Reducing downtime with automated lubrication in tissue converting

Whether planned or unplanned, every minute of downtime in the tissue converting business chips away at profitability. Unplanned stoppages often arise from chain wear, clogging due to dust and debris, and oil leaks contaminating products, while planned downtime for maintenance must be minimised to sustain efficiency. With conveyor systems at the heart of tissue converting, effective chain lubrication is the single most critical factor in reducing these interruptions. We have encountered these challenges time and again, which led us to develop an innovative solution that ensures precise lubrication where it matters most.

The problem with traditional lubrication methods

Conventional lubrication techniques – including manual application, brush systems, drip-feed or split systems – regularly fail to deliver lubricant precisely to the pivot points of the chain, where friction reduction is most crucial. In the humid environments of pulping and processing, ineffective lubrication leads to noisy chains, increased energy consumption and shorter service life, requiring frequent replacements and extended maintenance periods. Worse still, excess lubricant accumulates on chain surfaces, attracting dust and debris that clog mechanisms and contribute to product waste, directly impacting profitability.

RotaLube keeping your chain running smoothly

A game-changing approach to lubrication

To combat these issues, we designed a sprocket-shaped applicator that delivers precise amounts of lubricant directly to the pivot points of the chain. This applicator, connected via hoses to a pump system, engages with each chain link as the conveyor moves, ensuring optimal lubrication regardless of chain stretch (wear), conveyor speed or ambient temperature. The RotaLube system has been rigorously tested, in collaboration with Lancaster University and was awarded patents in the UK and US in 2012 and 2013. More than a decade later, our first commercial installation continues to operate effectively, demonstrating the long-term reliability of our solution.

Real-world impact: a case study

A major tissue manufacturer faced persistent disruptions in its Perini Log Accumulator due to poor chain lubrication. The brushing method in use caused chains to tighten and bend, leading to tilting gondolas and requiring manual chain tensioning every two weeks. Each adjustment forced a 15-minute production halt, significantly affecting productivity. Additionally, the continuous-pressure oil feed brush system over-lubricated the chain, causing dust accumulation that prevented oil from reaching the pivot points, accelerating wear and necessitating frequent chain replacements. Over a year, these inefficiencies resulted in substantial costs. We implemented the RotaLube system, using precision lubrication technology that applies oil directly at the correct points. This eliminated over-lubrication, preventing dust buildup and ensuring smooth chain operation. The system, controlled via the machine’s PLC, delivered controlled oil quantities through an electrically operated pump, reducing manual maintenance and ensuring consistent lubrication. The results were immediate: the manufacturer achieved a return on investment in just 128 days, saving £65,000 annually in maintenance and production costs, reducing lubricant consumption by £7,000 and improving power efficiency. Most importantly, chain-related production halts were eliminated entirely.

A comprehensive maintenance solution

RotaLube is compatible with any conveyor chain size and number of strands, ensuring reliability across the entire tissue converting process. We also provide a complete package, including recommended chain oils, as well as core inserter and core elevator chains for log rewinders, log saw pusher chains and infeed and overhead flight chains for wrapping, bundling and bagging machines. With RotaLube, effective lubrication is no longer a maintenance afterthought – rather a fundamental factor in ensuring continuous, high-speed production with minimal costs and downtime.