DryTrac Optimizes Lines and Reduces Energy and Water Costs

Food & Beverage

Case Studies:

Opportunity

The customer is a soda manufacturer. At this location, they fill both PET and returnable glass bottles. In a bottling facility, a conveyor lubricant is utilized to minimize friction between components of the conveyor, including between the chain or belt and the rails and pins. This prolongs the lifespan of the equipment and ensures that containers stay upright and easily more from more point on the conveyor system to the next, especially when changing directions or entering a process area.
The manufacturer runs PET bottles on a plastic conveyor and returnable glass on a stainless steel conveyor, utilizing a dry lubricant on the PET line and a wet lubricant on the glass line. As a part of a cost-saving initiative, they presented several goals for improvement:
1. Decrease energy costs.
2. Extend equipment life.
3. Reduce annual water usage.
4. Lower down bottle count and limit lines stoppages.
These goals provided DuBois the opportunity to implement a dry lube solution on both lines, designed to reduce overall friction throughout the conveyor.

The DuBois Solution

DuBois partnered with the manufacturer to implement DryTrac on both conveyors. DryTrac is a high performance, dry conveyor lubricant that is applied using a brush mechanism in contact with the conveyor surface. When build-up or lubrication issues occur on a line, the motor ramps up to overcome the friction. Especially if occurring for an extended amount of time, this can increase energy spending and decrease motor life. Similarly, this friction will reduce the belt of the life itself. DryTrac dries on lines to keep them clean and tack free. This improved cleanliness and lubricity is designed to eliminate friction and allow motors to run successfully with decreased amperage. DryTrac is applied undiluted, drastically reducing water usage compared to wet lubricants.

Results and Benefits

The customer implemented DryTrac on both their PET and glass lines. The PET line historically used a dry lubricant that developed friction-causing residue overtime. With the implementation of DryTrac, lines became noticeably cleaner and shinier. Across their ten belt motors, the customer saw a 5.6% decrease in amperage required. Over time, this will increase equipment life and continue to cut energy costs.
The glass line, running 8 hours per day, 5 days per week, previously utilized a wet lubricant that required 438,600 gallons (1,660,281 liters) of water annually. DryTrac, a dry lubricant, required only 8668 gallons (32,811 liters) per year. This resulted in a savings of 429,932 gallons (1,627,470 liters) or a 98% decrease.

*Product must be applied using a brush mechanism, wherein the brush bristles of each brush remain substantially in contact with the conveyor surface wherever dry lubricant is being applied during conveyor operation