A prominent British automotive and aerospace manufacturer in Northern England has seen extended maintenance intervals and significant cost reductions in their powder coating lines due to improved performance of the bearings, thanks to Arvina XR1, an extreme performance bearing grease.

Powder coating lines are conveyor systems that apply a coating to components, this is known as ‘finishing’. This process protects these components, reducing chipping, scratches, and overall wear and tear.

Powder coating lines use a conveyor system with rolling racks held on the line by bearings. These bearings pass through spraying, drying, and curing sections and require consistent lubrication from specialised bearing greases to function effectively.

The manufacturer was encountering issues with lubricant pumpability and was looking to reduce maintenance costs by extending maintenance intervals between bearing changes.

When reaching out to Molyslip, the manufacturer was facing several key issues during the powder coating process. Notably, the inability to pump the current grease into the applicator effectively. This was causing additional issues with production and slowing down efficiency as a result.

Additionally, the manufacturer was looking to reduce overall bearing failures and increase maintenance intervals to reduce costs associated with downtime.

Powder coating lines encounter several key issues during the powder coating process.  These include the following:

• Bearing failure – As the rolling racks rely on bearings which are put through significant thermal stresses, these bearings can frequently fail and cause issues for manufacturers. Minimising bearing failure is a vital part of efficient production.
• Improper lubrication – Without lubrication, rolling elements can often underperform and deliver poor results. Lubrication needs to remain consistent and resilient during manufacturing.
• Inability to pump grease – A key issue for the manufacturer was their inability to pump the previous grease, which caused significant issues, leading to maintenance costs and an ineffective product.
• Maintenance downtime – The manufacturer was looking to increase intervals between machine downtimes, reducing maintenance costs, improving efficiency and leading to higher output.
• Production costs – Reducing the cost of production and the spend on lubrication is a factor every single manufacturer considers. Keeping down production costs is vital for improving profitability across the board.

The manufacturer worked with Molyslip’s team and Business Developer Manager, Mike Green, to find a suitable replacement within our leading range of bearing greases.

Working with our technical support team, we determined that Arvina XR1, part of our larger XR range of extreme performance bearing greases, was the optimal solution.

And here’s why:

• A fully synthetic, perfluorinated grease
• Excellent high temperature capability up to 280°C
• Can be applied manually, via a standard grease gun or central lubricating system capable of pumping NLGI 1 grease
• Provides extended relubrication intervals compared to conventional greases
• Outstanding chemical resistance against aggressive chemical environments
• Optimised base oil, thickener and additive system
• NSF registered food-grade grease, ensuring it is safe for incidental food contact

The manufacturer’s most prominent issue was its inability to pump the previously used product, making application difficult. Switching to Arvina XR1, they were able to remedy this concern with ease.

Thanks to the Arvina XR range being available in a variety of NLGI penetration grades, we’re able to offer solutions to a wide variety of operating conditions and applications. At an NLGI 1, XR1 was the perfect fit to solve the manufacturer’s pumpability issues.

With its high heat resistance and excellent adhesion, Arvina XR1 was able to extend maintenance intervals from fortnightly to monthly, representing a 100% increase in maintenance interval periods.

Furthermore, by switching to Arvina XR1, the manufacturer was able to make a £30 cost saving on each cartridge used. The manufacturer also experienced no drip off when XR1 was applied.

In short:

• Solved manufacturers’ pumpability issues
• Extended maintenance intervals from every two weeks to one month
• A £30 cost saving on each product cartridge
• No lubricant drips off after use

By switching to Arvina XR1, the British automotive and aerospace manufacturer successfully addressed critical issues in its powder coating lines with the help of Molyslip’s Arvina XR1 bearing grease.

Arvina XR1, resolved the manufacturer’s pumpability problems that had been affecting production efficiency. Plus, this change not only extended maintenance intervals from two weeks to a month but also led to significant cost savings of £30 per cartridge.

The grease’s superior performance, including its high temperature capability, excellent chemical resistance, and enhanced lubrication, contributed to reduced bearing failures, improved efficiency, and more reliable production.

Ultimately, the collaboration with Molyslip resulted in longer-lasting, more effective bearing lubrication, reducing overall maintenance costs and ensuring smoother operations.

Want to learn more? Discover our bearing grease range or get in touch with one of our expert team below.