Cement industry
Machine by machine: what needs lubricating in a cement plant
Approximate lubrication-point counts, the components that need grease or oil, the main challenge and the method that usually suits.
Process machines
| Machine | Points (approx.) | Components to lubricate | Main challenge | Usual method |
|---|---|---|---|---|
| Gyratory crusher and apron feeder | 15+ | Pinion shaft and bearings, pinion and eccentric gears, eccentric bushing, spider bearing, step bearing, open gear drive, motor and gearbox | Heavy load, low speed, dust. Few machines, so an outage disrupts the plant | Extremely high viscosity EP grease; oil circulation; open-gear spray; dual-line |
| Belt conveyors | 30+ | Pulley bearings, drive system, high-torque motor, gearbox, motor | Dust, rock impact, remote and hard-to-reach locations | Semi-automatic progressive, single-point lubricators, dual-line |
| Vertical roller mill | 20+ | Grinding roller bearings, main drive bearings, separator bearings, motors and gearboxes | Moderate to high load, low speed, dust. Process-critical | Oil circulation, dual-line, open-gear spray, connected control |
| Rotary kiln | 20+ | Trunnion bearings, kiln tyres and pads, open gear drive (girth ring), pinion shaft bearings, motor and gearbox, riding ring | High temperature, heavy load, dust. One or two kilns per plant | Open-gear spray, riding-ring lubrication, oil circulation, progressive |
| Ball mill | 26+ | Open gear drive (girth ring), pinion shaft bearings, motor and gearbox, jacking systems, trunnion support, trunnion seals | Moderate to high load, low speed, dust | Open-gear spray, oil circulation, dual-line, connected control |
| Fans and blowers | 6+ | Bearings, motor | High loads, varying speed, rust and corrosion | Semi-automatic, single-point lubricators, progressive, connected |
Quarry and mobile fleet
| Machine | Points (approx.) | Components to lubricate | Main challenge |
|---|---|---|---|
| Shovels and draglines | 50+ | Joints, bolts, bearings, pivot points, axles, pins, bushings, hydraulic cylinders, steering, swing points, open gears, wire ropes | Harsh conditions and extreme temperatures. Too many points to manage by hand |
| Haul trucks | 40+ | Joints, bolts, bearings, pivot points, suspension, axles, bushings, hydraulic cylinders, steering | Water, dirt and abrasion. Hard-to-reach points and high lubricant consumption. Single-line systems suit large trucks, progressive systems small and medium ones |
| Wheel loaders | 23+ | Differentials, final drives, steering, hydraulic cylinders, joints, bearings, bolts, bushings, control valves | Quick reversals, frequent stops and starts, contamination and vibration. Manual lubrication halts the machine |
How to use the table
The counts are typical figures, not a count of your own machine. Use them to see where the points concentrate, and where a missed point has the largest consequence: the single kiln, the main mill and the crusher.
Takeaway. Count your own points. Where a few critical machines carry the plant, automate those first.
Put it to work in the tool