www.hpmag.co.uk HYDRAULICS & PNEUMATICS September 2026 33 When it comes to digitalisation, around 90% of manufacturers have now adopted some form of digital technology,1 with AI, digital twins, predictive maintenance and IIoT increasingly common place. Industry 4.0 technologies are transforming maintenance strategies and preventative maintenance is being replaced by many with predictive maintenance. As engineers adopt condition monitoring, along with vibration and oil analysis, remote diagnostics, AI-assisted maintenance planning and cloud-connected sensors, there is more emphasis on digitising lubrication schedules, through computerised maintenance management systems (CMMS). The sustainability agenda and engineering skills gap are also impacting lubrication processes. With many engineers now required to contribute directly to net zero targets, increasing numbers are wanting a well-designed lubrication strategy that contributes to their company’s environmental goals, whilst not compromising machine protection. In addition, the engineering skills gap is placing maintenance teams under growing pressure. With over 75% of engineering companies struggling to recruit skilled engineers,2 routine but essential tasks like manual lubrication are increasingly at risk of being overlooked. The ‘when and where’ of automated lubrication Even though manual lubrication is still the most popular way to keep the wheels turning in manufacturing settings, the balance is tipping towards automated lubrication as more producers want the precision, safety and uptime benefits that this solution offers. However, not every situation needs automated lubrication. So, when and where is it best to use automated lubrication? Although it’s a personal choice, the bottom line is that automated lubrication is best suited to high-value, high utilisation or hard-to-maintain equipment. The questions that need to be asked when thinking about switching from manual to automated lubrication include: ‘is this machine critical to production, is lubrication currently being missed or delayed, does the machine need to be stopped to lubricate it, are there many lubrication points or are they difficult or unsafe to reach, and what is the unplanned downtime cost?’ Answers to these questions will help inform any changes to the machine’s lubrication system. Benefits of hardwired and standalone units Once the decision has been made that automated lubrication is needed to improve efficiency, precision and health and safety, the next focus is on whether a hardwired (centralised) system or standalone (single-point) lubricator is needed. The choice will be led by the scale and criticality of the lubricator application. Hardwired systems are obviously best suited to larger, complex or mission-critical equipment and are popular where many bearings, gears or chains require regular lubrication. Standalone automated lubricators are simple, affordable and a great way to automate lubrication for individual machines that have an individual lubrication point or a small group of points. The units can be battery-powered, electromechanical or gasdriven to suit the application. Single-point solutions are good for retrofits, remote equipment and facilities that want to improve reliability, without investing in a centralised system. Real-world machine lubrication top tips Whether automated or manual lubrication is chosen, the ultimate aim for any maintenance agenda remains the same - peak performance with minimum downtime. And lubrication is one of the unsung heroes that can help achieve improved efficiency, while also help meeting ever-changing productivity targets. Here at Acorn, we receive many requests for help when it comes to assessing lubrication issues on machines and many fall into one of the following categories: A way to monitor potential blockages on single-point lubricators – One of the most basic yet simple ways to ensure accurate lubrication on single-point lubricators is to make use of a waterproof marker pen! On installation we recommend the maintenance engineer put the date on the unit, so it is quick and easy to see when it has reached its replacement date threshold. We would also recommend a line is drawn at the lubrication level and then this is checked 2 months after installation to ensure that the plunger has moved. We would then suggest a subsequent line is added at the new lubrication level and rechecking carried out after an additional time period. In this way, any potential blockages can be picked up quickly and easily. Avoiding air gaps in the lubrication system – Sometimes, due to the heat coming from a machine, it is necessary to mount the lubrication system away from the unit. However, is not uncommon for us to see incidents where the engineer has forgetten to prime the six inches of flexi-hose running from the lubrication solution to the machine on fitting. The subsequent Maximising machine lubrication performance The devil is in the detail as they say, and this is true right down to how and when machines are lubricated to maximise efficiency. Jay Goodgame, lubrications manager at Acorn Industrial Services discusses the ‘when and where’ of automated lubrication, the benefits of hardwired and standalone units and some top tips to maximise the efficiency of machine lubrication systems still further, based on real-world experience. SPECIAL REPORTS – AUTOMATION
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