GREASE MANUFACTURING PLANT

INTRODUCTION:

We are experienced Grease Manufacturing Plant Equipment Manufacturers & Suppliers in India and all over the Globe. Our goal is to provide world-class service through innovative, reliable manufacturing and supply of specialized high-end products. Our team is always ready to assist you with equipment designed for your specific requirements.

What is Grease:

Grease is a solid or semisolid lubricant formed as a dispersion of thickening agents in a liquid lubricant. Grease generally consists of a soap emulsified with mineral or vegetable oil.

A common feature of greases is that they possess a high initial viscosity, which upon the application of shear, drops to give the effect of an oil-lubricated bearing of approximately the same viscosity as the base oil used in the grease. This change in viscosity is called shear thinning. Grease is sometimes used to describe lubricating materials that are simply soft solids or high viscosity liquids, but these materials do not exhibit the shear-thinning properties characteristic of classical grease. For example, petroleum jellies such as Vaseline are not generally classified as greases.

Greases are applied to mechanisms that can be lubricated only infrequently and where a lubricating oil would not stay in position. They also act as sealants to prevent the ingress of water and incompressible materials. Grease-lubricated bearings have greater frictional characteristics because of their high viscosity.

Properties of Grease:

True grease consists of an oil and/or another fluid lubricant that is mixed with a thickener, typically a soap, to form a solid or semisolid. Greases are usually shear-thinning or pseudo-plastic fluids, which means that the viscosity of the fluid is reduced under shear. After sufficient force to shear the grease has been applied, the viscosity drops and approaches that of the base lubricant, such as mineral oil. This sudden drop in shear force means that grease is considered a plastic fluid, and the reduction of shear force with time makes it thixotropic. A few greases are rheotropic, meaning they become more viscous when worked. It is often applied using a grease gun, which applies the grease to the part being lubricated under pressure, forcing the solid grease into the spaces in the part.

Thickeners:

An inverse micelle is formed when soap is dispersed in an oil. This structure is broken reversibly upon shearing the grease.

Soaps are the most common emulsifying agent used, and the selection of the type of soap is determined by the application. Soaps include calcium stearate, sodium stearate, and lithium stearate, as well as mixtures of these components. Fatty acid derivatives other than stearates are also used especially lithium 12-hydroxy stearate. The nature of the soaps influences the temperature resistance (relating to the viscosity), water resistance, and chemical stability of the resulting grease. Calcium sulphonates and polyureas are increasingly common grease thickeners not based on metallic soaps.

Powdered solids may also be used as thickeners, especially as clays. Fatty oil-based greases have also been prepared with other thickeners, such as tar, graphite, or mica, which also increase the durability of the grease. Silicone greases are generally thickened with silica.

Types of Grease:

Grease is classified into two class

A) Soap type grease:

In this type, we prepare soap first and then mixed with base oil to formulate the grease below are the type of grease that comes in this class.

1. Lithium Grease

2. Calcium Grease

3. Aluminum Grease

4. Lithium Complex Grease

B) Non-Soap type Grease:

1. Urea Grease

2. Synthetic Grease

3. Bentonite Grease

Additives:

Some greases are labeled "EP", which indicates "extreme pressure". Under high pressure or shock loading, normal grease can be compressed to the extent that the greased parts come into physical contact, causing friction and wear. EP greases have increased resistance to film breakdown, form sacrificial coatings on the metal surface to protect if the film does break down, or include solid lubricants such as graphite or molybdenum disulfide to provide protection even without any grease remaining.

Solid additives such as copper or ceramic powder are added to some greases for static high pressure and/or high-temperature applications, or where corrosion could prevent disassembly of components later in their service life. These compounds are working as a release agent. Solid additives cannot be used in bearings because of tight tolerances. Solid additives will cause increased wear in bearings.

Grease Manufacturing Plant PDF

THE PUMPING SOLUTION:

Avoid costly downtime and keep your machine running at its peak performance with our gear pump for lubricant dosing inside the Grease kettle.

The three-piece design makes the pump easily cleanable, easily maintainable. Cleaning of the aerator and the suction arm can now be done without having to remove the cover first. Even more importantly, it is possible to replace worn out parts

The Pump is with mechanical seal The mounting bracket converts the pump to foot mounting & facilities to align the pump with the electric motor of appropriate ratings on the base plate at the same frame height.

The feed rate for the base oil pump will be around 20m3/hr to 50m3/hr at a pressure of 4 Bar to 10 Bar

THE FILTRATION SOLUTION:

Unfiltered liquid enters the basket housing and passes down them.

Solids are retained inside of basket mesh which is removed when the unit is serviced.

Basket Filters and strainers are normally supplied with a spring arrangement at the top of the filter element.

This will ensure any type of bypass & confirm the position of the basket filter even in case of reverse flow.
A fluid bypass around the basket is prevented by an optional “O” ring seal between the basket rim and the housing inside diameter.

For base oil basket filter provided with 200-micron mesh and For blending vessel basket filter provided with 50-micron mesh

STRUCTURAL SOLUTION:

The Platform structure design for Grease Kettle.
The steel structures can be created in all manner of shapes and sizes, are designed for short- or long-term use, and can serve as temporary or permanent structures.
They are made from standard rolled and cold-formed steel sections, which are reinforced using stabilizing rods with tensioners.
In order to use the platforms, it is necessary for the space to have a height of at least 5meters. Our design has a minimum ceiling height of 2.1 meters.
It is possible to equip the platforms with various accessories, such as elevators, chutes, mesh, labels, lighting, etc.

GREASE KETTLE (REACTOR):

Linus Projects is an Indian manufacturing company that has a board-level management team with a wealth of engineering, design, and manufacturing experience. We supply selected engineering products to meet the demand at the bottom line.
The Process Equipment People" designs, engineers and manufactures the Double Motion Grease Kettles that are extensively used in the production of lubricating greases for the automobile, aircraft, railroad and industrial applications.

Linus Projects Supply mainly three types of grease kettle (Reactor)

Pressure Kettle(Reactor)
Non Pressure kettle(Reactor)
Bottom Conical Kettle (Reactor)

Pressure Kettle(Reactor):
Double Motion Counter - Rotating Agitator Stirrer consisting of a stationary mounted drive Assembly and Grease Kettle Body that can be manually raised and lowered. A Flush Bottom Handwheel-operated Discharge/Sampling Valve is located on the Kettle's bottom.
Our Kettle is Autoclave-type Pressurized 6 kg Working capacity the Kettle comes complete with a double Motion Counter - Rotating Agitator Stirrer basically consisting of a Stationary Mounted Drive Assembly and Grease Kettle Body that can be manually raised and lowered - similar to a Drill Press Arrangement.

Kettle consist of two dishes and a shell. The bottom dish fitted with a flush bottom discharge valve. The agitator assembly consists of a simplex designed system where shafts fitted with agitators thoroughly blend the grease as well as move the entire mass. Scrapers are provided at the sides and bottom of the agitator assembly.

Non Pressure kettle(Reactor):
Kettle consist of the bottom dish, shell & top lid. The bottom dish fitted with a flush bottom discharge valve and one drain valve ball type for sample removing, testing, and checking. The agitator assembly consists of a simplex designed system where shafts fitted with agitators thoroughly blend the grease as well as move the entire mass. Scrapers are provided at the sides and bottom of the agitator assembly.

Bottom Conical Kettle (Reactor)
The Autoclave-Style Grease Kettle can be used for the complete grease manufacturing cycle - saponification, grease finishing, and cooling. However, The processing time is extended when compared to saponification being performed in a Linus Projects Grease Base Reactor. The Reactor with its jacketed vessel construction - jackets over both the shell and cone sections - and double-wall construction inner circulation tube offers a greatly increased surface area for transfer of heat to the soap. Coupled with this is the dramatically increased rate of product circulation brought about by the bottom propellor agitator that operates at full or half motor speed. This type of agitation/mixing action ensures a homogeneous soap base for transfer to the Grease Finishing-Cooling Kettle where the balance of oils and additives are charged and the final grease product manufactured.

BOILER FOR UTILITY PURPOSE:

Linus Projects Supply high-quality fuel-efficient burner with boiler both for steam and thermic fluid.

The main heater unit consisting of a double jacketed external shell made of sturdy M.S. Sheets with an Aluminum reflector to preheat the combustion air and provide heat insulation.

Specially designed multi-start, concentric helical coils assembly made from B.S, 3059,

Part I, 9 Gauge, Boiler Tubes for longer life and high-temperature operations.

Pressure jet burner assembly on/Off Design Make – RIELLO –ITALY with integral Oil Pump & Combustion blower assembly with the motor.

CLOSED CIRCUIT COOLING TOWERS UTILITY PURPOSE:

Hot Oil cooling framework comprising of S.S. cooling loops made out of S.S consistent lines. The curls are properly moved at a nearby pitch for productive cooling. The pitch, stature, and breadth of the curls are intended for speedy and effective cooling of the pots. The loops are clipped on a tough primary stand produced using moved steel segments.

A cooling tower of suitable besin size will be provided alongside GI louvers made out of GI sheets. The supporting construction is produced using substantial moved steel areas. On top of the pinnacle will be a GI line header having branch headers fitted with gunmetal shower spouts.

A monoblock siphon shaving release limit of 1500 liters each moment at 15mts head will be provided. All the underlying stand and GI louvers will be set apart for simple get together at the site. The cooling pinnacle will be provided without the base stockpiling bowl however with any remaining designs. The framework is finished with one 1000 liters cold oil stockpiling tank, 1000 liters development tank, and 10 m3/hr oil course siphon of 3 HP.

LOAD CELL FOR AUTOMATION: METTLER TOLEDO BRAND

The blending vessel is supplied with a high-quality precision load cell system which is suitable for automatic performance and batch control of the plant typically known as ABB technology.

Load cell having the following advantages

Built-in Safety against vessels tilting and build forces
Allows vessels expansion & contraction, which Occurs due to thermal effect.
Flexible copper earthing strip to protect the load cellfrom lightening or welding current
In built Load Cell cable protection plate & Overloadprotection plate with Heat Insulation Pad

INSULATION MATERIAL FOR HEATING LINE:

Linus Projects Supply high-quality Rockwool and aluminum sheet along with the plant for insulation of hot oil line and blenders etc.

All insulation shall be done by ROCKWOOL mattress50mm thick as required of Density 100Kg/ cu mtr of reputed make and cladded with aluminum/GI sheet 24 gauge. This part of the job shall be done on the site. The material shall be supplied loose and the client has to organize the same at the site under our guidance.

Insulation of pipelines below blenders to filling lines to be done on-site.

GREASE MILLING AND DEAREATION SYSTEM:

A. Grease Milling Machine:

Up-and-down Colloid Mill good for fine grinding, breaking up/spreading out, and blending and mixing together very well in one single operation. The Mill consists of an SS 304 water-cooled jacketed mill housing inside which is fitted a 3 stage Rotor and Stator group of device made up of smaller parts. The material is pumped into the mill and is forced to shearing, breaking up and moving away, mixing & blending and mixing together very well action. The rate and degree of the above process can be finely controlled manually during operation by changing to make better/changing to fit new conditions the gap between the rotor & stator. All rotating parts are balanced and well oiled/greased for trouble-free operation. The shaft is installed in a leak-proof housing complete with bearings, ~O~ rings, and oil seals. The electric motor gave/given is of 30 HP, 3000 RPM

B. Deareator Assembly:

A Deaerator is equipment that eliminates the gases and moisture from semi-fluids, fluids. Deaerators are ordinarily used to eliminate oxygen, caught air bubbles and disintegrated gases in oil. The air pockets and gases in oil will make genuine harm the quality and life of Grease. Deaerator is utilized in Grease Manufacturing Plant fiercely.

Deareator features:

Eliminates the caught air and bibble inside the oil or jam item
Effective blending, homogenizing the oil.
Expulsion of dampness or refining of residuals under specific conditions.

C. Vacuum Pump for Deareator:

A vacuum pump is a device that draws gas molecules from a sealed volume in order to leave behind a partial vacuum. The job of a vacuum pump is to generate a relative vacuum within a capacity. The first vacuum pump was invented in 1650 by Otto von Guericke, and was preceded by the suction pump, which dates to antiquity

ELECTRIC AND AUTOMATION PANEL FOR PLANT:

A.ELELECTRIC MOTOR CONTROL PANEL:

MCC stands for motor control center. It consists of feeders for motors and blowers. Feeders are designed according to the motor rating. In most of the MCCs, auto/manual provision will be there. With manual provision, motors can be operated manually. In auto-provision external signal is required to start the motor. The signal is given by the control panel. Indicators for the motor operation also will be present in the control panel.
A motor control center (MCC) is an assembly of one or more enclosed sections having a common power bus and principally containing motor control units. Motor control centers are in modern practice a factory assembly of several motor starters. A motor control center can include variable frequency drives, programmable controllers, and metering and may also be the electrical service entrance for the building.

The panel is accommodated working every one of the electrical engines. The board is properly pre-wired and encased in a sheet steel powder-covered walled-in area. An MCC board gave a far-off press button Station to control the engine. Every one of the engines is controlled through the MCC board If anything incorrectly occurs with the engines, the board will Trip to save the engine from harm. The board is given a decent brand of switches Like L&T etc.R-Y-B lights with Ammeter and voltmeter advanced sort is given. An electrical control board is accommodated working every one of the electrical engines. The board is properly pre-wired and encased in a sheet steel powder-covered fenced-in area.

B.AUTOMATION PANEL:

Automation panels combine the functions of a programmable controller and operator interface into a single unit. ... Automation panels, such as GE's QuickPanel, reduce hardware costs by combining the controller, operator interface, and remote connectivity into one device.

A total PLC-based SCADA is accommodated observing and controlling the progression of base oils to the Blenders. A formula the executes framework is given to taking care of up to 100 recipes

ADVANTAGES OF OUR AUTOMATION PANEL:

Automation panels combine the functions of a programmable controller and operator interface into a single unit. They came on the market about 15 years ago. Many early units were simply OI panels with some local IO, ladder logic, and a flat database. Modern panels, such GE’s QuickPanel+, include the full IEC61131 programming languages (ladder, structured text, function block diagram, sequential function chart, and instruction list), as well as user-defined data structures and function blocks.

GREASE PACKAGING SOLUTION:

A.GREASE FILLING MACHINE:

Fillers (or Grease filling machines) are used for packaging, mainly for food/beverage but for other products as well. These are used to fill either a bottle or a pouch, depending on the product.

There are several types of fillers used by the packaging industry. The type of Food or beverage filling machines to be used is usually determined by the type of product to be filled, speed requirements, quality and shelf life expectations, resources availability, technology feasibility, and many other variables. Type of food products may range from solid to semi-solids, from liquids to frozen, from hot to cold, from free-flowing to highly viscous products, etc. This wide range of product characteristics also suggests that filling machines with great flexibility and versatility are the most valuable. There are various filling technologies for liquid and dry products and product filling machines can be rotary or inline, intermittent or continuous motion, semi-automatic or fully automatic with various filling technologies to cater to the huge range of product variables and user requirements, each offering unique advantages.

The following are the most common:

Auger/agitator fillers: designed to fill dry mixes, such as flour and sugar. The fillers have a hopper shaped like a cone that holds the mix and puts it in a pouch using an auger conveyor that is controlled by the agitator. The mix is filled in a pouch that is made of paper or poly that is formed in a collar and the pouch gets sealed by a series of heaters and dies. The interface with the process supplying the powder is of prime importance to ensure an efficient filling.

Vibratory weigh fillers: provide you the perfect blend of accuracy, speed, and versatility across a comprehensive line of linear feeders. Every weighing-hopper is designed to handle the unique needs of precise weights.
Flow fillers: designed for liquids, oils, and thin food products. These fillers are designed when they fill a bottle or tub that enters the machine, the ejects the open bottle back onto another conveyor for sealing.
Tablet fillers: These are designed for products that are counted by pieces instead of weight. These are designed for small bottles (similar to some of the flow fillers), but the hopper of the filler is set up to permit scan counting of tablets or candy pieces.
Positive displacement pump fillers: positive displacement, pump filling machines easily handle a wide range of container sizes, fill volumes, and product types. While originally designed for filling creams, gels, and lotions these fillers also handle water-thin and heavy paste products. Some of the products this machine easily fills are cosmetic creams, heavy sauces, thick shampoo and hair conditioners, honey, hair gels, paste cleaners, and car wax.
Tube filling machinery: Tubes usually have viscous products and require special filling equipment.
Vertical form fill sealing machine: A vertical form fill sealing machine is a type of automated assembly-line product packaging system, commonly used in the packaging industry for the food and Grease industry.

B.GREASE CAPPING MACHINE:

The machine comprises of Cap Vibrator for cap orientation & capping unit.

The caps fed in the vibratory hopper are properly oriented here.

The properly oriented caps are brought out through chute and supported at the end by spring-loaded fingers the containers as it comes out of the filling station moves to the capping unit, where-in it picks up the cap and goes towards the capping head.

The caps are subsequently tightened through a magnetic clutch system. The capped bottles finally emerge out of the machine through a discharge conveyor.

The speed can be adjusted through the VFD on the conveyor Necessary Mechanism shall be provided for no bottle – no cap. The torque can be set on the PLC of the filling machine.

C. AUTOMATIC INDUCTION SEALING MACHINE

The technology of heating sealing the aluminum-plastic multiplex material by electromagnetic induction sealing machine manufactured of this principal becoming necessary equipment of medicine, pesticides, high-quality viscous oil, cosmetics, grease other trade require high-quality air sealing for plastics and other non-metal bottles.

Latest I.G.B.T. Solid State Induction Cap Sealing System Model LP- 2 for neck size up to 38mm is suitable to seal 70 to 80 bottles per min. & for a neck range, up to 53mm is suitable for 40 to 50 bottles per min.

Working principle: Machine is complete with the principal of metal object can bring blow wave to heat under the action of the high-frequency electromagnetic field. Making aluminum foil hot and melt the binding under aluminum foil then agglutinate to the mouse of the bottle, thus the accomplish the constant quick non-contact sealing operation.

D. CARTON TAPPING SOLUTION:

Linus Projects Supply sophisticated design carton taping machine.
Carton Taping Machine is put on the in-feed rollers & given a gentle push when the motorized conveyor takes over & starts pulling the carton forward. Here the top & bottom tape dispensers stick the BOPP type self-adhesive tape onto the Top & Bottom flaps of the cartons simultaneously along with rollers pressing the tape for a tight seal. When the taping is over, the cutter blades cut-off the tape & the sealed cartons passes through to the outfeed rollers for delivery.

we are offering Regular Carton Sealing Machine. These are designed and manufactured under the supervision of our professionals using high-grade quality raw material in adherence with the industry standards. The offered machines are widely used for packaging of various sizes and shapes of boxes.

Features:
Low maintenance/High performance/Corrossion resistance/Longer functional life.

SLURRY MIXER

Slurry mixers play a vital role in the grease manufacturing process by ensuring thorough and efficient mixing of base oils, thickeners, and additives to create high-quality grease products. In a grease manufacturing plant, slurry mixers are used to

Homogenize Ingredients:
The mixer evenly blends oils, soaps, and other thickening agents to ensure a uniform consistency in the grease.
Maintain Product Consistency:
Proper mixing ensures that the final grease product has the desired texture, performance characteristics, and stability, preventing ingredient separation.
Improve Efficiency:
Slurry mixers are designed to handle high-viscosity materials, which is crucial in the production of grease. They reduce mixing time and energy consumption while enhancing product quality.
Handle High-Temperature Operations:
Many grease formulations require elevated temperatures to facilitate chemical reactions. Slurry mixers can operate under these conditions, ensuring the mix is heated uniformly without localized overheating.
Scalability:
From pilot plants to full-scale production, slurry mixers are available in various capacities, allowing for flexibility in production volumes.