Reduce Friction for Energy Savings
A significant portion of energy loss in gearboxes is caused by internal friction between gears, bearings, and shafts. Under high loads, this leads to heat generation and premature wear.
The latest generation of lubricant additives, combined with relatively low-viscosity gear oils, can reduce internal resistance in heavily loaded gearboxes by 10 to 15%. This results in tangible benefits:
- Lower energy costs per operating hour
- Reduced operating temperatures
- Extended oil life
- Less wear on gear teeth and bearings
What Are the Practical Benefits?
Reducing energy consumption lowers CO₂ emissions and directly saves on energy costs for the organization. Additionally, it reduces the pressure on maintenance personnel by minimizing unexpected repairs and downtimes. This not only increases reliability but also enhances production safety and efficiency.
This approach is particularly effective for gearboxes operating at the limits of their capacity. This situation may arise in production lines with limited space or when the gearbox is positioned next to a heat source, leading to additional thermal stress.
Reliable Bearing Protection
Bearings are among the most sensitive components within gearboxes. Inadequate lubrication often results in premature bearing failure, a key cause of unplanned downtime. Factors such as steam, heat, water, or dust from the environment, as well as the use of incorrect lubricating grease or failure to follow prescribed lubrication intervals, can contribute to this issue. Specially formulated thermally stable lubricating greases resistant to water and other contaminants offer a solution by providing:
- Consistent lubrication at varying speeds
- Protection against water and dust
- Reduced wear under shock loads
- Long-lasting protection, even with extended lubrication intervals or deferred maintenance
These lubricating greases are suitable for both centralized grease lubrication systems and manual application using grease nipples.
Liquid Grease: An Alternative for Risk of Leakage
In certain situations, traditional oil lubrication may not be ideal, such as when there is a risk of leakage or gearboxes are difficult to access. Liquid grease combines the lubricating properties of oil with the sealing action of grease. It actively spreads and adheres to gear teeth, minimizing leakage through seals and resisting contamination more effectively.
When transitioning to liquid grease lubrication, attention must be paid to technical considerations:
- Gearboxes equipped with oil coolers or external filters are unsuitable
- Bearings previously lubricated via oil splash require active grease lubrication, for example, through a grease nipple on the bearing
Biodegradable Gearbox Oils
The demand for environmentally friendly lubricants is increasing, particularly in sectors like offshore, earthmoving, agriculture, and applications in natural areas. While earlier environmentally friendly lubricants often sacrificed performance, the latest generation of biodegradable lubricants now offer viable alternatives to conventional products.
This advancement is attributed to progress in base oil and additive technology. The newest generation of biodegradable oils exhibits greater resistance to aging from high temperatures, oxidation, and water contamination. This results in excellent protection against wear and corrosion, while ensuring the lubricant remains fully biodegradable.
Conclusion: Investing in the Right Lubrication Strategy
Prolonging the lifespan and reducing energy consumption of gearboxes does not always necessitate substantial investments. With the right lubricants and consideration for load and orientation, every maintenance department can achieve gains in efficiency, reliability, and sustainability.
Practical Solutions from Eurol
At Eurol, we develop lubricants specifically designed to address the challenges mentioned above. This is based on our proprietary SYNGIS Technology: a unique blend of additives that synergize to deliver optimal performance under harsh conditions, reduce friction, and prolong the lifespan of components.
Our solutions include:
- Additives that reduce friction in existing oils
- Rugged lubricating greases for heavy bearing loads
- Liquid greases for vertical mounting or in cases of leakage risks
- Biodegradable variants for environmentally sensitive applications
If you want to know which solution best suits your installation, contact our technical team. Our specialists are ready to assist you.
