Lubrication Systems
We offer a complete line of standard and custom distribution feeders, pumps, controls, auxiliary equipment and fixtures to build and support a wide variety of lubrication systems.
Our team specializes in engineering of lubrication solutions and systems. In addition we offer consulting, training, and stock all the accessories, parts and components which compose complex automatic grease systems, air oil lube systems, MQL systems, total loss, recirculating, single line, multi line and other systems.
What Are Lubrication Systems?
Lubrication systems describe the processes and materials that work together to reduce friction between moving parts. Friction can prove harmful to people and objects. It generates heat and produces wear and tear. In some cases, friction can even create fire hazards or lead to the complete shutdown of a machine.
Without the systems that reduce wear and tear, industries would need to prepare for frequent repairs and replacements. The cost would add up significantly over time. It would include not just company expenses but also their customers’ ownership costs. The more fast-moving parts involved, the more important this consideration is. Excellent examples include vehicles.
Lubricants increase the ease with which machine parts pass over each other. It also helps to carry the load. Most people think of oil when it comes to lubricants, but the specific substance depends on the machine, industry and application.
Why Are Lube Systems Important?
Lube systems play an indispensable role in business. This role reaches far beyond the cost savings of not needing to replace machine parts more often.
Productivity: Downtime is the kryptonite of any manufacturing business. When systems fail due to higher-than-normal rates of friction, companies might need to shut down an entire production line. This could create dangerous bottlenecks, especially if each step is time-sensitive.
Sustainability: The fewer resources a company needs to do business, the more sustainable that business is in the long run. A common example of this is the movement toward greater fuel efficiency. Constant replacement of parts creates more waste and hurts the environment.
Safety: Machines do not always come to a grinding halt without adequate lube systems. Instead, some continue to work while sparks fly. These sparks might ignite and cause a fire. Parts failure can also occur at dangerous times. Imagine car wheel parts failing at 70 mph on the highway or jet engines failing 30,000 feet above a large city.
Return on Investment: In most cases, the longer an asset remains viable, the greater the ROI. Consider, for instance, two companies that spend $50,000 on a brand-new machine. One company replaces parts for a year and replaces the machine within five years. The other company completes proactive maintenance and replaces the machine in 10 years. The second company achieves greater ROI.
What Are the Most Common Lubricants Used in Systems?
Over the years, the manufacturing industry has used and developed a wide range of substances for different types of lube systems. For example, the lubricants needed for food processing will differ from the lubricants required for car manufacturing. Different applications require varying degrees of viscosity. Also, the thicker the substance, the better its ability to resist strong and consistent force.
Oil: Oil has a high level of viscosity, which makes it ideal for heavy-duty applications. Note that oil is considered a liquid and organic oils tend to deteriorate more easily. Because of this, the best oils for hardcore use include petroleum and other mineral oils.
Grease: Grease is classified as semi-solid and has even higher levels of viscosity than oil. In food processing settings where food comes into contact with machines, manufacturers must consider edible options. In industrial systems, manufacturers use grease made from vegetable oil or mineral oil and soap.
Oil Systems vs Grease Systems?
Most applications provide flexibility for manufacturers to choose between oil and grease. However, the decision is not always an easy one. In fact, engineers often disagree on whether grease or oil is the better lubricant. Here are the pros and cons of both.
Oil
In most instances, engineers can think of more reasons to use oil than to choose grease. These are the most common points to consider:
Oil flows more freely and may better divert heat away from machine parts.
Unlike grease, oil eliminates the risk of incompatible thickeners creating problems in lube systems.
Oil does not mix well with most other substances, which makes filtration easier.
It is much easier to monitor and control oil than grease.
Grease
There are fewer reasons for choosing grease over oil. Even so, the arguments are compelling:
Grease performs better than oil for activating and shutting own a system.
Grease mixes well with other substances, so manufactures can use additives when necessary for manufacturing processes.
When connectors and seals become worn, grease protects the parts better.
Lube System Components
Five main components work together to create a successful lubrication system. If one component fails, it can create damage to other components. This is why proactive maintenance is so important.
Controller: As the name implies, this device serves as the brains of the operations. Without a controller, it would prove difficult for engineers to turn on, shut down and monitor a system. Activation would also become more troublesome.
Reservoir and Pump: To maintain a consistent supply of lubricant, systems need reliable pumps and reservoirs. Pumps tend to differ based on size and the type of lubricant. As lube systems manufacturers, our team of experts can help you determine which pump is right for you.
Regulator: Of equal importance as a consistent supply is a need for the right amount of lubrication. This might differ across multiple parts in the same machine, so metering devices assist with regulating lubricant dispersion.
Supply Lines: If regulating devices form the heart of a lube system, then think of hoses and fittings as the blood vessels and valves. These components make it possible to transport lubricants around the machine.
Add-Ons: Some applications, industries or individual companies might require additional capabilities. Our team of lubrication experts can help you determine whether you need these and other accessories for your system: Performance indicators, Blow-out discs, Low-level switches, High-pressure detection, and Simplified shutdown devices
Common Types of Lube Systems
There are several ways to categorize systems. The first is whether systems are automated or manually operated. Lube systems are also often categorized by the industries they belong to or the specific purpose they serve. Common examples include gas pump lubricators and chain spray lubricators. Most modern-day systems are automated and engineers categorize these by how they work.
Single Line Progressive Systems
This is the simpler system of the two and requires fewer components. In this setup, the pump distributes one type of lubricant along the supply lines. A timer feedback device then puts a stop to the system. While active, the system relies on piston shifts or valves to disperse lubricants.
Parallel Lubrication
This more complex system relies on a series of parallel supply lines, valves and injectors. It leads to the creation of several smaller systems in a larger ecosystem. A pressurized mechanism puts an end to the process when necessary.
What Are the Benefits of Auto Lube Systems?
Automation has created radical changes across a wide range of industries. Does it change lube systems for the better or should companies reconsider upgrading? Consider the following benefits:
- Internal systems are better at monitoring and distributing the right amount of lubricants, so machines use less lubricant.
- Using less lubricant cuts down on the waste released into the environment and contributes to sustainability efforts.
- Automatic systems are compatible with any industry, application and type of system.
- Manual lubrication puts technicians at risk of physical harm, which is virtually eliminated by automated systems.
- Properly lubricated systems reduce instances of downtime and cut down on the cost of ongoing maintenance.
Lubrication Solutions
Grease Lubrication
Paper mills, small machines and large-scale industrial equipment all require grease to maintain momentum and productivity. At DropsA USA, our centralized grease lubrication products allow parts to continue to move conveniently without grinding or other resistance.
Choose centralized automatic grease systems to avoid time-consuming maintenance with manual grease guns and grease points. A centralized system is powered by an intelligent controller and offers a highly controlled distribution of grease. We offer several options for setting up grease lubrication in your industrial workplace. Grease is a viable option for everything from small machinery to large-scale mills and more. These are three of our most popular systems:
Dual Line O2 System: This system offers a wide variety of configurations thanks to its modularity. It is a great choice for complex industrial equipment. In particular, it is a go-to option if you need to deliver grease over 60 meters or more.
Progressive Divider System 26: Using pumps that separate into progressive spool arrangements, these systems can distribute grease throughout a complex industrial lubrication system. This setup has the advantage of only requiring an UltraSensor on a single lubrication point for accuracy.
PoliPump Multioutlet: This is an excellent option for small machinery. This pump can operate up to 35 lubrication points with a single power source or battery.
Total Loss Lubrication
An overheating engine, conveyor belt or other piece of equipment can stall your production line. At DropsA USA, one of our most common systems is the total loss lubrication system. This uses a range of distribution and control techniques to ensure every contact point is coated with a thin, consistent film of lubrication.
High-viscosity oil or other fluid is necessary to keep your moving parts moving efficiently. When you use a total loss system, the oil is used up during use. This prevents contamination in the system. Control the flow of oil to avoid overuse and to keep your machinery operating efficiently. We offer a highly affordable solution as our total loss lubrication system. It can fit into a variety of applications. There are two versions of total loss lubrication that we offer.
Our single line restrictor, also known as the “O1 System,” includes consistent performance. The meter units balance the line pressure, maximizing reliability.
Alternatively, you can choose our single line injector system. With our push-lock technology, this option is reliable, low-cost and durable. This helps to make it a go-to solution for many industrial uses.
Oil Recirculation Lubrication
Save time and money by recirculating the oil in your lubrication system. These systems completely immerse the moving parts in oil and keep the fluid circulating. This is ideal for high-performance, high-speed equipment. It’s used in systems that don’t burn excess oil or drain it away from the equipment, so you can save money by reducing your oil use.
A series of drain pipes collects and recirculates the oil, dramatically reducing downtime. Instead of spending time refilling your oil reservoir, let your equipment continue to power through your manufacturing process. Our oil lube systems are custom designed to suit your unique needs. We provide two technologies that can help you to get better performance form your oil recirculation system. Our team is here to help you find the right equipment for your application.
We offer the Flowmaster, a patented device that enables rapid adjustment to the flow rate in the system. Through volumetric measurement and a regulating spindle, the device can improve results throughout the system.
Additionally, our Flow Automatic Control Technology is a touchscreen display that makes controlling your oil recirculation system easier. You can use it to easily adjust the flow rate and other variables.
MQL: Minimum Quantity Lubrication
MQL lubrication systems are designed to minimize mess and wasted oil. Reduced material waste improves the overall efficiency and affordability of your equipment. Choose an MQL system for high-speed cutting applications for precision performance. Exact lubrication distribution reduces heat and resistance without using excess lubricant.
Work with our team to dial in the exact oil amount for your MQL centralized system. This option is particularly popular for CNC machining and other precision devices that require a little amount of oil to keep things running smoothly. If you need a heavy amount of oil or grease, consider using an oil recirculation or grease lubrication alternative. Our minimum quantity lube systems feature several innovative components to help you customize your solution and achieve the best results. These are three of our most popular options:
MiQueL Lubrication: This component is used for internal lubrication. It is easy to install and automatically regulates based on the machining needs. This is popular for mid- to high-range applications.
MiQueL Modular: This solution provides calibrated lubrication that is user-friendly and provides excellent safety.
MiQueL EXT: With the EXT, you can provide an external pump source option to the modular system. That means you can customize your setup with even more choices for centralized pressure.
Air/Oil Lubrication
Finally, some systems require a particularly fine amount of oil for proper lubrication. In these situations, turn to an air/oil lubrication system. These units use a micro-spray combination of air and oil to provide the ideal amount of oil for gears, spindles, chains and other moving parts. They are ideal for compact spaces and minor oil use.
Too much oil can be a costly mistake and even result in slipping chains or other issues. Use an air/oil system to enjoy compact performance. These systems provide the same dependable performance and accuracy as our larger centralized models. Compare models to see the space requirements and the amount of oil they are capable of delivering for your company requirements. For our air/oil industrial systems, we have several advanced systems available. Each of the following three options can be custom installed to suit your needs.
VIP4 Air-Oil: This powerful lubrication system ensures a continuous air stream to clear debris and ensure proper lubrication with minimal oil. The system can be designed to match the quality standards and the industrial specifications of your application.
SMX Air-Oil: With this system and its unique mixing valve, you can bring the characteristics of an SMX progressive divider to an air/oil lubrication solution. This modular equipment makes fulfilling your requirements simple.
SBO Air-Oil: Our third option is another modular solution. The SBO metering valves work for a dual-line air-oil system. They have two parts: a base and a metering valve. They can be supplied with adjustable or fixed discharge.
Industrial Lubrication
Don’t spend time manually lubricating your equipment. Contact us today for leading lubrication solutions and systems that match your industrial needs. Reduce costs and improve the performance, lifespan and efficiency of your equipment with a system tailored to your lubrication needs.