Applica'onService&Por1olioTechnologyPlanningMaintenanceTasksDown'mesOp'miza'onOp'mizedMaintenanceCaseStudyICaseStudyIIConclusions
Bathanlubricantsoutpacetechnologyleadersinindustriallubrica'on.Theyreducewearandincreaselubrica'onintervals.• Solu'onProviderforseveralindustries• Co-Opera'onsinEurope,USA,LATAMandAsia• FullServicesupplierforpelletindustry• Flexibleandefficientlogis'cchain WoodProcessing
EnginesWindPowerCementPlantsPackagingFacili'esIndustrialGearsMiningShipping
Weofferconsul'ngforlubricants,andadvisepelletproducersregardingmaintenanceplanningandefficiencyini'a'ves.OurserviceteamprovidesmaintenanceservicesinOEMquality.Wedeliverwithreliableshippingcompaniesandguaranteehighestquality.
BathanKFGreases400gtube25kgHobbockkeg200kgdrumBathanAddi4ve500mlcan20lcanisterSparePartsPelletIndustryRollersRollerBearingsDies
Bathanisacombina'onofindustrialceramics,andhasadis'nctcrystallinestructurewithlowdensity,highlubricityandthermalconduc'vity.Theceramicpar'cleschangethestructureofsurfaces:Thermoplas'clevellingsmoothensthesurface,increasestheloadbearingcapacity,andreduceswear.HighlightsGreasing:• Reducinggreaseconsump'onby95%• Reducedpowerlossesbyupto9%• Lowermaintenance&opera'ngcosts• Lessfric'onandincreasedlife'me
Partially polished surface
Thegoalistoproducewoodpelletsinanadequatequalitywithanacceptableproduc'onrateatreasonablecosts.Plantdesignisvital.
Learn from the best
Use the knowledge of experts
Get it right from the beginning
Adjust plant design if necessary
Take all aspects into account
Smart Maintenance starts with the plant design
Moisturecontrol beforemoisteninganda\ermaturingvesselVisualinspec'on:die honeycombing,microcracks,wear,foreignmaterialVisualinspec'on:rollers adjustment,wear,temperature120-150°C(250-300°F)Greasepumpcontrol filllevel,greaseandairpressureGearcontrol oilpressure(1to5bar),
oilfilter, oilcoolerbelow 65°C(150°F),volume (oillevelglass)
Qualitycontrol pelletquality,abrasion,length,
moisture,bulkweight,density
Hammermillcontrol wearofsi\ersandhammers,cleanmagnetCondi'onerandfeeder cleanthoroughly,checkmagne'cseparatorMoisturizercontrol checkcalibra'on,recalibrateifnecessaryPelletmillcontrol cleanfeedchutesandsi\ers,
cleancrumbler,collector,fan, exhaust,androtoshaker
Knifes checksharpnessControltonnagereportsandhoursruntoplanmaintenance.
Dieandrollercontrol wearpahern,leakages,microcracks,clearanceGearcontrol wear,leakages,microcracks,(beltsifexis'ng)Conveyorscontrol lubrica'on,wear,beltsOther e.g.lubrica'onpipelines,
Oilandoilfilterchanges (accordingtomanufac- turerspecifica'ons)
Evaluateproduc'vityandcosts.Exercisedieandrollerchangetoensureshortmaintenancedown'mes!
Down'mesareabohleneckandanopportunity.PlannedDown'mes:• Plannedmaintenancetasks• Overhaulbyserviceengineer
Efficiency
Chance
PlanIssue
UnplannedDown'mes:• FailureàFixtheproblem• Other(weather,material)àAccordingto'meavailable
• Byassessingthestatusquo,weaknessesbecomevisible
• Thirdpar'eshelpovercomeorganiza'onalblindness
• Askyourteamofexpertstofindopportuni'es,thenconsultotherprofessionals
• Putyourplansintoac'on!
• Implementacon'nuousop'miza'onprocesstoremainexcellent
StatusQuo
In-houseExper4se
ExternalConsul4ng
PutPlaninto
Ac4on
LessonsLearned
Payahen'onwithnewrollerswhendeliveredonsite.• Inspec'onofdeliveredrollers
• Cleanlinessoflubrica'onintake
• Easymovabilityofroller
• Cleanstorageawayfromweatheringeffects
Refurbishrollersin-house
• Disassemblerollerwarm• Cleansha\s&bearingsthoroughly
• Inspectbearingsbeforeassembly
• Assemblerollerwarm• Movingpre-lubrica'onforseveralhours
Triplingthelife'meofbearingscausestwofewerdown'mes,anddecreasesworkinghoursandsparepartcosts.
•Refurbishrollersin-house
•Payahen'ontoassemblyofrollers•Usehigh-qualitylubricants •Keepeverythingclean
Regular Maintenance Plan
Improved Maintenance Plan
SwissPelletProducer,CPM,60’000tannualproduc'onStatusQuo: 1‘000opera'nghourslife'meofbearings
TemperatureØ115°C(240°F)Changes: Pre-lubrica'on,Ceramicgreaseand
distanceringswithimprovedlubrica'onImprovement: 95%lessgreaseconsump'on
upto10‘000opera'nghourslife'meofbearings Temperaturedecreaseby10°C(50°F) Savingsofapprox.100‘000CHF
GermanHD-PelletProducer,CPM,200‘000tannualproduc'onStatusQuo: 1’200opera'nghourslife'meofbearingsChanges: Ceramicgrease,rollersfromBathanAG,
andin-houserefurbishingofbearingsImprovement: 95%lessgreaseconsump'on
4’000opera'nghourslife'meofbearings Savingsofapprox.125’000EUR(140’000$)
• Preventa'veMaintenanceisbeherthancure• Externalprofessionalscanofferadifferentperspec've• Ahen'ontoqualityofrollerrefurbishmentpaysoff• High-qualitylubricantshelpimproveperformance• Evensmallchangescanhaveahugeimpact