|Lithium||Non soap and mixed soap||Complex|
Plants offered by Frigmoires are designed and tailor mode
to suit local conditions and customer requirements. Basic plants can range
from simple manually operated plants to highly sophisticated automated
Grease is o fine dispersion of on oil-insoluble thickening agent- usually soap in o fluid lubricant which is generally mineral lubricating oil. The soap is mode up of fatty acid, tallow or vegetable oil saponified with alkali which can be hydrated lime, caustic soda, lithium hydroxide or aluminum hydroxide. The lubricating oil component is refined base oilnaphthenic, of medium viscosity index, or cylinder oil stock. Structurally grease is a "water-in-oil" emulsion. Its appearance is smooth, mostly translucent, soft or hord.
Grease manufacturing procedure
Grease manufacturing can be described as an art as well as science. It is akin to cooking food In spite of detailed recipes the cooks personal attention and supervision at critical stoges only can give best results
Manufacturing of Greases
The monufocture of Greases therefore involves the following steps, some of which may be accomplished simultaneously.
The operations ore carried out in vessel known os Grease Kettle, which is equipped with some form of agitation and with heating facility. The rate of cooling is very important in the development of the proper structure for many types of Grease, hence, close temperature control is required to manufacture a grease of desired properties. The structure of the greose can be modified by milling which can be carried out in the kettle itself during the cooling period or may be done outside the kettle. For out side milling, a high shear Homogenizer or Colloid mill is normally used. Depending upon the types of grease, the totol time required for manufacture of a grease batch in a kettle varies from 1 0 / 20 hours.
Frigmoires assists in setting up the complete laboratoy and provide truing for carrying out tests and meeting specifications as required by NLG1. Some importont tests to be conducted are:
1. Copper strip corrosion test.. Cone penetration,
2. Water content
|NIG grade no||Penetration worked at 25°C||Typical method of application|
|1||310 - 340||Used in grease gun, Centralized systems|
|2||265- 295||Used in grease gun, Centralized systems|
|3||220 - 250||Used in grease gun, Centralized systems|
Pressurized Grease reactors ore like conventional grease kettles, except they ore pressurized. The pressure speeds up the soap- forming reaction, the batch time can be reduced by 30 -40% depending on the row materials used. The batch is inoccessible and invisible during this time as the reactor is closed. The kettles con be designed to withstand a pressure of 5-10 bar meeting ASME codes.The design of the agitator can be single- diredionol, which is vey inefficient or dual directional (counter rotating).For potentially much better mixing. some kettles are equipped with a high-speed impeller driven through the bottom, which imparts dispersion agitation to the botch being cooked.
Atmospheric kettles remain at atmospheric pressure during the cooking process. The kettle is open from the top and row materials con be added at any time during the process. These kettles con be used as o soap forming os well s finishing kettle. The batch con be obseved and adjustments can be made easily. Recirluation of the moss is possible during the process to attain proper homogenization. The reaction products, such os water. are removed by pulling scavenging air through the kettle top during cooking. The heating and cooling action is achieved by means of a heating jacket or limpet coils welded around the shell of the kettle. These kettles con have a very positive effect on grease thickening, stability, smoothness and quality. A high. pedormonce atmospheric reactor should have a efficient agitator to attain product quality.
Milling system with deaerator
This system ensures a higher yield per kg of soap used thus reducing the manufacturing cost. The unit is designed for online milling, deareating and filtering in a single operation. Frigmaires milling cum deareating system is fitted with a self cleaning filter. Thick greases with outputs ranging from 1 000 to 1 0,000 kgs/hr can be processed in these units. Entrapped air and undesired particles below 30 microns are removed during the milling process. Pockets of entrapped air in product results in oxidation which causes oils and fats to get rancid. This leads to discoloration and change in odor of the product. It also affects the specific weight of the product which results in incorrect packing.
Smooth and glossy appearance, foam free surface, chemically stable product, increased shelf life, denser product resulting in improved dosage allowing packing volumes to be reduced. Lab plant Frigmaires lab plants are offered to produce small batches of grease ranging from a minimum of 10 kgs to 100 kgs per batch. The units are provided with a single closed kettle provided with electrical heaters to heat upto 250c.The system comprises of a Grease kettle,Transfer pump, Milling machine, Interconnecting pipelines ,Valves and Instruments. An PLC control electric panel to operate the motors and monitor temp is provided. The entire unit is mounted on a skid and can be moved around the plant.
Packing machines offered range from filling of small cans from 500 gms to 20 kgs with capacity ranging from 1 -5mt/hr.Tthe units provided work on the Auger principal and are semi automatic PLC controlled. For filling of Grease in barrels we offer Barrel filling machines which work on the load cell principal with a capacity of filling 5-10mt/hr.
Autolube has been designed for controlling flow of lube oils and additives into the kettles. Every project is designed to meet specific customer requirements and budgets. we offer distributed software solutions for basic applications as well as for complex plant wide control upto product dispatch. Autolube helps the user to achieve total production control of the plant from raw material reception and storage right upto product dispatch. PLC and Scada based systems using hardware from reputed firms such as Siemens/Allen Bradley or equivalent are incorporated in the package.