-
Grease Plant
-
Grease Factory Layout
GREASE MANUFACTURING PLANT NIGERIA
LINUS PROJECTS LIMITED (NIGERIA) is an ISO9001:2015 certified Multinational organization established in the year 2014.
What is a Grease ?
Grease is defined as a solid or semisolid lubricant that is created through the dispersion of thickening agents in a liquid lubricant. It usually consists of soap that is emulsified with either mineral or vegetable oil. The various types of raw materials that are used in the production of grease include oils, metallic hydroxides, and fats. Fats are usually described as solid at room temperature.
Grease Manufacturing Process ?
The Manufacture of Grease involves the following steps:-• Filteration
• Saponification
• De-hydration
• Cooling
• Milling and Deaerating System
• Homogenizer
• Packaging
What is grease used for?
Grease is mainly utilized to lubricate and safeguard moving components in machinery and equipment by curtailing rubbing, preventing damage, and closing gaps in machinery. It's a semi-solid lubricant that remains in position and offers lubrication without dripping or leaking.
What are types of grease?
Grease is divided into Two Categories.A) Soap-based grease:
In this category, we first create soap and then blend it with base oil to produce the grease.
• Lithium Grease
• Calcium Grease
• Aluminium Grease
• Lithium Complex Grease
B) Non-Soap based Grease:
• Urea Grease
• Synthetic Grease
• Bentonite Grease
Nigeria Grease Industry
Nigeria is a major exporter of crude oil and petroleum products to various countries. Increased demand for grease in the country's industrial sector has created new business opportunities, generated employment, and stimulated economic growth. Grease is essential for reducing friction, wear, and tear, as well as corrosion in machine bearings and other components. It increases the lifespan of machinery, lowers maintenance costs, and enhances productivity. Grease plays a crucial role in Nigeria's journey towards becoming a thriving industrial hub. Significant oil reserves have been discovered in Ghana and Sierra Leone, transforming the economic landscape of West Africa. Upgrading the Grease Manufacturing Plant & Operations will minimise capital investment and provide assured Steady Returns and Sustainable Growth.
GREASE MANUFACTURING PROCESS & MACHINERY
Setting up a grease production plant necessitates specialised equipment and processes specifically designed to manufacture high-quality lubricating greases for industrial, automotive, and speciality uses.
Key Equipment in a Grease Production Plant:
1. Grease Kettles (Reactors) Types include: Pressure Kettles, Non-Pressure Kettles, Bottom Conical Kettles.
2. Grease Milling Machines it refine the grease's texture and ensure uniformity by breaking down particles and removing impurities.
3. Deaeration Systems expel trapped air from the grease to enhance consistency and performance.
4. Filtration Units Basket filters to eliminate solid contaminants.
5. Pumping Systems Gear pumps for dosing lubricants into kettles.
6. Finishing Kettles Used post-saponification to add additives and finalize the grease formulation.
7. Packaging Lines For filling grease into tubs, cans, or drums.
BASE OIL PUMPING & FILTRATION
Base oil is a lightweight oil. Base Oil Pumps are carefully designed to manage a range of base oil uses, guaranteeing durability and longevity even under extreme conditions.
Equipped with a mechanical seal, the Pump utilizes a mounting bracket that converts it to foot mounting, which also helps in aligning the pump with an appropriately rated electric motor on the base plate at the same frame height. The anticipated feed rate for the base oil pump is approximately 20 m³/hr to 50 m³/hr, with a pressure range of 4 Bar to 10 Bar.
Base Oil Filtration plays a crucial role in maintaining the cleanliness and performance of base oils by removing contaminants such as moisture, particulates, oxidation by-products, and sludge.
Unfiltered liquid flows into the basket housing and moves downward through it. Solids are trapped within the basket mesh, which is extracted during the unit's servicing. Generally, basket filters and strainers are provided with a spring setup at the top of the filter element. The base oil basket filter features a 200-micron mesh, while the blending vessel basket filter has a 50-micron mesh.
GREASE KETTLE
A grease kettle is an industrial container utilised in the manufacturing of lubricating greases. These kettles are engineered to manage processes such as saponification, mixing, and cooling of grease formulations, which are crucial for use in automotive, aerospace, railways, and heavy machinery.
There are Three Categories of Grease Kettles (Reactor):
• Pressure Kettle (Reactor)
• Non-Pressure Kettle (Reactor)
• Bottom Conical Kettle (Reactor)
Pressure Kettle (Reactor):
This Kettle is furnished with a double-motion counter-rotating agitator stirrer, which fundamentally comprises a Stationary-Mounted Drive Assembly and a Grease Kettle Body that can be manually elevated and lowered, resembling a Drill Press Configuration.
Non Pressure Kettle (Reactor):
The agitator assembly is designed with a simplex system where shafts equipped with agitators thoroughly mix the grease and shift the entire mass. Scrapers are positioned at the sides and bottom of the agitator assembly.
Bottom Conical Kettle (Reactor):
The Autoclave-Style Grease Kettle is suitable for the entire grease production process - saponification, grease finishing, and cooling.
GREASE MILLING DEAREATING SYSTEM
The Grease Milling and Deaerating System is an essential piece of equipment in the grease manufacturing process, specifically designed to refine and elevate the quality of grease formulations. Grease Milling & Deaerating System is a specialised configuration utilised in the production of grease to refine, homogenize, and enhance the quality of lubricants by eliminating trapped air and ensuring consistent uniformity. Contemporary grease deaerators are designed with ease of cleaning in mind, adhering to strict hygiene standards to ensure the purity of the product. If you are contemplating the establishment or upgrade of a grease manufacturing facility, this system is revolutionary.
Deaerator:
• Eliminates trapped air, gases, and moisture from grease.
• Prevents foaming, oxidation, and deterioration of product quality.
• Improves lubrication characteristics and extends shelf life.
Benefits:
• Produces chemically stable and shiny grease.
• Enhances shelf life and packing efficiency.
• Minimises oxidation and boosts lubrication performance.
• Facilitates automated, hygienic, and scalable production.
GREASE HOMOGENIZER
A specialized industrial machine known as a grease homogenizer is used in the production and processing of grease to ensure a uniform texture, consistent quality, and stable emulsification of its components. Grease, which is a mixture of oils, thickeners, and various additives, requires precise blending to achieve the desired consistency and performance properties. The homogenizer accomplishes this through high-shear forces that break down particles and evenly disperse them throughout the mixture. This process is critical for creating a uniform structure in the grease, which is essential for its lubrication properties, thermal stability, and resistance to water and oxidation.
Features:
• Homogenizers are designed with high-shear technology, which guarantees an even distribution of additives and ingredients for a uniform grease mixture.
• Constructed from robust materials and precision engineering, these homogenizers effortlessly manage high viscosity substances while ensuring quality remains consistent.
• Featuring intuitive controls, straightforward maintenance, and safety features, the grease homogenizers significantly improve operational efficiency.
• Engineered with components that save energy, our homogenizers contribute to lowering operational expenses without sacrificing performance.
CLOSED CIRCUIT COOLING TOWERS
Closed circuit cooling towers provide a vital and protected method for industrial heat rejection, ensuring the integrity of process fluids by preventing direct atmospheric exposure. Unlike open systems, these towers circulate the process fluid through a coil bundle, which is then externally cooled by a separate, clean water spray and ambient air drawn over the coils. This indirect heat exchange mechanism effectively isolates the process fluid from airborne contaminants, scale-forming minerals, and oxygen, significantly reducing maintenance requirements and the need for extensive water treatment in the primary loop. Ultimately, closed circuit cooling towers offer a robust, efficient, and contaminant-free cooling solution, safeguarding critical equipment and optimising operational costs.
The cooling framework for hot oil features stainless steel cooling loops made from seamless stainless steel pipes. A suitably sized cooling tower will be provided, along with GI louvres made from GI sheets. The cooling tower will be delivered without the base storage bowl, but will include all other necessary components. The system is outfitted with a 1000-litre cold oil storage tank, a 1000-litre expansion tank, and a 10 m³/hr oil transfer pump rated at 3 HP.
GREASE DRUM DECANTING UNIT
A Grease Drum Decanting Unit is a specialised Machine designed to efficiently move high-viscosity grease from large drums into smaller containers or dispensing systems. It is particularly useful in industrial environments where manual handling is impractical or can be hazardous. Grease drum decanting units are designed with a tilting mechanism, which permits operators to tilt the drums at an angle for easier grease pouring, providing precise control during the decanting process to ensure that grease is fully evacuated from the drums with minimal waste. Safety is of utmost importance in grease drum decanting units, and they often come equipped with various safety features to protect operators and prevent accidents.
Key Features:
Tilting Mechanism: Allows for the drums to be tilted for complete grease evacuation with minimal waste. This can be hydraulic, pneumatic, or manual.
Pumping System: Utilises Pneumatic or electric pumps along with hoses and valves to extract and transfer grease smoothly.
Drum Clamps & Locking Arms: Secure the drum during operation to prevent tipping or movement.
Control Panel: Includes start/stop buttons, an emergency stop, tilt and pump controls, and sometimes digital displays for monitoring.
Safety Features: The device contains guards, interlocks, and sensors to protect operators during use.
Mobility Options: Some units are designed with wheels or skids for easy movement within a facility.
LABORATORY TESTING
Laboratory testing is crucial for Quality Assessments. Testing lubricating greases in a laboratory is vital for determining their performance, stability, and suitability for use in machinery across various sectors, including automotive, aviation, marine, and manufacturing. After each batch of grease, samples are sent to the laboratory for testing of the Viscosity Index.
Typical grease testing includes:
Drop Point Test: Identifies the temperature at which grease turns fluid.
Oxidation Stability Test: Evaluates resistance to degradation over time.
Four-Ball Wear Test: Analyses anti-wear capabilities.
Copper Corrosion & Water Washout Test: Evaluates the protective qualities and water resistance of the material.
Elemental Analysis & PQ Index Test: Identifies wear metals and contamination.
Cone Penetration Test: Assesses consistency and firmness.
GREASE PACKAGING SOLUTION
GREASE FILLING MACHINE
A grease filling machine is a specialised industrial tool used to dispense precise amounts of grease into containers such as cartridges, jars, pouches, or drums. These machines are crucial in sectors such as automotive, manufacturing, and lubrication services, where consistent and clean grease packaging is essential.
Key Types of Grease Filling Machines:
• Semi-Automatic Machines: Require manual placement of containers; suitable for small-scale operations.
• Fully Automatic Machines: Manage container feeding, filling, and sealing; perfect for high-volume production.
• Drum Fillers: Designed for large containers (up to 25 litres or more).
• Volumetric & Net Weight Fillers: Ensure accurate quantities by volume or weight.
• PLC-Based Systems: Provide programmable control for precision and repeatability.
A grease capping machine is a dedicated piece of machinery used in the packaging process to effectively seal containers that are filled with grease. These machines are specifically designed to address the unique challenges associated with thick, sticky substances, ensuring that closures are both leak-proof and tamper-resistant. The capping machine includes a Cap Vibrator, which is tasked with orienting the caps, and a Capping Unit. Caps are introduced into the vibratory hopper, where they are carefully oriented for correct positioning. The caps are then securely tightened using a magnetic clutch system.
Key Features:
• Cap Orientation System: Employs a vibratory hopper to accurately sort and position caps.
• Spring-Loaded Fingers: Keep caps in place before they are picked up by containers.
• Magnetic Clutch System: Ensures consistent torque for securely tightening caps.
• PLC-Based Controls: Allows for precise control over the capping process, ensuring accuracy and repeatability.
• Adjustable Capping Heads: Suitable for various container sizes and cap types.
A grease sealing machine is usually found in industrial settings to fill and seal containers, like tubes or cartridges, for grease or similar thick materials. Tamper-proof seals are vital in the packaging of the grease manufacturing industries. The Induction Sealing Machine is essential for preserving the integrity of the final product, providing security for both manufacturers and consumers.
Types of Grease Sealing Machines:
• Ultrasonic Tube Sealers: Employ ultrasonic waves to seal plastic or aluminium tubes without using adhesives or heat. Ideal for cosmetics, shoe polish, and industrial greases.
• Induction Sealers: Utilise electromagnetic induction to seal foil liners onto bottle necks, creating tamper-proof seals. Great for lubricants and chemicals.
• Automatic Band Sealers: Designed for the continuous vertical sealing of pouches or sachets that contain grease.
Industry Applications:
• Food and Beverages.
• Lube Oil and Grease Industry.
• Pharmaceuticals.
A grease labelling machine is a specialised tool used in the packaging process of grease products to accurately and efficiently apply labels to containers. These machines are crucial in industries where grease is packaged in jars, tubes, or drums, ensuring both visual appeal and compliance with regulations. The Labelling Machine not only enhances the visual presentation of products but also plays a vital role in effectively communicating important information to consumers.
Key Features
• High-Speed Operation: Built for fast labelling to keep pace with production lines.
• Precision Placement: Ensures labels are applied consistently and neatly, even on curved or irregular surfaces.
• Versatile Label Handling: Able to handle various label sizes and shapes for different container types.
• User-Friendly Controls: Operators can easily modify label position, speed, and size settings.
• Integration with Printing Systems: Enables batch numbers, expiry dates, and other critical information to be printed directly on the label.
Common Applications
• Lube Oil and Grease Industry
• Food and Beverage Packaging
• Pharmaceuticals
A batch coding machine functions as a device for printing vital information, including batch numbers, manufacturing or production dates, and additional relevant details such as expiry dates and other variable data on products and packaging. This machine can operate in either a semi-automatic or automatic mode and is equipped with a very responsive built-in touch screen for quick operation.
The laser printer is a crucial component in this setup. It delivers high-resolution printing, which guarantees the creation of clear and easily legible markings on containers.
Carton taping machines are transformative tools in the packaging industry. They automate the process of sealing cardboard boxes with adhesive tape, making them suitable for industries such as oil, food, and pharmaceuticals. The top and bottom tape dispensers apply BOPP-type self-adhesive tape to the top and bottom flaps of the cartons simultaneously, while rollers press the tape down for a secure seal.
Types of Carton Taping Solutions:
• Semi-Automatic Machines: These require manual placement of cartons but automatically seal the top and bottom flaps, making them great for moderate-volume operations.
• Fully Automatic Machines: These handle everything from flap folding to taping with minimal human input, making them ideal for high-speed, high-volume packaging lines.
• Random Carton Sealers: These machines automatically adjust to different box sizes, making them perfect for operations with varied packaging dimensions.
Benefits:
• Quickness & Efficiency: Some models are capable of sealing up to 25 to 30 cartons per minute.
• Consistency: Provides uniform tape application and reliable seals every time.
• Cost-Effective: Cuts down on labor costs and reduces tape waste.
AUTOMATION GREASE PLANT
A significant challenge that the production industry faces is the ability to swiftly provide the exact quantity of grease that customers require. Success in this sector demands access to state-of-the-art technologies and design skills.
The integration of computerised technology has changed the landscape of grease processes and the production sector, ensuring uniform product quality and stringent control of additives, vital for enduring success in a competitive marketplace.
The automated transfer of additives and base oils to the Blenders, under computer oversight streamlines the blending process, cutting down on labor costs. Fast blending is realised with a reduced number of blending vessels, maximising their use.
The installation comprises a variety of pumps that are controlled by VFD (variable frequency drive), along with flow meters and automated valves. The full operation is directed by automation and PLC control, supplemented by a SCADA interface.
Grease Plant PDF
Complete Project of Grease Plant Layout Designing to Commissioning planning as per client’s project capacity and requirement.
Download Grease Plant PDF© Copyright 2024 All Rights Reserved. Linus Projects Limited Nigeria