Lubrication Technologies was asked to upgrade a pre-existing lubrication system responsible for oiling multiple chains on a large Stacker Reclaimer unit. Stacker-reclaimer machines are used to both stack and reclaim bulk materials like coal, iron ore and fertilizer.
This system was unreliable and known to waste expensive lubricant due to poor design. As explained to LTI, two situations commonly occurred when the old lubrication system malfunctioned: the entire assembly would start to shake due to lack of lubrication, or lubricant consumption could be as high as one 55-gallon drum per week.
Lubrication Technologies created seven identical stand-alone lubrication systems, each with an after-blow feature to keep the spray nozzles clean after use. Using separate systems simplified the design, with each rake assembly on the reclaimer having its own dedicated panel and hardware on the traveling bridge. Six systems run simultaneously, with one spare panel ready for quick replacement if needed. This setup allows for easy maintenance while the Stacker Reclaimer remains operational.
With the implementation of the new lubrication systems, uniform lubrication has been achieved, and lubricant consumption has been reduced to one 55-gallon drum every five weeks. At a cost of approximately $1,100 per drum, this translates to an average cost savings of $4,400 per month/$52,800 per year!