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How a Brazilian cement manufacturer considerably reduced his operating costs

July 22. 2014

How a Brazilian cement manufacturer considerably reduced his operating costs

Synthetic oil for increased energy efficiency of air compressors and reduced maintenance costs

Energy consumption and maintenance of air compressors are major elements of operating costs in the cement industry. This recent example from Brazil shows how changing over to a highly efficient compressor oil increases energy efficiency and extends maintenance intervals. A leading manufacturer of cement and related products in Brazil wanted to increase the efficiency of his oil-injected screw compressors and asked the lubricant specialists from Klüber Lubrication for advice.

"Mineral oil-based lubricants are normally used for compressors of this type", explains Júlio Viana, Klüber Lubrication Brazil. "The procurement costs of these conventional products may seem attractive at first glance, however, maintenance requirements and lubricant amounts used are considerably higher compared to synthetic speciality lubricants."

In this case, the oil change intervals with mineral oil were 4,000 hours. Klüber Lubrication recommended to change over to Klüber Summit SH-46, an air compressor oil based on a synthetic hydrocarbon mixture, which facilitates oil change intervals of up to 10,000 operating hours. Klüber Summit SH-46 offers high evaporation stability, ensuring clean compressed air and reduced cleaning costs while avoiding gumming and unplanned downtime. The lifetime of oil filters and separators increases with reduced oxidation residues, contributing to considerably lower maintenance costs.

The cement manufacturer performed comparative tests over a certain period of time. He operated selected compressors with a mineral oil-based lubricant and measured operating temperature, energy and lubricant consumptions. After two months, he cleaned both compressors thoroughly and operated them using Klüber Summit SH-46.

When the measurement results were analysed, it was found that the efficiency of the compressors increased significantly when operated with Klüber Summit SH-46. Operating temperature was reduced from 96 °C to 86 °C. Despite higher purchase costs of the synthetic oil, overall costs were reduced by 2,000 euros per year and compressor due to energy savings, longer oil filter life, reduced lubricant consumption and maintenance costs. The plant operates approximately 50 compressors and thus saves around 100,000 euro per year with synthetic lubricants. The Brazilian customer decided to use Klüber Summit SH-46 also for air compressors in other plants.

About Klüber Lubrication
Klüber Lubrication is one of the world's leading manufacturers of speciality lubricants, offering high-end tribological solutions to virtually all industries and markets worldwide. Most products are developed and made to specific customer requirements. During its more than 80 years of existence, Klüber Lubrication has provided high-quality lubricants, thorough consultation and extensive services, which has earned it an excellent reputation in the market. The company holds all common industrial certifications and operates a test bay hardly rivalled in the lubricants industry.

Klüber Lubrication, set up as a retail company for mineral oil products in Munich in 1929, is today part of Freudenberg Chemical Specialities SE & Co. KG, a Business Group of the Freudenberg Group, Weinheim. Klüber Lubrication has about 2.000 employees in more than 30 countries.

About Freudenberg Chemical Specialities
Freudenberg Chemical Specialities Munich, was founded in 2004 as a new Business Group within the Freudenberg Group, Weinheim, Germany, a family-owned, diversified technology company with a history of more than 160 years. Freudenberg Chemical Specialities has a lean, market-oriented organisation with Management Board and Corporate Functions. Its objective is to promote innovation potentials in its field of activities and to expand world-wide market leadership in special lubricants and release agents. The Business Group includes five largely independent divisions which are active in more than 50 countries: Klüber Lubrication, Chem-Trend, SurTec, Capol and OKS.

Press contact
Klüber Lubrication München SE & Co. KG
Andreas Hasslinger, Marketing Communications
Geisenhausenerstr. 7
81379 München, Germany
Tel.: +49 89 78 76-467

Michael Jurischka
Gotzkowskystr. 11
10555 Berlin, Germany
Tel.: +49 30 28 44 95 95