SKF’s Single Line automatic grease system has streamlined operations across six sugar mills, delivering peak efficiency while ensuring the producer upholds rigorous international health and safety standards. SKF supports the customer in partnership with its authorised distributor, CG Trading, based in the Kingdom of Eswatini. In addition to supplying bearings and power transmission products, CG Trading operates and maintains the onsite workshop to meet ongoing operational requirements.
International health and safety standards discourage the use of bitumen-based lubrication products in sugar mill applications, citing significant environmental and operational risks associated with disposal of used bitumen oils. In addition, excessive grease consumption driven by limited control over dispensing volumes, results in high operating costs.
The sugar producer explored a new lubrication system for its mills, along with a more reliable system to integrate into the overall project. The goals were to reduce grease consumption, enhance lubrication reliability, and ensure compliance through the introduction of the new product.
SKF, in collaboration with CG Trading, conducted a site visit to assess requirements and determine the most effective solution to meet all of the customer’s needs. SKF’s Single Line system was identified as the best solution delivering a range of benefits that include precision, compliance, and operational savings for the customer.
SKF application engineering manager, Donatien Makopo explains the principle of Single Line lubrication: “The system consists of a central pump station which automatically delivers lubricant through a single supply line to individual lubricant metering devices. Each metering device serves one lubrication point only, and can be adjusted to deliver the precise quantity of grease or oil required. These versatile systems can be designed to serve a single machine, multiple zones on one machine, or several separate machines. By ensuring accurate dosing and eliminating waste, the system not only meets international health and safety standards, but also presented the most effective solution for the customer’s operational and regulatory needs.”
SKF supplied three Single Line lubrication systems for six sugar mills, with each system covering two mills and a total of 108 lubrication points. Makopo details the key benefits delivered by the Single Line lubrication system: “Precise, adjustable grease dosing at each lubrication point reduces grease consumption, while the optimised pump station configuration ensures minimal pressure losses. Lubrication accuracy is further enhanced through visual confirmation of correct grease delivery at each point. In addition, panel mounted equipment engineered for dusty environments strengthens system reliability and protection.”
The design of SKF’s Single Line system won the customer’s confidence, offering a solution far superior to their previous multi-line lubrication system that failed to provide full control over the quantity of grease dispensed to the mill lubrication points. According to Makopo, the customer observed results within just one week of operation, with measurable benefits quickly evident, most notably, a reduced frequency of grease drum replacements across the six mills. “Over an eight month period, grease consumption is projected to fall sharply from 60 000 litres to approximately 12 350 litres. At an average grease cost of R48 per litre, this equates to a substantial annual cost saving and a marked improvement in operational efficiency. Moreover, the upgrade enhances overall asset reliability, minimises unplanned downtime and maintenance risks, and secures a strong return on investment for the customer.”
Comprehensive training was delivered to the customer’s mechanical and instrumentation teams, ensuring a thorough understanding of system operation. In parallel, SKF also trained CG Trading personnel, equipping them as the first line support team responsible for ongoing system maintenance.
CG Trading’s onsite team will serve as the customer’s first point of contact, while more complex issues requiring additional expertise will be escalated to SKF for further assistance and support.
This project demonstrates of SKF’s capability to engineer lubrication solutions that deliver measurable cost reductions, ensure compliance with international standards and enhance reliability across critical operations. By combining technical innovation with customer focused design, SKF can drive efficiency, sustainability, asset optimisation and long-term value for its customers.
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