From leakage to 41.7% lower energy draw and 2.6× longer oil life

Initial situation

A leading manufacturer in the aerosol filling industry was experiencing persistent problems with the gear reducers on its conveyor systems. The plant faced two recurring issues: oil leakage through shaft seals and rising energy consumption. The gearboxes required complete replacement every 1.5 years, leading to high maintenance workload during planned shutdowns.

The goal was to stabilise gearbox performance by:

• Preventing lubricant leaks and contamination
• Reducing internal friction and motor power consumption
• Extending relubrication and replacement intervals

Solution

To address these challenges, the maintenance team selected Interflon Grease MP00, a semi-fluid PFAS free grease specifically formulated for use in enclosed gear units. This grease, enhanced with MicPol® technology, provides superior film strength, adhesion and resistance to leakage, especially in systems where traditional oils tend to escape through seals.

Key product characteristics:

• Maintains lubrication without leaking, even in units with worn seals
• Reduces friction and operating temperature
• Allows for extended maintenance intervals
• PFAS-free and compliant with environmental goals

Results

The switch to Interflon Grease MP00 delivered the following measurable benefits:

• Leak-free gearbox operation, improving workplace safety and reducing lubricant waste
• 41.7% reduction in electric motor current draw, indicating lower internal resistance
  - Before: 1.2 A
  - After: 0.7 A

(Measured under identical operating conditions and comparable load)

• Oil change interval extended from 1.5 years to 4 years
  - More than 2.6× longer service life
  - Fewer shutdowns and lower lubricant consumption
• 40% cost reduction over four years
  - Previous total: TL 65,064
  - New total: TL 39,224
  - Savings: TL 25,840 in energy and maintenance combined

Conclusion

This case demonstrates how a targeted lubrication upgrade, without hardware modification, can reduce operating costs and environmental impact in demanding conveyor applications. With leakage eliminated, energy use down by over 40%, and oil life extended more than 2.6×, the plant now operates with greater reliability, lower maintenance burden and improved cleanliness. The financial savings, TL 25,840 over four years, reflect a structural improvement. Based on consistent energy reduction and extended maintenance intervals, these results are expected to recur year over year, provided the current lubrication strategy is maintained.

The outcomes are particularly relevant for production environments facing similar challenges: enclosed gear drives, seal leakage, frequent shutdowns and high maintenance effort.

Interflon Turkey