Lubrication Excellence

Best practices for safety and uptime in food processing

Brandon Brownlee, Motion

The increasing cost of food and beverage machinery makes running equipment to failure not just impractical, but potentially devastating to your bottom line. However, there are solutions that can lead to significant savings, and an often overlooked one is implementing an effective lubrication program. A well-structured program delivers a trifecta of benefits: reduced downtime, a cleaner and safer work environment, and easier compliance with the stringent regulations of the food processing industry. 

Moving beyond basic lubrication, many companies find even greater returns by integrating lubrication into a comprehensive reliability-centered maintenance program. This approach, built on measurable goals, timely execution and consistent discipline, provides a framework for continuous improvement and drives significant payback. This focus on lubrication empowers you to achieve optimal asset health, consistent production output and the holy grail of zero downtime.  

To Lube or Not to Lube?

Apologies to William Shakespeare for contorting his line from Hamlet. While the decision “to lube or not to lube” might seem straightforward, developing and maintaining an effective program requires planning, dedication and an initial investment. However, the return on investment is undeniable: Lubrication programs consistently save money and reduce waste. Don’t wait for a contamination incident, regulatory action or equipment failure to force your hand. Protective lubrication is the key to keeping your assets producing, healthy and profitable.

Organizing a Lubrication Team

Once the decision to implement a new lubrication process is made, assembling a cross-functional team is critical. The team should include representatives from maintenance, operations, engineering, and even your lubricant and equipment suppliers. The initial meeting serves as a crucial discovery phase, allowing the team to assess the current state of lubrication practices and define desired outcomes. Remember, clearly defined objectives are essential for achieving success.

This process is key to identifying and training dedicated, full-time lubrication technicians. Lubrication is not a task to be relegated to part-time or light-duty roles. It demands a specialized skillset, honed through comprehensive training and ongoing development, ensuring these technicians can effectively maintain the health of your assets. 

Choosing the Best Lubricants and Usage

This is where your cross-functional team shines and third-party partners bring their expertise. Focus on: 

• Consolidation and Standardization: Collaborate to identify and consolidate the optimal lubricants (including aerosols and oils) for your needs. Determine the most effective lubrication methods (centralized systems, automatic lubricators, manual lubrication) and establish sanitary dispensing procedures for your food production environment.
• Equipment-Specific Requirements: Define lubrication requirements for each machine type and location, consulting equipment manufacturers for recommended lubricants and intervals. Work with bearing and gear reducer manufacturers to specify proper lubrication for those critical components.
• Optimize Lubrication Delivery: Explore grease guns and automatic lubricators for optimal grease and oil application, especially in areas with difficult access or safety hazards. Selecting the right dispensers ensures reliable lubricant delivery, a crucial element of a successful program.
• Creating a Lubrication Legend: Develop a clear visual legend using color codes and symbols to match lubricants with specific equipment (Figure 1). Your lubricant and equipment provider can be invaluable in this process. Include clear warnings against mixing fluids—debunking the myth that all greases and oils are compatible with mixing. Verifying compatibility upfront prevents costly problems down the line.
• Implementing an Oil Analysis Program: Establish a robust oil sampling program to identify potential issues before they impact production. Regular analysis can also enable extended drain intervals, maximizing equipment life and minimizing downtime. This proactive approach, combined with conditioning monitoring, provides insights that visual inspections alone cannot.
• Prioritizing Food Safety: Ensure appropriate food-grade lubricants and oils (H1, H2 or H3, along with other relevant subcategories). Food safety is number one.

Storage Best Practices

Proper storage and dispensing are crucial for maintaining lubricant integrity, promoting safety and ensuring efficient application.

• Dedicated Lubrication Room: Designate a well-lit, restricted-access lubrication room for storing bulk containers, pails, greases and aerosols. This room should have lockable (and potentially fireproof) cabinets, climate control to prevent moisture buildup and appropriate equipment for storage, dispensing and transportation.
• Spill Prevention and Control: Install spill containment decks or pallets beneath all dispensing equipment. Ensure spill kits are readily available in the storage area for immediate cleanup.
• Designated Transport and Equipment Areas: Define specific areas for storing lubrication equipment and filter carts, adhering to company policies for safe lubricant transportation within the plant.
• Clear Identification System: Implement a consistent identification system that mirrors the usage legend established for equipment and ensure a legend copy is posted in this room. Use color-coded labels and shapes to identify lubricants in storage and at dispensing points throughout the plant. This visual system enables lubrication technicians to quickly and accurately locate the correct lubricant for each application.

Waste Disposal

Protecting the environment and complying with regulations are integral to a successful lubrication program. 

• Designated Disposal Area: Establish a designated disposal area well away from food production areas. Never dispose of used lubricants in undesignated trash bins or drains.
• Safe Waste Oil Management: Implement a system for safely managing waste oil from oil changes, empty grease tubes, pails and bulk containers. Utilize a skid-mounted waste oil unit and avoid mixing different types of lubricants. Adhere to all local and national regulations for proper disposal, documenting all activities for audit and compliance purposes. Consult your lubricant provider or Environmental Health and Safety (EHS) representative for guidance.
• Exploring Recycling Options: Investigate the potential for recycling used lubricants. While regulations for food-grade lubricants vary, consult with recycling companies to identify opportunities to reduce waste and enhance sustainability.

Remember, minimizing should be a primary objective of your lubrication program. Following best practices for lubrication selection, application and storage, along with utilizing tools like automatic lubricators, can significantly reduce waste generation.

Training 

Elevate your lubrication program by investing in comprehensive training for your team. Partner with a reputable organization that can tailor a program to your plant’s needs and goals. This will empower your team with enhanced skills and credibility, and ultimately deliver a strong ROI. 

Strive for comprehensive certification across your lubrication team. Organizations like the International Council for Machinery Lubrication (ICML) and the Society for Maintenance & Reliability Professionals (SMRP) offer valuable certifications in machinery lubrication, oil analysis and best practices for maintenance and reliability. A well-trained team is essential for building a world-class lubrication program. 

Changing Needs

Building a successful lubrication program requires ongoing effort and adaptation. Regularly review and adjust your plan to align with your plant’s evolving needs. Factors like new equipment installations, upgrades or decommissioning of older assets will necessitate modifications. Stay informed about changing regulations, whether due to plant expansions, relocations or general industry updates, to maintain continuous compliance. Remember, meticulous and consistent documentation is crucial for success.

This comprehensive approach to lubrication will contribute to improved asset health, a cleaner and safer food production environment and increased uptime. Prioritizing food safety benefits both your plant and consumers. By implementing these strategies and collaborating with your qualified lubricant and lubricant-equipment provider, you can establish a robust lubrication program as a cornerstone of your overall plant operations.

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