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Increasing equipment reliability in a cocoa factory

Challenge

A five-roller mill ensures the distribution of particles in the soft solid flow of cocoa mass. Insufficient grease on the roller bearings has caused bearing failure. The equipment is an important step in the production of cocoa and could not be stopped for maintenance so was left to run. Excessive wear led to the replacement of the bearing, and the original grease used could not reduce the equipment vibration causing even more damage.

Bearing failure due to insufficient amount of grease on Five Roll Mill equipment

Solution

The maintenance manager requested an inspection of the plant with the report highlighting the need for a procedure to improve maintenance and avoid issues previously encountered. Chesterton’s Lubri-cup EM Series with the Chesterton 615 HTG#2 was installed on 4 units of the Five Roll Mill Equipment at the correct dispense rate for 12 months (2 cycles at 0.7cc/day). The 615 HTG#2 grease with built in QBT was able to ensure that the equipment vibration was not affecting the bearing performance.

About the Chesterton Lubri-cup EM Series:

  • Excellent corrosion protection
  • Best-in-class water and chemical washout resistance
  • QBT Quiet Bearing Technology
  • Automatic grease dispensing

Chesterton Lubri-Cup EM Series

 

About the Chesterton 615 HTG:

  • Superior water resistance
  • Excellent corrosion protection
  • Compatible with most popular greases
  • Will not bleed or age harden

Chesterton 615 HTG

 

Results

The Chesterton Lubri-cup EM with the Chesterton 615 HTG#2 improved five-roll mill equipment production. The downtime was reduced and contributed to good savings.

Total Savings for 1 Five Roll Mill Equipment : First Year
USD 43,376.00  (Manual Greasing)

– USD 1,382.00  (Lubri-cup EM with 615 HTG#2)

 = USD 41,994.00

Total Savings for 1 Five Roll Mill Equipment : Following Year
USD 43,376.00 (Manual Greasing)

– USD 364.00  (Service Pack Replacement)

 = USD 43,012 .00

Chesterton Lubri-cup EM improves production, extends bearing life and saves costs.

About us

Chesterton® is a world leader in helping process industry companies and manufacturers improve the reliability and efficiency of their rotating, stationary, and fluid power equipment platforms. We are known across a wide range of industries for our award-winning pump and valve sealing solutions, applications expertise, equipment maintenance and wear-prevention products, and knowledgeable hands-on local service. Chesterton product range includes mechanical seals, packing and gaskets, industrial lubricants and coatings.

® Registered trademark owned by A.W. Chesterton Company

APAC0077.  Issued 05/2023.

Technical data reflects results of laboratory tests and is intended to indicate general characteristics only. A.W. Chesterton Company disclaims all warranties expressed or implied, including warranties of merchantability and fitness for a particular purpose. Liability, if any, is limited to product replacement only. Any images contained herein are for general illustrative or aesthetic purposes only and are not intended to convey any instructional, safety, handling, or usage information or advice respecting any product or equipment. Please refer to relevant Safety Data Sheets, Product Data Sheets, and/or Product Labels for safe use, storage, handling, and disposal of products, or consult with your local Chesterton sales representative.

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