In-Line Post-Processing
Most products need some form of in-line post-processing once the reacting and mixing stages are complete. In grease manufacture, this typically involves homogenising, filtering, de-aerating, and packaging. The right equipment is critical here, as it directly affects both the performance and the appearance of the finished product.
These are the main in-line machines we use in our projects:
Pumps
The two main types of pumps we use are gear pumps and progressing cavity pumps.
Gear pumps perform well across a wide range of temperatures, viscosities and grease consistencies. Progressing cavity pumps handle high viscosities equally well and, when fitted with a rubber stator, can generate a full vacuum on the suction side. However, it is important to ensure the stator has the correct temperature rating to prevent softening or melting during operation.
Colloid Mills
We commonly use two types of colloid mills in our projects: one with a ribbed stator and rotor, and one with a smooth stator and rotor.
- The ribbed design is preferred for grease manufacture, as it both pounds and shears the material for improved texture.
- The smooth design is ideal when precise control over particle size is required.
Some plants opt for homogenisers instead of mills. A homogeniser uses a high-pressure reciprocating pump feeding a spring-loaded orifice, creating shear in two planes instead of one. While technically superior, homogenisers are more expensive and require more frequent maintenance due to higher wear rates.
Filters
We use basket, duplex and scraped-surface self-cleaning filters in our systems.
These filters are especially effective in the production of EP and anti-wear greases where no solid powders are present. They remove undissolved soap or raw materials, resulting in quieter bearing performance compared to unfiltered greases. In some cases, filtering is a mandatory quality assurance requirement specified by the customer.
De-aerators
We have developed a unique orifice-type de-aerator for clarifying cloudy products. When required, we can integrate a vacuum chamber to remove a higher proportion of trapped air.
De-aerators can be configured for gravity or line feed, depending on the plant layout. We can also incorporate automatic shut-off equipment, allowing the de-aerator to function as a gravimetric filling machine when needed.
Filling and Packaging Equipment
We generally recommend gravimetric filling, as it aligns with the weight-based units by which grease is typically sold. However, we can also provide volumetric filling systems for smaller package sizes where appropriate.
