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How a hydraulic fluid upgrade helped save $10,708 by reducing maintenance costs and extending oil drain intervals.
Plastics manufacturer Amaray specialises in injection-moulded covering inlays for DVD trays. The company was looking to lower the operating costs of its two Engel Victory VC 500/150 Plastic Injection Molding Machines. The customer turned to the Shell Lubricants team for advice.
Shell Lubricants technical experts evaluated the injection moulding machines and identified that savings depended on reducing maintenance costs, extending oil drain intervals (ODIs), lowering energy use and reducing production loss during equipment downtime. They proposed switching the hydraulic fluid to Shell Tellus S4 ME 46, which offers longer ODIs than the lubricant previously used by the customer. Shell Tellus S4 ME 46 worked without any problems in the machine for over 45,000 hours – over 7 times longer than OEM recommended oil change of 6,000 hours. The product is also designed to help improve energy efficiency for hydraulic systems without compromising system protection. In addition to upgrading the product, the recommendation was also to make use of the Shell LubeAnalyst oil and equipment monitoring service.
The company reported savings of $10,708 or 14% for the two machines. The savings come from:
How high quality multipurpose grease reduced grease consumption by over 16%, saving almost $10,000.
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.
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.
Compressor oil upgrade and lubricants technical training helps save USD $12,185 per year.
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.
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:
Technical training in lubricant handling and application was also recommended, to better equip the company’s staff to manage ongoing lubrication management.
How a product upgrade and improved lubrication management can extend oil drain intervals by 50%, saving $21,000.
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.
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.
How improving lubrication management and upgrading gear oil saved $106,787.
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.
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.
How upgrading hydraulic fluid and improving lubrication management helped extend oil drain intervals, saving $16,500.
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.
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.
Please note: Case study savings/benefits were reported by one customer. Actual savings/benefits will vary. More details available on request.
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