The increasing cost of food and beverage machinery makes running equipment to failure not just impractical, but potentially devastating to your bottom line. However, there are solutions that can lead to significant savings, and an often overlooked one is implementing an effective lubrication program. A well-structured program delivers a trifecta of benefits: reduced downtime, a cleaner and safer work environment, and easier compliance with the stringent regulations of the food processing industry. 

Moving beyond basic lubrication, many companies find even greater returns by integrating lubrication into a comprehensive reliability-centered maintenance program. This approach, built on measurable goals, timely execution and consistent discipline, provides a framework for continuous improvement and drives significant payback. This focus on lubrication empowers you to achieve optimal asset health, consistent production output and the holy grail of zero downtime. 

To Lube or Not to Lube?

Apologies to William Shakespeare for contorting his line from Hamlet. While the decision “to lube or not to lube” might seem straightforward, developing and maintaining an effective program requires planning, dedication and an initial investment. However, the return on investment is undeniable: Lubrication programs consistently save money and reduce waste. Don’t wait for a contamination incident, regulatory action or equipment failure to force your hand. Protective lubrication is the key to keeping your assets producing, healthy and profitable.

Organizing a Lubrication Team

Once the decision to implement a new lubrication process is made, assembling a cross-functional team is critical. The team should include representatives from maintenance, operations, engineering, and even your lubricant and equipment suppliers. The initial meeting serves as a crucial discovery phase, allowing the team to assess the current state of lubrication practices and define desired outcomes. Remember, clearly defined objectives are essential for achieving success.

This process is key to identifying and training dedicated, full-time lubrication technicians. Lubrication is not a task to be relegated to part-time or light-duty roles. It demands a specialized skillset, honed through comprehensive training and ongoing development, ensuring these technicians can effectively maintain the health of your assets. 

Choosing the Best Lubricants and Usage

This is where your cross-functional team shines and third-party partners bring their expertise. Focus on: 

Consolidation and Standardization: Collaborate to identify and consolidate the optimal lubricants (including aerosols and oils) for your needs. Determine the most effective lubrication methods (centralized systems, automatic lubricators, manual lubrication) and establish sanitary dispensing procedures for your food production environment.

Equipment-Specific Requirements: Define lubrication requirements for each machine type and location, consulting equipment manufacturers for recommended lubricants and intervals. Work with bearing and gear reducer manufacturers to specify proper lubrication for those critical components. 

Optimize Lubrication Delivery: Explore grease guns and automatic lubricators for optimal grease and oil application, especially in areas with difficult access or safety hazards. Selecting the right dispensers ensures reliable lubricant delivery, a crucial element of a successful program.

Creating a Lubrication Legend: Develop a clear visual legend using color codes and symbols to match lubricants with specific equipment (Figure 1). Your lubricant and equipment provider can be invaluable in this process. Include clear warnings against mixing fluids—debunking the myth that all greases and oils are compatible with mixing. Verifying compatibility upfront prevents costly problems down the line. 

Implementing an Oil Analysis Program: Establish a robust oil sampling program to identify potential issues before they impact production. Regular analysis can also enable extended drain intervals, maximizing equipment life and minimizing downtime. This proactive approach, combined with conditioning monitoring, provides insights that visual inspections alone cannot.

Prioritizing Food Safety: Ensure appropriate food-grade lubricants and oils (H1, H2 or H3, along with other relevant subcategories). Food safety is number one.