In March 2020, a new regulation mandated the use of food-grade lubricants in the UK animal pellet feed sector. This article provides an overview of the adoption of food-grade lubricants in this sector and presents a case study highlighting the benefits of choosing a high quality, application specific product.
Introduction
The production of animal pellet feed is a crucial industry in the United Kingdom, serving as the backbone for the livestock and pet food sectors. To ensure the highest standards of food safety, a new regulation was introduced in March 2020 requiring the use of food-grade lubricants in all pellet press applications. This shift towards food-grade lubrication has had a significant impact on the industry, prompting companies to re-evaluate their lubrication strategies and product choices.
The Case Study: A Shift to Food-Grade Lubricants
One company's experience serves as a compelling case study of the transition to food-grade lubricants. The company had traditionally used industrial-grade grease in its pellet press applications for many years. However, following the regulatory change, they transitioned to a semi-synthetic food-grade grease in April of the previous year.
Soon after the switch, the operators encountered several issues. The new grease left no residue within an hour of operation, necessitating frequent re-greasing with approximately 50 shots of grease per application. The presses, which operated under high temperatures and loads due to the use of steam, experienced increased wear rates despite the increased grease usage, with grinder bearing failures every 4 months on average.
This had a knock-on effect on the rolls, with the company writing off several sets due to excessive wear and flat spots. This, in turn, damaged the dies, adding to the downward trend in reliability and spiralling maintenance costs.
The Solution: Activate Foodcare Pelletex
Recognising the need for a superior lubrication solution, the company turned to Activate Lubricants and their specialised product, Activate Foodcare Pelletex. Upon transitioning to this high-performance food-grade pellet press grease, immediate improvements were observed. The grease remained visible at the end of the shift, and the re-greasing requirement decreased significantly, from 50 shots to just a few.
During the Pelletex trial and subsequent 12 months of use, there were zero bearing failures and therefore no knock-on damage to rolls and dies.
Measurable Benefits
The results of this transition were not only visible but also quantifiable:
Combined engineering costs reduced by £50,000 annually.
Additional runtime value of over £240,000 annually.
Remarkably, the performance of Activate Foodcare Pelletex exceeded that of the industrial grease previously used, demonstrating the clear advantages of adopting the right food-grade lubricants.
Conclusion: Investing in Efficiency and Reliability
The case study presented here underscores the importance of adhering to regulatory requirements and choosing high-quality lubricants in the animal pellet feed sector. The return on investment in a dedicated lubrication improvement plan, coupled with the use of premium synthetic products, is evident in the significant cost savings achieved and runtime won back.
Product Information: Activate Foodcare Pelletex
Activate Lubricants offers the ideal solution for those seeking a fully compliant, reliable food-grade grease for pellet presses, crucial components in feed mills. Available in NLGI grades 1 or 2, and in 12.5kg, 50kg and 180kg sizes, Activate Foodcare Pelletex is a high-performance food-grade pellet press grease designed to enhance efficiency, reduce breakdowns, and extend the life of machinery and assets.
This lubricant is manufactured in the UK and is available for next-day delivery from UK stocks.
As a manufacturer and supplier of specialist Feed Mill food grade lubricants, Activate Lubricants ensures all products are 100% foodsafe, non-toxic, and crafted to handle the demanding conditions of pet and animal food-processing plants.
In a sector where food integrity and safety are paramount, the adoption of food-grade lubricants has become not only a regulatory requirement but also a key driver of enhanced performance and cost savings. The top 5 feed groups in Europe are already using Pelletex to their commercial advantage.
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