UNLOCKING THE

HIDDEN POTENTIAL
OF MANUFACTURING
How lubricants can help increase productivity
and reduce total cost of ownership 

1
FOREWORD
A message from Yin Jie,
Shell Lubricants Global Sector Manager
for General Manufacturing

Evolving technology, changing In general, the cost of lubricants accounts for around
consumer demands and tightened 1% to 2% of a manufacturing company’s total maintenance
regulations are just a few of expenditure. Shell Lubricants technical experts have helped
the forces behind the ongoing manufacturing companies achieve savings that equal
transformation of the global their total lubricants spend and further impact up
manufacturing market. to 30% of maintenance budget, by adopting the right
approach to lubrication. Savings derive primarily from
To stay competitive, manufacturing lower maintenance costs, reduced equipment downtime
companies are striving to increase and productivity improvements.
productivity and reduce downtime
in order to meet deadlines while still maintaining product quality. There are two key elements to seizing this opportunity;
the first is selecting the right lubricant or grease, the second
Many companies already apply Total Cost of Ownership is effective lubrication management.
(TCO) evaluations to measure operational performance,
knowing that reducing TCO over the lifetime of machinery This paper explores the substantial business benefits possible
enables them to extract the best possible value from the from effective lubricant procedures. Case studies illustrate
asset. However, the impact of lubrication on TCO how manufacturing companies have successfully worked with
is too often underestimated.

An international survey of manufacturing companies

Shell Lubricants to upgrade their lubrication and extract value
by reducing TCO and improving equipment productivity. CONTENTS
commissioned by Shell Lubricants found that while the I hope you find it both informative and useful.
majority (59%) of companies recognise that effective 1. TOTAL COST OF OWNERSHIP: UNDERSTANDING THE POTENTIAL 4
lubricant selection and/or management can help reduce
costs by 5% or more, they undervalue the opportunity -
2. LUBRICANT SELECTION 5
fewer than 10% realise that the impact of lubrication
2a. Lubrication Challenges
could be up to six times greater1.
2b. Delivering Savings with High Quality Lubricants – Case Studies
Shell Lubricants believes lubrication can deliver significant
business value. When considering the potential savings, 3. LUBRICATION MANAGEMENT 15
we expand upon the typical definition of TCO to include 3a. Challenges and Solutions
productivity, and the costs of lost production resulting from 3b. Unlocking Value – Case Studies
equipment downtime2.

4. REALISING VALUE THROUGH LUBRICATION 20

4a. A Structured Approach to Upgrading Lubrication
4b. Helping Boost Manufacturing Productivity with Effective Lubrication – Infographic

5. WHAT’S NEXT? 22

6. APPENDIX 23
Lubricant Technology – Key Facts

1. This study commissioned by Shell Lubricants and conducted by research firm Edelman Intelligence, polled 493 decision-makers in the manufacturing industry in eight countries (Brazil, Canada, China,
Germany, India, Russia, the UK and the US) from November to December 2015
2. Total Cost of Ownership (TCO) is defined by Shell Lubricants as the total amount spent on industrial equipment, including cost of acquisition and operation over its entire working life, including costs
of lost production during equipment downtime

2 3
 1. TOTAL COST OF OWNERSHIP: 2. LUBRICANT SELECTION
UNDERSTANDING THE POTENTIAL
Shell Lubricants believes that there is potential for lubrication to deliver significant business value by contributing to improved Each piece of manufacturing equipment made by different original equipment manufacturers (OEMs) has its specific
productivity and reduced costs. However, the potential impact of lubricants is often significantly underestimated. lubrication requirements. OEMs define the minimum requirements from a lubricant or grease, but not all products that
meet these standards deliver the same level of performance.
Understanding how lubricants contribute to Total Cost of Ownership (TCO) is the first step to realising potential savings.

Total Cost of Ownership (TCO) 2a. LUBRICATION CHALLENGES

When evaluating the effect of lubricants on TCO, THE IMPACT OF Equipment design, operational parameters and surrounding THE BENEFITS OF HIGHER
Shell Lubricants considers the end to end impact on LUBRICATION environment can all pose different challenges for lubrication. QUALITY LUBRICANTS
maintenance budget and processes, but also any costs IS UNDERRATED. ARE OVERLOOKED 1
related to lost production during equipment downtime. Selecting the right lubricant or grease is a critical first
Optimising lubrication can have a significant impact step in improving productivity and realising significant
59% of companies believe they can TCO savings. 61% do not expect a higher quality lubricant
on component life, maintenance costs, and unplanned reduce costs by >5% through lubricant to help reduce unplanned downtime.
downtime so can contribute to cost savings far higher selection and/or management. The hydraulic system is at the heart of many critical
than the price of the lubricant itself. pieces of manufacturing equipment. Most companies Only 46% of companies believe product
But only 1 in 4 think savings could understand that proper equipment maintenance is essential performance should be an important
exceed 10%.1 to operational efficiency, but the impact of the hydraulic consideration when purchasing lubricants.
Seizing the Opportunity
fluid is often underestimated.
Lubricant product selection or management can impact many
elements of a company's maintenance budget. Seizing the
cost-saving opportunity depends on addressing two equally
important elements:

1. Selecting the right lubricant or grease - the right product

2. Effective lubrication management – including the right

storage & handling, the right place, the right time, the
FACTORS INFLUENCING
right amount, the right monitoring and the right people EQUIPMENT RELIABILITY

COMPONENTS OF TOTAL COST OF OWNERSHIP

Storage &
Handing

KPI Standard
Planning Procedure

Downtime and loss of production

Product costs
Total Impact of Lubricants on Cost

1. Lubricants
Decreased component life EQUIPMENT
Maintenance costs
2. Leaks RELIABILITY
Total cost of 3. Handling and dispensing
Equitment
Training
Increased maintenance costs ownership Optimisation
4. Oil analysis
5. Disposal
Business costs
Total Operating

6. Inventory
Maintenance & Business Processes 7. Administration
Costs

Oil Condition Contamination

and management Monitoring Centre
8. Training
Lubricants & Greases

4 5
THE CRITICAL ROLE OF HYDRAULIC FLUIDS “EVEN IF A HYDRAULIC SYSTEM
Hydraulic fluid plays a vital role in ensuring continuous and smooth equipment operation, energy savings and long machine
lifespan. This can help to reduce maintenance costs and increase productivity, thereby helping maximise the return on investment.
IS PERFECT IN DESIGN AND
CONSTRUCTION, IF THE HYDRAULIC
Wear protection System efficiency
The hydraulic fluid helps keep moving components apart
to avoid metal-to-metal contact and wear. To help ensure
A hydraulic fluid needs to protect, lubricate and transmit
FLUID IS UNSUITABLE OR IN IMPROPER
CONDITION THE EQUIPMENT’S
power efficiently. A product that offers excellent air release,
equipment remains protected in all conditions, the hydraulic
foam control and filterability helps enable equipment to
fluid must remain thin enough in cold environments to circulate
operate more efficiently.

OPERATION WILL BE UNSATISFACTORY

quickly to critical components, and then thick enough when
equipment is operating at higher temperatures to continue
to protect against abrasive wear.

Longer equipment life AND MAY RESULT IN DAMAGE TO

Oxidation of the lubricating fluid can result in the formation
of acids that can corrode equipment. A lubricant that offers
greater resistance to oxidation helps equipment operate
THE UNIT. SELECTING THE RIGHT,
under higher stresses for longer.
HIGH QUALITY HYDRAULIC FLUID
AND THEN ENSURING IT IS PROPERLY
Multiple surveys conducted by hydraulic equipment
manufacturers and other industry bodies have shown that
Selecting the proper type and grade of hydraulic fluid and
then performing proper fluid maintenance can help reduce
MANAGED IS JUST AS IMPORTANT
50% to 70% of equipment failures are related to ‘improper
hydraulic fluid condition’3.
the severity and frequency of equipment malfunction.
TO THE EFFICIENT OPERATION
KEY CAUSES OF OPERATING DIFFICULTIES OF A HYDRAULIC SYSTEM AS THE
IN INDUSTRIAL HYDRAULIC SYSTEMS CHOICE OF THE EQUIPMENT ITSELF.”
Improper hydraulic fluid condition – Ahmet Guven, Shell Lubricants Product Application Specialist for hydraulic
Improper diagnosis of a problem, or lack of knowledge in making repairs and circulating oils.
Mechanical failures (bearing failures due to misalignment, seal failures
due to dirt, etc.)

Operating units beyond recommended limits of speed, pressure, or volume

Miscellaneous causes (ranging from excessive packing friction on hydraulic rams,

to chatter resulting from inadequate lubrication of ways)

3 Source: multiple surveys by industry bodies including additive companies, filter manufactures, hydraulic equipment manufacturers. One source includes Parker Hannifin GmbH Bulletin: HY30-3248/
UK: Hydraulic Fluids for Parker Axial Piston Pumps Series PV

6 7
“SELECTING A LESS EFFECTIVE 2b. DELIVERING SAVINGS WITH
HIGH QUALITY LUBRICANTS 43% do not believe choosing

LUBRICANT MAY NOT RESULT IN

A high quality lubricant or grease that keeps equipment higher quality lubricants can help
clean of deposits and effectively protects against wear and improve productivity1.
corrosion can help extend equipment life, reduce frequency of

IMMEDIATE EQUIPMENT FAILURE, breakdowns and increase the machine’s availability. This could
significantly decrease spend on spare parts and maintenance.

BUT CAN LEAD TO INCREASED

MAINTENANCE EXPENSES OVER The reality of better product performance
Shell Tellus S4 ME hydraulic fluid lasts up to Shell
Higher is better

TIME. THESE MOUNTING COSTS

10 times longer 4 than the industry minimum- Tellus S4 ME
standard oil life. Long oil life enables customers Shell
to operate equipment for longer without Tellus S3 ME

CAN FAR OUTWEIGH THE SAVINGS interruption, and helps prolong hydraulic
pump life through excellent wear protection.
Shell
Tellus S2 ME
Industry-standard minimum life (100%)

FROM SELECTING A LOWER PRICED

Shell
The product is also proven to help improve Tellus S1 ME
energy efficiency. In a controlled test cycle, one 0 200 400 600 800 1,000

LUBRICANT. AS SUCH, IT IS IMPORTANT

injection moulding equipment maker measured Relative oil life, typical (%)
energy savings of up to 4%5 in the hydraulic (Industry-standard test ASTM D943)

systems using Shell Tellus S4 ME.

FOR COMPANIES TO THINK ABOUT

LUBRICATION AND EQUIPMENT
MAINTENANCE HOLISTICALLY, SELECTING THE RIGHT
RECOGNIZING THAT SHORT-TERM LUBRICANT HELPS
REDUCE TCO -
COST SAVINGS MAY BE LEADING CASE STUDIES
TO BIGGER, PREVENTABLE EXPENSES
The following case studies demonstrate how Shell Lubricants
OVER THE LONG TERM.” has worked together with manufacturing companies to
support them in selecting high quality lubricants and
greases to help generate substantial cost savings.6

– Yin Jie, Shell Lubricants Global Sector Manager for General Manufacturing.

As demonstrated in Shell laboratory testing. Actual savings/benefits will vary based on operating conditions and application
4

The actual energy savings depend on the application, the current oil, the maintenance procedures, the equipment condition, the operating conditions and the intensity of hydraulic power usage
5

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UPGRADING HYDRAULIC FLUID HELPS SAVE USD HIGH QUALITY MULTIPURPOSE GREASE REDUCES
$10,708 BY REDUCING MAINTENANCE COSTS GREASE CONSUMPTION BY OVER 16%, SAVING
AND EXTENDING OIL DRAIN INTERVALS6 ALMOST USD $10,0006

The Challenge Results The Challenge

Plastics manufacturer Amaray specialises in injection- The company reported savings of A year after installing a new production line, a fibreboard
moulded covering inlays for DVD trays. The company $10,708 or 14% for the two machines manufacturer based in China’s Shandong Province, Dongying
was looking to lower the operating costs of its two Engel Artificial Board Factory, was experiencing frequent failures
Victory VC 500/150 Plastic Injection Molding Machines. Savings derived from of its spherical roller bearings and high grease consumption.
The customer turned to Shell Lubricants for advice. The company wanted to reduce operating and maintenance
nn Lower maintenance costs
costs by changing the grease used to lubricate the bearings,
nn Longer ODIs resulting in lower lubricants and approached Shell Lubricants for advice.
The Solution costs and savings on oil change
Shell Lubricants technical experts evaluated the injection nn Reduced production loss during
moulding machines and identified that savings depended The Solution
oil change and maintenancew
on reducing maintenance costs, extending oil drain intervals Shell Lubricants technical experts recommended Shell Gadus
(ODIs), lowering energy use and reducing production loss S2 V220 2 to help the company cut its grease consumption
during equipment downtime. and thus reduce costs. This high-quality, multipurpose,
extreme-pressure grease is designed for heavy-duty plain
They proposed switching the hydraulic fluid to Shell Tellus and rolling-element bearings operating under harsh
S4 ME 46, which offers longer ODIs than the lubricant conditions, including shock loading in wet environments
previously used by the customer. Shell Tellus S4 ME and at a wide temperature range. The technical team also
46 worked without any problems in the machine for held a customised seminar for the factory on equipment
over 45,000 hours – over 7 times longer than OEM maintenance and lubricant storage.
recommended oil change of 6,000 hours. The product
is also designed to help improve energy efficiency for
hydraulic systems without compromising system protection.
The Results
In addition to upgrading the product, the recommendation
was also to make use of the Shell LubeAnalyst oil and nn After changing to Shell Gadus S2 V220 2, the company
equipment monitoring service. reduced its grease consumption by more than 16%,
from 600 to 500 kg a year

nn The company has experienced fewer bearing failures

and consequently less production downtime

nn Reported annual savings amount to US $9,848

nn The company is also benefiting from frequent on-site

visits and advice on equipment maintenance provided
by the Shell Lubricants technical experts

6 Case study savings/benefits were reported by one customer. Actual savings/benefits will vary.
More details available on request

10 11
COMPRESSOR OIL UPGRADE AND LUBRICANTS HELPING IMPROVE PRODUCTIVITY AND
TECHNICAL TRAINING HELPS SAVE USD $12,185 ENERGY EFFICIENCY OF HYDRAULIC EQUIPMENT
PER YEAR6

The Challenge The Results: By protecting, lubricating and helping transmit power
Dissatisfied with the poor performance of its existing effectively, the hydraulic fluid can help maintain or even
nn Changing to Shell Corena S4 R 68 reduced the improve the efficiency of hydraulic systems, contributing
compressor lubricant and seeking to reduce operational company’s operational costs by 50% and increased
costs, Turkish plastics technology and production capacity to lower costs of operation.
the oil-drain intervals from 5,000 to 10,000 hours.
company Pilsa Plastic Products Inc. turned to Shell Lubricants Customer field trials validate lubricant performance in
for support. Oil analysis indicated the oil had poor thermal nn The cost savings resulted from lower oil consumption real-life scenarios. This contributes to the development
and oxidation stability, which resulted in the need for an and labour costs, less oil waste for disposal and of products that are designed to help improve
oil drain every 5,000 hours. improved maintenance practices. performance, productivity and profitability.
nn The company reports saving US$12,185 a year. The following examples demonstrate how Shell Tellus
S4 ME helped improve hydraulic equipment productivity
The Solution
and energy efficiency.
Shell Lubricants technical experts monitored and analysed
the existing oil’s performance using the Shell LubeAnalyst
service, and recommended that the company should
change to Shell Corena S4 R 68, which would suit
its operation better. 1. Shell Tellus S4 ME 46 delivers overall energy 3. Shell Tellus S4 ME 46 Delivers Energy
Designed to deliver excellent protection and compressor efficiency gain of 2.4% per unit production7 Savings of 3.2%9
performance, Shell Corena S4 R offers: The hydraulic fluid in a model FN3000 injection moulding Trials aiming to improve energy efficiency were carried
machine was changed to Shell Tellus S4 ME 46. After two out in a Systec 160/840 injection moulding machine.
nn Long oil life - capable of providing oil maintenance runs, each based on a fresh charge of Shell Tellus S4 ME Two different viscosity grades of hydraulic oil were tested;
intervals of up to 12,000 hours (where allowed 46, an average energy efficiency gain of 1.2% and Shell Tellus S4 ME 46 and Shell Tellus S4 ME 68. The oils
by manufacturers) even when operating at maximum a productivity gain of 1.3% was observed. were tested by operating the machinery with three different
discharge temperatures in excess of 100°C. types of manufactured part at two different fluid temperatures10.
After ten minutes under each set of conditions, the mean power
nn Outstanding wear protection - helps provide exceptional and cycle time was determined. Compared to the reference
protection and protection of internal metal surfaces from
2. Boosting energy efficiency and productivity
oil, Shell Tellus S4 ME 68 delivered average energy savings
corrosion and wear. with Shell Tellus S4 ME 46 of 2.2%, while Shell Tellus S4 ME 46 achieved 3.2%.
In two separate trials with the same company, Shell
nn Maintains system efficiency - designed to provide rapid Tellus S4 ME 46 was introduced into a Cincinnati Magna
air release without excessive foaming to give trouble-free 500 ton injection moulding machine and Husky Hyelectric
operation even under cycling conditions 650/1000V model machine. After monitoring energy
consumption of both machines, the results showed8 an
Technical training in lubricant handling and application
overall specific energy efficiency gain in the Cincinnati
was also recommended, to better equip the company’s
machine of 3.6% per manufactured part (energy efficiency
staff to manage ongoing lubrication management.
1.0%; productivity gain 2.7%) and 2.6% per manufactured
part in the Husky (energy efficiency 1.1%; productivity
gain 1.5%).

7
Shell Global Solutions Field Demonstrations of Shell Tellus S4 ME energy efficiency. More details available upon request
8
Field trial results are from a single charge of Shell Tellus S4 ME 46 in each machine. More details available upon request
9
Shell Global Solutions Field Demonstrations of Shell Tellus S4 ME energy efficiency. Performance compared to the company’s in-house reference oil More details available upon request
10
The oils were tested under Euromap 60 conditions: a standard method for assessing energy consumption of injection moulding machines published by European trade association for plastics
and rubber machinery manufacturers, Euromap

12 13
3. LUBRICANT MANAGEMENT 3a. CHALLENGES AND SOLUTIONS
The following examples highlight some of the different
DID YOU KNOW?
lubrication management challenges commonly faced by
companies, the importance of taking action to address these, Shell Lubricants has one of the world’s largest teams
as well as the available Shell Lubricants Technical services. of technical lubricants experts. This 260-strong team
Even the best product cannot perform effectively of Shell Lubricants technical specialists supported
if it is not applied and managed correctly. by distributor partners, provides a suite of lubrication
SHELL LUBRICANTS’ Effective lubrication management is vital to unlock The Challenge: Right storage and handling management services across various industries.
They combine a thorough understanding of equipment,
SIX STEPS TO GOOD potential TCO savings. It helps deliver value from
improved productivity and reductions in lubricant
Contamination control is critical to maximising the overall
performance of the lubricant in equipment. How the oil
usually resulting from years working for a manufacturing
company or OEM, with in-depth knowledge of lubrication.
LUBRICATION consumption, maintenance and operating costs. or grease is stored, handled and transported through
the manufacturing site greatly impacts the likelihood
This enables Shell Lubricants to help manufacturing

MANAGEMENT of contamination.
customers maximise equipment productivity whilst
reducing TCO.
Storing drums in a sheltered place and wiping the top clean

1 Right storage & handling –

the lubricant must be stored in the right
LACK OF TRAINING AND LACK
before it is opened will help limit the risk of contamination
by water and particles. Applying filtration can also help
conditions and handled correctly to maintain and enhance product cleanliness before oil Out in the Field
OF PROCESS ARE OBSTACLES
avoid contamination and preserve its enters equipment. Ahmet Guven is a Global Product Application
key characteristics TO EFFECTIVE LUBRICATION
Specialist for Shell Lubricants, specialising in hydraulic
63% of businesses think they do not conduct and circulating oils. With over 24
staff training on lubricants and greases
2 Right place – for the oil or grease
to reach the right surface it must be as regularly as they should and only 42% The Solution: Expert advice and staff training
years’ experience in the industrial
application of lubricants, his role
properly applied to the equipment have all the correct lubrication management Underpinning good lubrication management practices is to provide technical advice
procedures* in place1 is industry knowledge and expertise. One of the core and support to customers across
lubrication management services offered by Shell Lubricants
3 Right time – the correct frequency
of oil change or re-greasing ensures is building technical competency across a customer’s
Europe and North Africa, whilst
also working closely with major
the lubricant reaches the surface at organisation. This is delivered through Lubricant Technical hydraulic OEMs and applying
the right time. Delays can result in Advisors, supported by a team of Global Product his extensive field-based experience to help guide
accelerated wear Application Specialists and Lubricants Services Experts. product research and development.
They regularly visit manufacturer sites to share expertise
with customers about lubrication management.
4 Right amount – the correct volume
of lubricant or grease applied and topped
up to protect moving parts effectively
The Challenge: Right Monitoring
5 Right monitoring – regular sampling
and analysis to ensure the lubricant
Regular monitoring and analysis is critical to ensure the
lubricant or grease is functioning well and remains fit for
Only 31% of companies are clear
remains fit for purpose and check for on how contamination control can
early indications of equipment wear. purpose. Lubricant analysis is vital to business continuity. correspond to TCO savings 1.
Inspections also ensure the consistent Owners and operators of mission-critical assets need
application of the first four steps. advance warning of mechanical problems that are likely
For a complete analysis service, to damage equipment, reduce productivity and increase
Shell offers LubeAnalyst maintenance costs.

6 Right people – the competence

of those who lubricate equipment
The Solution: Oil Condition Monitoring Services
can greatly affect its positive impact,
particularly when it comes to ensuring Oil condition monitoring services, such as Shell LubeAnalyst,
all of the above happens. can provide early warning of equipment wear or lubricant
degradation, enabling the lubricant to be changed before
issues escalate and thereby helping reduce the frequency,
time and cost of maintenance. This also helps improve
productivity due to greater equipment availability.

* Procedures include: delivery and storage of lubricants and/or greases, oil change procedures, oil dispensing systems, efficiency of grease lubrication systems, oil analysis and employee training on
lubricant selection and/or management

14 15
DELIVERING BUSINESS VALUE 3b. UNLOCKING VALUE THROUGH
THROUGH LUBRICATION SERVICES EFFECTIVE LUBRICATION Over the last five years, Shell Lubricants has
MANAGEMENT – CASE STUDIES documented $139 million in savings delivered
to customers worldwide; $72 million of which
The following case studies demonstrate how Shell Lubricants resulted from Shell Lubricants services12.
technical experts have worked together with manufacturing These savings represent only a portion of the
companies to help upgrade lubrication management real-world total, and indicate great potential for
processes and generate substantial cost savings11. TCO reduction and productivity increases across
Lubricant Analysis Identifying and Seizing Value Opportunities the industry through lubrication excellence.
A global oil and equipment monitoring service that helps Specialised Shell Lubricant Technical Advisors (LTAs) conduct
customers assess lubricant condition, identify potential site surveys to help customers identify areas for improvement
problems, and benchmark equipment performance against in lubrication. All stages of the lubrication process are
comparable oil samples from around the world. Available addressed, including product selection, delivery, storage,
in 95 countries and 28 languages, it has more than 60,000 distribution across the site, product application and disposal
users worldwide, and analyses over 750,000 samples a
year. The service allows customers to monitor equipment
of used lubricants. Changes are implemented and measured
through ‘Value Improvement Projects’.
PRODUCT UPGRADE AND IMPROVED LUBRICATION
without interrupting operations, and provides guidance MANAGEMENT EXTENDS OIL DRAIN INTERVALS BY
50%, SAVING USD $21,00013
on interpretation of results.

The Challenge: The results:

Granite and ceramic manufacturer Seranit Granit Seramik
Sanayi ve Ticaret produces 25% of the total granite products nn Oil-drain intervals increased from 4,000 to 6,000 hours,
in Turkey. While working with an alternative supplier, Seranit’s which resulted in annual oil consumption being reduced
Upskilling Employees Tailored Lubricants Advice by 6,400 kg
hydraulic tile press was experiencing frequent oil changes:
A customised training programme, led by Shell technical An easy-to-use online service that recommends the right
approximately every 4,000 hours. As the existing supplier
experts with substantial in-field experience, which offers choice of oil and grease for specific industrial applications. nn Total reported annual savings from reduced product
offered limited technical support and advice to address
practical coaching to customers’ staff on lubricant It provides jargon-free guidance on the benefits of different consumption was approximately US $21,000
the issue, the company turned to Shell Lubricants
management techniques. lubrication products. It is available in 120 countries and
for a solution. nn Using Shell LubeAnalyst to monitor oil condition enabled
26 languages, making it the most comprehensive and
integrated lubricant selection tool on the market. the company to benefit from lower maintenance and
labour costs as fewer mechanical failures reduced
The Solution: maintenance needs
Shell Lubricants technical experts conducted an extensive
oil analysis using the Shell LubeAnalyst oil and equipment
condition monitoring service. Following this, Shell Tellus
S2 V 46 was recommended for use in the hydraulic press.
The solution also included ongoing oil condition monitoring
and reporting using Shell LubeAnalyst, and on-site technical
visits and training of maintenance staff.

11
Case study savings/benefits were reported by one customer. Actual savings/benefits will vary. More details available on request
12
Documented customer savings from 2011 to 2015. More information available upon request.
13
Savings/benefits reported by one customer. Actual savings/benefits will vary. More information available upon request

16 17
IMPROVING LUBRICATION MANAGEMENT AND UPGRADING HYDRAULIC FLUID AND IMPROVING
UPGRADING GEAR OIL SAVES USD $106,78713 LUBRICATION MANAGEMENT HELPS EXTEND OIL
DRAIN INTERVALS, SAVING USD $16,50013

The Challenge The Results The Challenge

Water company Sino French Water Development Company nn The company reported savings of USD $106,787 Plastics processing company, Alpla D.O.O., was using
Limited (Sino French Water) provides six core services across (CNY 667,834) OEM-recommended VG 68 hydraulic oil in its Netstal-
China: water production, full water services, industrial water Maschinen AG plastic injection moulding machine.
treatment, municipal waste water treatment, sludge treatment nn Six months later, equipment was still working smoothly The product delivered oil drain intervals (ODIs) of 5,000 hours.
and O&M services. with no unplanned downtime. Easier management of the The company was looking to extend the ODIs as a way to
lubricant system meant the company had experienced help reduce costs, and contacted Shell Lubricants for advice.
The company had recently purchased 30 machines,
no operational errors causing machine downtime
including secondary settling tank scraper, concrete mixers,
sludge dewatering, and a submersible mixer. After running
The Solution
the equipment 24/7 for 900 hours (almost one month),
the company experienced an unplanned shutdown due Shell Lubricants technical experts recommended upgrading
to overheating of the gearbox oil. Oil temperature had the hydraulic fluid to Shell Tellus S3 M 68, designed to
reached 100o C, the lubricant was dark brown in colour deliver long oil life and improved system efficiency. They also
and could no longer be used, forcing equipment shutdown. recommended making use of Shell LubeAnalyst to conduct
regular lubricant condition monitoring, and implementing
an additional oil filtration system with a filter of 3 microns.
Finally, a technical training session was hosted for Alpla
The Solution staff, to upskill them in lubrication management.
Shell Lubricants technical experts visited the company’s
site and inspected the equipment to analyse the reasons
for the oil overheating. It became apparent that, contrary
Results
to OEM recommendation, gearbox oil of the same viscosity
had been used in all the different pieces of machinery nn After upgrading to Shell Tellus S3 M 68 hydraulic fluid,
in an attempt to simplify lubrication management. implementing regular lubricant monitoring using Shell
LubeAnalyst, and using the new filtration system, the
Shell Lubricants technical experts recommended flushing all
company realised savings estimated at USD $16,500.
of the gearboxes and changing the gear oil to Shell Omala
S4 GX 460, which met OEM recommendations. The technical nn Oil life extended from 5,000 to 15,000 hours, helping
team also offered follow-up support with the Shell LubeAnalyst to reduce equipment downtime by extending fluid
service, conducting regular visits to sample and test the oil. maintenance intervals.

18 19
 HELPING BOOST MANUFACTURING
4. REALISING VALUE HELPING BOOST MANUFACTURING
PRODUCTIVITY WITH PRODUCTIVITY
THROUGH LUBRICATION WITH EFFECTIVE LUBRICATION
EFFECTIVE LUBRICATION

COMPANIES UNDERESTIMATE POTENTIAL PRODUCTIVITY IMPROVEMENTS FROM EFFECTIVE EQUIPMENT LUBRICATION

A STRUCTURED APPROACH For example: 43% 6 in10

TO UPGRADING LUBRICATION nn What is the hourly cost of maintenance
do not believe choosing higher companies are unclear how lubrication can
quality lubricants can help influence unplanned down time or
A look at companies who have successfully implemented and time required for repairs? improve productivity equipment availability
structured, TCO-driven lubrication projects together with
nn What is the cost of replacement parts?
Shell Lubricants reveals a number of initial actions that THEY RECOGNISE BUT UNDERVALUE THE OPPORTUNITY FOR TOTAL COST OF OWNERSHIP1 SAVINGS
help drive success. nn What is the benchmark failure frequency?
nn What is the monetary value of downtime for each 59% But fewer than In reality, lubricants
nn Senior management support of the TCO-driven approach
piece of equipment, in terms of lost production? of companies believe they can savings
1in10 can impact up to
to lubrication, to help overcome challenges such as
resourcing alongside the demands of daily operations nn Setting measurable targets to ensure that progress
reduce costs by >5%
through lubricant selection
>5%
think savings could
exceed 25%
30%
and/or management of maintenance budget2
can be tracked
nn Appointing a project lead and allocating appropriate time
and resources to a team tasked with implementing changes These steps will help companies form a strong foundation LACK OF LUBRICANTS EXPERTISE, TRAINING AND PROCESS ARE BARRIERS TO SAVINGS
from which to successfully incorporate a TCO-driven
nn A good relationship with the lubricant supplier,
whose technical teams play a key role in identifying
approach to lubrication into daily operations, carry out
lubrication improvement projects, and realise the associated
Only
4 in10 43% 63%
and delivering value cost savings. have all the correct do not expect higher quality think they do not conduct
lubrication lubricants to help increase staff training on lubricants
nn A comprehensive analysis to identify, quantify and As equipment and lubrication technology continue to management productivity as regularly as they should
procedures in place3
prioritise TCO-related projects. Importantly, aligning evolve, regular review of the approach will help companies
on how value is measured enables savings to be continue to focus effort and resources on projects that deliver
THIS IS HAVING A FINANCIAL IMPACT
recorded accurately. greatest value. 

20% believe unplanned equipment shutdowns due to their incorrect lubricant

selection and/or management have cost their business $250,000 or more4

EFFECTIVE LUBRICATION CAN HELP COMPANIES REDUCE TOTAL COST OF OWNERSHIP (TCO) THROUGH LOWER
MAINTENANCE COSTS, REDUCED UNPLANNED DOWNTIME, AND PRODUCTIVITY IMPROVEMENTS

Driving down maintenance costs SHELL LUBRICANTS WORK WITH CUSTOMERS TO HELP DELIVER TCO SAVINGS

At least $139 million savings delivered 260 Shell Lubricants technical OEM and customer
There are many factors impacting maintenance 100%
to customers worldwide (2011-2015) 5 specialists help customers reduce collaborations enable
costs, but a direct correlation can be seen, where TCO through effective lubrication Shell Lubricants to develop
all other factors remaining equal, higher quality products that help improve
lubrication leads to lower maintenance costs. $$$ equipment reliability and
260 productivity
Achieving excellence in lubrication (product
selection and management) can result in far more Lubrication
Quality
significant cost savings than purchasing lubricants Shell Lubricants Services
based primarily on product price. Maintenance to help upgrade lubrication
Costs management: Helping identify and seize savings Expert advice on-site Lubricant monitoring Staff training

This study commissioned by Shell Lubricants and conducted by independent research firm Edelman Intelligence, polled 493 decision-makers in the manufacturing
industry in eight countries (Brazil, Canada, China, Germany, India, Russia, the UK and the US) from November to December 2015
1. Total Cost of Ownership (TCO) is defined by Shell Lubricants as the total amount spent on industrial equipment, including cost of acquisition and operation
over its entire working life, including costs of lost production during equipment downtime
60% 2. Potential impact calculated based on Shell Lubricants site surveys with customers.
3. Recommended procedures are delivery and storage, oil change, oil dispensing systems, efficient grease lubrication systems, oil analysis and training employees in lubricant selection or management.
4. $ figure based on converting local currency into equivalent $ amount
5. Based on savings delivered to Shell Lubricants customers from 2011– 2015

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 5. WHAT’S NEXT? APPENDIX
LUBRICANTS TECHNOLOGY – KEY FACTS
With productivity paramount, customers are seeking Base oils and Additive Packages
to increase output capacity by minimising unplanned
equipment shutdowns and extending maintenance cycles.
FOUR FUNCTIONS Base oils typically make up 75% to 95% of the finished product
and influence many of its key characteristics. They are key
Machinery is required to work under higher temperatures, OF LUBRICANTS to determining factors like viscosity and lubricity.
greater power density and higher operating pressures.
What’s more, as equipment is becoming smaller and Each key function plays a different role in helping The additive package comprises up to 25% of a lubricant’s
more compact, but with better efficiency and higher output cut TCO. The aim is to achieve the best balance composition and works to enhance key performance
demands, this places increased demands on the lubricants. of the four, to maximise the impact of the lubricant aspects of the base oil, to achieve optimum performance
or grease on TCO and equipment productivity. of the finished product.
In many countries, such as China, there have also been
rapid technological advances. For example, the growing
REDUCE FRICTION
prevalence of industrial robots are making the need for Examples of how this is achieved include:
Each key function plays a different
reliable, precise, unmanned equipment operation more
role in helping cut TCO. The aim nn Protection against wear to extend component life and
vital than ever. That requires lubricants and greases that
is to achieve the best balance of the help reduce maintenance costs. This is delivered through
can be trusted to deliver efficient performance without
four, to maximise the impact of the anti-wear additives that prevent metal-to-metal contact,
close monitoring or interruption.
lubricant or grease on TCO and extreme pressure agents that separate metal surfaces
To respond to the industry’s needs and meet future challenges, equipment productivity. at high pressure and sometimes solid fill additives that
Shell Lubricants is continually developing products to help protect against shock loads at low speeds.
reduce energy consumption and operating costs, and to CLEAN
raise productivity, product quality and equipment uptime. Lubricants flush away contaminants, nn Operating performance, delivered through detergents
removing dirt and wear particles from and dispersants that help manage the build-up of soot
Shell Lubricants has long-standing relationships with many vital areas for removal via filtration. and other impurities. This helps avoid abrasive wear
OEMs. Many of these companies supply their equipment Many also contain active detergents that can impair equipment performance.
containing a lubricant from Shell as an essential component for more powerful cleaning.
of the machine. nn Reduced cost of lubrication as a result of longer oil
PROTECT or grease life. This is achieved through anti-oxidants
The Shell Lubricants portfolio of products for general
Lubricants and greases form a protective that help the oils deal with higher temperatures
manufacturing has over 3,000 equipment manufacturer
barrier between moving surfaces, and loads, prevent corrosion, and guard against
recommendations or approvals, including approval from:
preventing metal-to-metal contact and lubricant breakdown.
nn The American Gear Manufactures Association (AGMA) wear. They also contain additives
that neutralize harmful acids such as
nn The American Society for Testing and Materials (ASTM) combustion by-products that can impact

nn Deutsches Institut für Mormung (DIN)

equipment life. Enhanced protection
helps limit wear and extend the life LUBRICANT FORMULATION
nn International Organization for Standardisation (ISO) of components, helping to reduce
spend on spare parts. A lubricant’s precise blend of base oil and additive package
helps ensure that it is able to deliver optimum performance
for the longest possible time in a cost effective manner.
COOL
Lubricants absorb excess heat from The process of creating a new oil or grease – from
high friction zones and transfer it away |selecting components, to rigorously testing the formulation
Collaborating with industry leaders for cooling. This allows the equipment and conducting field trials – is highly complex and can
to function efficiently. (Not a critical take several years. In some cases lubricants evolve over
Shell Lubricants works closely with many of the world’s OEM collaborations include: Bosch, Schaeffler Group, function of greases) decades, in line with developments in chemistry, and
leading OEMs and leading industrial committees. Husky, Parker, Flender, Hanshin, Honeywell, CompAir, technology innovations.
Collaborating with the companies that are leading ABB, Bridgestone, Bonfiglioli, Textron, Bosch Rexroth
technology advancements in general manufacturing helps Group, Mitsubishi, SEW Eurodrive
shape the development of advanced lubricants designed
to help customers get the best out of their machinery.

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 Typical composition of base oil
GREASE THICKENERS
and additives for an industrial oil Greases are designed to release lubricating fluid under
(Factory Plant Maintenance Oil) pressure and then reabsorb it. The life of the grease
is determined by its ability to do this without changing
consistency – its mechanical stability.

Grease thickener is one key component of a grease and

impacts its quality. In most countries, lithium or lithium
complex thickeners are used for the majority (~80%) of all
applications. These deliver good water resistance, excellent
mechanical stability and corrosion resistance, and remain
fully viscous at high temperatures.

PARTNERING FOR INNOVATION EXCELLENCE

Committed to delivering value to customers, nn Shell Lubricants manufacturing portfolio has
Shell Lubricants invests significant resources thousands of approvals and certifications from
in developing new lubricants and greases manufacturing industry OEMs, such as Denison,
for the manufacturing industry. Eaton Vickers, Bosch Rexroth, Siemens,
Cincinatti -Milacron
A network of collaborations strengthens the innovation
capabilities of Shell Lubricants Research & Development nn Innovation is key to addressing the next generation
teams located in Technology Centres in Shanghai, of lubrication challenges. The Shell Lubricants
Hamburg and Houston. Discovery Hub is a global, multi-disciplinary team
focused on pushing the boundaries of current
nn Technical Partnerships with OEMs help ensure
lubrication technology
that oils and greases are optimised for the latest
equipment technology

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