For traditional bushing materials like bronze, lubrication is simply a requirement of the material. Lubrication requirements mean not only more maintenance but more muck. While precise needs will vary by application, it’s important to understand that we’re not talking about “little drops” of grease. In this post, we wanted to provide a concrete example of just how much grease a bronze bushing can require when employed in a high-performance application.
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How much grease do bronze bushings need?
Unlike self-lubricating polymer options, bronze bushings require abundant amounts of lubricating grease to keep industrial equipment running. But have you ever wondered just how much grease they need? We did, so we asked a client to show us the sludge that was left behind after a routine cleaning. Since a picture is worth a thousand words, today we want to share this incredible image. Even our experienced engineers were amazed at the amount of greasy sludge that was removed!
An entire barrel (nearly 42 gallons/159 liters) of grease. Nearly 400 pounds worth!
That’s the amount of excess lubricant our partner removed from just one machine during routine maintenance of their bronze bushings. In this case, our client had two full-time workers assigned to degreasing their manufacturing and packaging lines. Because bearings that are left with excess grease are prone to seizure which can lead to a halt in production.
Do bronze bushings need grease? Always?
Bronze bearings need some sort of lubricant to reduce friction in virtually every application. While oil is sometimes used, most applications call for grease. Either way, this substance not only requires regular maintenance and cleaning but can be a magnet for contaminants like dust and particulate matter, negatively affecting machine lifespan. While some bronze bearings are impregnated with oil to generate some “self-lubricating” properties, these designs don’t change the need for cleaning. With these drawbacks in mind, more and more businesses are using alternative materials.
What to use instead of bronze bearings with grease?
Advanced materials like Rulon and other polymers and composites offer a powerful alternative bronze bushings/bearings. The right material choice will depend on your application, but these materials have self-lubricating properties that prevent the need for traditional lubricants like grease (you can read about how self-lubricating bearings work here).
Once our client replaced the high-maintenance bronze with no-maintenance plastic bearings, they realized immediate production gains. They were able to reassign the maintenance crew to other areas of the line, and experienced far fewer work stoppages. Ultimately, our partner estimates they will recover over 2,000 hours a year in lost labor. And their plant will provide a greener footprint.
Is it any surprise that they decided to say goodbye to bronze bushings forever and switch to greaseless plastic composites?Want to learn how you can end bearing lubrication? And save a barrel in maintenance costs? Ask the plastic composite bearing experts ― we can help!
To learn more about the different kinds of bearings, bearing failure, and more check out our Bearings 101 feature article.
I've spent considerable time delving into materials used in industrial applications, particularly bushings and bearings. Bronze, a classic choice, demands substantial lubrication, and I've seen this firsthand in various industrial settings. Lubrication is pivotal for bronze to function optimally, preventing friction-induced wear and ensuring smooth operation. However, this requirement entails meticulous maintenance, leading to considerable challenges, such as the accumulation of muck and sludge.
This article touches on crucial aspects:
Bronze Bushings and Lubrication
- Bronze Bushings: Known for their durability, bronze bushings require significant amounts of lubricating grease, contrasting with self-lubricating polymers.
- Maintenance Requirements: The text vividly illustrates the magnitude of grease required for a high-performance application, showcasing a staggering removal of nearly 400 pounds (nearly 42 gallons/159 liters) of excess lubricant from just one machine.
Lubrication and Alternatives
- Lubrication Necessity: The necessity of lubrication for bronze bearings is emphasized, pointing out that while some have self-lubricating properties, regular cleaning remains crucial due to excess grease accumulation.
- Alternatives: Highlighted alternatives like Rulon and other polymers/composites offer self-lubricating properties, eliminating the need for traditional lubricants and significantly reducing maintenance requirements.
Impact of Switching Materials
- Operational Impact: Switching from high-maintenance bronze to maintenance-free plastic bearings led to immediate production gains, reduced work stoppages, and freed up labor for other critical tasks.
- Sustainability: Additionally, this shift to greaseless plastic composites not only improved operational efficiency but also contributed to a greener footprint.
Conclusion and Call to Action
- Adoption of Greaseless Plastic Composites: The article concludes by highlighting the advantages of greaseless plastic composites over bronze bearings, inviting readers to explore the possibility of eliminating bearing lubrication by consulting experts in plastic composite bearings.
This comprehensive breakdown illustrates the challenges posed by traditional bronze bushings, the necessity of lubrication, and the transformative impact of switching to advanced, maintenance-free materials in industrial applications.
