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Project Overview:

In this project, we replaced an outdated lubrication system on a food sterilization machine with a more efficient, automatic lubrication system. The previous system utilized copper tubing, which is not ideal for high-pressure lubrication systems. Our updated design focused on simplicity, reliability, and ease of maintenance, while addressing key issues from the previous installation.

The new system pumps lubricant directly from a 120 lb. drum using a 60:1 air-operated grease pump. This pump, with a 3.15” bore and stroke, generates up to 6,000 psi at 100 psi air pressure. To ensure optimal performance, the pump is equipped with a low-level switch that monitors lubricant levels and a vent valve that controls pressure within the system.

At the heart of the operation is a 110VAC programmable controller, which automates the lubrication process. The controller manages the pump’s operation, ensuring consistent pressure is built within the distribution system, which is made up of ¾” tubing and manifolds equipped with injectors. Each injector is dedicated to a specific lubrication point and can be adjusted to deliver the precise amount of lubricant required.

Key components of the system include:

  1. 110VAC Programmable Controller with digital monitoring and fault notifications.
  2. Air solenoid and pressure switch to control air flow and monitor system pressure.
  3. Strobe light for fault notifications, such as low lubricant levels or system pressure issues.
  4. NEMA 4X Fiberglass enclosure with stainless steel hardware, protecting the system from environmental factors.
  5. 60:1 Air-operated drum pump, ensuring consistent lubricant delivery.
  6. 150 feet of ¾” OD tubing, connecting to a network of 28 injectors mounted on manifolds.
  7. Stainless braided hoses with Teflon lining, custom cut and crimped on site to connect each injector to the lubrication points.

Benefits of the Automatic Lubrication System:

  • Reduced Downtime: Automated lubrication ensures that every critical point on the machine receives the proper amount of lubricant without manual intervention, reducing machine downtime and the risk of breakdowns.
  • Extended Equipment Life: Consistent lubrication prevents wear and tear on moving parts, increasing the longevity of the sterilizer and reducing repair costs.
  • Improved Safety and Maintenance Efficiency: The system’s design allows personnel to visually confirm lubrication at each point and manually grease if necessary, making it easier to maintain and service.
  • Greater Reliability: With automated control and pressure management, the system ensures continuous, reliable lubrication even under high-pressure conditions.

By replacing the old system with this advanced lubrication setup, the machine now operates more smoothly and requires less manual maintenance, significantly improving overall efficiency.