Maximised – Set and Forget Single-Point Lubrication

The world of condition monitoring and predictive maintenance continues to become more complex with increasingly detailed systems that generate voluminous quantities of data.  While there is no data how useful this data is in planning and scheduling but in the field, it is often better to keep things simple and effective.

That is certainly the case when it comes to lubrication where ultimate reliability is critical to the life of all fixed and mobile plant.  A myriad of methods have been used to lubricated equipment – from manually-operated grease guns to computer-controlled delivery systems.  However, each of these systems have their weaknesses, which is where a tried and tested, single-point, automated lubrication delivery system comes into its own.

GreaseMax is exactly such a product.  It has proven itself for many decades and has functioned flawlessly in the world’s harshest mining environments – from extreme heat to extreme cold, from bone-jarring vibrating screens to fully submerged conveyors.  This simple but ingenious device delivers a constant flow of grease – even when the machine is in operation.

Milton Holmes is the director of Delta Sales International, the company behind GreaseMax.  He brought the concept of single-point automated lubrication to Australia in the 1980s and has been developing the delivery of this technology ever since.

A controlled chemical reaction is the heart and soul of each GreaseMax unit.  Once installed and activated a galvanic process is initiated that generates gas.  As the resulting gas pressure increases, it acts upon a steel piston, pushing it downwards against a flexible diaphragm, which contains the grease.  This pressure is slow, gradual and precisely timed to supply grease at a constant rate – even when the machine is in operation.

According to Milton, "Reliability is the key, the piston is the only moving part in each unit. There is no circuitry to corrode, no mechanical components to fail, no setting dials that permit human error.

“Its simplicity and bullet-proof reliability are the reasons it performs faultlessly in extreme mining environments around the world."

For ease of use, each GreaseMax unit is colour-coded according to its discharge period.  White units operate for one month, blue for three months, red for six months and grey for 12 months. There is no need for pressure sensors or programmable controls as each unit discharges at a constant, perfectly timed rate – regardless of its environment or application.

Each unit holds 125ml of lubricant and is prefilled with high-grade grease options that include: multipurpose calcium sulfonate grease for high-load applications; heavy-duty moly for slow-moving, shock-loaded bearings and food-grade H1 grease for sensitive production areas.

Its versatility extends to its tolerance of wide temperature variations - from -40°C to over 180°C.  As it is internally pressurised units can be mounted in any orientation and operate through extension lines, flexible tubing and brackets.

Maintenance planning is a complex role with millions of dollars at stake – not only in the value of the equipment itself but also in the cost of potential unplanned shutdowns.  Maintenance supervisors have a preference for tools that do their job – without the need to maintained themselves.  They want reliable, integrated and predictable results from any system they implement.  GreaseMax delivers that predictability and gives the team the ability to individually set and forget each lubrication point and know with clockwork accuracy exactly when it will need to be replaced.

"Maintenance scheduling requires known start and end points," Milton said. "GreaseMax provides exactly that - you activate it, install it and you know exactly when it will be empty and need replacing."

The units are also TÜV-certified for use in hazardous locations, including underground coal mines and petrochemical plants. Because they are self-contained with no electrical components, they are intrinsically safe, there is no risk of electrical ignition and no need to interact with them in dangerous or enclosed areas while equipment is in operation.

Milton’s voice of experience adds, "It is safer because there is no temptation to manually grease live equipment, you don’t have to clamber over machinery to get to inaccessible bearings."

One of the most persistent issues in mining lubrication is contamination. Dust, fines and water ingress degrade grease performance, reduce film strength and accelerate wear. Water contamination, in particular, is often overlooked. Once water enters a bearing, it promotes corrosion, reduces grease adhesion and increases the likelihood of metal-to-metal contact.  When particles enter the bearing, they effectively turn grease into a grinding paste and damage worsens exponentially.

Manual lubrication practices often exacerbate this problem. Grease is applied intermittently, allowing contaminants to remain trapped inside the bearing housing between service intervals. Over-greasing can also damage seals, further increasing contamination risk.

GreaseMax addresses this issue by supplying fresh grease at a controlled, consistent rate, while equipment is operating, which ensures grease is distributed evenly within the bearing when rotational forces are present, improving film formation and heat dissipation.

This approach also promotes a continuous purge of contaminants and moisture from the bearing cavity, significantly improving operating conditions for rolling elements and raceways.  This simplicity is particularly valuable in mining environments, where complex systems often struggle to survive exposure to dust, moisture and mechanical shock.

GreaseMax lubricators are used extensively across both fixed and mobile mining equipment, including:

The system’s ability to pump grease through long feed lines allows lubricators to be installed in safe, accessible locations while servicing bearings in hard-to-reach or hazardous areas. This flexibility makes it suitable for large processing plants and complex conveyor systems where access constraints are a significant maintenance challenge.

From a reliability engineering perspective, continuous lubrication offers measurable benefits. Bearings that receive a constant supply of clean grease operate at lower temperatures, experience reduced friction and show slower wear rates.

This leads to:

By minimising lubrication-related failures, operators can reduce the secondary damage often associated with bearing collapse, such as shaft scoring, housing damage and misalignment.

The economic case for automatic lubrication is compelling. Manual greasing is labour-intensive, particularly in large-scale mining operations where lubrication points may be elevated, remote, or located near moving machinery. Automating lubrication reduces routine labour requirements and allows maintenance personnel to focus on higher-value reliability tasks.

Even more significant, however, are the indirect cost savings. Unplanned downtime in mining environments is extremely expensive and often impacts entire process streams. By reducing lubrication-related stoppages, continuous lubrication systems deliver substantial gains in overall equipment effectiveness.

As mining operators focus more sharply on reliability, cost control and safety, lubrication strategies are receiving renewed attention. Continuous automatic lubrication systems such as GreaseMax, represent a practical, proven solution to long-standing lubrication challenges.

By delivering clean grease consistently (over a fixed period of time), purging contaminants and reducing reliance on manual intervention, GreaseMax plays a critical role in extending asset life, improving reliability and lowering total cost of ownership across mining operations worldwide.

After more than four decades in the single-point lubrication arena, Milton sums up the situation succinctly, “Smart simplicity – that is what people really want when reliability matters. And that is what we have always delivered."