Author: Nguyen Phuc

Vietnam’s textile and garment industry is developing rapidly, leading to a high demand for machine maintenance. To ensure continuous and stable performance, the use and sourcing of high-quality high-temperature greases are key factors.

This article delves into the importance of specialized lubricating greases, analyzes the types of high-temperature greases used for weaving machines and dyeing machines, and provides optimal selection guidance. Through this, you will better understand the necessary technical standards when buying and selling high-temperature greases, as well as choosing the most effective lubrication solution.

The industrial sector constantly demands lubrication solutions that can adapt to high operating intensity and significant thermal fluctuations, making the service of selling high-temperature greases an indispensable part of the technical supplies chain.

1. The Importance of Specialized High-Temperature Grease in the Textile Industry

The production environment in textile factories always poses major challenges to lubrication systems. Purchasing and using inappropriate grease will lead to serious failures; therefore, the service of selling specialized high-temperature greases is crucial. The unique textile environment not only involves high temperatures but also the influence of cotton dust, fibers, and dyeing/cleaning chemicals, requiring products to have superior mechanical and chemical stability.

1.1. The Harsh Operating Environment of Textile Machinery

Equipment such as weaving machines, dyeing machines, and drying chambers often operate at very high temperatures, sometimes reaching 200°C or more. These are ideal conditions for poor-quality products to quickly lose their structure, increasing the need to find suppliers who sell high-temperature greases. High temperatures accelerate the oxidation process of the base oil, leading to a rapid decline in lubricating properties.

In addition to temperature, high humidity and the presence of steam in dyeing/finishing areas also pose a major challenge. Water and humidity reduce grease stability, causing it to wash out and rust metal components. Therefore, businesses selling high-temperature greases must ensure their products offer superior water resistance and anti-corrosion capabilities.

Furthermore, lint and fiber dust from the weaving process are significant contaminants. This dust can penetrate open bearings, combining with the lubricant to form an abrasive mixture, degrading the grease’s performance. Choosing grease with good sealing properties and high adhesion is essential to prevent the infiltration of these particles.

1.2. The Impact of High Temperatures on Equipment Lifespan

Excessive heat causes conventional grease to melt, liquefy, and leak out, leaving moving parts unprotected. The consequence is rapid machine wear, costly repairs, and production line interruptions while seeking new suppliers. When grease melts, the protective oil film disappears, causing direct metal-to-metal contact, leading to bearing seizure.

The degradation of grease at high temperatures also creates hard carbon deposits. These deposits not only lose their lubricating ability but also act as an abrasive, damaging the surface of machine components. Reputable businesses selling high-temperature greases always recommend low-volatility grease to minimize deposit formation, thereby extending the lifespan of bearings and rotating shafts.

Another serious issue is the deformation of machine components. When temperatures exceed the design limit, load-bearing parts like bearing cages can soften or deform, leading to mechanical failure even if the lubricant remains. Using high-quality grease that has good heat transfer capabilities helps stabilize the localized temperature of the bearing, serving as an effective preventative solution.

1.3. The Need for High-Performance Lubrication

Specialized high-temperature grease is designed to maintain viscosity and structure at high thermal thresholds, ensuring the lubricating film remains stable. This continuous protection is why factories need to find reliable partners who sell high-temperature greases. High-performance greases use synthetic base oils and advanced thickeners, offering superior shear stability and thermal resistance, maintaining the grease’s original consistency for longer.

Switching to high-performance lubricants offers dual benefits: reduced maintenance frequency due to extended relubrication cycles, and reduced energy consumption due to lower friction coefficients. Consultants selling high-temperature greases can help you calculate the long-term economic benefits of investing in these products, compared to using low-cost conventional grease.

2. Classification and Technical Characteristics of Suitable High-Temperature Greases

Choosing the correct grease type is the most critical step to optimize performance and extend machine life. When looking for high-temperature grease suppliers, you need to understand the differences between grease types to make accurate purchasing decisions.

2.1. High-Temperature Grease for Weaving Machines (Looms, Spinning Frames)

Weaving machines operate at high speeds, requiring grease to have good load-carrying capacity and anti-wear properties in addition to heat resistance. Therefore, businesses selling high-temperature greases often recommend products with high mechanical stability, suitable for high-speed bearings and precise drive mechanisms in weaving machines.

2.1.1. Lithium Complex Grease and Applications

Lithium Complex grease is a popular choice, offering temperature resistance up to 150°C – 180°C and high mechanical stability. This type of grease is often recommended by suppliers for moderately loaded components and not overly extreme temperatures, such as main weaving machine motors and intermediate rotating shafts.

In terms of composition, Lithium Complex grease uses a Lithium hydroxystearate thickener, creating a more robust fiber structure than conventional Lithium grease. This complex thickener helps the grease maintain a stable structure, resisting liquefaction even under strong mechanical churning and rising temperatures. Suppliers selling high-temperature greases highly value this type for its flexibility and reasonable cost.

Typical applications for Lithium Complex grease include fan bearings, weaving frame motion mechanisms, and light-duty gearboxes. When selecting, the grease’s penetration index (ASTM D217) should be checked to ensure the consistency is compatible with the factory’s automatic lubrication system.

2.1.2. Synthetic Grease for Ultra-High Temperatures

For lubrication points near heat sources, Synthetic grease is the optimal solution, maintaining performance at temperatures above 200°C. This is a premium product segment that quality high-temperature grease suppliers always promote. Synthetic base oils (typically Polyalphaolefins – PAO or Ester) provide excellent anti-oxidation and thermal stability.

PAO synthetic grease is widely used for lubricating stenter chains in drying chambers, where the grease must withstand peak temperatures. The outstanding advantage is extremely low volatility, which significantly reduces grease consumption and relubrication frequency. Factories seek partners selling synthetic high-temperature greases because they can extend maintenance cycles by 3-4 times compared to mineral-based greases.

A specialized form of synthetic grease is Fluorocarbon grease (PFPE/PTFE), often used in furnace bearings operating above 250°C. This grease is non-flammable, chemically inert, and leaves absolutely no residue. Although it has a higher cost, PFPE grease offers long-term economic efficiency when factoring in maintenance and bearing replacement costs. The sale of these high-temperature greases usually comes with deep application consulting.

2.2. High-Temperature Grease for Dyeing Machines (Drying Chambers, Boilers)

Dyeing machines and drying chambers frequently face steam, dyeing chemicals, and extreme temperatures, creating a corrosive environment. Companies selling high-temperature greases must ensure the grease has superior water and oxidation resistance to protect equipment under wet, chemical operating conditions.

2.2.1. Water and Chemical Resistance Requirements

Lubricants in dyeing machines must not only be heat-resistant but also resist washout and chemical ingress. This requires products to have special additives, including anti-rust agents and oxidation inhibitors that can function effectively in a pH-changing environment due to dyeing chemicals.

The ingress of steam into bearings can cause grease hydrolysis, destroying the thickener and reducing lubrication effectiveness. Experts selling high-temperature greases always recommend using grease with excellent adhesion, creating a physical barrier against water and chemical ingress, protecting metal components from corrosion.

2.2.2. Choosing Polyurea-Based Grease

Polyurea grease is known for its excellent thermal resistance and superior durability in humid, chemical environments, making it an ideal choice for bearings in drying ovens. Professional partners selling high-temperature greases always stock this type due to its unique structure.

Polyurea thickener is a non-soap thickener; therefore, it has inherently high anti-oxidation capability and an almost undetermined (non-melting) dropping point. This means Polyurea grease can maintain a stable structure at temperatures far exceeding the limits of Lithium Complex grease, perfectly suited for high-speed electric motors and bearings subject to continuous temperatures above 180°C. When seeking a supplier, Polyurea should be the priority choice for critical applications.

The mechanical stability and washout resistance of Polyurea grease are also key factors, especially important in dyeing machines operating in environments with steam pressure. The Polyurea structure is less likely to break down under high shear forces, ensuring the grease consistency remains stable throughout the equipment’s operation.

2.3. Key Technical Indices to Consider

When evaluating products sold by high-temperature grease suppliers, you cannot overlook the following key technical parameters to ensure quality and compatibility with factory equipment.

2.3.1. Dropping Point and Thermal Stability

The Dropping Point is the temperature at which the grease begins to liquefy and leak out, and it must always be higher than the equipment’s operating temperature. When purchasing, ask suppliers selling high-temperature greases to provide this index. This index is typically measured according to the ASTM D2265 standard.

However, the Dropping Point is only a safety index, not the maximum operating temperature. More important is the grease’s Thermal Stability, which is the grease’s ability to resist oxidation and deposit formation at high temperatures over an extended period. When consulting, quality suppliers will provide data on high-temperature bearing life tests (e.g., ASTM D3336 or SKF R2F) to demonstrate actual performance.

2.3.2. Penetration (NLGI Grade)

The grease consistency (NLGI Grade) affects the ability to pump and retain the grease at the lubrication point, typically NLGI 2 or 3. High-temperature grease experts will advise on the appropriate consistency for your factory’s automatic lubrication system. Consistency is measured by the ASTM D217 standard (Worked Penetration).

For centralized lubrication systems, selecting the correct NLGI Grade is crucial. Grease that is too stiff (NLGI 3 or higher) can clog pipelines and grease pumps, especially in low-temperature conditions or long pipelines. Conversely, grease that is too soft (NLGI 1 or lower) will easily leak out of the bearing when the temperature increases. Suppliers selling high-temperature greases must balance pumpability and retention capability.

3. Guide to Correctly Selecting and Using High-Temperature Grease

Choosing products from reputable high-temperature grease suppliers is only the first step; correct usage determines the final effectiveness of the lubricant. Strict adherence to technical procedures will ensure the grease maximizes its heat resistance and protective capabilities.

3.1. Grease Application Procedure and Relubrication Frequency

Perform regular greasing procedures according to the guidelines of the equipment manufacturer or the high-temperature grease supplier. Avoid using too much or too little grease, as this will reduce heat resistance effectiveness and cause waste. Excess grease will increase temperature due to churning, causing the grease to degrade faster.

The relubrication frequency should be determined based on operating factors such as temperature, rotation speed (RPM), and load, often calculated using SKF or FAG formulas. Companies selling high-temperature greases can provide specialized software or spreadsheets to determine the optimal greasing cycle for each machine type, ensuring continuous performance.

3.2. Common Mistakes When Replacing Grease

Mixing greases with different base types is a common mistake that can cause a chemical reaction and destroy the grease structure. Always consult an expert when needing to switch between different high-temperature grease products, especially when transitioning from metal-soap based grease to Polyurea grease or vice versa.

Incompatibility reactions between different thickeners can cause sudden grease softening, leading to leakage and loss of lubrication after just a few hours of operation. Professional high-temperature grease suppliers will provide grease compatibility charts and recommend a bearing cleaning procedure (purging) with solvent or the new grease before completely switching.

3.3. Economic Benefits of Purchasing and Using the Right Grease

Investing in quality products from reputable high-temperature grease suppliers helps extend bearing life, reduce machine downtime, and save energy costs. This yields much greater economic benefits than the initial purchase cost of the grease. A failed bearing can cause tens of millions of VND in damage, not to mention the cost of interrupted production.

Extending bearing life from 6 months to 1-2 years thanks to using high-quality high-temperature grease is the clearest evidence of economic effectiveness. The frequency of bearing replacement and maintenance labor costs are significantly reduced. Companies selling high-temperature greases should focus on selling holistic solutions rather than just selling products.

Energy costs are also a key factor. High-performance grease has a significantly lower friction coefficient than conventional mineral-based grease, helping to reduce heat load and motor electricity consumption. Although premium high-temperature grease has a higher price, operating costs and maintenance costs will be optimized.

3.4. Life Cycle Cost (LCC) Analysis When Choosing High-Temperature Grease

LCC (Life Cycle Cost) is a method for evaluating the total cost a lubricant product brings throughout the equipment’s lifespan. Finding a high-temperature grease partner must be based on LCC analysis, not just the purchase price.

The main components of LCC include: initial grease purchase cost, energy consumption cost (due to friction), relubrication and labor costs, and equipment repair/replacement costs due to premature failure. Cheap grease can reduce the initial purchase cost but increases energy costs, labor costs, and especially failure costs, leading to a much higher overall LCC.

When evaluating a supplier, ask them to present an LCC model. A reasonable LCC model will demonstrate that synthetic high-temperature grease, even if 3-4 times more expensive than mineral grease, reduces the total LCC by 20% to 40% due to extended bearing life and minimized downtime.

4. VieTextile – The Leading High-Temperature Grease Supplier for the Textile Industry

VieTextile is proud to be a strategic partner, specializing in supplying and selling premium high-temperature greases, specially formulated for the harsh operating environment of the textile industry. We are committed to providing optimal lubrication solutions, helping machinery operate reliably under continuous high-temperature conditions. Our product catalog is imported from the world’s leading brands, ensuring uniform and stable quality.

VieTextile’s capabilities are affirmed through a diverse product portfolio, including Lithium Complex, Polyurea, and Fluorocarbon synthetic greases, ensuring compliance with all technical requirements from high-speed weaving machines to steam drying chambers. We do not just sell high-temperature greases but also provide deep technical consulting services (such as LCC analysis, grease compatibility testing) so customers can accurately select the necessary products.

Every product sold by VieTextile comes with quality certifications (C.O.A, M.S.D.S) and detailed usage instructions, giving customers confidence in performance and safety. We maintain large warehouse stocks, ensuring timely supply to factories, minimizing the risk of production interruptions. If you are looking for a high-temperature grease supplier that can accompany your factory’s sustainable development, VieTextile is the trusted choice.

5. Frequently Asked Questions About High-Temperature Grease in Textile Factories (FAQ)

Q: What is the minimum dropping point for high-temperature grease used in drying chambers? A: When purchasing, you should choose high-temperature grease products with a minimum dropping point of 250°C or higher to ensure safety and thermal stability in a drying oven environment.

Q: What are the advantages of Synthetic base grease compared to mineral base grease in weaving machines? A: Synthetic grease offers superior thermal stability and anti-oxidation capabilities, helping to extend the relubrication cycle and lubricating performance at extreme temperatures, which is why we sell synthetic high-temperature greases for the most demanding applications.

Q: Is it necessary to completely clean the bearing before replacing it with new high-temperature grease? A: Yes. Cleaning is mandatory to remove old grease and contaminants, avoiding incompatibility reactions when using different high-temperature grease products, thereby ensuring maximum lubrication effectiveness.

Q: Which high-temperature greases does VieTextile recommend for spinning frames? A: We recommend using high-performance Lithium Complex grease or synthetic grease for spinning frames, depending on the specific operating temperature and rotation speed of the equipment.

Q: When should I switch from mineral-based high-temperature grease to synthetic-based? A: The switch should be made when equipment frequently operates at temperatures exceeding 150°C or when the relubrication cycle of mineral-based grease is too short. This conversion should be advised by high-temperature grease experts.

Q: Is Polyurea high-temperature grease compatible with Lithium Complex grease? A: No. Polyurea and Lithium Complex greases are generally incompatible due to differences in thickeners. Mixing them can destroy the grease structure. You need to consult your high-temperature grease supplier for guidance on the cleaning process before switching.

Q: Does using inappropriate grease affect the quality of woven fibers? A: Yes. Poor-quality or leaking grease can contaminate the woven fibers (oil stain), causing product defects and increasing waste disposal costs. Choosing a non-staining high-temperature grease supplier is crucial for maintaining the quality of the final product.

Q: How is the relubrication cycle calculated for drying oven bearings? A: The relubrication cycle is calculated based on bearing lubrication formulas (focusing on speed, bearing diameter, and temperature factor). Professional high-temperature grease suppliers will help you determine this cycle. For drying ovens, the cycle is often shorter due to high temperatures.

To find the optimal solution and specialized high-temperature greases for weaving machines, dyeing machines, and textile factories, contact VieTextile today!

Contact Information:

Hotline: 0901 809 309 

Email: info@vietextile.com 

Website: https://vietextile.com

Kluber high-temperature grease has long established its leading position in the industrial lubricant market. With its ability to operate stably in extreme conditions, the Kluber high-temperature grease product line is the top choice for businesses. Let’s explore the reasons why Kluber high-temperature grease is dubbed the gold standard in the industry.

In the modern industrial manufacturing environment, machinery and equipment often operate under high pressure, high speed, and especially extremely harsh temperatures. These factors pose enormous challenges to the maintenance and lifespan of bearing systems, gears, and other moving parts. Traditional lubricants quickly break down, evaporate, or leak out, leading to premature wear, sudden failure, and disruption of the entire production line.

Recognizing the critical need for a superior lubrication solution, Klüber Lubrication developed the Kluber high-temperature grease line. This is not just an ordinary lubricant, but a combination of advanced chemical technology, premium synthetic base oils, and specialized additive systems researched in the world’s leading laboratories.

This article will delve into a comprehensive analysis, thoroughly explaining why Kluber high-temperature grease has surpassed all rivals to become the “gold standard” in industrial lubrication. We will explore core technical aspects such as thermal stability, anti-wear performance, practical applications in heavy and textile industries, and provide guidance on optimal product selection and use.

1. Overview of Kluber High-Temperature Grease and the Core Difference

Kluber high-temperature grease is a lubricant product line specifically designed to maintain stable performance and structural integrity when exposed to working temperatures ranging from medium to very high, often exceeding 120°C. Kluber’s difference lies not only in simple temperature resistance but also in the philosophy of creating specialized lubrication solutions, perfectly suited to each individual application.

1.1. History and Philosophy of Klüber Lubrication

Klüber Lubrication is a global company based in Germany, with over 90 years of experience in the field of specialty lubricants. Their philosophy is: “Maximizing customer value through specialized lubrication solutions.” Instead of offering mass-market products, Kluber focuses on researching proprietary formulas for the most demanding industries. This specialization is what has built the superior reputation and quality of every Kluber high-temperature grease product.

Kluber does not just sell grease; they sell engineering solutions that help customers reduce maintenance costs, enhance equipment performance, and extend relubrication intervals. This is a key factor in earning the absolute trust of leading original equipment manufacturers (OEMs) worldwide. Close collaboration with OEMs allows Kluber to test and improve its high-temperature grease under real-world conditions, ensuring optimal effectiveness.

1.2. Classification and Exclusive Formulas of Kluber Grease

The Kluber high-temperature grease product line is diverse, mainly classified based on the base oil (Synthetic or Mineral) and the thickener type. Common types include Perfluoropolyether (PFPE) based greases for extremely high temperatures, Polyalphaolefin (PAO) based greases for balanced performance, and Lithium Complex based greases for high mechanical stability.

Each Kluber high-temperature grease formula is a unique combination of three main components: base oil, thickener, and additives. Crucially, the anti-oxidation, anti-wear, and anti-corrosion additives are internally researched and developed by Kluber, providing superior protection that competing products struggle to replicate. This is the secret that helps Kluber high-temperature greases retain their physical and chemical properties even when temperatures exceed 200°C.

1.3. Important Technical Parameters of High-Temperature Grease

When evaluating the performance of Kluber high-temperature grease, core technical parameters must be considered. First is the Service Temperature Range, indicating the maximum and minimum temperature limits within which the grease can operate effectively. The Dropping Point indicates the temperature at which the grease begins to liquefy, a critical parameter for grease operating in furnaces or dryers.

Second is the Base Oil Viscosity, which affects the ability to form a protective oil film at specific speeds and loads. Finally, the NLGI Consistency Class (penetration grade) determines the grease’s stiffness, ensuring it is compatible with the installed pump system and lubrication mechanism. The variety of parameters in Kluber high-temperature grease allows engineers to select the exact product needed for every application.

2. Superior Thermal Resistance and Stability of Kluber High-Temperature Grease

The ability to withstand and maintain lubricating properties under high temperatures is the most outstanding feature and the main reason why Kluber high-temperature grease has become the gold standard. This difference stems from the use of the highest quality components and proprietary blending technology.

2.1. Dropping Point and Service Temperature Range

Premium Kluber high-temperature greases often have a very high, or even “undetermined,” Dropping Point for PFPE (Perfluoropolyether) based greases using PTFE (Teflon) thickeners. This means the grease will not liquefy or structurally deform even when temperatures exceed 250°C. This is a huge advantage compared to ordinary Lithium greases, which typically withstand a maximum temperature of about 120-150°C.

The wide operating temperature range of Kluber high-temperature grease also ensures stable performance in both cold and hot environments. For example, some Kluber products can operate from -50°C up to +280°C without hardening or becoming too soft. This capability minimizes seasonal maintenance risks and ensures smooth machine startup in all climatic conditions.

2.2. Oxidation Resistance and Structural Stability Under High Temperatures

When grease is exposed to high temperatures and air, oxidation occurs, causing the grease to harden, form deposits (carbon residue), and lose its lubricating ability. Kluber high-temperature grease uses highly saturated synthetic base oils (like PFPE, Ester, or PAO) and powerful anti-oxidation additives, effectively counteracting this degradation.

High oxidation resistance means longer relubrication cycles, reducing maintenance frequency and saving operational costs. Furthermore, the complex thickeners in Kluber high-temperature grease create a stable fibrous network that securely holds the base oil, even under intense churning or continuous vibration at high temperatures, preserving the grease’s gel structure.

2.3. Advanced Synthetic Thickener Technology

The thickener acts as the “skeleton” of the grease. Kluber utilizes specialized inorganic or complex thickeners, such as Polyurea, Lithium Complex, or PTFE. Polyurea thickener, an advanced technology, provides superior thermal and mechanical stability, less oil separation, and enhanced water resistance.

Meanwhile, Kluber’s PFPE-based greases use PTFE as the thickener, which has no dropping point and is chemically inert. This combination ensures that Kluber high-temperature grease does not form carbon deposits upon degradation (at extremely high temperatures, it only evaporates without leaving abrasive residues), keeping machine components clean and running smoothly for longer periods.

3. Peak Lubrication Performance in Harsh Environments

The lubricating capability of Kluber high-temperature grease goes beyond just thermal resistance; it also provides comprehensive protection under the toughest working conditions such as heavy loads, exposure to water, chemicals, and dusty environments.

3.1. Load-Carrying Capacity and Wear Protection

The EP (Extreme Pressure) and AW (Anti-Wear) additives in Kluber high-temperature grease are selected and blended in precise proportions. These additives create a protective chemical film on the metal surface when pressure suddenly increases, preventing direct metal-to-metal contact.

In standard tests such as the Four-Ball Test, Kluber high-temperature grease consistently yields superior results in terms of weld point and wear scar compared to competing products. This demonstrates that Kluber grease can effectively protect bearings operating under shock loads or heavy vibrations, especially crucial in presses, crushers, and heavy equipment.

3.2. Excellent Water Resistance and Washout Protection

In many industries, equipment is subjected not only to heat but also to steam, cold water, or coolant liquids. When grease dissolves or washes out, the protective layer disappears, leading to rust and failure. Kluber high-temperature grease utilizes excellent water-resistant formulas.

Kluber’s Calcium Sulphonate Complex based greases, for example, have inherent rust and corrosion protection, along with high adhesion. The grease adheres tightly to metal surfaces, creating a physical barrier that prevents water penetration and subsequent damage. As a result, bearing life is significantly extended, even in humid environments or under cleaning water sprays.

3.3. Energy Savings and Extended Equipment Life

Using high-quality Kluber high-temperature grease is not just an expense but an investment that yields long-term economic benefits. Thanks to a low friction coefficient and stability at high temperatures, Kluber minimizes frictional drag during operation, helping machinery consume less energy.

When friction is reduced, the bearing’s operating temperature also decreases, thereby slowing down the aging process of the grease and the metal itself. Studies have shown that switching to the appropriate Kluber high-temperature grease can double or triple the bearing life, minimizing the cost of expensive component replacement and labor costs for maintenance.

4. Widespread Practical Applications of Kluber High-Temperature Grease in Various Industries

The flexibility and reliability of Kluber high-temperature grease have made it a trusted product in almost every industrial sector, from those requiring stringent hygiene to those with the harshest working environments.

4.1. Steel and Heavy Industry (Furnaces, Rollers)

In the steel manufacturing industry, the bearings of furnace cars or the rollers in continuous casting lines must withstand extremely heavy loads and temperatures up to 250°C. Kluber’s synthetic-based high-temperature greases and complex thickeners are engineered to meet these challenges.

They provide reliable lubrication for hard-to-reach locations where manual relubrication is hazardous or impractical. The non-carbonizing nature of certain specialized Kluber greases ensures that raceways and rollers do not become clogged, maintaining high precision and production speed.

4.2. Textile Industry and Heat Setting Machines (VieTextile focus area)

The textile industry is a vital sector where machine components in tentering frames, dryers, and sizing machines operate under continuous high heat. Temperatures in drying chambers can reach up to 180°C. If ordinary grease is used, the base oil will quickly evaporate, leading to machine jamming and fabric damage.

Kluber high-temperature grease features specialized formulas for the textile industry, minimizing deposit formation and preventing yellowing or staining of the fabric fibers. We, VieTextile, highly recommend dedicated Kluber product lines to ensure the precision and longevity of conveyor chains, slide rails, and bearings in the high-temperature environment of textile machinery.

4.3. Automotive and Manufacturing Industries (Bearings, Joints)

In the automotive industry, Kluber high-temperature grease is widely used in critical components such as wheel bearings, constant velocity (CV) joints, and transmission mechanisms. These parts require grease to withstand high shear forces, high speeds, and heat generated by brake friction or engine operation.

Kluber grease not only protects components from heat and wear but also provides excellent protection against Noise, Vibration, and Harshness (NVH). This contributes to improving the overall quality and driving experience of the final product.

4.4. Food and Pharmaceutical Industries (NSF H1 Certified)

For applications with a risk of incidental contact with food or pharmaceuticals, Kluber offers a special line of Kluber high-temperature grease that meets NSF H1 certification. This grease is formulated from non-toxic, odorless, and tasteless ingredients, ensuring absolute safety for consumers.

Despite being food-grade grease, they maintain superior heat resistance and load-carrying capacity, suitable for packaging lines, mixers, and industrial ovens. Using Kluber NSF H1 high-temperature grease helps businesses strictly comply with international food safety regulations.

5. Differentiating Kluber High-Temperature Grease from Other Conventional Greases

The difference between Kluber high-temperature grease and other lower-cost industrial greases is not just in price but in performance, lifespan, and the Total Cost of Ownership (TCO).

5.1. Base Oil Difference (Mineral vs. Synthetic)

Most conventional greases use mineral oil, which has a non-uniform molecular structure. When the temperature increases, mineral oil quickly degrades, evaporates, and leaves carbon deposits. Conversely, most premium Kluber high-temperature greases use synthetic base oils (PAO, Ester, or PFPE).

Synthetic oils have a uniform molecular structure, providing superior thermal stability and viscosity over a wide temperature range. They evaporate less, have a lower friction coefficient, and maintain lubricating properties many times longer than mineral oils, ensuring the excellent lubricating efficiency of Kluber high-temperature grease.

5.2. Specialized Additives and Additive Technology

While conventional greases use basic additive packages, Kluber invests heavily in developing specialized additive packages. These additives are not just ordinary anti-wear or anti-rust agents but advanced thermal stabilizers, antioxidant agents, and adhesion enhancers optimized for each specific Kluber high-temperature grease line.

For instance, some Kluber products contain micro-sized solid lubricating particles like PTFE or Molybdenum Disulfide (MoS2), which help maintain the protective film even if the main base oil breaks down, ensuring continuous protection for the equipment.

5.3. Life Cycle Cost (LCC) Analysis

Although the initial cost of Kluber high-temperature grease may be higher than conventional grease, when analyzing the Life Cycle Cost (LCC), Kluber proves to be the more economical choice. LCC includes the cost of buying grease, maintenance costs (component replacement, labor), and downtime costs.

Because Kluber’s relubrication cycle is 2-5 times longer, equipment lifespan is increased, and the risk of sudden failure is minimized, the Total Cost of Ownership (TCO) for businesses using Kluber high-temperature grease is proven to be significantly lower. Choosing Kluber high-temperature grease is an effective asset management strategy.

6. Guide to Correctly Selecting and Using Kluber High-Temperature Grease

Correctly selecting and using the right type of Kluber high-temperature grease is crucial to maximizing product performance and ensuring machine longevity. Mistakes in selection can lead to serious consequences.

6.1. Criteria for Selecting the Right Grease for Specific Applications

When selecting Kluber high-temperature grease, engineers must consider four main factors:

1. Operating Temperature: Determine the maximum and minimum temperature of the application to select grease with the appropriate Service Temperature Range.
2. Load and Speed: Heavy loads require grease with high base oil viscosity and strong EP/AW additives. High speeds require lower viscosity grease to reduce friction.
3. Environment: Exposure to water, chemicals, or dust requires grease with high washout resistance and corrosion protection (such as Calcium Sulphonate based grease).
4. Compatibility: Ensure the new Kluber grease is compatible with old grease and sealing materials (seals), especially when switching to synthetic greases like PFPE.

Consulting the Kluber Product Selector Chart or directly seeking advice from VieTextile’s specialists is an indispensable step to choosing the most suitable Kluber high-temperature grease.

6.2. Standardized Relubrication Procedure

Relubrication must strictly follow the guidelines of the equipment manufacturer (OEM) or Kluber. Using too much grease is as dangerous as using too little. Excessive grease can increase friction, raise temperature, and destroy the grease structure.

Before relubricating with Kluber high-temperature grease, the old grease should be completely removed (if possible) to avoid mixing incompatible types. Use clean lubrication tools and ensure the relubrication quantity is accurate. Correct relubrication helps Kluber high-temperature grease maximize its lifespan and protective capabilities.

6.3. Common Mistakes When Using High-Temperature Grease

A common mistake is using the same Kluber high-temperature grease for every application. Since Kluber specializes its products, each grease is optimized for a specific operating condition (e.g., grease for dusty environments differs from grease for extreme high temperatures).

The second mistake is neglecting thickener compatibility. Mixing Lithium-based grease with Polyurea-based grease can soften the grease and significantly reduce the Dropping Point, damaging the thermal resistance advantages of Kluber high-temperature grease. Always check compatibility before switching grease.

7. VieTextile – The Trusted Partner for Genuine Kluber High-Temperature Grease and Comprehensive Lubrication Solutions

As a leading industrial lubrication solutions provider, VieTextile is proud to be a reliable partner, offering genuine Kluber high-temperature grease products, ensuring quality and origin. We understand that in the industry, the quality of the lubricant directly affects production efficiency and business profitability.

VieTextile’s technical team is deeply trained in Kluber’s product lines, ready to provide comprehensive technical consulting services. We not only supply Kluber high-temperature grease but also help customers analyze operating conditions, select the most suitable grease type, and establish optimal maintenance cycles. This ensures peace of mind regarding the continuous operational performance of your machinery.

We place special emphasis on solutions for the textile industry, where high temperature is the biggest challenge. VieTextile provides specialized Kluber high-temperature greases for dryers, tentering frames, and conveyor chains, helping minimize machine jamming and save energy. Our commitment is to ensure that every customer receives the highest quality Kluber high-temperature grease product and the best after-sales service.

VieTextile always maintains a diverse inventory of the most commonly used Kluber high-temperature greases, ensuring rapid supply capabilities, minimizing waiting time and production interruptions. Partnering with VieTextile is a strategic move that helps your business adopt the gold standard in industrial lubrication.

8. Frequently Asked Questions About Kluber High-Temperature Grease

8.1. What is the maximum temperature at which Kluber High-Temperature Grease can be used?

Answer: The operating temperature range of Kluber high-temperature grease is very wide, depending on the specific formula. Premium PFPE-based greases can operate stably and lubricate effectively at temperatures up to +280°C, and even higher in some special cases.

8.2. Should Kluber Grease be mixed with any other lubricant?

Answer: Absolutely not. Mixing Kluber high-temperature grease with any other type of grease is not recommended as it can lead to a loss of compatibility, a reduction in the Dropping Point, and destruction of the grease’s stable structure, severely reducing its thermal lubrication performance.

8.3. How do I know when to relubricate my equipment with Kluber Grease?

Answer: The relubrication cycle for Kluber high-temperature grease is generally much longer than conventional grease. It depends on factors such as temperature, speed, load, and bearing size. The best practice is to use Predictive Maintenance through grease sample analysis or consult with a VieTextile expert.

8.4. Is there a food-safe version of Kluber High-Temperature Grease?

Answer: Yes. Kluber offers a line of Kluber high-temperature greases that are NSF H1 certified, specially designed for applications in the food, beverage, and pharmaceutical industries where there is a possibility of incidental contact with the final product.

8.5. Is the initial cost of Kluber High-Temperature Grease worth it?

Answer: The initial cost of Kluber high-temperature grease may be higher, but when considering the Life Cycle Cost (LCC), which includes extending equipment lifespan, reducing maintenance costs, and eliminating downtime costs due to failure, Kluber grease offers superior economic value and return on investment.

To optimize lubrication performance with professional Kluber high-temperature grease, contact VieTextile today!

Contact Information:

Hotline: 0901 809 309 

Email: info@vietextile.com 

Website: https://vietextile.com

In the modern industrial environment, especially in heavy manufacturing, steel, cement, and textile sectors, it is inevitable that machinery components endure high temperatures, extreme pressures, and continuous operating speeds. To maintain stable performance and extend equipment lifespan, lubrication using High-Temperature Grease Supply is the premier solution. A high-quality high-temperature grease not only reduces friction and prevents wear but must also maintain its structural stability at temperatures exceeding 150°C, and even 200°C.

However, reality shows that maintenance failures are not always due to grease quality, but mostly stem from mistakes during usage. From selecting the wrong type of grease to inaccurate re-greasing procedures, these minor errors can accumulate and cause major failures, interrupting production and incurring expensive repair costs.

This article is developed based on in-depth experience in the field of High-Temperature Grease Supply and industrial maintenance, aiming to highlight the 7 most serious mistakes. We will delve into each error, analyze the root causes, and provide detailed corrective actions, thereby helping businesses optimize usage efficiency and find the best High-Temperature Grease Supply solution for their systems.

1. What is High-Temperature Grease and its Crucial Role?

High-temperature grease, also known as high-temperature lubricating grease, is a semi-solid lubricant specially designed to operate effectively in environments with temperatures exceeding those suitable for conventional greases (typically 120°C and above). The basic composition of grease includes base oil (70-95%), thickener (5-20%), and additives (0-10%). The biggest difference between high-temperature grease and multi-purpose grease lies in the thickener and additives.

1.1. Composition and Distinctive Ingredients of High-Temperature Grease

The thickener determines the thermal resistance and mechanical stability of the grease. While conventional greases often use a Lithium base, premium high-temperature greases utilize complex bases such as Lithium Complex, Aluminum Complex, Polyurea, or even inorganic clay (Bentonite) to prevent melting, decomposition, or oil separation when temperatures rise. These thickeners help the grease maintain its structure, keeping the base oil at the lubrication point. Understanding this component is the foundation for avoiding later mistakes. An unsuitable high-temperature grease will quickly lose its lubricating structure as the temperature increases, leading to grease drying out and direct metal-to-metal wear.

1.2. Essential Characteristics of Quality High-Temperature Grease

A reputable High-Temperature Grease Supply provider will always emphasize the following characteristics:

• High Dropping Point: This is the temperature at which the grease transitions from a semi-solid to a liquid state. High-temperature grease must have a Dropping Point above 250°C, ensuring structural stability.
• Superior Oxidation Stability: At high temperatures, the base oil oxidizes rapidly, forming hard carbon deposits that cause seizing and destroy the bearings. Good high-temperature grease requires strong anti-oxidation additives.
• Extreme Pressure / Anti-Wear (EP/AW) Capability: Reduces friction and protects heavily loaded machine parts.
• Mechanical Stability: The grease must not soften or be sheared down under continuous cutting forces and vibration, which is especially important when sourcing High-Temperature Grease Supply for high-speed bearings.

2. Mistake 1: Using Multi-Purpose Grease Instead of High-Temperature Grease

This is the most common mistake, often occurring due to a desire to cut costs or a lack of technical knowledge. Many technicians believe all greases are the same and can be used interchangeably.

2.1. Consequences of Substituting High-Temperature Grease with Multi-Purpose Grease

Multi-purpose grease (typically regular Lithium base) has a Dropping Point ranging from 180°C to 200°C. When used in an environment with operating temperatures of 150°C or higher, multi-purpose grease quickly encounters the following problems:

• Melting and Oil Separation: At high temperatures, the thickener is insufficient to retain the base oil. The grease turns liquid, leaks out of the lubrication point, leaving the contact surfaces unprotected.
• Rapid Carbonization: The base oil, not designed for high temperatures, will oxidize and degrade, forming hard carbon deposits. These deposits act as abrasive particles, causing severe wear on the bearings and bushings.
• Lubrication Structure Failure: Lacking protection, bearing lifespan drastically decreases, potentially failing after only a few hundred hours of operation instead of the thousands of hours anticipated.

2.2. Appropriate Temperature Classification Standards for High-Temperature Grease Supply

When selecting and utilizing High-Temperature Grease Supply, it is crucial to accurately determine the equipment’s actual operating temperature. International standards typically classify grease by:

• Continuous Operating Temperature: The temperature at which the grease can maintain its lubricating properties for extended periods. For high-temperature grease, this level must be above 140°C.
• Peak Temperature: The maximum temperature the grease can withstand for a short duration without complete structural breakdown.

Using Synthetic Base Oil Grease: If temperatures exceed 180°C, greases with synthetic base oils (PAO, Ester) are mandatory because they possess significantly higher thermal and oxidation stability than mineral base oils. Professional High-Temperature Grease Supply companies always advise on synthetic base oils for extremely hot applications.

2.3. Solution to Correcting the Wrong Grease Substitution Mistake

The only solution is strict adherence to the recommendations of the equipment manufacturer (OEM) and the High-Temperature Grease Supply specialist.

• Temperature Assessment: Use an IR thermometer gun or thermal sensors to determine the actual surface temperature of the bearing, not just the ambient temperature.
• Use Special Base Greases: Substitute with Lithium Complex, Polyurea grease (common for electric motor bearings), or Teflon/PTFE grease (for extremely high temperatures, above 250°C).
• Develop a Lubrication Manual: Create a detailed list of the grease type and lubrication cycle for each piece of equipment to prevent accidental mixing. Train maintenance personnel to correctly identify high-temperature and multi-purpose greases.

3. Mistake 2: Over-Greasing or Under-Greasing During Maintenance

Both over-greasing and under-greasing are extremely detrimental mistakes, causing over 80% of premature bearing failures.

3.1. Risk Analysis of Over-Greasing with High-Temperature Grease

This mistake often arises from the thought that “more is better.” However, pumping too much High-Temperature Grease Supply into a high-speed, high-temperature bearing will lead to:

• Sudden Temperature Increase: As the bearing rotates, the excess grease is continuously churned by the rollers/balls. This churning generates internal friction, significantly raising the bearing temperature, sometimes exceeding the grease’s own thermal limit. This creates a destructive loop: grease heats up -> loses structure -> grease turns liquid -> friction increases further.
• Increased Internal Pressure: The excessive amount of grease with no place to escape creates high pressure inside the seal. This pressure can force the seal open, causing seal damage, allowing the High-Temperature Grease Supply to leak out, and, more importantly, permitting dirt and water to infiltrate the bearing cavity.
• Increased Power Consumption: The increased internal friction not only causes heating but also raises the load on the motor, leading to higher-than-normal power consumption.

3.2. Serious Consequences of Under-Greasing with High-Temperature Grease

Conversely, under-greasing is also a common problem due to maintenance neglect or fear of over-greasing.

• Direct Wear: Insufficient grease fails to form a perfect protective film between metal surfaces. Components come into direct contact, causing rapid wear, especially in high-temperature environments where residual grease has oxidized and dried out.
• Increased Vibration and Noise: Lack of lubrication increases equipment vibration. This is the clearest sign of an impending failure. At this point, seeking a High-Temperature Grease Supply solution is too late to save the bearing.
• Increased Downtime: A failed bearing necessitates an emergency machine stop, causing significantly more damage than the cost of the grease.

3.3. Accurate Greasing Method (Re-Greasing Standard)

To correct this, apply a precise time and volume-based lubrication method:

• Calculate Time Interval: The lubrication cycle is calculated based on bearing type, speed (RPM), diameter, and operating temperature (K factor).
• Calculate Volume: The required amount of grease is usually calculated using the formula: G = 0.005 x D x B (where G is the grease volume in grams, D is the bearing’s outer diameter, and B is the bearing’s width, in mm).
• Use Support Tools: Use a grease gun with a meter or automatic lubrication devices to accurately control the amount of grease added, avoiding errors in the High-Temperature Grease Supply process for the machinery.

4. Mistake 3: Infrequent Compatibility Check of Greases

Mixing two incompatible high-temperature greases is one of the leading causes of grease structure breakdown and equipment failure.

4.1. Incompatibility Phenomenon and the Mechanism of Failure

High-temperature grease is composed of base oil, thickener, and additives. Incompatibility primarily occurs when two different thickeners are mixed.

• Thickener Breakdown: When Lithium Complex grease is mixed with Polyurea-based grease (two common types), the fiber structure of the thickener can fracture, leading to sudden grease softening. The grease rapidly loses its consistency (NLGI Grade), becomes much thinner, and leaks out.
• Additive Reaction: The additive packages (such as EP, AW, rust inhibitors) in the two greases can chemically react with each other, reducing protective effectiveness, or even creating corrosive byproducts.
• Reduced Dropping Point: The Dropping Point of the grease mixture can significantly decrease, sometimes falling below the equipment’s actual operating temperature, causing the grease to immediately turn liquid. This is a critical error when utilizing High-Temperature Grease Supply for hot applications.

4.2. Compatibility Classification Chart for Common High-Temperature Greases

To ensure safety, the Grease Compatibility Chart must be consulted. Greases are considered compatible if, when mixed, they maintain their consistency, Dropping Point, and mechanical stability.

• Generally Compatible: Lithium with Lithium, Lithium Complex with Lithium Complex.
• Borderline (Use Caution): Lithium Complex with Calcium Complex.
• Incompatible (Causes Failure): Lithium with Polyurea, Sodium with Lithium Complex, Barium with Polyurea.

Note: Even if two greases have the same base (e.g., Lithium Complex) but come from two different High-Temperature Grease Supply providers, they should be checked carefully due to differences in additives.

4.3. Safe High-Temperature Grease Conversion Procedure

If switching from one type of grease to another is mandatory, the procedure must be thorough:

• Purging/Flushing: Completely remove the old grease from the lubrication point. In sensitive applications, manual disassembly and cleaning are necessary. In other cases, pump a large amount of the new grease to push the old grease out (flushing), then re-grease with the exact standard volume.
• Stability Monitoring: After conversion, monitor temperature, vibration, and noise for the first few days. If the temperature rises abnormally, the machine must be stopped and compatibility checked again. High-Temperature Grease Supply must come with a commitment to safe conversion capabilities.

5. Mistake 4: Neglecting the Importance of Seals

High-temperature grease can only work effectively when kept in place and away from contaminants. Seals act as a protective barrier. Ignoring the condition of the seals is a fatal mistake.

5.1. High-Temperature Grease Contamination from the Environment

The operating environment of equipment using high-temperature grease is often harsh, with dirt, moisture, chemicals, or metallic dust.

• Solid Contaminant Ingress: Damaged or hardened seals allow solid particles (dust, debris) to enter the lubrication cavity. These particles quickly turn the high-temperature grease into an abrasive substance, similar to sandpaper, damaging the surfaces of the rollers and the bearing raceway.
• Effect of Water/Moisture: Water is the greatest enemy of grease. It reduces lubrication capability, causes bearing rust, and changes the grease’s consistency. Lithium Complex grease has better water resistance, but if the seal is damaged, no grease can withstand large water ingress.

5.2. Consequences of Choosing Seals Incompatible with High-Temperature Grease

A less-noticed technical error is the incompatibility between the grease and the seal material.

• Chemical Impact on Seals: Some base oils or additives in high-temperature grease can cause the seal material (often NBR, FKM/Viton, Silicone) to shrink, swell, or harden. A deformed seal loses its sealing ability, leading to grease leakage and contaminant ingress.
• Example: Greases with synthetic Ester base oils are often incompatible with standard NBR (Nitrile Butadiene Rubber) seals, causing the seal to swell. Specialized High-Temperature Grease Supply providers must have this data to advise customers.

5.3. Seal Inspection and Replacement Strategy

• Routine Visual Inspection: During each maintenance cycle, the seals should be checked for cracks, deformation, or signs of grease leakage. If the seal is hard or has an abnormal color (due to excessive temperature), it must be replaced immediately.
• Seal Material Consultation: When purchasing and receiving High-Temperature Grease Supply, ask the supplier for recommendations on the appropriate seal material for that grease type. For example, for synthetic greases, FKM (Viton) seals are often a safer choice than NBR.

6. Mistake 5: Skipping Used Grease Analysis

Used Grease Analysis is a powerful predictive maintenance diagnostic tool, similar to oil analysis. Ignoring this tool means missing the opportunity to detect early potential equipment problems.

6.1. Core Value of High-Temperature Used Grease Analysis

Used grease analysis provides deep insight into both the condition of the grease and the condition of the equipment. It helps answer three key questions:

• Is the Grease Still Good? Check consistency (NLGI), Dropping Point, and remaining oxidation stability to determine if the high-temperature grease has been thermally degraded.
• Are There Contaminants? Detect the level of solid particles, water, dirt, or chemicals. High levels of contamination signal a failed seal or poor cleanliness procedures.
• Is the Equipment Failing? Analyze the content of Wear Metals. The presence of high concentrations of Iron (Fe), Copper (Cu), and Chromium (Cr) is direct evidence that the bearing, shaft, or housing is undergoing wear and is nearing failure.

6.2. Cost and Benefits of Conducting Analysis

While sending a grease sample for analysis incurs a cost, the benefits it provides far outweigh it:

• Extend Lubrication Cycles: If the analysis results show the high-temperature grease is still good after the expected period, the company can safely extend the lubrication cycle, saving costs on purchasing and sourcing new High-Temperature Grease Supply.
• Prevent Catastrophe: Early detection of high wear metal content helps schedule downtime for repair before catastrophic failure occurs, minimizing material damage and downtime.
• Product Quality Check: Sometimes, the detection of poor-quality or thermally unstable grease is thanks to analysis. This gives the company a basis to re-evaluate their current High-Temperature Grease Supply provider.

6.3. Accurate Grease Sampling Procedure

Sampling must ensure representativeness:

• Sample from the Operating Area: The grease sample must be taken directly from the load zone of the bearing, where the grease experiences the highest load and heat.
• Use Clean Tools: Sampling tools must be completely clean to avoid cross-contamination from other grease or debris. The sample must be taken after the machine has run stably at its normal operating temperature.

7. Mistake 6: Ignoring Grease Consistency (NLGI Grade)

Consistency (NLGI Grade) is an extremely important technical parameter, determining lubrication ability and grease retention. Ignoring this factor, especially in specialized applications, is a common error.

7.1. The Significance of the NLGI Index in High-Temperature Grease Supply

NLGI (National Lubricating Grease Institute) Grade classifies grease consistency from 000 (thinnest) to 6 (thickest).

• NLGI 2 Grease (Common): This is the standard consistency, similar to peanut butter, widely used for most general bearing applications.
• NLGI 1 Grease (Thinner): Often used for centralized lubrication systems or bearings operating at extremely low temperatures, where a softer grease is needed to be easily pumped.
• NLGI 3 Grease (Thicker): Suitable for high-speed bearings, those with high vibration, or vertically oriented shafts, where a thicker grease is needed to resist flowing and leakage.

7.2. Consequences of Choosing the Wrong Consistency in High-Temperature Applications

In a high-temperature environment, selecting the wrong NLGI can cause problems:

• Choosing Grease That is Too Thin (NLGI 1 or lower): Although high-temperature grease is formulated not to melt, if the grease is too thin from the start, as the temperature rises, it will quickly flow out of the bearing, leaving an insufficiently thick layer for lubrication.
• Choosing Grease That is Too Thick (NLGI 3 or higher): Grease that is too thick will be difficult to pump through the small lines of a centralized lubrication system, especially in cold environments (even high-temperature grease can still thicken at ambient temperatures). Grease not reaching the lubrication point will cause under-lubrication, similar to Mistake 2. Furthermore, excessively thick grease can cause higher internal friction, leading to a temperature increase.

7.3. How to Choose the Optimal Consistency

The consistency choice must be based on three main factors:

• Equipment Speed: Higher speeds require thicker grease (NLGI 3). Low speeds (heavy loads) require slightly softer grease (NLGI 2 or 1) to ensure good lubrication.
• Distribution System: Centralized lubrication systems require grease with NLGI 1 or 2 consistency for easy pumping.
• Grease Retention Capability (Sealing Capability): If seals are slightly worn or the shaft is vertical, a thicker grease (NLGI 3) should be chosen to aid in grease retention. A professional High-Temperature Grease Supply provider must be familiar with these standards.

8. Mistake 7: Using the Same Grease Gun for Multiple Grease Types

Similar to the incompatibility mistake (Mistake 3), this error relates to cross-contamination, but the cause is the maintenance tools.

8.1. Cross-Contamination Risk from Tools

In large factories, the maintenance department often only has a few grease guns and only cleans them superficially between uses. This leads to:

• Transfer of Incompatible Thickeners: The residual old grease, often a few grams, left in the gun and hose can contain an incompatible thickener. When the new High-Temperature Grease Supply is pumped, this old grease mixes, causing a reaction that breaks down the grease structure right at the lubrication point.
• Transfer of Contaminants: The grease gun may contain dirt, sand, or carbon deposits from failed grease. These substances are pumped directly into the bearing along with the new high-temperature grease, causing immediate wear. This is the fastest way to reduce bearing lifespan.

8.2. “One Gun, One Grease” Standard in Maintenance

To completely eliminate this risk, modern maintenance standards always adhere to the “One Gun, One Grease” principle:

• Clear Identification: Every grease gun, every pneumatic pump, and every grease container must be color-coded or numbered to designate a single type of grease exclusively. Example: A red gun is only used for High-Temperature Lithium Complex Grease, a blue gun is only used for Heavy-Duty Calcium Sulfonate Grease.
• Use Specialized Couplers: Customize different types of grease fittings for each grease type to prevent personnel from accidentally using the wrong gun. Organizing the High-Temperature Grease Supply process must be accompanied by organizing storage and tools.

8.3. Grease Gun Cleaning Procedure (If Shared Use is Mandatory)

If, due to economic or other limitations, guns must be shared, the cleaning procedure must be rigorous:

• Purge: Pump a large amount of the new grease (the type to be used next) through the gun until there are no signs of the old grease. This action consumes grease but is necessary to clean the hose.
• Store Guns: Always store grease guns with a small amount of the new, designated grease in the hose to prevent dust and moisture from entering the gun.

9. Mistake 8: Ignoring Temperature Monitoring with Modern Methods

Relying on intuition to assess temperature is a major mistake. Equipment fails quickly when the temperature exceeds the grease’s allowable threshold.

9.1. The Destructive Effect of High Temperature on High-Temperature Grease

Temperature has a cumulative effect. Each time the temperature exceeds the continuous operating limit (e.g., 150°C), the lifespan of the high-temperature grease can be halved.

• Accelerated Oxidation: Increased temperature accelerates the oxidation reaction of the base oil. The grease quickly hardens, losing its lubricating ability.
• Oil Bleed: High temperature causes the thickener to lose its ability to retain the base oil. The oil separates faster, leading to premature grease drying.
• Sudden Failure: If the temperature approaches the Dropping Point, the grease can suddenly turn liquid, leading to immediate catastrophic failure.

9.2. The Importance of Non-Contact Temperature Measurement Methods

Temperature checks must be conducted regularly and systematically:

• Infrared Thermometer Gun (IR Thermometer Gun): This is the most basic tool, allowing quick and safe measurement of the bearing housing surface temperature.
• Thermal Imaging Camera: Provides a visual image of heat distribution, helping to detect abnormal Hot Spots caused by excessive friction or poor lubrication.
• Vibration Monitoring System: When grease fails, increased friction will increase vibration. Monitoring vibration is an indirect but effective way to detect lubrication and temperature issues.

9.3. Establishing Safe Warning Thresholds

Businesses need to establish temperature warning thresholds:

• Normal Operating Threshold: Stable operating temperature, no action required.
• Alert Threshold: Temperature increases by 5^\circ C – 10^\circ C compared to the baseline temperature. Lubrication should be checked, considering whether to pump a small amount of additional High-Temperature Grease Supply.
• Alarm Threshold: Temperature increases by 15^\circ C – 20^\circ C compared to the baseline. The machine must be stopped for immediate inspection because the bearing may be undergoing destruction.

10. Mistake 9: Using Outdated Lubrication Methods

Maintaining old maintenance habits, lacking updates on lubrication technology, is also a mistake that causes equipment to fail quickly.

10.1. Limitations of Fixed Time-Based Lubrication Schedules

Many factories still use rigid lubrication schedules: “Grease every 3 months.”

• Lack of Flexibility: A fixed cycle does not reflect actual operating conditions (load, speed, temperature, humidity). Under harsh conditions, 3 months can be too long, leading to failure.
• Risk of Over-Greasing: Under lighter operating conditions, a 3-month cycle can lead to over-greasing with High-Temperature Grease Supply, causing Mistake 2.

10.2. Trend Towards Condition-Based Lubrication (CML)

Advanced maintenance systems are moving towards CML:

• Vibration/Temperature-Based Lubrication: Only pump grease when vibration or temperature sensors indicate an increase in friction, signaling that the lubricating film is breaking down.
• Ultrasonic Greasing: This is the optimal method. Technicians use ultrasonic equipment to “listen” to the friction noise of the bearing. When the noise increases (due to lack of grease), they slowly pump High-Temperature Grease Supply until the friction noise reduces back to normal. This ensures the grease volume is always at the optimal level, avoiding both over- and under-greasing.

10.3. Updating Modern High-Temperature Grease Supply Solutions

To correct outdated mistakes, businesses need to invest in:

• Automatic Lubricators: Install compact, automatic lubricators programmed to pump a small amount of High-Temperature Grease Supply at short, regular intervals (e.g., 0.1 gram daily). This helps maintain a stable grease film, especially important for hard-to-reach locations.
• In-Depth Training: Train the maintenance team on modern diagnostic techniques such as vibration analysis and ultrasonic greasing, enhancing their capability to use specialized High-Temperature Grease Supply products.

11. VieTextile: Quality High-Temperature Grease Supply Solution for All Industries

VieTextile is proud to be a strategic partner in the field of High-Temperature Grease Supply and leading industrial lubrication solutions in Vietnam. We understand that product quality is only one part of the value chain; more important is providing knowledge and specialized consulting services to help customers avoid the 7 common mistakes that lead to premature equipment failure. Our commitment extends beyond just the High-Temperature Grease Supply to ensuring maximum operating efficiency for your machinery systems.

VieTextile’s technical team has extensive experience in evaluating harsh operating environments, from kilns, high-temperature drying lines to high-speed motors. We offer premium High-Temperature Grease Supply lines, diverse in thickener base (Lithium Complex, Polyurea, Calcium Sulfonate) and base oil (Mineral, PAO, Ester), proven to maintain structural stability at temperatures up to 280°C. The diversity of our products allows us to provide High-Temperature Grease Supply custom-designed to perfectly match each type of seal material and maintenance cycle you are applying.

We prioritize technical consultation before, during, and after the High-Temperature Grease Supply. This includes supporting customers in building grease compatibility charts, setting up lubrication thresholds based on actual machine conditions (Condition-Based Lubrication), and training maintenance personnel on accurate re-greasing techniques. With VieTextile, you don’t just purchase a lubricant; you purchase a comprehensive solution that helps extend equipment lifespan, minimize downtime, and optimize operating costs. We are always ready to support all your High-Temperature Grease Supply requirements.

12. Frequently Asked Questions (FAQ) About High-Temperature Grease

12.1. Q: How do I know if the high-temperature grease I am using has failed due to temperature?

A: The clearest signs are abnormally high bearing temperature (Mistake 8), the grease hardening, forming carbon deposits (also known as coking), or the grease turning liquid and leaking out. The Dropping Point and consistency need to be checked. VieTextile provides High-Temperature Grease Supply with clear technical specifications to facilitate comparison.

12.2. Q: Can I mix two high-temperature greases with the same Lithium Complex base but from two different manufacturers?

A: Theoretically, yes (Compatible), but it should be avoided. Additives and base oils can differ, causing a reaction that reduces the grease’s performance or stability. Always seek a stable High-Temperature Grease Supply source to avoid mixing greases.

12.3. Q: Which NLGI index is best for high-temperature grease?

A: There is no “best” index. The most common NLGI Grade is 2. However, if the equipment has extremely high rotational speeds or vertical shafts, NLGI 3 will be better to resist leakage. If it is a centralized lubrication system, NLGI 1 or 0 may be necessary. VieTextile provides diverse NLGI High-Temperature Grease Supply to suit specific applications.

12.4. Q: Is the mistake of over-greasing with high-temperature grease more serious than under-greasing?

A: Both are serious, but over-greasing (Mistake 2) often causes a rapid increase in temperature and pressure, leading to seal damage and structural breakdown of the grease. Under-greasing causes gradual wear. Both significantly shorten equipment lifespan.

12.5. Q: Which industries does VieTextile supply high-temperature grease to?

A: VieTextile provides High-Temperature Grease Supply to many industries such as textiles (drying, boilers), steel (furnace bearings), cement (rotary kilns, grinding), electricity (electric motor bearings), and manufacturing plants facing high temperature and load conditions.

To professionally and effectively correct the 7 mistakes in using high-temperature grease that lead to premature equipment failure, contact VieTextile today!

Contact Information: 

Hotline: 0901 809 309 

Email: info@vietextile.com 

Website: https://vietextile.com

In the knitting industry, the knitting machine needle is a fundamental tool that plays a decisive role in the final quality of the product. Whether it’s a high-speed circular knitting machine or a specialized flat knitting machine, the precision and perfect condition of each needle directly influence the fabric’s structure, uniformity, and aesthetic appeal.

Any minor defect on the needle shank, hook, or latch can cause serious faults in the fabric, leading to reduced quality, increased waste costs, and production disruption.

This article will delve into the core function of the knitting machine needle and provide a detailed analysis of the 5 most common fabric faults that originate from the needle, including fabric tears, wrinkles, and stripes.

1. The Core Role of the Knitting Machine Needle

The knitting machine needle is the component that executes the complex knitting cycle (loop creation, yarn drawing, cast-off) through reciprocating motion within the cam track. Despite its simple structure, each needle must ensure 3 main functions:

1. Catching and Drawing New Yarn: The needle hook must catch the newly supplied yarn smoothly.
2. Securing the Old Loop: The latch must close in time to secure the old stitch loop as the hook moves through.
3. Casting Off the Old Loop: The hook must release the old stitch loop cleanly so that the new yarn can form a new loop.

The precision and surface condition of the knitting machine needle are prerequisite factors for this cycle to occur perfectly at high speed.

2. Common Fault 1: Holes and Tears – Direct Physical Damage

Tears or holes are the most severe faults, often requiring the machine to be stopped immediately for resolution. Tears usually appear as single punctures or long rips along the stitch column.

2.1. Fault Mechanism Originating from the Needle

The main cause is that the knitting machine needle has transitioned from a knitting state to a destructive state:

• Broken Hook: When the needle hook breaks, the remaining needle tip forms a sharp, pointed edge. Instead of catching the yarn, this sharp edge snags the previously formed yarns or loops on the fabric, stretching and tearing them. This fault typically appears as a clear puncture hole.
  • Technical Solution: The broken knitting machine needle must be replaced immediately. A careful check of adjacent needles and the sinker is necessary to ensure they are not broken or chipped due to collision with the damaged needle.
• Deformed or Stuck Latch: The knitting machine needle latch must open and close under inertial force. If the latch is bent, warped, or stuck partially open by oil residue, it creates a sharp gap. As the needle moves down, this gap scratches and rips the old stitch loop.
  • Technical Solution: Intensify cleaning of the needle slots and latches. Only use high-quality knitting oil (typically ISO VG 22 or 32) with self-cleaning capabilities to ensure the needle latch moves smoothly.

2.2. Detection and Prevention Methods

• Needle Inspection: Use a magnifying glass to check the integrity of the needle hook and latch. Small cracks on the hook are early signs of fatigue breakage.
• Rust Prevention: Rust creates rough patches and sharp edges. Store spare knitting machine needle components in a dry, temperature and humidity-controlled environment. When the machine is stopped for an extended period, specialized anti-rust oil must be applied to the entire needle area.

3. Common Fault 2: Vertical Fabric Stripes (Needle Lines) – The Problem of Stitch Uniformity

Vertical fabric stripes are lines running parallel to the stitch column, causing differences in density and light reflection, reducing the aesthetic quality of the fabric. The core cause is the non-uniformity of the Stitch Length.

3.1. Fault Mechanism Originating from the Needle

• Uneven Needle Wear: This is the leading cause. Over time, the knitting machine needle hook wears down, reducing the actual distance between the hook and the knitting point. A worn needle creates a tighter and shorter loop than a new needle. This difference in stitch length (even if only 0.01mm) will create fabric stripes.
  • Technical Solution: Implement a Proactive Replacement strategy by replacing all needles simultaneously according to an operating hour schedule (typically 2500–3000 hours) rather than waiting for the needle to break. This ensures all knitting machine needle parts on the cylinder have the same level of wear, maintaining stitch uniformity.
• Butt Height Error: The needle butt is the part that contacts the cam. If the needle butt is bent, worn, or has a manufacturing error, it alters the timing of when the needle is activated by the cam. A needle activated at the wrong time will draw the new yarn from an incorrect position, leading to stitch length deviation.
  • Technical Solution: When installing new knitting machine needle components, use needles with extremely low butt height tolerance (below ± 5 microns). Absolutely discard any bent or warped needles.

3.2. Control and Analysis

• Stitch Length Measurement: Use a Stitch Length Meter to determine the difference between stitch columns.
• QC Report Analysis: Only use knitting machine needle components that come with a QC report guaranteeing absolute uniformity in shank thickness and butt height tolerance.

4. Common Fault 3: Fabric Wrinkles and Loop Distortion – Failure Due to Friction

Fabric wrinkles, also known as tight or twisted loops, occur when the knitting machine needle does not move smoothly or when the yarn is excessively pulled due to high friction.

4.1. Fault Mechanism Originating from the Needle

• Bent or Misaligned Needle: The knitting machine needle is slightly bent due to impact or cyclic stress. A bent needle significantly increases friction between the needle shank and the cylinder slot wall. The increased friction causes the needle to move unevenly, leading to a delay in the cast-off process and loop distortion.
  • Technical Solution: Use knitting machine needle components with high Core Toughness, vacuum-hardened to increase resistance to deformation. Check the straightness of the needle before installation.
• Damaged Anti-Friction Coating or Rough Needle: Conventional Chrome plating can wear out quickly, exposing the high-roughness steel substrate. When yarn passes through a rough needle, friction increases sharply, causing the yarn to be “pulled” and “twisted” instead of “sliding,” leading to loop tightening.
  • Technical Solution: Switch to knitting machine needle components with a DLC (Diamond-Like Carbon) coating. The DLC coating has an extremely Low Coefficient of Friction, allowing the yarn to glide easily over the needle, reducing loop tightening, and enabling the machine to operate at higher speeds without excessive heat generation.

4.2. Lubrication Management

This fault can also be a sign of insufficient knitting oil supply or deteriorated oil. Ensure the knitting oil is of the appropriate viscosity and high anti-oxidation quality to always maintain a perfect lubricating film between the knitting machine needle and the cylinder slot.

5. Common Fault 4: Frequent Yarn Breaks – Cutting Fault

Frequent yarn breaks not only affect productivity (constant machine stops) but also increase stress on the needle, leading to the risk of needle breakage.

5.1. Fault Mechanism Originating from the Needle

The main cause is the presence of sharp edges or gaps in the hook and latch area of the knitting machine needle, transforming the needle from a “knitting device” into a “cutting device”:

• Overly Sharp Hook Edge or Burrs: Although the knitting machine needle hook needs to be sharp to easily catch the yarn, an overly sharp hook edge or burrs due to manufacturing errors/localized wear will cut thin yarns, especially synthetic yarns with low tensile strength.
  • Technical Solution: Only use knitting machine needle components from suppliers with strict Hook Profile inspection procedures. Inspect the needle with a microscope before installation to check for burrs.
• Sharp Gap Between Hook and Latch: If the knitting machine needle latch is bent or warped, it can create a small, sharp gap at the contact point with the needle hook. When the yarn passes through or gets caught in this gap under tension, it will be cut.
  • Technical Solution: Replace the knitting machine needle immediately upon detecting a bent or incompletely closing latch.

5.2. Cumulative Impact

Yarn breakage also increases when the yarn has poor strength, is defective (knots, fuzz), or when the humidity in the workshop is too low (making the yarn dry and brittle). High-quality knitting machine needle components minimize physical impact on the yarn, compensating for environmental factors or imperfect yarn.

6. Common Fault 5: Dirty Fabric – Surface Hygiene Fault

Dirty or stained fabric with yellow/black streaks is the result of accumulated sludge and oxidized oil, which the knitting machine needle transfers directly onto the fabric.

6.1. Fault Mechanism Originating from the Needle

• High Surface Roughness: Poor-quality or excessively worn knitting machine needle components have high surface roughness (Ra). The rough surface creates micro-holes and grooves where oxidized oil residue, lint, and other dirt particles easily adhere and accumulate.
  • Technical Solution: Only use knitting machine needle components that have been professionally surface-treated, achieving extremely high smoothness (typically below Ra 0.2 µm). The use of DLC-coated needles also helps prevent this adhesion.
• Needle Reaction with Lubricating Oil: Needles with incompatible material or surface coating can react with the detergent additives or anti-oxidants in the knitting oil, leading to the formation of chemical sludge.
  • Technical Solution: Check the compatibility between the knitting oil brand and the needle manufacturer’s recommendations. Only use specialized, washable knitting oil that has been tested.

6.2. Preventive Cleaning

Regularly clean the needle, sinker, and cylinder area with compressed air or specialized cleaning solution to remove sludge before it has a chance to transfer to the fabric.

7. New Needle Selection Strategy: 3 Mandatory Technical Factors

To prevent the above faults, selecting high-quality knitting machine needle components is the most cost-effective investment strategy. Here are 3 mandatory technical factors to check:

7.1. Absolute Geometric Precision and Micro Tolerance

The difference between a knitting machine needle that causes fabric stripes and a perfect needle lies in tolerance:

• Shank Tolerance: The shank thickness must be absolutely uniform across the entire batch, usually allowing a deviation of only ± 0.005 mm (5 microns).
• Butt Height: The height must be strictly controlled to ensure synchronous activation by the cam, eliminating the risk of vertical stripe faults due to timing deviation.

Reputable knitting machine needle suppliers always provide detailed QC reports on this tolerance.

7.2. Anti-Friction and Anti-Adhesion Surface Treatment Technology

Prioritize knitting machine needle components with advanced coatings, which determine the needle lifespan and fabric quality:

• DLC (Diamond-Like Carbon) Coating: Maximizes friction reduction, increases yarn gliding capability, reduces heat generation, and extends needle life, while also preventing the adhesion of lint and oil residue.
• Surface Finish: The needle surface must be super smooth (low Ra) for the yarn to glide over without damage and without retaining dirt.

7.3. Core Hardness and Fatigue Strength

The knitting machine needle must be vacuum-hardened to achieve the optimal balance:

• Surface Hardness: High (60–65 HRC) to resist wear from friction.
• Core Toughness: Sufficient to resist brittle fracture when subjected to shocks or cyclic stress repeated millions of times at high speed.

8. Preventive Maintenance Solutions from VieTextile

VieTextile understands that the knitting machine needle is a critical component. We provide high-quality knitting machine needle solutions that help knit manufacturers minimize faults and optimize productivity.

We are committed to supplying genuine knitting machine needle products, manufactured from specialized tool steel alloys, applying DLC coating technology, and adhering to the strictest tolerance standards.

9. Frequently Asked Questions about Knitting Machine Needles (FAQ)

9.1. How often should knitting machine needles be replaced simultaneously?

Answer: The replacement of knitting machine needle components should be based on operating hours (typically 2500 to 3000 hours) or the total weight of fabric produced (e.g., 80–100 tons), even if the needle is not yet broken. Simultaneous replacement according to a Proactive Replacement schedule is the best strategy to prevent vertical fabric stripe faults (Needle Lines) caused by uneven wear between old and new needles.

9.2. What is the function of the DLC (Diamond-Like Carbon) coating on the needle?

Answer: The DLC coating is an advanced surface treatment technology that helps:

• Maximize Friction Reduction: Helps the needle move smoothly in the cylinder slot, reduces heat generation, and minimizes fabric wrinkling and Loop Distortion.
• Increase Lifespan: Enhances surface hardness, resisting wear more effectively than conventional Chrome plating.
• Anti-Adhesion: Prevents the accumulation of oxidized oil residue and lint, reducing the risk of dirty or stained fabric.

9.3. How to distinguish between fabric stripes caused by the needle and those caused by the yarn?

Answer:

• Needle Stripes: Typically clear, vertical stripes, fixed according to the needle column position, appearing continuously and not changing with the yarn batch. The cause is a worn needle or a Butt Height error that changes the stitch length at a specific needle column.
• Yarn Stripes: Often faint, horizontal or vertical stripes, not fixed, which may change or disappear when the yarn batch is changed (due to differences in yarn twist, count, or dye affinity).

9.4. Can a rusted knitting machine needle continue to be used?

Answer: Absolutely not. A rusted knitting machine needle creates rough patches and sharp edges, increasing friction tremendously. When this needle moves, it will scratch, score, and tear the yarn, causing severe Holes and fabric tears. Rust also damages the cylinder slot and adjacent needles.

9.5. What role does lubricating oil maintenance play for the knitting machine needle?

Answer: High-quality lubricating oil is the “lifeblood” of the knitting machine. It has 3 main roles for the needle:

• Friction Reduction: Ensures the needle moves smoothly, reducing fabric wrinkles and extending needle life.
• Cooling: Reduces the heat generated by friction at high speed.
• Cleaning & Anti-Rust: Knitting oil must have the ability to clean lint and dirt particles, while also protecting against oxidation and rust on the needle surface.
• Note: Only use specialized, washable knitting oil to avoid dirty fabric faults.

Please contact us for expert consultation on selecting the appropriate knitting machine needle for your yarn type and machine Gauge, as well as effective preventive maintenance strategies.

Contact Information: 

Hotline: 0901 809 309 

Email: info@vietextile.com 

Website: https://vietextile.com