Lubricants forcontinuous extrusion

Your specialist for extruder gearbox oils

Lubrication is our World

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Content Page

Oiling your productivity 3

The chemistry’s right 4

Specialized to fulfill maximum requirements

Klübersynth GH 6 oils 5

Klübersynth GEM 4 N oils 6

Klübersynth UH1 6 oils 7

Klüberoil GEM 1 N mineral oils 8

Solutions for your productivity

Testing is part of our service 9

Your partner in development 9

Quality pays

Saving potential for extruder gearboxes – example 10

Your benefit 11

There for you – around the world 12

Product overview 12

Request for Information 14

❑ Increased efficiency throughreduced coefficient of friction

❑ Reduced energy consumptionand associated costs

❑ Reduced operating andmaintenance costs

❑ Reduced wear and prolongedmachine service life

❑ Extended oil change intervals(15,000–25,000 h)

❑ Increased oil service life (3–5 times)

❑ Minimal oil consumption andassociated costs, together withthe consequent reduction inused oil quantities and disposalcosts

Benefits:

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Whether operating continuously, 24 hours a day, 365 days a year, orsubjected to daily start-up, demandson plastic extruders are constantlyincreasing. Thanks to the implementa-tion of optimized gear drives andscrews, extruder throughput has dou-bled over the last few years. Operatingconditions for the entire drive and lubri-cation regime have changed in line with

Oiling your productivity

these new demands: Torque, tempera-tures and loads have increased asmachine design has become morecompact, thus increasing the require-ments made on gear oils. Mineral oilsare now reaching the limits of theircapabilities, and because a reliablelubricant film needs to be formed undera wide range of service conditions, syn-thetic oils are coming into their own.

We can support you in selecting thecorrect gear oil for your drive, as yourchoice of lubricant will affect the long-term operational reliability, up-time and profitability of your machinery. Synthetic gear oils, such as Klübersynth GEM 4 N, KlübersynthUH1 6 and Klübersynth GH 6 offer asignificant number of advantages overstandard mineral oils.

Continuous profit with continuous profiles through continuous productivity

We also provide consulting service and technicalsupport for product changeover. Bringing you:

Optimized performance, productivity and profitability.

Synthetic gear oils, such as polyglycolsand polyalphaolefins, which are thebase oils of our Klübersynth productlines, should offer similar compatibilitywith seals, viewing glasses and gearhousing paints as well-establishedmineral oils.

As part of the Freudenberg Group,Klüber Lubrication cooperates closelywith Freudenberg Seal and VibrationTechnology, the market leader forextruder gear seals. Therefore, Klüberspecial lubricants offer good compati-bility with NBR and FKM sealing mate-rials, and test data to back it up.

Gear oil approvals from various gearmanufacturers and the long-standingexperience of gear operators are proofthat our chemistry is right.

In our laboratories, we can also checkthe compatibility of our special oilswith the seals, interior paint andviewing glasses of your extrudergearboxes.

Klüber chemistry supports yourproductivity.

The chemistry’s right

The quality of the base materials we use

is not tied to any one manufacturer, which

ensures that all our high-performance

gear oils, greases and other special

lubricants contain base materials with the

highest quality characteristics. This is an

additional benefit for you.

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These synthetic high-performanceextruder gear oils, based on polyglycoloil, offer the following excellent perfor-mance characteristics:

❑ Higher load-carrying capacityimproves wear protection andoperational reliability under highloads. In the enhanced FZG FourSquare Gear Oil Test (A/16.6/140),these oils achieve a scuffing loadstage >12 and a specific change inweight < 0.2 mg/kWh. KlübersynthGH 6 oils also offer excellentmicro-pitting resistance.

❑ A consistent lubricant film isformed under full load at tempe-ratures up to 160 °C due to thehigh viscosity index of the poly-glycol base oil. This ensurestrouble-free production even undersevere operating conditions.

Specialized to fulfill maximum requirements

❑ High efficiency reduces opera-ting costs and prolongs the ser-vice life of your machines. Lowerwear, reduced energy consumptionand costs.

❑ Oil change intervals of up to 5 years or 25,000 service hoursare achieved due to specific addi-tives which improve the oxidationstability and ageing resistance ofthe oil. This results in lower oilconsumption and disposal costswhile increasing operating effi-ciency and cost effectiveness.

❑ Good compatibility with NBRand FKM sealing materials.

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Extruder gear oils need to fulfill continuously rising demands. We have developedsynthetic gear oils to meet these exceptionally high requirements and are dedi-cated to being your specialist partner for maximum demands.

We recommend checking compatibility of the materials used with the selected lubricants,especially prior to series production.

Klübersynth GH 6 oils – take performance to the limit

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Based on synthetic polyalphaolefinoils, this product line offers some ofthe well-proven characteristics of min-eral oils, while providing the addedbenefit of synthetic chemistry. Klübersynth GEM 4 N oils are misciblewith mineral oil products and, there-fore, are the perfect choice for a quickchangeover from mineral to syntheticgear oils:

❑ Special additives extend oilchange intervals to up to 3 yearsor 15,000 service hours. Youradvantages: less downtime, lowermaintenance expense, less oil con-sumption and reduced disposalcosts.

❑ Better wear protection and ope-rational reliability through opti-mum load-carrying capacity. In the enhanced FZG Four SquareGear Oil Test (A/16.6/140), theseoils achieve a scuffing load stage>12 and a specific change inweight ≤ 0.2 mg/kWh. Klübersynth GEM 4 N oils alsooffer high micro-pitting resistance.

❑ Trouble-free operation under fullload and high temperatures dueto a high viscosity index.

❑ Reduced operating coststhrough optimized efficiency.Lower energy consumption, morecost effectiveness and longermachine service life.

❑ Good compatibility with NBRand FKM sealing materials.

Klübersynth GEM 4 N oils – rapid changeover to synthetic technology

We recommend checking compatibility of the materials used with the selected lubricants, especially prior to series production.

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Klübersynth UH1 6 is not only anexcellent gear oil for extruders operat-ing under high loads: This product lineis based on a special polyglycol oil andoffers you all important food industryapprovals and homologations. Theycomply with the German law governingfoodstuffs and associated ancillaries(LMBG, §5 para 1/1) and meet therequirements set forth in the guidelinesof sec. 21 CFR 178.3570 of FDA regu-lations. Klübersynth UH 6 oils are NSFH1 registered so you can manufactureyour products safely for any type ofcustomer whilst retaining all the advan-tages of synthetic lubricating oils:

❑ Oil change intervals are 3 timeslonger thanks to the high ageingand oxidation resistance of theseoils. The benefits are extended ser-vice life and lower maintenancecosts.

❑ Less wear and longer machineservice life thanks to trouble-freeoperation, even under full load. Inthe enhanced FZG Four SquareGear Oil Test (A/16.6/90), these oilsmeet the requirements of loadcarrying capacity > 12 and a speci-fic loss of weight < 0.2 mg/KWh.

❑ Reduced operating costs due toimproved efficiency. Lowerenergy and oil consumption plusreduced disposal costs whileensuring higher cost effectivenessand extended machine life.

❑ Good compatibility with NBRand FKM sealing materials.

Klübersynth UH1 6 oils –designed for the food industry

We recommend checking compatibility of the materials used with the selected lubricants, especially prior to series production.

While mineral oil performance cannotbe compared with synthetic oils, thereare still significant performance differ-ences among the various mineral oils.Our Klüberoil GEM 1 N oils are top-quality products based on the carefulselection of ingredients and over 75years of experience in the formulationof special lubricants, offering excellentprotection against corrosion, wear,oxidation and ageing:

❑ Klüberoil GEM 1 N oils offergood wear and corrosionprotection achieving a scuffingload stage > 12 (A/8.3/90) in theFZG Square Gear Oil Test and ahigh micro-pitting resistance. They also meet the API GL4requirements.

❑ These oils offer good compatibi-lity with all non-ferrous metals,sealing materials and most com-monly used gearbox paints.

❑ Klüberoil GEM 1 N oils extendthe service life of your gearboxbearings. Long-term tests on theFAG FE8 test rig indicate theexcellent properties of these well-proven high-performance andmulti-purpose oils.

Klüberoil GEM 1 N mineral oils –proven quality

We recommend checking compatibility of the materials used with the selected lubricants, especially prior to series production.

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❑ Lower friction

❑ Increased efficiency

❑ Less wear

❑ Higher operational reliability

❑ Reduced machine down-time

❑ Extended machine lifetime

Friction-free productivity.

Under maximum operating conditions, 24 hours a day – 7 days a week,production and operational reliability are issues of top priority. Machine down-time can lead to considerable costs. Synthetic high-performance extruder gearoils, particularly polyglycols such as Klübersynth GH 6 and UH1 6, offersignificant advantages in preventative maintenance:

Solutionsfor your productivity

Testing is part ofour service

When oil change intervals are fivetimes longer than you’re used to, it’sreassuring to conduct regular used-oilanalysis. You’ll see the proof in testresults. This service is available tocustomers using either our synthetic or mineral based products.

Your partner indevelopment

We offer our development partnershipto machinery manufacturers. With over75 years experience in the research,development and application of lubri-cants, we can provide in-depth know-how and the use of more than 100 testrigs. When possible, we test our lubri-cants on OEM original equipment and,when required, are able to design cus-tomized test rigs.

Our objective? Developing a highperforming lubricant that fulfills all ofyour expectations and creating a long-lasting partnership with you.

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Saving potential for extruder gearboxes – example

Quality pays

Mineral oil Polyglycol

2 €/l 7 €/l

98.0 98.5

181,000 kWh 136,000 kWh

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750 l 200 l

1,500 € 1,400 €

12,670 € 9,520 €

3,750 € 1,000 €

6,000 €

Lubricant purchasing costs

Efficiency

Power loss

Oil changes during machine lifetime

Total oil quantity during machine lifetime

Costs of oil

Costs of energy losses

Costs of oil changes

Cost savings with polyglycol oil

Saving potential for extruder gearboxes – example

Worm size: 90 single-screw extruder

Oil sump temperature: approx. 70 °C

Drive capacity: 93 KW

Operating time per annum: 6500 h

Machine lifetime: 15 years

Oil filling: 50 l

Electricity: 0.07 €/KWh

The calculation does not account for increased up-time and productivity of themachines.

Your investment is worthwhile.

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The investment in synthetic oils pays off due to theirextended oil change intervals. Cost effectiveness isenhanced by lower oil and energy consumption, reduceddisposal costs, less wear and extended machine lifetime.

Energy costs–> lower energy consumption

Oil costs–> prolonged oil change

intervals–> lower maintenance costs

Maintenance costs –> extended machine life due

to lower wear–> reduced maintenance costs

Operational costs –> less down-time of machinery

particularly with 24 houroperation, 7 days a week

–> lower running costs

Savings on your extruder gearboxes with Klüber Lubrication special gear oils

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Your benefit

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Product overviewExtruder gear oils

Klüberoil GEM 1 N

Klübersynth GEM 4 N

Klübersynth GH 6

Klübersynth UH1 6

Product name of Oiltype ISO VG RemarksKlüber gear oil DIN 51519

Mineral oil

Polyalphaolefin

Polyglycol

Polyglycol

100 to 680

100 to 680

100 to 1000

150 to 680

Standard high-performance

gear oil

Synthetic high-performance

gear oil for extended service

life

Synthetic gear oil with excellent per-

formance characteristics for high

loads and extremely long service life

To fulfill additional requirements made

by the food and pharmaceutical industry

As a lubrication specialist for all industries, Klüber Lubrica-tion operates worldwide. Our global network of productionand sales companies ensures that we are nearby for opti-mum customer care and service.

On the reverse of this brochure you will find a contactpartner for your region, eager to answer your questions on lubrication.

You will find additional, comprehensive information in our product information leaflets, which you can order under+49 89 78 76-0. Or visit us on our websitewww.klueber.com.

There for you – around the world

K e ep

the

wo

rmt u rning!

Synthetic extruder gear oils from the specialist source: Klüber Lubrication.

Some run 24 hours a day, 365 days a year, others are brought up from zero to full speed day after day:

at any rate, extruders operate under increasingly demanding conditions – yours won’t be an exception.

For a higher output and optimised operation, we offer innovative, synthetic special gear oils. Low friction

coefficients lead to higher machine power combined with less wear and energy consumption. Oil change

intervals can be extended three to five fold, service lives increased and operating costs reduced. We also

offer oil analyses as part of our standard service. So make sure the worm turns for you. Call us.

Klüber Lubrication München KG · Geisenhausenerstraße 7 · 81379 München · GermanyA company of the Freudenberg Group

Tel. +49-89-78 76 404 · Fax +49-89-78 76 333 · www.klueber.com

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Publisher and Copyright:Klüber Lubrication München KG

Reprints, total or in part, are permittedif source is indicated and voucher copyis forwarded.

9.40 eEdition 03.05

The data in this technical brochure isbased on our general experience andknowledge at the time of printing andis intended to give information ofpossible applications to a reader withtechnical experience. It constitutesneither an assurance of productproperties nor does it release the user from the obligation of performingpreliminary tests with the selectedprodcut. We recommend contactingour Technical Consulting Staff todiscuss your specific application. If required and possible we will be pleased to provide a sample for testing.

Klüber products are continually im-proved. Therefore, Klüber Lubricationreserves the right to change all thetechnical data in this technicalbrochure at any time without notice.

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Would you likemore detailed informationon our product range?

Do you needMaterial Safety Data Sheetson any of the above products?

You can orderusing the form overleaf or ourwebsite www.klueber.com.