Open-Gear & Girth Gear Lubrication & Reliability Services
Heavy-duty open gears in cement and mining plants demand more than lubrication — they demand a lifecycle protection strategy.
At Droplex, we implement a complete A-B-C-D open-gear lubrication system supported by inspection, diagnostics, and optimization services to maximize gear life and minimize downtime.
The A-B-C-D Open-Gear Protection System
Our structured five-step approach ensures protection from installation through full operational life:
A – Gear priming » B – Running-in » C – Operation » D – Gear Repair » Comprehensive gear service
A – Priming (Corrosion & Surface Protection)
Protects tooth flanks before the first rotation.
Applications:
- Long-term storage
- Initial installation and alignment
Priming Lubricants:
- Klüberplex AG 11-462
- Grafloscon A-G 1 Ultra
Application: Manual (brush/spatula)
B – Running-in (Surface Conditioning)
Optimizes contact pattern and reduces early-stage damage.
Benefits:
- Improved surface condition
- Controlled load distribution
- Reduced risk of scuffing
Running-in Lubricants:
- Klüberfluid B-F 2 Ultra
- GRAFLOSCON B-SG 00 ULTRA
C – Operation (Long-Term Protection)
Ensures stable, efficient gear performance.
Operational Benefits:
- Reduced lubricant consumption
- Higher load-carrying capacity
- Lower vibration levels
- Reduced tooth flank temperatures
- Energy savings through reduced friction
- OEM-approved solutions
Operational Lubricant:
- Klüberfluid C-F 3 Ultra
D – Gear Repair (Surface Reconditioning)
Used when gears show scoring, scratches, or surface distress.
Restorative Effects:
- Reduces asperities
- Improves contact pattern
- Smoothens minor plastic deformation
- Extends gear service life
Repair Lubricants:
- Klüberfluid D-F 1 Ultra
- GRAFLOSCON D-SG 00 ULTRA
Girth Gear Protection & Reliability Services
Lubricant selection alone does not guarantee gear reliability.
We provide comprehensive inspection, diagnostics, and optimization services.
1. Gear Inspection Services
We assess the complete mechanical and lubrication condition of your open gear system:
- Vibration measurements on pinion bearings
- Tooth flank temperature monitoring
- Pitch circle alignment inspection
- Spray lubrication system & spray pattern inspection
- Silicone rubber tooth flank impressions
- Visual inspection & load distribution assessment
2. Reporting & OEM-Aligned Recommendations
- Detailed inspection reports
- Photo documentation
- Root cause analysis of gear damage
- Lubrication optimization recommendations
- Central lubrication system performance evaluation
- Recommendations aligned with OEM standards
3. Repairs & Optimization Services
When damage is detected, we provide:
- Surface reconditioning using repair lubricants
- Mechanical tooth flank treatment (if required)
- Spray system calibration & optimization
- Spray timing and lubricant consumption adjustment
- Central lubrication system service & upgrades
Why This Matters for Cement & Mining Plants
A poorly lubricated girth gear can result in:
- Catastrophic gear failure
- Costly kiln downtime
- High replacement costs
- Loss of production
Our structured approach transforms open-gear lubrication from reactive maintenance into a controlled reliability program.
This is how we go Beyond The Engineering.