IE B048TEST REPORT ON XADO SPECIAL HIGH-TEMPERATURE GREASES
Waffle oven mould: friction units at 450 °C run without lubricant top-up
Rollers that had stopped due to coking rotated freely again, grease was not replenished.
at a working production sitesigned by the plant and the contractor, stamped
Key result
| EQUIPMENT | DUTY AND CONDITION AT THE START OF THE TRIALS | WHAT WAS MONITORED |
|---|---|---|
| Waffle oven, German-made, in service since 1989 | Three-shift duty; temperature at the friction units 450 °C, conveyor speed 6 m/min | Lubrication interval of the friction units |
| Mould No. 8, plain bearings of the rollers, latch and hinges | Rear support rollers and the cam-follower roller did not turn because of coking; carbon deposits, scratches, metal flaking; hinge rotation about 30° | Condition of the friction pairs at the weekly teardown |
Friction units of mould No. 8 — before and after treatment
| PARAMETER | BEFORE TREATMENT | AFTER TREATMENT, 13.07.2001 |
|---|---|---|
| Lubrication of the units | Every 3 h of oven operation | 31 days of service with no lubricant top-up |
| Bearing rotation | Rear support rollers and the cam-follower roller did not turn | Turn freely, no seizing |
| Friction pair surfaces | Carbon deposits from the standard grease, scratches, metal flaking, mechanical wear | Covered with a metal-ceramic layer; no scoring, flaking or wear marks |
| Slag build-up on the mould | Cleaning by selective teardown every 1–2 weeks | No traces of coking on the friction surfaces |
Monitoring — weekly teardown and inspection of the mould friction units; the oven ran on three shifts, and the treatment was carried out without taking the equipment out of production.
Decision of the plant following the trials
| DECISION | DETAILS |
|---|---|
| Roll-out | Treat all moulds of the waffle oven by the XADO technology |
| Initial treatment | 7 g of consistent grease per point after cleaning the friction pairs of carbon deposits |
| Layer build-up | After 2 and 4 days of operation — 5 g of gel grease per point, without dismantling the units |
| Layer maintenance | 5 g of gel grease per point once a month |
| Continuation of the trials | Mould No. 8 stays in service without a repeat treatment, with weekly inspection — the maximum running time on a single lubrication cycle is being determined |
Maintenance lubrication is carried out without stopping the process line.
Report conclusions
Current equivalent
Revitalizant gel for compressors and bearings →
Piston, screw and centrifugal compressors; rolling and sliding bearings running in an oil bath; machine-tool spindle units and slideways.
How such units are treated:
Limits of this report: The results refer to plain bearings of waffle oven moulds operating at temperatures up to 450 °C on a three-shift schedule; under other conditions the figures may differ. The treatment was performed by the official XADO dealer LLC “Prydniprovska Transport Company”; the report is signed by representatives of the plant and the contractor.