Grease Manufacturing Process

We offer state-of-the-art grease machinery for manufacturing of wide range of industrial grease & lubricant such as Lithium, Calcium, Soda, Aluminum complex, polyurea, synthetic and speciality greases. We have employed highly qualified and experienced partners and grease technologists who have hands on experience for manufacturing of quality greases based on NLGI specifications. We work in tandem with our customers to ensure that the entire process of setting up the plant is made simple & user-friendly.

We consider the following parameters for determining equipment and plant design:

Our grease plants are superior in quality and capacity and they offer multiple advantages. Made from superior quality material and equipment, these offer long trouble free life, easy to handle, user friendly, high performance and can be customized to suit user specific requirements. With the help of these superior quality plants and machinery our clients can produced superior quality grease. Some of our special advantages are:

• Clients scope of work limited to minimum.
• Knowhow and training is superior and based on years of manufacturing experience.
• State-of-the-art laboratory set-up to meet international specifications.
• Plant design complies with international standards and safety features.
• Reduced manpower requirement.
• Greases manufactured in these plants are known for their purity, uniformity and stability with some extra desirable qualities.

Our manufacturing process varied for different variety of greases. Our manufacturing process is superior and based on latest methods and technology to produce superior quality reliable products that can fulfill most of the needs of our clients. Some brief outlines of manufacturing process are:

In manufacturing of lithium based grease, we can use open kettle, as reaction of lithium hydroxide with fatty acid is quite rapid. The process involves following steps.

• Heating the fatty acid to melt and then mixing it with 10-20% of total lube oil as per formula.
• Addition of dilute solution of lithium hydroxide while mixing and start heating.
• Saponification takes place in about 2 hours.
• When the reaction is completed, the solution is heated to dehydrate the mass.
• Dispersing the lube oil in soap to form grease.
• Final step is homogenizing using grease mill or homogenizer.

In manufacturing of soda based grease also the reaction of caustic soda with fatty acids is rapid hence we can use open kettle. The various stages involve in its manufacturing are:

• Heating the fatty acid to melt and then adding lube oil in it as per formula.
• Addition of caustic dye while mixing.
• The mixture is then heated to start reaction. Foam is controlled by using anti foam compound.
• When foam subsides, full heating is applied to cook soap and complete the reaction.
• Testing the fibrous soap and adjusting reaction.
• Now the soap is dehydrated at about 175 deg C. When soap melts, balance lube oil is added. Testing and penetration is done finally.
• Cold milling is done in the kettle or in a grease mill to get smooth, paste like structure.

Note: Product is taken out hot between 80deg C - 90 deg C.

As calcium hydroxide is a mild alkali, its reaction with fatty acids and vegetable oils require pressure cooking and high temperature for complete saponification in least amount of time. Various stages involved in manufacturing process are:

• If the fat is solid, it is heated to melt.
• Hydrated lime is added in it while mixing.
• Partial amount of lube oil and water is added in mixture. Finally the pressure is closed.
• Heat is applied to start reaction and cooking under pressure, which is between 0.21 atm to 0.28 atm at 150 deg C.
• Pressure is released and heating is discontinued.
• Addition of balance quantity of lube oil(retaining 5%) slowly, ensuring that it is fully absorbed by the soap.
• Water is added to form grease structure.
• Testing is done to check consistency (penetration) and finally adjusting it as required by addition of retained 5% oil.