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Bel-Ray Specialty Lubricants: Tech Notes, Vol 2, Issue 7

July, 2011

POWERSPORTS DIVISION

Bel-Ray Moto Chill Racing Coolant

The engineers who designed the coolant system of your motorcycle took a lot of variables into consideration. The coolant system must provide enough heat transfer during maximum performance use to keep the engine cool. The type of coolant that you use in your coolant system makes a difference in the system’s ability to perform its function.

Bel-Ray Moto Chill Racing Coolant is a special non-toxic propylene glycol formula designed for better heat transfer and higher boiling point to help keep the engine cool. The non-toxic formula will not harm the environment and is fully biodegradable. The coolant will not cause irritation in the event of skin contact. Bel-Ray Moto Chill Racing Coolant protects coolant system components from corrosion including those with magnesium and aluminum components. The non-abrasive and non-acidic organic additives clean existing deposits, and reduce scale formation preventing radiator plugging.

Under extreme racing conditions, engine temperatures approach the boiling point of water at 212ºF at atmospheric pressure. The boiling point of any liquid can be increased by increasing the pressure the liquid is held under. The boiling point of Bel-Ray Moto Chill Racing Coolant is 228ºF at atmospheric pressure, 247ºF with a 7 psi cap or 254ºF with a 10 psi cap. Always check with the OEM to make sure the coolant system can operate under pressure other than the original cap pressure provided with the motorcycle.

Bel-Ray Moto Chill Racing Coolant also provides freeze protection down to -36ºF and can be used in all sealed, liquidcooled powersport engines including road, racing and off-road motorcycles, ATVs, snowmobiles and utility engines such as pumps, compressors, generators, etc.

INDUSTRIAL DIVISION

Bel-Ray Cost Savings Proven & Documented

It’s not often when we get a chance to put our lubricant in an application wherein the performance will be accurately measured, and cost savings, if any, will be calculated with extreme accuracy.

Imagine, if you will, the last time you were watching a movie or TV and the scene turned to a hospital emergency room, or operating room scene, where a patient was hooked up to all the monitoring devices checking/measuring the patient’s vital signs on a continuum. Think of the beeps and the lines on the monitoring devices.

No, we are not in a hospital scene but a manufacturing facility that must be efficient in all phases of the manufacturing process to make a profit. If for any reason the process terminates prematurely, or does not function within process guidelines due to lack of machine performance, all material being processed is lost. All phases of the process are measured and scrutinized to the highest order.

The monitoring devices blinking, lighting up, blinking, and the process operators in an observing position behind a glass wall are observing and measuring very large conveyor chains (7,200 feet of double pitch conveyor chain, see illustration of chain type) pulling a very corrosive product that is not friendly to machine components through a drying oven at temperatures over 350 degrees Fahrenheit. This phase of the manufacturing process is the most important and most costly.

Double pitch chain components

The power source is electric motor drives. The energy required to pull the heavily loaded conveyor chains through the process is incredible and is most significant to the cost of the finished goods. Therefore, this part of the process must be controlled and any reduction in energy will reflect in cost savings. In fact, the consumption of lubricant is directly related to the amperage required to drive the system. As the preset amperage reaches the set point, the lubrication system is activated and applies lubricant until the amp draw drops below the set point. What this means is that lubricant consumption is directly related to performance and that is precisely what happened here. After moving to our Bel-Ray Molylube MD-88-E Fluid, the amp draw dropped significantly to allow for consumption to be cut in half, from 30 drums usage annually of a competitor’s product to 16 drums annually of Bel-Ray Molylube MD-88-E Fluid.

This is where the “rubber-meets-the-road” in our business of lubrication; reducing friction to the point of significant cost savings in energy means that we are simultaneously reducing wear on the components, leading to more cost savings. Wow—that is powerful!

Our competitor serviced this application for over 20 years until we got a chance. We had one shot at this opportunity; therefore, our recommendation had to be on the mark.

As mentioned in my opening comments, this is a very controlled environment and all operating processes are measured and monitored.  We asked that our competitor’s product performance be documented for one month before we put our product Bel-Ray Molylube MD-88-E Fluid on trial. They did, and our servicing Distributor delivered our material and installed it into the autolube delivery system for a month trial. Our lab did a side-by-side comparison of our competitor’s product and our recommendation, Bel-Ray Molylube MD-88-E Fluid, to ensure we were on track with our recommendation and gave us some insight into what to expect.

What were the customer’s expectations in this event that would effect change?

  1. Reduce energy.
  2. Reduce lubricant consumption.
  3. Better corrosion control.
  4. Increase chain life.

It took no more than two weeks in the application and the decision was made to change out to our product. This decision was based on a significant drop in energy required to drive the process.

After extended run time did we measure up? You bet, and beyond any and all expectations.  We are going on two years of servicing this application and the documented cost savings in the first year alone totaled more than $85,000 and energy cost savings are not included as yet. We are looking forward to another round of cost saving statistics next month and from what information I recently received, they could reach a high six figure amount!

Our documented cost savings mirrored customer expectations:

  1. Bel-Ray Molylube MD-88-E Fluid significantly reduced energy consumption (we are waiting for this figure to come in, but it is estimated to be well over $12,000 for the year).
  2. Consumption was cut in half from 30 drums per year of competitor’s product to 16 drums per year of Bel-Ray Molylube MD-88-E Fluid totaling $18,139 in cost savings for one year.
  3. Bel-Ray Molylube MD-88-E Fluid significantly reduced corrosion per visual inspection.
  4. Bel-Ray Molylube MD-88-E Fluid increased overall chain life – chain/attachment replacement amounted to over $65,000 in cost savings in one year.

Yes, the theme was medical in nature, therefore, when you must diagnosis and prescribe a lubricant for high temperature chains think of Bel-Ray Molylube MD- (yes, MD!) 88- E Fluid!

Our Distributor plays a significant role in servicing and managing this business. The name of the account and very specific data are confidential to the account.

MINING DIVISION

Prevention of Contamination - Lubricant Storage Optimization

Bel-Ray / Des-Case Breathers

Whatever maintenance program your mine uses, you would never intentionally put dirty oil into your equipment or add water to an oil reservoir. However, you do not need to intentionally add these particles because the environment is always trying to work against your useful lubricant and component life. Most mines take the normal atmospheric conditions and add their own unique challenges of keeping equipment and components clean and dry.

The two major sources of lubricant contamination are dirt and water. Microscopic particles are the most harmful particles when it comes to damaging your equipment, particularly in components with tighter tolerances such as hydraulic systems. The best programs to prolong lubricant life and control contaminates incorporate a multifaceted program involving three simple steps; detection, prevention and removal.

It costs nearly ten times as much to remove contaminants from reservoirs, tank and components compared to keeping them clean in the first place. However, most maintenance programs focus on removing contaminants after they are already in the system through filtration carts and on-machine filtration.

Nearly all gearboxes and storage reservoirs are designed to breath and this breathing is one of the main sources of dirt and moisture into reservoirs and gearboxes. Unfortunately, original equipment vents and breather caps do not provide adequate protection against ingression of dirt and moisture. Often times these breather caps are merely screens that offer little protection to the most harmful silica contaminants and no protection against moisture ingression. The opportunities for contamination through ingression occur each time fluid is drawn from the tank and during normal expansion and contraction of the tank throughout the day from changes in temperature. Each time that new air is drawn from outside the tank, there are additional contaminants being absorbed by the lubricants.

Inasmuch as removal of contaminants costs ten times more than prevention of contaminants, consider the following best practices for your mine site bulk fluids.

Bulk Containers

Often sites will keep bulk containers of lubricants near their maintenance shop to feed a system of hose reels throughout the shop. Observe the following best practices:

Screen-type air
breather captures
larger particles
but lets smaller
particles into system.

Bel-Ray/Des-Case
desiccant style
breather with
silicant for removing
moisture and filtration
for removing smaller
dust particles.

Lubricant Management System - your Bel-Ray representative can work with you to design a system that integrates filtration, breathers and storage best practices.

Sampling - On a periodic basis, sample containers for contaminants and manage the level to the ISO Cleanliness Level of the Lubricant Manufacturer/Supplier.

Breathers - On vents on bulk tanks, use a Bel-Ray/Des-Case filter designed for the tank.

Filter - Before pumping onto machines, filter your lubricants to the ISO level you are trying to attain.

Drums

Customers often prefer to use drums of lubricants when the equipment is not readily available for transportation to the centralized lube point or when the volume of lubricants used does not justify a bulk tank.  What makes the drum convenient for the customer also puts the lubricant at risk for contamination.

Best Practices with 55 Gallon Drums:

  • Store inside a clean, dry warehouse whenever possible. Storage inside an active workshop is not recommended.
  • If you must store drums outdoors, store drums on their side in a rack to prevent damage and do not store drums directly on the ground.
  • Store drums so that their bungs are at 3 o’clock and 6 o’clock position. This keeps moisture from being drawn into the drum.
  • Sample leaking and damaged drums for contamination prior to use.
  • Use a first-in-first-out practice for managing the shelf life of drums.
  • Use a drum filter cart or a drum topper to filter any contaminants.
  • Don’t mix pumps between different types of lubricants.

These best practices are just the start of a good contamination control program at your mine. A contamination process is just that, a process. If your mine does not have a formal contamination control process, talk to your local Bel-Ray representative for a formal audit of your current contamination control practices.