Lubricating greases: the silent heroes for maximum machine lifespan

In industrial production, it is often the small things that make the difference. High-performance lubricating greases from Rhenus Lub help minimize friction, reduce maintenance costs, and significantly extend the lifespan of your machines.

They are the largely invisible workhorses that minimize friction, protect against wear, and ensure the lifespan of critical components. However, not all lubricating greases are created equal: the demands of modern systems, extreme operating conditions, and industry-specific requirements call for highly developed solutions. Simply using just any grease can have fatal consequences – from increased wear and system failures to safety risks.

A lubricating grease is a carefully composed system consisting of three components: a base oil (mineral or synthetic) that performs the main part of the lubrication, a thickener (e.g., based on metal soaps like lithium, calcium, aluminum complex soaps, inorganic thickeners like bentonite, or organic thickeners like polyurea) that binds the base oil like a sponge and holds it at the lubrication point, and additives that specifically improve properties such as pressure absorption capacity, corrosion protection, or aging stability. At Rhenus Lub, we use a wide range of thickener technologies – from proven calcium and lithium soaps to high-performance lithium complex and polyurea greases for special requirements. The consistency, specified in NLGI classes (from very soft 000 to very firm 6), is precisely matched to the application to ensure optimal pumpability and adhesion.

Modern machines and systems place the highest demands on the lubricating greases used. We have developed the right solution for every challenge:

Challenge 1: Extreme temperatures – from arctic cold to blazing heat

At low temperatures, greases can harden, lose their pumpability, and drastically increase starting torques. At high temperatures, on the other hand, they can liquefy, leak from the lubrication point, or thermally decompose, leading to lubrication film breakdown and component failure.

Rhenus Lub Solution Approach: For these extremes, we offer synthetic-based greases. Special low-temperature greases, such as those for high-speed rolling bearings, ensure lubrication down to -60 °C. For the highest temperature loads, perfluoroalkyl ether greases (PFPE) are suitable, withstanding operating temperatures of up to +300 °C. Products like rhenus LKZ 2 or rhenus LKK 15 cover a wide automotive and industrial temperature range.

Challenge 2: High Mechanical Loads, Shock Loads, and Wear

In many applications such as rolling and plain bearings in presses, construction machinery, or gearboxes, high pressures and shock loads occur. Unsuitable greases are displaced from the lubrication point, the lubricating film tears, leading to metal-to-metal contact, increased wear (pitting, seizing), and ultimately premature component failure.

Rhenus Lub Solution Approach: Here, EP-additivated (Extreme Pressure) high-performance greases are used. Products like rhenus LZN 2, rhenus ADD 2, LKX 2, rhenus LKP 15, and rhenus CAZ 2 are characterized by excellent pressure absorption capacity and, in some cases, the addition of solid lubricants. They form a resistant lubricating film that reliably protects against wear even under the highest loads and vibrations, extending the lifespan of components.

Challenge 3: Influence of Water, Moisture, and Corrosive Media

Water and aggressive media can wash out lubricating greases, destroy their structure, or cause corrosion on the lubricated components. This is particularly critical in heavy industry, mining, construction machinery, or humid process environments.

Rhenus Lub Solution Approach: We rely on water-resistant thickener systems (e.g., calcium or aluminum complex soaps) and special corrosion protection additives. rhenus CAZ 2, for example, offers excellent corrosion protection even under saltwater influence and prevents tribocorrosion. rhenus ADD 2 and rhenus LCA 2 are also very water-resistant. For applications with exposure to weak acids or alkalis, rhenus BCN 2 is available.

Challenge 4: Specific Industry Requirements and Certifications

Many industries have very specific requirements for lubricating greases that go beyond mere lubricating properties. These include physiological harmlessness (food industry), OEM approvals (automotive), biodegradability (environmentally sensitive areas), or special electrical properties.

Rhenus Lub Solution Approach:

Choosing the optimal lubricating grease is crucial for the performance and lifespan of your systems. Important selection criteria include the specific application (rolling bearings, plain bearings, open/closed gears, guides), the operating temperature range, mechanical load, speeds (nDM value), environmental influences (water, dust, chemicals), any requirements for food compatibility or biodegradability, and necessary manufacturer approvals. Our experts will assist you in selecting the appropriate grease. Thanks to our development expertise, we are also able to meet individual customer requirements. This means: instead of relying on standard solutions, formulations can be specifically adapted to your technical, regulatory, or process-related requirements if needed – for example, by selecting special base oils, additive packages, or thickener technologies. Combinations of several requirements – such as extreme temperatures with simultaneous water or chemical exposure – can also be reliably addressed through customized developments. This results in lubricating greases that are precisely tailored to the respective application and ensure maximum operational reliability.

The development of lubricating greases takes place in our in-house research and development laboratory in Mönchengladbach and usually starts with a specific customer request. State-of-the-art testing technologies – including low and high-temperature test rigs, corrosion tests according to DIN, emulsification and mechanical stability tests, as well as analytical systems such as XRF, ICP, and GC/MS – enable lubricating greases to be specifically tested for their performance under realistic conditions. This depth of development and testing makes Rhenus Lub a reliable partner for any company that wants to improve machine performance through the use of precisely matched greases.

Dr. Marco Pfeiffer, Head of Product Management at Rhenus Lub, emphasizes: “Our high-performance greases are specially designed to remain powerful under extreme conditions. This means protection against wear, extended machine lifespan, and ultimately an increase in operational efficiency.” This is not just about the product itself, but also about its contribution to resource conservation through less material wear and longer maintenance cycles – one example is the switch lubricant rhenus LSN 04 XT, which could halve lubricant-related maintenance efforts.