Tag: Oil

How Long is Lubricant’s Shelf Life?

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

When buying lubricants, you have to consider how long they will last. For high-volume users, this is not as much of an issue compared to smaller-volume users. High-volume users’ regularly consumer and reorder lubricants and typically have systems in place to monitor usage and spending. Small-volume users might be spread a drum or two of a lubricant through the course of a year. When consumption is spread out, you have to start to consider shelf-life into your purchasing decisions and operational processes.

Where can I find Shelf-Life Information?

Table made by George Wills and Dr. A.R. Landsdown

Information on a lubricant’s shelf life can be found on a technical or safety data sheet. If it is no t clearly defined, manufacturers and distributors can provide guidance on shelf life for its products. However, this information might be based on storage only or based on typical operations. George Wills and Dr. A.R. Landsdown provide a brief list of lubricants and their shelf-lives for products that have shorter shelf-lives.

Some technical data sheets (TDS) can show how long a lubricant can last in use before losing oxidation stability. This is measured in operating hours. Most oxidation tests will show a lubricant can last 5000+, 8000+, 10000+, etc. hours. However, like all scientific tests, this is done in a controlled environment (usually set by ISO or ASTM standards and specifications). We know that not every operating environment is like an ASTM or ISO test.

What Determines a Lubricant’s Shelf Life?

A lubricant’s shelf life depends on a variety of factors; some of which depend on the lubricant itself and some depend on usage. Greases have much shorter shelf life due to the presence of thickeners than oil-based lubricants. Highly-refined and synthetic oils have longer shelf lives due to better molecular stability. This is much more straight-forward and lubricant suppliers can inform you which lubricants last longer than others.

Using a lubricant is different for each operation. Some operations happen at low temperatures, others occur at high temperatures. The Arrhenius rate is a chemistry term that demonstrates how chemical reactions increase by changing temperature. For lubricants, as temperature increases by 10°C (18°F), the oxidation rate will double. The more oxidation that occurs, the faster a lubricant will break down and reduce the shelf life and effective use life.

Machinery Lubrication compiled a chart from its experts to show what can increase or decrease a lubricants shelf life.

Table Courtesy of Noria Corporation and Machinery Lubrication

 

How can you Reduce Oxidation?

Oxidation occurs when the lubricant comes into contact with air. Certain lubricants are more susceptible to faster oxidation and degradation due to the composition of the lubricant. However, these are known and can be accounted for, whereas human factors are a much greater influence on degradation and chemical stability.

Storage is key to maintain longer shelf-life and higher lubricant performance. Some things that can improve shelf-life include:

  • Storing lubricants in proper ambient temperatures. Cooler temperatures around 68°F are ideal.
  • Storing lubricants in dryer environments. Ambient humidity and moisture increase oxidation and lubricant breakdown.
  • Storing lubricants indoors. Outdoor storage can expose lubricants to more extreme and volatile conditions.
  • Storing lubricants in proper containers. Poor-quality steel containers can expose the oil to iron and fuel oxidation. Plastic or plastic-lined drums are ideal for storage.
  • Reduce agitation of the lubricant. The move the lubricant is agitated or moved, the more surface area of oil is exposed to air and can oxidize.
  • Evaluate usage and purchase lubricants accordingly. This smooths out spending, but also reduces the likelihood of using older products.
  • Practice First-In-First-Out (FIFO) when using lubricants. This prevents lubricants from sitting and aging.
  • Label lubricants, containers, and machines. Knowing when a lubricant was made or put into use allows individuals to be more mindful of when to change lubricants.

How do I Get Informed?

Unfortunately, there is no industry consensus on shelf-life. Following the tips above will extend and maintain shelf-life. Speaking with manufacturers, distributors, and engineers is the best option in getting product-specific shelf-life information. Manufacturers will know exactly what goes into their products and can provide shelf-life information and best practices for storage.

Twin Specialties can provide information about Best Practices for Lubricant Storage and Managing Metalworking Fluids. We work with manufacturers to provide transparency and information about lubricant shelf-life and usage. Contact Twin Specialties for information about lubricants, best practices, and shelf-life.

How to Manage your Metalworking Fluids

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

Metalworking fluids may not contribute that much to your manufacturing costs, but when fluids begin to fail or not work as intended, the costs could be astronomical. With the increasing costs of more technological fluids and rising disposal costs, managing your fluid and fluid consumption is more important than ever. Managing your fluids and dedicating a fluid management program could pay dividends by: reducing fluid usage, extending tool life, and improving manufacturing performance.

Monitoring Concentration

Fluid technology has advanced by leaps and bounds over the years and have improved performance for manufacturers. However, these advanced fluids have been engineered to work at specific concentrations. Running a coolant too thin or too rich will limit its ability to do its job. Running a coolant too rich might cause problems of over lubricity, but the main problem is overconsumption of the fluid.

The big problems occur when a fluid is too thin. This means the concentration in the sump is below the manufacturer’s recommendation. The additive packages are designed based on these minimum concentrations and provide enough of each additive to perform its function properly. Less concentrate means fewer biocides, fewer rust inhibitors, fewer emulsion stabilizers, etc. Eventually, the fluid breaks down quicker requiring more frequent change-outs. Some managing fluids, some operators use coolant additives/boosts to improve performance. If you vigilantly monitor concentration, the need for additives will lessen and thus reduce costs.

To monitor concentration, use a refractometer to measure concentration frequently. It is recommended to measure concentration every day or twice a day (depending on your operating schedule). The same person should measure to ensure consistency and ensure reliable measurements. When charging or recharging sumps, using automatic mixers helps ensure concentration is consistent. Remember, do not add just coolant or just water to the sump to balance out concentration. Some facilities use digital coolant monitoring systems to manage concentration, pH, and other factors. Facilities with large coolant systems may benefit from the technology.

Assessing Water Quality

Water comprises 90% or more of the fluid in the sump, thus it is crucial to make sure you are using good water. A common problem is hard water. The ions in hard water can cause chemical instability and increase the likelihood for emulsion splitting. Testing and treating your water is recommended to make sure your sump mix is working as intended. Twin Specialties can test samples of your tap water to ensure it is suitable for use in your metalworking fluid. If your tap water is excessively hard, installing a de-ionized water line is recommended for your facility. Coolant mixers can be connected directly to these lines to ensure proper mixing.

Once your water is deemed suitable, mixing the oil and water is all that is left in preparation. For the best performance and increased emulsion stability, follow the acronym O.I.L.: oil in last. This is an easy to remember acronym that will help you manually mix coolant; automatic mixers already mix using best practices.

Monitoring pH

Alkalinity is critical in the performance of your fluid. If the pH dips too low, it will no longer work and will need to be changed out. If pH drops below 8, it is imperative to raise it immediately. If pH drops below 7, the coolant is lost and must be changed. As the coolant gets more acidic (decreasing pH) you increase your risk of rusting problems. Some additives boost pH, but those may not be needed if you actively monitor your concentration. Monitoring is relatively easy, mix the fluid in the sump to get a more homogenized solution then dip a pH testing strip into the solution. Give the strip some time to change color and then match the strip to a reference sheet (usually provided with the strips). Then you can act accordingly armed with the pH information you need.

Tramp Oil Removal

Slideways and spindles require oil lubricants in order to function properly and ensure proper machining operations. These oil lubricants will leak into the sump and can cause havoc on your metalworking fluid. Some of the lubricant will be emulsified and disrupt the chemical composition of your metalworking fluid. The more oil content in the concentrate, the more likely the tramp oil will be emulsified.

This causes the growth of anaerobic bacteria. This bacterium creates hydrogen sulfide gas, which is the “rotten egg” or “Monday morning” smell that indicates coolant rancidity. The hydrogen sulfide in water also produces acids that drive down pH and alkalinity, which further damages coolant.

Synthetic coolants are excellent in rejecting tramp oils and prevent them from being emulsified. These floating oils can easily be skimmed and removed before causing damage. Using coolants below recommended concentrations limit the tramp oil rejecting additives and can accelerate this process of degradation.

Floating tramp oil can increase oil mist and smoke formation that can damage machines. The tramp oil mist also increases residues on the machine that can clog filters and destroy critical electronic components. Removing floating oil is relatively easy. Installing a skimmer, centrifuge, and/or coalescer will remove tramp oil from the sump and extend your coolants life.

Filtration

Metal fines and chips may find their way into the sump. It is important that they do not remain there and are not cycled through the machine. These fines can cause wear and damage to the machine and workpiece. The fines can build up and create dead-zones when additives are trapped and do not work. The trapped additives cannot work and lead to accelerated coolant breakdown.

Filtration used to be a cost-prohibitive endeavor, but the economics of coolant management and consumption make filters a worthwhile tool. The costs of filtration have come down and filtration technology has improved, thus implementing them will reduce coolant consumption and coolant spending.

Removing Foreign Substances from the Sump

Dirt and other foreign substances can cause problems such as abrasion and pump damage. Filtering solid substances and removing them will improve coolant performance. Sump cleaners might not be fully removed and can cause excessive foaming. If that happens, using a defoamer should alleviate these issues. However, be sure to properly remove the cleaner before recharging the sump. Prevention and proper preparation are usually the best maintenance.

Managing Straight Oil/Neat Oil

Neat oils require much less maintenance than water soluble coolants. This is because neat oils do not require water, which is a breeding ground for bacteria, fungi, and mold. However, there are still a few things that you should do to maintain and extend fluid life. The main thing should be done is filtering metal fines. Removing these metal fines improve finishing and fluid performance.

Takeaways

Given the rising costs and improving technology of metalworking fluids, it is more important than ever to proactively manage your fluids. This can lead to extended use intervals and improved performance. Following these steps will allow your machine to get the most out of these fluids.

Twin Specialties provides a full line of metalworking fluids and additives. Additionally, our sales team will work with you to test your fluids and water to troubleshoot the problem. Contact Twin Specialties for more information about our metalworking fluids, technical expertise, and our testing and sampling program.

Pros & Cons of Biodegradable Lubricants

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

In the next installment of our Biodegradable Lubricants series we examine the pros and cons of biodegradable lubricants. How do these lubricants compare to their petroleum-based counterparts? Previously we examined: biodegradability standards, biodegradable base stocks and biodegradable lubricant products. However, are these products right for you? We will look at some pros and cons to see if biodegradable lubricants are the right choice for you.

Pros of Biodegradable Lubricants

  • Excellent lubricity; superior to that of mineral oil
  • Higher viscosity index than mineral and synthetic oils
  • Higher flash point than mineral and synthetic oils
  • Less toxic and readily biodegradable
  • Renewable and reduce dependency on imported petroleum
  • New biotechnology has produced genetically-modified seeds designed for use in lubricants
  • Metal-wetting attraction makes them good for keeping dirt and debris off metal surfaces
  • Water-soluble PAGs are ideal for fire-resistant lubricants
  • Ideal for industries and applications where oil comes in contact with the environment
  • No potential for bioaccumulation (build-up in organism fatty tissue)
  • Price premiums are expected to decline with further market development

Cons of Biodegradable Lubricants

  • Lubricity so potent, friction modifiers must be added to reduce slippage in certain applications
  • Insufficient oxidative stability; oil must be treated or modified to ensure performance (which increase costs)
  • Small amounts of water can cause serious foaming and degradation
  • Cannot withstand high reservoir temperatures (usually greater than 80 C)
  • Vegetable base stocks must be hydrogenated to combat low oxidative stability
  • Low pour point; can be improved by winterization
  • Synthetic esters can be used for cold-temperature environments, but reduce bio-based properties
  • Synthetic oils are limited to which additives they can use due to biodegradability standards
  • PAGs can emulsify water, which can cause foaming, sludge, and corrosion
  • High price premiums for synthetic-based products

Conclusion

Biodegradable lubricants have significant potential to perform better than mineral oils. Developments in biotechnology could allow for specially formulated base oils that will address the current short comings of vegetable oils. As demand increases, price premiums will decrease and the we will become less dependent on petroleum. Synthetic oils already provide superior performance, albeit at a higher cost. Environmental concerns will drive these developments and shift the lubricant market towards biodegradable and environmentally accepted lubricants. To learn more, check out this EPA report on Environmentally Accepted Lubricants (EALs).

Twin Specialties Offers Biodegradable Lubricants

No matter your application or environmental requirements, Twin Specialties can meet your manufacturing, marine, or agricultural needs. We offer a variety of lubricants including: Shell Naturelle, Castrol Performance Bio, and various Food Grade lubricants. Contact Twin Specialties for a quote.

Best Practices for Lubricant Storage

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

Lubricants are a critical component to any machine, engine, or tool. How you manage and store the lubricants is as important, if not more so than the actual lubricant selection. In controlled situations, higher quality lubricants will consistently outperform their inferior counterparts. This difference is clearly seen in comparisons of oil-based lubricants (Group I-III) and synthetic lubricants (Group IV – V). However, controlled tests are not going be perfectly replicated in the work environment. Proper storage and monitoring can be the difference between high performance and early breakdowns.

The shelf life for lubricants depends on a variety of factors such as: base oil, additives and thickeners. It is often best to consult the manufacturer to determine the shelf life for your lubricants. Regardless of the lubricant’s shelf life, it will never be actualized if it is not stored properly. This leads to many problems on the manufacturing floor that have a major impact on the bottom line. This can lead to increased costs, machine breakdowns and lower-than-expected productivity.

Consistency is Key

What is the key characteristic for storage best practices? Consistency. By having consistent and routine storage practices, you will have the confidence that your lubricants will perform up to manufacturer’s stated standards. A consistent and controlled environment can also help you diagnose and remedy issues that may arise in your lubricant. For example, if your oil analysis shows that there are higher levels of moisture, you can more effectively diagnose the root cause of moisture. In poor conditions, there are many factors that can affect moisture found in oil-based lubricants, but controlled environments eliminate many of these root causes or isolate them to one-off instances (e.g. a loose oil cap, a small leak or the occasional spill).

Creating the Ideal Environment

The best way to ensure an optimal environment is to dedicate a room solely for lubricant storage. The room should be climate controlled thus protecting lubricants from the heat or the cold. As temperatures reach extremes on either end, the lubricant can breakdown and fall short on performance and shelf life. This is especially important with greases where low temperatures can affect additives. Indoor storage also protects lubricants from airborne moisture. Moisture in lubricants reduces reliability and performance and will lead to more machine breakdowns and downtime.

The storage room should be further away from any external entrance such as a shipping and receiving area or an employee exit. Lubricants near these areas are at risk to exposure outdoor weather and particle contamination. Particles in the lubricants must be filtered out or else machinery will experience greater wear and a reduce life expectancy. By storing lubricants away from shipping and receiving areas, this allows facilities to have less congested work areas and allow for efficient movement or parts, supplies, products and people.

What is the ideal environment for storing lubricants? We recommend a cool, dry area that protects the products from moisture and extreme temperatures. This means storing them in a room or floor area that is away from any external windows or doors, in a well ventilated area, and clearly separated from any workstation.

Improving Storage for End-Users

The lubricant storage room should efficiently use space, but also have the capability to expand. It is important to have all lubricants to be easily accessible so you can properly fill up the right amount of lubricant without spilling and potentially contaminating other lubricants. Many machine breakdowns occur when two incompatible lubricants are mixed. This error is preventable and the best way to ensure proper collection is to have clear and visible labels on each container. This includes having manufacturers labels clearly displayed, having color-coded labels to indicate product type, end-use or receiving date.

Another good idea is to organize containers based who uses them at their workstation. If one person uses the majority of a certain lubricant, it is sensible to store that product close to other products he or she may use. This creates an efficient process for people to collect their lubricants and reduces potential confusion and human error.

One of the greatest root causes of lubricant mismanagement and machine breakdown is human error. It happens to all of us. We are not perfect, but it is critical to strive to improve and implements rules and procedures to minimize these errors. Having properly tuned equipment ensures lubricants are properly measured out each time. Another good measure is to limit who has access to the lubricant room and ensure it is locked when not in use. When access is well controlled this reduces spillage, waste and in some cases, theft.

Conclusions

Theses some of the basic measures that can be taken to ensure a stable and consistent environment. We cannot control the weather, but we do have authority on the thermostat. Storing the lubricants in cool, dry area will ensure maximum shelf life. The additive packages will work properly and the performance you seek from a lubricant, will be realized and performance will improve.

Accidents happen and we learn from our mistakes. The most important thing to learn is preventing similar accidents in the future. This may involve changing processes, reworking access, or using different equipment. Making these changes ensure that mistakes are limited. It is important to regularly assess these processes ensure your lubricants are up to specifications and waste or damage is reduced. By following these best practices, your facility will be cleaner, organized and more efficient.