KlüberLubrication;smoothing the food-chain with Kluberfood

•    Elimination of expensive manual lubricant application
•    Significantly reduced lubricant consumption
•    Cleaner lower friction chain operation
•    Reduced power consumption in operation Introduction

Following a close examination of their chain lubrication, a major bakery group changed their lubricants and application method. With these measures, they reached their goal of reducing the operating costs in one of their production lines. An automatic lubricating system combined with a high-performance chain oil rendered many maintenance jobs unnecessary and led to a considerable reduction of energy and lubricant consumption. 

Background

With crumpets being such a popular f bread snack, production runs day after day on industrial baking lines with annual output of several million crumpets. The Bakery needed to optimise their crumpets production line and turned to Klüber Lubrication. The bakery's explicit goal was to optimise oven chain lubrication such that downtime and consequent production loss could be reduced and expenses on energy lowered. 

Chains running in automatic baking lines are exposed to regular high temperatures, which constitutes a high stress on the lubricants used. Chain oil that does not withstand these temperatures evaporates rapidly and leaves hard residues on the chain. As a consequence, the chain then has to be frequently cleaned and re-lubricated. The oil used should therefore not only offer very good wear protection but also have a low evaporation rate and leave only a minimum of residues. Furthermore, it has to be in line with the stringent national and international food law regulations.

The high-temperature chain oil Klüberfood NH1 CH 2-220 offered by Klüber Lubrication fulfils all these requirements. 

Examining the Production Process 

The new chain oil, however, was only one element of the bakery's improvement project. Before it was applied, the whole baking process had been comprehensively evaluated, including an analysis of the ovens and the chains used in the baking line. Klüber Lubrication recommended to also change the lubrication technique, replacing the manual application with an automatic lubricating system. The bakery and Klüber Lubrication worked out an action plan together which determined the individual steps for the conversion and key performance indicators to measure improvements. 

Solution – Successful Implementation

With automatic lubrication system introduced, and the synthetic high temperature  lubricating oil Klüberfood NH1 CH 2-220 replacing the previously used graphite-containing oil, the following results were attained:

•    The automatic lubricating system applies oil for 15 minutes each day eliminating manual lubrication previously requiring 48 man-hours per year unnecessary; leading to a considerable reduction of maintenance costs and, at the same time, more reliable lubrication
•    Lubricant consumption was reduced by almost 90 percent – from previously 8 to now 0.84 litres per month
•    Due to the low residue formation, chains now remain clean for longer with laborious cleaning no longer required – reducing maintenance and cleaning costs
•    As chains are cleaner, the oil can penetrate better to the main friction surfaces and ensure more effective wear protection, which in turn leads to longer chain life •  Lower friction and residue formation have reduced power consumption by approximately nine percent; energy costs have gone down accordingly
 
The example of crumpet baking shows the vast potential for optimisation resulting from a detailed analysis of the manufacturing process with a view to the lubricant and its application. In this example, the new application method and lubricant enabled savings amounting to 87 percent of operating costs, i.e. almost 1500 euros per oven per year. Regarding the purchase of the automatic lubricating system, return on investment was attained in the second year after the changeover. 

Klüber Lubrication GB Ltd  / Hough Mills, Northowram, Halifax HX3 7BN / UK / Phone +444 (0)1422 205115 / Fax +44 (0)1422 207365
 
The data in this case study are based on our general experience and knowledge at the time of printing and are intended to give information of possible applications to a reader with technical experience. They constitute neither an assurance of product properties nor do they release the user from the obligation of performing preliminary tests with the selected product. We recommend contacting our Technical Consulting Staff to discuss your specific application. If required and possible, we will be pleased to provide a sample for testing. Klüber products are continually improved. For this reason, the unlimited validity of all technical data in this case study cannot be ensured. Product information leaflets and material safety data sheets can be downloaded or requested via our website www.klueber.com. You may also obtain them through your contact person at Klüber Lubrication.
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