Case studies

Environmental impact

Current bottling operating procedures rely on the use of a detergent based lubricant, the toxicity of which is exacerbated by the use of biocides. This method of operation requires large volumes of water and detergent, which is not recycled or reused. The environmental impacts include:
- High water usage
- Increased risk of spillages due to high volumes
- Increased safety risk
- Regular cleaning to maintain the health and safety standards

The Dry Lubrication System

The Dry Lube system is based on a departure from traditional chemical based detergent lubricants to a synthetic food safe lubricant manufactured from the ingredients on the FDA food safe ingredients list. The properties of the Dry Lube include very low toxicity when swallowed, very low toxicity in an aquatic environment, no skin or eye irritation and it is non-sensitizing.
Environmental benefits are:
- Typical product volume reductions of over 99%
- Elimination of requirement for water consumption
- Elimination of waste waster/detergent mix requiring disposal
- Elimination of using biocide which is added to detergents for stopping bacteria growth
- Reduced Health and Safety risk providing a safer working environment by eliminating slip/trip accidents attributable to floors wetted by detergent lubricants. Improvement rates of 50% pa on an ongoing basis have been recorded in slip/trip accidents

Source: The Robertson Partnership, Consulting Civil Structural & Environmental Engineers.

Financial benefits

The Dry Lubrication System vs Traditional Water-based Systems

The high speed conveyors necessary to meet demand in the highly competitive soft drinks industry need efficient and reliable lubrication. The lines transfer bottles and cans from manufacture of the product right through to palletizing and shrink wrapping machines for dispatch.

A traditional water based system delivers a water based soap solution directly onto the lines on a continuous basis at concentrate levels of about 0.75%-2%. The water and soap solution is then collected in drip trays and disposed of through the drainage and effluent system.

The drawbacks of traditional water based lubrication:
- The quantity of water necessary for each unit of product in some cases equals an additional 300ml per litre of product
- Overflowing drip trays mean the floor area around the packaging lines is covered in soapy deposits and froth causing hazardous working conditions
- Effluent treatment of waste water solution is required before disposal
- Lines need to be regularly cleaned to remove build up of soap deposits and bacteria, which results from water.
- High levels of friction between bottles and belts causing product losses, damage and more conveyor downtime
- Unpleasant odours resulting from build-up of bacteria and damp working conditions

A significant step change from traditional lubrication, the Dry Lubrication System takes minor quantities of Food Grade approved oil lubricant and pumps it onto the conveyor through a distribution manifold.

The benefits of the Dry Lubrication System are:
- Elimination of water
- Elimination of effluent
- Elimination of bacterial build-ups
- Elimination of bad odours
- Elimination of high friction between bottles and belt
- Elimination of slip and trip incidents around the lines 

The savings from the Dry Lube System come from:
Saved soap concentrates – up to €90,000
Saved water costs – up to €2,800
Saved Effluent treatment costs – €6,000
Reduced maintenance costs – €3,000
Increased belt longevity – €15,000

A wet system uses	The Dry Lubrication system uses	Savings	Value €
Detergent	none	100%	90,000
Water	none	100%	2,800
Effluent	none	100%	6,000
Belt life	doubled	50%	15,000
Lubrication maintenance	none	100%	3,000
Direct Savings			€117,000
Additional Benefits
Productivity	Up 2-5%	2-5%
Shut-downs	Down 50%	50%
Power Costs	Down 2-4%	2-4%

Source: M V Patel BSc, CEng, MIChemE  2005/09