At chemical company Ketjen in Amsterdam, a global producer of catalysts, the reliability of a large extruder was under pressure due to the short service life of the lubricating oil used. To reduce downtime and high maintenance costs, Ketjen turned to Van Meeuwen for an effective improvement of its lubrication system.
Conversion project for chemical giant Ketjen
Ketjen aimed to improve the reliability and efficiency of its production process. One of their large extruders operated with a standard oil that had a relatively short service life, leading to frequent oil changes, higher costs, and unwanted downtime.
Van Meeuwen was asked to provide a solution that would significantly extend the service life of the lubricating oil, without compromising performance or the safety of the installation.
By introducing the high-performance Bel-Ray 100 Extreme Pressure Gear Oil and improving the ventilation and oil sampling setup, Van Meeuwen not only extended the oil’s lifespan but also enhanced overall operational reliability.
Unwanted production downtime
The extruder drive was originally lubricated with a standard oil, which needed to be replaced every two to three years. This led to considerable costs, time loss, and unplanned production downtime.
Due to the limited service life of the existing oil, a switch to a higher-quality lubricant proved necessary. A more durable oil would not only reduce the frequency of oil changes but also contribute to a more reliable production process.
During an oil analysis performed by Van Meeuwen, it was found that the oil had been contaminated by external factors. This contamination negatively affected the cleanliness of the lubricant and increased the risk of wear and drive failure.
To prevent future damage and production interruptions, both the oil quality and protection against external contamination needed to be improved.
Bel-Ray Extreme Pressure Gearl Oil
Van Meeuwen carried out the conversion from the standard oil to Bel-Ray 100 Extreme Pressure Gear Oil 320, a high-quality gear oil from our premium lubricant range.
Thanks to its special Extreme Pressure additives, this oil is ideally suited for heavily loaded applications such as in this project.
To further improve the air quality around the system and prevent oil contamination, the system’s ventilation was equipped with an RMF breather filter. This filter purifies both incoming and outgoing air, significantly reducing the risk of dirt or moisture entering the system.
Daarnaast werd afgesproken om voortaan op regelmatige basis oliemonsters te nemen. Hiervoor is een monsternamepunt geïnstalleerd door Van Meeuwen waardoor steeds op dezelfde plek onder de beste condities en op een veilige manier een betrouwbaar oliemonster genomen kan worden. Door deze analyses structureel uit te voeren, kan de kwaliteit van de olie nauwgezet worden gemonitord en kunnen eventuele afwijkingen vroegtijdig worden opgespoord.
Three times longer oil service life
The replacement of the standard oil in the large extruder with Bel-Ray 100 Extreme Pressure Gear Oil has resulted in a significantly longer service life, up to three times longer.
These results show how a targeted lubrication improvement directly contributes to sustainability, efficiency, and cost savings, which is essential for an internationally operating company like Ketjen.
Thanks to the stronger lubricating film, several additional benefits were also achieved:
The amount of waste oil was reduced by nearly 60%;
Wear in the gearbox was significantly reduced;
Energy consumption decreased, allowing the gearbox to run noticeably cooler;
The extended oil life led to a direct cost reduction of nearly 30%.
Curious to find out if we can help you?
Would you like to know more about how we can contribute to more efficient, safer and smarter lubrication maintenance? Whether it concerns the right lubricant, automatic lubrication, digital support or reliable analyses, we are glad to contribute our ideas. Please feel free to contact us.
