Our case studies

How high quality multipurpose grease reduced grease consumption by over 16%, saving almost $10,000.

The Challenge:

A year after installing a new production line, a fibreboard manufacturer based in China’s Shandong Province, Dongying Artificial Board Factory, was experiencing frequent failures of its spherical roller bearings and high grease consumption. The company wanted to reduce operating and maintenance costs by changing the grease used to lubricate the bearings, and approached the Shell Lubricants team for support.

The Solution:

Shell Lubricants technical experts recommended Shell Gadus S2 V220 2 to help the company cut its grease consumption and thus reduce costs. This high-quality, multipurpose, extreme-pressure grease is designed for heavy-duty plain and rolling-element bearings operating under harsh conditions, including shock loading in wet environments and at a wide temperature range. The technical team also held a customised seminar for the factory on equipment maintenance and lubricant storage.

The Results:

• After changing to Shell Gadus S2 V220 2, the company reduced its grease consumption by more than 16%, from 600 to 500 kg a year
• The company has experienced fewer bearing failures and consequently less production downtime
• Reported annual savings amount to US $9,848
• The company is also benefiting from frequent on-site visits and advice on equipment maintenance provided by the Shell Lubricants technical experts
   

Compressor oil upgrade and lubricants technical training helps save USD $12,185 per year.

The Challenge:

Dissatisfied with the poor performance of its existing compressor lubricant and seeking to reduce operational costs, Turkish plastics technology and production capacity company Pilsa Plastic Products Inc. turned to Shell Lubricants for support. Oil analysis indicated the oil had poor thermal and oxidation stability, which resulted in the need for an oil drain every 5,000 hours.

The Solution:

Shell Lubricants technical experts monitored and analysed the existing oil’s performance using the Shell LubeAnalyst service, and recommended that the company should change to Shell Corena S4 R 68, which would suit its operation better.

Designed to deliver excellent protection and compressor performance, Shell Corena S4 R offers:

• Long oil life - capable of providing oil maintenance intervals of up to 12,000 hours (where allowed by manufacturers) even when operating at maximum discharge temperatures in excess of 100°C.
• Outstanding wear protection - helps provide exceptional protection and protection of internal metal surfaces from corrosion and wear.
• Maintains system efficiency - designed to provide rapid air release without excessive foaming to give trouble-free operation even under cycling conditions.

Technical training in lubricant handling and application was also recommended, to better equip the company’s staff to manage ongoing lubrication management.

The Results:

• Changing to Shell Corena S4 R 68 reduced the company’s operational costs by 50% and increased the oil-drain intervals from 5,000 to 10,000 hours.
• The cost savings resulted from lower oil consumption and labour costs, less oil waste for disposal and improved maintenance practices.
• The company reports saving US$12,185 a year.

How a product upgrade and improved lubrication management can extend oil drain intervals by 50%, saving $21,000.

The Challenge:

Granite and ceramic manufacturer Seranit Granit Seramik Sanayi ve Ticaret produces 25% of the total granite products in Turkey. While working with an alternative supplier, Seranit’s hydraulic tile press was experiencing frequent oil changes approximately every 4,000 hours. As the existing supplier offered limited technical support and advice to address the issue, the company turned to Shell Lubricants for a solution.

The Solution:

Shell Lubricants technical experts conducted an extensive oil analysis using the Shell LubeAnalyst oil and equipment condition monitoring service. Following this, Shell Tellus S2 V 46 was recommended for use in the hydraulic press. The solution also included ongoing oil condition monitoring and reporting using Shell LubeAnalyst, and on-site technical visits and training of maintenance staff.

The Results:

• Oil-drain intervals increased from 4,000 to 6,000 hours, which resulted in annual oil consumption being reduced by 6,400 kg
• Total reported annual savings from reduced product consumption was approximately US $21,000
• Using Shell LubeAnalyst to monitor oil condition enabled the company to benefit from lower maintenance and labour costs as fewer mechanical failures reduced maintenance needs

How improving lubrication management and upgrading gear oil saved $106,787.

The Challenge:

Water company Sino French Water Development Company Limited (Sino French Water) provides six core services across China: water production, full water services, industrial water treatment, municipal waste water treatment, sludge treatment and O&M services.

The company had recently purchased 30 machines, including secondary settling tank scraper, concrete mixers, sludge dewatering, and a submersible mixer. After running the equipment 24/7 for 900 hours (almost one month), the company experienced an unplanned shutdown due to overheating of the gearbox oil. Oil temperature had reached 100o C, the lubricant was dark brown in colour and could no longer be used, forcing equipment shutdown.

The Solution:

Shell Lubricants technical experts visited the company’s site and inspected the equipment to analyse the reasons for the oil overheating. It became apparent that, contrary to OEM recommendation, gearbox oil of the same viscosity had been used in all the different pieces of machinery in an attempt to simplify lubrication management.

Shell Lubricants technical experts recommended flushing all of the gearboxes and changing the gear oil to Shell Omala S4 GX 460, which met OEM recommendations. The technical team also offered follow-up support with the Shell LubeAnalyst service, conducting regular visits to sample and test the oil.

The Results:

• The company reported savings of USD $106,787 (CNY 667,834)
• Six months later, equipment was still working smoothly with no unplanned downtime. Easier management of the lubricant system meant the company had experienced no operational errors causing machine downtime

How upgrading hydraulic fluid and improving lubrication management helped extend oil drain intervals, saving $16,500.

The Challenge:

Plastics processing company, Alpla D.O.O., was using OEM-recommended VG 68 hydraulic oil in its NetstalMaschinen AG plastic injection moulding machine. The product delivered oil drain intervals (ODIs) of 5,000 hours. The company was looking to extend the ODIs as a way to help reduce costs, and contacted Shell Lubricants for advice.

The Solution:

Shell Lubricants technical experts recommended upgrading the hydraulic fluid to Shell Tellus S3 M 68, designed to deliver long oil life and improved system efficiency. They also recommended making use of Shell LubeAnalyst to conduct regular lubricant condition monitoring, and implementing an additional oil filtration system with a filter of 3 microns. Finally, a technical training session was hosted for Alpla staff, to upskill them in lubrication management.

The Results:

• After upgrading to Shell Tellus S3 M 68 hydraulic fluid, implementing regular lubricant monitoring using Shell LubeAnalyst, and using the new filtration system, the company realised savings estimated at USD $16,500.
• Oil life extended from 5,000 to 15,000 hours, helping to reduce equipment downtime by extending fluid maintenance intervals.