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Lubricants: The hidden Savings in Your Production

They’re classed as low-value C-items, yet they have a direct impact on downtime, wear costs and machine life. A guide for finance, controlling and legal leaders.
by Dipl.-Ing. Gert Neukirch
Why Lubricants Are More Than a C-Item

A small budget line with a big downtime risk

As a managing director or head of department, you probably don’t give lubricants much thought. That’s understandable: they’re classed as C-items, and that’s how most people think of them.

But the moment a rolling bearing turns and starts contributing to your company’s revenue, things get interesting. As a critical machine element, it plays a key role in keeping production running smoothly, in every sense of the word. To do that reliably, it needs a lubricant, either an oil or a grease.

“Lubricate well, and your machines will run longer.”
→ In maintenance, this principle holds true without exception.

All lubricants degrade over time. If they aren’t replaced or topped up in time, the result sooner or later is a breakdown, often at the worst possible moment. That’s why preventive maintenance matters so much.

Three Levers for Measurable Cost Savings

Lubricants often have significant, underestimated savings potential, both in terms of the product itself and the process. Depending on the application, a better lubricant can extend machine life, reduce maintenance effort or lower consumption. Compared with the savings achieved, the cost of the lubricant itself is usually negligible.

  • Prevent wear and downtime
The right lubricant, used correctly, significantly reduces machine failures and spare parts costs, especially on expensive equipment.
  • Cut consumption and energy costs
With consumable lubricants, better lubrication means you use less. Lower friction also reduces energy consumption, with a noticeable effect on machines drawing 20 A or more at 400 V.
  • Lower maintenance costs
Higher quality means less maintenance → fewer labour hours and longer service intervals. 

How much could your business save?

It starts with an honest look at how lubrication is handled today.

Talk to us. We’re happy to help.
Overview

Standard or High-Performance:

What Do You Need, and When?
There are over 3,000 different lubricating oils and around 64,000 greases available for industrial use. Broadly speaking, they fall into two categories:

Standard lubrication

Used in over 80% of applications, including conventional hydraulic oils, gear oils and general-purpose greases. Reliable, proven and cost-effective, as long as there are no special requirements.

High-performance lubrication

For applications with particularly demanding or specialised requirements. These lubricants cost considerably more than standard products, but the difference can pay for itself very quickly in practice.

As a rule, high-performance lubricants offer the biggest savings, but standard lubricants can also have considerable potential, depending on the application. Once you factor in the cost of switching, realistic savings start at around €5,000 a year and can easily exceed €100,000 a year in high-volume production.

Learn More

High-Performance Lubricants Compared

Lubricating oils

These oils come into play whenever conditions are too extreme for standard oils to handle. They help keep production running smoothly, economically and with minimal wear. Each one is developed for a very specific, narrowly defined application. Their relatively high price reflects high-quality raw materials and development costs spread across comparatively small volumes.

Switching products: Moving to a different high-performance oil requires a high level of expertise. The cost benefits need to be compelling, as the upfront effort is often considerable. If price is the only reason for switching, always weigh the effort against the actual savings.

Greases

These are usually the greases that seem expensive, but their job justifies the price. Like a machine element, each one is specifically tailored to its application.

Recommending alternatives is the ultimate test of tribological expertise and should only be done by qualified engineers. Standard lubricant knowledge isn’t enough. In-depth knowledge of rolling bearings, lubrication design and the specific application is essential.

How to spot good advice: For small quantities, a reputable supplier will usually recommend sticking with your current provider. Only when switching makes real financial sense will they offer dedicated advice, which may also reduce maintenance effort and the associated costs. Price is one thing; the changeover and its consequences are another.

Frequently asked Questions

Typical warning signs include:

  • Bearing or gearbox damage before the end of the manufacturer’s warranty
  • Rising spare parts costs while production stays the same
  • Unusually short maintenance intervals, or lubricants bought ad hoc without technical advice

Reviewing how lubrication is currently handled usually reveals quickly where the real potential lies. We’re happy to help. Call us Monday to Friday, 9 am to 4 pm (CET), on +49 9342 9169393, or email us at support@neukirchlubrication.de.

Standard lubricants can usually be switched in-house, provided the equipment manufacturer has approved the new product. High-performance products are a different matter and need expert support, because the right choice depends on the application, temperature range, load profile and material compatibility. Switching to the wrong product can do more damage than the problem you were trying to fix.

Switching makes financial sense when wear, frequent maintenance or high energy consumption are driving up running costs. Once you factor in the cost of switching, realistic savings start at around €5,000 a year and can be well over €100,000 a year in high-volume production.

Still Have Questions?

You’ll find more answers on our FAQ page. Or just get in touch directly. Call us Monday to Friday, 9 am to 4 pm (CET), on +49 9342 9169393, or email us at support@neukirchlubrication.de.

All information is based on our current knowledge and development experience. It does not constitute a guarantee of specific properties or of a product’s suitability for any particular application. For further details, please contact our technical service team.