Deciding on the right lubricants

By Staff Report October 29, 2024 7:52 pm IST

The machinery used in manufacturing needs constant lubrication for efficient functioning. Thus, selecting an accurate lubricant requires varied considerations, covering the machine type, the end product, and the industry.

Several factors come into play when selecting lubricants for high-stress environments in India, such as aerospace or automotive manufacturing. The first is viscosity stability, as lubricants maintain their viscosity under varying climate conditions. High-performance synthetics suit environments where machinery must perform under extreme pressure and temperature fluctuations.

Another consideration is wear protection. Indian manufacturing operates at high speeds and often under challenging environmental conditions like dust or high humidity. Lubricants require anti-wear additives that can prevent metal-to-metal contact and reduce the friction between components to extend the lifespan of expensive machinery.

Francisco José Hurtado Mayén, an Independent Industrial Consultant, says oxidation resistance is key. India is expanding its industrial landscape, which creates long operational hours and harsh conditions that lead to lubricant degradation. Thus, the selected lubricant has to resist oxidation so that machinery remains functional over extended periods without frequent re-lubrication or maintenance. 

For high-stress industrial environments, selecting the right lubricant is crucial for maintaining machinery performance and reliability. Golnaz Aboutorabian, Director of Dazed N Konfused Pvt. Ltd says lubricants must handle extreme pressures and heavy loads, particularly for machinery, automotive, and industrial equipment. Industrial environments involve exposure to dust, chemicals, and metal particles. Lubricants must resist these contaminants to maintain equipment integrity.

Selection of lubricants

Lubricant selection varies based on specific operational needs. Automotive and aerospace manufacturing requires high-performance lubricants to handle high speeds, extreme temperatures, and pressure conditions. Heavy industrial equipment requires lubricants bearing severe environmental conditions and heavy loads, such as mining or construction.

Lubricants used for precision manufacturing must be exceptionally clean and stable to avoid interference with delicate operations. A common misconception is that one lubricant can universally fit all types of machinery across various sectors. Saifullah Khalid, Quebec Petroleum Resources Ltd’s Deputy General Manager, shares that each machine type and industry has unique requirements, and using inappropriate lubricants can lead to reduced efficiency, increased wear, and early equipment failure.

Synthetic and nano-lubricants impact India’s heavy-duty manufacturing sectors, such as steel, mining, and cement. These lubricants have superior thermal stability and oxidation resistance, making them suitable for Indian industries that operate in harsh environments. Synthetic oils are required where machinery runs continuously in high-temperature environments, such as cement kilns or steel mills. These lubricants maintain their protective properties even under extreme heat.

Nano-lubricants contain microscopic particles that reduce friction. These lubricants minimise wear and tear at the molecular level and can make machinery run 24/7. They also enhance energy efficiency, thus saving its consumption.

Biodegradable lubricants are an option. They are derived from renewable resources and have a lower environmental impact than traditional petroleum-based lubricants. In industries with strict environmental regulations, biodegradable lubricants can help ensure compliance.

Condition-based lubrication (CBL) systems can monitor lubricant conditions and predict when maintenance is needed. They have sensors and analytics to act. CBL can reduce waste and extend lubricant life by avoiding unnecessary oil changes.

Multifunctional lubricants are a great alternative for multiple applications as they reduce the need for different lubricants. They can simplify maintenance procedures and reduce the risk of lubricant contamination.

Lubricant Analysis Techniques such as infrared spectroscopy, geography, and particle counting can provide valuable insights into lubricant conditions and identify potential problems. Manufacturers can implement preventive maintenance measures by monitoring lubricant conditions to avoid costly breakdowns.

By adopting these advanced lubricant technologies, manufacturers in heavy-duty industries can significantly improve their machinery’s efficiency, reliability, and lifespan while reducing maintenance costs and environmental impact.

Lubricants for the food processing industry

Lubricants used in food processing must comply with safety certifications like NSF H1 or ISO 21469. Indian manufacturers must select a lubricant that meets these stringent safety standards while performing effectively in industrial applications. For example, food-grade lubricants must be non-toxic, tasteless, odourless, and contamination-resistant while providing lubrication under high temperatures or in environments with frequent washdowns. One of the biggest hurdles Indian manufacturers face is balancing the cost of these specialised lubricants with their performance. Food-grade lubricants tend to be more expensive, and smaller Indian food processors may struggle to justify the higher costs while still meeting compliance. Indian food manufacturers often have to meet domestic and international regulations, and failing to comply can lead to shipment rejections, recalls, or loss of business. 

Indian manufacturers must stay informed about advancements in lubricant technology and carefully consider each sector’s unique demands. As the industry continues to evolve, understanding the critical role of lubricants will help companies in India improve efficiency, reduce downtime, and ultimately enhance their competitive edge in domestic and global markets.

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Golnaz Aboutorabian, Director of Dazed N Konfused Pvt. Ltd

The right lubricant must be selected to maintain machinery performance and reliability. Mainly, those lubricants that improve energy efficiency and machinery operations are always in demand.

Francisco José Hurtado Maén – Independent Industrial Consultant

Lubricants should contain anti-wear additives to prevent metal-to-metal contact and reduce friction, extending the lifespan of costly machinery equipment.

Saifullah Khalid, Quebec Petroleum Resources Ltd, Deputy General Manager

While selecting lubricants for aerospace or automotive manufacturing, manufacturers carefully consider lubricant properties, compatibility, performance requirements, and regulatory compliance.