Petron Plus Global Inc.
Industrial
Customer Challenges

 

 PETRON PLUSTM

INDUSTRIAL CUSTOMER CHALLENGE’S & TRAIL’S

Customer Challenge:

A leading cement plant in Missouri experienced a major failure on their #2 trunnion bearing.  The trunnion bearing shaft was badly cut.  To change-out the trunnion would require several unscheduled days to change out.  They took a chance in changing out only the failed bearing, leaving the scored trunnion which weights approximately 50 tons in place.

PPGI Solution:

They added Petron Plus Transmission & Gear Box Supplement to the high pressure lube system.  The trunnion bearing lasted until scheduled outage.  The bearing under the scored shaft did not have a mark on it.

They also switched to Petron Plus High-Temp Lithium Complex Grease, and reported a 30 (400 lbs) drums savings from the previous year with a competitor grease.

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Customer Challenge:

A leading Cement plant in Pennsylvania uses a Elmco slurry mixer drive developed a torque and high amperage problem.  Normal amperage averaged 6 but had risen to 12 and the potential existed for an overload.

PPGI Solution:

They added Petron Plus Transmission & Gear Box Supplement to the system, the amperage dropped to 6 within 30 minutes, and had no further problems.

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Customer Challenge:

A major elevator company in Ohio had experiences high amps in their geared elevators.

PPGI Solution:

After adding Petron Plus Transmission & Gear Box Supplement to  the gear case, they checked the amperage a week later to fine it had dropped to 50 amps.

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Customer Challenge:

A leading grain company in Kansas reported a heat build-up in the gear box on one of their bucket elevators.  They changed the oil, and after one hour, again had a significant heat build-up.

PPGI Solution:

They added Petron Plus Transmission & Gear Box Supplement,  the operating temperature dropped, and this produced a 16% reduction in amperage as well.

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Customer Challenge:

 A leading cement plant in Missouri had a gear box overheating on a raw mill I. D. fan motor.

 PPGI Solution:

 They added Petron Plus Transmission & Gear Box Supplement to the bearings enabled them to delay changing a rough bearing or 2,000 H.P motor until time was convenient.  It also dropped temperature from 165°F to 135°F.

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Customer Challenge:

 A major manufacture of coated fabrics for the automotive industrial in Massachusetts has 6 vinyl extruders.  The Gloucester Engineering gear box on number 2 extruder had always run hot.  High heat required machinery shut down, causing interruptions in mfg. process.  Normal operating temperature was 185°F, peak load was 115 amps and regular load was 94 amps.

 PPGI Solution:

 Oil was changed with 15% Petron Plus Transmission & Gear Box Supplement.  The temperature drooped 60 degrees, peak load dropped 24 amps, normal load drooped 10 amps.

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Customer Challenge:

 A small oil produced in Kansas was having problems with the gear boxes on their pump jacks.

 PPGI Solution:

 After adding Petron Plus Transmission & Gear Box Supplement to the gear boxes, they reported the following on 5 pump jacks:  16% reduction in amps,  35% reduction in amps,  7% reduction in amps,  8% reduction in amps,  and 10% reduction in amps.

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Customer Challenge:

 A nationally known grocers-retailer warehouse in Kansas operated 20 Crown Reach-Forks and 35 Crown Pallet Jacks.  They were experiencing an alarming bearing failure rate on Reach-Forks averaging 87 per month at an average of $17.00 per bearing; Pallet Jack failures averaged 17 per month at an average of $14.00 per bearing.

 PPGI Solution:

 They switched to Petron Plus High-Temp Lithium Complex Grease, and have reported a $20,000 savings on bearing and a substantial amount on maintenance man hours.  They also reported grease consumption was roughly half that of their former grease.

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Customer Challenge:

 One of the largest Ski Resorts in Colorado reported problems with grease dripping from the ski lift cables onto customers jackets. 

 PPGI Solution:

 They switched to Petron Plus High-Temp Lithium Complex Grease, with no drips reported, and saved money on grease consumption and laundry bills.

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Customer Challenge:

A European Tractor manufacturer was experiencing lubrication failure on their paint shop conveyor while operating in a series of hostile environments, including water, heat and paint.

PPGI Solution:

The added Petron Plus Industrial Super Lube (10%) by volume to their existing lubricant.  This produced the following reported drops in amps: Drive A - 24%,  Drive B - 16%, Drive C -  12%,  and Drive D - 10%.

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Customer Challenge:

A European Exhaust manufacture was experiencing problems with Cam Follower Bearings on a Silence Box End Seamer.

PPGI Solution:

 They switched to Petron Plus High-Temp Lithium Complex Grease, which extended the bearing life from one month to over three months.

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Customer Challenge:

 A County In Michigan had been experiencing difficulties with lubrication on King Pins on 93 road trucks.

 PPGI Solution:

 They switched to Petron Plus High-Temp Lithium Complex Grease, and reported it has solved their problems.

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 Customer Challenge:

 A internationally known oil field company was having high bearing failures on their equipment in their Egypt location.

 PPGI Solution:

 They switched to Petron Plus High-Temp Lithium Complex Grease, and after one year have had no failures.

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 Customer Challenge:

 A large plastic company in Michigan was having problems with molds.  Preventive Maintenance (P.M.) was performed every 10,000 cycles.

 PPGI Solution:

 Today, because of Petron Plus High-Temp Lithium Complex Grease, their P.M. cycle have been increased to 25,000 cycles.  This represents a reduction in moldmaker labor of 14 hours per month.

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 Customer Challenge:

 A Army Ammunition Plant in Missouri was having to change the oil in their production equipment before it was scheduled for change do to high heat and speed of the equipment.

 PPGI Solution:

 They added Petron Plus Transmission & Gear Box Supplement to their existing gear oil, the interval between changes has been increased by 63%.  They also switched to Petron Plus High-Temp Lithium Complex Grease, they reported increased bearing life by 73% in their high speed production line.

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Customer Challenge:

 A European SUV manufacture was expressing high electrical bills.

 PPGI Solution:

 A energy survey was carried out on each machine before and after the application of Petron Plus Transmission & Gear Box Supplement, and the results were seen on graphs.  The average energy consumption after Petron Plus T&GB was added, decreased by 5.34%.  Cost savings based on 168 hours week, times 50 weeks produced a annual net savings of £7,247.00

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Customer Challenge:

 A European Nuclear Fuel plant conducted a test on their 35 ton crane.

 PPGI Solution:

 They added Petron Plus Transmission & Gear Box Supplement to the gear box existing lubricant.  They reported the results by graphs.  The average energy consumption after Petron Plus T&GB was added, decreased by 10.75%.

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Customer Challenge:

 A international grain company had a trail conducted at one of their European plants.  Energy consumption was monitored for 2 months while the equipment was operating under normal load, fully loaded and under continuous operation; before and after the application of Petron Plus product.

 PPGI Solution:

 After Petron Plus Transmission & Gear Box Supplement was added, they reported an average energy reduction of 7% under continuous operating condition.  Based on 24 hours day x 7 day/week x 48 weeks/year, energy savings were calculated to be £5,033.55

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Customer Challenge:

 A UK auto manufacture had a trial conducted on a Broomewade VM 750 Compressor.  Energy consumption was monitored while the equipment was operating under normal load, fully loaded and under continuous operation; before and after the application of Petron Plus product.

 PPGI Solution:

 After Petron Plus Transmission & Gear Box Supplement was added, they reported an average energy reduction of 6.81% under continuous operating condition.  The net annual energy savings were calculated to be £1,126.00 after the cost of the Petron Plus product.

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 Customer Challenge:

 A trial was conducted at a European steel manufacture.  Energy consumption was monitored while the equipment was operating under normal load, fully loaded and under continuous operation; before and after the application of Petron Plus product.

 PPGI Solution:

 After Petron Plus Transmission & Gear Box Supplement was added, they reported an average energy reduction of 3% on one unit, and 6.5% on a second unit that were under continuous operating condition. 

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Customer Challenge:

 A trial was conducted at a international known manufacture of household tools and appliances in one of their European plants.  Energy consumption was monitored while the equipment was operating under normal load, fully loaded and under continuous operation; before and after the application of Petron Plus product.

 PPGI Solution:

 After Petron Plus Transmission & Gear Box Supplement was added, they reported an average energy reduction of 6% on one unit, and 1.7% on a second unit that were under continuous operating condition. 

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Customer Challenge:

 A large city in China tested Petron Plus Engine Conditioner in their city buses.

 PPGI Solution:

 Following strict standards the test allowed no adjustments to the buses, before and after adding the Petron Plus products.  They reported:  On the five buses test fleet, they had an average fuel savings of 16.2% and the operating conditions improved dramatically.  Engine noise was cut down, lube oil consumption dropped 50% and emissions dropped significantly.

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Customer Challenge:

 A rubber molding plant in Connecticut, was having problems with bumper cam life on their compression molding machines.

 PPGI Solution:

 They reported:  ...As indicated in the “15 Month Analysis” of your product, prior to the introduction of your oil these cams had needed repair or wholesale replacement on the average of every 3 to 4 months.  Now that every machine in the plant has been rebuild and switched to your products we can conservatively estimate (50% repaired & 50% replaced) that we will realized $54,000 in savings for the new bumping cams alone (minimum: $900. each) over 2½ years for our rubber molding compression wheels.

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  Customer Challenge:

 A Rock Quarry company in New York was experiencing problems with their out board bearing on a manual clutch on a large 600 horsepower crusher.  The bearings problems that occurred in the past was costing the company between $5,000 to $7,000 in parts and labor, plus 2-4 days of down time on the crusher.

 PPGI Solution:

 After adding Petron Plus Transmission & Gear Box Supplement to their equipment they reported:  ..we have not experienced any more problems with the bearing failure.

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Customer Challenge:

 A FAA facility in Kansas, was overhauling their long range antenna radar pedestal every 5 years.  It operates 24 hours a day seven days a week.

 PPGI Solution:

 They switched to Petron Plus High-Temp Lithium Complex Grease and reported:  ...it looks like-we will be able to extend this from 8 to 10 years now, Also,, it enabled us to reduce the frequency of greasing by 75%. 

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Customer Challenge:

 A plant in Connecticut

 PPGI Solution:

 After switching over to Petron Plus High-Temp Polyurea Grease, Transmission & Gear Box Supplement, Industrial Super Lube, Hydraulic Supplement products, they reported in a 13 page report:  “A Minimum of $291,000.00 up to More than $437,000.00 in Maintenance & Production Savings Generated form use of PETRON PLUS & PETRONOMICS Lubrication Products” at this one plant.

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Customer Challenge:

 A Aerospace Engineering Lab at a Kansas University Reported: ...we have 3 testing machines in the department which are used on a very sporadic basic.  The machines many not be used at all for 6 months and then used continually for 2 months.  These machines are water cooled and if run without water will overheat and shut down, usually in a mater of minutes.  ...sure enough the first test after the Petron Plus Hydraulic Supplement was added the students forgot to turn on the water and ran for almost 2 hours before they noticed it.

 PPGI Solution:

 They Reported: The machine did not overheat after 2 hours of non cooled operation.  You can bet that Petron Plus Hydraulic Supplement is going to stay in our testing machines form now on.

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 Customer Challenge:

 A Maintenance Engineer for a International Auto Parts Mfg., Reported:  ...their old European-made “deburring” pressure chamber hydraulic head-door pump was making noise and nothing seemed to solve the problem.  Everything they tried failed...

 PPGI Solution:

 They Reported:  out of desperation they replaced 6 to 8 gallons of ...with Petron Plus Hydraulic Supplement in a 60 gallon reservoir in this high pressure system.   They have not had a noise from pump in 5 years!

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Customer Challenge:

 A independent trucker reported he was getting 5 mpg on his over the road truck.

 PPGI Solution:

 He Reported: With-in the month after adding Petron Plus Diesel Engine Conditioner, and Petron Plus Ultra All-Season Diesel Fuel Conditioner to his truck, his mileage went to 5.8 mpg, 6.1 mpg, 6.9 mpg to 7.4 mpg a 21.62% increase in fuel economy.

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Customer Challenge:

 A company in Connecticut that operates a Davis & Furber felt machine experienced a failure when a teflon drive belt broke during processing.  In the past, when this ...occurred, the very high heat of the rollers would weld the bearings to the roller shaft and replacement was necessary.  This would require unexpected downtime & loss of production as well as labor and parts costs (parts: $4,000).

 PPGI Solution:

 ...We had recently switched from a well known high temperature NLGI-2 grease to Petron Plus’s Polyurea grease.  We were amazed that all we had to do was replace the drive belt to continue on our production schedule.  The bearings had survived the high heat.  This would have been impossible without your grease!

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Customer Challenge:

 A company in Connecticut operating a Farrel 1040 Roto-Cure mill were experiencing high temperatures and amp loads.

 PPGI Solution:

 With the addition of minimal levels of Petron Plus Transmission & Gear Box Supplement to our 124 gallon central lubricating system, ...we experienced a 11% drop in operating temperature.  ...the amperage draw of the 10 hp. main gear drive motor dropped an average of 18% in both load and normal running conditions, which should lead to much longer life.

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Customer Challenge:

A company in Connecticut operating a Farrel 1040 Roto-Cure mill, ...the rollers in this machine are controlled by a 1000 psi hydraulic system with a 14 gal. sump. 

PPGI Solution:

As an experiment, only 2% of Petron Plus Hydraulic Supplement was added and the temperature of the system dropped 10%. 

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Customer Challenge:

 Two trucking companies in Canada reported their mileage was costing them to much for their over the road trucks.

 PPGI Solution:

 Reported: They both with-in the month after adding Petron Plus Diesel Engine Conditioner, and Petron Plus Ultra All-Season Diesel Fuel Conditioner to their truck, they have a 23%, and 13% increase in fuel economy.

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Customer Challenge:

 A shipping company in the Southeast US, reported spending 6.1 million for fuel for their fleet of ships.

 PPGI Solution:

 Reported: They adding Petron Plus Diesel Engine Conditioner, and Petron Plus Ultra All-Season Diesel Fuel Conditioner to one of their ships, they reported the ship went from 5.2 to 6.1 nautical miles increase in fuel economy, a 14.8% increase.

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INDUSTRIAL TRIALS  CONDUCTED  IN  EUROPE

 

TRAIL CONDUCTED AT  ALCOA,  SWANSEA, ON NO. 4 BRIDLE GEAR BOX

SUMMARY OF THE MONITORING CARRIED OUT ON THE NO. 4 BRIDLE GEARBOX BEFORE AND AFTER THREATMENT WITH (PPX) PETRON PLUS TRANSMISSION & GEARBOX SUPPLEMENT.

Average power consumption Before PPX . . . . 29.902 kw

Average power consumption After PPX . . . . 26.179 kw

Power Savings Same Material & Conditions . . . 03.723 kw

Percentage Savings . . . . . . 12.5%

Energy reduction per year at 3p/kw hr continuous use . . .£978.00

Cost of PPX . . . . . . . £150.00

Net Savings . . . . . . . £827.50

The drip in power is caused by a reduction in friction.  The reduction in friction supposes less wear, which will significantly extend the gearbox life and maintenance intervals.

A reduction in Friction is also reflected by the following temperatures reductions noted:

Temp. of the 2 Gearboxes before PPX . . 45°C. 44°C

Temp. of the 2 Gearboxes after PPX . . 32.9°C 31.2°C.

Temperature reduction (%) . . . 27% 29%

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TRAIL CONDUCTED AT AP LOCKHEED, LTD, (AUTOMOTIVE PRODUCTS) - LEAMINGTON SPA ON MULTI-HEAD SPINDLE GEARBOX-

A multi-head spindle gearbox, which suffers regular bearing failure was selected for field trials.

Bearings were replaced at four monthly intervals.

The multi-head was re-built, with new bearings fitted, gear oil supplement with 10% PPX T&GB, and put back into operation.

One year and five months later, the multi-head was stripped for another reason but the opportunity was taken to examine the bearing condition.  No visible wear was apparent.  The gearbox is now re-built and back in operations

TRIAL DETAILS:

MULTIHEAD-65 bearings (of which 59 are thrust type INA31103) are used at £296.00 per set.  Total savings in 16 months were £11,184.00 less £10.00 cost of PPX for net savings £1,174.00

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TRAIL CONDUCTED AT  ALUMAX-KAWNEER,  LLANTRISANT, ON PAINT SHOP CONVEYOR.

Trials were conducted on plant shop conveyor to determine friction reduction qualities of PPX at high temperatures (200°C / 392°F) with the ultimate objective of reducing maintenance costs in this segment of the plant.  An energy survey was conducted which recorded a 6.7% reduction in energy after application of the PPX product. 

Continued monitoring has confirmed expected reduction in wear, and maintenance downtime.

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TRAILS CARRIED OUT AT AVESTA SHEFFIELD STEEL (FORMERLY BRITISH STEEL STAINLESS), PANTEG,  ON NO. 3 WINCH DRIVE GEARBOX

The 1st stage of the energy survey was carried out on the above mentioned gearbox before the application of PPX T&GB.

PPX was then applied at 10% to the SHELL GL 320 Gear Oil, and the 2nd stage of the survey carried out.

The result of the survey was as follows:

Average Energy on lifting/lowering, before PPX . . . 17.87 kw

Average Energy on lifting/lowering after PPX . . . 15.80 kw

ENERGY SAVINGS . . . . . . 2.07 kw

PERCENTAGE SAVING . . . . . 11.50%

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TRAILS CONDUCTED AT BP CHEMICALS, LTD., BARNSLEY, ON REDUCER  GEARBOX / EXTRUDER UNIT 17:

                                                                                                      
                                                                                                                   Before PPX                  After PPX        
Average Energy   .                .                 .                .                 .                131.665 kw                             83.426 kw

Temperature        .                .                 .                .                  .                     43°C                                          36°C

ENERGY REDUCTION             .            .            .          48.24 kw,  or  36.6%

TEMPERATURE REDUCTION .          .            .            7°C or 16.3%

Annual energy savings are estimated to be in excess of £3,000.00

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TRAILS CONDUCTED AT BRITISH STEEL STAINLESS, PANTEG WORKS, ON 45 TON AUXILLARY HOIST GEARBOX.

The 1st stage of the energy survey was carried out on the above mentioned gearbox before the application of PPX T&GB.

PPX was then applied at 10% to the SHELL GL 320 Gearbox Oil, and the 2nd stage of the survey carried out.

The results of the survey was as follows:

Average Energy consumption on lifting before PPX . . 27.75 kw

Average Energy consumption on lifting after PPX . . . 26.60 kw

ENERGY SAVINGS . . . . . .   1.15 kw

PERCENTAGE SAVING . . . . .   4.20%

 

Average Energy Consumption on lowering before PPX . . 27.35 kw

Average Energy Consumption on Lowering after PPX . . 25.14 kw

ENERGY SAVINGS . . . . . .   1.21 kw

PERCENTAGE SAVING . . . . .   4.4%

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TRAILS CONDUCTED AT BRITISH STEEL WELDED TIBES, CORBY, ON BRONX STRAIGHTENER MACHINE.

Following are results of the energy survey carried out:

Bronx Straightener Machine before PPX (no load) . . . 23.10 kw

Bronx Straightener Machine After PPX (no load) . . . 20.50 kw

Energy Saving . . . . . . .   2.60 kw

Percentage Savings . . . . . . 11.30 kw

Bronx Straightener Machine Before PPX (on line-constant load and material)  39.752 kw

Bronx Straightener Machine After PPX (on line-constant load and material)     35.142 kw

Energy Saving . . . . . . . 4.610 kw

Percentage Saving . . . . . . 11.6%

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TRAILS CONDUCTED AT BROOK CROMPTON PARKINSON, LTD., GUISELEY, ON WINDER TEST BED.

Trials were conducted on “Winder Test Bed” and then subsequently in a Broadbent Lathe, Radial Drill and “Gack” Facing And Centering Machine.

Initial trials were conducted on severely damaged Winder Test Bed to evaluate preventive maintenance potential of PPX Friction Reducer.  Test bed was operated over twenty hours with no sign of further deterioration in gear or bearings condition.

Following highly successful result on initial trials with Winder Test Bed, it was decided to further evaluate the products by treating several gearboxes with PPX Friction Reducer.  Energy consumption was monitored on a Broadbent Lathe, Radial Drill and Gack Facing and Centering Machine under like conditions before and after the application of the PPX product.  15%,  12%,  and  12,7% energy reductions were noted.  The energy savings alone more than compensated for the cost of the PPX product.

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TRAILS CONDUCTED AT  CARGILL PLC, HULL, ON K2 OIL PRESS MAIN DRIVE GEARBOX.

Energy consumption was monitored between Nov 24 and Jan 16 while the equipment was operating under normal load, fully loaded, and under continuous operation; before and after application of PPX.

An average energy reduction of 7% under continuous operating conditions was recorded.

On a basis of 24 hr/day 7 day/week 48 weeks/yr. @ 4 pence/kw hr. energy savings were calculated to be £5,033.55.  Total cost of PPX product was £500.

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TRAILS CONDUCTED AT MASSEY-FERGUSON-UK,, CONVENTRY, ON PAINT SHOP CONVEYOR.

Problem:  Ensuring lubrication of chain, whilst operating in a series of hostile environments, including water, heat, and paint.

“PPX Friction Reducer (ILX), mixed at 10% of the volume, was supplemented to the existing high temperature lubricant.  This new mixture was applied via an automatic applicator system, designed to apply oil where required and reduce unwanted contamination from excess lubricant.  This is normally applied once a week for a complete circuit of the chain.

Tension pre load, via pneumatic ram, was set at 55-60 psi to ensure smooth running.

Results after PPX:  The chain ran smoother to the extent that pre load via the tension unit was reduced to 25 psi.  (The following motor current reading was noted:)

Before PPX After PPX % Reduction

w/c 7/10 w/c 14/10

Drive A 5.0A 4.0A 3.8A 24

Drive B 5.0A 4.2A 4.2A 16

Drive C 3.4A 3.2A 3.0A 12

Drive D 3.0A 2.8A 2,7A 10

 

Conveyor Speed (ft/min.) 10 11 11

 

Since the introduction of PPX on the conveyor chain, it has been necessary to remove several links from the chain for maintenance reasons.  We noted that the links had a coating of oil on the inside, even after Lubricant consumption has been reduced by 80%”

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TRAILS CONDUCTED AT  MILLIKEN CARPETS, LTD., BEECHILL PLANT, ON NAUTA VINYL MIXER GEARBOX.

Energy consumption was monitored before and after application of PPX Friction Reducers; special attention being given to monitoring under comparable operating/load conditions.  Peak energy consumption was logged and Average Energy Consumption.

Logging results on the vinyl mixer gearbox showed a reduction in average energy consumption of 17%.

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TRAILS CONDUCTED AT  SEVERN TRENT WATER, LTD., ON SCREW PUMP GEARBOX.

An Energy survey was conducted on the No. 2 Screw Pump Gearbox before and after application of PPX Friction Reducers:  Following results were recorded.

Average energy consumption before PPX . . . 61.92 kw

Average energy consumption After PPX . . .   5.89 kw

Energy savings . . . . . .   6.03 kw

Percentage reduction . . . . 9.7 %

 

Predicted energy savings (three year lubricant change interval operating)

24 hrs/7 days/50 weeks/3 years,. . . . . . £6,747.00

Cost of PPX . . . . . . . £   796.00

Net energy savings per gearbox . . . . £5,951.00

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TRAILS CONDUCTED AT SOUTHERN WATER SERVICES, LTD., FAREHAM, ON ARCHIMEDES SCREW PUMP GEARBOX.

PPX Friction Reducer was applied at 10% to the BP GRKP 220 gear oil in the FLENDER KZN 320 Gearbox, which drives the Archimedes Screw Pumps.

The pumps operate 24 hrs x 7 Days/Week x 52 Weeks/Year, and the gearbox oil is changed every 5 years.

The minimum energy cost of running these pumps is 3.6 pence/kw hr.

The energy consumption on each of the 2 pumps was logged and recorded before and after the application of PPX Friction Reducer to the gearbox oils.

Pump No. 1

Average energy consumption Pump No. 1 before PPX . . 88.17 kw

Average energy consumption Pump No. 1 after PPX . . 81.14 kw

Average energy savings . . . .   7.03 kw

Percentage Savings . . . .   7.9%

Pump No. 2

Average energy consumption Pump No. 2 before PPX . . 87.05 kw

Average energy consumption Pump No. 2 after PPX . . 81.37 kw

Average energy savings . . . .   5.68 kw

Percentage Savings . . . .   6.5%

These results represent an energy cost savings of £11,054.00, and £8,932.00 respectively over the 5 years after deducting the initial £600.00 spent on PPX (£300.00 to treat each gearbox).

Large cost savings were also achieved using Lithium Complex Grease on bearings.

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TRAILS CONDUCTED AT SOUTH WEST WATER, PLC., HILLBARTON TREATMENT WORKS,  ON PADDLE ROTOR GEARBOX.

Use of PPX Friction Reducer in Gearbox of Paddle Rotor 3 at Hillbarton.

An energy log was made before and after the gearbox was supplemented with PPX Friction Reducers.

The summary at an exact repeat of operating conditions is as follows:

Average power before PPX . . . . . 8354 kw

Average power after PPX . . . . . 7391 kw

Average energy savings . . . .   963 kw

Percentage Savings . . . .   11.5%

Based on 3 pence per kw hr. running 24 hours/day-365 days/year, savings = £233/year after deducting the £20 cost of PPX.

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TRAILS CONDUCTED AT  THOMAS’S EUROPE*, BIRSTALL, WEST YORKSHIRE.

Energy trials were performed on four (4) separate pieces of plant equipment including:

Line 1 extruder gearbox

Extrusion pump (U3) gearbox

Mixing Vessel No. 1 (KM$) gearbox

Ciba packing machine gearbox

Energy reduction were achieved after addition of PPX Friction Reducer of 13.25%,  15%,  8%,  and  8.8%  respectively.  After 18 months of trials and evaluation the company has elected to use PPX Friction Reducer in all gearboxes.

 

*PET FOOD Subsidiary of the Mars Company

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TRAILS CONDUCTED AT  TRICO, LTD., PONTYPOOL,  ON PAINT SHOP CONVEYOR.

Trials were conducted on the paint shop conveyor chain to determine the PPX Friction Reducer’s ability to reduce wear under high temperature conditions (200°C).  PPX Friction Reducer (Industrial Lube) were introduced to the existing high temperature synthetic lubricant.  Energy logs were conducted before and after.  A 7.9% reduction in energy consumption was recorded.  Continued monitoring has confirmed significant reductions in wear and extended maintenance intervals.

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TRAILS CONDUCTED AT WYCOMBE MARSH PAPER MILL, HIGH WYCOMBE, ON FIRST PRESS GEARBOX.

The results of our energy survey on the 1st Press Gearbox, were as follows:

Average Power before PPX . . . . . 48.1884 kw

Average Power after PPX . . . . . 43.7501 kw

Average energy savings . . . .    4.4380 kw

Percentage Savings . . . .    9.21%

Note that the power drop multiplied by an estimated 3 pence per unit by 130.5 hours per week running time for 50 weeks per year results in the following energy savings on this gearbox:

 

Power Drop . . . . . 4.438 kw

Units saved per year . . . . 28.957.95

Energy savings per year . . . . £868.74

Cost of PPX . . . . . £150.50

Total Savings . . . . . £718.24

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TRAILS CONDUCTED AT YORKSHIRE WATER, OWLWOOD W.P.C. TO EVALUATE COST SAVING POTENTIAL OF PPX FRICTION REDUCER.

Gearboxes Treated:

8 No. Activated Sludge Stirrer Gearboxes.

1 No. A.S.P. Screw Pump Gearbox.

1 No. Inlet Screw Gearbox.

Method Used for Comparing:

The activated sludge weirs were set at the same height throughout the tests so no variation in load should occur.

The test instrument was an elcontrol VIP MK3 Energy Analyzer.

Readings were taken before oil changes, after oil changes and after the addition of PPX. 

The total reduction in power consumption was then worked out as follows:

Total power savings OVER 10 GEARBOXES = 3.365 kw.

Per Hour = 3.097%  Cost Per kw = 4.757p.

Total cost savings per year assuming 24 hr. operation =

3.365 x 24 x 365 x 4.757p divided by 100 = . . . . .     1,402.23p.

Therefore over four (4) years power consumption savings will be: . . .   £5,608.92

There is also a man-hour and oil cost savings of 3 annual oil changes:

(3 x 2 man days x 3 times = 18 days @ 8 hrs = 144 hrs @ £15/hr) = . . £2,160.00

Therefore total cost savings of  = . . . . . . . £7,768.92

Less initial cost of PPX @ £1,998 =  . . . Net Savings . £5,770.92

NOTE:  Each gearbox was monitored for 24 hrs x 15 minute intervals and them the average reading used in the calculations.  Additional trials were conducted on an Archemedes Screw Pump gearbox.

Independent continuous monitoring results showed a 5.7% reduction in energy consumption after two months rising to a total of 11% after 10 months.  Temperature and vibration reading on the PPX-treated gearbox steadily reduced vs. a steady increase in other gearboxes monitored but not treated with PPX.

Cost savings on the PPX treated gearbox was estimated at £16,000 for the four (4) year period.

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TRAILS CONDUCTED AT  ABINGTON CARPETS, LTD, GWENT,

PPX LITHIUM COMPLEX GREASE VS. KLUBER ISOFLEX LD 18 SPECIAL “A” LUBRICATION OF END CAP AND CENTER BEARINGS ON YARN TWISTING MACHINES

Two trials on end cap bearings lubricated with PPX were compared to the Kluber “standard” Shock Pulse Analyses were performed using the SPM (Shock Pulse Monitor).  Both trials using PPX Lithium Complex Grease were monitored as “Code A.”  Code A means that the bearing is in good condition.  There is no detectable damage to the surface of the load carrying parts and no extreme lack of lubricant in the rolling interface.

The two Kluber Trials were monitored as “Code D.”  Code D indicates occurrence of bearing damage.*

Two sets of trials were conducted on the center bearing with exactly the same results as the end cap bearing trials.

 

*The SPM measures shock pulse magnitude on a decibel scale.  It takes a sample count of the shock pulses occurring over a period of time filtering out machine vibrations and determines:

-LR (Low Rate of occurrence) i.e. the value for the relatively small number of STRONG SHOCK PULSES.

-HR (High Rate of occurrence) i.e. the value for the relatively high number of WEAK SHOCK PULSES

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TRAILS CONDUCTED AT  BCD STEELS, WEST BROMWICH, ON ANNEALING OVEN FAN BEARING.

Two bearings were selected for trials which support the shaft on an annealing oven fan.  The bearings were lubricated with a premium grease (Croda LG113).  The bearings were monitored to ascertain that both were in good condition and no extreme lack of lubricant on surface was detected.

23 shots of PPX LITHIUM COMPLEX GREASE were injected.

After a short passage of time each bearing was re-monitored (shaft RPM’s being constant at 2278).  The first bearing monitored showed a 30% reduction in the Low Rate* of shock pulses was registered along with an 8% reduction in the High Rate.  Continuous monitoring has verified that the bearings are running cooler, quieter, smoother, and with less apparent wear.

*”LOW RATE” of occurrence is the value for the relatively small number of STRONG SHOCK PULSES “High Rate” of occurrence is the value for the relatively high number of WEAL SHOCK PULSES.

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TRAILS CONDUCTED AT BRITISH STEEL STAINLESS, PANTEG WORKS, ON GRINDING MACHINE SHAFT SUPPORT BEARINGS.

Bearings lubricated with premium grease* were monitored.  Grease was purged and replaced with PPX Lithium Complex Grease.  After six days bearings were again monitored.

Substantial improvement was noted in lubrication condition along with significant reductions in LOW and HIGH RATES of shock occurrence, indicating significant improvement in predicted fatigue life of bearings.

BEARING # 1 KLUBER LR 55 HR 52/BEARINGS # 2 KLUBER HR 52

BEARING # 1 PPX LR 40 HR 36/BEARING # 2 PPX LR 44 HR 40

*KLUBER ISOFLEX NBU 15

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TRAILS CONDUCTED AT CAMMELL LAIRD SHIPBUILDERS, MERSEYSIDE, ON FAN BEARINGS OF CLIMAVENT PORTABLE EXTRACTORS.

SUMMARY:       

The use of PPX Lithium Complex Grease has extended bearing life from less than one month to at least twelve months with no actual failures noted since the changeover.

COSTS PRIOR TO PPX PER CLIMAVENT:

Two bearings fail at least every month @ £10.00 each         . . . £     20.00

One shaft replacement at least every month . . . . £     48.00

One man day labour to replace the above @ estimated 8 hours x £8 per hour        . £     64.00

Grease cost estimated at 1/4 kg per month: @ estimated £40/25 kg Shell Alvaria £        0.40

Total per Climavent/year . . . . . . £   132.40

Total 14 Climavent/year . . . . . . . £1,588.80

USING PPX AFTER ONE YEAR:

No Bearing failures

No shaft replacements

No replacement labour

Grease cost for all Climavents . . . . . . $      963.00

Total cost per year . . . . . £      963.00

COST SAVINGS PER YEAR . . . £21,280.00

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TRAILS CONDUCTED AT GILLET EXHAUSTS, TREDEGAR, SOUTH WALES, ON CAM FOLLOWER BEARINGS - SILENCER BOX END SEAMER.

PPX Lithium Complex Grease was used to lubricate bearings. *Bearing life was extended from one month to over two years (bearings currently performing well without failure).

COST PRIOR TO USING PPX:  

Four bearings changed every 3-4 weeks at a cost of. . . £912.00

One man 1/2 day labour to replace at estimated cost of £8.00/hour x 4   . £  32.00

Grease usage: 3/4 kg per month at estimated £35/25 kg Century Lithium £    1.05

Total per end seamer/month . . . . £945.05

Total Maintenance Cost for 6 machines/year . . . . £68,043.60

AFTR APPLICATION - PPX LITHIUM COMPLEX GREAE

No bearing failures-two years . . . . . . £        0.00

No replacement labour . . . . . . . £        0.00

Estimated cost of PPX grease . . . . . . £1,200.00

Total Net Cost Savings per Year . . . . . £66,843.60

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TRAILS CONDUCTED AT
O&K ESCALATORS, LTD., KEIGHLEY.

“Field Trials have shown a 30% reduction in wear upon chain pins lubricated with PPX (Lithium Complex Grease).  In addition, the extent of corrosion was minimal using PPX.  As a result of these findings, we will be using this grease upon all applicable external installations.”  N.B. further trials conducted in Germany indicated that the fire resistance qualities of the PPX product makes it suitable for use in enclosed public facilities.

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TRAILS CONDUCTED AT ROTHERHAM ENGINEERING STEEL, ROTHERHAM, ON WORTHINGTON-SIMPSON CIRCULATING PUMPS SERVING WATER TREATMENT PLANT.

SPM monitoring was conducted on 4 bearings (No. 2 driver) lubricated by Shell EP 2 Grease.  The Shell grease was purged and replaced with PPX Lithium Complex Grease.  Considerable improvement in Lubrication code and shock pulse values were recorded.  No further trails were conducted for six months until a bearing on the M320 drive motor showed signs of deterioration and it was decided to lubricate this bearing (as well as the bearings previously monitored) with the PPX Lithium Complex Grease.  All bearings lubricated with PPX grease (including the drive bearing) showed substantial improvement after monitoring.  No further bearing deterioration was noted.

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TRAILS CONDUCTED AT TWIFLEX, LTD, TWICKENHAM,

KLUBER GREASE VS. PPX LITHIUM COMPLEX GREASE USED IN UNDERGROUND CONVEYOR BRAKING SYSTEMS.

KLUBER PPX

Grease squeezed out and noisy operation No squeeze-out or noise and loads in excess of 18 KN.

6% Friction losses 4.5% Friction losses

Fretting/scoring at 10,000 cycles no fretting/scoring at 30,000 cycles

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TRAILS CONDUCTED AT WADKIN LABORATORIES, LEICESTER, ON SPINDLE TEST TIG BEARINGS COMPARING PERFORMANCE OF PPX LITHIUM COMPLEX GREASE TO “BEST AVAILABLE GREASE”*.

Two bearings (each) were selected on side by side test rigs running at 14,550 RPM’s.  Each rig was checked to verify alignment and condition.

 PPX Lithium Complex Grease was introduced into two pairs of angular ball bearings on rig no. 1, and the “BA” grease into rig no. 2.  Condition, lube number, and shock pulses were monitored on a regular basis.

Lube no. on the PPX lubricated bearings were considerably higher (9 vs. 4+2), Low Rate shock pulses with PPX were 53 + 51 vs. 57 + 61 with “BA”, high Rate with PPX was 48 + 48 vs. 53 + 57 with “BA”.**

 

*KLUBER

**The most important influence on the service life of a bearing is it lubrication, or to be precise, the lubricant film between the load carrying rolling elements and the raceway.  By preventing or inhibiting metallic contact between the loaded bearings parts, the lubricant film reduces the local peak stress in the rolling interface.  The greater the lubricant film thickness, the more even the load distribution in the contact area, and the better the fatigue life of the bearing.  By measuring the variations in the shock pulse patterns of undamaged bearings the SPM (Shock Pulse Monitor) employed in these trials can evaluate the effect of the lubricant film and display a LUB no. which is scaled to increases with film thickness.  Comparisons of lube no. and shock pulse readings indicate superior lubricating qualities using PPX Lithium Complex Grease resulting in extended fatigue life for the bearings.

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TRAILS CONDUCTED AT AMOCO (U.K.) EXPLORATION COMPANY, SOUTH YARMOUTH, ON 16 CYLINDER GAS-FIRED (CAT) DIESEL ENGINES.

Results:  Extended lube change and maintenance intervals.  No Sudden failures or breakdowns.  Substantial reduction in running noise:

a) Oil change (per oil analysis) Before PPX - 700 hrs., After PPX - 2,100 hrs.

b) Oil top-up Before PPX - 2 gals/day,  After PPX - 4 gals/month.

“The potential savings suggested by trials are in the order of £20,000. per year for 4 engines in the Inde field...Note this applies to the Inde field only.  If the Leman de-manned platform generator engines are included in the scheme then the usage of PPX would increase but the time between overhauls would be greatly increased.  It would, in my opinion, be a sensible way to go on these new engines as the platforms would be unmanned and anything that will reduce the chance of an engine shutting down can only be beneficial.  An additional benefit of reduced oil changes on unmanned platforms is that the hours for mechanical maintenance will be greatly reduced & the limited time allowed on the board can be better utilized.”

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TESTS CONDUCTED  IN  CHINA

  

TESTS CONDUCTED AT INSIDE THE TSINGTAO CITY DEVELOPMENT ZONE, CHINA, TWO TESTS ON BUSES.

TEST No. 1.   Five buses were selected and added Petron Plus Diesel Engine Conditioner to the engines.  Following strict experimental standards the test allowed no adjustments to the buses.  Before and after adding the Petron Plus products, the buses ran for 100 kilomiles.  Fuel consumption went from 15 liters (3.96255 gallons) before down to 12.14 liters (3.2070 gallons) after.  That was a fuel consumption drop of 19%.

TEST No. 2.  Five buses following the same testing procedures had an average fuel savings of 16.2% and the operating conditions improved dramatically.  Engine noise was cut down, lube oil consumption dropped 50% and emissions dropped significantly.

This test data was confirmed in a meeting held by the Tsingtao City Economic Committee in conjunction with the EPA Bureau, Energy Consumption Bureau and the city’s Scientific Bureau.

Due to these findings the city has announced that the public busing program is prepared to push a new program with these products to improve and protect the environment and increase the savings in the energy consumption rate.

  

TESTS CONDUCTED AT  SHENGYANG CITY ECONOMIC TRADE & TECHNOLOGY DEVELOPMENT BUREAU, CHINA, ON TOYOTA.

TEST was conducted on a Toyota car in a similar experiment as the buses.  The results showed a 25 liter savings in fuel consumption in a drive from Shengyang to Dailin.  That was a savings of 17.9%.

As a result of the above tests, many mining and industrial businesses in the Shengyang area are applying this “nano” anti-friction lubrication technology in their big machinery and equipment.  All the applications have experienced very good results.  Due to these tests, the Liaoning Provincial Economic Committee held an informational seminar about the technology for the industrial and transportation industry in their province.

 

METALWORKING
CUSTOMERS CHALLENGE'S



Customer Challenge:

A machine tool manufacture in Kansas rebuilt a shop lathe for a customer. The lathe worked fine, but the noise level was very close to the maximum allowed by OSHA standards, 80 db. They tried everything they could, but nothing worked.

PPGI Solution:

They added Petron Plus Transmission & Gear Box Supplement to the main gear box. It reduced the decibel level from 79 db to 73 db, and it only took five minutes of operation to notice the difference. They added Petron Plus Transmission & Gear Box Supplement to a smaller gear box, and in approx. 15 minutes they recorder a decibel reading of 71 db, well within OSHA standards.
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Customer Challenge:

A major aircraft manufacture in California had reported high scrap problems on the aluminum skins (while being stretched) used on a fighter plane.

PPGI Solution:

Petron Plus Metalform 2000 (a concentrate) was added to their existing metal form fluid. The orange peel problem no longer existed, and they could pull and stretch more parts without having to coat every part. They approved Petron Plus Metalform 2000-P (a finished product) to be used in this application.
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Customer Challenge:

A machine shop in Kansas that does mostly government work, was having problems on their horizontal milling machine, milling 1½” x 3” slots, and used 5 milling cutters which cost approx. $75. each.

PPGI Solution:

They used Petron Plus Industrial Super Lube on the next job, and only used 3 milling cutters to do the same job. A savings of $150.00
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Customer Challenge:

A European Automotive manufacture was experiencing high cost on a Herbert Detroit Broaching Machine.

PPGI Solution:
They added Petron Plus Metalpro Alpha to their existing coolant, extended the regrind interval on a trail new broach from 500 parts to 2,500 parts. This saves on broach and regrind costs and provides longer uninterrupted production runs.
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Customer Challenge:


A major Aerospace company in Europe was having problems in milling five exotic aerospace material; QAJ Nickel, EAK St. Steel, 611C Corrodible Steel, TAF Titanium, & INCO (901).


PPGI Solution:


They added Petron Plus Metalpro Alpha to their existing coolant. They reported the following: A 22.22% wear reduction, a 9.18% wear reduction, A 0.01% wear increase, A 22.20% wear reduction, A 18.98% wear reduction.

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Customer Challenge:


A major Aerospace company in Europe was having problems in milling five exotic aerospace material; QAJ Nickel, EAK St. Steel, 611C Corrodible Steel, TAF Titanium, & INCO (901).


PPGI Solution:


They added Petron Plus Metalpro Alpha to their existing coolant. They reported the following: A 22.22% wear reduction, a 9.18% wear reduction, A 0.01% wear increase, A 22.20% wear reduction, A 18.98% wear reduction.

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Customer Challenge:


A large Aerospace Machine Shop in Connecticut mills aircraft structural parts for major aircraft and aerospace companies.  They work mostly with 7050, 7075, and 2219 aluminum alloy, as well as titanium. They were experiencing difficulty in milling these parts with their current lubricants.


PPGI Solution:


They switched to Petronomics Heavy-Duty, General-Purpose Soluble Machining Oil. They reported: Increase Tool Life as Much as 150% to 200%, Increased Production, Dramatically Improved the General Working Environment, Eliminated Smoke and Odor, Reduced Make-Up Demand, Reduced Down-Time and Parts Costs.

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Customer Challenge:


The same Aerospace Machine Shop in Connecticut listed above submitted an up-dated report 2 years later.


PPGI Solution:


They Reported: ...we continue to experience the extended tool life and improved working environment by using your ...coolant in our milling operation. We have also determined that the finish of our aerospace parts has much improved. ...the need to now remove only 30% to 40% of what we used to in the finishing dept. saves time and money with a vastly better finished look.

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Customer Challenge:

Reserved for your company metalworking story.

PPGI Solution:

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