— CASE STUDIES
The Work That
Proves the Promise.
Every plant that failed the same way twice had a system problem — not a luck problem. These are the plants that found out what was actually wrong, fixed the system, and stopped the failure. Real plants. Real outcomes. Every one of them the result of fixing the cause — not replacing the symptom.
INDUSTRY
Cement & Mining
5 case studies
CS-01
Coal Mill Open Gear Spray Lubrication System Upgrade
THE PROBLEM
Inconsistent manual lubrication was causing uneven gear wear and increasing the risk of premature open gear failure on the coal mill.
WHAT DROPLEX DID
Engineered and installed a precision spray lubrication system to deliver controlled, uniform high-viscosity Klüberfluid C-F 3 Ultra open gear lubricant across the full gear face.
OUTCOME
Improved girth gear protection, reduced lubricant waste, and consistent lubrication — extending open gear service life and stabilising mill operation.
CS-02
Mining Kiln Open Gear Lubrication Optimisation
THE PROBLEM
The mining plant kiln girth gear was operating under extreme load and temperature conditions. The existing lubricant was not providing adequate wear protection or film stability.
WHAT DROPLEX DID
Assessed the application and implemented Klüberfluid C-F 3 open gear lubricant — optimising spray pattern, film formation, and load-carrying performance for the specific kiln operating conditions.
OUTCOME
Enhanced gear surface protection, improved lubricant film stability under high temperatures, and reduced the risk of costly kiln downtime.
CS-03
Cement Mill Open Gear Lubrication System Upgrade
THE PROBLEM
The cement mill open gear required consistent, controlled lubrication to prevent surface damage and premature wear under heavy operating loads. The existing approach was not delivering uniform coverage.
WHAT DROPLEX DID
Engineered and installed a precision spray lubrication system delivering uniform lubricant application across the full gear face under load.
OUTCOME
Enhanced gear protection, optimised lubricant consumption, and improved operational stability — reducing the risk of unplanned shutdowns.
CS-04
Komatsu HM300 Dump Truck Automatic Lubrication System Installation
THE PROBLEM
Heavy-duty dump truck components designed for operation under extreme load and contamination conditions would make manual lubrication inconsistent — increasing the risk of wear on a new fleet asset before it had even started work.
WHAT DROPLEX DID
Engineered and installed a centralised automatic lubrication system on a new Komatsu HM300 prior to deployment — ensuring consistent, controlled grease delivery to all critical points from day one.
OUTCOME
Reduced manual maintenance dependency, improved component protection, and enhanced fleet uptime in demanding mining operations.
CS-05
Automated Lubrication System Refurbishment — Cement Aggregate Plant
THE PROBLEM
Automatic lubrication systems in a high-dust aggregate environment had deteriorated — leading to inconsistent grease delivery and increased wear risk on critical equipment.
WHAT DROPLEX DID
Removed, inspected, and refurbished system components at our technical facility — restoring pump performance, metering accuracy, and overall system reliability before reinstallation.
OUTCOME
Re-established consistent lubrication across critical machinery, extended component life, and reduced maintenance intervention in a demanding operating environment.
INDUSTRY
Food & Beverage Processing
4 case studies
CS-11
Water-Resistant Lubrication Upgrade — Chicken Plucker Bearings
THE PROBLEM
The chicken plucker machine operated in a high-moisture washdown environment. Grease was washing out constantly — causing frequent bearing failures, excessive grease consumption, and repeated unplanned stops.
WHAT DROPLEX DID
Assessed the operating conditions and replaced the existing grease with Klüberfood NH1 94-402 — a water-resistant, NSF H1 food-grade grease designed for washdown environments. Optimised relubrication intervals and quantities.
80% reduction in grease consumption
$30K annual lubricant savings
OUTCOME
Bearing failures eliminated. Machine smoothness improved. Grease consumption reduced by 80%. Annual lubricant savings of approximately USD 30,000.
CS-12
Centralised Lubrication System — Beverage Conveyor Line
THE PROBLEM
Frequent bearing failures on the beverage conveyor line. Several grease points were difficult to access — so they were being missed or lubricated inconsistently during routine maintenance.
WHAT DROPLEX DID
Engineered and installed a centralised lubrication system — routing all grease points to an easily accessible distributor block, ensuring reliable servicing without requiring access to difficult locations.
OUTCOME
Missed lubrication points eliminated. Bearing failures reduced. Conveyor uptime improved — supporting uninterrupted beverage production.
CS-13
Food-Grade Lubricant Storage & Handling Optimisation
THE PROBLEM
Food-grade lubricants were stored across multiple plant areas without standardised containment — creating cross-contamination risk, misapplication risk, and audit non-compliance exposure.
WHAT DROPLEX DID
Engineered and manufactured dedicated lubricant storage cages for each plant section — ensuring secure, organised, and clearly segregated storage of food-grade lubricants throughout the facility.
OUTCOME
Improved lubricant control, enhanced food safety compliance, and simplified maintenance access — the plant passed its next audit with the lubrication programme as a strength, not a risk.
CS-14
High-Viscosity Glucose Syrup Transfer System
THE PROBLEM
Transferring high-viscosity glucose syrup from an IBC tank into the production line was inefficient and difficult — risking product loss, inconsistent flow, and production delays. Glucose transfer time was 9 hours.
WHAT DROPLEX DID
Designed and installed an AODD pump-based transfer system capable of handling high-viscosity fluids with controlled, reliable delivery directly into the production process.
Transfer time reduced from 9 Hours to 40 mins
OUTCOME
Improved transfer efficiency to 40 mins, minimised product wastage, and ensured consistent syrup flow — supporting stable, hygienic production.
INDUSTRY
Transportation
3 case studies
CS-21
Integrated Oil Management System — Heavy-Duty Truck Workshop
THE PROBLEM
A newly established heavy-duty truck service workshop would rely on manual oil handling — limiting service throughput, reducing visibility into consumption, and increasing the risk of oil losses from day one.
WHAT DROPLEX DID
Designed and installed a structured oil management system — organised new and used oil handling, controlled dispensing units, and accurate consumption tracking. Replaced manual handling with a standardised, accountable process.
OUTCOME
Improved service efficiency, reduced oil losses, enhanced consumption visibility, and enabled higher workshop capacity compared to the old workshop right from the start.
CS-22
Lubrication Storage & Oil Management System Rehabilitation
THE PROBLEM
The containerised lubrication storage and oil management system was in poor condition — compromising lubricant integrity, organisation, and maintenance efficiency across fleet operations.
WHAT DROPLEX DID
Carried out a full system rehabilitation — restoring storage functionality, contamination control, and organised lubricant dispensing across the operation.
OUTCOME
Improved lubricant quality control, enhanced maintenance efficiency, and strengthened fleet equipment reliability through properly managed oil handling.
CS-23
Oil Management System — FMCG Fleet Workshop
THE PROBLEM
The FMCG fleet workshop lacked structured oil storage and consumption tracking — leading to oil losses, inconsistent records, and poor visibility into lubricant costs across the fleet.
WHAT DROPLEX DID
Designed and installed a comprehensive oil management system — bulk storage, controlled dispensing, and structured consumption recording per vehicle. Replaced informal habits with a disciplined, trackable process.
OUTCOME
Reduced lubricant losses, strengthened consumption accountability, and improved service team efficiency across the workshop.
INDUSTRY
Power & Wind Energy
2 case studies
CS-41
Specialty Lubrication Support — Wind Farm Operations
THE PROBLEM
Wind turbines operate under continuous load and varying environmental conditions. Standard lubricants were not providing adequate protection for gearboxes, bearings, and critical rotating components — creating reliability risk across the wind farm.
WHAT DROPLEX DID
Supplied application-specific specialty lubricants tailored to each critical turbine component — with ongoing technical support to maintain lubrication reliability across all turbines in the wind farm.
OUTCOME
Strengthened turbine operational reliability, reduced lubrication-related risk, and supported consistent renewable power generation across the wind farm.
CS-42
Pre-Installation Gearbox Inspection — Africa’s Largest Wind Farm
THE PROBLEM
Wind turbine nacelles destined for Africa’s largest wind farm had travelled by high sea and overland transit. Undetected gearbox damage before installation would have meant costly replacements after turbines were already mounted — a significant project and financial risk.
WHAT DROPLEX DID
Conducted detailed borescope inspections of all 365 wind turbine gearboxes — both in transit and on site — verifying internal gearbox condition before any turbine was commissioned.
365 turbine nacelles inspected
OUTCOME
Prevented costly post-installation rework, protected high-value turbine assets, and supported seamless execution of Africa’s largest wind farm development.
Renewable Energy
Specialty Lubrication Support – Wind Farm Operations
Supplied application-specific specialty lubricants to protect critical wind turbine components, improving operational reliability and supporting consistent renewable power generation.
Wind Turbine Gearbox Inspection – Major Wind Farm Project
Inspected 365 turbine nacelles prior to installation, preventing costly gearbox failures and protecting critical renewable energy infrastructure during Africa’s largest wind farm development.
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Coal Mill Open Gear Spray Lubrication System Upgrade
Challenge:
Inconsistent manual lubrication was causing uneven gear wear and increasing the risk of premature open gear failure.
Solution:
Engineered and installed a precision spray lubrication system to deliver controlled, uniform high-viscosity Klüberfluid C-F 3 Ultra open gear lubricant.
Reliability Impact:
Improved girth gear protection, reduced lubricant waste, and ensured consistent lubrication, thereby extending open gear service life and stabilizing mill operation.
Mining Kiln Open Gear Lubrication Optimization Using Klüberfluid C-F 3
Challenge:
The mining plant kiln girth gear was operating under extreme load and temperature conditions, requiring superior wear protection and reliable lubricant adhesion to prevent surface damage and premature gear failure.
Solution:
Conducted an application assessment and implemented Klüberfluid C-F 3 open gear lubricant, ensuring optimal spray pattern, film formation, and load-carrying performance tailored to kiln operating conditions.
Reliability Impact:
Enhanced gear surface protection, improved lubricant film stability under high temperatures, and reduced the risk of costly kiln downtime, thereby safeguarding a critical plant asset.
Cement Mill Open Gear Lubrication System Upgrade
Challenge:
The cement mill open gear required consistent, controlled lubrication to prevent surface damage and premature wear under heavy operating loads.
Solution:
Engineered and installed a precision spray lubrication system to deliver uniform lubricant application across the gear face.
Reliability Impact:
Enhanced gear protection, optimized lubricant consumption, and improved operational stability, thereby reducing the risk of costly unplanned shutdowns.
Komatsu HM300 Dump Truck Automatic Lubrication System Installation
Challenge:
Heavy-duty dump truck components operate under extreme load and contamination conditions, making manual lubrication inconsistent and increasing wear risk.
Solution:
Engineered and installed a centralized automatic lubrication system on a new Komatsu HM300 prior to deployment, ensuring consistent and controlled grease delivery to critical points.
Reliability Impact:
Reduced manual maintenance dependency, improved component protection, and enhanced fleet uptime in demanding mining operations.
Automated Lubrication System Refurbishment for Cement Aggregate Plant
Challenge:
Automatic lubrication systems operating in a high-dust aggregate environment had deteriorated, leading to inconsistent grease delivery and increased wear risk on critical equipment.
Solution:
Removed, inspected, and refurbished system components in our technical facility, restoring pump performance, metering accuracy, and overall system reliability.
Reliability Impact:
Re-established consistent lubrication across critical machinery, extended component life, and reduced maintenance intervention in a demanding operating environment.
Food & Beverage Plants
Water-Resistant Lubrication Upgrade for Chicken Plucker Bearings
Challenge:
The chicken plucker machine operated in a high-moisture washdown environment, causing grease washout, frequent relubrication, excessive grease consumption, and repeated bearing failures.
Solution:
Evaluated operating conditions and replaced the existing grease with Klüberfood NH1 94-402, a water-resistant, NSF H1 food-grade grease designed to withstand washdown conditions. Optimized relubrication intervals and reduced grease quantities per application.
Reliability Impact:
Eliminated bearing failures, improved machine smoothness, reduced grease consumption by 80%, and delivered annual lubricant savings of approximately USD 30,000, strengthening operational reliability and cost control.
Centralized Lubrication System for Beverage Conveyor Line
Challenge:
Frequent bearing failures were occurring because several grease points were difficult to access, leading to missed or inconsistent lubrication.
Solution:
Engineered and installed a centralized lubrication system, routing multiple grease points to an easily accessible distributor block to ensure reliable servicing.
Reliability Impact:
Eliminated missed lubrication points, reduced bearing failures, and improved conveyor uptime—supporting uninterrupted beverage production.
Food-Grade Lubricant Storage & Handling Optimization
Challenge:
Food-grade lubricants were stored in multiple areas without standardized containment, creating risks of cross-contamination, misapplication, and audit non-compliance.
Solution:
Engineered and manufactured dedicated lubricant storage cages for various plant sections, ensuring secure, organized, and clearly segregated storage of food-grade lubricants.
Reliability Impact:
Improved lubricant control, enhanced food safety compliance, and simplified maintenance access—supporting audit readiness and operational discipline.
High-Viscosity Glucose Syrup Transfer System Integration
Challenge:
Transferring high-viscosity glucose syrup into the process line was inefficient and difficult, risking product loss and inconsistent flow.
Solution:
Designed and installed an AODD pump-based transfer system capable of handling high-viscosity fluids with controlled, reliable delivery into the production process.
Reliability Impact:
Improved transfer efficiency, minimized product wastage, and ensured consistent syrup flow—supporting stable production and hygiene standards.
Plastics Manufacturing & Recycling
Fixed Hazardous Gas Detection System for Plastics Recycling Facility
Challenge:
Recycling operations presented potential exposure to hazardous gases, creating safety risks for personnel and compliance concerns.
Solution:
Engineered and installed a fixed gas detection system to continuously monitor critical areas and provide early warning alerts in case of gas leaks.
Reliability Impact:
Improved worker safety, strengthened regulatory compliance, and enhanced operational continuity through real-time hazard monitoring.
Fleet & Logistics Operations
Lubrication Storage & Oil Management System Rehabilitation
Challenge:
The containerized lubrication storage and oil management system was in poor working condition, compromising lubricant integrity, organization, and maintenance efficiency.
Solution:
Carried out a full system rehabilitation, restoring storage functionality, contamination control measures, and organized lubricant dispensing systems.
Reliability Impact:
Improved lubricant quality control, enhanced maintenance efficiency, and strengthened fleet equipment reliability through proper oil management practices.
Integrated Oil Management System for Heavy-Duty Truck Service Workshop
Challenge:
A newly established heavy-duty truck service workshop aimed to increase service capacity and operational efficiency. The previous workshop relied on manual oil handling processes, which limited throughput, reduced consumption visibility, and increased the risk of oil losses.
Solution:
Designed and installed a structured oil management system incorporating organized new and used oil handling, controlled dispensing units, and accurate oil consumption tracking. The system replaced manual oil handling and introduced standardized, accountable lubrication processes across the workshop.
Reliability Impact:
Improved service efficiency, reduced oil losses, enhanced consumption visibility, and enabled higher workshop capacity—supporting scalable and disciplined fleet maintenance operations.
Oil Management System Installation for FMCG Fleet Workshop
Challenge:
The FMCG company’s fleet workshop lacked structured oil storage and consumption tracking, leading to oil losses, inconsistent record-keeping, and reduced service efficiency. Limited visibility into lubricant usage made cost control and accountability difficult.
Solution:
Designed and installed a comprehensive oil management system, including organized bulk storage, controlled dispensing units, and structured consumption recording processes. The system enabled accurate tracking of oil usage per vehicle and improved workshop organization.
Reliability Impact:
Reduced lubricant losses, strengthened consumption accountability, and improved service team efficiency—creating a more disciplined, data-driven maintenance operation.
Chemical Plants
FLUX Drum Pumping System for Safe & Efficient Chemical Transfer
Challenge:
Manual drum handling and overhead positioning created safety risks, consumed forklift resources, and slowed down chemical transfer into the production process.
Solution:
Installed FLUX drum pumping systems to enable safe, direct transfer of chemicals from drums into the process line without overhead lifting.
Reliability Impact:
Reduced production time by 50%, eliminated safety risks associated with elevated drum handling, freed up forklift capacity, and enabled production to finish four hours earlier each day.
Renewable Energy
Specialty Lubrication Support for Wind Turbine Operations
Challenge:
Wind turbines operate under continuous load and varying environmental conditions, requiring high-performance lubricants to protect gearboxes, bearings, and critical rotating components. Reliable lubrication is essential to prevent costly downtime and ensure uninterrupted power generation.
Solution:
Provided application-specific specialty lubricants tailored to key turbine components, ensuring optimal protection, long service intervals, and consistent performance under demanding operating conditions. Ongoing technical support was delivered to maintain lubrication reliability across the wind farm.
Reliability Impact:
Strengthened turbine operational reliability, reduced lubrication-related risk, and supported consistent renewable energy generation—contributing to stable power supply for the national grid.
Pre-Installation Gearbox Inspection for Africa’s Largest Wind Farm
Challenge:
Wind turbine nacelles destined for Africa’s largest wind farm required thorough inspection to detect any potential gearbox damage during high-seas transport and inland transit. Undetected internal damage prior to installation would have resulted in significant replacement costs and project delays once turbines were mounted.
Solution:
Engaged to conduct detailed borescope inspections of wind turbine gearboxes both in transit and on site prior to installation. Over several months, successfully inspected all 365 nacelles to verify internal gearbox condition and ensure no transport-related damage was present before commissioning.
Reliability Impact:
Prevented costly post-installation rework, protected high-value turbine assets, and supported seamless project execution for a critical renewable energy infrastructure development.