Author: Twin Specialties

What are Aerospace Lubricants?

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On May 30, 2020, NASA and SpaceX partnered to send American astronauts from US soil to the International Space Station for the first time since 2011. As a new era spaceflight begins, government entities like NASA and private enterprises like SpaceX will work to innovate their rockets and push boundaries for human space flight. Lubricant manufacturers are tasked with the same challenges to create lubricants that will aid in the journey to reach our ambitious goals.

What are Aerospace Lubricants?

Lubricants in used in aerospace applications such as, space travel, commercial airlines, and defense, are like other lubricants, but face more stringent performance demands. In order to be classified as an aerospace lubricant, products must pass tests that are created by the Department of Defense (DoD) known as “MILSPECS.” To ensure safety and performance for aerospace applications, the MILSPECS create standardization to meet DoD objectives. These MILSPECS test different performance factors such as: corrosion protection, shear stability, compatibility, and water sensitivity.

What Differentiates Aerospace Lubricants?

In addition to meeting various MILSPECS, aerospace lubricants are engineered specifically for aircraft engines and fuel systems. The key difference between aerospace lubricants and non-aerospace lubricants is weight. In space operations, weight is crucial because more fuel is needed, which can become costly. It could also put a strain on how many other supplies could be included in the launch. As the safety of astronauts and functionality of equipment is vital, these lubricants cannot fail.

In space applications, lubricants face the most demanding tests. With temperatures in space at near Absolute-Zero and reentry temperatures reaching 5000 F, lubricants must perform in a wider-range of temperatures than their Earth-bound equivalents. Additionally, lubricants must be able to operate in a vacuum environment. This is on top of all of the crucial navigational and life-supporting machines that make space travel possibly. These machines cannot suffer any breakdowns or down time as they support life and other functions both in space and on Earth. Aerospace lubricants must have a long life to maintain these critical operations.

In defense operations, completing the objective is key and your lubricant must perform to ensure the objective is met. These lubricants have to: withstand extreme-temperature jet engines, cargo aircraft landing gears, precise navigational tools, and other wide-temperature components. By selecting lubricants that meet the right MILSPECS you can ensure proper performance and success in your aerospace operations.

Aerospace Lubricant Manufacturing

Aerospace lubricants in today’s markets can be in the form of liquids or greases. Most use synthetic base oils to achieve desired results and improve efficiency. Most of these lubricants are made of perfluoropolyether (PFPEs) or Multiply Alkylated Cyclopentane (MACs). Several large manufacturers produce these products that meet various MILSPECS. Twin Specialties has access to a wide variety aerospace and MILSPEC lubricants from Shell and Castrol. Contact us to learn more about our catalog.

What are Friction Modifiers?

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What are Friction Modifiers?

Friction modifiers are mild anti-wear additives used to minimize light surface contact, such as sliding and rolling. These can also be referred to as boundary lubrication additives. These additives are used in lubricants to modify the coefficient of friction (hence the name, Friction Modifiers). Friction modifiers are deployed to prevent wear on metal surfaces. Mostly used in transmission fluids and engine oils, these additives help slow down wear and increase fuel economy.

How do Friction Modifiers Work?

Source: Machinery Lubrication – Noria

A friction modifier molecule consists of two parts: a polar end (head) and an oil-soluble end (tail). The head attaches itself to the metal surface to create a cushion for the metal surface against another metal surface. The tails stand up like a carpet; vertically stacked besides each other in a Nano-sized sheet covering the metal surface. These molecules hold up when cushioned surfaces come in light contact with each other. This forms a thick boundary film that is softer than metal surfaces.

These additives have multiple functions beyond friction modification. They work as antioxidants and corrosion inhibitors as well. As the contact or load becomes heavier, the polar molecules are brushed off, thus rendering the additive useless in reducing friction.

Friction Modifier Applications

Friction Modifiers are typically used in engine oils and automatic transmission fluids. In engine oils, friction modifiers are deployed to improve fuel economy by reducing friction. In transmission fluids, friction modifiers are deployed to improve engagement on clutches. Some situations require some traction to operate properly.

Their use in engine lubricants increased in the 1970s due to the oil embargo. The lack of fuel led the automotive industry to improve fuel economy, thus reducing fuel usage. Continuous development has led to lower viscosity lubricants. Now, lubricants require robust friction modifiers to reduce wear and friction to offset the lower viscosity.

However, friction modifiers in these applications act differently based on shear conditions. This ensures equipment does not wear while also preventing too much slippage. This smooths the transition from a dynamic condition to static condition. For example, this is used in a gear change in a transmission.

Anti-Wear and Extreme Pressure (EP) Additives

As loads become heavier, engineers must adjust their lubricant to meet the tougher demands of heavier loads and higher temperatures. You should switch to a modifier that is classified as an anti-wear additive. A common and effective anti-wear agent is Zinc dialkyldithiophosphate (ZDDP). These additives react with metal surfaces once the environment reaches a high enough temperature.

As loads continue to increase, in addition to metal contact, the friction modifier must become more robust. In this instance, your lubricant must include extreme pressure (EP) additives. These additives are either temperature-dependent or not. Temperature-dependent EP additives activate as the metal surface temperature increases due to the extreme pressure. The reaction is driven by the heat produced from friction.

Final Thoughts

Lubricants with friction modifiers create more efficient operating environments. This leads to less wear, downtime, and carbon dioxide emissions. As friction modifier additives improve, lubricant manufacturers will aim to reduce to viscosity to reduce shear conditions. Conversely, this creates more components operating in thin boundary lubrication conditions. We will see continuous innovation of these additives to meet the performance and efficiency demands.

How Mineral Base Oils are Made

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Oil-based liquid lubricants are composed of two (2) key ingredients: base oil and additive packages. Additive packages in a lubricant will tend to vary based on applications. This post will focus on the main ingredient, base oils. Base oils will comprise typically 80-99% of an oil-based lubricant. Before we look at the base oil in a finished lubricant, we have to understand how oil gets from a drilling site to a refinery and finally into your lubricant.

Extracting and Transporting Crude Oil

After crude oil is extracted from the ground at wellhead or platform drilling sites, it is transported via rail, ship, or pipeline. It is then stored at a terminal or hub. Oil & Gas Manufacturers then take the crude and refine it to meet product specifications. Some of these products include gasoline, heating oil, fuel oils, asphalt and road oil, and lubricants.

Separating the Crude Oil

The typical barrel of crude is 42 gallons. According to the American Petroleum Institute, only 0.5 gallons of crude oil in each barrel are used to make lubricants.

This is because lubricants require longer chain hydrocarbons. Most lubricants have hydrocarbon molecules with 26-40 carbon atoms. Crude oil is heated and vaporized then condensed; this process is known as distillation. The distilled oil is easily separated by hydrocarbon chain lengths. Shorter molecules rise to the top and longer molecules sink to the bottom. After the hydrocarbons with 26-40 carbon atoms are separated, they are sent to a refining process specific to lubricants.

Refining the Crude Oil

The distilled oil is refined using two different processes: extraction and conversion. Extraction involves four steps:

  1. Deasphalting: Takes residue at the bottom and separates into tar and compounds similar to lube distillates.
  2. Solvent Extraction: Remove most the aromatics and undesirable constituents of oil distillates. Results in neutral oil base stocks called reaffinates.
  3. Dewaxing: Reaffinates are dewaxed to produce a wax and dewaxed oil. The dewaxed oil becomes base stock for lubricants.
  4. Hydrofinishing: Changes polar compounds in oil by a chemical reaction. Oil becomes lighter in color and exhibits improved chemical stability.

The conversion process involves three steps and is becoming popular for refining. This process involves converting undesirable products into desirable products using hydrogen, heat, and pressure:

  1. Hydrocracking: Distillates are subjected to a chemical reaction at high temperatures and high pressure. The aromatic and naphthene rings are broken and joined using hydrogen to form an isoparaffin structure.
  2. Hydrodewaxing: A hydrogenation unit is used to deploy a catalyst that converts waxy normal paraffins to desirable isoparaffin structures.
  3. Hydrotreating: The first two processes broke chemical bonds, therefore it is necessary to saturate unsaturated molecules. By adding more hydrogen, the molecules saturate and become more stable and better able to resist oxidation

Classifying Refined Oil

This results in mineral oil base stocks that are classified into three different groups. API Groups I, II, and III are all mineral oil-based, but differ based the level of refining. The chart below gives a breakdown of each of the 3 mineral groups.

The key factors are: sulfur (%), saturates (%), and viscosity index. Some refer to Group III base stocks as “synthetic” due to the chemical processes they undergo. The natural chemical structure is altered from the natural structures found in mineral oil. However, the API classifies Group III oils as mineral because they originate from crude oil

The conversion process is more effective in reducing aromatic content, but the process is more expensive. Typically, the costs are passed along to end-users, but they get a higher quality base oil and better performance. Group II and Group III are becoming more prevalent as preferences shift towards conversion processes rather than extraction processes. Once refined, base stocks are blended with additives and additive packages to form a final product lubricant.

How to Dispose of Aerosol Cans

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The Environmental Protection Agency (EPA) believes that the management of hazardous waste aerosol cans can be best implemented through a universal waste approach where handlers operate within a streamlined management system with regulatory oversight. On December 9, 2019, the EPA finalized the rule to add Aerosol Cans to the federal list of Universal Wastes. This final rule will impact the labeling and marking, accumulation time limits, employee training, responses to releases, export requirements, and, for large quantity handlers of universal waste, notification and tracking.

What is the definition of Aerosol Can?

As of February, 2020, the EPA defines an aerosol as a non-refillable receptacle containing a gas compressed, liquefied or dissolved under pressure, the sole purpose of which is to expel a liquid, paste, or powder and fitted with a self-closing release device allowing the contents to be ejected by the gas. Because the DOT language is more inclusive than the proposed language, it better matches the intent of the proposal to apply to all types of aerosol cans, including cans that dispense product in the form of paste or powder, and would not require states that have already added aerosol cans to their universal waste program to change their regulations.

Current Regulations

On March 16, 2018 the Environmental Protection Agency (EPA) proposed adding aerosol cans to the federal universal waste list. This proposal recognized that the inclusion of this waste stream as a universal waste could better ensure that aerosol cans are managed appropriately from cradle to grave. Aerosol cans are widely used for dispensing a broad range of products including paints, solvents, pesticides, food and personal care products.

The Consumer Specialty Products Association (CSPA) estimates that 3.8 billion aerosol cans were filled in the United States in 2015 for use by commercial and industrial facilities along with households. Aerosol cans may be dangerous if mismanaged, particularly when exposed to excessive heat, which may result in increased internal pressure and eventually could cause the container to burst and release its contents. If the propellant or product is ignitable, this could result in a rapidly burning vapor “fireball.” Even if the propellant is not ignitable there are dangers from a bursting aerosol can as parts of the aerosol can could become a projectile. After the proposed rule-making was announced the EPA took public comment on the proposed standards. The docket number for this rule-making is EPA-HQ-QLEM-2017-0463.

The Environmental Protection Agency (EPA) has added hazardous waste aerosol cans to the universal waste program under the Federal Resource Conservation and Recovery Act (RCRA) regulations. The aim of this rule is to benefit the establishments generating and managing hazardous waste aerosol cans. These establishments include retail stores and others that discard hazardous waste aerosol cans. The rule will ease the regulatory burdens on these establishments and promote the collection and recycling of these cans and encourage the development of municipal and commercial programs to reduce the amount of aerosol cans from going to municipal solid waste landfills or combustors. This final ruling will impact the following areas for all handlers: Generator Status Universal Waste Aerosols do not count towards Generator Status.

Guidelines and Best Practices

The final rule requires aerosol cans to be labeled as “Universal Waste—Aerosol Can(s),” “Waste Aerosol Can(s),” or “Used Aerosol Can(s).”

  • The final rule allows for generators to store aerosol cans for up to one-year.
  • Employees must be trained on handling and how to safely puncture and drain universal waste aerosol cans – if applicable to facility.
  • Aerosol cans will now be exported as Universal Waste.
  • Notification and Tracking will only be impacted for large quantity universal waste handlers. Handlers must make a notification before beginning to puncture the aerosol cans.
  • Under the universal waste rule, a handler of universal waste can send the universal waste to another handler, where it can be consolidated into a larger shipment for transport to a destination facility.
  • Universal waste destination facilities are subject to all currently applicable requirements for hazardous waste treatment, storage, and disposal facilities (TSDFs) and must receive a RCRA permit for such activities.
  • This will make it more economical to send hazardous waste aerosol cans for recycling for recovery of metal materials. This final action is estimated to result in an annual cost savings of $5.3 million to $47.8 million.
  • The EPA is requiring leaking or damaged aerosol cans that show evidence of leakage to be packaged in a separate closed container, overpacked with absorbents or immediately punctured and drained in accordance with the aerosol can Universal waste requirements.

Gemini Disposal Services can help you disposal of your aerosol cans and/or universal waste in a safe and economic matter. If you need to dispose of your aerosol cans, request a quote and we will work with you to properly manage your universal waste.

A Guide to Grease Thickeners

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Used for over 3000 years, grease is a key lubricant used to operate a variety of machines and bearings. Over 80% of the world’s bearings are lubricated with grease. Grease is an excellent lubricant to use when liquid lubricants fail to do the job. Greases are made of three main components: base oil (70-95%), thickener (3-30%), and additives (up to 10%). We are going to examine the second component: thickeners. Thickeners are essential as they are the “sponge” that holds the base oil and additives.

What are Thickeners?

When combined with the base oil and additives, the thickener forms a semi-fluid structure. Conventional thinking suggests the structure indicates the grease is mainly thickener, however, the thickener is a material that holds the lubricant until it is dispersed. As mentioned above, the overwhelming majority of any grease is composed of base oil. There are many types of compounds that can be used as thickeners.

Greases are classified into two major families: soap and non-soap thickeners. Over 90% of greases worldwide are classified as soap thickeners. Soap-based thickeners are produced via an acid-base reaction known as saponification. The end-result is a soap and water mixture. The water is removed and the remaining soap is used as a thickener for grease. The type of soap thickener will depend on which acids and bases are used in saponification. Some common compounds used are:

  • High molecular weight fatty acids: Stearic and 12 Hydroxy Stearic Acid (12 HSA)
  • Short chain complexing acids: Tallow, Azelaic, and Sebacic Acid
  • Most bases are a metallic hydroxide compound (i.e. lithium, calcium, etc.).

Types of Soap Thickeners

Simple Soap: This results from the reaction of one fatty acid and a metallic hydroxide. The most common soap, lithium soap, is produced

Types of Soap Thickeners – Source: NYE Lubricants

with 12 HSA and lithium hydroxide. The metallic hydroxide defines the thickener and other types besides lithium can be used.

Mixed Soap: Less common than simple soap, mixed soap is created in similar fashion as simple soap. However, the “mixed” characteristic is derived from mixing multiple metallic hydroxide compounds with a fatty acid. A common mixed soap is Ca/Li soap, which is made with calcium hydroxide and lithium hydroxide.

Complex Soap: Like simple soaps, complex soaps use a single metallic hydroxide. In order to create the complex-thickened grease, a fatty acid is combined with a short chain complexing acid. The acid mixture is then combined with a metallic hydroxide to for a complex thickener. Lithium complex grease, the most popular in North America, is made with lithium hydroxide, 12 HSA, and azelaic acid. These thickener types have an advantage over simple soap because of better high-temperature properties.

Types of Non-Soap Thickeners

Urea: Also known as polyurea, these thickeners are a reaction product of di-isocyanate combined with mono and/or diamines. The ratios of the ingredients will determine the characteristics of the thickener. This classification includes diurea, tetraurea, urea-urethane and others. Since there are no metallic elements in polyurea grease, the grease is ashless and subsequently more oxidatively stable. Polyurea greases are the most popular non-soap grease today.

Organophilic Clay: Also referred to as organo clay or clay thickeners, these thickeners are mineral based usually made from bentonite, hectorite, or montmorillonite. The minerals are purified into a clay and treated to be compatible with organic chemicals. The clay is dispersed in a lubricant to form a grease. Clay greases have no melting point and are traditionally used in high-temperate greases (however the oil will oxidize quickly at elevated temperatures).

Other: Polyurea and clay thickeners are the most used non-soap greases, but there are some other specialty thickeners that are used. These include:

  • Teflon
  • Mica and silica gel
  • Calcium sulfonate
  • Polytetrafluoroethylene (PTFE)
  • Carbon blacks
NLGI Grades – Source: Noria

NLGI Classifications

In addition to composition, the other key classification for grease is quite obvious: thickness. Defined as consistency, a grease’s consistency is its resistance to deformation by applied force. This is measured by penetration. A standard test, specifically ASTM D217, measures cone penetration after five (5) seconds for a grease at 77 F (25 C). The unit of measure is tenths of a millimeter and the NLGI classifies grease based on its penetration. The range of grades is 000 to 6. See the chart to the left for a full breakdown NLGI grades.

Most greases today fall in between the 1 and 3 grades with NLGI 2 being the most common. High penetration greases such as 00 and 0 can be used in central systems and colder environments.

Selecting the Appropriate Thickener and Grade

The right grease could vary greatly depending on your application, operating environment, and other factors. High temperature environments may require firmer (higher NLGI grade) greases and certain thickeners with high-temperature properties. It is best to consult OEM guides or speak with your grease manufacturer or distributor to get a recommendation.

Switching and mixing greases could either prove to be extremely costly. Most thickeners do not mix together and there are specific greases that are not compatible with others. It is recommended to match “like-for-like.” If you plan to make a switch, it is best to completely drain your equipment before applying new grease.

What is Viscosity Index?

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While researching lubricants, there are many factors to consider in selecting a lubricant: viscosity, flash point, pour point, and oxidation stability. Viscosity is the most important parameter since the viscosity grade can be the difference between optimal performance and machine breakdown. However, the ISO Viscosity Grade (VG) is determined at 40⁰C and will fluctuate depending on operating temperature. Viscosity index is a measure of how much the viscosity will change as temperature rises or falls.

Viscosity Index Explained

Viscosity requirements are based on things such as: component design, loads, and speed. Machine recommendations do not account for operating temperatures and temperature ranges. Therefore, it is imperative to take into account average operating temperature when selecting a viscosity. To account for changing temperatures, the viscosity index was developed to measure viscosity stability as temperatures change. Viscosity index is a unit-less number that is derived by measuring a fluid’s viscosity from 40⁰C to 100⁰C.

The higher the viscosity index, the greater the stability of the lubricants viscosity. As shown in the chart below, the difference in viscosity index could greatly affect lubricant viscosity and performance:

Source: Machinery Lubrication, Noria

As temperatures move towards extreme highs and lows, the difference in Oil A and Oil B is magnified. Oil B, which has a VI of 150, maintains a viscosity closer to its ISO VG of 150 as temperatures rise and fall. On the other hand, Oil A fluctuates much more and could adversely affect performance at extreme temperatures. If your operation will have fluctuating loads, speeds, temperatures, etc., it is imperative to select a lubricant with a higher viscosity index.

Viscosity indexes, which can be found on most product data sheets, typically range from 90 to 160, but can exceed 400 and be as low as -60. The viscosity index can also give insight into the type of base oil and its quality. More refined mineral oils and synthetics will have higher VIs than lower quality base oils. Some products may include viscosity-index improver additives to help stabilize the lubricant in extreme conditions. VI-improver additive molecules adopt a coil shape in cold temperatures and have little effect on viscosity. In higher temperatures, the molecules uncoil and thicken the oil to stabilize viscosity. However, it is important to note that oils with VI-improvers will see permanent loss of VI and viscosity over time.

When Should You Opt for Higher VI

If your operations are going to have variable loads, variable temperatures, variable speeds, and other environmental variables, it is important to select a lubricant with a higher viscosity index. As these variables change, so will the lubricants viscosity. Therefore, it is crucial to invest in a lubricant that will maintain an optimal viscosity across different operating conditions. Conversely, if your operation is fairly consistent, it may suit you to select a lubricant with a lower viscosity index in order to save money.

Some machines may not possess data to identify the optimum viscosity, which could be problematic as ISO viscosity grades are separated by 50% increments between grades (e.g. 46 → 68, 100 → 150). With such large increments, finding the precise optimal viscosity becomes even more difficult. This problem is magnified at lower temperatures, where differences in lubricant viscosity are much larger (as shown in the chart above).

Calculating VI

If you are unsure of a lubricants viscosity or viscosity index, there are online calculators available to help you. If you are unsure of a viscosity index, simply enter the viscosity at two different temperatures and it will return the viscosity index. If you are unsure of a viscosity at a given temperature, enter a known viscosity, known temperature and viscosity index to find the desired temperature to find the new viscosity.

Key Takeaways

In conclusion some of the key reasons to have a lubricant with a higher viscosity index include:

  • Optimal operating viscosity is unknown
  • Varying operating temperatures and/or extreme operating temperatures
  • Other operating variables such as speed and load
  • You want to increase energy efficiency
  • You want to extend oil service and machine service life

Most of these involve improving performance that may be adversely affected by operating uncertainties. In these instances, it is ideal to opt for lubricants with higher VI. In the following instances, using cost-effective lower VI lubricants may prove beneficial to your bottom line:

  • Constant speeds and loads
  • Operating temperature remains the same
  • Optimal viscosity is known and can be consistently reached

If there is more certainty with your operating process, it may not be necessary to invest in a lubricant with a higher VI. It is important to evaluate your operating processes and consult machine manuals to understand your operating conditions. If you are faced with uncertainty and variance in your operations, a higher viscosity index will help smooth operations and increase performance across different loads, speeds, and temperatures.

What are Lubricant Detergents?

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Detergents Defined

Detergent additives perform two key functions. Like household detergents, the additives keep metal components clean and free of deposits. Additionally, detergents neutralize acids that form in the oil. This is key for systems where component cleanliness is essential. Originally developed for engine oils, detergents addressed carburetor deposits that could hamper performance. Detergent additives were also found effective in fuel injectors. The detergents reduced deposits that affected fuel spray patterns.

How do Detergents Work?

Detergent additives are basic in nature, thus serve as a neutralizer for acidic contaminants that may arise in your lubricant. In the past, these detergents were barium-based, however modern chemistry has allowed manufacturers to move to different formulations. Today, most additives use either calcium-based chemistry or magnesium-based chemistry. As an oil is subjected to oxidation, it will start to collect acids. As these acids build up, the oil’s Total Acid Number (TAN) will increase. The basic and alkaline detergent will neutralize the acids and reduce the TAN. However, as the detergent is used, the Total Base Number (TBN) will decrease to point where the oil will need to be replaced. Therefore, measuring TBN is crucial to engine performance and lubricant effectiveness.

In high-temperature applications, metal compounds leave an ash deposit when burned. This residue buildup requires many OEMs to require low-ash oils. Detergent additives are used to clean these deposits. However, dispersants are included as well to help clean the engine. Dispersants are used to keep engine soot particles suspended and prevent agglomeration (forming larger soot deposits). The dispersant and detergent work together to suspend contaminants and neutralize acids. Eventually, the additive capacity will exceed its limit and require users to change the oil and replenish the additives.

Detergent v. Non-Detergent Oil

How do you know if you need a lubricant with detergent additives? Usually, an OEM will specify whether the equipment needs a detergent oil or non-detergent oil. Applications that could face high levels of water and contamination are good fits for detergent oil. Some examples include: off-road equipment, marine equipment, trucks & fleets, and many more. The high levels of contamination need to be neutralized with dispersants in order to keep pumps and valves clean and running.

Sometimes, OEMs require oils to not have detergent additives. Some manufacturers will produce special Non-Detergent oil to meet these specifications since, most oils now have detergent additives for better performance. Non-detergent oils are used in bearings and chains in non-critical once-through systems. It is also recommended for gas-powered appliances such as lawnmowers and tractors. Some non-detergent oils are not recommended for automotive gasoline engines (detergent oils are recommended).

Detergent Oil Today

With the developments in detergent and dispersant technology, most oils now have some sort of detergent additive to help combat high TANs and prevent sludge build-up. Even though non-detergent oil is still marketed today, it is only required for a few specific applications and not recommended by many OEMs. When selecting your lubricant, detergency is important to consider because high detergency will protect your parts, keep your system clean, and maximize performance. If you are using non-detergent oil, consider making the switch to an oil that has detergent additives.

Twin Specialties offers both detergent and non-detergent oils to meet your specifications and OEM requirements. We also offer a variety of motor oils and heavy duty engine oils with high-quality detergent additives to meet your specifications and budget. Contact us today for more information.

A Guide to Food Grade Lubricants

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In the food and beverage industry, health, safety, and quality are of the utmost importance. The ever-evolving standards of food and beverage safety make it important to ensure your plant is deploying the proper lubricants and cleaners. Not only do you have to meet performance standards, you also have to monitor leakage to ensure that final products are not getting contaminated. We will examine the evolving standards of food-grade lubricants and cleaners as well as the challenges in finding the right products to meet both health and performance standards.

From USDA to NSF

The original designations created by the USDA sought to organize food-grade lubricants into three categories. The current standards are listed below for each category:

  • H1 lubricants are used in food-processing environments where there is the possibility of incidental food contact. These lubricants are tasteless, odorless and inert. H1 lubricants are safe for human consumption in small amounts, under 10 parts per million (ppm). They are most often used in for machinery such as conveyors and mixers. Applications of these lubricants include: blending, cutting, bottling, brewing and many more.
  • H2 lubricants are used on equipment and parts where there is no possibility of incidental food contact, such as forklifts. Even though there is no contact, H2 lubricants must adhere to strict toxicology standards. H2 lubricants may not contain trace elements of: carcinogens, mutagens, teratogens, mineral acids or heavy metals.
  • H3 soluble oils are used to prevent rust on hooks, trolleys, and similar equipment. These products are typically made of edible oils such as: corn oil, sunflower oil or soybean oil. H3 lubricants are inherently biodegradable and comply with 21 CFR Section 172.860 and 172.878. They also comply with 21 CFR 182 and 184 in regards to GRAS substances.
  • 3H release agents are used on surfaces with direct contact to prevent food from adhering during processing. These lubricants can be used to aid in processes where contact is unavoidable, such as removing baked goods from a mold.
  • HT1 are heat transfer fluids used in primary and secondary heating and cooling systems in food processing facilities. These must comply with 21 CFR 178.3570 and 21 CFR 172.

The USDA served as an authority for approval and compliance. Manufacturers had to prove all components were allowable substances under 21 CFR 178.3570. The USDA stopped issuing registrations on September 30, 1998. Since then, many organizations have adopted and modified these standards.

After 1998, The German Institute for Standardization (DIN) submitted a standard to the International Organization for Standardization (ISO). Eventually the ISO adopted ISO 21469, which pertains to lubricant manufacturing, and ISO 22000, which pertains to food safety systems. However, the most recognized standards are those put forth by the National Sanitation Foundation (NSF).

As a successor to the USDA, the NSF has updated the USDA standards to improve health and safety for consumers. The current NSF standards are similar to the old USDA standards, using the H1, H2, and H3 designations. Additionally, the NSF created the HX-1 standard for ingredients. These HX-1 ingredients are pre-screened and meet requirements for finished H1 lubricants. The NSF has established itself as the recognized international standard and operates in over 80 countries around the world.

Selecting your Food-Grade Product

In the food & beverage industry, health and safety is by far the most important concern. One contamination, recall, or illness outbreak can do irreparable damage to a company’s brand and business. Therefore, it is imperative to consider selecting products that go beyond required standards. Opting to use H1 lubricants is an excellent example of meeting compliance and protecting your brand. This eliminates the possibility of using an H2 lubricant when an H1 is required. H1 lubricants can act as insurance to your brand’s equity and will reduce liability in the event of equipment or plant issues.

Performance is key when selecting a lubricant, but achieving peak performance may be more difficult with food-grade lubricants. H1 products tended to fall short compared to their H2 counterparts. This was due to the limited number of H1-registered additives compared to H2-registered additives (including zinc-based components).Food & Beverage

New NSF HX-1 additive packages have dramatically improved the performance of H1 lubricants while also meeting the rigorous standards set forth by NSF H1 lubricants. For grease thickeners, aluminum sterate, aluminum complex, organo clay, polyurea and calcium sulfonate meet H1 standards (lithium thickened greases do not). You can now use an H1 lubricant and achieve the high performance demanded from your business. It simplifies the selection process by allowing you to use H1 lubricants throughout your plant.

These additives are now paired with synthetic base oils such as polyalphaolefins (PAOs), polyalkylene glycols (PAGs), and esters. These base oils along with HX-1 additives can deliver premium performance while protecting the integrity of your brand. Selecting a product also depends on your specific processes and it is important to consider unique contaminants that may affect product performance.

Other considerations may include dietary standards. It is important to ensure your lubricant meets any Kosher or Halal requirements. Failing to do so may result in products not suitable for those whose follow Kosher or Halal diets. This results in a smaller customer base and will affect bottom lines. It could damage brand integrity if a product is marketed as Kosher or Halal and is later found to fall short of these requirements.

Takeaways

Although no government is responsible for food-grade lubricant standards, the NSF has established itself as a leader in food-grade lubricant regulations. Operating as a nonprofit in over 80 countries, the NSF ensures that your food-grade lubricants meet their rigorous standards. Modern advancements in additive technology and base oil technology have led to lubricants that are NSF compliant and meet the highest performance standards. There is no need to sacrifice safety for quality anymore.

Twin Specialties offers a wide-range of food-grade products including lubricants and cleaners. We offer products from Castrol, CRC, Lubriplate, and many more to meet your food and beverage manufacturing needs. Contact us to learn more or get a quote.

What is E-Waste?

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Electronic waste (e-waste) is one of the fastest-growing waste streams in the world. However, according to the United Nations, only 20 percent of global e-waste is recycled each year. If that number startles you, it should.  The International Solid Waste Association believes that there needs to be a much stronger focus on e-waste, and out worldwide neglect has become a major concern.

Generators of e-waste have an increased responsibility to dispose of their waste responsibly.  Effectively disposing of this waste stream helps the economy by reducing the cost of producing new products, aside from the obvious – not sending this waste streams to already over-filled, landfills.  Also, the parts within each device that is recycled, are salvageable, and can be reused in the manufacturing process.  This cost savings can often be passed on to consumers.

Defining E-Waste

E-waste refers to any electrical and electronic equipment that has been discarded by its owner as waste, without the intent to reuse it. The term covers a very wide range of products. It can include:

  • households with circuitry or electrical components for delivering power;

    E-Waste
    E-Waste: Obsolete smart phones
  • Business products that do the same;
  • Temperature exchange equipment for cooling and freezing, like refrigerators, air conditioners and heat pumps;
  • Screens or monitors;
  • Large equipment like washing machines, clothes dryers, dish-washing machines, electric stoves, large printing machines, etc.
  • Smaller equipment like microwaves, ventilation equipment, video cameras, electronic tools, etc.
  • Small IT and telecommunication equipment like mobile phones, pocket calculators, printers, etc.

For many of these products, there’s an increasingly short replacement cycle as technological advances keep updating each device on a regular basis, offering consumers a new and improved model. And it’s not just smartphones that consumers replace frequently. Upgrades can include higher speeds and newer technologies, so older equipment gets replaced even if it’s not broken or obsolete. What it becomes, in the minds of the consumers, is outdated – too slow, or without the latest features.

In many countries, people own multiple devices. That means they also have multiple devices to discard.

The Future of E-Waste

Many forecasters predict that there will be up to 52.2 million metric tons of obsolete electronics by 2021, which would make e-waste the fastest growing part of the world’s continuous steam of discarded household items. The annual growth rate of e-waste is expected to be between 3-4 percent.

The concerns about the rising amount of discarded equipment are not just economic. There are also serious environmental concerns, and even serious fears, about the health risk of devices that contain toxic substances like lead and mercury not being treated adequately.

Allowing e-waste to pile up in landfills significantly increases these risks, when they can be lowered by having e-waste treated through appropriate recycling methods. This trend also shows how valuable resources are being wasted on a very large scale.

Gemini Disposal Services can help you with your E-Waste.  If you are a large or small generator of this type of waste stream, our company can dispose of this stream efficiently, responsibly, and cost effectively. Request a quote and we will help you properly dispose your E-Waste.

Should I Switch to Synthetic Coolants

Posted on by Twin Specialties in Blog Tagged , , , , , , ,

For your metalworking operation, you have a variety of options in selecting a coolant to use. The first decision is selecting which classification of metalworking lubricant to use. The four main classifications are:

When selecting which fluid classification, it is important to consider: cooling, lubrication, chip removal, and corrosion protection. Each classification has its strengths and weaknesses, which should be considered when evaluating coolant needs. For certain processes, a neat oil may be better than a semi-synthetic and vice versa.

Let’s examine synthetic coolants. These contain zero mineral oil content, hence synthetic coolant. When diluted, the fluid appears transparent and is a true solution with no droplet formation. One of the main benefits of synthetic coolants is zero foaming. Foaming generally appears in fluids with higher mineral oil content. If your synthetic fluid begins to foam, it is a clear sign that the coolant is contaminated.

The chemical composition of synthetic coolants makes for a robust product and more durable solution. Synthetics are much more stable than other classifications of metalworking fluids. The robust chemistry can create solutions that can reject all tramp oils. With less tramp oils in the sump, this creates a higher performing product and less likely to become contaminated.

This allows for a longer-lasting solution and higher efficiency in recycling the fluid. To offset the higher costs of synthetic coolants, fluid consumption is reduced because the fluid is a true solution. Less concentrate is needed to recharge the solution; therefore, it will take longer to use entire container.

Metalworking fluid selection is based on finding the balance between cooling and lubrication. Synthetic lubricants are preferred in operations where cooling is important in a metalworking fluid. They are formulated for rapid heat dissipation. If your process generates a lot of heat, synthetics may be preferable to ensure temperature control and high performance.

The fluid will last longer, however that is only if you are using best practices in fluid management. Synthetics are designed for specific concentrations and are less forgiving than other classifications of metalworking fluids. Tighter concentration control is needed for synthetics and you have to monitor the solution daily. Even though fluid management is more rigorous, it is easier to control and measure concentration because it is a transparent and droplet-free solution.

Whether you are facing foaming problems, high temperature operations or shorter coolant lifespans, the decision to switch to a synthetic coolant may be one to consider. Even though synthetic coolants are generally more expensive than other coolant classifications, the benefits will reveal themselves as you use the synthetic coolant. A synthetic coolant will last longer than a soluble oil and is much easier to reclaim and recycle. The performance of synthetic coolants is superior than semi-synthetics and will cool the work-piece and tool more effectively. Superior chemical formulation will protect your sump from tramp oils and other outside contamination. This protection along with zero-foam will keep your operation running longer with reduced downtime. Your coolant concentrate will last longer and can create significant cost savings over time.