TEST REPORT ON XADO SPECIAL HIGH-TEMPERATURE GREASES
Waffle oven mould: friction units at 450 °C run without lubricant top-up
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
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. The original report with signatures and stamp is published in full and available for download.
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: