{"id":28357,"date":"2025-05-03T08:37:06","date_gmt":"2025-05-03T05:37:06","guid":{"rendered":"https:\/\/www.droplex.com\/ke\/?page_id=28357"},"modified":"2026-06-10T14:34:21","modified_gmt":"2026-06-10T11:34:21","slug":"case-studies","status":"publish","type":"page","link":"https:\/\/www.droplex.com\/ke\/case-studies\/","title":{"rendered":"Case Studies"},"content":{"rendered":"\n
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\u2014 CASE STUDIES<\/strong><\/h1>\n\n\n\n

The Work That
Proves the Promise.<\/mark><\/em><\/h2>\n\n\n\n

Every plant that failed the same way twice had a system problem \u2014 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 \u2014 not replacing the symptom.<\/strong><\/p>\n<\/div>\n<\/div>\n\n\n\n

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JUMP TO INDUSTRY<\/a><\/div>\n\n\n\n
Cement & Mining<\/a><\/div>\n\n\n\n
Food & Beverage Processing<\/a><\/div>\n\n\n\n
Transportation<\/a><\/div>\n\n\n\n
Plastics & Chemicals<\/a><\/div>\n\n\n\n
Power & Wind<\/a><\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n
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INDUSTRY<\/strong><\/p>\n\n\n\n

Cement & Mining<\/h2>\n\n\n\n

5 case studies<\/strong><\/p>\n\n\n\n

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CS-01<\/mark>
Coal Mill Open Gear Spray Lubrication System Upgrade<\/h3>\n<\/div>\n<\/div>\n\n\n\n
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\"\"<\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

Inconsistent manual lubrication was causing uneven gear wear and increasing the risk of premature open gear failure on the coal mill.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Engineered and installed a precision spray lubrication system to deliver controlled, uniform high-viscosity Kl\u00fcberfluid C-F 3 Ultra<\/strong> open gear lubricant across the full gear face.<\/p>\n\n\n\n

OUTCOME
Improved girth gear protection, reduced lubricant waste, and consistent lubrication \u2014 extending open gear service life and stabilising mill operation.<\/strong><\/p>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div><\/div>\n\n\n\n
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CS-02<\/mark>
Mining Kiln Open Gear Lubrication Optimisation<\/h3>\n\n\n\n
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\"\"<\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

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.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Assessed the application and implemented Kl\u00fcberfluid C-F 3<\/strong> open gear lubricant \u2014 optimising spray pattern, film formation, and load-carrying performance for the specific kiln operating conditions.<\/p>\n\n\n\n

OUTCOME
Enhanced gear surface protection, improved lubricant film stability under high temperatures, and reduced the risk of costly kiln downtime.<\/strong><\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div><\/div>\n\n\n\n

CS-03<\/mark>
Cement Mill Open Gear Lubrication System Upgrade<\/h3>\n\n\n\n
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\"\"<\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

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.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Engineered and installed a precision spray lubrication system delivering uniform lubricant application across the full gear face under load.<\/p>\n\n\n\n

OUTCOME
Enhanced gear protection, optimised lubricant consumption, and improved operational stability \u2014 reducing the risk of unplanned shutdowns.<\/strong><\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div>\n\n\n\n
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CS-04<\/mark>
Komatsu HM300 Dump Truck Automatic Lubrication System Installation<\/h3>\n\n\n\n
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\"\"<\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

Heavy-duty dump truck components designed for operation under extreme load and contamination conditions would make manual lubrication inconsistent \u2014 increasing the risk of wear on a new fleet asset before it had even started work.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Engineered and installed a centralised automatic lubrication system on a new Komatsu HM300 prior to deployment \u2014 ensuring consistent, controlled grease delivery to all critical points from day one.<\/p>\n\n\n\n

OUTCOME
Reduced manual maintenance dependency, improved component protection, and enhanced fleet uptime in demanding mining operations.<\/strong><\/p>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div>\n\n\n\n

CS-05<\/mark>
Automated Lubrication System Refurbishment \u2014 Cement Aggregate Plant<\/h3>\n\n\n\n
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\"\"<\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

Automatic lubrication systems in a high-dust aggregate environment had deteriorated \u2014 leading to inconsistent grease delivery and increased wear risk on critical equipment.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Removed, inspected, and refurbished system components at our technical facility \u2014 restoring pump performance, metering accuracy, and overall system reliability before reinstallation.<\/p>\n\n\n\n

OUTCOME
Re-established consistent lubrication across critical machinery, extended component life, and reduced maintenance intervention in a demanding operating environment.<\/strong><\/p>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div><\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n
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INDUSTRY<\/strong><\/p>\n\n\n\n

Food & Beverage Processing<\/h2>\n\n\n\n

4 case studies<\/strong><\/p>\n\n\n\n

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CS-11<\/mark>
Water-Resistant Lubrication Upgrade \u2014 Chicken Plucker Bearings<\/h3>\n<\/div>\n<\/div>\n\n\n\n
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\"\"<\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

The chicken plucker machine operated in a high-moisture washdown environment. Grease was washing out constantly \u2014 causing frequent bearing failures, excessive grease consumption, and repeated unplanned stops.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Assessed the operating conditions and replaced the existing grease with Kl\u00fcberfood NH1 94-402<\/strong> \u2014 a water-resistant, NSF H1 food-grade grease designed for washdown environments. Optimised relubrication intervals and quantities.<\/p>\n\n\n\n

80% reduction in grease consumption<\/strong><\/p>\n\n\n\n

$30K annual lubricant savings<\/strong><\/p>\n\n\n\n

OUTCOME
Bearing failures eliminated. Machine smoothness improved. Grease consumption reduced by 80%. Annual lubricant savings of approximately USD 30,000.<\/strong><\/p>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div><\/div>\n\n\n\n
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CS-12<\/mark>
Centralised Lubrication System \u2014 Beverage Conveyor Line<\/h3>\n\n\n\n
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\"\"<\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

Frequent bearing failures on the beverage conveyor line. Several grease points were difficult to access \u2014 so they were being missed or lubricated inconsistently during routine maintenance.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Engineered and installed a centralised lubrication system \u2014 routing all grease points to an easily accessible distributor block, ensuring reliable servicing without requiring access to difficult locations.<\/p>\n\n\n\n

OUTCOME
Missed lubrication points eliminated. Bearing failures reduced. Conveyor uptime improved \u2014 supporting uninterrupted beverage production.<\/strong><\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div><\/div>\n\n\n\n

CS-13<\/mark>
Food-Grade Lubricant Storage & Handling Optimisation<\/h3>\n\n\n\n
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\"\"<\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

Food-grade lubricants were stored across multiple plant areas without standardised containment \u2014 creating cross-contamination risk, misapplication risk, and audit non-compliance exposure.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Engineered and manufactured dedicated lubricant storage cages for each plant section \u2014 ensuring secure, organised, and clearly segregated storage of food-grade lubricants throughout the facility.<\/p>\n\n\n\n

OUTCOME
Improved lubricant control, enhanced food safety compliance, and simplified maintenance access \u2014 the plant passed its next audit with the lubrication programme as a strength, not a risk.<\/strong><\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div>\n\n\n\n
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CS-14<\/mark>
High-Viscosity Glucose Syrup Transfer System<\/h3>\n\n\n\n
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\"\"<\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

Transferring high-viscosity glucose syrup from an IBC tank into the production line was inefficient and difficult \u2014 risking product loss, inconsistent flow, and production delays. Glucose transfer time was 9 hours.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Designed and installed an AODD pump-based transfer system capable of handling high-viscosity fluids with controlled, reliable delivery directly into the production process.<\/p>\n\n\n\n

Transfer time reduced from 9 Hours to 40 mins<\/strong><\/p>\n\n\n\n

OUTCOME
Improved transfer efficiency to 40 mins, minimised product wastage, and ensured consistent syrup flow \u2014 supporting stable, hygienic production.<\/strong><\/p>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div><\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n
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INDUSTRY<\/strong><\/p>\n\n\n\n

Transportation<\/h2>\n\n\n\n

3 case studies<\/strong><\/p>\n\n\n\n

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CS-21<\/mark>
Integrated Oil Management System \u2014 Heavy-Duty Truck Workshop<\/h3>\n\n\n\n
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\"\"<\/a><\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

A newly established heavy-duty truck service workshop would rely on manual oil handling \u2014 limiting service throughput, reducing visibility into consumption, and increasing the risk of oil losses from day one.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Designed and installed a structured oil management system \u2014 organised new and used oil handling, controlled dispensing units, and accurate consumption tracking. Replaced manual handling with a standardised, accountable process.<\/p>\n\n\n\n

OUTCOME
Improved service efficiency, reduced oil losses, enhanced consumption visibility, and enabled higher workshop capacity compared to the old workshop right from the start.<\/strong><\/p>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div><\/div>\n\n\n\n

CS-22<\/mark>
Lubrication Storage & Oil Management System Rehabilitation<\/h3>\n\n\n\n

<\/p>\n\n\n\n

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\"\"<\/a><\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

The containerised lubrication storage and oil management system was in poor condition \u2014 compromising lubricant integrity, organisation, and maintenance efficiency across fleet operations.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Carried out a full system rehabilitation \u2014 restoring storage functionality, contamination control, and organised lubricant dispensing across the operation.<\/p>\n\n\n\n

OUTCOME
Improved lubricant quality control, enhanced maintenance efficiency, and strengthened fleet equipment reliability through properly managed oil handling.<\/strong><\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div><\/div>\n<\/div>\n<\/div>\n\n\n\n
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CS-23<\/mark>
Oil Management System \u2014 FMCG Fleet Workshop<\/h3>\n\n\n\n
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\"\"<\/a><\/figure><\/div>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

The FMCG fleet workshop lacked structured oil storage and consumption tracking \u2014 leading to oil losses, inconsistent records, and poor visibility into lubricant costs across the fleet.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Designed and installed a comprehensive oil management system \u2014 bulk storage, controlled dispensing, and structured consumption recording per vehicle. Replaced informal habits with a disciplined, trackable process.<\/p>\n\n\n\n

OUTCOME
Reduced lubricant losses, strengthened consumption accountability, and improved service team efficiency across the workshop.<\/strong><\/p>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div><\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n
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INDUSTRY<\/strong><\/p>\n\n\n\n

Plastics & Chemicals<\/h2>\n\n\n\n

2 case studies<\/strong><\/p>\n\n\n\n

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CS-31<\/mark>
FLUX Drum Pumping System \u2014 Chemical Processing<\/h3>\n\n\n\n
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\"\"<\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

Manual drum handling and overhead positioning of chemical drums created safety risks for operators, consumed forklift resources, and slowed chemical transfer into the production process every day.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Installed FLUX drum pumping systems enabling safe, direct transfer of chemicals from drums into the process line \u2014 eliminating the need for overhead drum lifting entirely.<\/p>\n\n\n\n

50% reduction in chemical transfer time.<\/strong><\/p>\n\n\n\n

OUTCOME
Production time reduced by 50%. Safety risks from elevated drum handling eliminated. Forklift capacity freed for other operations. Production finished four hours earlier each day.<\/strong><\/p>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div><\/div>\n\n\n\n

CS-32<\/mark>
Fixed Gas Detection System \u2014 Plastics Recycling Facility<\/h3>\n\n\n\n
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\"\"<\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

Recycling operations presented potential exposure to hazardous gases \u2014 creating safety risks for personnel and compliance concerns with no early warning system in place.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Engineered and installed a fixed gas detection system to continuously monitor critical areas \u2014 providing real-time alerts in the event of gas leaks before they reach dangerous levels.<\/p>\n\n\n\n

OUTCOME
Improved worker safety, strengthened regulatory compliance, and provided the plant team with advance warning capability \u2014 so the problem is seen before it becomes an incident.<\/strong><\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n

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<\/div><\/div><\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n
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INDUSTRY<\/strong><\/p>\n\n\n\n

Power & Wind Energy<\/h2>\n\n\n\n

2 case studies<\/strong><\/p>\n\n\n\n

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CS-41<\/mark>
Specialty Lubrication Support \u2014 Wind Farm Operations<\/h3>\n\n\n\n
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\"\"<\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

Wind turbines operate under continuous load and varying environmental conditions. Standard lubricants were not providing adequate protection for gearboxes, bearings, and critical rotating components \u2014 creating reliability risk across the wind farm.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Supplied application-specific specialty lubricants tailored to each critical turbine component \u2014 with ongoing technical support to maintain lubrication reliability across all turbines in the wind farm.<\/p>\n\n\n\n

OUTCOME
Strengthened turbine operational reliability, reduced lubrication-related risk, and supported consistent renewable power generation across the wind farm.<\/strong><\/p>\n<\/div>\n<\/div>\n\n\n\n

<\/div><\/div><\/div>\n\n\n\n

CS-42<\/mark>
Pre-Installation Gearbox Inspection \u2014 Africa’s Largest Wind Farm<\/h3>\n\n\n\n
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\"\"<\/a><\/figure>\n<\/div>\n\n\n\n
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THE PROBLEM<\/strong><\/p>\n\n\n\n

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 \u2014 a significant project and financial risk.<\/p>\n\n\n\n

<\/div><\/div>\n\n\n\n

WHAT DROPLEX DID<\/strong><\/p>\n\n\n\n

Conducted detailed borescope inspections of all 365 wind turbine gearboxes \u2014 both in transit and on site \u2014 verifying internal gearbox condition before any turbine was commissioned.<\/p>\n\n\n\n

365 turbine nacelles inspected<\/strong><\/p>\n\n\n\n

OUTCOME
Prevented costly post-installation rework, protected high-value turbine assets, and supported seamless execution of Africa’s largest wind farm development.<\/strong><\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n

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<\/div><\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n
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\u2014 YOUR PLANT<\/strong><\/p>\n\n\n\n

Every plant\/equipment that keeps failing
is a system problem.<\/mark><\/em><\/h2>\n\n\n\n

The plants in these case studies all had one thing in common \u2014 a failure or inefficiency that kept repeating until someone looked at the system, not just the symptom. Start with a Reliability Assessment. We visit your plant, discuss, and find a way to fix it. No obligation.<\/p>\n\n\n\n

\n
Request a Reliability Assessment \u2192<\/a><\/div>\n\n\n\n
Speak to a Specialist \u2192<\/a><\/div>\n<\/div>\n\n\n\n

We make sure it works. And we stay accountable \u2014 always.<\/em><\/p>\n<\/div>\n<\/div>\n","protected":false},"excerpt":{"rendered":"

\u2014 CASE STUDIES The Work ThatProves the Promise. Every plant that failed the same way twice had a system problem \u2014 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 […]<\/p>\n","protected":false},"author":2,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_uag_custom_page_level_css":"","site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"disabled","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"set","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center 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