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Almasol® High Temperature Lubricant significantly reduced SGL Carbon Fibres' costs and bearing failures.

Sgl Carbon Fibres · Evanston, Wyo.

Industrial Equipment|Ovens

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key takeaways

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Challenge

SGL Carbon Fibres faced 16 to 20 annual bearing failures, excessive grease consumption, and safety issues due to runny grease while using a commercial grade lubricant.

LE solution

Almasol® High Temperature Lubricant (1250), recommended by lubrication consultant Mike Carter, is designed for high-temperature applications and features LE’s exclusive wear-reducing additive, Almasol®.

Results

Switching to Almasol 1250 eliminated bearing failures, saving $161,616 to $200,020 annually by avoiding costs of bearings, labor, product loss, and cleanup.

LE 1250 has saved us a lot of money, increased uptime and made my life a lot easier.

- Dan Velikaneye, Maintenance Manager
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Customer Profile

SGL Carbon Fibres, LLC manufacture carbon fiber for use in the aerospace, automotive, marine and sporting goods industries. They have been in business since 1998 and an LE customer since 2004.

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Application

They use a proprietary oven to manufacture the carbon fiber. Each stage has 55 roller bearings to support the carbon strands as they pass through each heat treatment stage. Temperatures can exceed 400°F (204°C) at some of the oven stages.

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Challenge

While using a commercial grade lubricant, SGL Carbon Fibres were experiencing:

  • 16 to 20 bearing failures per year
  • Excessive grease consumption
  • Cleanup and safety concerns of runny grease
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LE Solution

Mike Carter, LE lubrication consultant, recommended Almasol® High Temperature Lubricant (1250). Almasol 1250 is for use where a high temperature grease is required. It contains Almasol®, LE’s exclusive wear-reducing additive.

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Results

Normal bearing failure and replacement was at 16-20 bearings per year. Since the conversion to Almasol 1250, there have been no bearing failures.

  • Bearings cost $350 each
  • Labor cost $691 per bearing
  • 800 lbs of product lost at $8,560
  • Cleanup cost 4-5 hours per week with the prior grease = $8,000 a year

Total savings per year are estimated at $161,616 to $200,020 using Almasol 1250.

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