Testimonials
Kayline Processing significantly improved machine reliability using Duolec® Vari-Purpose Gear Lubricant.
key takeaways
Challenge
Kayline seeks to enhance their maintenance program’s efficiency without increasing the time spent on physical repairs.
LE solution
Switching to Duolec® Vari-Purpose Gear Lubricant (1605) resulted in significant man-hour savings due to extended change intervals and allowed proactive maintenance through the Xamine® oil analysis program, preventing downtime.
Results
Kayline experienced less than 1% downtime due to non-production issues last year, attributed to increased machine reliability and satisfaction with Lubrication Engineers’ cost-effective products.
I am very happy with Lubrication Engineers. I feel we get a great product at a reasonable cost.
- Pete Burns, Engineer
Customer Profile
Kayline Processing is a converter of flexible vinyl films, specializing in the printing and lamination of vinyl films to various woven and nonwoven fabrics, knits and sheeting for industry-specific requirements. The materials go into many different products such as table pads, instrument cases and amplifiers. Located in Trenton, N.J., Kayline is a family-owned company that started in the 1950s and now has customers in many industries all over the world.
Application
Kayline runs three rotogravure print presses and two laminators. These machines were all built in the 1960s. Many motors and gearboxes are still original. The machines have run two shifts, five days a week for decades. Kayline also relies daily on other machines such as air compressors and hydraulic pumps.
Challenge
Kayline is always trying to improve their maintenance program without adding wrench-time.
LE Solution
An LE consultant came around and claimed some energy reduction if we were to switch to Duolec® Vari-Purpose Gear Lubricant (1605).
Pete Burns, an engineer at Kayline, gave this account: “I was skeptical but tried a before-and-after current reading. The gearbox I chose was small so the current readings were low. Savings could not be measured. I did notice the reading was erratic prior to the oil change, and after the change the Amprobe needle stayed nice and steady. I was impressed and changed every gearbox over to LE. Later, we realized a big savings in man-hours due to extended change intervals.”
“Another benefit (provided by LE) is the Xamine® oil analysis program. We had a high metal flag on a sample. Inspection found bearing journal wear on one shaft. We had time to procure and install a new gearbox without an hour of downtime.”
Results
Kayline tracks downtime when a whole line goes down due to factors other than production problems. In the most recent year, this downtime was less than 1 percent.
“We have increased reliability in our machines overall,” Pete said. “I am very happy with Lubrication Engineers. I feel we get a great product at a reasonable cost.”