With pellet mill applications, the constant presence of heat, high pressure, contaminants, and in some cases, moisture, work to break down the thin lubricating film protecting the equipment from metal-to-metal contact.
Once that breakdown occurs, increased levels of wear and corrosion are generated and expensive unplanned downtime results. LE can work with you to improve the performance and lifespan of your pellet mill equipment over typically accepted limits.
With our field experience, technical expertise and comprehensive line of enhanced lubricants we can help you understand your current lubrication practices and uncover suffering points that can be corrected such as:
- Over or under lubrication
- Using inferior lubricant for the application
- Failing to prevent or remove contaminants
- Relying on inconsistent manual lubrication when an automatic system could produce better results
We start by gathering information with our Pellet Mill Data Collection Form. After assessing your situation, we provide a phased improvement plan – based on your budget – to extend component life, reduce lube consumption, improve safety, and reduce costs.
Identify Suffering Points
Move forward with LE’s proven solutions for extending pellet mill equipment life.
Short Component Life, Equipment Failures & Other Problems
Pellet mill operations often overgrease with the intention of better lubricating the bearings, they may use an inadequate amount of grease or use a grease with the wrong base oil to effectively lubricate the bearings. Overgreasing or using the wrong type will contribute to a larger-than-needed amount of grease purchased each year. Contaminants that aren’t prevented or removed also cause failures and unplanned downtime.
An onsite equipment assessment is needed to ensure the proper lubricants are used, as well as the proper amount, relubrication interval and application method. An LE consultant will gather information onsite using our Pellet Mill Data Collection Form, identifying make and model of the pellet mill, bearing part numbers, operating parameters, and current lubrication method. Based on the load, temperature, speed and environment for each piece of equipment, our Technical Services group will then recommend the most advantageous lubricant, lubrication interval, quantity, and application method. Along with this technical report, a cost analysis will be provided to determine if the changes will make sense financially.
Inadequate Grease Protection
Are you obtaining the L10 (or B10) life of the roll and quill bearings in your pellet mill or are they wearing out prematurely? In a 24/7 operation, lost production time is gone forever and cannot be made up. Failed bearings are a common yet avoidable problem in pellet mills; the right grease can make a huge difference. It has to be able to handle difficult conditions such as severe levels of particulate contamination, high heat, extreme pressures, and moisture – all of which affect the grease’s ability to lubricate effectively
Almasol® High Temperature Lubricant has been formulated for bearings operating in or near heat-generating equipment and subject to temperatures that cause ordinary greases to melt and run out of the bearing. This long-lasting, nonmelting grease has the right base oil viscosity and wear-reducing additives to significantly resist oxidation, vaporization and bleeding out of the bearing. It is used successfully in pellet mills around the world, and is proven at extending regreasing intervals and reducing grease consumption. For food-grade applications, H1 Quinplex® Food Machinery Lubricant (4025-4022) and H1 Quincal® Syn FG Grease (4070-4072) are recommended for pellet mill applications.
Manual lubrication can be unreliable; additional maintenance responsibilities can lead to overgreasing and undergreasing, both of which are detrimental to bearing life and lead to premature failure Lubricants applied manually tend to be applied on an inconsistent schedule and not necessarily when the bearing requires it; results can be hit or miss. Manual lubrication can also be unsafe due to lube points being in hard-to-reach locations or lubrication being done when the machinery is in operation.
Automatic lubrication systems are precise; they apply the right amount of lubricant, at the right time, in the right place, to ensure maximized bearing life. They keep the system closed and sealed from contaminants, while keeping operators safe. LE’s Xport™ Automatic Lubrication Systems have been designed with pellet mills in mind and are effective at eliminating errors and extending the useful life of the bearings.
Lubrication Engineers can help put together a lubrication reliability program for your pellet mills to help them last longer, eliminating downtime and reducing maintenance costs. Our certified lubrication experts can be onsite to help put together a program that will bring lubrication excellence to your operation. Get started by finding your local LE consultant or registering to purchase online.