Polishing machine of lens manufacturer
Preventing seal degradation, longer maintenance intervals
Initial situation
In the production of optical lenses, a polishing machine is used to refine the lens surface. A critical component of this machine is the spindle, which is sealed with an NBR rubber ring to prevent polishing fluid from infiltrating the shaft. However, this rubber seal deteriorated within 1-2 weeks, allowing the fluid to reach the spindle and compromising the quality of the lenses. The issue was only discovered after defective lenses were produced, as there was no predictive method to anticipate seal failure.
The premature failure of the NBR ring was primarily caused by the polyglycol-based oil used in the previous lubricant. Polyglycol is known to be aggressive to certain seal materials, including NBR, and caused the rubber to degrade, losing elasticity and sealing performance.
(As a general consideration, NBR materials are also not well suited to temperatures above 75ºC, which can further accelerate degradation in certain applications, though this was not confirmed as a factor in this specific case.)
Solution
The initially used high-quality lubricant failed to prevent premature seal failure, allowing polishing fluid to enter the spindle area and compromise lens quality. Switching to Interflon Food Grease HD00 fully resolved the issue.
The advantages of this solution included:
- Extended lubrication intervals: The maintenance interval increased from two weeks to two months, significantly reducing downtime and labour costs.
- Elimination of scrap: The improved lubrication ensures consistent lens quality and eliminating defective products.
- Seal protection: Due to the formulation of Interflon Food Grease HD00, the NBR seal is no longer affected, dramatically increasing its lifespan.
- Certified safety and compliance: Interflon Food Grease HD00 is PFAS-free and holds an NSF H1 registration.
- Advanced lubrication technology: The grease is enhanced with MicPol® technology, providing exceptional wear protection and water resistance.
- Cost savings: Although precise calculations were not performed, estimated annual savings amount to approximately HUF 1 million (~EUR 2,600), due to reduced waste and maintenance efforts.
Conclusion
By implementing Interflon Food Grease HD00, the lens polishing machine became far more reliable. The risk of spindle contamination was eliminated, maintenance frequency was drastically reduced, and production waste was brought down to zero.
With its unique combination of MicPol® technology and PFAS-free formulation, this lubricant provides a safer and more efficient alternative to conventional greases. These benefits are why more and more engineers are making the switch to advanced lubrication solutions. Given the success of this solution, further extension of the lubrication intervals may be considered in the future.
