20 dB quieter conveyor belt at wholesaler-distributor Febelco

A 100-metre-long plastic chain conveyor belt in Febelco's distribution centre in Sint-Niklaas had long been causing excessive noise, dust formation and high wear. With a targeted dry lubrication strategy based on Interflon Food Lube AL and a mobile Interflon Oil Dispenser, this critical line has been transformed into a quieter, low-maintenance conveyor belt. What started as a trial on one line has now been extended to several conveyor belts in two other Febelco branches.

Situation: noise, dust and stick-slip on a chain conveyor

Febelco is the largest cooperative wholesaler and distributor of (para)pharmaceutical products in Belgium and supplies more than 3,200 pharmacies from seven branches. However, at the branch in Sint-Niklaas, a 100-metre-long plastic chain conveyor was causing serious problems. Febelco Sint-Niklaas supplies the Waasland region and a large part of East Flanders.
 

The conveyor belt transported containers of medicines through the facility and generated more than 80 dB of noise – comparable to a passing lorry. The main cause was stick-slip: a start-stop effect in the curves, whereby the plastic links and guides slid over each other under high contact pressure. The belt was not previously lubricated, allowing friction and wear to run rampant. 

The consequences for the operation were clear:

• Noise: a continuous disturbance for employees at the workstations under the belt.
• Dust formation: friction between plastic parts caused a fine white dust that settled on workstations and screens.
• Wear and risk of downtime: visible material loss indicated premature wear and an increased risk of unplanned downtime and replacement costs.

Solution: dry lubrication, automatically dispensed 

Interflon technical advisor Tom Peckstad developed a lubrication strategy based on dry lubrication, in line with the hygiene requirements in the pharmaceutical environment. The aim was to reduce friction and noise with a dry lubricating film that also prevents dust and dirt from adhering, thereby minimising the risk of contamination and dripping.

Lubrication strategy and product selection

These conveyor belts involve boundary and mixed lubrication at low speeds, high loads and frequent start-stop movements. In this regime, conventional lubricating films are often quickly displaced and stick-slip occurs. Interflon Food Lube AL with MicPol® technology was therefore chosen. This NSF H1-registered, PFAS-free dry film lubricant is ideally suited for automatic lubrication in the food, beverage and pharmaceutical industries and delivers very high performance even in these types of difficult plastic applications.

Due to the capillary action of the lubricant, the MicPol® technology penetrates deep into the spaces between the links and pin-bus connections. The lubricant is, as it were, ‘sucked’ into the clearance between the parts, allowing it to reach even the most difficult to access areas. The friction-reducing properties of MicPol® technology greatly reduce friction and wear and substantially lower noise levels. 

The dry lubricating film does not attract dirt and dust and does not leave a film on the underside of the containers being transported. Interflon Food Lube AL can be applied very thinly and has a very long effective life even in minimal quantities. This means that very little product is needed for very high protection and lubrication intervals can be safely extended.

Application method: mobile, automatically dosed lubrication 

An Interflon Oil Dispenser is used to achieve consistent and optimal lubrication over the entire length of the belt. This automatic, compressed air-powered system applies a precisely adjustable amount of lubricant via two nozzles.

The belt does not consist of a single continuous loop, but of multiple sections with interruptions. Each section forms its own rotating belt, with the following sections connecting seamlessly to each other so that the containers can continue to roll.
Because lubrication must take place for each individual belt section, a mobile Oil Dispenser was chosen. This can be easily moved and connected at various points along the installation. In this way, all critical areas, including the bends, are reliably lubricated without the need to invest in multiple lubrication systems.

Results: 20 dB less noise and lubrication intervals of 6 weeks

The new lubrication strategy yielded immediately measurable improvements.

• Noise reduction
  The noise level dropped from approximately 80 dB to 60 dB. A difference of 10 dB is usually perceived by the human ear as approximately half the noise level. A reduction of 20 dB therefore leaves roughly a quarter of the original noise level. This has a major impact on comfort and safety, especially during prolonged exposure.
• Less dust and wear
  The use of Interflon Food Lube AL with MicPol® technology virtually eliminated all friction-induced dust. There was hardly any visible material loss on the plastic parts, indicating lower friction and wear. In addition, the dry lubricating film does not attract dust and dirt, keeping both workstations and the conveyor belt itself clean.
• Extended lubrication frequency
  Initially, the belt was lubricated weekly with Interflon Food Lube AL. The interval has now been extended to one complete cycle of the belt every six weeks. This significantly reduces the maintenance load and also reduces lubricant consumption.
  The success of the first application in Sint-Niklaas has led Febelco to implement the same approach on conveyor belts at two other sites. This underlines the reproducibility and scalability of the solution.

Experience of the maintenance coordinator:

Are you facing similar challenges in terms of noise, wear or contamination on your transport systems, or do you have another question?

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