Case Studies

Challenges of Lubrication in Underground Mining Environments

Underground mining operations are typically characterised by wet and dusty conditions, which present significant challenges for equipment reliability—particularly in conveyor systems. The commonly used lithium-based greases for bearing lubrication often lack the extreme pressure (EP) additives required to withstand the high loads encountered in these environments. As a result, inadequate lubrication can lead to metal-to-metal contact, bearing pitting, and surface scouring. Moreover, conveyors in mining operations often run continuously, making frequent maintenance impractical due to the associated production downtime. Lithium greases are also limited in their ability to perform under elevated temperatures caused by friction, which further contributes to equipment degradation and unplanned shutdowns.

Sacrificial conveyor in the underground mining industry.

The Way To The Market 

In the mining industry, the use of inappropriate lubricants can significantly compromise equipment performance and lifespan, resulting in unexpected breakdowns and costly operational delays. Every hour of unplanned production stoppage can translate to losses amounting to thousands—or even millions—of dollars. Beyond the financial impact, prolonged equipment downtime may pose serious safety risks to personnel and erode the company’s reputation for reliability and operational excellence. As such, mining companies must place a strong emphasis on preventive maintenance strategies, particularly the use of high-quality, application-specific lubricants. Doing so not only ensures smoother and more efficient operations but also helps minimise unplanned interruptions and sustain long-term productivity.

Introductory Strategy: Enhancing Bearing Reliability through Lubrication Solutions

A technical seminar focused on Bearing Reliability was conducted with the active participation of the technical team, introducing the use of Lubri-Cup EM™ automatic lubricators and Chesterton 615 HTG #2 High-Temperature Grease. The session provided valuable insights into the advantages of automatic lubrication systems, particularly in improving equipment reliability and reducing manual maintenance demands. The team also gained a deeper understanding of the unique properties of 615 HTG #2—an advanced, high-temperature grease engineered for harsh environments. Its superior resistance to water washout, dust contamination, and elevated operating temperatures makes it especially suitable for underground mining conditions, where such factors often accelerate wear, corrosion, and premature bearing failure.

Photos below were taking during the Installation of Chesterton Lubri-cup EM™ with 615#2 High Temperature Grease.

Smart Implementation for Improved Conveyor Reliability

A total of 12 Lubri-Cup EM™ units, filled with Chesterton 615 HTG #2 High-Temperature Grease, were strategically installed on sacrificial conveyors. Each unit was calibrated to dispense at a rate of 1.4 cc per day over a 6-month cycle (4 cycles total), ensuring consistent and controlled lubrication. This setup optimises grease consumption, effectively prevents bearing failure, and reduces the need for manual maintenance. By automating lubrication and selecting a grease formulated for extreme conditions, this initiative enhances equipment reliability, improves workplace safety, and minimises downtime. The result is a more efficient conveyor system, supporting higher production output and delivering a measurable return on investment through operational stability.

Sacrificial conveyors.

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.

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EN601813. Issued 07/2025

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.