1. What is Carbonization?
- It is the formation of dark, sticky, or solid residues due to the decomposition of grease's base oil and additives at high temperatures.
- It typically occurs above 200–250°C, but can also occur at lower temperatures with some greases.
- Carbonized grease:
- Hardens and becomes sticky
- Increases friction in bearings and gears
- Reduces equipment efficiency
2. Main Causes of Carbonization
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Excessive Temperature
- Grease remaining above its operating temperature for extended periods.
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Oxidation
- Chemical degradation of grease by air and heat → leads to the formation of carbon-like residues.
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Incorrect Grease Selection
- Using standard or low-temperature greases at high temperatures.
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Insufficient Lubrication / Excessive Friction
- Insufficient grease or excessively high load increases friction, leading to localized heat and carbonization.
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Contamination
- Contact with water, steam, or cleaning chemicals → accelerates base oil breakdown.
3. Consequences of Carbonization
- Bearing and chain wear → shortened equipment life
- Production line downtimes → increased maintenance costs
- Risk of contamination in the food line → hygiene and safety issues
- Increased frequency of grease changes → higher maintenance costs
4. Preventive Measures
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Using High-Temperature Greases
- NSF H1 certified, heat-resistant greases with high oxidation resistance should be preferred.
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Temperature Control and Monitoring
- Bearing temperatures should be monitored with sensors, and production should be stopped in case of excessive heat.
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Regular Maintenance and Greasing
- Grease quantity and change interval should be adjusted according to temperature.
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Correct Grease Application
- Avoid applying too much or too little grease; both can trigger carbonization.
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Contamination Prevention
- Contact of water, steam, and cleaning chemicals with bearing and housing areas should be prevented.
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