Optimised lubrication for animal feed pellet presses
Extending bearing life and reducing lubrication costs
Problem
A leading animal feed manufacturer sought to lower maintenance costs and improve equipment reliability. Their previous lubricant had a short service life, was difficult to pump, and led to frequent bearing replacements to prevent costly downtime.
The pellet machine features an external Crown housing with two rollers, each supported by two bearings (four per machine). During operation, flour is compressed against the Crown surface, forming pellets. Normally, rollers required replacement every two months, the Crown every four, and bearings every six.
To prevent blockages and downtime, the client replaced bearings early as part of preventive maintenance, leading to excessive lubrication costs and waste.
Solution
Interflon recommended Interflon Food Grease HD2 - an NSF H1, Kosher- and Halal-compliant, lubricant with MicPol® technology, specifically developed for demanding food-grade applications.
Key benefits:
- Grease consumption reduced 44x: From 153 kg in 40 days to just 3.42 kg in 43 days.
- Cost savings: Grease cost per tonne of product dropped from €0.267 to €0.081 (-69.7%).
- Lower environmental impact: PFAS-free lubricant reduces waste and supports sustainability goals
- Higher production efficiency: 5% increase in output due to smoother operation.
- Longer component lifespan: Bearings lasted significantly longer, reducing unplanned downtime.
These improvements saved the company thousands in maintenance costs while ensuring more reliable production and a competitive edge.
Conclusion
Implementing Interflon Food Grease HD2 significantly reduced grease consumption, maintenance needs, and operational costs. The company achieved annual savings exceeding €6,000, with additional benefits from longer component life and reduced downtime.
By switching to PFAS-free lubricant with MicPol® technology, they joined a growing number of manufacturers improving reliability while ensuring regulatory compliance and sustainability.
