Klüber Lubrication GB

1. With rising operational costs and increasing demand for efficiency, how are paper manufacturers rethinking lubrication as a strategic enabler rather than just a maintenance function?

The biggest shift I see is that lubrication is increasingly being considered as part of a broader reliability and asset management strategy, rather than solely a maintenance task. As organisations face rising operational costs, many are evaluating decisions based on total cost of ownership rather than purchase price alone. While initial cost remains an important consideration, the selection of a lubricant may also influence factors such as relubrication intervals, maintenance requirements and equipment performance, depending on the application and operating conditions.

At Klüber Lubrication, we work with customers to assess lubrication requirements and support the development of lubrication strategies tailored to their operating conditions. In my experience, effective lubrication strategies are built on selecting an appropriate lubricant and ensuring it is applied in the correct quantity, at suitable intervals and using the appropriate method. When combined with good lubrication management practices, this approach can help support reliability objectives and contribute to operational efficiency. Ultimately, the focus should be on the overall value that a lubrication strategy can provide within a specific operating environment, rather than on purchase price alone.

2. In your experience working closely with clients, what recurring gaps do you observe in traditional lubrication practices across paper mills?

One common challenge we observe across paper mills is lubrication being treated as a routine maintenance task rather than as a process that benefits from the same level of control and oversight applied to other maintenance activities.

Examples can include over- or under-lubrication, inappropriate lubrication intervals, and the application of incorrect lubricant quantities. We also frequently see opportunities to improve lubricant storage, handling and contamination control practices. For example, open oil containers or grease guns stored in unsuitable environments may introduce contaminants into the lubricant before it reaches the equipment. There can also be challenges associated with lubricant identification, storage and control processes, potentially increasing the risk of incorrect product selection.

In our experience, industries such as food and beverage often place a strong emphasis on lubricant storage and handling practices due to their regulatory requirements. Many of these principles may also be relevant to other sectors, including paper manufacturing.

There is also increasing interest in the use of automation and condition monitoring within lubrication programmes. While many lubrication activities continue to be carried out at fixed intervals, sensor data may, in certain applications, be used to help inform lubrication frequency and quantity decisions.

This is one area where Klüber focuses its support for customers. Our approach is not centred solely on lubricant products. Through our Lubrication Management programme, we support customers across various aspects of lubrication management, including storage and handling practices, training, lubrication systems and condition-based lubrication strategies, where appropriate.

3. How does your organization differentiate itself in addressing these challenges within the highly competitive paper and pulp industry?

I think one of the key aspects of Klüber's approach is that we do not view our role solely as a lubricant supplier. Product performance and technical expertise are important aspects of our offering, but we also focus on the wider lubrication strategy and its role within maintenance operations.

When working with customers, we take a broader view of lubrication management, considering factors such as product selection, storage and handling practices, application methods, lubrication intervals, and whether technologies such as automation or condition monitoring may be appropriate for the application. Through our Lubrication Management approach, we bring these elements together to support a structured lubrication programme.

This support may include product selection, reviews of lubrication practices, storage and handling guidance, training, lubrication systems, and condition-based lubrication strategies, where appropriate. The aim is to help customers assess their lubrication processes and identify opportunities to support maintenance and reliability objectives.

4. Your portfolio includes advanced lubrication solutions—how are these specifically engineered to meet the high-load, high-temperature demands of paper manufacturing environments?

Paper manufacturing can present challenging conditions for lubrication. Equipment may be exposed to high loads, elevated temperatures, high operating speeds, water ingress and contamination, sometimes within the same process. In addition, some applications are expected to operate for extended periods between maintenance activities.

Our approach is to understand the operating conditions and then select lubricant technologies that are appropriate for the specific application. This may involve different lubricant chemistries depending on the operating environment. For example, formulations designed to support temperature and oxidation stability, additive technologies intended for load-carrying and wear protection requirements, or thickener systems selected for applications involving exposure to moisture or wet operating conditions.

It is also important to consider factors beyond the lubricant itself. Lubrication practices, including application methods, quantity and frequency, can influence lubrication outcomes. In some applications, automatic lubrication systems may help support more consistent lubricant application.

One aspect of Klüber's approach is its focus on technical application knowledge. Rather than considering only whether a lubricant meets a specification, we seek to understand the operating conditions, equipment requirements and lubrication objectives to support the selection of an appropriate lubrication solution for the application.

5. Could you share how tailored lubrication programs or customized solutions have helped clients achieve measurable performance improvements?

One of the key things we do is start by understanding a customer's existing lubrication practices rather than simply recommending an alternative or like-for-like product.

This typically begins with a lubrication audit designed to assess key areas associated with lubrication management and identify potential opportunities for review. From there, a site-specific improvement plan may be developed. This often includes a comprehensive site survey, examining equipment, applications, lubricant selection, lubrication intervals and application quantities.

Based on these findings, it may be possible to identify opportunities to optimise lubrication practices, support reliability objectives, review lubricant usage, standardise products where appropriate, or evaluate the suitability of technologies such as automatic lubrication systems and condition monitoring. The focus is on developing an approach tailored to the individual site's operating conditions and requirements.

Where changes are implemented, their impact can be assessed using relevant operational and maintenance indicators, which may include lubricant consumption, downtime trends, component service life and lubrication-related maintenance events.

6. How are technologies like synthetic lubricants and smart lubrication systems helping your customers extend equipment life and reduce unplanned downtime?

I think both technologies play an important role, although they address different aspects of lubrication management.

Synthetic lubricants can offer benefits in demanding applications, depending on the operating conditions and the lubricant formulation selected. Depending on the chemistry, they may support temperature and oxidation stability, address wear protection requirements and, in some applications, support extended lubrication intervals. This may contribute to maintenance and reliability objectives where appropriate. For example, we offer lubrication solutions for both the hot end and wet end of paper machines, where operating conditions can be particularly challenging.

Smart and automatic lubrication systems can help deliver lubricant at predefined quantities and intervals, supporting a more controlled lubrication process. This may help reduce the likelihood of over- or under-lubrication and can reduce reliance on manual lubrication activities, particularly for critical or difficult-to-access applications.

For example, on paper machines with hard-to-reach lubrication points, automated lubrication systems may be used to support the lubrication of roll bearings. These systems can help provide a consistent lubricant supply while reducing the need for manual lubrication activities in challenging working environments.

7. How is your organization leveraging digital tools such as condition monitoring or predictive maintenance to enhance lubrication management for clients?

Condition monitoring is an area of increasing interest as organisations look to further support their lubrication practices.

Traditionally, lubrication strategies have often been based on fixed time intervals. Advances in technology can support a more condition-based approach, where information such as temperature, vibration and other equipment data may be used to help inform lubrication decisions.

Sensors have been used in industrial applications for many years. More recently, developments have focused on integrating sensor data with lubrication management practices, including automatic lubrication systems.
Klüber Lubrication has developed an automatic lubrication system that can be connected to condition monitoring sensors. Depending on the application and system configuration, lubricant dispensing can be adjusted based on data received from the sensor, supporting a condition-based approach to lubrication management.

For us, the key consideration is that technology should support, rather than replace, effective lubrication fundamentals. We assess each application individually to determine where condition monitoring may be appropriate and beneficial. It is not a one-size-fits-all approach. For example, in some critical applications, condition monitoring data may help maintenance teams detect changes in equipment condition and make informed maintenance decisions. In other cases, particularly where equipment is less critical or easily accessible, a manually managed lubrication programme based on predetermined intervals may remain an appropriate option.

8. Can you provide examples of how data-driven lubrication strategies are transforming maintenance from reactive to predictive in paper mills?

A good example of this trend is the increasing use of condition-based lubrication approaches alongside traditional fixed-interval lubrication programmes. Historically, bearings may have been lubricated at predetermined intervals based on manufacturer recommendations, operating experience or site maintenance practices. However, these intervals may not always reflect the current operating condition of the equipment.

Some organisations are incorporating techniques such as ultrasonic testing to support lubrication decision-making. By providing additional information about bearing condition, these methods can assist maintenance personnel in determining when lubrication may be appropriate, rather than relying solely on a fixed schedule.

A similar approach can be applied to oil-lubricated equipment. Oil analysis has been used for many years, but its application is becoming increasingly common on critical assets, including paper machine circulation systems. By assessing parameters such as oil condition and contamination levels, maintenance teams can obtain information that may support decisions regarding lubricant maintenance activities, including oil change intervals.

9. From a business perspective, how do advanced lubrication solutions contribute to tangible ROI for paper manufacturers?

I think it's important to look beyond the purchase cost of the lubricant and consider the role lubrication plays in supporting equipment reliability and maintenance objectives. In paper manufacturing, equipment issues can have a wider operational impact, so many organisations assess lubrication programmes on their contribution to reliability and maintenance performance rather than product cost alone.

When lubrication practices are appropriately managed, they can help support equipment performance and reduce maintenance challenges. That's why Klüber takes a broader approach, combining lubricant technology with lubrication management practices to help customers support their maintenance and reliability goals.

10. What key performance indicators (KPIs) should decision-makers track to evaluate the effectiveness of a lubrication optimization program?

We encourage customers to track relevant technical and operational metrics when evaluating lubrication programmes. The KPIs used will depend on the objectives of the programme, whether that is supporting reliability, maintenance performance or operational efficiency.

For example, organisations may monitor indicators such as lubrication-related equipment issues, component performance, lubricant consumption and maintenance resource requirements.

Our focus is on supporting customers through both lubricant technology and lubrication management practices. The effectiveness of a programme can then be assessed against the customer's own maintenance, reliability and operational objectives, rather than solely on the volume of lubricant purchased.

11. Sustainability is a growing priority—how are your lubrication solutions helping paper manufacturers reduce environmental impact and meet ESG goals?

One area where Klüber Lubrication has considerable experience is the assessment of energy efficiency opportunities associated with lubrication. Our energy efficiency measurement methodology has been independently assessed by TÜV SÜD and is aligned with recognised standards, including IPMVP and ISO 50015.

This provides a structured framework for assessing and verifying energy performance improvements where they occur. Depending on the application and operating conditions, results may be quantified in terms of energy consumption, operating costs and associated CO₂ emissions.

For paper manufacturers, where energy costs can represent a significant proportion of operational expenditure, this information can support maintenance and asset management decisions. For example, paper machines often incorporate large gearboxes operating continuously. In certain applications, lubricant selection may influence frictional losses and energy consumption. Where measurable improvements are identified, they can be assessed using an independently reviewed methodology, helping organisations evaluate opportunities related to operational efficiency and sustainability targets.

12. How do you balance performance and sustainability, especially when introducing biodegradable or environmentally acceptable lubricants?

Sustainability and technical performance should be considered together when selecting a lubricant. The suitability of any lubricant will depend on the application and operating conditions, including factors such as wear protection, temperature requirements and service life.

Where biodegradable or environmentally acceptable lubricants are appropriate, we look to identify solutions that address both environmental and technical requirements. The aim is to find an appropriate balance for the application, ensuring that environmental considerations are assessed alongside operational needs.

13. What approach do you recommend for companies looking to implement a comprehensive lubrication management strategy across multiple facilities?

One of the things we often observe when working with organisations operating multiple sites is that each facility has its own requirements. While equipment may be similar, factors such as processes, maintenance practices and lubrication knowledge can vary considerably.

For this reason, it is often helpful to establish a baseline through a lubrication assessment. In some cases, a single site may be selected to pilot a lubrication management programme, allowing approaches and practices to be evaluated before being considered for wider implementation.

Implementing a lubrication strategy across multiple sites is typically a gradual process. The aim is to establish a consistent framework and set of standards while allowing flexibility to reflect the specific needs and operating conditions of each site.

14. As Head of Sales, how do you see customer expectations evolving, and how is your organization preparing to lead the next phase of innovation in lubrication solutions for the paper industry?

Customer expectations are evolving, with many organisations looking beyond lubricant products and taking a broader view of reliability, maintenance and operational performance. Increasingly, there is interest in understanding how lubrication strategies fit within wider maintenance objectives.

At Klüber, our focus extends beyond lubricant selection to include areas such as lubrication assessments, standardisation, training, lubrication systems and condition monitoring. Our Lubrication Management approach brings these elements together to support a structured lubrication programme.

Condition-based lubrication is an area of growing interest within the industry. Advances in sensor technology and condition monitoring are creating opportunities to use equipment data to help inform lubrication decisions. In some applications, this may support a move away from purely time-based lubrication schedules towards approaches that take equipment condition into consideration.

As Head of Sales, I believe technology, data and lubrication expertise will continue to play an increasingly important role in supporting maintenance and reliability objectives within the paper industry.

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