Track:Technology&PlantOpera4onsHolgerStreetz

Applica'onService&Por1olioTechnologyPlanningMaintenanceTasksDown'mesOp'miza'onOp'mizedMaintenanceCaseStudyICaseStudyIIConclusions

Bathanlubricantsoutpacetechnologyleadersinindustriallubrica'on.Theyreducewearandincreaselubrica'onintervals.•  Solu'onProviderforseveralindustries•  Co-Opera'onsinEurope,USA,LATAMandAsia•  FullServicesupplierforpelletindustry•  Flexibleandefficientlogis'cchain WoodProcessing

EnginesWindPowerCementPlantsPackagingFacili'esIndustrialGearsMiningShipping

Weofferconsul'ngforlubricants,andadvisepelletproducersregardingmaintenanceplanningandefficiencyini'a'ves.OurserviceteamprovidesmaintenanceservicesinOEMquality.Wedeliverwithreliableshippingcompaniesandguaranteehighestquality.

BathanKFGreases400gtube25kgHobbockkeg200kgdrumBathanAddi4ve500mlcan20lcanisterSparePartsPelletIndustryRollersRollerBearingsDies

Bathanisacombina'onofindustrialceramics,andhasadis'nctcrystallinestructurewithlowdensity,highlubricityandthermalconduc'vity.Theceramicpar'cleschangethestructureofsurfaces:Thermoplas'clevellingsmoothensthesurface,increasestheloadbearingcapacity,andreduceswear.HighlightsGreasing:•  Reducinggreaseconsump'onby95%•  Reducedpowerlossesbyupto9%•  Lowermaintenance&opera'ngcosts•  Lessfric'onandincreasedlife'me

Partially polished surface

Thegoalistoproducewoodpelletsinanadequatequalitywithanacceptableproduc'onrateatreasonablecosts.Plantdesignisvital.

Learn from the best

Use the knowledge of experts

Get it right from the beginning

Adjust plant design if necessary

Take all aspects into account

Smart Maintenance starts with the plant design

Moisturecontrol beforemoisteninganda\ermaturingvesselVisualinspec'on:die honeycombing,microcracks,wear,foreignmaterialVisualinspec'on:rollers adjustment,wear,temperature120-150°C(250-300°F)Greasepumpcontrol filllevel,greaseandairpressureGearcontrol oilpressure(1to5bar),

oilfilter, oilcoolerbelow 65°C(150°F),volume (oillevelglass)

Qualitycontrol pelletquality,abrasion,length,

moisture,bulkweight,density

Hammermillcontrol wearofsi\ersandhammers,cleanmagnetCondi'onerandfeeder cleanthoroughly,checkmagne'cseparatorMoisturizercontrol checkcalibra'on,recalibrateifnecessaryPelletmillcontrol cleanfeedchutesandsi\ers,

cleancrumbler,collector,fan, exhaust,androtoshaker

Knifes checksharpnessControltonnagereportsandhoursruntoplanmaintenance.

Dieandrollercontrol wearpahern,leakages,microcracks,clearanceGearcontrol wear,leakages,microcracks,(beltsifexis'ng)Conveyorscontrol lubrica'on,wear,beltsOther e.g.lubrica'onpipelines,

Oilandoilfilterchanges (accordingtomanufac- turerspecifica'ons)

Evaluateproduc'vityandcosts.Exercisedieandrollerchangetoensureshortmaintenancedown'mes!

Down'mesareabohleneckandanopportunity.PlannedDown'mes:•  Plannedmaintenancetasks•  Overhaulbyserviceengineer

Efficiency

Chance

PlanIssue

UnplannedDown'mes:•  FailureàFixtheproblem•  Other(weather,material)àAccordingto'meavailable

•  Byassessingthestatusquo,weaknessesbecomevisible

•  Thirdpar'eshelpovercomeorganiza'onalblindness

•  Askyourteamofexpertstofindopportuni'es,thenconsultotherprofessionals

•  Putyourplansintoac'on!

•  Implementacon'nuousop'miza'onprocesstoremainexcellent

StatusQuo

In-houseExper4se

ExternalConsul4ng

PutPlaninto

Ac4on

LessonsLearned

Payahen'onwithnewrollerswhendeliveredonsite.•  Inspec'onofdeliveredrollers

•  Cleanlinessoflubrica'onintake

•  Easymovabilityofroller

•  Cleanstorageawayfromweatheringeffects

Refurbishrollersin-house

•  Disassemblerollerwarm•  Cleansha\s&bearingsthoroughly

•  Inspectbearingsbeforeassembly

•  Assemblerollerwarm•  Movingpre-lubrica'onforseveralhours

Triplingthelife'meofbearingscausestwofewerdown'mes,anddecreasesworkinghoursandsparepartcosts.

•Refurbishrollersin-house

•Payahen'ontoassemblyofrollers•Usehigh-qualitylubricants •Keepeverythingclean

Regular Maintenance Plan

Improved Maintenance Plan

SwissPelletProducer,CPM,60’000tannualproduc'onStatusQuo: 1‘000opera'nghourslife'meofbearings

TemperatureØ115°C(240°F)Changes: Pre-lubrica'on,Ceramicgreaseand

distanceringswithimprovedlubrica'onImprovement: 95%lessgreaseconsump'on

upto10‘000opera'nghourslife'meofbearings Temperaturedecreaseby10°C(50°F) Savingsofapprox.100‘000CHF

GermanHD-PelletProducer,CPM,200‘000tannualproduc'onStatusQuo: 1’200opera'nghourslife'meofbearingsChanges: Ceramicgrease,rollersfromBathanAG,

andin-houserefurbishingofbearingsImprovement: 95%lessgreaseconsump'on

4’000opera'nghourslife'meofbearings Savingsofapprox.125’000EUR(140’000$)

•  Preventa'veMaintenanceisbeherthancure•  Externalprofessionalscanofferadifferentperspec've•  Ahen'ontoqualityofrollerrefurbishmentpaysoff•  High-qualitylubricantshelpimproveperformance•  Evensmallchangescanhaveahugeimpact

HolgerStreetz MemberoftheBoardofDirectors

BathanAG web www.bathan.ch email h.streetz@bathan.ch