Molykote® Synthetic Fluids Offer up to
40% Better Cost/Performance Over
Conventional Mineral Oils
Smart Lubrication™
ECONOMIC MODEL
Plant Lubricants
Maintenance managers may achieve UP TO a 40 percent cost saving in air
compressor maintenance and better efficiency from gearboxes by replacing
conventional mineral lubricants with Molykote® brand synthetic lubricants
in high-volume applications. Here’s an analysis explaining how the benefits
are achieved.
Formulation saves money by
extending oil lifetime and lowering
labor workload.
Reduced Compressor Maintenance Cost
Lubricating rotary screw and reciprocating compressors with Molykote®
Synthetic Compressor Oils is a cost-effective way to extend maintenance
intervals and optimize compressor performance. Savings are possible
beacuse synthetic oils greatly extend changeout intervals and eliminate
varnish buildup inside compressors.
For example, a rotary screw compressor system requiring 30 gallons of
lubricant typically needs only one fill of Molykote Synthetic Compressor Oil,
compared with five fills of conventional mineral oil in the same time period.
This represents a saving in oil cost of about 13 percent. Add to this the
savings in labor, fluid disposal, less frequent demister changes, and the total
annual cost saving is 40 percent. Details are provided in the table below:
Table I: Annual Cost of Compressor Fluid Changeouts Reduced by $650 – 40%
Oil Type
Cost per
Change
Molykote® L-1200
Series Synthetic
Compressor Oil
$780
(30 gallons
@ $26/gal)
Mineral Oil
$150
(30 gallons
@ $6/gal)
Total Fluid
Cost
Total Labor
Cost
Total Fluid
Demister
Disposal Cost Change Cost
Grand Total
Annual Cost
1X
$780
(30 gallons
@ $26/gal)
$995
(2 hours
@ $30/hr)
$995
(30 gallons
@ $1.50/gal)
$995
(once/year)
$995
5X
$900
(150 gallons
@ $6/gal)
$300
(10 hours
@ $30/hr)
$225
(150 gallons
@ $1.50/gal)
$220
(twice/year)
$1,645
Fills per Year
Gearbox Efficiency Improvements
Using Molykote® Synthetic Gearbox Oils should also reduce costs associated
with maintaining and lubricating gearboxes throughout the plant. Because
the synthetic gearbox oils typically last about three times as long as conventional mineral oil products, the annual cost in each case is about the same.
This chart compares the costs:
Table II: Comparative Annual Cost of Gearbox Oils*
Oil Type
Cost per
Change
Fills per Year
Total Fluid
Cost
Total Labor
Cost
Total Fluid
Grand Total
Disposal Cost Annual Cost
Molykote®
Synthetic Gear Oils
$130
(5 gallons
@ $26/gal)
1X
$130
(5 gallons
@ $26/gal)
$15
(.5 hours
@ $30/hr)
$7.50
(5 gallons
@ $1.50/gal)
$152
Mineral Oil
$30
(5 gallons
@ $6/gal)
3X
$90
(15 gallons
@ $6/gal)
$45
(1.5 hours
@ $30/hr)
$22.50
(15 gallons
@ $1.50/gal)
$157
*5 gal. fill, mfr. rec. 2500-hr. service.
The Real Payoff Is in Performance
Because the synthetic gearbox oil lubricates more efficiently, it reduces the
amount of horsepower required to achieve a targeted level of torque. Unit
efficiencies are significantly improved by the use of synthetic lubricants,
so that the input horsepower consumption will be less for a given torque
capacity.
Table III: Comparative Input HP Needed to Achieve Output Torque Rating of Worm Gear Speed Reducers*
Gearbox Lubricant
Input RPM
Input HP
Output Torque
HP Savings
Molykote®
Synthetic Gear Oil
1750
0.35
557
16.6%, compared
to mineral oil
Conventional
Mineral Oil
1750
0.42
557
*Example is a 2-inch center distance, 60:1 ratio. Improvement in efficiency increases as ratio increases.
Improved lubricant performance and gearbox efficiencies associated with
synthetic lubricants offer several benefits. The energy that would have been
lost to friction is saved. Lower power consumption reduces cost. Less friction
means lower operating temperatures. Gearboxes with synthetic oils suffer
less wear during warmup from starting. Gearboxes filled with synthetic oils
run cooler, which means that the lubricant may last even longer than its
rated lifetime.
Keys to Performance
Both the cost/performance and efficiency improvements result from the
lubrication performance of synthetic Molykote products.
Because conventional mineral oils are produced in a conventional refining
process, they contain a significant amount of “impurities.” The high
percentage of impurities shortens the oil’s service lifetime by providing
many sites for oxidation to occur. Above the operating temperature range
of 140-160°F, the lifetime of a mineral-based lubricant is cut in half by every
20°F increase in temperature. As a mineral oil degrades, by-products of its
breakdown may cause a build-up of a hard, sticky “varnish” on the internal
metal surfaces. This build-up adversely affects performance.
By comparison, synthetic lubricants are made by chemically building complex
molecules from hydrocarbon “building blocks.” They feature identical,
strong molecular bonds in a saturated molecular structure. This provides
more resistance to oxygen attack at rated operating temperatures and less
heat-generating friction. Synthetic lubricants achieve full lubrication at
start-up more quickly and, therefore, reduce component wear. The synthetic
lubricant’s resistance to oxidation and other properties leads to longer
service lifetime, more efficient lubrication and less formation of undesirable
by-products in the lubricant.
Synthetic lubricants offer another benefit to food and beverage processors.
Many food plants have adopted a policy of using only food-grade synthetic
lubricant products for their MRO needs. All Molykote Synthetic Compressor
and Gearbox Oils are available in formulations that are approved for use in
food processes according to USDA standards. Price/cost benefits are detailed
in the tables. Standardizing on food-grade products eliminates the possibility
that plant workers will confuse food-grade and non-food-grade products.
Summary of Typical Benefits
• Fewer oil changes
• Lower waste lube disposal costs
• Fewer filters
• Lower labor costs
• Power and energy savings
• Lower operating temperatures
• Fewer replacement parts
• Fewer scheduled maintenance interruptions
• Fewer breakdowns/unscheduled interruptions
WARRANTY INFORMATION – PLEASE READ CAREFULLY
The information contained herein is offered in good faith and is believed to be accurate. However,
because conditions and methods of use of our products are beyond our control, this information
should not be used in substitution for customer’s tests to ensure that Dow Corning’s products are
safe, effective, and fully satisfactory for the intended end use. Dow Corning’s sole warranty is that
the product will meet the Dow Corning sales specifications in effect at the time of shipment. Your
exclusive remedy for breach of such warranty is limited to refund of purchase price or replacement
of any product shown to be other than as warranted. Dow Corning specifically disclaims any other
express or implied warranty of fitness for a particular purpose or merchantability, unless Dow Corning
provides you with a specific, duly signed endorsement of fitness for use. Dow Corning disclaims
liability for any incidental or consequential damages. Suggestions of use should not be taken as
inducements to infringe any particular patent.
Dow Corning and Molykote are registered trademarks of Dow Corning Corporation.
We help you invent the future is a trademark of Dow Corning Corporation.
©2000 Dow Corning Corporation. All rights reserved.
Printed in USA
AGP12457
Form No. 10-1016A-01