The problem faced during the operations and shutdown of clinkers can be taken care of with an automatic lubrication system that would provide automatic, hands-free lubrication 24/7.Clinker coolers endure extremely high operating temperatures and dust levels. Because of these conditions, as well as the central role that clinker coolers play in cement production, they are generally shut down frequently for manual re-lubrication and inspection. While these planned shutdowns are labour-intensive and drive maintenance costs, the alternative – unplanned shutdowns due to lubrication-related bearing failures – can be far more costly in terms of repairs and lost production. SKF can help.SKF automatic lubrication system with FB pumpBy providing every lubrication point with the appropriate lubricant, in the right quantity, at the right time, the SKF automatic lubrication system with FB pump enables precise, hands-off, 24/7 bearing lubrication. The system uses a high-pressure pump in combination with a progressive divider to deliver the exact quantity of grease or oil to every clinker cooler lubrication point. This highly precise timing and dosing can cut lubricant costs by as much as 70 per cent and bearing failures by more than 50 per cent.The end result? Far fewer planned and unplanned shutdowns, improved productivity and worker safety and the ability to deploy maintenance resources elsewhere. Plus, the system is flexible enough to handle a range of medium to large systems, thanks to several performances.Features:??FB pump available with 6, 15, or 30 kg tanks??Displacement volumes between 0.04 cm3 and 7 cm3??1-24 pump elements that can be configured to match the application??Oil or grease compatibilityBenefits:??Cut bearing failures by more than 50 per cent??Cut lubricant costs by up to 70 per cent??Limit lubrication-related breakdowns??Reduce planned and unplanned shutdowns??Limit production losses due to downtime??Extend maintenance intervals??Improve worker safety??Reallocate maintenance resourcesSKF boosts clinker cooler uptime and saves plant $ 10,000 (Rs 5.50 lakh) per year in grease costs aloneThe problemA cement mill in the Dominican Republic was experiencing problems with clinker cooler availability. Bearings were being over-lubricated and the reliability of the system, which did not cover all the necessary lubrication points, was poor. The result was downtime and a lot of money spent on grease every month. Furthermore, as some points were manually re-lubricated, maintenance staff risked being burnt by hot clinker particles. Looking for a solution that would increase process availability, cut costs, and increases the safety of their workforce, the mill turned to SKF.The SKF solutionSKF suggested a progressive lubrication system that would provide automatic, hands-free lubrication 24/7. The system that SKF ultimately installed featured an FB30 pump, a 30 kg tank, four outlets with progressive feeders, plus piston detectors for system reliability.The resultsThe SKF progressive lubrication system slashed cooler downtime, substantially increasing lubrication effectiveness and process availability. As a plant representative describes, "The arms of the transmission system had seven failures in the two months prior to the installation of the new system and, since it was installed, there has been zero failures." The SKF system also reduced the facility’s lubricant consumption, cutting it from an average of 100 kg of grease per week to 35 kg, for a monthly savings of nearly $1000 (Rs 55,000). The system also enabled the facility’s maintenance team to begin focusing on other duties, and kept them safely away from hot clinker cooler particles.