How much do automated lubricators reduce bearing failures?

Properly applied automated lubrication eliminates up to 75% of premature bearing failures caused by contamination, wrong lubricant volume, or aged grease. The savings come from removing the manual greasing variability — sealed cartridges deliver a precise, continuous amount without exposing the bearing to plant contaminants.

What's the difference between single-point and multi-point lubrication?

Single-point lubricators (like perma Star Vario) mount directly on or near a single bearing and deliver lubricant continuously over weeks or months. Multi-point systems centralize the lubricant supply and distribute it through tubing to multiple bearings — appropriate when bearings are clustered or in unsafe-to-access locations.

Can Adams design a multi-point lubrication system for difficult applications?

Yes. Adams has built multi-point systems for building-materials cooling rollers, pulp and paper mill motors, and fertilizer-plant conveyor bearings — all applications where manual greasing was causing premature failure or operator safety issues. Designs include centralized supply, remote-mounted cartridges, and protective housings.

What is the perma Star Vario used for?

The Star Vario is a battery-powered single-point lubricator with a programmable dispensing timeframe (1–12 months) and cartridge sizes from 60cc to 250cc. It's used on roller and sliding bearings, sliding guides, open gears, spindles, shaft seals, and chains. Bluetooth versions allow status monitoring without physically accessing the unit.

Can automated lubricators be remote-mounted away from the bearing?

Yes. perma systems can push grease through extension lines up to 10 feet from the bearing. This is critical for bearings located in dangerous or hard-to-reach areas — operators can change cartridges and purge lines from ground level instead of scaffolding or shutting down equipment for access.

Automated Lubrication

Lubrication plays a crucial role in manufacturing across various industries. It involves the application of lubricants to moving parts of machines and equipment, ensuring smooth operation, reducing wear and tear, and extending the lifespan of machinery. By implementing effective lubrication practices, you can prevent up to 75% of premature bearing failures. What was once a manual task, typically executed by operators using grease guns, has now been transformed by automation. Automatic lubrication guarantees precise lubricant dispensing and prevents contamination, greatly extending equipment longevity. It also improves operator safety and enables workers to concentrate on more complex and creative tasks.

Cooling Roller Multi-Point Lubrication Project

In this critical and dirty application, a building materials manufacturer was experiencing premature bearing failure and unplanned downtime associated with their cooling rollers. We optimized the greasing process by utilizing a multi-point system to grease all bearing sevenly from a centralized, safe location. The multi-point system seals grease points and provides positive pressure in the bearings, preventing constant exposure to contamination. It also eliminated safety risks, reduced labor (swapping grease cup every 3 months vs. manually greasing daily), and significantly extended bearing life due to consistent grease dosing, which keeps the bearing in optimal lubrication range.

Pulp and Paper Mill Motors

Due to the large-scale layout of the facility, limited technicians, and the aim to prolong equipment life, a collaboration was initiated with a pulp and paper mill to optimize greasing practices. The objective was to shift from the conventional manual greasing approach to an automated lubrication method utilizing Perma Star Vario greasers. This transition has not only liberated the technicians to focus on more critical tasks, but also ensures that the bearings receive a steady and precise supply of grease, thus maintaining ideal lubrication conditions.

Four Station Remote Mounted Greasers

In this application, four Perma Star Vario auto greasers were strategically mounted on a heavy-duty 4-station bracket, positioned approximately 10 feet away from the grease point and shielded by a protective housing. This setup allows operators to easily change the grease cartridges and purge the lines when necessary, using the remote zerk fittings. This innovative solution ensures peak operator safety and delivers precise bearing lubrication, significantly extending bearing life.

Fertilizer Manufacturer Conveyor Bearings

Large conveyors in fertilizer manufacturing facilities often span long distances and multiple levels, making them challenging to access. Ideally, relubrication should occur while the equipment is running, but this poses significant safety risks. To eliminate operator hazards and prevent equipment shutdowns, two Perma Ultra units were remotely mounted in a safe location. These units continuously grease the conveyor bearings, ensuring safety and minimizing downtime.