饮料行业智能灌装机的自动润滑（中英文）

升级到自动润滑系统可以为食品和饮料制造商带来诸多好处，包括经济效益和其他方面。

Upgrading to an automated lubrication system can bring food and beverage manufacturers a score of benefits, economic and beyond.

只需观察在当地商店的饮料区，就会发现瓶装饮料已成为日常消费品，而且种类繁多，令人眼花缭乱。全球城镇化趋势推动着人们在工作场所、学校、健身房、交通等便利场所（例如工作场所、学校、健身房、交通工具）对饮料的需求日益增长，而人口的持续增长又进一步加剧了这一趋势。不可避免地，滚雪球式的消费给制造商及其所依赖的机器带来了更大的压力。

难怪饮料行业的竞争日益激烈。制造商通常要求24小时不间断生产，几乎没有时间进行维护，并且需要在设备仍在运行时进行保养。机器故障会严重影响可用性；80%或更高的整体设备效率 (OEE) 目标往往与60%左右的现实情况相冲突。

在饮料制造过程中，决定整体OEE的最关键应用之一是灌装机本身。制造商需要将水、茶、冰沙、酸奶等各种液体灌装到玻璃瓶、罐、袋、管、PET 或其他容器中，因此他们寻求的是精准、多功能、卫生可靠的灌装设备，即使在连续高速运行且无需计划内维护的情况下也能保持稳定。

自动润滑系统为饮料灌装机提供了一种全新的解决方案。

You need only stroll down the beverage aisle of your local store to know that bottled drinks have become a consumer staple and that the range of products is overwhelming. The growing demand for drinks at convenient locations – work, school, gym, transport– is being driven by the global trend towards urbanization, fuelled in turn by inexorable population growth. Inevitably, snowballing consumption increases the pressure on manufacturers as well as on the machines upon which they rely.

Small wonder then that the beverage industry is becoming increasingly competitive. It is common for manufacturers to demand 24-hour production, leaving little time for maintenance and requiring that upkeep be performed while the equipment is still in operation. Machine failures have a dramatic impact on availability; the goal of overall equipment effectiveness (OEE) at 80 percent or higher often clashes with a reality of around 60 percent.

One of the most critical applications determining overall OEE in beverage manufacture is the filling machine itself. Faced with the need to fill glass bottles, cans, pouches, tubes, PET or other containers with anything from water or tea to smoothies and yoghurt, manufacturers look for filling equipment that is accurate, versatile, hygienic and reliable, even when operating continuously, at high speeds and without planned maintenance breaks.

Automated lubrication systems offer a new approach in beverage filling machines.

递进式自动润滑系统是食品饮料行业最常见的润滑系统。该系统适用于润滑点分散、需要不同量润滑脂或润滑油的中小型机器。

Progressive automatic lubrication systems are the most common lubrication systems in the food and beverage industry. They can be used on small to medium-sized machines with dispersed lubrication points that require varying quantities of grease or oil.

灌装机与润滑

Filling machines and lubrication

SKF食品饮料行业的客户可以列举许多影响灌装机性能的润滑挑战。

• 润滑脂过少：润滑脂不足会缩短轴承和机器的使用寿命。润滑不足和过度都可能是由于计量不精确，也可能是因为一些润滑点被遗忘，尤其是那些难以触及或在机器运转时无法触及的润滑点。

• 润滑脂过多：这里最大的风险是产品污染，造成高昂的成本。但同样严重的问题是，润滑脂可能会进入用于清洁机器的水中，需要水处理工艺符合环保法规。

• 复杂性：一台灌装机可能有多达 80 个润滑点，其中许多位于旋转的机械部件内部，因此在机器运转时无法触及。出于安全考虑，手动操作可能会变得复杂。部件种类繁多，其高效润滑可能非常复杂。例如，齿轮的润滑对机器的性能至关重要。

• 腐蚀：润滑系统的设计可能不适合在饮料行业的恶劣条件下运行，例如高湿度，这会导致计量装置、油嘴和管道腐蚀。装瓶生产线必须频繁进行高压冲洗，这对装瓶机械装置的完整性及其润滑构成了真正的挑战。简而言之，腐蚀对饮料生产基地具有破坏性。

SKF customers in the food and beverage sector can cite a number of lubrication challenges that affect the performance of filling machines.

• Too little grease: Lack of lubricant shortens the lifetime of the bearing and that of the machine. Both under- and over-lubrication can be due to imprecise metering and also because some lubricating points are simply forgotten, especially those that are difficult to reach or cannot be accessed while the machine is in motion.

• Too much grease: The paramount risk here is costly contamination of the product. But an equally critical problem is that grease can enter the water used to clean the machine, requiring water treatment processes to meet environmental regulations.

• Complexity: A filling machine can have as many as 80 lubrication points, many of which are located inside rotating mechanical parts and therefore impossible to access while machinery is running. Manual access can be complicated by safety concerns. Components vary, and their efficient lubrication can be complex. Gear wheels are an example, and their lubrication is fundamental to a machine’s performance.

• Corrosion: Lubrication systems may not be designed to operate under the aggressive conditions of the beverage industry, such as high humidity, which can lead to corroded metering devices, grease nipples and piping. Frequent high-pressure washing is mandatory on bottling lines and poses a real challenge to the integrity of bottling mechanisms and their lubrication. In short, corrosion is damaging for beverage manufacturing sites.

自动化解决方案

Automated solutions

集中式自动润滑系统(ALS)能够提高机器可用性，同时减少对稀缺人才的依赖。这些系统能够以正确的间隔提供适量的润滑，最大限度地减少摩擦和磨损，并优化轴承和机械的使用寿命。ALS专为润滑单台机器以及整个工厂而设计，能够为所有需要的点提供适当、精确的润滑剂补充，从而在生产过程中带来一系列优势。

因此，采用防腐蚀材料制成的智能机器能够消除上述常见问题。通过在正确的时间将正确的润滑剂以正确的量输送到正确的润滑点，自动化系统可以消除人为错误，极大地简化润滑管理，减少润滑剂消耗，并提高装瓶流程的整体效率。

选择哪种系统？

在为特定灌装机选择正确的解决方案时，需要考虑以下几个主要因素：

• 尺寸：灌装机的尺寸决定了润滑点的数量，从而决定了润滑剂的总消耗量。

• 变化：所选系统必须能够向每个润滑点输送精确量的油脂或润滑油，具体量可能因机器中需要润滑的部件而异。

• 技术参数：系统必须考虑润滑点的背压、工作温度范围、润滑剂本身的选择以及供油泵的驱动能量、控制和监控。

• 需要润滑的机构类型：包括轴承、齿轮、选择螺钉等。

• 工厂环境：在大多数情况下，不锈钢部件对于避免腐蚀至关重要。然而，并非所有自动润滑系统都使用防腐蚀材料。

Centralized automatic lubrication systems (ALS) have the potential to increase machine availability while reducing reliance on scarce talent. These systems provide the appropriate quantity of lubrication at the correct intervals, minimizing friction and wear and optimizing bearing and machinery service life. Designed to lubricate individual machines as well as entire plants, ALS provide proper, precise lubricant replenishment to all required points, enabling a range of benefits in the process.

An intelligent machine, made from non-corrosive materials, therefore has the potential to eliminate the common problems listed above. By delivering the correct lubricant, in the right quantity, at the right time and to the correct lubrication point, automation removes human error, hugely simplifies lubrication management, reduces lubricant consumption and enhances the overall efficiency of the bottling process.

What system to choose?

There are several main factors at play in determining the correct choice of solution for a particular filling machine:

• Dimensions: The size of the filling machine determines the number of lubrication points, and thus total lubricant consumption.

• Variation: The chosen system must have the capacity to deliver an exact quantity of grease or oil to each lubrication point, which may vary according to the part of the machine to be lubricated.

• Technical parameters: The system must consider back pressures at the lubrication points, operating temperature range, the choice of lubricant itself and the feed pump’s drive energy, control and monitoring.

• Types of mechanisms to be lubricated: These include bearings, gears, selection screws, etc.

• Factory environment: In most circumstances, stainless steel components are essential to avoid corrosion. However, not all automated lubrication systems use corrosion-free materials.

自动润滑系统的类型

Types of automated lubrication systems

• 单线自动润滑系统

泵将润滑剂输送到可调节的计量装置，该计量装置为润滑点提供精确的油脂或润滑油量。单线润滑系统可用于为多台独立的机器、一台机器，甚至一台机器上的不同区域提供服务。监控由传感器完成，这些传感器监测系统压力，并在预设的临界值时向控制单元发送信号。控制单元可按预定的时间间隔自动触发润滑。单线润滑系统可为机器中多达 900 个润滑点提供服务，润滑距离可达 100 米。小型系统由紧凑型泵组（包括润滑剂储液罐）供油；大型系统由桶泵供油。安装比渐进式油脂润滑系统更容易，但单线油脂润滑系统的初始投资可能更高。

• 渐进式自动润滑系统

这是食品和饮料行业最常见的润滑系统。它适用于润滑点分散、需要不同用量的油脂或润滑油的中小型设备。递进式润滑系统由一台连接到主计量装置的泵组成，主计量装置的出口通过管道或高压软管连接到加注机的润滑点。泵将润滑剂输送到计量装置，计量装置将润滑剂分成预定的量。然后将润滑剂泵送到润滑点，或者泵送到二次计量装置的入口，从而可以润滑更多的点。递进式润滑系统可以向大约15米范围内多达150个润滑点分配精确计量的润滑剂。

• Single-line automatic lubrication systems

A pump delivers lubricant to an adjustable metering device that services the lubrication points, delivering a precise amount of grease or oil. Single-line lubrication systems can be used to service several separate machines or a single machine or even different zones on a single machine. Monitoring is done by sensors that monitor system pressures and send signals to the control unit at preadjusted critical values. The control unit enables lubrication to be triggered automatically at predetermined intervals. Single-line lubrication systems can serve as many as 900 lubrication points in machines over distances of up to 100 metres. Smaller systems are fed by compact pump units, including lubricant reservoirs; bigger systems are fed by barrel pumps. Installation is easier than with a progressive grease lubrication system, but the initial investment in a single-line grease lubrication system may be higher.

• Progressive automatic lubrication systems

This is the most common lubrication system in the food and beverage industry. It can be used on small to medium-sized machines with dispersed lubrication points that require varying quantities of grease or oil. Progressive lubrication systems consist of a pump connected to a primary metering device, outlets from which are connected via pipes or high-pressure hoses to the lubrication points of the filling machine. The pump supplies lubricant to the meter, which splits the lubricant into predefined amounts. The lubricant is then pumped to the lubrication points or – alternatively – to the inlet of a secondary metering device, thereby enabling more points to be lubricated. Progressive lubrication systems can dispense a precise, metered amount of lubricant to as many as 150 lubrication points over distances of approximately 15 metres.

集中自动润滑系统 (ALS) 可以提高机器可用性，同时减少对稀缺人才的依赖。

Centralized automatic lubrication systems (ALS) have the potential to increase machine availability while reducing reliance on scarce talent.

99.5% 的饮料灌装机采用手动润滑。

99,5% of operated beverage filling machines are manually lubricated

虽然安装自动润滑系统 (ALS) 需要一定的初始成本，但其投资回报速度可能比预期更快。首先，人工成本显著降低。其次，停机时间减少，部件寿命延长，也带来了可观的节省。无需停机润滑，只需保持系统润滑和维护，从而提高效率。轴承旋转时进行的润滑还能改善润滑剂的分布。少量润滑脂保持流动，即使在恶劣环境下运行，也能有效防止污染。

Although there is an initial cost to installing an ALS, the return on investment can come faster than might be assumed. Firstly, labour costs are significantly reduced. And there are also considerable savings from reduced downtime and extended component life. There is no need to stop the machine for lubrication, only to keep the system filled and maintained, so efficiency is enhanced. Lubrication that takes place while the bearings are rotating also improves the distribution of lubricant. A small amount of grease remains flowing, keeping out contamination even when the machine is operating in a harsh environment.

投资回报

Return on investment

智能传感器和数字测量设备还能持续监控整个润滑过程。监控和控制对于润滑系统的高效运行至关重要。与智能监控设备配合使用，自动润滑系统可以实现经济高效的润滑。生成的数据可以提前预警润滑或机器故障，从而采取预防措施。

SKF发现，自动润滑系统在灌装机中的应用潜力可以用经济角度来衡量：

• 提高资产可用性：自动润滑系统带来的可靠性，可以大幅降低因机械故障导致的停机频率和停机时长。SKF拥有丰富的应用经验，停机时间减少了高达 80%。

• 降低备件消耗：消除润滑故障后，轴承、链条和齿轮等备件的年消耗量平均可减少约50%。

• 降低维护成本：精准合理的润滑可以消除机器故障的主要原因之一。

• 速度更快：装瓶厂可将螺旋输送机的速度提高一倍，因为自动润滑的传动链可以更快地运行而不会损坏瓶子。

自动润滑系统还具有许多其他优势：

• 更高的生产力：除了增加机器正常运行时间外，自动化还能减少日常润滑所需的劳动力，从而显著提高效率。

• 改善健康和安全：工人在机器运行过程中无需再承受手动润滑带来的潜在危险。

• 降低产品污染风险：自动化消除了过度润滑导致饮料污染的危险。

• 快速投资回报：以上所有因素共同作用，使饮料灌装机自动润滑系统的投资能够快速获得回报。

Smart sensors and digital measuring devices also make it possible to constantly monitor the entire lubrication process. Monitoring and control are essential to the efficient operation of lubrication systems. Installed in conjunction with intelligent monitoring devices, automatic lubrication systems can facilitate economical and optimal lubrication. The resulting data can give operators advanced warning of lubrication or machine failure, enabling preventive action to be taken.

SKF has found that the potential of automatic lubrication systems for filling machines can be measured in economic terms:

• Increased asset availability: With the reliability that comes with automated lubrication, the frequency and duration of downtime because of mechanical failures is sharply reduced. SKF has experience of applications in which downtime reduction has been as much as 80 percent.

• Lower consumption of spare parts: With lubrication failures eliminated, annual consumption of spare parts such as bearings, chains and gear wheels is reduced by around 50 percent on average.

• Reduced maintenance costs: Accurate and appropriate lubrication removes one of the main causes of machine failure.

• Higher speed: A bottling plant can as much as double the speed of a spiral conveyor, because automatically lubricated transmission chains can run faster without damaging the bottles.

Automated lubrication systems offer a number of additional benefits:

• Higher productivity: Apart from the increase in machine uptime, the reduction in labour necessary to carry out routine lubrication makes automation an obvious route to increased efficiency.

• Improved health and safety: Workers are no longer exposed to potential hazards during manual lubrication of machines during operation.

• Lower risk of product contamination: Automation eliminates the danger of contaminating beverages through over-lubrication.

• Rapid return on investment: All the above factors combine to deliver a swift return on investment in automated lubrication systems for beverage filling machines.

润滑对于灌装机的性能至关重要。

Lubrication is critical to the performance of filling machines.

遵守食品安全法规

Compliance with food safety regulations

法规对全球食品和饮料生产的影响日益加深，越来越严格的规定要求食品加工商改变其工艺流程或改造其设备。在一些国家，关键的机器部件必须采用不锈钢材质。在潮湿区域使用的部件必须防腐蚀，并能承受高压清洗。在食品和饮料生产过程中使用不合适的润滑剂也引发了越来越多的健康担忧。润滑剂本身必须经过认证，确保不会与人类食用的物品偶然接触，并且必须符合世界主要宗教的饮食规范。升级到自动润滑系统还可以带来额外的好处，即符合现有或预期的法规要求。部件必须采用不锈钢涂层或置于不锈钢机柜中，以确保污染物的迁移量（即使发生）完全无害。

Regulation is increasingly affecting global food and beverage production, with stricter rules that require food processors to change their processes or modify their machines. In some countries, stainless steel is already obligatory for critical machine parts. Components for use in damp areas must be corrosion-free and amenable to high-pressure cleaning. Health concerns are also rising with regard to the use of inappropriate lubricants in the manufacture of food and beverage products. Lubricants themselves must be certified safe for incidental contact with items to be consumed by humans, and they must be compliant with the dietary specifications of the world’s major religions. Upgrading to automated lubrication can bring the additional benefit of compliance with existing or anticipated regulations. Components must be coated in stainless steel or housed in a stainless steel cabinet, ensuring that migration of contaminants takes place, if at all, in completely harmless amounts.

结论

Conclusion

SKF及旗下Lincoln润滑产品、系统和服务通过全球分销商网络提供，并由遍布全球的统一销售机构提供支持，提供交钥匙解决方案和广泛的售后支持，包括针对饮料行业量身定制的食品级润滑剂。致力于通过优化润滑管理来助客户取得成功。

SKF and Lincoln lubrication products, systems and services are available through a global network of distributors, supported by a unified sales organization around the world to offer turnkey solutions and extensive aftermarket support, including food-grade lubricants tailored to the beverage sector. We are committed to your success through optimizing your lubrication management.