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FLUID POWER A step forward in lubrication technology

Apr 17, 2019

The textile industry in India is one of the oldest in the Indian economy and is extremely varied. In this context, the case study explores how a textile venture switched to a technological solution that significantly improved productivity & enhanced sustainability of manufacturing operations.

The textile sector is an integral component of the Indian economy, contributing an impressive 13 per cent to the country’s exports and a robust 4 per cent to India’s GDP. The Indian textiles industry, currently estimated at around USD 150 billion, is poised for sharp growth and is expected to reach USD 230 billion by 2020. The size of the textile machinery industry alone is expected to grow from the present ₹22,000 crore to ₹35,000 crore in five years.

India’s textile industry, which includes spinning, apparel and garments sectors, deploys state-of-the-art machinery and world-class production technologies. Lubrication is integral to the smooth functioning of these modern machines, ensuring maximum productivity and operational excellence. Preventive Maintenance is the key to achieving good performance and improved durability of textile machineries, and an effective lubrication programme is key to seamless operations.

A breakthrough in lubrication technology

The right gear oil extended the oil drain interval and increased equipment protection, thus enabling the textile major, Shiva Texyarn to achieve its productivity, sustainability and energy-efficiency goals, leading to profitability.

Shiva Texyarn, a Tamil Nadu-based textile company, is one of India’s leading manufacturers of yarns, fabrics, garments and home textiles. The textile giant has 36 LK64 Comber Machines in operation at its two plants. With the increasing consciousness towards environment and the dynamic market competitiveness, Shiva Texyarn needed to upgrade to a breakthrough lubrication technology. Keen to make a substantial difference to their manufacturing processes, Shiva Texyarn turned to Field Engineering Services (FES), which is a part of ExxonMobilTM, and its team of technical experts that work closely with manufacturing companies to offer them advice on the best-in-class lubrication and maintenance practices.

The recommendation

With the intent of delivering technologically advanced lubrication solutions to further advance the productivity and profitability of Shiva Texyarn, ExxonMobil’s FES team assessed the on-site usage conditions. They worked closely with the technical team at Shiva Texyarn to understand the machine’s lubrication requirements.

Based on their in-depth analysis, Shiva Texyarn was recommended the Mobil SHC Elite 150 gear oil, which would significantly extend the oil drain interval and improve the energy efficiency of the machine. The gear box is the heart of textile machinery and the right gear oil plays a crucial role in extending the oil drain interval and ensuring that the gear box delivers optimum performance. The new lubricant would do away with disposal of four litres of used lubricant for every oil drain saved, as well as enhance safety by reducing exposure by three hours for every change of oil. The Mobil SHC Elite 150 was not only an ecofriendly replacement for Shiva Texyarn, but also a lubricant that yielded noteworthy reductions in operation & maintenance costs.

The result

The Mobil SHC Elite 150 proved to be the perfect long-lasting gear oil for the Comber gear boxes in the textile machinery. The oil change interval increased exponentially from just 7,000 hours to a remarkable 15,998 hours. The wear elements remained at a minimum level throughout the trial. There were also safety benefits in terms of reduced storage and handling labour due to reduced usage of lubricants. In terms of cost effectiveness, the move to Mobil SHC Elite 150 across the company’s 36 Comber gearbox units yielded a huge saving of USD 2040 (approx ₹1.4 lakh) annually.

The advantage

The SHC Elite 150 has thermal/oxidation stability that provides up to two times oil life versus other synthetic gear and circulating oils, reducing maintenance downtime. It has deposit and varnish control that helps to deliver cleanliness and extended oil and filter life. The high performance synthetic base stocks with high viscosity index and enables wide temperature range capability and effective lubrication at high temperatures. It also has resistance to rusting and corrosion, with good anti-wear properties, demulsibility, foam control and air release, besides seal compatibility that helps reduce contamination and leakage.

The composite benefits achieved by using Mobil SHC Elite 150 are:

  • Long lubricant life: Reduced employee and equipment interaction due to ODI

  • Environmental care: Reduced amount of waste lube generated for disposal

  • Expenditure reduction: Reduced cost of lube purchased due to extended ODI

Courtesy: ExxonMobil Lubricants

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  • The Mobil SHC Elite 150 proved to be the perfect long-lasting gear oil for the Comber gear boxes

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