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Dow Corning introduces 42 new food-grade industrial lubricating fluids in Europe

Dow Corning - EEI : 05 May, 2007  (New Product)
Dow Corning has expanded its line of industrial lubricants for customers in Europe by adding 42 new food-grade synthetic fluids and ultra high-purity mineral oils that can last up to ten times longer than conventional products.
Marketed as “Molykote brand High-Performance Industrial Fluids,” the new fluids are particularly suited for plant operations in the food and beverage industry due to their resistance to emulsification with water, which causes viscosity degradation that contributes to mechanical wear and premature loss of machine usefulness. Molykote fluids are available in a wide range of viscosities, and are formulated for use in hydraulic, compressor and vacuum pumps; gearboxes, chains; and a wide variety of machines and components. The Molykote fluids conform to requirements under H-1 or H-2 designations of the U.S Department of Agriculture and many are kosher approved.

Lubrication Solutions for Virtually Every Plant Lubrication Need
These new fluids are part of the “Molykote Lubrication Management Program” from Dow Corning, which is designed to help customers reduce overall maintenance costs, extend equipment life, and simplify the purchasing process. The Program offers products and services to meet virtually every plant lubrication need.

In addition to the new fluids, the Molykote brand product line includes the company’s traditional offering of specialty greases, compounds, pastes, anti-friction coatings, and dispersions. To meet the dramatic temperature variations from freezers to ovens, the product line includes lubricants with operating temperature capabilities ranging from, 226°C to 1400°C (-375°F to 2550°F).

The Program features an Integrated Oil Analysis Service, lubrication management software, and local technical support. In addition to their use in the food and beverage industries, Molykote fluids and lubricants are typically used in chemical/petrochemical processing, automotive manufacturing, power generation, and the pulp and paper industries as well as a wide variety of maintenance and repair operations in general business and industrial facilities. The Program was introduced in North America last year and is being extended to customers in Europe, South America, Mexico and Asia.

Resists Oxidation, Emulsification With Water
The superior performance of Molykote industrial lubricants is mainly due to a proprietary additives package that significantly reduces oxidation rates due to elevated pressures and temperatures, which can cause premature lubricant breakdown. In addition, their special “engineered” base fluid chemistry makes them inherently more resistant to oxidation and emulsion than competitive products.

Whereas most competitive mineral oils are manufactured by refining, a solvent-based process that can retain contaminants from the crude-oil source, Molykote mineral oils are custom engineered at a molecular level to formulate unique, ultra-high purity base oil that meets target performance specifications. This process also avoids problems associated with conventional solvent-refined mineral oils, which retain contaminants that can lead to acid development and premature aging of the oil.

Longer Service Life
Molecular reconstruction makes it easier for Dow Corning to tailor lubricant properties to meet customer requirements. And, for even better performance, Dow Corning blends its ultra-high purity mineral oils with powerful synthetic polyalpha olefin oils, which are well known for their hydrophobic properties. The resulting molecules are super-saturated; which provides increased resistance to oxygen attack and heat-generating friction. Synthetic lubricants achieve full lubrication more quickly at start-up, so the Molykote brand PAO fluids and MO/PAO blends reduce component wear. Furthermore, the synthetic lubricants’ resistance to oxidation and other contaminants leads to longer service life, more efficient lubrication and less formation of undesirable by-products in the lubricant. The blends offer lower pour points, more stable viscosity in wider temperature ranges, and even longer service life. In addition, the saturated molecular structure of these unique blends has no receptive sites to attract water, which makes Molykote fluids inherently better able to resist emulsification in high-moisture environments than competitive lubricants.

The resistance to emulsification virtually eliminates problems associated with high-humidity environments where conventional fluids tend to bond to water, which causes oil breakdown and a build up of varnish, sludge and/or deposits. Molykote fluids are particularly suited for use in humid climates and wet processing environments. And, since Molykote brand fluids provide less misting from vacuum-pump discharge and are low odor, they are particularly ideal for use in the food processing industry.

“This is a common problem in these environments,” says Jim Stutelberg, lubrication channel manager for Dow Corning. “In the food and beverage industry, for example, the environment is often wet due to the nature of the manufacturing process itself as well as the daily wash downs,” he explains.

Resistance to emulsion is due to the nature of the base oils themselves, which include poly alpha olefin synthetics and high-purity, hydrocracked mineral oils designed to extend oil life and improve machine efficiency. The synthetic formulations are inherently highly resistant to emulsification with water. And, unlike traditional mineral oil formulations, the hydrocracked Molykote mineral oils resist emulsification due to their ultra-high purity, which also contributes to extended oil life and improved additive performance. In addition, both base oils feature anti-oxidant additive packages based on new proprietary technology that extend service lifetime beyond conventional oils.

Total Industrial Lubricant Consolidation
With the addition of its new line of high-volume Molykote brand fluids to the company’s line of specialty industrial lubricants Dow Corning says it now offers the most complete selection available to meet virtually every plant lubricant need.

“The Molykote Lubrication Management Program offers the world’s most complete package of industrial lubricants and related services available,” says Stutelberg. “Other companies offer parts of the package, but none offer one as complete as this one. What makes this point compelling is that by consolidating lubrication purchases, customers can produce better bottom-line results than what is otherwise possible while at the same time simplifying the purchasing process.”

Stutelberg explains that the new offerings dramatically expand the company’s ability to provide a complete range of solutions for industrial lubrication.

“Our intention is to be the preeminent industry leader in industrial lubrication,” he says. “This is the most extensive and most complete package of industrial lubricant supply, services and expertise that is available from a single company. We believe prospects for success are excellent because it is designed to meet customer demands for significant efficiency improvements and reduced costs than what is otherwise possible.”

Longer Lifetime, Reduced Cost
Dow Corning claims longer equipment lifetime will result from better lubricant selection and consolidation, superior lubricant performance, and integrated oil analysis. Reduced overall maintenance cost will result from extension of oil service intervals, longer oil life, and work saved by effectively applying lubrication maintenance scheduling software. “Consolidating to Dow Corning’s lubrication program will also result in savings and management benefits by simplifying the purchasing process,” said Stutelberg.

Integrated Oil Analysis. Unlike typical oil analysis programs, the Integrated Oil Analysis Service from Dow Corning contains a proprietary aging marker that tells exactly how Molykote brand fluids have aged and, given specific application requirements, precisely when to change them. In addition, the analysis measures seven critical content factors to determine deviations from each product’s original content. This helps track wear trends, maximizes product lifetime, and ensures that the right product is used for each application.

Lubrication Management Software. This service offering also includes Lube-ItTM management software and SurveyViewTM data base software, which help customers achieve significant savings by enabling them to automate the lubrication management process. This state-of-the-art software tracks and schedules thousands of lubrication operations to ensure accurate, cost-effective maintenance of plant lubrication. It does so by helping customers optimize lubrication routes and schedules, and by keeping records and procedures on every lubrication point in their plant, or multiple plants. In so doing, this software provides lubrication maintenance crews with the critical information they need, when they need it, and in virtually the most reliable, cost-effective manner possible.

Dow Corning claims six categories of benefits for a typical industrial customer who consolidates with this product and service package:

Better return on capital investment through longer machine life
Improved overall productivity through extended fill intervals
Streamlined inventory through elimination of items with similar properties
Better preventative maintenance through integrated oil analysis
Better equipment performance through selection and quality of lubricant
More effective maintenance management through better informed decision making

Even without total consolidation, many plants can expect to take advantage of the oils’ superior performance and gain immediate savings from reduced oil consumption, reduced disposal cost, labor savings and fewer production interruptions. For instance, new technology oils for gearboxes and chains extend service life and prevent wear and process interruptions in power transmission systems and components. Synthetic air compressor oils are formulated to offer greater resistance to oxidation and stable performance at high temperature and under high loads, compared to conventional lubricants.

The company's line of oils for compressors and vacuum pumps is formulated to meet or exceed the performance of all comparable OEM fill products. Synthetic grade compressor and pump oils are also compatible systems designed for mineral oil lubrication.

The single-source Lubrication Management Program can minimize inventory working capital through product consolidation, reliance on local partner inventory and use of longer lasting products. Other general management benefits include standardized product identification and single sourcing of food-grade lubricants.

The package of Molykote brand lubricants from Dow Corning and related services is being implemented as a comprehensive program through the company’s channel partners with field locations throughout the world.

Dow Corning currently offers more than 7,000 products to customers around the world. Dow Corning is a global leader in silicon-based materials with shares equally owned by The Dow Chemical Company and Corning Incorporated. More than half of Dow Corning's sales are outside the United States. Molykote has been a well-known brand for industrial lubrication Globally since the 1950s.
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