Lube extends lives of cooker bearings to 12 years
A
Kluber Lubrication GB product story
Edited by the Engineeringtalk editorial team
Sep 22, 2009
On two sites, a multi-national food producer has a range of 14 FMC, Storkmollenaar and Mather and Platt rotary cookers.
These units cook the food in the cans and operate for 19 hours a day for five days a week.
The cookers have two main support bearings 22228 cck c3 w33, which require regular lubrication.
The cooker bearings operate in a wet steamy environment and are very heavily loaded.
When in full production the cookers can produce 17000 cans / hour.
Unfortunately however, the company suffered a major failure of one of the cookers due to a massive bearing failure.
This failure stopped production for 10 days, equating to GBP180,000 and a cost of engineering repair of GBP10,000.
The breakdown inevitably had a high impact on 'on time delivery' of a premium branded product to their high-profile customers.
The failed bearing was passed to Kluber for analysis and after an in-depth study, it was evident that the following was happening.
The grease being used, although regularly applied, was not capable of surviving in the environment of 100C+, high-pressure steam and heavy loads.
It could be seen that the oil content of the grease had evaporated leaving only the thickener, which in turn had hardened and was blocking all the access into the bearing.
Failure was inevitable.
The Kluber solution was to recommend Stabutherm GH 461 due to the fact that the grades from Kluber have base-oil viscosities of approximately 500mm/s (cst) at 40C, whereas typical EP2 greases tend to have base-oil viscosities of approximately 150mm/s at 40C.
The recommendation for the use of Stabutherm GH 461 was based on a number of factors: it has a similar base oil viscosity to the OEM recommendation and is used in elevated temperatures up to 180C, slow-speed applications with very heavy loads.
It has a higher base-oil viscosity than previous materials, which improved wear protection under operating conditions.
In addition to the above, the Stabutherm GH 461 also has NSF H2 authorisation, meaning it is suitable for use in food processing environments where there is no possible risk of contact.
As a result of the recommendations put forward by Kluber, all cookers were converted to the Stabutherm GH 461 with immediate effect and a visual management process was put in place to ensure zero cross-contamination.
Reconfiguration of the lubrication frequencies now ensure that lubrication is performed immediately after wash down prior to each weekend shutdown hence preventing corrosion occurring.
Recent analysis of the grease showed no sign of the previous thermal degradation and the expected bearing life should be above 12 years with this new regime.
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