03 Giu DIEFFENBACHER Approves Metalube Chain and Belt Oils
With rising costs and tight margins, wood-based panel manufacturers are facing more pressure than ever to operate at maximum efficiency.
For most producers, the key factor in determining operational efficiency is the continuous press. These highly complex machines must operate reliably, in extreme conditions of temperature and pressure for days, weeks or even months on end.
- Higher thermal stresses
- Wear on press components
- Extended lubrication cycles
- Increased maintenance and downtime risks
As with most machines, effective lubrication is vital to the operation of the press and plays a critical role in determining efficiency.
Whether that be in ensuring smooth operation or reducing wear to extend the service life of components, the lubricant must be up to the challenge created by the arduous conditions.
There are thousands of moving parts to lubricate, and the oils must accomplish this while being subjected to continuous thermal degradation and destructive oxidative attack.
As if the standard operating conditions aren’t difficult enough, presses have also been evolving – becoming longer and running faster than ever before – placing even greater demands on the lubricants to perform.
It is essential that press lubricants evolve too – using the latest technology base fluids and additives to maximise performance.
It was with these challenges in mind that Metalube developed its next generation of continuous press lubricants: metacatena™ CB-310 (for bending rods and chains) and metacatena™ CB-633 (for belt and rollers).
Following a rigorous development process, independent laboratory testing and a long-term user trial, full approval from leading continuous press manufacturer, DIEFFENBACHER GmbH Maschinen un Anlagenbau, has now been achieved.
The approval by DIEFFENBACHER of Metachain™ CB-310 and CB-633 was the culmination of several years’ work that, as with all of Metalube’s products, started in the state-of-the-art development laboratory.
Advanced techniques such as high-pressure differential scanning calorimetry (HP-DSC), thermogravimetric analysis (TGA) and oscillating friction and wear (SRV) were used to optimise the formulations. However, this was just the start.
Product Testing Phase
Prior to commencing the customer trial, testing of the formulations was carried out by the renowned independent laboratory, GWP Society for Materials Testing mbH. The stringent evaluation process assessed both the thermal stability of the oils and compatibility with press components.
A key requirement of any oil used on the press is that it does not negatively affect the metals used in its construction. During testing, components are exposed to the oil at high temperature for extended periods and then analysed for signs of corrosion using scanning electron microscopy.
Both Metachain™ CB-310 and CB-633 passed with flying colours.
Trailing Phase
Having successfully completed both laboratory phases, the next stage was to undertake a full customer trial.
However, even with good laboratory testing and simulations, they can never fully replicate real-world conditions. So controlled trials are the critical stage in lubricant validation.
Starting in November 2023, a leading European wood panel manufacturer introduced Metachain™ CB-310 and CB-633 on their DIEFFENBACHER CPS+ press system.
The OSB producing press was suffering malfunctions in the chain roller bar systems due to heavy caking caused by PMDI residues, causing production stoppages and a negative effect on operational efficiency, a situation that was simply not sustainable.
Although at this stage, Metachain™ CB-310 and CB-633 were still considered to be experimental products, both Metalube Commercial Manager Matteo Buffin and senior engineers from the wood panel producer assessed that the issues were largely due to inadequate lubrication, and a radical option of next-generation oils should be considered.
Trail Results
After a year of operating the press with CB-100, CB-200, CB-310 and CB-633, the results speak for themselves:
- Rollers remained lubricated throughout production
- Greatly reduced alarms
- High savings in production costs
- Reduced downtime intervals
In short, the new oils were a complete success!
By utilising our next-generation technology, the manufacturer remedied the previous issues with inadequate lubrication and made significant efficiency improvements.
Creating The Next Generation Wood Panel Solution
This experience played a key role in obtaining approval from one of the world’s leading wood panel press manufacturers for Metalube’s next-generation oils. It highlights our industry-leading solutions for wood panel manufacturers.
Learn more about Metachain™ and our entire range of industrial lubricants by speaking to our expert team today.
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