Grease Products and Information

What is Grease?

Grease is a specialized lubricant that’s crucial for applications where traditional oils fall short. Think of heavy-duty machinery operating in tough conditions or equipment that sits idle for long periods. Unlike oils, which can flow away under gravity or pressure, grease stays put, clinging to surfaces and maintaining a lubricating layer. Essentially, grease is composed of three main components: the thickener, the base oil, and various additives that may be included to enhance its characteristics. This makes it perfect for scenarios where maintaining continuous lubrication is critical, like in industrial gears, bearings, or exposed machinery parts.

When is Grease the Right Choice?

Grease is the go-to solution when conditions demand a lubricant that won’t run off or dry out. Whether it’s a piece of equipment that only runs occasionally or machinery exposed to outdoor conditions, grease ensures protection and smooth operation. It’s often found in wheel bearings, industrial fans, or heavy machinery that encounters dust and water, areas where a resilient, stay-in-place lubricant is a must. The right substances to lubricate these components are crucial in maintaining performance under various conditions.

Grease Anatomy

1. Base Oil: The Foundation of Grease

The base oil forms the backbone of any grease, making up about 80-90% of its composition. Synkhem uses high-quality mineral and synthetic base oils that excel in extreme conditions. For instance, Synkhem Calcium Sulphonate EP 2 M utilizes a robust mineral base oil, providing excellent performance even in the punishing environments of steel mills. Meanwhile, synthetic base oils like those in Synkhem Lithium EP 2 Moly offer a broader temperature range, ensuring consistent lubrication from deep-freeze to high-heat scenarios.

2. Thickener

The thickener in grease acts like a sponge that holds the oil in place. It gives grease its semi-solid structure, allowing it to resist being squeezed out under pressure. Synkhem’s use of advanced thickeners, like the calcium sulphonate and lithium-based options in their Calcium Sulphonate EP 2 and Lithium EP 1, ensures excellent mechanical stability. These thickeners are specifically chosen for their ability to maintain structure under heavy loads and high temperatures, making them perfect for applications like heavy-load bearings or continuous casting machines.

3. Additives

Additives are the unsung heroes that transform standard grease into a specialized solution. Synkhem’s formulations include advanced anti-wear and extreme pressure (EP) additives, making products like Synkhem Lithium EP 2 Moly ideal for heavy shock loads. In addition, corrosion inhibitors ensure that equipment remains rust-free even in high-moisture environments, while oxidation stabilizers help the grease maintain its properties over longer intervals, reducing the need for frequent reapplication.

Additives also boost water resistance, a critical factor in outdoor or marine applications where exposure to moisture is common. For example, Synkhem’s Calcium Sulphonate EP 2 offers exceptional water washout resistance, making it a top choice for equipment exposed to harsh weather or wash-down conditions.

Grease Classification and Standards

Greases are classified based on their operational properties, such as temperature range, water resistance, load-bearing capacity, and NLGI consistency number. The National Lubricating Grease Institute (NLGI) provides a widely recognized scale for consistency, rating greases from 000 (fluid) to 6 (very hard). This classification system helps in determining the appropriate grease for various applications, ensuring optimal performance and longevity of machinery. By understanding these classifications, users can select the right grease that meets the specific demands of their equipment and operating conditions.

Classification of Greases

Greases can be categorized into different types based on their thickener, base oil, and additives. The most common types of greases include:

• Lithium-based greases: Known for their high melting point and water resistance, these greases are widely used but are not suitable for extremely high-temperature applications.
• Calcium-based greases: These greases offer excellent water resistance but have a lower melting point compared to lithium-based greases, making them suitable for applications where water exposure is a concern.
• Sodium-based greases: With a high melting point and good water resistance, sodium-based greases are used in various applications but are not ideal for high-temperature environments.
• Polyurea-based greases: These greases are designed for high-temperature applications, offering a high melting point and excellent water resistance, making them suitable for demanding conditions.

Applications of Grease

Grease is often the best choice for lubricating ball and roller bearings, ensuring smooth operation even under heavy loads. Synkhem Lithium EP 2 Moly, with its advanced formulation, is designed for heavy-duty bearings, making it ideal for industrial settings where machinery faces constant pressure and shock loads.

In gearboxes and open gear applications, where components are exposed to dust, dirt, and other contaminants, greases like Synkhem Calcium Sulphonate EP 2 provide a protective barrier. This not only reduces wear but also extends the lifespan of gears by keeping contaminants at bay.

Greases are particularly effective in extreme temperatures, offering consistent lubrication from deep cold to high heat. Synkhem’s High-Temperature Grease is engineered to maintain its consistency across a wide temperature range, making it perfect for machinery that operates in fluctuating climates or near heat sources.

Functional Properties

One of the standout features of grease is its ability to act as a sealant. This property helps prevent lubricant leakage and keeps out contaminants such as dust, dirt, and moisture. In environments where equipment is exposed to harsh conditions, this sealing capability is crucial to maintaining clean and efficient operation.

Additionally, grease can hold solid lubricants like molybdenum disulfide (MoS2) in suspension, providing extra protection against wear in high-pressure scenarios. Synkhem Lithium EP 2 Moly leverages this feature to enhance its load-bearing capability, making it suitable for shock-loaded bearings and gears.

Characteristics of Grease

Pumpability

Pumpability is the ease with which grease can be moved through dispensing systems under pressure. It’s an essential characteristic in automated lubrication systems, where grease needs to travel through lines, nozzles, and fittings to reach remote or difficult-to-access areas. The consistency and viscosity of grease significantly influence its pumpability. A thicker grease might struggle to flow through narrow lines, especially in colder conditions, requiring higher pressure to maintain proper flow.

Water Resistance

The ability of grease to resist water is crucial, especially for machinery exposed to moisture or submerged conditions. Water-resistant grease maintains its lubricating properties without breaking down or washing away when in contact with water. If grease lacks this resistance, it can form an emulsion, reducing its effectiveness and potentially damaging equipment. For example, Synkhem Calcium Sulphonate EP 2 is formulated to maintain its structure and resist washout, making it ideal for marine environments or machinery that frequently faces water exposure.

Consistency

Consistency determines how thick or thin a grease is and how well it resists deformation under pressure. It is influenced by the type of thickener and the viscosity of the base oil. Greases are classified based on their consistency, which ranges from very soft, fluid-like types to firm, solid ones. This characteristic is measured using penetration tests, providing a guide to selecting the right grease for specific applications. A balanced product like Synkhem Lithium EP 2 offers a consistency that ensures stability in moving parts while remaining easy to apply.

Performance Properties

Two key performance properties are the dropping point and oxidation stability. The dropping point reflects the temperature at which a grease softens and begins to liquefy, marking its heat tolerance. A higher dropping point indicates that the grease can maintain its lubricating qualities even under elevated temperatures, which is critical for high-speed bearings or machinery operating near heat sources. On the other hand, oxidation stability measures how well a grease can resist reacting with oxygen. This reaction can create sludges and deposits, which hinder smooth operation. Stable greases, like Synkhem’s High-Temperature Grease, prevent such build-up, ensuring longevity and efficiency in high-temperature applications.

Selecting the Right Grease

Choosing the appropriate grease for an application requires considering the environment, operating conditions, and compatibility with materials. For instance, the conditions where the grease will be used, whether in a high-speed bearing or a heavy-duty industrial press, dictate the type of grease required. High-temperature operations call for greases with a high dropping point and robust oxidation stability, ensuring they don’t degrade under heat. In contrast, cold environments demand greases that remain pumpable even at low temperatures.

The nature of the load and speed of the machinery also plays a role. High-speed bearings benefit from lighter greases that can reduce friction without overheating, while equipment facing heavy shock loads needs products with strong extreme pressure properties, like Synkhem Lithium EP 2 Moly, to prevent wear.

Material compatibility is another critical factor. Some greases may react with seals or metal surfaces, potentially causing damage or reducing the effectiveness of the lubrication. Ensuring that the selected grease is compatible with the materials in use helps maintain the integrity of both the lubricant and the machinery.

By taking these aspects into account, selecting the right grease becomes a matter of aligning the lubricant’s properties with the specific needs of the machinery. This approach ensures not only smooth operation but also long-term reliability, minimizing downtime and extending the life of mechanical systems.