Introduction to Specialist Lubricants Mako-Lube Lubricants Limited Presentation by: Gavin Armitage Mako-Lube Lubrication Ltd Managing Director

Background to Mako-Lube Lubricants Mako-Lube Lubricants is an independent specialty lubricant manufacturer based in Manchester, United Kingdom. Mako-Lube Lubricants is the sister Company of Brit-Lube who were formed in year 2000. Mako-Lube formed in 2011 as the export division. “ An exciting new brand for Distribution only !” Current Distributors in UK, Ireland, China, Thailand, Canada, South Africa, Brazil, Norway, Sweden, Ecuador…….. Mako-Lube Lubricants have purpose built modern production facilities in the UK. All product are manufactured & packaged in the UK.

Background to Mako-Lube Lubricants Group Mako-Lube Lubricants offers a world class range of products. Mako-Lube Lubricants has affiliate companies & distributors. Mako-Lube Lubricants are represented worldwide. Mako-Lube Lubricants specialise in high performance lubricants and lubrication including a complete range of synthetic oils, high performance, high and low temperature greases, fluid and dry film coatings.

Product Range Unrivalled Product Portfolio Food-Tek Indu-Tek Ultra-Tek Xtreme-Tek Manufactured to a quality, not a cost High performance Application Specific Bespoke to customers specification Access on www.mako-lube.com - Members Area !

Mako-Lube Lubricants service many sectors…. Automotive Food Industry Aerospace Electrical Industry Conveyors & Chains Textile Machinery Faucets, Valves & Fittings Corrugating Machines Casting Metalworking Moulding Oxygen

BASIC LUBRICANT TRAINING

The Refining Process WSR Atmos tower desulphuri- ser units Naphtha KEC Light Oils WSR Atmos tower desulphuri- ser units Naphtha KEC Kerosine Kerosine Gasoil Diesel Sulphurplant Sulphur Vacuum tower Lube Oil Unit Base Oils pda Bitumen Heavy Oils

Crude Oil Distillation CNG LPG gasoline heavier fuels: bigger molecules aromatics alkenes (olefins) cycloalkanes (naphthenes) alkanes (paraffins) Distillation is fluid separation on boiling point

INTRODUCTION Lubrication has been practiced for centuries. Early lubrication involved the use of water or animal fat to improve free running and reduce wear. Chariot wheels were lubricated with rendered animal fat. Modern lubricants are more sophisticated, but similar principles are involved. Reduction of friction & wear.

BASIC LUBRICATION THEORY At a microscopic scale, even apparently smooth surfaces are actually quite rough. Friction and wear result when these rough surfaces move across each other. *

BASIC LUBRICATION THEORY Lubricants act between the opposing surfaces, reducing friction and wear. Maintenance of the lubricant film is paramount; loss of lubrication leads to huge increases in friction; hence wear, seizure and component failure.

FRICTION REGIMES HYDRODYNAMIC BOUNDARY MIXED ‘Aquaplaning’ ‘Last ditch’ MIXED EHD (lowest friction)

SLA - Solid Lubricating Additives Explained PTFE Oil Graphite MoS2 *

SOLID LUBRICANTS SOLIDS WITH SPECIAL PROPERTIES LOW INTERNAL FRICTION, SOFTNESS EXTREME TEMPERATURE RESISTANCE, CAN BE USED ALONE OR AS ADDITIVES… GRAPHITE, MOLYBDENUM DISULPHIDE (MOLY or MoS2), PTFE (TEFLON), MINERALS, SOFT METALS… MOLY & GRAPHITE: The crystals are arranged in layers which slide easily over one another, GRAPHITE…up to 600°C, MoS2…up to 450°C DECK OF CARDS Other solids include Talc, Mica, Boron Nitride, Zinc sulphide and Tungsten disulphide, similar layer structure. PTFE/ TEFLON: Very low friction solid “Described as the Slipperiest Substance in the World!” Struggles under very high load. PTFE SAMLPLES, GRAPHITE & MOLY

COEFFICIENT OF FRICTION This is a measure of the ‘slipperiness or lubricity of a system. For a simple bearing, it varies with rotational speed, loading and viscosity of any lubricant. An Inclined plane

BASIC TYPES OF LUBRICANTS OILS GREASES SOLID LUBRICANTS DRY FILM COATINGS OTHER FLUIDS

OILS LUBRICATING OILS are made from a blend of base oils and additives BASE OILS may be of many different types ADDITIVES are included to improve the performance of the base oil

TYPES OF BASE OIL VEGETABLE (OR ANIMAL) MINERAL OIL SYNTHETIC HYDROCARBON SYNTHETIC NON-HYDROCARBON *

TYPES OF ADDITIVES VI IMPROVERS CORROSION INHIBITORS ANTI-WEAR AGENTS ANTI-OXIDANTS EP ADDITIVES DETERGENTS ANTI-FOAMS

VEGETABLE OILS CHEAP BIODEGRADABLE NATURALLY VARIABLE QUALITY LIMITED RANGE UNSUITABLE FOR EXTREME TEMPERATURES CHEMICALLY UNSTABLE

MINERAL OILS CHEAP MODERATE CHEMICAL STABILITY WIDE RANGE OF GRADES NATURALLY VARIABLE QUALITY UNSUITABLE FOR EXTREME TEMPERATURES NON-BIODEGRADABLE

SYNTHETIC HYDROCARBONS PURE MOLECULES HIGHER CHEMICAL STABILITY RELATIVELY EXPENSIVE MAY BE BIODEGRADABLE

TYPES OF SYNTHETIC HYDROCARBONS POLY ALPHA OLEFINS (PAOs) Synthetic mineral oil without the impurities. Higher temperature resistance, less lacquer, same additives. POLY ALKYLENE GLYCOLS (PAGs) Can be oil soluble, water soluble or neither. Very low lacquer, higher temperature resistance. PAG additives are generally less effective. ESTERS DIESTERS. Better temperature resistance than PAGs. More expensive. TRIESTERS. Better temperature resistance than diesters. Still more expensive POLYOL ESTERS. Best temperature resistance of the esters. Unlike the previous synthetic oils these are biodegradable. Yet more expensive.

NON-HYDROCARBON OILS SILICONES Wide temperature range, high price FLUOROSILICONES Wider temperature range, higher price FLUOROCARBONS, PFPEs Widest temperature range, highest price *

BENEFITS OF NON-HYDROCARBONS COMPATIBLE WITH SEALS VERY HIGH CHEMICAL STABILITY CHEMICAL INCOMPATIBILITY EXPENSIVE TO EXTREMELY EXPENSIVE

VISCOSITY & VI Viscosity is an important parameter. Film thickness increases with viscosity, but so does friction. At low speeds, a viscous oil is best, at high speeds a light mobile fluid is preferred, as long as it is viscous enough to keep the surfaces separate! The standard temperatures of measurement are 40°C & 100°C. The unit of measurement is the ‘centistoke’ cSt. The viscosity also determines the ‘grade’ of oil. For example, ISO VG 220 oils are around 220 cSt @ 40°C The property of viscosity varying with temperature is measured by the Viscosity Index, or VI – different oils have different Viscosity indexes. The VI is calculated from the difference in the viscosity at 40 & 100°C, Less change in Viscosity with temperature = a higher VI

Oil Viscosities - Explained High Load, Low Speed High Speed, Low Load *

Conclusion :- Oils All oils are not the same Finished products are basically a blend Finished products of the same nature i.e. Esters, Mineral Oils etc. may perform differently as performance is due to specific “Additive Packages” used. Rule of Thumb – Higher the Viscosity – Lower the speed, higher the load Some Mako-Lube products have SLA’s Solid Lubricating Additives added for improved performance & friction reduction. i.e. MOS2 & Teflon/PTFE

GREASES Greases are thickened oils. Formulated greases therefore contain:- BASE OIL ADDITIVES THICKENER

COMPOSITION OF GREASES BASE OIL + (70 – 95%) THICKENER + (3 – 20%) ADDITIVES (0 – 10%) GREASE = 100 % More Common MINERAL OILS Paraffinic Naphthenic SIMPLE SOAPS Lithium Calcium Sodium Aluminium Barium (rare) ADDITIVES Corrosion inhibitors Anti wear Extreme pressure Antioxidant Polymers Anti copper Solid Lubricants Colourings Friction Modifiers Metal powders SYNTHETIC OILS Dialkylbenzène Polyalphaolefins Esters Polyglycols Silicones Perfluoropolyethers Polyphenylethers COMPLEX SOAPS Calcium Lithium Aluminium Barium (rare) INORGANIC Bentone Silica Polyurea PTFE & other solids Less Common

Grease Composition What is a Grease? A grease is a mixture of a base lubricating fluid (usually a mineral or a synthetic oil) and a thickener (usually a soap) dispersed in the oil. Designed to provide extended lubrication intervals by gradually allowing the base fluid to provide lubrication between working surfaces. More specialised greases contain additional additives to enhance high temperature and anti-wear performance and to provide corrosion protection. 31 MAY 04 31

SOAPS & COMPLEXES These are the most common greases. They contain no solid matter and are suitable for general purpose applications SOAPS are simpler cheaper formulations. Limited by melting point Most common Lithium i.e. Lithium EP 2 Grease COMPLEXES have greater resistance to high temperatures, water & steam “Act Like a Sponge” to draw the oil film back into the grease. Sponge Demo Lithium Complex, Calcium Complex, Aluminum Complex, Barium Complex etc. Properties depend upon the chemical attributes of the thickener Note: Lithium Grease & Lithium Complex have completely different performance characteristics but “Sound” the same

Grease Composition What goes into a specialised grease? Base Oil Thickener EP / Anti-wear Additives Solid Lubricants Oxidation Inhibitors Corrosion Inhibitors 33 MAY 04 33

Provides hydrodynamic lubrication Grease Composition Base Oil Provides hydrodynamic lubrication Types of Base Oil Mineral Oil (-30ºC to 150ºC) Synthetic Oil (-70ºC to 300ºC) Vegetable Oil (-10ºC to 130ºC) 34 MAY 04 34

Grease Composition Thickener Types of Thickener Acts as a sponge and releases small quantities of oil when worked Types of Thickener Soaps: Lithium, Calcium, Aluminum, Sodium Powders: Silica, Clay (Bentone), PTFE – Teflon WHEN CHANGING FROM ONE TYPE OF GREASE TO ANOTHER, ALWAYS CHECK COMPATIBILITY! 35 MAY 04 35

Grease Composition EP Additives Solid Lubricants Chlorine, Sulphur, Phosphorus. EP Additives react with the metal surface when friction generates momentary high temperatures Solid Lubricants Molybdenum Disulphide (MoS2) Graphite PTFE White Solids * 36 MAY 04 36

Grease Composition Anti-oxidants Anti-corrosion agents Protects base oil by delaying the onset of oxidation caused by high temperatures. This is one of the key ingredients in extending grease life. Anti-corrosion agents Provide protection of metal surfaces operating in wet, corrosive conditions. 37 MAY 04 37

Cone Penetration – NLGI Grading – National Lubricating grease Institute Cone is set so that it just touches surface of grease. Temp 25ºC Cone is released and allowed to sink into the grease for 5 secs. Depth of Penetration measured in 0.1mm 38 MAY 04 38

Synfood EP 2 Synfood EP 1 Synfood EP 000 HOW IS GREASE THICKNESS MEASURED? Synfood EP 2 Synfood EP 1 Synfood EP 000 NLGI 6 NLGI 5 NLGI 4 NLGI 3 NLGI 2 NLGI 1 NLGI 0 NLGI 00 NLGI 000

Consistency - NLGI NLGI No. (National Lubricating Grease Institute) No. Penetration Consistency Food Comparison 6 85 – 115 Block grease Cheddar Cheese 5 130 - 160 Extremely stiff grease Smooth Pate 4 175 - 205 Very stiff grease Frozen Yogurt 3 220 - 250 Stiff grease Lard 2 265 - 295 Standard grease (85% of grease market) Peanut Butter 1 310 - 340 Soft grease (for centralised lube systems) Tomato Paste 0 355 - 385 Very soft grease ( “ “ “ ) Mustard 00 400 - 430 Semi fluid grease Apple Sauce 000 445 - 475 Fluid ‘slumping’ grease Cooking oil Cone released onto a flattened surface of a worked sample of grease, left for 5 seconds, depth of penetration measured in 0.1mm * 40 MAY 04 40

Penetration - Grease Worker To establish “Worked Penetration”, the grease is subjected to 60 strokes in a grease worker, where the grease is forced backwards and forwards through a perforated disc. 41 MAY 04 41

Shell 4 Ball 42 MAY 04 42

Selection of the correct lubricant is key No lubricant satisfies all working conditions 68% of bearings fail prematurely Half of this due to incorrect lubrication Causes: Initial over-lubrication Over-lubrication at frequent lube intervals Infrequent lubrication Mixing greases of different types Incorrect lubricant 43 MAY 04 43

Over-lubrication Recommended lubrication 60% Over-Lubrication So often grease is applied until it is seen to extrude through the bearing housing. 44 MAY 04 44

Selection of the correct lubricant is key Why the wrong lubricant? Misjudgment of operating conditions: Temperature Water Speed Dust Load Chemicals Bearing Type Method of application Wrong recommendation by supplier 45 MAY 04 45

Selection of the correct lubricant is key Recommending an equivalent or alternative: How often does the lubricant supplier ask about the application and working conditions? How sure is the lubricant supplier that the product put forward is the best one for the job? Never match a current grease always Specifiy what “YOU” determine is best for the application ! 46 MAY 04 46

Non – Grease Compounds ANTI SEIZES-SOFT METALS Soft metals can be used as anti-seize materials (e.g. Anti-Seize 1100 ) at extreme temperatures. (i.e. over 600°C) Sacrificial layer of soft metal allows release from seizure. Nickel & Lead are toxic Copper is an environmental hazard Aluminium is not as effective at high temperatures. They are NOT greases and should not be used for bearing lubrication Used for bolts, threaded fittings, slides, sleeves etc. Protection against seizure of threads caused by high temperature or corrosive conditions, dismantled parts can be re-used *

Other Products DRY FILM COATINGS Dry film lubricants are used in many areas as a thin film of a low friction ‘paint’ or coating to provide lubrication and corrosion protection: SOLVENT / WATER DISPERSIONS – solid particles of lubricant held in a carrier solution or dispersion – Mako-Cote Range BONDED COATINGS –They contain solvent, resin (to bond to the surface) & lubricant. The dried film is resin + lubricant:- a compromise. Dry Moly & PTFE Sprays *

Conclusion :- Oils & Greases are Blends! Performance is defined by base fluid properties & additives packages etc SLA’s Reduce friction & improve performance Oils & Greases come in many different forms, Fluid, Semi-Fluid, Compounds, Greases, Water-Based, Aerosols, Trigger Sprays, Solvent Based, Resins etc

Thank you for your time! Any questions? Mako-Lube Ltd Units 2&3 Mayfield Industrial Estate Liverpool Road Irlam Manchester M44 6GD +44(0)161 777 9970 info@mako-lube.com