Crown-wheel lubrication
Problem: The client has a continuous mill that is operated by a pinion-crown transmission. They lubricate with a bituminous base compound contained in a sealed carter . The product becomes difficult to manage when temperature variations occur. It's too thick when cold and this makes it impossible to draught, because the formed cavity does not get refilled. It loses its consistence and adhesive strength when hot and this besides accelerates the oxidation process causing an inalterable increase of its viscosity. The lubrication so becomes inadequate and difficult the refill.

Solution: When having to manage considerably huge and powerful systems, we would like to clarify that the ideal lubrication can be obtained by installing an automatic spray lubrication system, fit to apply specific graphite grease such as our SIGNAL CEP 380. In the case such an option is not possible, technically or economically speaking, lubrication results can be improved by using more modern conceived products.
Our SIGNAL GRASSO INGRANAGGI EXTRA has a high viscosity adhesive, and possesses EP (extreme pressure) and antiwear characteristics. It's made of synthetic polymers, completely bitumen-free and available in two viscosity grades.
Its particular formulation allows for a minimizing of the viscosity changes due to temperature variations. This is possible because of its bitumen-free base which allows the lubricant to be more fluid when cold and more viscous/adhesive when hot. You are able to use it for long working periods, without alterations, thanks to its outstanding oxidation-resistance.
This lubricant guarantees the presence of an efficient lubricating film on the wheel-joints and the solution of previous refill problems, with longer intervals of change.
SIGNAL GRASSO INGRANAGGI EXTRA can be used to lubricate sealed carter gears of locomotives; it can be applied directly on the crown-wheel by hand, brush or paddle.

Cap deep-drawing for car filters
Problem: the client/company manufactures car filters To this end it also produces protection/retention cap for the filtering parts by deep-drawing of thin steely straps.

The preceding process of depth deformation appears rather hard, and is accomplished thanks to the aid of EP oil with a high viscosity grade(ISO 150). It is applied manually on the strap with a brush.

The following painting process of the caps results in an unwanted build-up of oil residual. The removal of the latter affects the timetable chain and adds to the production costs, as well as looking after the disposal of scavenging residuals.

Solution: After evaluating our past experience in other industrial fields, where operations of light shearing and plastic deformation of metal straps are conducted, and a subsequent process of galvanic/painting treatments is carried out, we chose SIGNAL PROTEX G 10/133.

SIGNAL PROTEX G 10/133 is an element of the "evaporable oils"category, done so erroneously because their surface tension characteristics don't allow for evaporation at room temperature. Elements of this category are formulated with synthetic lubricants with low viscosity (1-2 cst at 40°C), unctuous products and chlorine-free EP additives.

The function of this category of oils is to provide a sufficient lubricant power so as to allow a positive process outcome. The usage of these oils may form a thin film on the manufactured goods, however it doesn't interfere with the following surface treatments.

To reach such a positive result, it is absolutely necessary to distribute the product uniformly and constantly. It is ideal to use a micro-lubrication system able to distribute with precision (spray or buff method) minimal controlled quantities of the fluid.

The lubrication capability of SIGNAL PROTEX G 10/133 has remarkable been tested as equal to a product with a higher (100 times) viscosity grade, thanks to its special additives. The untreated cap can go through the painting process without further cleaning procedures, thanks to a minimum quantity of residual.

Various products of this category can be employed successfully in other application areas of automotive part production, such as: copper alloy connectors manufacturing and stainless steel engine gasket seals. These products are characterized by diverse viscosity grades and additives, and can be regulated according to the type and thickness of the worked material. We can find in this category: SIGNAL PROTEX G 10/133, SIGNAL 1000 LF, SIGNAL 1200 G and SIGNAL PROTEX 10.

Grease lubrication for hot rolling slabbing-mill bearings
Problem: It is difficult to lubricate hot rolling slabbing-mill bearings that are located on the side of an oven; obstacles may include elevated temperatures, heavy loads, anomalous shocks and exogenous agents, such as water and scale.

The plant's geometry renders it impossible to install a centralized lubrication system, which would be able to ensure a constant and continuous re-lubrication of the needed parts. Many attempts have been made to improve the system, but, unfortunately, a deterioration came about; the heat irradiation caused a hardening of the grease in the adduction pipes of the control unit, even if they have been shielded; the absence of new grease in the bearings produced more frequent breaking.

Various lubricants, also recommended by bearings manufacturers, having EP characteristics or high temperature complex, were applied monthly on the occasion of programmed maintenance procedures. These lubricants did not give way to any improvement, since the percentage of breaking remained elevated and the functioning of the bearings lasted no more than two months.
Solution: This problem could have been solved by using a highly sophisticated synthetic lubricant, which unitary cost is 15 to 50 percent higher then the initial one. Bear in mind that the achieved results would not be completely satisfying and adequate.

In fact the environmental conditions would have hindered the excellent lubrication qualities of the latter, and the abundant presence of water and scale would have reduce in any case the theoretical duration of the bearings, as estimated by the DIN 622 and ISO 281-1/77 standard. An additional unjustified cost would be added by the transfer of lubricant retained in those parts subject to breaking caused by inevitable anomalous shocks.

The need to meet the above requirements and to find a balance between product performance and its cost, lead us to choose SIGNAL CALOR 280. This choice is also rooted in the usage of "for life" lubrications in the steel industry, having similar conditions and on similar parts.

The product's cost is not superior to twice its initial one. The product has been thickened by organic compounds that confer to it an elevated dropping point (>260C) and an excellent resistance in high temperatures. Its formulation includes a fluid with an adequate viscosity grade(ISO 460) and micronized fluorinated telomeres, which allow an efficient lubricating film to form. This film is able to support heavy loads with low rotation speed (limit friction conditions) and to achieve excellent performance in the presence of water.

SIGNAL CALOR 280 was applied monthly on the occasion of programmed maintenance procedures, and its usage has improved and increased the functioning cycle of the bearings. It can now last up to twelve months, an estimated six times increase on the former ones.