One of the processes during beer brewing is the “clarification” of the malt mash. In kettles, the malt residues are separated from the wort, the base for the final product. A regional brewery uses a special machine for this. That machine proved to be a major headache. The complex and costly drive of the machine was subject to severe wear and frequently broke down. The result: production downtime and damage. To solve the problem, experts were called in for assistance.
Costly Unique Gearbox with Specially Manufactured Parts
In the kettles containing the malt mash, a large rotating fork is placed to “clarify” the mixture. The fork is driven by a Flender HL3V transmission consisting of three parts. The secondary part is a costly unique gearbox specially made for this application. Parts must be custom manufactured. For the maintenance manager, it is important to minimize wear on this expensive part of the transmission.
Maintenance Wanted Insight into the Technical Condition
The transmission was filled at the factory with approximately 235 liters of gearbox oil from a well-known brand, guaranteed for 5,000 maintenance-free operating hours. The maintenance manager wanted insight into the technical condition of the transmission and contacted a specialized company. They advised analyzing a sample of the gearbox oil after 2,500 operating hours following the first oil change.
Excessive Wear After Only 2,500 Operating Hours
After just 2,500 operating hours, excessive wear on the gears was already observed. The additive in the oil prescribed by the machine manufacturer offered barely any protection. This would lead to gear damage due to pitting, meaning the gearbox would need to be overhauled within 5,000 hours. This was unacceptable as it would cause unplanned production downtime and significant costs. The maintenance manager called in experts for a solution.
Advice: Gearbox Oil with DUOLEC Additive
Based on the technical data of the transmission and an on-site inspection, the experts recommended the use of industrial gearbox oil Vari-Purpose 1605 with DUOLEC additive from Lubrication Engineers. This ISO VG 220 oil is developed for applications in gear transmissions where extreme pressure occurs between the meshing gear surfaces. This oil has extremely high thermal stability, providing sufficient lubrication even at high temperatures and preventing pitting.
Clear insight with condition monitoring
To maintain the oil condition optimally, Xclude breathers were installed, supplemented with an Xtract filtration system. With condition monitoring, a visual inspection through oil sight glasses, and periodic analysis of oil samples in an independent lab, there is clear insight into the degree of wear and the general technical condition of the transmission.
At Least 9 Years Service Life with DUOLEC
After no less than 8 years (25,000 operating hours), the first oil change was performed. The oil analysis showed no significant wear. The service life of the DUOLEC oil in this application was determined to be at least nine years. This is more than 10 times longer than the oil originally supplied by the gearbox manufacturer. Just on gearbox oil replacement, the company saves €2,000 annually. The costs avoided by not having to overhaul the gearbox and the savings from lower electricity consumption due to reduced friction resistance are not included.
Would you like to know more about DUOLEC 1605 Vari-Purpose oil? Then read the product page in our catalog.