Mastering viscosity: the key to high quality lubricants
Finding the right viscosity in lubricant manufacturing
The secrets of formulation: Challenges of an ideal Viscosity
The formulation and production of high-performance lubricants require precise viscosity control in order to ensure consistent product quality.
Lubricants can be obtained by blending two distinct base oils. The correct ratio between the two oils must be reached to achieve the desired final properties. Ensuring accurate viscosity measurement during this process is critical, as variations can affect lubricant properties and performance.
Understanding viscosity and temperature
Viscosity refers to a fluid resistance to flow. As temperature increases, viscosity decreases—the oil becomes thinner. Conversely, when the temperature drops, the oil thickens and its viscosity increases. This explains why oil flows much more easily on a warm summer day than during a cold winter morning.
However, not all oils react the same way to temperature changes. Some high-performance oils are specially formulated to better maintain their viscosity across a wide range of temperatures. This behavior is described by the term viscosity index. The higher the viscosity index, the less the oil’s viscosity is affected by temperature fluctuations.
When lubrication conditions deteriorate
When lubrication conditions deteriorate, boundary lubrication may occur. This means that the protective oil film becomes so thin that there is intermittent contact between moving surfaces, leading to wear and potential damage. If this situation is not addressed quickly, the lack of sufficient lubrication can cause equipment failure within just a few hours.
For lubricant manufacturers, factors like kinematic and index viscosity must be carefully considered when formulating lubricating oils. But what does this mean for the end user? Simply put, viscosity is the first and most crucial factor to consider when choosing the right oil for a specific application.
From Laboratory to In-Line viscosity measurements: the Key to process efficiency
Limitations of laboratory control
Before adopting a process viscometer, most companies rely on a lab viscometer. This method is not only time-consuming and causes delays but also introduces discontinuities that doesn’t show the variabilities of the process.
The need for reliable and continuous monitoring
The need for a more efficient and reliable viscosity measurement solution becomes evident, as the production process requires many samples to make sure the lubricant meets quality standards. “We needed something reliable and that took less time so we reached out to Sofraser for a solution”, said a lubricant manufacturer.
Sofraser Warrants Reliable & Continuous Measurements
Three adapted solutions for lubricant manufacturing
To address these challenges, Sofraser large range of viscometers is the solution.
Three solutions are suitable for this application: an online THERMOSET analyzer, an in-line MIVI viscometer or a benchtop SOFAST viscometer.
Each one of these solutions delivers precise measurement and each has their own specificities.
The THERMOSET is an analyzer at reference temperature that requires no oil bath nor oven. The MIVI is a versatile process viscometer and the SOFAST is a benchtop viscometer. All of them use the Sofraser vibrating type technology, which delivers state-of-the-art of measurements.
By offering fast, easy and precise viscosity control directly in the production environment, Sofraser viscometers ensure that each blend meets the required specifications without delays or inconsistencies.
Optimized process efficiency & Product quality
“The implementation of the new viscometer minimized the risk of human error, leading to greater repeatability and precision in viscosity control” a Sofraser viscometer user said.
The quick measurement capabilities of the sensors allow for fast adjustments, ensuring optimal formulation accuracy while making sure the production line is not slowed down.
This optimization not only enhances product quality but also increases overall operational efficiency, allowing manufacturers to maintain high manufacturing standards while streamlining their processes.
Sofraser’s Benefits: A smoother & More Reliable Process
Integrating Sofraser’s solution ensures faster, more accurate, and more reliable lubricant production. The adoption of a new Sofraser monitoring solution reinforces a company’s commitment to precision and efficiency in lubricant formulation, positioning it for continued success in the industry.
