Background – Wood Pellet Manufacturing in Southeast Asia

Arvina XK1, our leading bearing grease solution for wood pellet manufacturing, enhances bearing life, leading to an annual saving of over £40,000 at a Southeast Asian wood pellet manufacturer.

The manufacturer’s operations depend heavily on maintaining efficient and uninterrupted machinery performance in a high-temperature environment, which is critical to producing quality wood pellets at a competitive cost.

Facing persistent issues with their incumbent grease for their KAHL Pelletizer machine as the operational temperatures regularly exceeded the machine’s design limits.

The machine was designed to operate at a maximum temperature of 180°C, but actual production data revealed frequent temperature spikes up to 200°C.

These conditions strained the bearings, leading to rapid oxidation and degradation of the incumbent grease. The additional strain and decreased grease efficiency ultimately reduced the bearings’ lifespan.

With annual bearing maintenance costs reaching approximately £200,000 across the manufacturer’s five machines, the company was eager to explore a lubrication solution that could withstand their unique operating conditions and, as a result, reduce maintenance costs in their production.

Challenge – Meeting Engineering Requirements for the Wood Pellet Industry

The Southeast Asian wood pellet manufacturer previously used an industry-standard grease, which allowed a bearing life of approximately 839 hours. However, this product saw excessive oil bleed after 800 hours, compromising both the bearings and production quality.

Consequently, the manufacturer sought a solution to extend bearing life, reduce grease consumption, and cut down on overall operating costs. Molyslip proposed a trial of Arvina XK1, a high-performance grease specifically designed to handle extreme temperatures and extended operational hours.

Solution – Trailing Molyslip Arvina XK1

Working with our technical advisor in the region Shahrin Aku Bakar, we conducted a trial of Molyslip’s Arvina XK1 at the Southeast Asian manufacturer from February to August 2024, aiming to test its durability under the high-temperature conditions typical of the wood pellet manufacturer’s production environment.

“After conducting a thorough site visit and discussing the unique requirements of the manufacturer, we determined that our high performance Arvina XK1 bearing grease was the right solution to meet this unique challenge.”
– Shahrin Aku Bakar – Technical Sales Assistant

The trial’s objective was straightforward: exceed 800 hours of continuous bearing operation before requiring replacement, surpassing the performance of the industry-standard product.

Trial Preparations

Before the main trial, preliminary testing included an oven-heating test at 160°C to simulate the high-heat conditions the bearings would endure. The Arvina XK1 grease underwent a burning test where it was monitored for stability and performance.

The results were promising, as Arvina XK1 remained intact for four days, while the competitor product began to bleed under similar conditions.

Execution and Monitoring

The primary trial involved applying Arvina XK1 to one KAHL Pelletizer machine, with measurements taken over six months. Key metrics monitored included:

• Production Running Time: Time before bearing replacement.
• Grease Consumption: Both per minute and per month.
• Bearing Temperature: Monitored to observe any reductions or increases under continuous operation.
• Bearing Condition and Performance: Assessments of bearing condition at intervals to ensure optimal performance and longevity.

Results and Outcomes

The trial results exceeded expectations and successfully validated Arvina XK1’s effectiveness in high-temperature, continuous-use environments.

Speaking on the result of this successful trial our technical lead Shahrin Aku Bakar said:

“This is an incredible result for our leading grease technology. The superior resilience of Arvina XK1 proves our capabilities to deliver truly revolutionary results for our customers.”

1. Extended Bearing Life: Arvina XK1 achieved a remarkable 1,017 hours of operation before requiring bearing replacement, representing a 21% improvement over the previous product. This allowed the wood-pellet manufacturer to extend their bearing replacement intervals and reduce associated costs.
2. Consistent Grease Consumption: Grease consumption remained consistent at 3.5 grams per minute, mirroring the previous product’s usage rate. Monthly consumption held steady at 62 kg, maintaining predictable cost and usage without excessive grease loss.
3. High-Temperature Stability: Operating temperatures for the bearings using Arvina XK1 averaged 70°C, just slightly above the industry standard’s 65°C. Despite the high machine temperature, Arvina XK1 resisted any oil bleed and maintained stability, which prevented contamination issues that had previously impacted product quality.
4. Reduced Bearing Oxidation and Wear: By avoiding grease excessive oil bleed and oxidation, Arvina XK1 preserved the bearings’ structural integrity. At 1,017 hours, the rollers and bearings remained in optimal condition, whereas the incumbent grease displayed significant wear by 839 hours.
5. Cost and Efficiency Gains: Given the 21% increase in operational life for each bearing, the manufacturer can now expect to reduce annual bearing replacement costs significantly. With a 21% increase in lubricant life that’s a £40,000+ saving on the previous £200,000 annual maintenance cost within the factory. With fewer maintenance interventions, machine downtime decreased, thereby enhancing production efficiency.

Conclusion

Molyslip Arvina XK1 proved to be a highly effective solution for the manufacturer’s operations, particularly under high-temperature and high-stress conditions.

With an impressive 21% improvement in bearing life and reliable performance at elevated temperatures, Arvina XK1 exceeded the trial objectives.

Our leading bearing grease has not only demonstrated its suitability for pelletising manufacturing environments but also proven its potential for a number of high-performance applications in industries where durable, high-temperature lubrication solutions are required.

The success of Arvina XK1 in this trial underscores Molyslip’s commitment to innovative lubrication technology and reinforces our role as a leader in high-performance industrial lubricants and greases.

The manufacturer has now planned for long-term use of Arvina XK1 across their machines, setting the foundation for improved cost savings, efficiency, and machine reliability moving forward.

To learn more about how our leading solutions can maximise your manufacturing, get in touch with our expert team today.