Improving Reliability in Pulp & Paper Facilities with perma Single-Point Lubrication Systems
Overview
One of our most recent installations took place in a pulp and paper facility, an industry known for its demanding operating conditions: high heat, humidity, dust, dirt, and moisture. Equipment in these plants often runs at high speeds, with spread-out lubrication points that are difficult to access. These challenges make reliable lubrication critical to maintaining productivity and reducing costly downtime.
The Challenge
The facility was experiencing multiple fan bearing failures across its operations.
- Bearings were exposed to high heat and humidity, leading to premature wear.
- The existing central lubrication system was not delivering consistent lubrication to critical points.
- Manual lubrication was difficult due to the hard-to-reach locations and rotating machine parts, limiting how often maintenance could be performed.
- Failures were frequent, resulting in increased maintenance costs and reduced productivity.
The Solution
perma was invited onsite to evaluate the situation. Together with the facility team, the perma team provided hands-on support, training, and installation.
- The outdated central lubrication system was removed.
- A new installation was completed: Two-point heavy-duty bracket kits with single-point lubricators were installed. Each lubricator was configured to feed both the top and bottom bearings of the fans.
- In total, 21 fans were equipped, with lubricators installed at each bearing point.
- The installation was done by perma ensuring full product support and reliability.
Key Benefits & Results
Consistent lubrication: Bearings now receive precise lubrication directly at the point of need.
Reduced failures: Early signs show a significant reduction in bearing breakdowns compared to the previous system.
Improved safety: Maintenance staff no longer need to access dangerous or hard-to-reach lubrication points as frequently.
Training & support: perma’s onsite involvement & perma Academy ensured proper installation and empowered the facility team with knowledge for ongoing maintenance.
Future Plans
The facility plans to expand perma lubrication solutions to other applications throughout the plant, including pumps, dryers, conveyors, and motors. By leveraging advanced systems like perma STAR VARIO (with direct or remote mounting and digital monitoring via perma CONNECT), operators will gain:
- Centralized management of lubrication points.
- Real-time monitoring of lubrication status.
- Improved coordination of maintenance schedules.
- Enhanced workplace safety by relocating lubrication tasks to accessible areas.
"By replacing a failing central lubrication system with perma's single point lubricators, this pulp and paper facility has taken a major step toward eliminating fan bearing failures, improving safety and setting the foundation for a digitally connected lubrication ecosystem."
Industry Context
The pulp and paper industry operates under extreme conditions and faces mounting challenges: rising energy costs, stricter safety and environmental regulations, along with intense global competition. To stay competitive, facilities must boost productivity while reducing operating costs. One of the most effective ways to achieve this balance is through reliable lubrication systems.
Key Mechanical Challenges:
- High temperatures in dryers and digesters cause rapid bearing wear without proper lubrication.
- Moisture, steam, and chemicals wash out lubricants and corrode components.
- Dust, fibers, and dirt infiltrate lubrication points, accelerating failures.
- Hard-to-reach lubrication points make manual servicing inconsistent and unsafe.
- High-speed rotating equipment generates friction and heat, leading to bearing seizures.
- Thousands of lubrication points across a single mill make manual lubrication time-consuming and error-prone.
Proper Lubrication Technique as the Fix:
- Reduces bearing failures and unplanned shutdowns.
- Improves worker safety by minimizing hazardous manual lubrication tasks.
- Extends equipment life under harsh operating conditions.
- Boosts productivity with continuous, precise lubrication.
- Supports sustainability by reducing wasted energy and replacement parts.
Challenges in pulp and paper are mechanical reliability, safety, and maintenance efficiency. Advanced lubrication systems from perma directly address these issues, keeping bearings, gears, and motors running even in the toughest environments.
