How Luck Stone was able to successfully eliminate manual lubrication tasks

In aggregate production, conveyors are the backbone of material movement. From primary crushing through stockpiling, conveyor systems operate continuously under harsh conditions including dust, vibration and exposure to the elements. One of the most common failure points in these systems is the head pulley bearing. When lubrication is inconsistent or difficult to perform, bearing life drops quickly and unplanned downtime follows.

At Luck Stone's Boscobel, Virginia plant, manual lubrication practices were contributing to frequent bearing failures and high maintenance risk. By transitioning to automated lubrication, the plant achieved significant improvements in reliability, safety and overall cost control.

The Challenge: Manual Lubrication

Before the upgrade, various Luck Stone sites relied on manual greasing, a labor-intensive and risk-prone process. With countless 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

This combination created a cycle of reactive maintenance, higher safety risks and avoidable downtime across the operation.

The Solution: Lubrication Automation

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?

• Long-range communication capabilities. One gateway covers the entire site.

• Real-time monitoring and alerts

• Accountability and data transparency

• Scalability for future expansion

Solution Spotlight: perma STAR VARIO

The perma STAR VARIO is an automatic single-point lubrication system designed to deliver precise lubricant volumes to critical components.

By supplying small, controlled amounts of grease at consistent intervals, the system improved lubrication consistency while equipment is operating.

Key Benefits

Prevents overgreasing and pressure spikes
Reduces contamination in dusty environments
Minimizes manual lubrication in hazardous areas
Supports longer bearing life and improved uptime

The Result: Reliability, Safety & Cost Savings

Automated perma lubrication extended bearing life beyond 24 months, reduced failures by 75 percent and cut inspection time by 85 percent, delivering significant long-term cost savings and improved reliability.