Engineered for Uptime: Turnkey Automated Lubrication System Modernizes a High-Demand Manufacturing Operation

Posted by Pneumatic and Hydraulic Company LLC on

Case Study Overview

A leading industrial mat manufacturer operating a high-output continuous-production facility was relying on a lubrication process that was fully manual. The outdated system required maintenance personnel to climb ladders, access confined spaces and individually grease dozens of bearings and rotating components throughout a multi-story industrial press structure. The press was divided into two distinct operating sides, including a “hot” side where process fluid continuously circulated at temperatures exceeding 400°F. During operation, this portion of the press became too hot for personnel to safely access, preventing routine lubrication activities and limiting maintenance to scheduled shutdown periods.

In some cases, the press required up to two days to cool to a safe ambient temperature before lubrication could begin. The existing process resulted in unplanned shutdowns and production interruptions valued at approximately $200,000 per day. Failure to properly lubricate the press also created the risk of catastrophic bearing failures.

Pneumatic and Hydraulic Company (PHC) designed, turnkey-managed and installed an automated centralized lubrication system using Graco® technology. The system incorporated a centralized grease pump supply package, a large grease header line routed throughout the press structure, 160 grease points, stainless steel tubing and flexible hose assemblies serving lubrication points across the machine, including moving components that could not be effectively serviced through rigid tubing alone.

The project eliminated the need for manual greasing across the press, reduced scheduled downtime, improved lubrication consistency and lowered the risk of catastrophic bearing failures capable of shutting down production for days. Executed during a tightly scheduled two-week shutdown window, the installation demonstrated PHC’s ability to engineer solutions for harsh industrial environments and deliver large-scale turnkey maintenance optimization improvements under demanding operating conditions. 

Project Scope

At its Gulf Coast manufacturing facility, the customer operates a multi-story industrial press measuring approximately 25 feet tall, 25 feet wide, and nearly 100 feet long. Critical to continuous production operations serving heavy industrial and infrastructure applications, portions of the structure extend into below-ground confined spaces beneath the production floor, creating significant maintenance access and safety challenges. The press is also divided between ambient and high-temperature operating zones, with one side continuously exposed to process fluid temperatures exceeding 400°F. During operation, that portion of the structure becomes unsafe for personnel access, further complicating routine maintenance and lubrication activities.

Prior to PHC’s involvement, the lubrication process was entirely manual. Maintenance technicians were required to physically access approximately 160 grease points throughout the press using ladders, lifts and confined-space access routes. Bearings and moving components had to be greased individually with handheld grease guns on a recurring schedule to prevent wear, seizure and equipment failure.

The process created several operational and safety challenges:

  • Labor-intensive maintenance requiring significant technician intervention and elevated-access procedures
  • Scheduled downtime required to perform manual lubrication tasks
  • Difficult access points to the multi-story industrial press, including below-ground confined spaces and elevated access areas
  • Elevated safety risk around high-temperature production equipment
  • Lack of oversight on lubrication points caused by manual maintenance processes
  • Potential for catastrophic bearing and rotating component failures
  • Production interruptions capable of costing approximately $200,000 per day 
  • Narrow outage window with no tolerance for schedule overruns

The manufacturer turned to PHC based on a proven working relationship established through previous repair and service projects. Confidence in PHC’s execution capabilities and responsiveness led the customer to entrust PHC with a turnkey implementation during a critical planned shutdown window.

Turnkey Solution

PHC designed and installed a centralized automated lubrication system engineered specifically for the geometry and operating conditions of the customer’s press. The system automated lubrication delivery to 160 grease points using a centralized grease pump supply package, a large grease header line, stainless steel tubing, and flexible hose assemblies. The system delivered consistent lubrication to bearings and rotating assemblies throughout the press, including moving lubrication points that could not be served through rigid tubing alone.

The turnkey solution included:

  • Centralized automated grease distribution system
  • Graco® pump and control technology
  • One centralized grease pump supply package
  • Large grease header line routed throughout the press structure
  • 160 grease points served by the automated lubrication system
  • Stainless steel tubing and flexible hose assemblies routed across multiple elevations and confined spaces
  • Electrical integration and programming support
  • Integrated project execution and implementation
  • On-site fabrication and installation support
  • Full installation performed within the customer’s shutdown schedule

The operating environment introduced several engineering and installation challenges:

  • Extreme heat generated by the composite mat pressing process
  • Multi-story press geometry with difficult access points
  • Below-ground confined spaces requiring specialized routing and installation methods
  • Tight installation schedule tied directly to production restart requirements
  • Approximately 160 lubrication points requiring automated grease delivery throughout the press structure, including moving lubrication points requiring flexible hose assemblies

Installation execution required work across elevated access areas, confined spaces and high-temperature operating zones while maintaining schedule integrity during the planned shutdown window. To improve installation efficiency and long-term mounting durability, PHC implemented a best-practice mounting approach using custom steel brackets fabricated in-house and welded directly to the press structure on-site.

Implementation

  1. Initial Evaluation and Planning: PHC evaluated the existing manual lubrication process, identified approximately 160 lubrication points throughout the press structure and coordinated system design requirements with Graco® technology partners.
  2. Shutdown Coordination and Mobilization: The project was scheduled to align with the customer’s planned facility shutdown, creating a narrow execution window with no tolerance for schedule overruns.
  3. Installation and Routing: The installation required work across elevated platforms and below-ground access areas, demanding careful planning to safely execute within tight spaces and high-temperature operating zones.
  4. System Integration and Testing: The automated lubrication system was connected, tested and commissioned to ensure grease distribution reached all designated lubrication points consistently and reliably.
  5. Final Delivery: The completed system automated lubrication delivery across the press while improving lubrication consistency, reducing maintenance burden and supporting long-term equipment performance.

Outcomes

Executed within a critical two-week shutdown window, the turnkey automated lubrication system improved production continuity while reducing operational risk, maintenance burden and safety exposure in a high-demand manufacturing environment.

  • Turnkey execution: PHC delivered complete system implementation, including system design, grease pump supply integration, 160 grease points, stainless steel tubing and flexible hose assembly installation, automated system integration and commissioning
  • Reduced downtime: Automated lubrication eliminated the need for recurring maintenance shutdowns previously required to manually grease bearings and rotating components throughout the press
  • Improved lubrication consistency: Automated grease delivery to 160 lubrication points reduced the risk of missed lubrication intervals, catastrophic bearing failures and production interruptions valued at approximately $200,000 per day
  • Enhanced safety: Significantly reduced technician exposure to confined spaces, elevated work areas and high-temperature operating zones where process fluid temperatures exceeded 400°F
  • Continuous operation: The automated system lubricates critical equipment while the press remains in operation, reducing reliance on scheduled greasing activities and supporting uninterrupted production
  • Labor efficiency: Eliminated the need for maintenance personnel to manually grease approximately 160 lubrication points throughout the press, allowing greater focus on higher-value maintenance activities

Pneumatic & Hydraulic Company supports industrial operations with turnkey fluid power, lubrication and maintenance optimization solutions designed to improve equipment performance, reduce downtime and simplify maintenance across challenging operating environments. From manufacturing and industrial processing to infrastructure and energy-related operations, PHC delivers integrated solutions for uptime-critical facilities where reliability, safety and operational continuity matter most. Learn more at Pneumatic and Hydraulic Parts | Pumps, Valves, Fittings.