CASE STUDY - Automatic Grease System for Concrete Batch Plant

Location: Dallas, TX
Date: September 2021
Application: Ready-Mix
Client:  Independent Dry Batch Ready-Mix Concrete Producer in North Texas

Key Outcomes:

• Developed a custom lubrication design to improve bearing and gate maintenance

• Lowered grease consumption about 44%

• Enables a safer working environment to meet OSHA regulations

• $4,000 In estimated annual labor savings

Bill Spitzer & Associates delivered a modern way to simplify concrete plant grease lubrication, increase personnel safety, and achieved ROI between 2 to 3 months.

Overview:

Besides water, concrete is the most consumed and used product in the world and is manufactured in several ways with various types of equipment.  All the required manufacturing equipment requires lubrication to assure the concrete is mixed and transported to specification and location.

Site Facility Situation:

The client wanted to discover safer methods to lubricate their ready-mix concrete plant and decrease maintenance costs.  As a result, Bill Spitzer & Associates (BSA) visited the site and quickly designed an automatic grease system that would save time and improve safety.  The 12 volt 8L pump operates every 2 hours with a calculated delivery of lubricant to the 28 points on the batch plant.  The grease reservoir is large enough to enable a full week (5-7 days) of production before refilling is needed.  BSA installed the entire system within 10 hours, with 2 technicians, around the organizations operation schedule.  Everything went according to plan and will install similar lubrication systems on the other plants.  Additionally, BSA will develop auto-lube systems for the ready-mix trucks 24 lubrication points.      

Bill Spitzer & Associates (BSA) can create customized systems to fit the client’s needs, obstacles, or specifications for any concrete manufacturing plant.  The customized approach enables BSA to provide a turnkey solution for design, installation, commission, and preventative maintenance.

Bill Spitzer & Associates Automatic Concrete Plant Grease System & Service:

• Diagnosis, System Design, Installation, Commissioning, and Preventative Maintenance

• Review application requirements, operating conditions, location, and access by on-site walkdown of the facility

• Determine the most reliable method of delivering grease to bearings and the metering devices, supply and distribution piping/tubing, and lubrication rates

  • Motor driven pumps, pneumatic pumps, & manual pumps

  • Divider blocks or injectors

  • Pressure switches & gauges, cycle switches, controllers, custom panels, & tubing recommendations

• Field matter experts install grease system and provide commissioning, start-up, and training

• Overview of preventative maintenance plan that fits the needs of the system and customer

• Ideal for Ready-Mix, Precast, Prestress, Drycast, Central Mix, Paver, Block, and Pipe Plants

 BSA Automatic Grease System:

• Quicklube Motor Driven Grease Pump

• Divider Block, Divider Valves, Proximity Switch, and Adapters

• Stainless Steel Tubing, Fittings, and Gauges

• 16 lb. Reservoir

• Low Level and Gault Indication

• 1/8” Hose and Reusable Hose Ends

• Guarding Accessories

• On-Site Installation and Commissioning

  • Available to install during business hours, after hours, Saturdays, and Sundays

 Results:

• 28 Points of lubrication

• 2 Total planned installation days

• 0 Change orders & on-time installation

• ROI was achieved between 2 to 3 months

• $4,000 Estimated annual labor savings

• Lowered grease consumption about 44%

• Enabled a safer working environment to meet OSHA regulations