BOOST YOUR PRODUCTIVITY
Prolong AFMT Oil and EP-2 Grease has proven itself, in the extreme environments of US industry and Detroit-style manufacturing, for over two decades:
VISTEON Corp., CONNERSVILLE, IN: 10% Prolong AFMT increased production by over $500,000 per month through obtaining zero gearbox failures on production line for more than 8 years.
SAND & STONE AGGREGATE GROUPS: Rock-crusher showing Coast-Down Times significantly longer in the first 12 hours after addition of Prolong AFMT; amp and temps reduced; bearing life has been increased plant-wide for over 5 years.
AK STEEL- OH & PA: Grueling conditions of heat and pressure offset by improved lubrication that actually seeks out high temp/high pressure areas; reduction in cost of operations and increased productivity gained in many plant divisions for over a decade.
MORTON SALT- FL: Two plants near Cape Canaveral deal with salt water and corrosion on a permanent basis. Prolong has virtually eliminated corrosion in their equipment through use of Prolong SPL100 and EP-2 Grease.
CODELCO COPPER MINE, EL TENIENTE, CHILE, SA: Prolong EP-2 Grease is now being used for bearings in the massive grinders, some 30 feet across, which are used to break down the boulder-size ore for processing. These bearings were becoming so heated they failed,” bringing the grinders to a complete and expensive halt, seriously backing up all mine operations. Prolong Grease has radically lowered the bearing temperatures, keeping the grinders operating efficiently and is also being used in the hydraulic lube network and in stand-alone applications on timing systems.
STATE of the ART… NEW Grease launched 2011!
EP-2.5 Grease with AFMT
Aggregate & Mining Applications: PROLONG EP-2 Grease
A Midwest underground mine and aggregate plant has been using Prolong EP-2 Grease since January 2006. Prolong Grease has replaced all other greases at this location. These are some of the characteristics this grease has demonstrated over a 24 month period.
PRODUCTION BUCKET LOADERS:
5 production loaders (Caterpillar) consisting of 988 series F, G & H
The cost to replace bucket pins could range from $10,000 to $30,000. If all pins were replaced on a loader, the labor, cost of pins and line boring could easily amount to $30,000 and require 2-3 days of downtime, with a resultant lack of productivity.
A sub-contractor (Caterpillar) must visit the site to perform some of the more “complete” pin replacements
Historically, every single pin in the Loader fleet must be replaced at least once each year.
- There have been NO pin replacements in 24 months, nor has there been any pin “wear.”
- There has been no need for line boring, a costly, and time consuming task.
The center pins require greasing every day, due to the standing water in the underground mine. If the equipment is not being maintained by an experienced, conscientious operator, a suboptimal amount of grease might be applied. There are 25 employees operating equipment at the mine…. At any one time 10 of these operators are fairly new and may not realize the amount of care necessary for the equipment to be maintained for ultimate performance and equipment life.
Prolong Grease offers more ‘forgiveness’ and protection, in this regard. Four pumps of the Prolong Grease do the job of 12-14 pumps of the previous greases used.
40 conveyors on site- each conveyor has at least 4 bearings and some have up to 16 bearings
Bearing sizes range from 2 7/16” to 5 15/16” shaft diameters and cost upwards of $200.00 per bearing Tail and Head pulleys are fairly easy to change out and may require an hour of labor; if it is necessary to remove a gearbox in order to get to a bearing it may take up to 4 hours of labor.
Historically, bearing replacement occurs all the time- at least one per week, with the smaller bearings being replaced more frequently. A 6-7 month period occurred with no bearings of ANY size requiring replacement… it could not be remembered the last time a bearing replacement occurred. The current bearing inventory was unknown, because so seldom is it necessary to utilize new bearing stock.
HYDRAULIC DRILLING EQUIPMENT
- Prolong AFMT added to the hydraulic drilling equipment (10% by volume) extended tool life substantially, dropped the equipment temperature and reduced the down-time of the equipment, such that our teams could be more productive.
Mining Giant Hails Cost Savings with Prolong
Irvine, CA, July 4, 2005- Prolong Super Lubricants, Inc. announced that the use of its Prolong EP-2 Grease is being expanded in the Codelco copper mine in El Teniente, Chile after operations management recorded significant increases in equipment longevity and reduction in servicing down time.
The Teniente division, eighty kilometers South of Santiago and 2,500 meters above sea level, its operations is the exploitation of the underground copper mine, which is the largest of its kind in the world. This mine, which began activities in 1904, has 2,400 kilometers of underground drifts.
Super Lubricantes Ltda., Prolongs’ distributor in Chile since the late 1990’s initially introduced Prolong EP-2 Grease to the El Teniente division of Codelco for use in their 100 ton loaders that scoop up loosened earth. Management was looking for a solution to the serious problem of brass bearings at the pivot points of the scoops which were failing at a high rate causing costly down time and refurbishing. Since the introduction of Prolongs’ lubrication technology, the bearings have not been failing and intervals between maintenance work and down time have more than doubled.
Success with the loader bearings led the mine management to try Prolong grease in other applications with equally impressive results. During a recent visit to the El Teniente operations, both management and line operators enthusiastically told Prolongs’ Vice President of Industrial Sales and International Sales Manager, Jeff Victer that “Prolong EP-2 Grease is now being used for bearings in the massive grinders, some 30 feet across, which are used to break down the boulder sized ore for processing. These bearings were becoming so heated they failed, bringing the grinders to a complete and expensive halt, seriously backing up all mine operations. Prolong Grease has radically lowered the bearing temperatures, keeping the grinders operating efficiently and is also being used in the hydraulic lube network and in stand-alone applications on timing systems.”
Codelco, the Corporacion del Cobre de Chile, a mining, industrial and commercial company owned by the Chilean State, is the main copper producer in the world. Its El Teniente division, located 80 kilometers south of Santiago and 2500 meters above sea level, operates the largest underground mine on earth, producing 334,306 metric tons of copper a year.
“It is extremely satisfying to be able to demonstrate such significant savings in an operation of this scale, magnitude and technological level”, stated Jeff Victer. “We know that there are many more applications for our grease, hydraulic fluid and gear treatments to help the Codelco mine control its’ efficiency and profitability.”
North Texas Cement Company
Re: Prolong EP-2 Grease
Prolong Super Lubricants’ EP-2 Grease was given the chance to prove itself at NTTC. NTTC operates a Fuller Kovako to unload cement from the hold of cargo ships. The Fuller boom supports a 24” vacuum pipe and rotating nozzle. To extract cement, the nozzle must be buried in the cement, creating an abrasive situation for the bearing. THE BEARING MUST BE GREASED EVERY 6 HOURS and the procedure takes approximately 45 minutes. Since we began using Prolong EP-2 Grease, the time between greasing has increased to ONCE EVERY TWO DAYS.
To put this in perspective, The Fuller can unload 290 tons per hour. This yields an increase in performance of 761 tons per day, or approximately an 11% increase in production. If the man-hours and operating cost of the Fuller are figured into the equation, the savings are “substantial.” Using our previous grease, we had to replace the bearing every 6 months at a cost of approximately $5,000.00.
We have also begun using Prolong EP-2 Grease on the basket elevator that lifts the cement from the conveyor to the silos. Originally we greased the bearings every other day. Since using Prolong EP-2 Grease, we now grease the bearings twice a week. The reduction in grease usage has more than offset the minor additional cost associated with using Prolong EP-2 grease.
Currently we are using Prolong EP-2 Grease in all of the equipment at our facility. The performance of Prolong EP-2 Grease has convinced me that you have a remarkable product. I look forward to using other Prolong products as the situations arise.
Lubrication Specialists of NE FL- Indianapolis, IN / Jacksonville, FL