SUGAR MILL LUBRICANTS

Speciality Lubricants for Crusher Mill Bearing

An important stage in the sugar manufacturing process is the pressing/milling process to extract juice from the cane. The crushing mill defines the capacity of a sugar mill. Rollers in the crushing mill supported by journal bearings are subjected to both heavy and shock loads and operate under slow rotational speeds of 5 to 50 RPM.

The work environment is severe as these bearings are exposed to acidic cane juice, water and also dirt-laden environments. Ideal lubrication condition for a journal bearing to perform with minimal wear is when the bearing performs at the hydrodynamic lubrication regime characterized by minimal loads and high speeds. However, journal bearings employed at a sugar-crushing unit usually operate in boundary and mixed lubrication regime due to slow speeds and heavy loads.

Why Berulit SM Super?

Understanding nuances of the sugar manufacturing process and criticality of crushing mill, BECHEM has developed the advanced lubricant, BECHEM Berulit SM Super for the journal mill bearing application.

Adaptable with Centralised and Individualised Systems.
BECHEM’s product range is adaptable to both individualised as well as centralised lubrication systems. Trials conducted in both these systems with BECHEM Berulit SM Super have shown substantial savings in consumption.

LUBRICANTS FOR SUGAR MILL

High performance journal bearing grease developed with high base oil viscosity, metal complex thickener and solid lubricants for high load applications. High base oil viscosity enables Berulit SM Super to form a thick, high pressure lubricant film between the shaft and sleeve, minimising metal to metal contact. Presence of solid lubricants and additives. makes it ideal for emergency running and loading conditions of the bearing. Berulit SM Super is pumpable grease and offers excellent corrosion protection even in presence of water. Presence of special additive package ensures perfect lubrication in harsh environments with low consumption rate while ensuring extended bearing life.

Applications: Recommended for critical journal bearings in the crushing/pressing mills of sugar processing industries.

ProductBase OilThickenerNLGI-gradeTemp Range °CSend Your Queries
Berulit SM Super

  • Plain bearings
  • Open gears
  • High loads
  • Resistant to water
  • Corrosion protection
Mineral oil/synthetic oilMetal soap complexNLGI 1 & 00-5  to +200

Fully synthetic high temperature grease for long life lubrication of bearings exposed to elevated temperatures and high loads. This high performance grease has excellent consistency-temperature behaviour. Does not form residues at high temperatures. Berutox FH 28 EPK II has good sealing properties against water and corrosive media. Provides protection against corrosion and wear .

Applications: Berutox FH 28 EPK II is recommended for bearings and applications exposed to high temperatures and loads in cooling beds, rotary kilns, conveyor systems, annealing and drying furnaces, electric motors, hot air fans, gate valves in bulk material container systems etc.

ProductThickenerBase OilTemp Range °CSend Your Queries
Berutox FH 28 EPK II

  • High
    load
  • Resistant to water
  • High Tempratures
  • Roller bearings
PolyureaPolyalphaolefin-30 to +180

High performance synthetic lubricant with anti wear and corrosion protection properties. Advanced additives provide resistance to hot, cold water and vapour as well. The NSF H1 approved grease is neutral in smell and taste.

Applications: Recommended for plain and roller bearings, cam discs, guides and rollers in food and pharma industry including diaries, breweries, bottling plants, canning factories, coffee roasters, potato peelers etc. Can be used in central lubrication systems.

ProductThickenerBase OilTemp Range °CSend Your Queries
Berulub FB 34

  • Roller
    bearings
  • Plain bearings
  • Food grade / Pharmaceutical technology
  • Low temperature
  • High loads
  • Resistant to water
  • High speed
  • Corrosion protection
Aluminium complex soapPolyalphaolefin-40 to +160

Berulub FA 46 is a new generation multipurpose grease with reliable wear and corrosion protection. This special grease has good adhesive and sealing properties and provides stiff resistance to hot, cold water and vapour as well. NSF H1 approved, the product is neutral in smell and taste. Berulub FA 46 has good oxidation stability and ageing resistance as well. Solid lubricants within Berulub FA 46 ensures good load carrying capability.

Applications: Recommended for plain, roller bearings and UCP bearings in conveyors, machine parts, guides, in food and pharma sectors such as diaries, edible chip processing, breweries and bottling plants, pulp processing industry etc.

ProductThickenerBase OilTemp Range °CSend Your Queries
Berulub FA 46

  • Plain
    bearings
  • Roller bearings
  • Food grade / Pharmaceutical technology
  • Corrosion protection
  • Resistant of water
Aluminium ComplexWhite oil-20 to +120

BECHEM Ceritol HT Plus is a high temperature grease to lubricate and seal roller and plain bearings in industrial installations with ability to reduce friction and wear on mechanisms subjected to extreme temperatures. HT Plus protects applications and bearings from corrosion in presence of aggressive waters and harmful contaminations. Developed for central lubrication systems which supply points of lubrication in high temperature areas.

Applications: Recommended to lubricate seal guide rollers such as in slab and billet casters. Also to provide effective lubrication of asphalt mixing and finishing installations, hot rollers such as in paper mills or card-board box production, machinery and installations used in glass and ceramics industry, travel gate mechanism in sugar processing industry etc.

ProductBase OilThickenerNLGI-gradeService temperature °CSend Your Queries
BECHEM Ceritol HT Plus

  • Roller
    bearings
  • Plain bearings
  • High loads
  • High temperature
Mineral oilSpecial PolyureaNLGI 1-2-10 to +160

Based on metal complex thickener, Beruplex LI EP 2 is a long term lubricating grease for applications exposed to high and shock loads. This high performance multipurpose grease has very good corrosion protection property as well as provides wear protection to contacting frictional surfaces. Has good pumpability for central lubrication systems.

Applications: Recommended for lubrication of automotive wheel hub bearings, joints, cardan shafts, clutch pressure bearings, braking cylinder, ventilation systems, starter motor sliding parts and bearings, electric motors, blower fans, pellet mill bearings, barker section and rollers in drying plants of paper mills, fiberizer, motor, fan bearings, centrifuge bearings etc.

ProductThickenerBase OilTemp Range °CSend Your Queries
Beruplex LI EP 2

  • Roller
    bearings
  • Plain bearings
  • High speed
  • High loads
  • Automotive Industry
  • Good pumability
  • High temperature
Lithium ComplexMineral Oil-30 to +150

Based on metal complex thickener, Beruplex LI EP 3 is a long term lubricating grease for applications exposed to high and shock loads. This high performance multipurpose grease has very good corrosion protection property as well as provides wear protection to contacting frictional surfaces. Has good pumpability for central lubrication systems.

Applications: Recommended for lubrication of automotive wheel hub bearings, joints, cardan shafts, clutch pressure bearings, braking cylinder, ventilation systems, starter motor sliding parts and bearings, electric motors, blower fans, pellet mill bearings, barker section and rollers in drying plants of paper mills, fiberizer, motor, fan bearings, centrifuge bearings etc.

ProductBase OilThickenerNLGI-gradeService temperature °CSend Your Queries
Beruplex LI-EP 3

  • High
    temperature
  • Corrosion protection
  • Roller bearings
  • High loads
Mineral oilLithium complex soapNLGI 3-30 to +150

BECHEM Premium 2 is a new generation long life universal grease for roller and plain bearings experiencing high loads. BECHEM Premium 2 provides reliable corrosion protection as well as good resistance against water. This multi-purpose grease prolongs re-lubrication intervals and minimises wear of contacting surfaces. Also, available in NLGI – grade 3, 1, 0, 00, and 000.

Applications:  Recommended for plain and roller bearings under loads such as steering stems of motor bikes, plastic injection moulding machines with centralised lubrication systems. Also suitable to meet lubrication requirements of forging presses exposed to low loads.

ProductBase OilThickenerNLGI-gradeService temperature °CSend Your Queries
BECHEM Premium 2

  • Roller
    bearings
  • Corrosion protection
  • Resistant to water
Mineral oilLithium complex soapNLGI 2-30  to +130

BECHEM Premium 1000 is a specially designed grease for dip lubrication of open gears. The grease is equipped with special extreme pressure additives and a selection of solid lubricants including graphite which enables the grease to provide superior lubrication in boundary regime stage of lubrication. The high base oil viscosity of the grease enables film formation at high loads. BECHEM Premium 1000 improves pressure absorption and emergency running properties for gears/plain and antifriction bearings in continuous operation.

Applications: Recommended for open gears lubricated through dip lubrication system in rotary kilns, ball mills, coolers etc.

ProductBase OilThickenerNLGI-gradeService temperatureSend Your Queries
BECHEM Premium 1000

  • High
    loads
  • Corrosion protection
  • Resistant to water
  • Open gears
Mineral oilLithium soapNLGI 0-30 to +150

Berulub MG Paste is a multipurpose assembly paste with MoS2 to prevent seizure and wear during running-in phase by smoothening surface roughness of plain bearings, toothed-wheels, worm gears or gear boxes. The multipurpose paste prevents stick slip phenomenon at low sliding speeds and high surface pressures. MG Paste resists water and protects applications against fretting corrosion. MG Paste has good thermal stability.

Applications: Recommended for press fits, slide bars, guides and support of tooling machines, threaded spindles, splined shafts and tailstock centers etc.

ProductBase OilThickenerNLGI-gradeService temperature °CSend Your Queries
Berulub MG Paste

  • High
    loads
  • Corrosion protection
  • High temperature
  • Plain bearings
  • Thread lubrication
Mineral oilGelNLGI 2-3-25  to +450

High temperature, anti seize paste for screw and plug connections that are exposed extreme temperatures. Contains fine copper particles and solid lubricants that ensures long term anti seizure effect. Provides effective protection against regular corrosion as well as fretting corrosion and guarantees separation effect of components for long duration’s. Berulub VPN 13 reduces the initial breakaway torque of bolted connections. Suitable for high alloys threaded steels as well as stainless steel. Prevents seizure of screws and nuts used in furnaces of power stations. Does not leave any abrasive residues after active life.

Applications: Suitable as corrosion protection agent for screws, pins, bolts, flanges, spindles or press fits such as used in refineries. Can be used as a seal and functional agent for mechanisms such as valves, slides or metal seals used in Chemical plants, Cement plants, Mining equipment, Shipping etc. Also available in spray form as as Berulub VPN 13 Spray.

ProductBase OilThickenerNLGI-gradeService temperature °CSend Your Queries
Berulub VPN 13

  • High
    loads
  • High temperature
  • Thread lubrication
PolyglycolBentoniteNLGI 1*-30 to +1150

Berusynth EP series are Polyglycol based, high quality synthetic gear oil available from ISO VG 68 to 1000 with service temperature range of -30˚C to +180˚C. Berusynth EP range of gear oils provide excellent oxidation and shear stability, superior load carrying capacity and wear protection. With very high ageing resistance, Berusynth EP series allows for extended oil changing intervals.Possesses good viscosity-temperature behaviour. The gear oil series with reduced coefficient of friction results in lower sump temperatures, minimum power loss and extended oil change intervals.

Applications: These specially formulated gear oils are recommended for heavily loaded spur gears, bevel gears, spiral and worm gears in rolling mills, paper mills and textile manufacturing units. Berusynth EP range also provide superior results in roller and plain bearing applications where operating temperature are constantly above 100˚C.

Please consult a BECHEM Application Engineer for selection of the suitable grade of ‘Berusynth EP’ series for your application.

ProductBase OilViscosity [mm²/s] at 40 °CFlash point [°C]Viscosity indexSend Your Queries
Berusynth EP 68  1000

  • High
    loads
  • High temperature
  • Roller bearings
  • Closed gears
Polyglycol77
109
158
228
326
464
680
1020
≥ 285
≥ 288
≥ 290
≥ 270
≥ 278
≥ 294
≥ 238
≥ 300
201
203
196
198
212
231
245
278

Advanced range of high viscous service lubricant that is devoid of solid lubricants and can be applied by spraying or dipping systems. Offering superior wear resistance, Berugear HV series are extremely adhesive and form pressure resistant film that do not harden or break. The bitumen and heavy metal free lubricant reduces consumption and extends lubrication intervals. Available in varying base oil viscosities.

Applications: Berugear HV series are recommended for open gear drives of ball mills, rotary kilns, rotary barrel mixers and dryers with high width to diameter ratio. Please consult a BECHEM Application Engineer for selection of the suitable grade of ‘Berugear HV’ series for your application.

ProductThickenerViscosity [mm2/s] at 40 °CFlash point °CSend Your Queries
Berugear HV 20

  • High loads
  • Noise damping
  • open gears
  • Plain bearings
Mineral oil/Synthetic oil18,500≥ 160

How can we optimise lubrication consumption in Crusher mill bearings?
Journal bearings at cane crusher mills operate in boundary and mixed lubrication regime due to slow speeds and heavy loads. Traditional lubrication approach has been to continuously pump the conventional lubricant to avoid metal to metal contact between the frictional surfaces and thereby undesired wear. Additionally water is continuously pumped to reduce bearing temperatures. This approach however results in significant lubricant consumption as well as a messy shop floor.

To provide effective lubrication and thereby reduce consumption, a lubricant with high base oil viscosity that can form thick film between the shaft and sleeve and thereby reduce metal to metal contact is required.

Why should you consider Berulit SM Super for Crusher Mill bearing ?
Specially developed for high load applications, Berulit SM Super has high base oil viscosity of 2500 cSt which enables it to form a thick film between the contacting surfaces and thereby significantly minimizing wear rate of journal bearings.

Multiple field trials have proven reduction in consumption by 8 to 10 times when compared to conventional bituminous oils and by approximately 30% against low viscosity greases and high viscous oils.

Due to inherent properties of this special grease, minimal lubrication is sufficient to maintain the ideal bearing temperature. This also eliminates the need for external cooling of bearing and also reduces loads on ETP.

How does shock loads impact mill bearings? Can lubricants mitigate its impact?
Due to the nature of operation, shock loads on mill bearings are unavoidable in the crushing area. Conventional lubricants that are unable to withstand such extreme pressures, ooze out under these conditions allowing the contact surfaces to absorb the impact. Repeated impact of such loads might result in burn marks and cracks in the bearing. Lubricants with good EP properties can help mitigate the affect of shock loads on the bearings.

The special additive package along with high base oil viscosity, equips Berulit SM Super with a high load carrying capacity of over 8000 N. Additionally solid lubricants as additives, provide emergency lubrication properties and thereby guards bearing from critical loading conditions.

How to avoid abrasive damage to the shaft ?
Conventional greases are thick and have a tendency to hold onto contaminants during regular crushing operations leading to abrasive wear on the shaft and sleeve. An ideal lubricant for the crushing mill application should not only be able with withstand high loads but also possess good flushing and pumping properties.

Berulit SM Super is a fluid grease with excellent flushing property. Additionally, the fluid grease based on special metal complex thickener that has superior pumping properties in comparison to other thickeners has excellent flow-ability and pump-ability. This avoids choking of lubrication lines and points and any undesired damage to bearing by line choking and lubricant run-out.

FREQUENTLY ASKED QUESTIONS

Greases are made by mixing a solid material, called a thickener, with a base oil and property enhancing additives; but it’s the oil that forms the lubrication film. For better understanding, grease thickener can be thought of as a sponge saturated with oil. Moving parts squeeze the oil out of the sponge like thickener for forming the lubrication film. Typically, the base oil constitutes the largest proportion of grease weight at about 80-90%, followed by thickener at 10 to 20% and additives under 10%.

Dropping point of a lubricating grease is an indicator of the heat resistance of the grease. and is the temperature at which the grease is no more a thickened lubricating medium. The dropping point indicates the upper temperature limit at which a grease retains its structure, not the maximum temperature at which a grease may be used.

Few greases have the ability to regain their original structure after cooling down from the dropping point.

The most important feature of a grease is its consistency. A grease that is too stiff may not get pumped into areas requiring lubrication. While a grease that is too fluid may leak out. Grease consistency depends on the type and amount of thickener used and the viscosity of its base oil. A grease consistency is its resistance to deformation by an applied force.

The measure of consistency is called penetration. Penetration depends on whether the consistency has been altered by working. Standard test procedures established by American Society for Testing and Materials International (ASTM) and accepted by industry are ASTM D 217 and D 1403, measure penetration of unworked and worked greases.

The NLGI has established consistency numbers ranging from 000 to 6, corresponding to specified ranges of penetration distance of the standard cone into the test grease. Table below lists the NLGI grease classifications along with a description of the consistency of each classification.

Viscosity: It is a measure of resistance to flow of a lubricating oil.

Viscosity index: It is defined as rate of change of viscosity with respect to temperature.

Significance:

  • It is the most important property which determines the performance of lubricating oils under the influence of temperature
  • A lubricating oil should have sufficient viscosity to retain a lubricating film on the surface
  • On machine part moving at slow speeds under high pressures, a high viscous oil should be used as it better resists being squeezed out from between the rubbing parts.  Light oils can be used for lower pressures and high speeds.
  • It is not possible to maintain a liquid oil film between two moving or sliding surfaces if the viscosity is too low and hence excessive wear will occur.

The pour point of an oil is the minimum temperature at which the oil turns into semi solid and almost losses its flow characteristic. At low temperatures, the viscosity of the oil will be very high, causing the oil to resist flow. This is important in equipment that operates in a cold environment or handles cold fluids.

Mr-Harry-Hofmann
life-at-bechem-career
Akshaya-Patra-7
Quenching thirst