Tag: Twin Specialties

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.

Should I Switch to Synthetic Coolants

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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.