⎪ Power transmission, bearings, bushes and seals ⎪
The cost of incorrect lubrication Sam Kekana, technical sales representative at Lubrication Engineers (LE) South Africa, shares his experience of where lubrication goes wrong. “L ubrication is critical for most types of machinery across an industrial plant," says Sam Kekana of Lubrication Engineers (LE). "It bolts or an uneven machine base. These issues can significantly reduce bearing life and cause costly mechanical failures.
without failure since,” says Kekana. For plant operators, the initial cost of a high- quality lubricant is almost always lower than the combined cost of an unplanned breakdown. Kekana suggests adopting a systematic approach to lubrication, covering product selection, proper storage and handling, correct application quantities and intervals, and ongoing monitoring through oil analysis. Along with the high-quality, long-lasting lubricants that LE supplies, Kekana says that the company’s on-site technical support, oil analysis for predictive maintenance, training and con- tamination control services will help customers get the most benefit from their lubricants and avoid downtime and equipment failures. https://lubricationengineers.co.za/ Proper lubrication reduces friction and wear, prevents corrosion and suppresses foaming that can compromise the oil film.
Some equipment is particularly sensitive to the quality of lubrication. Electrical motors need the right amount of lubricant to operate reliably, while gearboxes require the correct viscosity grade of oil. When either of these conditions is not met, the consequences show up quickly. When lubrication fails, Kekana says there are four main direct cost implications: breakdown costs from replacing damaged machinery; labour costs from calling in contractors during unplanned stoppages; spare parts procurement; and lost production, including damaged product and the revenue lost while equipment is down. “I have been to a site where the client had an issue with grease leaking out of a bearing because of high temperatures. Replacing the bearing meant about four hours of downtime, which directly affected their production. I rec- ommended the correct lubricant for the appli- cation, and the bearing has remained in service
directly supports machine reliability, but only when the right product is chosen, stored cor- rectly, applied properly and backed up with planned maintenance and condition monitoring. When any one of those elements fails, you start to see problems.” Across the sites he visits, Kekana finds the same issues recurring. Poor lubricant storage and handling top the list, followed by incorrect product selection, over- or under-lubrication, cross-contamination and a lack of lubricant monitoring. Each of these failures leaves a physical trace. Excessive heat is often a sign of over- or under-lubrication. Unusual noise typically points to insufficient lubrication or a product that cannot handle the load. Vibration, while commonly associated with low lubrication levels, can also result from misalignment, loose
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July-August 2026 • MechChem Africa ¦ 17
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