How Luck Stone was able to successfully eliminate manual lubrication tasks
Overview
Luck Stone, a leading aggregates manufacturer based in Leesburg, Virginia, has taken a bold step toward operational excellence by transitioning from manual lubrication to a fully automated, connected lubrication system across its expansive site. The company installed 40 perma STAR VARIO LONG RANGE automatic lubricators marking a significant leap in both technology and safety.
The Challenge
Before the upgrade, Luck Stone relied on manual greasing, a labor-intensive and risk-prone process. With 84 conveyors requiring regular lubrication, the manual approach posed several challenges:
• High labor hours spent in hazardous zones
• Inconsistent lubrication leading to equipment failures
• Increased exposure to dangerous lubricants
• Difficulty in tracking and maintaining lubrication schedules
The Solution
Luck Stone implemented perma STAR VARIO LONG RANGE automatic lubricators equipped with Long Range wireless technology. This setup allows the entire site to be monitored remotely via perma CONNECT, eliminating the need for physical checks at each lubrication point.
Why did they opt for perma STAR VARIO LONG RANGE? perma STAR VARIO LONG RANGE was chosen for its:
• Long-range communication capabilities. One gateway covers the entire site.
• Real-time monitoring and alerts
• Accountability and data transparency
• Scalability for future expansion
Key Benefits
Safety: Workers are now isolated from 90% of lubrication-related risks. Direct contact with hazardous lubricants is eliminated, and time spent in dangerous areas is drastically reduced.
Efficiency: The Single-Point Lubricators deliver fresh lubricant consistently, preventing ingress of dirt and moisture into bearings. This leads to fewer bearing failures and higher equipment availability throughout the plant.
Cost Savings: Automatic lubrication prevents up to 75% of bearing failures, reducing machine repair costs, downtime, and enabling predictable service intervals.
Time Savings: Luck Stone’s maintenance team now saves significant manpower hours by monitoring lubricators remotely. There is no more need to regularly walk to No need to walk to each lubrication point.
Precision: Compared to manual greasing the lubrication settings are now optimized for bearing size, type, speed, temperature and environment, eliminating over-lubrication and starvation risks.
Results
The transition from manual greasing to connected automatic lubrication has revolutionized maintenance operations at Luck Stone:
• Grease consumption is optimized, reducing waste
• Maintenance is proactive, not reactive
• Plant efficiency is up, thanks to reduced friction and wear
• Downtime is down, with fewer unexpected failures
• Workplace safety is increased, with administrative controls and remote monitoring
Comprehensive Support from perma
perma provided comprehensive support throughout the entire journey. From the very beginning, perma’s Application Engineering team was hands-on. They conducted a full site survey, assessing every lubrication point in detail: identifying challenges, determining the correct grease type, calculating the required volume and frequency, and advising on installation methods, whether remote-mounted or directly mounted. They further helped select the right accessories, ensuring every component was tailored to the site’s specific needs.
“perma didn’t just sell us lubricators, they became a partner in our success,” explains Stephen Rigsby Foreman at Luck Stone. “Their engineering services were outstanding. From the initial asset and equipment survey to the technical recommendations and the change-out service, they were with us every step of the way. They thought of everything when it came to accessories: installation kits, tools, heavy-duty and standard-duty options."
"perma didn't just sell us lubricators, they became a partner in our success. Their engineering services were outstanding."
Beyond hardware, perma CONNECT proved to be a game-changer. More than just software, it offers a clear, organized visualization of the entire lubrication structure. The ability to monitor, manage, and optimize lubrication remotely has dramatically improved safety and efficiency.
The local aspect of perma’s operations also played a key role. With over 400 different stock lubricants filled in Charlotte, NC, Luck Stone appreciated the proximity and responsiveness of their support. The next phase includes in-house training at perma and on-site sessions tailored to Luck Stone’s team.
Conclusion
Luck Stone’s implementation of perma STAR VARIO LONG RANGE lubricators has transformed lubrication management from a manual, high-risk process into a streamlined, intelligent system. The project reduced grease consumption and maintenance hours while increasing safety, efficiency, and reliability. With perma’s technology and support, Luck Stone set a new benchmark for smart automation in the aggregates industry, demonstrating how digital transformation can improve industrial operations.
