Reliable bearing lubrication in –28 °C spiral chiller zones with no unplanned stoppages
Eliminating frozen bearings in spiral chillers
Initial situation
A Belgian poultry plant operated spiral chillers with ambient air temperatures in the chiller zone reaching –28 °C. While bearing and metal temperatures at the lubrication points were higher than the surrounding air, the environment remained extremely challenging due to condensation, moisture ingress and frequent sanitation.
Conventional oils and greases either hardened in cold conditions or washed out under condensation and cleaning. Bearings frequently froze or seized, leading to downtime, high spare part costs and hygiene risks from lubricant leakage.
Bearing replacement cost: ~€500–€700 per unit
Failures: 2–3 bearing replacements per year per chiller
Downtime per incident: 1–2 hours, estimated at ~€2,000–€4,000 per hour in lost production
Solution
Bearings were lubricated with Interflon Food Grease LT2, a PFAS-free, NSF H1 low-temperature grease designed to remain stable in cold, wet zones and under washdowns. Its water resistance and low-temperature performance helped prevent washout and maintain a consistent lubrication film, reducing the risk of seizure in cold-zone bearings.
Results
Frozen bearing failures eliminated
Annual savings on spare parts: ~€1,500–€2,100 per chiller
Downtime avoided: ~3–6 hours/year, equivalent to ~€6,000–€12,000 saved in lost production
Hygiene improved: reduced risk of lubricant leakage and contamination in cold zones
Conclusion
By switching to Food Grease LT2 for the bearings, the plant eliminated frozen-bearing failures in spiral chillers, improved uptime and reduced maintenance costs, while supporting HACCP and BRC requirements.
