Cost saving of € 1.677,45 every 6 months
Crane gearwheel in tank of a treatment plant
Initial situation
The customer is a treatment plant. The bridge crane used on the treatment plant tank is driven by a gear reducer, which employs a single wheel to provide motion. The enclosed gears experience high loads, leading to the expulsion of the lubricating product from the gear pair. Consequently, frequent re-lubrication, often as often as once per week, with approximately 500 ml of black-colored grease is required. The repeated application of this large quantity of grease results in dispersion, leading to significant environmental issues. Additionally, the dripping of excess grease beneath the rubber wheels of the crane causes slipping and hinders its movement.
Our Solution
To address this challenge, we began with a thorough cleaning of the gearwheel using Interflon Degreaser EM30+ (aerosol). Subsequently, a layer of Interflon Grease OG (aerosol) is applied to provide long-lasting lubrication, ensuring optimal performance of the component. This solution offers a significantly longer lubrication interval, reducing the need for frequent cleans, minimizing the environmental impact, and improving overall plant efficiency.
Result
The customer expressed high satisfaction with the level of cleaning and the long-lasting lubrication achieved. The lubrication interval has been extended to 6 months, resulting in substantial cost savings.
Moreover, the plant's overall efficiency has improved significantly. Previously, monthly cleaning procedures were required for both the rack and pinion unit and the surface over which the bridge crane traveled. These cleaning procedures are no longer necessary, leading to further efficiency gains in the plant's operations.
Cost saving
Previous situation
0.5l of Berner lubricant at € 8/l per application.
In 6 months = 24 applications.
Application time: 15 minutes at €37/h.
0.5l x €8 x 24 = €96 (cost of grease)
0.25l x €37/h x 24 = €222 (cost of labour)
For cleaning:
0.5h per month x €37/h x 6 months = €111,- (cost of cleaning)
Total costs: €96 + 222 + 111 = €429 x 4 wheel units = €1,716
Current situation
1/5 of aerosol spray at €32.79/pc. per application.
In 6 months = 1 application.
Application time: 5 minutes at €37/h.
0.2 x €32.79 x 1 = €6.56 (cost of grease)
0.0833 h x €37 /h x 1 = €3.08 (cost of labour)
For cleaning: € 0
Total costs: €6.56 + €3.08 = €9.64 x 4 wheel units = €38.55
Saving
€1,716 - €38.55 = € 1,677.45 every 6 months.
