MEMOLUB CONNECT Pro

Delivery of real-time lubrication monitoring in demanding conditions!

Context

In one of Scandinavia’s largest sugar-processing facilities, the steam dryer plays a critical role in transforming residual sugar beet material into a dry, stable product suitable for use as animal feed. The dryer relies on steam as the heating medium, ensuring efficient moisture removal while significantly reducing CO₂ emissions compared to conventional drying technologies. By bringing the material to the required dryness before the next stage, the system both improves process efficiency and protects downstream equipment.

The operating conditions in this area of the plant are demanding. Several bearings function at temperatures exceeding 80–100°C, and the surrounding environment is heavily contaminated with highly abrasive beet pulp. This not only increases wear risks but also makes lubrication essential for sealing, particularly in the intermediate bearings where grease prevents pulp ingress. Maintaining stable lubrication performance under these thermal and contamination stresses is therefore vital to securing reliable production throughout each campaign.

Problem

Before implementing an improved lubrication system, the facility faced recurring issues with intermediate bearings and sluice-related components. Previous lubricators, including low-pressure automatic units, were unable to deliver grease effectively into bearings with higher resistance. This resulted in uneven emptying, insufficient lubrication and ultimately reduced bearing life. Some bearings even required replacement during the campaign, adding cost and maintenance pressure.

The reliability of several lubrication points depended heavily on manual checks and interventions. With bearings operating in high-heat zones and exposed to abrasive beet pulp, inconsistent lubrication increased the likelihood of premature wear and overheating. The engineering team planned a more thorough evaluation after the campaign, including bearing-clearance measurements, but the ongoing issues with lubrication delivery already demonstrated the need for a more robust, high-pressure, automated solution.

Solution

To improve lubrication consistency and address the previously observed bearing failures, the facility implemented a structured automatic lubrication solution using Memolub Connect Pro units. Ten systems, in both 480 cc and 240 cc capacities, were installed across all critical lubrication points within the steam-dryer area. Their placement covered intermediate bearings on the transport screws, bearings on the feed unit and key locations around the feed sluice where lubrication also provides essential sealing against beet-pulp contamination.

Each lubricator was programmed according to the specific needs of its application. Lubrication intervals range from one to three months depending on load, exposure and temperature. One of the large intermediate bearings, known for previous reliability issues, was equipped with a dual 480 cc configuration to ensure sufficient grease volume and stable delivery under operating pressure. All units were filled with Matrix Foodmax CAS S2LS, selected for its high-temperature performance and suitability for food-related industrial environments.

Results

Although full performance evaluation will be completed after the current production campaign, early indications point to noticeable improvements. The temperature of the large intermediate bearing has already decreased, suggesting more stable lubrication conditions. Up to this point, no bearings have required replacement, which contrasts with earlier campaigns where failures had already occurred by this stage.

The lubrication systems are emptying evenly, confirming that grease is being delivered consistently, something the previous low-pressure units failed to achieve. Maintenance teams report increased confidence thanks to the system’s monitoring features, allowing them to confirm correct operation and intervene quickly if alerts arise. Cartridge replacements and follow-up checks are performed jointly with operators during the campaign, ensuring continuous optimisation and validation of system performance

Early results are promising, and further inspection after the campaign, supported by bearing-clearance measurements and comparative maintenance cost data, will provide a more complete assessment of long-term benefits.