CASE STUDY Steel - Lubrication of Turntables and Output Machines : More than $300k Annual Savings QUAKERTEK™ UX 4615-EP The Challenge
The Benefits
A large steel mill was accumulating plates at extreme temperatures on their output tables, causing the bearings to work under high loads and extreme temperatures.
Since using the QUAKERTEK™ UX 4615-EP there have been no more crashes or roll breaks.
As a result the output table rolls were constantly locking and breaking. On average there were 4 roll breaks per month which was interrupting production and increasing the risk of not meeting delivery dates. Additionally, there was increased risk to worker safety with the amount of roll changes needed around machines still in operation, and cranes moving hot plates around the site. The mill was looking for a lubricating grease that would:
• Not melt in the bearing when exposed to the extreme • Remain temperatures • • Improve worker safety
Eliminate the locking and breaking of the rollers
The Solution Due to Quaker Houghton’s relationship with the steel mill - providing other products and continuous technical assistance, the mill requested a replacement for the current grease.
QUAKERTEK™ UX 4615-EP did not melt and remained at the application point on the roll neck
Savings from Converting to QUAKERTEK™ UX 4615-EP MONTHLY BASED
YEARLY BASED
Grease based saving
$73.76
$885.12
Roller based savings
$27,697.27
$332,367.28
Waste based savings (reparing the grease filling system leak)
$2,624.86
$31,498.37
$30,395,86
$364,750.77
Total Savings
Through a series of field visits, Quaker Houghton was able to assess the situation and suggested the mill convert to QUAKERTEK™ UX 4615-EP (polyurea) for lubrication of the tables. From the start of the trial, QUAKERTEK™ UX 4615-EP did not melt away and remained at the application point on the roll neck. Due to the positive results on the roll neck the grease was also applied to the output tables and swivel.
©2019 Quaker Houghton. All rights reserved.
quakerhoughton.com | info@quakerhoughton.com
The Product
Comparative Costs Before and After Use of QUAKERTEK™ UX 4615-EP
GREASE Usage/Month without leaking Lubrication cycle (cycles per hour) Drop Point Monthly Rollers Replacement (roller price 6,339.64) Labor Cost (4 mechanics plus 2 welders) per 8 hour period, cost $12.18/ men hour
Total Monthly Costs
COMPETITOR CALCIUM-LITHIUM GREASE WITH BLACK SOLIDS
QUAKERTEK™ UX 4615-EP POLYUREA
UNIT
1,067
400
kg
4
1.5
170
304
4
0
°C
QUAKERTEK™ UX 4615-EP is polyurea thickened lubricating grease that has been specifically formulated and manufactured to provide outstanding lubrication in high temperature applications. Because of its high dropping point and excellent lubricating properties, QUAKERTEK™ UX 4615-EP:
replace lithium and lithium complex greases in high • Can temperature applications
• Provides excellent corrosion protection • Provides good oxidation stability • Can be used in a broad range of service temperatures
Process and Equipment $584.68
0
$30,699.13
$2,928.09
OUTPUT TABLES Operation
Lubrication of turntables on Machines
Application
Grease filling machine 3 inch spout and hose
UX 4615-EP was supplied is disposable • QUAKERTEK™ cardboard containers and packed in a plastic bag which is pressurized by an air regulator
spout is a 3 inch quick hitch, and can be used with • The the 3 inch pump hose of the grease filling machine
©2019 Quaker Houghton. All rights reserved.
quakerhoughton.com | info@quakerhoughton.com
V001.19.01.EN.GL