Why Choosing the Proper Lubricant is Essential
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Did you know that 60 to 80% of bearing failures are directly related to poor lubrication? It’s a staggering statistic that shows just how crucial lubrication is to equipment performance.
Yet, in many industrial environments, lubrication remains an afterthought, a box to check during routine maintenance rather than a strategic focus area.
This article aims to shift that mindset by showing how choosing the right lubricant, and applying it properly, can significantly improve equipment reliability and reduce unexpected failures.
What Is Industrial Lubrication and Why It Matters
Industrial lubrication is the application of oils, greases, or specialized substances to reduce friction between moving parts in mechanical systems. While the concept might sound simple, its impact is anything but. Good lubrication not only ensures smoother operations but also helps dissipate heat, prevent corrosion, minimize wear, and extend the service life of critical components.
There are three main types of lubricants commonly used in industrial settings: oils, greases, and specialty lubricants.
- Oils are typically used in systems where speed and precision matter, such as gearboxes and hydraulics.
- Greases, being thicker and more adhesive, are ideal for applications involving heavy loads or components that operate intermittently.
- Specialty lubricants are formulated for specific conditions, like extreme pressure, temperatures or food-grade environments, where conventional products may not perform adequately.
Learn more about machine lubrication in this article!
Key Factors in Choosing the Right Lubricant
Choosing the right lubricant requires more than picking a product off the shelf. Several factors must be considered to ensure compatibility and performance. First, it’s essential to understand your equipment’s operating conditions. Speed, load, and temperature all influence how a lubricant will behave. A high-speed bearing, for example, may require a low-viscosity oil to reduce drag, while a heavily loaded gearbox may benefit from a high-viscosity product to maintain a protective film.
Environmental factors also play a crucial role. Dust, humidity, temperature extremes, or outdoor conditions can all affect lubricant stability and performance. For example, a lubricant used in high temperature, dusty environment must resist oxidation and prevent the ingress of contaminants.
Material compatibility is another key consideration. Lubricants must be chemically stable with seals, metals, and other materials in the system to avoid wear and tear, swelling, or loss of effectiveness. In addition, manufacturers often provide recommendations or require compliance with specific standards such as ISO or NSF certifications. These guidelines should not be ignored, as they reflect extensive testing and validation.
Best Practices for Lubrication Management
Even the best lubricant won’t perform well if it’s applied incorrectly or inconsistently. That’s why lubrication management should be treated as a core pillar of a preventive maintenance strategy. Establishing a centralized preventive maintenance lubrication program helps standardize procedures, eliminate guesswork, and ensure consistency across teams and facilities.
Proper planning and scheduling of lubrication routes ensure that every asset receives the right product at the right time. Labelling lubricants clearly and storing them in clean, designated areas reduces the risk of cross-contamination or product degradation.
Equally important is the training of lubrication technicians. Lubrication may seem simple, but understanding how to inspect, apply, and monitor lubricants effectively requires technical knowledge. Well-trained personnel can recognize early signs of over- or under-lubrication and adjust practices accordingly.
Technology also plays a growing role in modern lubrication management. Tools like ultrasound can detect friction changes in real time, oil analysis can reveal contaminants or viscosity shifts, and smart sensors can track lubricant condition automatically.
Smarter Lubrication with Spartakus APM
For organizations looking to digitalize their lubrication strategy, Spartakus APM is a platform capable of streamlining and elevate your lubrication program. With Spartakus, maintenance teams can plan lubrication schedule and monitor routes in detail, track the quantity and frequency of grease or oil applications, and link this data directly to asset health dashboards.
By aligning lubrication efforts with real-time equipment conditions, organizations can shift from time-based routines to condition-based practices. This proactive approach not only reduces the risk of failures but also ensures that lubrication is truly optimized.
Learn more about how Spartakus APM can help you optimize your lubrication program here.
Business Case Overview
A few years ago, a sawmill reached out to us to help optimize its lubrication practices. Since implementing the new program, the site has saved over $3 million.
Here’s what we put in place:
- A structured lubrication system with the use of the correct lubricant
- Clear mapping of lubrication tasks and maintenance schedule
- Lubrication management software
- Equipment modifications
- Personnel training
- Key performance indicators (KPIs)
Want to explore the full story?
How a Sawmill Saved $3M with Better Lubrication Management.
Conclusion
Selecting and applying the right lubricant can make a measurable difference in equipment reliability, maintenance efficiency, and overall operational performance. Small changes, like choosing the proper lubricant for each application, contamination control, storage and handling, or improving route planning, can yield significant results.
If you haven’t already, now is the perfect time to review your lubrication strategy. Are you using the right products, the right way, at the right time? With the right approach, lubrication can become a powerful lever for continuous improvement.
Frequently Asked Questions (FAQ)
What happens if the wrong lubricant is used?
Using an incorrect lubricant can result in excess friction, overheating, and accelerated wear. It may also damage seals or introduce chemical incompatibilities, leading to equipment failure and safety risks.
How do I know if my equipment is over- or under-lubricated?
Using condition-based lubrication is the best way to know. Otherwise, look for failure modes. Over-lubrication can cause grease to leak or create excess pressure, leading to elevated temperatures or seal failure. Under-lubrication often results in abnormal noise, vibration, or wear. Monitoring tools like ultrasound and oil analysis can help detect these issues early and guide corrective actions.
Raphael Tremblay,
Spartakus Technologies
[email protected]
