled. Most bearings and shafts become “frozen” fromgtoo much lubricant than are damaged by insufficient lubrication: LIQUID FRICTION.

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S St Success StoryPharmaceutical LaboratoryPharmaceutical Laboratory

ADVANTAGE NO. 2:NO LUBRICANT CONTAMINATION

Since the products made are all intended for human consumption, they obviously must be free of all impurities.Indiscriminate or uncontrolled use of lubricants could

d ld t t bl bland would create an untenable problem.

The positive control of oil mist systems protects productsThe positive control of oil mist systems protects products against lubricant contamination.

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Success StorySuccess StoryFood Industry/Tomato Peelers

Problem AreasCONTADINA FOODS in California has two peelers, each p ,with its own peel eliminator. Each eliminator has 72 one inchFafnir two hole flange bearings and 36 umber 50 drive h i All h i d b i l b i d b h dchains. All chains and bearings were lubricated by hand

daily. Also during each day the units were washed downwith a hot water & ammonia solution resulting in waterwith a hot water & ammonia solution, resulting in watergetting into the bearings and oil being flushed from the chains. All 144 bearings and 72 chains required replacement everyhalf season.

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Success StorySuccess StoryFood Industry/Tomato Peelers

Solutions & Results After using oil mist to lubricate bearings and chains, g g ,CONTADINA FOODS did not replace any bearings or chains in 2 full season. In other words oil mist i h lif f h i d b i f lincreases the life of chains and bearings for at least three times - maybe more.SecretsSecrets* Water residual (during wash down) is purged out of

the bearings and chainsthe bearings and chains.* The flushed oil (during wash down) is filled in by fresh

oil mist.

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Success StorySuccess StoryMining Industry/Shaker Screens

Problem AreasIndependence Mine in Nevada has three Allis ChalmersIndependence Mine in Nevada has three Allis Chalmersshaker screens operating in a very dirty, dusty environmentwhere winter temperature is as low as zero degree F.p gEach shaker screen has two FAG bearings with labyrinthseals operating at 900 RPM. The bearings were lubricatedby rotating the bearings through an oil sump.Independence experienced 22 bearing failures in 1995.

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Success StorySuccess StoryMining Industry/Shaker Screens

Solutions & ResultsI J 1996 th il d i d d Al itIn January 1996 the oil sumps were drained and an Alemiteoil mist system was installed.No bearing was replaced in 1996 No bearing was replaced in 1996. Oil consumption is reduced by 50%.SecretsSecretsOil mist system provides a continuous supply of fresh, clean oil to the bearings, and a positive pressure inside the bearinghousings, which eliminates contamination.

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Success StorySuccess StoryFood Industry/Sugar Beet Defuser

Problem AreasS k l S C i C lif i ff d fSpreckels Sugar Company in California suffered fromthe problems existing in chains and sprockets on their sugar beet defuser equipment: oil reservoirs (for lubricating chainsbeet defuser equipment: oil reservoirs (for lubricating chains and sprockets) were contaminated with product, housekeeping was impeded due to oil reservoirs overflow, large sprockets and 11 of 150 ft long chains were replaced every year, oilconsumption was 240 gallons in two years.

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Success StorySuccess StoryFood Industry/Sugar Beet Defuser

Solutions & ResultsA single Alemite oil mist unit was installed for lubricatingA single Alemite oil mist unit was installed for lubricatingall the 28 chains and sprockets in 1995. In two year time frame little or no wear of chain or sprocket was recorded, p ,oil consumption rate dropped to 12 gallon, housekeepingproblems had been reduced by 90%.SecretsOil application is well controlled that minimizes oil consumption, eliminates housekeeping problems. Freshand clean oil is continuously supplied to chains and sprockets that prevents contamination

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sprockets that prevents contamination.

Success StorySuccess StorySawmill/Edger Arbor Bearings

Problem AreasH d L b Mill i C lif i h f d E hHarwood Lumber Mill in California has four edgers. Eachedger has two arbor bearings with 100 mm I.D. Three edgersuse double row bearings running at 1750 RPM the fourthuse double row bearings running at 1750 RPM, the fourthedger has two Cooper bearings on the arbor running at 1,435RPM. All of them operate in areas that expose them to high amounts of contamination from saw dust and water. The grease lubricated edgers’ failure rate was total 16 per year.

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Success StorySuccess StorySawmill/Edger Arbor Bearings

Solutions & ResultsIn 1990 Harwood Lumber installed an Alemite oil mist system. 50 degree bearing temperature drop wasnoticed immediately, no failure had been seen in four yearsIn one occasion when air supply was turned off in error inIn one occasion when air supply was turned off in error in the 5th year, only two bearings failed. The other six werestill running in good conditions in 1997. g gSecretsOil mist eliminates “wet friction” that reduces temperature byp y50 degree, constantly purges bearing housings keeping housing clean.

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Textile Mill Applications

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Cold Rolling Mill Application

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When the oil mistWhen the oil mist carrier, AIR, is

ti l h t dcontinuously exhausted into the workplace area and may be carrying some oil in it, potential, pusers are concerned with this stray mistwith this stray mist.

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What is the acceptableWhat is the acceptable level of oil content?

OSHA in the USA and the Ministry of Labor in Canada have established exposure limits for oil mist in a plant:p p

Both standards allow a workplace exposure limit of 5 mg oil/m3 air time-weighted average exposure value (TWAEV).

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Research ResultsAn independent laboratory, Guelph Chemical Laboratoriesused strict NOSH methods for measuring oil in stray mist. A cross section of industry including an aluminum millA cross-section of industry including an aluminum mill, steel rolling mill, pulp & paper industry and automotive parts manufacturing were selected and tests made toparts manufacturing were selected and tests made tomeasure stray mist in the workplace area surrounding theequipment using oil mist systems, over an 8 hour period sometimes extending into the night. The results show:

i 0 675 3 f dmaximum 0.675 mg/m3 was found at mist cloudy area in a steel mill.

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RESULTS

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RESULTS* ALUMINUM MILL 0.35mg - 0.45mg by commercial gear lubricant

b i bl l b i 0.20mg - 0.40 mg by mistable lubricant* COLD ROLLING MILL 0 40mg 0 67mg in 5 days 0.40mg - 0.67mg in 5 days.* PAPER MILL 0.22mg - 0.29mg in 5 daysg g y* AUTO PARTS MANUFACTURING 0.04mg - 0.13mg in 4 daysOPEN GEARS & CHAINS BEARING MFG* OPEN GEARS & CHAINS (BEARING MFG.)

0.8mg - 1.0mg in 4 days

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CONTROL(A) Make sure that application fittings are

used on the equipment.(B) Use correct size application fittings for

the bearing. [Oversizing can create stray mist.](C) Apply proper air temperature.

i bl il i d h d(D) Use mistable oil instead that cuts down oil in the stray mist

l f [example: from 0.6 mg to 0.32 mg] (E) Properly ventilate workplace.

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