SAVING ENERGY WHEN EXTRUDING | HWU LUBTEC

Example: Koellmann screw extruder

SAVE ENERGY WITH MOBIL SHC™ GEAR 320

The gear oil Mobil SHC™ Gear 320 not only has excellent lubrication behaviour, but also the potential to save energy and reduce CO2 emissions. In our practical example from a customer in the plastics processing industry, switching to the high-performance oil reduced the energy consumption of screw extruders with Koellmann gearboxes by 3.8%. Find out more insights here!

3.8 %

Annual energy savings

40,000 kWh

Annual energy savings per system

By 9°C

Reduced oil temperature

3 months

ROI

5x

Extended oil drain intervals

Customer testimonial plastics industry

This customer testimonial is based on the experience of a single customer on screw extruders with Koellmann gearboxes. The actual results achieved may depend on the type of machine used and its maintenance, operating and environmental conditions and the lubricant previously used.

Initial situation

A plastics processing company uses extrusion to produce plastic sheets for the kitchen furniture and automotive industries. A mineral oil-based CLP 320 lubricant was used to lubricate the gear unit of the electric motor. The oil service life at temperatures of 60°C was 1 year. The company would like to optimise production in terms of energy consumption and have the energy management system certified in accordance with ISO 50001. Resource efficiency is also to be further increased by extending the oil drain intervals.

Recommendation

Our lubricant expert has recommended the use of Mobil SHC™ Gear 320, a synthetic high-performance gear oil of viscosity class ISO VG 320. The optimum viscosity-temperature behaviour and the chemical structure of Mobil SHC™ Gear 320 promise a reduction in power loss in the gearbox and a reduction in oil temperature. This enables a reduction in power consumption and an extension of the oil service life.

Field trial & evaluation

In a field trial on a screw extruder with Koellmann gearbox, measurements were carried out under comparable conditions with the mineral oil product and Mobil SHC™ Gear 320. A demonstrable saving in electrical power consumption of 3.8 % was measured when using Mobil SHC™ Gear 320. Switching to Mobil SHC™ Gear 320 therefore results in energy savings of 40,000 kWh/year and system. The oil temperature has fallen by 9°C in the comparison period, confirming the increase in gearbox efficiency.

In addition, the 5-fold increase in the oil drain interval and the significant increase in the service life of the gearbox seal contribute to lower oil and material consumption, a reduction in waste and lower maintenance costs, meaning that maintenance and disposal costs have been reduced. The amortisation of the implemented measure was achieved after just 3 months. Mobil SHC™ Gear 320 thus increases productivity throughout the entire manufacturing process and supports the company's sustainability goals as part of its DIN EN ISO 50001 certification.

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