In food and beverage bottling operations, conveyors are the backbone of continuous production. Frequent washdowns, strict sanitation requirements and around-the-clock operation place significant stress on conveyor bearings. Maintaining proper lubrication is essential to preventing premature failures, unplanned downtime and contamination risks.
At a leading food and beverage bottling facility in Southern California, the maintenance team focused on improving conveyor lubrication practices to enhance equipment reliability, worker safety and overall production efficiency.
The Challenge
The facility relied on manual lubrication for poly conveyor bearings across the bottling line, including standard 2 bolt flange bearings commonly used throughout the food and beverage industry.
Operating in a demanding production environment, the facility faced several lubrication-related challenges:
- Inconsistent lubrication caused by missed bearings, human error and limited access during production
- Frequent washdowns during every shift continuously displaced lubricant from bearings, increasing the risk of corrosion and premature wear
- Several drive-side bearings located behind motors and gearboxes were difficult to access and were frequently overlooked
- Mixed greases were being applied across the line, reducing lubrication consistency and effectiveness
- Excess grease buildup around lubrication points created housekeeping concerns and increased contamination risk
- Manual lubrication consumed valuable maintenance time and could only be performed during planned downtime
As a result, the facility experienced bearings failures nearly every year, with downtime costs reaching up to $15,000 per hour if production was interrupted.
The Solution
perma USA implemented a simple and effective automatic lubrication solution using 40 perma FLEX 60 cc units installed both directly and remotely on conveyor bearings.
Key elements of the solution:
- Combination of direct mount and remote mount installations to ensure all bearings were serviced
- Remote mounts specifically installed on previously missed drive side bearings
- All units set to a 1 year discharge period to prevent over lubrication
- Standardization of lubricant, eliminating mixed grease issues
- Closed system design to prevent contamination and excess grease discharge
This ensured every lubrication point received the correct amount of lubricant continuously, even during operation and washdown conditions.
Key Benefits & Results
• Continuous lubrication helps protect bearings from washdown-related lubricant loss
• Consistent grease delivery reduces wear and extends bearing service life
• No bearing losses reported since implementation
• Every bearing is lubricated continuously without relying on manual intervals
• Precise metering prevents over application and waste
• No excess grease on the ground or surrounding equipment
• Closed system reduces contamination risk
• Reduced time spent manually greasing
• Weekly visual checks replace time intensive lubrication routines
• Remote mounted units ensure drive side bearings are no longer missed
• Especially because of the remote-mounted units.
• Reduced need for technicians to access bearings behind motors, gearboxes and conveyor structures
• Less time spent working around operating equipment
Expansion & Future Plans
The initial installation included approximately 40 perma FLEX units, with an additional 40 units planned for expansion to other conveyor lines.
Due to the simplicity of the application and strong results, the customer is continuing to standardize automatic lubrication across the facility.
"What impressed us most was the simplicity of the solution. Once the lubricators were installed, we immediately gained confidence that every critical bearing was being serviced properly. The reduction in failures, cleanup and manual maintenance has delivered real value to our operation." Maintenance Manager at the Food & Beverage Plant
Conclusion
This application demonstrates how a straightforward automatic lubrication upgrade can deliver significant impact in food and beverage production.
By replacing inconsistent manual lubrication with perma FLEX, the facility achieved:
- Reliable conveyor operation
- Improved safety and cleanliness
- Lower maintenance effort
- Zero bearing losses
A simple solution, executed correctly, created a measurable difference across the entire operation.
"By standardizing lubrication and eliminating missed bearings, the facility improved reliability, reduced maintenance requirements and achieved zero bearing failures." Anthony Di Bernardo Regional Sales Manager perma USA.