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News Release from: Dow Corning | Subject: Synthetic lubricant
Edited by the Manufacturingtalk Editorial
Team on 15 June 2007
Synthetic lubricants best for bearings
and gears
Dow Corning explains how synthetic lubricants are best for complex bearing and gear applications in extreme pressure situations, reducing costs and energy consumption.
Today's industrial lubricants need to meet higher performance requirements than ever before, especially when it comes to complex bearing and gear applications in extreme pressure situations That's why many plant managers are turning to synthetic oil lubricants to improve plant efficiency and performance, while reducing costs and energy consumption
This article was originally published on Manufacturingtalk on 19 Jul 2006 at 8.00am (UK)
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In complex bearing and gear applications in extreme pressure situations, many plant managers using synthetic oil lubricants to improve plant efficiency and performance.
Synthetic lubricants are different than traditional mineral oils in that they are engineered by combining smaller molecular "building blocks" to meet targeted performance specifications - such as size and structure.
This means that the lubricant can be customised to meet each customer's individual needs.
In addition, because synthetic oils are formulated under carefully controlled conditions, manufacturers can minimise impurities, which often lead to oil degradation and machinery damage.
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One advantage to synthetic lubricants is their efficiency.
Synthetic gear oil, for example, dramatically improves efficiency by reducing tooth-related friction by 30 percent and as a result lowering tooth-related friction losses.
At the same time, using synthetic gear oil allows for smaller gears with smaller motors to provide the same power output.
In addition, higher power output can be achieved with the same power input.
In the same vein, synthetic oils provide improved lubrication of gear box bearings and ball bearings in electrical motors, fans, calendars, presses, metal working machines, generators, utility switch contacts, spindles, dryers and other applications.
Bearing grease is uniquely positioned to handle high speeds, high loads and high temperature combinations with extreme efficiency.
This is due to the fact that synthetic bearing grease has a high load-carrying capacity that protects against metal-to-metal contact and extends the life of the component parts.
Synthetic bearing grease also provides trouble-free operations at a wide range of temperatures, from -45 to 185 C (-50 to 360 F).
Although in many cases these synthetic oils are initially more expensive per unit than traditional oils, their superior performance lowers total production costs and adds value over time.
Synthetic oils help reduce oil and operating temperatures thereby making the interval between oil changes three to five times longer.
In general, synthetics provide excellent resistance to emulsification and last longer; this extends maintenance intervals, which offsets the higher price.
Another related benefit of new synthetic oil technology is energy savings.
Good lubrication reduces friction in machines, which means less energy is required for them to operate.
Worm gearboxes, for example, are a great candidate for new oil technology and can improve energy savings by seven to eight percent, or more.
Even a small percentage reduction in energy use will typically pay for a plant's total lubrication expense within a few months.
Industrial plants still using mineral oils for lubrication may want to consider changing to new synthetic oil technology because it outperforms mineral oils in many areas.
Manufacturers who use synthetic oils find that the oils have an inherently high viscosity index and provide no place for oxidants to bond, reducing the chance of rust.
Synthetic oils also perform well at low temperatures with low evaporation loss and minimal tendency to form residue.
In addition, unlike mineral oils, synthetic oils have improved resistance to ambient media and are food grade compliant.
Applying a successful lubrication management strategy that involves changing from a mineral oil product type to a high-performance synthetic often results in real dollar cost savings for your plant.
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