Estimated annual savings of over €4,800,-
Lubrication of smoke extraction fan bearings in the assembly department
Initial situation
An automotive manufacturer operates a fume extraction system consisting of 11 extractor fans, each equipped with two bearings — 22 bearings in total. The estimated cost per bearing is €60.
Lubrication requires two maintenance technicians and takes approximately 30 minutes per fan, totalling 5.5 labour hours per cycle. With an hourly labour cost of €25, the associated personnel costs are significant.
Before lubrication — performed using a dedicated grease pump — the customer also uses cleaning products. This means inventory must be maintained for degreasers, dosing equipment and lubricants.
Due to bearing overheating, relubrication is required every three months. These interventions can only be performed during shutdowns, resulting in four production stoppages per year.
Our solution
Interflon Grease MP2/3
Benefits achieved
- Technical contribution to World Class Manufacturing (W.C.M.)
- Reduced energy consumption (−0.5 A)
- Extended lubrication intervals
- Lower lubricant consumption
- Reduced use of cleaning agents Less inventory required
- Fewer maintenance interventions and unplanned stops
Result
At the first three-month inspection, the bearings lubricated with Interflon Grease MP2/3 were found to be in excellent condition. Based on this early result, the customer expects:
- A significant reduction in lubricant usage, lowering environmental impact
- Less cleaning agent required due to the longer-lasting protective film
- Simplified inventory management with fewer products to store
- Fewer maintenance shutdowns, increasing equipment availability
Thanks to Interflon Grease MP2/3 with MicPol® technology, the customer plans to double the lubrication interval to once every six months.
In addition to reducing labour and downtime, the observed reduction in current draw (−0.5 A) is expected to save over €1,600 in energy costs annually.
Formulated to meet NSF H2 registration standards and entirely PFAS-free, the product also supports safer, more sustainable maintenance practices — especially in environments with high demands on cleanliness and compliance.
When factoring in the extended lubrication interval, reduced energy use, and simplified maintenance procedures, the total projected annual cost reduction exceeds €4,800 — for this application alone.
