The Hidden Cost of Over-Lubrication

Lubrication is crucial in bearing health, ensuring smooth operation and longevity. However, too much lubrication can be even more harmful than too little. One industrial facility struggled with frequent bearing failures, leading to costly downtime and maintenance expenses. To identify the root cause, we implemented real-time ultrasound monitoring, and the findings were surprising.

What Our Condition Monitoring Revealed

We continuously tracked bearing performance throughout lubrication cycles using advanced ultrasound sensors. The data uncovered a critical issue:

Excessive greasing increased vibration:  Instead of improving performance, additional grease caused higher friction and wear.

Higher failure risk: Over-lubrication created excessive heat and stress, accelerating component degradation.

Unnecessary maintenance costs: Bearings were being replaced prematurely, driving up expenses.

Optimizing Lubrication for Maximum Efficiency

Based on our findings, we adjusted the lubrication schedule, implementing a 10-day pause to assess the impact. The results spoke for themselves:

52% reduction in bearing vibration, a clear indicator of improved performance.

Lower alarm thresholds, enhancing predictive maintenance capabilities.

Eliminated emergency repairs, preventing unplanned downtime and costly replacements.

The Financial and Operational Impact

By fine-tuning lubrication practices, the facility achieved:

$11,416 in prevented downtime and repair costs.

Two hours of production time saved.

Extended bearing lifespan by eliminating over-greasing.

Key Takeaway: Smarter Lubrication, Fewer Failures

More lubrication is not always better. By leveraging predictive maintenance, condition monitoring, and real-time data, industries can optimize lubrication practices, prevent equipment failures, and significantly cut maintenance costs.

Discuss how our predictive maintenance solution can save you time and money. 

Book a demo today.