The new MEMOLUB® ONE LPS utilizes the same reliable patented positive displacement pumping system as the MEMOLUB® HPS but, with reduced output pressure, is specifically designed for single point lubrication.  The simple MEMO system, used to set the programming of the MEMOLUB® ONE LPS, eliminates the risk of inadvertently changing the lubricant output frequency setting, thus avoiding human error.  MEMOLUB® ONE LPS can be remotely mounted up to 6 feet from the lube point, minimizing the danger of accessing critical points.  The low cost, easy-to-change, replaceable lubricant cartridge (available with the customer’s choice of grease or oil) and battery pack are the only consumables required, reducing not only the environmental impact, but also the ongoing cost of use when compared to other similar systems.

Power Source

When thinking about the proper setup for a cold temperature application the first thing I think about is the power supply to the lubricator.  As alluded to, several options are available for powering mechanical lubricators such as:

• alkaline batteries
• lithium batteries
• PLC (Program Logic Control); and
• external AC  or DC

In a typical cold temperature application, the simplest solution is to use a lubricator that is battery powered.  Most automatic lubricator sales personnel would recommend lithium batteries in cold weather as well.   Mechanical lubricators also come with the ability to be remotely mounted from its application (which is a great feature) but, getting the lubricator as close to the lube point as possible is best.  With that said, directly mounting on the lube point is ideal for cold weather applications.

The Correct Lubricant

One of the most important (and at times, most difficult) issues to address in a cold temperature application is the lubricant.  Finding a lubricant that not only meets the application’s needs, but also flows well at low temperatures can be quite an undertaking.  With few exceptions, greases tend to resist flow as temperatures lower.  A grease that flows like syrup at room temperature could flow like molasses at near-freezing temperatures.  This resistance to flow is critical when using automatic lubrication devices, as the device will have to generate enough pressure to push this semi-solid to your lube point.  Your average hand grease gun has a pressure output of 10,000psi, which is more than sufficient to push even the thickest of greases.  In contrast, a typical self-contained mechanical lubricator generates somewhere in the neighborhood of 300-400psi, which is usually sufficient to push a light- to medium-weight grease at temperatures above freezing, but can be an issue at colder temperatures.  Understanding how your lubricant’s flow is affected by cold temperatures is imperative and should not be taken lightly.

A good place to start finding the best lubricant for your application is the OEM (Original Equipment Manufacturer), but finding a lubricant that in addition is suitable for use in automatic lubricators requires some further consideration.  It doesn’t matter how good the lubricant is for your application if it never reaches the intended lube point. Some important characteristics to look for are the base oil viscosity, grease consistency/thickener, and lubricant additives.

Base Oil Viscosity (ISO) is the measure of a fluid’s resistance to flow when under stress.  This is probably the most important characteristic to speak of and is commonly confused with Grease Consistency, which is a measure its relative thickness.   A greases consistency is characterized by its Thickener, which is responsible for keeping the lubricant intact on the lube point.  The consistency is rated by an NLGI number on a scale from 000-to-6 where the higher the number, the thicker the lubricant.  Lastly, substances added into the lubricant in order to enhance their performance are referred to as Lubricant Additives.

These variables make up the performance properties of a lubricant and the properties needed are determined by the application.  In cold temperature applications it is very important to make sure that the lubricant can operate in a lubricator effectively.  A good rule of thumb for this is the colder the application, the lower the NLGI weight and ISO numbers should be.  To learn more about selecting lubricants read Step-by-Step Grease Selection found in Machinery Lubrication.

In Conclusion

Automatic lubricators are a great option to employ on your cold temperature applications; however, the success of properly lubricating your equipment comes down to carefully planning the setup of the application. Using an electromechanical lubricator with a lithium battery pack can produce a reliable and consistent result.  Make sure to limit the distance between the lubricator and the lube point, and if at all possible, directly mount the lubricator for best results.   Choose a lubricant with a lower NLGI weight and ISO number that is going to work in the lubricator as well as meeting your applications needs.  Using an automatic lubricator on your cold weather application will not eliminate the need of checking on your lube point, but it will certainly limit the number of times you have to do it.  It is important to note that automatic lubricators are pieces of equipment and do require monitoring and maintenance.

A Successful Setup

For cold temperature applications, having the correct setup is vital to achieving success. The first step in evaluating your setup is to quantify “cold temperature”, as this is relative and means very little out of context.  The typical cold working temperature of most automatic lubricators is 0°F (17°C) with a variance of (+/- 5°).  It is possible to lubricate at even lower temperatures, however this usually necessitates some adjustments to the lubricant and/or the type of automatic lubricator used. If you are not already familiar with the different types of lubricators that are available, you may have to do a little homework prior to continuing.  There are a number of resources out there comparing and contrasting the different types, including a whitepaper we authored found here.

The most commonly used lubricators found in industry today are either electrochemical (also referred to as“gasgenerators”) or electromechanical in nature.  Although gas generator type lubricators can be used in cold weather they are generally not ideal due to their sensitivity to ambient temperatures.  As the name suggests, the means of expelling lubricant from electrochemical lubricators is through a chemical reaction which generates a gas.  As the gas expands inside this closed space, lubricant is forced out.  The more volatile the reaction, the faster the gas expansion, and thus the faster the flow rate of the lubricant.  This process is subject to the laws of physics which (in very simple terms) dictates that the colder the ambient temperature, the slower the reaction.  Conversely, the warmer the temperature the faster the reaction takes place.  The bottom line is unless you’re in a geographic area that tends to have constant temperatures year-round; the rate of lubricant flow to your lube point will be somewhat unpredictable (at best) using this type lubricator.

Electromechanical lubricators, on the other hand, rely on mechanical means to dispense the lubricant, and as such are more reliable and consistent in any given environment.  Inherently, this technology has the added benefit of generating greater output pressures, which means greater flexibility in how and where they are used.  Many come with various power options and are capable of being remote-mounted significant distances from the application point.  In fact, we have several “cold temperature” customers that exploit this ability by mounting the lubrication system inside a building or heated enclosure, and then running a lube line to the outside lube point.

Limited Exposure

These systems limit the exposure a lube point has to its environment because they are fitted right onto its lube point.  The only time the lube point is when a new lubricant cartridge or lubricator is being installed.  For a MEMOLUB® application, changing the cartridge takes less than a minute to complete.  See for yourself by watching our video on “How to Change a Cartridge.”

Better Identification

Also these systems dramatically decrease the chances of cross contamination because they are identified with the correct type of lubricant.  You cannot just grab a grease gun and filled a lube point…you need a replacement cartridge.  In essence, this takes more effort to replenish a lube point with lubricant, rather than grabbing the nearest grease gun filled with…well, whatever is in the grease gun.   In sum, these systems have more checks and balances to cross before applying a lubricant forcing you to think about what you are doing. 

So What to Do?

These closed systems make up for a lot in cost savings because they limit equipment down time due to bearing failures.  If you want more production don’t let contaminants infect your lube points, instead, put an automatic lubricator to work and protect your lube points.  

A lubricant is anything that separates two moving surfaces in order to reduce friction, heat, and surface degradation.  The results of proper lubrication increases efficiency, and prolong the life of whatever it is lubricating.

A contaminant is anything that interrupts this relationship from taking place.   Things such as dust, water, and small particles are prone to getting into lubricants when they are not stored and/or not dispensed correctly.  Contamination is a leading cause of machinery failure by directly impairing the lubricant’s ability to control friction, wear and corrosion.

To find out more about this topic read this case study dealing with handling and dispensing lubricants.

By using an automatic lubrication device you will decrease the likelihood of contaminants interfering with a lube point because it is a closed system. This is a great option to better monitor your lube points, and reduce the risk of contamination.

Many manufactures in the U.S. are yet to implement effective lubrication practices.  It is said that over $4 billion is lost annually to ineffective lubrication approaches.  Below is a summary of the some of the most common challenges with lubrication practices:

Over-Lubrication: This will raise the temperature of a bearing which then causes excess wear, compromises seals, and causes oil shedding from its base thickener.

Under-Lubrication: This causes surface-to-surface friction and wear.

No Lubrication: this causes severe mechanical wear and thermal degradation of seal and bearing material.

The good news is that it will not cost nearly as much as $4 billion to improve your plants lubrication practices.   By using preventative measures, major costly problems can be prevented by a strategic plan.  To overcome these challenges that face your lubrication practices, it could be as easy as being more attentive to your bearings, or lightening the load of your maintenance team by implementing lubrication systems.

Automating lubrication practices has been linked to reducing man hours, effectively lubricating bearings only when needed, and an extremely cost effective way to prevent bearing failures.

As we head into the fall this year, take a moment and think about what preventative measure can be used to help your operation run smoother and without bearing failures.  Then follow up those ideas by creating a strategic plan to prevent bearing failures from happening.

Improper lubrication can lead to unnecessary costs for an operation.  These cost could include the replacement bearing, labor for replacement install, labor for inefficient manual practices, downtime or lost production, and excess energy consumption from equipment not working efficiently.

Manual lubrication programs can get the job done, but a lot of times just getting the job done is not enough.  When making the comparison from manual lubrication to automatic lubrication the difference is that automating a lubrication practice provides the right amount of the right lubricant at the right time to the right place.  Manual lubrication practices have a tendency to be on a set schedule (once a day, week, month, etc) rather than when the bearing needs the lubrication.  Not to mention in order to compensate for the lubrication schedule an operator will often over lubricate a bearing allowing lead time in between lubrication applications.  This is improper lubrication and sets up the “over-lubrication and under-lubrication scenario.”

In short, why not automate your lubrication practices with today’s technology?  It will save you time, money, and all the headache of human error.