Proper lubrication is essential for maintaining the efficiency and longevity of grease-lubricated bearings. Yet, many industries struggle with under- or over-lubrication, leading to premature bearing failure and costly production halts.
The solution lies in adopting precise automated lubrication management, such as Minimum Quantity Lubrication (MQL) and leveraging innovative technologies like Easylube®’s RFID-enabled single-point grease lubricators. These advancements significantly enhance bearing reliability, reduce downtime, and optimise maintenance costs.
In this blog, Catmacs Automated Lubrication will break down the following topics below:
Without further ado, let’s dive in!
When a grease-lubricated bearing is not greased properly, the machinery part will stop working.
Underlubrication will cause a premature bearing failure. On the other hand, overgreasing will lead to catastrophic failure of the bearing (grease churning and overheating), eventually damaging electromotor coils and windings.
These avoidable production halts can cost millions each day in downtime and lost production. Unfortunately, maintenance technicians still do not realise this issue, leading to poor control of greasing pressure and over- or under-lubrication.
Automated lubrication is widely recognised and proven to:
That’s where Easylube® continues to be innovative. It currently produces the market's most advanced total lubrication management systems, which include a range of automatic lubricators and use the latest technology.
Catmacs can deliver Easylube® products across a broad range of industries. We can provide any lubricant of your choice in the cups you order. These products feature:
The maturity level of a maintenance program (corrective, preventive, predictive, etc.) will dictate the skill and knowledge level required for personnel involved in lubrication-related activities.
To achieve optimum reliability and maximum benefits from automatic lubrication systems, several factors need to be taken into account. These factors are summarised by the well-known five "R"s of lubrication:
Setting up a computerised patrol management system with RFID may take a little time initially, but the built-in database will be a great tool to enhance the overall efficiency and effectiveness of maintenance and uncontrolled downtime of machinery.
The concept of expendable materials refers specifically to cost-effective, replaceable components such as the grease cup and battery, while the expected lifespan of an Easylube® lubricator exceeds five years. This longevity contributes to its stability and reliability for reuse, making it ideal for various applications, especially in equipment located in hard-to-reach or hazardous areas.
Controlling grease volume has been a long-standing problem for the industry. Simply following OEM recommendations may not be enough. MQL calculation is the only solution that provides a simple and logical formulation to determine grease volume and the re-greasing interval to be added.
The MQL (Minimum Quantity Lubrication) formulation has proven processes and procedures for providing the correct "Grease Volume" and "Re-Lubrication Interval" to optimise bearing reliability. These are the two main keys to maintaining bearing efficiency. Therefore, conducting MQL for each bearing is vital.
Easylube® is easy to operate, economical, and suitable for use at any location.
Most grease-lubricated points are tagged with an "RFID tag" for Patrol Monitoring. This will enable each lube point to be managed effectively under MQL demand.
The purpose of routine inspections is to strictly check grease digestion on-site from the lubrication system's dispensing rate, which should completely perform according to a set period of quantification. Hence, maintenance technicians must identify an irregularity in running by listening, feeling, and looking, which is an important part of preventive lubrication maintenance.
The "RFID tags" can be read by NFC-enabled devices, such as a hand-held unit PDA or Smartphone, which the Easylube® Guardwatch program could use in its operation system.
The Guardwatch enables maintenance technicians to handle, identify, and record all lubrication-related issues promptly, ensuring bearings are in the best working condition and thus achieving higher greasing accuracy and effectiveness of routine inspection.
MQL calculation helps determine the right re-greasing interval and grease volume for each bearing by considering the actual operating condition, using OEM as the baseline.
To prevent premature bearing failure, first, ensure the dispense time setting of the Easylube® single-point automatic lubricator is set based on each bearing's MQL formulation. Next, attach a tag to the Easylube® PMS and the Guardwatch to monitor and manage each lube point's status during routine inspection.
Although the re-greasing interval can be determined by experience, reports, and charts, over or under-lubrication is unavoidable. MQL formulation ensures the exact setting of re-greasing intervals by considering each bearing specification and actual operating conditions, making it useful in application.
Easylube® Single-Point Automatic Lubricator is a maintenance-free, cost-effective, and easy-to-operate device specially designed for MQL formulation. Its reliability and simplicity of dispense setting have earned it a reputation in the marketplace. It ensures bearings are in good working condition regardless of weather, operation requirements, and harsh environments.
It provides an adjustable dispense setting of 1 to 12 months. Easylube® imposes minimum lubrication pressure to maintain grease quality and avoid oil seal failure. The patented infra-red control system provides 24-hour continuous monitoring to track feed blockage. An LED warning light flashes to alert users to be aware and take corrective steps.
Easylube® RFID is a scientifically designed automatic lubricator that helps to solve bearing lubrication and management problems. Here are some fast facts for you to know:
So, choose the Easylube® RFID automatic lubricant dispensing devices to remove uncertainty, eliminate human mistakes, and improve employee safety, especially for equipment located in isolated, scattered, dangerous, and negligible areas.
We go further to provide the options which work for you:
Need help with quality industrial lubrication solutions? Contact Catmacs Automated Lubrication for expert advice and quality Easylube® products!
Accurate lubrication is key to preventing machinery downtime, reducing maintenance costs, and extending the life of grease-lubricated bearings. Easylube®’s advanced RFID systems and MQL formulation allow industries to achieve unparalleled precision in lubrication management.
By choosing Catmacs as your Easylube® provider, you benefit from reliable products, personalised support, and long-term cost savings.
Take control of your lubrication processes today and safeguard your operations with solutions designed for modern industrial challenges.
