Dolphin automates lubrication in a humid, heavily contaminated environment

Anyone who thinks the ash left behind after household waste is incinerated has no value would be mistaken. Every day, Dolphin in Harderwijk recovers kilos of valuable metals from this residual material. These are sorted using a range of separation methods, including a robotic system. The various rotating components and conveyor belts are lubricated using automatic lubrication systems from Interflon. “They’ve made a real difference,” says Head of Technical Services Gerbert van de Vlekkert.

Dolphin Metal Separation processes 40,000 tonnes of residue every year, originating from 40 million households across Europe. Through a series of complex separation processes, metals such as aluminium and stainless steel are recovered, along with heavier fractions including copper, brass and zinc. The cleaner the fractions, the greater their value.

Dolphin Metal Separation chooses automatic lubrication in a humid, heavily contaminated environment

Machinery

The separation processes take place in Harderwijk, where Dolphin operates an impressive plant equipped with machinery and installations that separate materials according to a range of principles, including specific gravity and visual, magnetic and electrical properties. Materials are also identified using X-rays and AI cameras that recognise shapes, combined with a robotic arm.

Machines and installations separating materials in a dirty, humid environment

The sheer number of rotating drums, vibrating screens and conveyor belts involved is considerable. Head of Technical Services Gerbert van de Vlekkert is responsible for maximising the availability and reliability of all installations. He explains: “Good maintenance is essential, but it is far from straightforward in an environment dominated by moisture and dirt. Fortunately, when it comes to lubrication maintenance, Dolphin started working with Interflon thirteen years ago.”

Together with his account manager, Van de Vlekkert recalls a time when Dolphin was experiencing problems with a motor whose bearings were wearing out too quickly. Interflon recommended replacing the oil in the gearboxes with a semi-fluid grease, which completely solved the problem.

He continues: “When the owner heard about the results, he asked Interflon to replace all the original lubricating oils and greases with Interflon products, just two days before our new plant was due to open. They managed to get it done. The new plant started up with the new lubricants and has been running to our complete satisfaction ever since.”

Automatic lubrication

Van de Vlekkert himself joined Dolphin just over two years ago. Like many technical companies, Dolphin is also facing a shortage of suitably qualified technical staff.

“This means you can be forced to leave certain maintenance tasks undone. That’s not what you want, so you start looking at automation. Which maintenance tasks could be taken over by a technical solution?”

Dolphin Metal Separation opts for automatic lubrication in a humid, heavily contaminated environment.

Lubrication was an obvious candidate. Once again, Interflon had a suitable solution in the form of automatic lubrication systems. These systems consist of a central grease reservoir, with the lubricant automatically distributed to the individual lubrication points through plastic lines. The systems are divided into sections, making it easier to monitor and safeguard their reliability.

Van de Vlekkert says: “We initially automated the lubrication points that were difficult to reach, but in the end, automatic lubrication systems offer benefits throughout the plant. We also use the grease to help keep dirt out of the bearings by applying slightly more than is strictly necessary. With this solution, we can be confident that every lubrication point receives enough grease.”

Planning

The first system was installed just over a year ago. According to the current schedule, the final system will be installed by the end of 2027, by which point around 95% of all lubrication points will be covered.

Van de Vlekkert is pleased with the results: “You can imagine how much work this saves our maintenance team. It also reduces the workload for our operators, who carry out first-line maintenance. Thanks to automatic lubrication, they have more time to focus on their main job, which includes continuously monitoring the process. The operators are very happy with it. And Interflon? They’re much more than a supplier. They’re a true partner.”