Grease Manufacturing Process

LINUS PROJECTS LIMITED (NIGERIA) is an ISO9001:2015 certified Multinational organization established in the year 2014.

Grease Manufacturing Process Explained

1) Raw Material Acquisition & Storage in Tanks:

• Base Oil: Generally made from mineral oil, synthetic oil, or sometimes vegetable oil.

• Thickener: Comprises metallic soap (lithium, calcium, aluminum, sodium), polyurea, or non-soap materials (clay, silica).

• Additives: Feature anti-oxidants, rust inhibitors, EP (extreme pressure) agents, anti-wear substances, and corrosion inhibitors.

2) Grease Kettle / Reactor:

The reactor (kettle) is filled with base oil and heated. After that, the thickener components are added and mixed well.
Three Categories Of Grease Kettles (Reactors):
• Pressure kettle (reactor)
• non-pressure kettle (reactor)
• Bottom conical kettle (reactor)

3) Dehydration / Cooking:

The combination is heated to a significant temperature, often between 160°C and 200°C, with continuous stirring to commence a chemical reaction referred to as saponification. At this point, water, a byproduct of the reaction, is typically removed through evaporation.

4) Shearing and Cooling Section:

The heated mixture is meticulously and progressively cooled. The remaining base oil and additives are added in this phase. Proper control of the cooling is vital, as it facilitates the crystallization of soap fibers, forming a stable, gel-like network that provides the grease with its semi-solid consistency and structure.

5) Additive Mixing Tank:

Performance additives are mixed in after the cooling process. When the grease cools to a specific temperature (for example, 80-100°C), various performance-enhancing additives, such as anti-wear agents, corrosion inhibitors, antioxidants, anti-rust agents, and extreme pressure agents, are incorporated to achieve the desired final properties. These additives improve oxidation stability, load-carrying performance, and corrosion resistance.

6) Homogenization / Milling:

The Grease Milling and Deaerating System is a crucial component in the grease production process. This system is utilized in grease manufacturing to refine, homogenize, and improve the quality of lubricants by removing trapped air bubbles, ensuring uniform consistency, and enhancing overall quality and stability, while complying with stringent hygiene standards to maintain product purity.

7) Filtration Unit:

The Grease Filtration Unit is essential for ensuring that the final product is thoroughly filtered to remove any solid contaminants, impurities, undissolved particles, soap fibers, dust, or unreacted solids. It provides a smooth texture, reduces the need for rework or rejection, and guarantees consistent quality.

8) Grease Storage Tanks:

Grease Storage Tanks are specifically designed vessels that safely hold finished grease products or intermediate grease materials before they are packaged or undergo further processing. Grease has a semi-solid form and can differ greatly in viscosity. These tanks maintain grease at a stable temperature and consistent texture. They act as buffer tanks linking production and packaging operations.

9) Laboratory Testing:

Various forms of grease are manufactured, each with its own set of properties, qualities, and uses. Quality testing of grease in a laboratory setting ensures that it meets the performance, consistency, stability, and protection standards necessary for its intended applications.
Types of Gease Testing:
• Drop Point Test
• Oxidation Stability Test
• Four-Ball Wear Test
• Water Resistance & Washout Test
• Corrosion & Rust Tests
• Load Carrying & Wear Properties
• Cone Penetration Test

10) Filling & Packing (Cartridges / Drums)

The produced grease undergoes testing for consistency and performance before being packaged for distribution. It is filled into various containers, including cartridges, jars, pouches, drums, or smaller containers. Grease Filling Machines can be either Semi-Automatic, ideal for small-scale operations, or Fully Automatic, designed for high-volume production.