Read our winning case studies
Shell Gadus S3 helped in smoother operations with annual savings of €13,895 on wood pellet machines
The Challenge:
One of the leading wood pellet manufacturers in Serbia, operates three Munch RMP 520/80 pellet machines. The machines work 24 hours a day and are exposed to harsh working conditions: heavy loads, wood and dust contamination, and high operating temperatures. When using a competitor’s grease, the customer had observed significant downtime and high operational costs due to the short bearing life of 500 working hours.
The Solution:
Local Shell Macro Distributor Orbico Trgovina I Usluge D.O.O. recommended Shell Gadus S3 T460 1.5 grease with polyurea thickener, which is characterised by exceptional mechanical stability at high working temperatures.
Results:
After applying Shell Gadus S3 T460 1.5 grease, the customer noticed less production downtime. Increasing the bearing life to 700 working hours from the 500 working hours experienced with the previously used grease resulted in lower total cost of ownership. The leading wood pellet manufacturers D.O.O. has calculated an annual saving of €13,895 for the three wood pellet machines.1
Saving $161,834 annually with Shell Morlina S4 B 220: Application calendar bearings
The Challenge:
One of the leading paper manufacturers in Setúbal, Portugal, was using Shell Omala S2 G 220 in the calender section of its papermaking equipment. The company was experiencing lubricant leakage from the bearings caused by oxidation residue accumulating on the rolling surface and in all the joins, gearboxes and side support bearings. The company also noticed a brown film on the metallic surfaces that interfered with normal operations.
The Solution:
The Shell technical team inspected the equipment and discovered varnish on the rolling surface and in the gearboxes and bearings. After dismantling the equipment and removing the varnish, Shell proposed that the manufacturer should change from Shell Omala S2 G 220 to Shell Morlina S4 B 220, which has a higher thermal stability, to prevent the formation of varnish. During a trial, Shell experts analysed the condition of the equipment and the lubricant using the Shell LubeAnalyst monitoring service.
Results:
Paper manufacturer found that Shell Morlina S4 B 220 performed better at high temperatures than the previous lubricant. It was longer lasting and had better oxidation resistance and less tendency to form residue deposits. The company has reported total annual savings of US $161,834 through lower oil consumption and labour costs, less equipment replacement and improved productivity since switching to Shell Morlina S4 B 220.1
300% longer oil-drain intervals achieved in paper mill equipment with advanced lubrication services
The Challenge:
A paper production line faced high operating temperatures, with soft roller bearings reaching up to 100°C. The goal was to find the right lubricant to maximise reliability and productivity.
The Solution:
Based on results from similar applications, the Shell Lubricants team recommended high-quality synthetic oil Shell Omala S4 GX 150. Technical support and oil monitoring were provided through Shell LubeAdvisor, Shell LubeCoach and Shell LubeAnalyst.
Results:
The new product has enabled the company to extend its oil drain interval from one to four years. Oil change costs are down by 80%, annual maintenance by 25% and downtime by 25%. The benefits associated with longer oil life have delivered estimated annual savings of US $47,000.1
1The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site and from time to time, depending on, for example, the application, the operating conditions, the current products being used, the condition of the equipment and the maintenance practices.
2ShellLubeAnalyst: from 2008 to 2018, the Shell LubeAnalyst service delivered $105 million3 in customer savings.
3Data points from end 2018.
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