In 2019, a quarry site operating a METSO Locotrack LT 125 mobile crusher faced ongoing challenges with lubricating its key mechanical components. These included the jaw holder bearings, the coupling bearing, and the conveyor rollers. The harsh and dusty environment placed these components under intense mechanical stress, making regular and precise lubrication essential for maintaining performance and avoiding costly downtime. At the time, lubrication was carried out manually by technicians who spent an estimated two to three hours per week servicing the equipment. However, the mobile crusher’s design made many lubrication points difficult to access, significantly limiting the efficiency and safety of maintenance operations.
MEMOLUB HPS
How a quarry reduced maintenance costs and downtime on a mobile crusher.
Context
Problem
The quarry encountered two critical issues with its lubrication approach. Firstly, the inaccessibility of lubrication points posed a safety hazard and often led to delays or incomplete servicing. This was especially true for components such as the jaw assembly and conveyor rollers, which required technicians to work in tight, awkward spaces. Secondly, due to the pressure of daily operations and the reliance on manual scheduling, lubrication was irregular and inconsistent. As a result, certain components were either under-lubricated or entirely missed during routine checks. These shortcomings increased the likelihood of premature wear and unplanned equipment failures. Each bearing failure had the potential to cost the operation between €2,000 and €5,000 in repair expenses alone, not accounting for the production losses caused by unexpected downtime.
Solution
To resolve these issues, the quarry implemented MEMOLUB HPS automatic lubrication systems, tailored to the demands of each component. On the jaw holder bearings, four MEMOLUB HPS 480cc units were installed and programmed to deliver Castrol Tribol GR 100-2 PD lubricant on a monthly cycle. The coupling bearing was equipped with a single MEMOLUB HPS 240cc lubricator, using Castrol Tribol GR 400-2 PD, operating on a three-month schedule. For the conveyor rollers, two MEMOLUB HPS 240cc units were connected to a two-point distribution system, also using Castrol Tribol GR 400-2 PD, with a service interval of six months. This setup allowed each lubrication point to receive accurate, consistent doses of grease without the need for technician intervention. In total, the transition to automatic lubrication reduced annual technician labor from an estimated 130 hours to nearly zero, while ensuring full coverage and eliminating the variability of manual greasing.
Results
The switch to automatic lubrication delivered immediate and measurable improvements. Lubrication coverage became fully consistent across all critical points, eliminating the risks associated with human error or skipped service routines. Manual labor dedicated to lubrication was reduced by over 90 percent, translating into annual savings estimated between €4,000 and €5,000 in technician time. Over the course of the first year, no bearing-related failures were reported, effectively avoiding repair costs that could have amounted to as much as €10,000. In addition to the financial savings, the site saw a notable improvement in technician safety, as staff no longer had to access high-risk areas under or around the crusher. The total investment in the Memolub system was offset within the first year through reduced maintenance labor and the elimination of breakdown-related expenses. Overall, the project demonstrated a clear return on investment and significantly enhanced the operational reliability of the mobile crusher.
