Lubrication Points and Schedules: Keeping Your Machine Running Smoothly

Introduction

Lubrication is the single most important maintenance task for preventing mechanical wear in flow wrappers. Yet it’s also one of the most commonly neglected. The bearings in your flow wrapper’s drive system, film transport, and sealing mechanism operate under constant stress—high speeds, variable loads, and continuous motion. Without proper lubrication, metal surfaces grind against metal, generating heat, producing wear particles, and ultimately failing catastrophically.

This comprehensive guide identifies every lubrication point in a typical horizontal flow wrapper, explains the correct lubricants for each application, and establishes maintenance schedules that balance thoroughness with practicality. You’ll learn to recognize signs of inadequate lubrication before they become failures, understand why certain points require special lubricant types, and develop a lubrication routine that keeps your equipment running smoothly for years.

The principles apply across all major flow wrapper brands including Paxiom, Ilapak, Wolf-Packing, and Path Pack systems. While specific locations may vary slightly between manufacturers, the underlying requirements remain consistent.

Why Lubrication Matters

The Physics of Friction

Every bearing, gear, and sliding surface in your flow wrapper generates friction. Friction produces heat, and heat accelerates wear. When metal surfaces contact without adequate lubrication, friction coefficients can be 10-100 times higher than with proper lubrication. This dramatic increase in friction leads to:

• Rapid surface wear (measurable in hours rather than years)
• Increased energy consumption (up to 30% more power required)
• Heat generation that can damage seals, bearings, and surrounding components
• Noise and vibration that indicate accelerated wear
• Premature failure requiring expensive replacement

Cost Analysis: Lubrication vs. Repair

Consider the economics: A single bearing replacement on a flow wrapper costs $150-500 in parts, plus $500-2000 in labor and downtime. A complete drive system rebuild can exceed $5000. Contrast this with annual lubricant costs of $50-200 and a few hours of operator time.

The National Lubricating Grease Institute estimates that proper lubrication can extend bearing life by 5-10 times compared to neglected lubrication. For a flow wrapper with 20 bearings, this difference represents potential savings of $10,000-50,000 over the machine’s operational life.

How Many Type of Lubricant ?

Grease vs. Oil: When to Use Each

Grease is the preferred lubricant for most flow wrapper applications because it:

• Stays in place better than oil in open mechanisms
• Provides sealing action that prevents contaminant ingress
• Requires less frequent application
• Handles vertical and angled mounting orientations

Oil is preferred for:

• High-speed bearings where grease would cause excessive heat
• Systems with automatic lubrication systems
• Applications requiring heat dissipation through oil circulation
• Precision mechanisms requiring consistent film thickness

Common Lubricant Specifications

What to Avoid

• Multi-purpose automotive greases: May contain additives incompatible with plastic components or food contact
• Used motor oil: Contains contaminants and combustion byproducts harmful to precision components
• WD-40 as lubricant: Excellent cleaner, poor lubricant—never use as permanent lubricant
• Any lubricant not rated for the application: Verify compatibility with seals, plastics, and operating conditions

What is Primary Lubrication Points

Drive System Components

Main Drive Motor Bearings

• Location: Inside the main drive motor housing
• Lubricant: Manufacturer-specified grease (typically sealed bearings require no relubrication)
• Interval: Check monthly; most modern motors have sealed bearings lasting 5-10 years
• Warning signs: Unusual noise, vibration, or heat at motor housing

Gearbox

• Location: Between motor and driven equipment
• Lubricant: Gear oil or gear grease per manufacturer specification
• Interval: Check oil level monthly; change per manufacturer schedule (typically 2000-5000 hours)
• Warning signs: Oil discoloration, metal particles in oil, increased operating temperature

Drive Chains and Sprockets

• Location: Between gearbox and driven shafts
• Lubricant: Penetration oil or chain lubricant spray
• Interval: Weekly application, more frequently in dusty or humid environments
• Application method: Apply to inner plate surfaces while rotating chain by hand

Couplings

• Location: Connecting motor shaft to gearbox input
• Lubricant: Check manufacturer specification—many are permanently lubricated
• Interval: Inspect monthly for wear, replace per manufacturer schedule
• Warning signs: Vibration, misalignment symptoms, unusual noise

Film Transport System

Idler Rollers

• Location: Throughout film path—unwind stand, dancer bar, film guides, pull rollers
• Lubricant: Light grease on bearings, oil on shafts (depends on construction)
• Interval: Monthly inspection, lubricate as needed
• Key point: Ensure film path remains free of lubricant contamination

Tension Dancer Bars

Related: Daily Maintenance Checklist for Flow Wrappers:

• Location: Between unwind stand and main film path
• Lubricant: Bearing grease on pivot points
• Interval: Every 3 months or if binding observed
• Warning signs: Uneven film tension, irregular dancer movement

Pull Rollers (Nip Rollers)

Related: Cleaning and Sanitation Procedures for Packaging

• Location: Downstream of forming area, before sealing station
• Lubricant: Bearing grease on roller shafts
• Interval: Monthly inspection, every 6 months active lubrication
• Critical function: These rollers control package length—any irregularity affects quality

Slitter Blades (if equipped)

• Location: For cut-to-length film applications
• Lubricant: Light machine oil on pivot points
• Interval: Weekly application
• Note: Some slitter systems are permanently lubricated—check specifications

Sealing System

Sealing Jaw Pivot Points

Related: Electrical System Maintenance: Preventing and Solving

• Location: Where sealing jaws open and close
• Lubricant: High-temperature grease (sealing generates significant heat)
• Interval: Monthly application
• Critical: Use only high-temperature lubricants rated for continuous operation above 150°C

Pneumatic Cylinder Rods

• Location: Actuating sealing jaws and other mechanisms
• Lubricant: Thin oil applied to rod surface
• Interval: Monthly
• Application: Light coating only—excess oil attracts contamination

Cam Followers and Timing Mechanisms

• Location: In mechanically timed wrapping systems
• Lubricant: Grease or oil per manufacturer specification
• Interval: Every 3 months or per operating hours
• Warning signs: Irregular timing, skipping, or hesitation in motion cycle

Product Handling System

Conveyor Rollers

• Location: Product infeed and outfeed conveyors
• Lubricant: Bearing grease for belt-driven rollers; appropriate for washdown environment
• Interval: Monthly inspection, every 6 months lubrication
• Special consideration: Food-grade lubricants required for food-contact applications

Flight Bars and Chains

• Location: Intermittent motion product transport
• Lubricant: Food-grade oil or grease as appropriate
• Interval: Weekly
• Critical for food applications: Only NSF H1-rated lubricants allowed

Product Guides and Rails

• Location: Side guides, infeed funnels, product lanes
• Lubricant: Food-grade dry lubricant or light oil depending on product contact
• Interval: Monthly, more frequently if squeaking observed
• Note: Some applications require dry lubricants to prevent product contamination

How Do You Build a Lubrication Schedule Framework?

Daily Checks (5 minutes)

During the pre-shift inspection:

• Visually check all visible bearings for lubricant presence (no dry bearings, no excessive leakage)
• Listen for unusual bearing noise—high-pitched squealing often indicates inadequate lubrication
• Check for lubricant leaks that indicate failed seals
• Verify oil levels in any visible reservoirs or sight glasses

Weekly Tasks (30-45 minutes)

• Apply lubricant to chain drives and open mechanisms
• Check and top off oil levels in gearboxes with accessible reservoirs
• Wipe excess lubricant from areas prone to product contamination
• Inspect for early warning signs of lubrication problems

Monthly Tasks (1-2 hours)

• Manual lubrication of all specified points (if not automatic)
• Clean lubricant fittings and transfer devices
• Check for lubricant contamination or degradation
• Inspect seals around bearings for signs of leakage or wear
• Document all lubrication activities

Periodic Tasks (3-6 months)

• Change oil in gearboxes (follow manufacturer schedule)
• Replace seals on critical bearings
• Flush and replace lubricant in systems showing contamination
• Calibrate automatic lubrication systems if equipped
• Full bearing inspection with vibration analysis if available

What is Automatic Lubrication Systems ?

Benefits of Auto-Lube

Modern flow wrappers increasingly incorporate automatic lubrication systems:

• Consistent lubricant application regardless of operator attention
• Reduced labor requirements for lubrication maintenance
• Better distribution of lubricant in hard-to-reach locations
• Ability to lubricate during operation without stopping

System Maintenance

Automatic systems require their own maintenance:

• Check reservoir levels weekly
• Verify line integrity monthly (look for leaks, kinks, blockages)
• Clean or replace filters per manufacturer schedule
• Test cycle timing to ensure proper lubricant delivery
• Replace system components (lines, pumps, injectors) per schedule

How to Consider the Special Environment ?

High-Temperature Environments

Sealing areas of flow wrappers operate at elevated temperatures. Lubricants in these areas must:

• Maintain viscosity at operating temperatures (typically 100-180°C)
• Not decompose or vaporize excessively
• Remain chemically stable without oxidizing
• Not migrate into food products or packaging materials

Use only manufacturer-specified high-temperature lubricants for sealing mechanism components.

Washdown and Food-Grade Environments

Food and pharmaceutical applications require special consideration:

• Only NSF H1-rated lubricants allowed for food contact surfaces
• H2-rated lubricants acceptable for non-food contact areas in food facilities
• Lubricants must resist washdown chemicals
• Frequent lubrication may be necessary after washdown cycles

Dusty or Abrasive Environments

Dusty facilities (powder packaging, grain products) present unique challenges:

• Dust combines with lubricant to form abrasive paste
• More frequent relubrication required
• Sealed bearings preferred over open designs
• Consider upgrading to sealed bearing packages

How Do You Handle Troubleshooting Lubrication Problems?

Excessive Noise

• Squealing/Whining: Usually indicates insufficient lubricant or wrong lubricant viscosity
• Grinding: Metal-to-metal contact—stop immediately and inspect bearing
• Rattling: Could indicate loose components, worn bearings, or insufficient lubrication

Excessive Heat

• Bearings running hot: Check for overloading, incorrect lubricant quantity, or imminent failure
• Normal operating temperature: Varies by location, but generally should not exceed 60-70°C above ambient
• Warning threshold: Any bearing noticeably hotter than adjacent components warrants investigation

Visible Problems

• Lubricant leakage: Indicates failed seal—investigate and address before contamination occurs
• Discolored lubricant: Dark oil may indicate oxidation; whitish grease may indicate water contamination
• Metal particles in lubricant: Critical warning sign—imminent bearing failure possible

Performance Changes

• Increased power consumption: Friction increase often traces to inadequate lubrication
• Irregular motion: Could indicate binding from contaminated or dried-out lubricant
• Reduced output quality: Some quality variations link to inconsistent film transport, which can result from bearing issues

What Documentation Do You Need for Records?

What to Document

Maintain lubrication records that include:

• Date and time of each lubrication activity
• Operator performing the work
• Equipment or component lubricated
• Lubricant type and quantity used
• Any abnormalities observed
• Corrective actions taken if problems found

Record Retention

• Daily records: Minimum 1 year, longer if required by regulation
• Major lubrication events (oil changes, bearing replacement): Life of equipment
• Equipment history file: Include all lubrication-related information for troubleshooting and resale value

FAQ

How do I know if a bearing needs lubrication?

Signs include: unusual noise (squealing, grinding), visible dryness or dust accumulation around the bearing, heat generation above normal, or performance degradation. When in doubt, lubricate—over-lubrication is rarely harmful, but under-lubrication causes most bearing failures.

Can I use any grease on my flow wrapper?

No. Use only lubricants specified by your equipment manufacturer or lubricants proven compatible with the application. Wrong viscosity, wrong base oil, or incompatible additives can damage seals, contaminate products, or fail to protect bearings adequately.

How often should I change gearbox oil?

Follow your manufacturer’s schedule, typically every 2000-5000 operating hours. However, oil analysis can provide more accurate timing. Dark oil, metal particles, or unusual odor indicate the need for immediate change regardless of schedule.

What happens if I use the wrong lubricant?

Consequences range from reduced bearing life to product contamination to complete mechanical failure. Never use lubricants not rated for the application. When uncertain, consult the equipment manufacturer or a lubrication specialist.

Are sealed bearings maintenance-free?

Sealed bearings require no manual relubrication, but they’re not maintenance-free. They should be inspected regularly for signs of seal failure, unusual noise, or heat generation. Sealed bearings eventually require replacement—typically after 5-10 years of service.

Conclusion

Lubrication is the foundation of reliable flow wrapper operation. A well-lubricated machine runs smoothly, operates efficiently, and lasts for years. A neglected machine fails prematurely, costs thousands in repairs, and creates unpredictable production disruptions.

Implement a systematic lubrication program starting with this guide. Identify every lubrication point on your equipment, establish appropriate schedules, train operators on proper techniques, and maintain records that demonstrate consistent execution.

The investment is minimal—simple greases, basic oils, and a few minutes of operator attention. The return is maximum—years of reliable service from equipment that could otherwise fail catastrophically at the worst possible moment.

For flow wrappers engineered for reliability and designed for maintainability, contact Path Pack. Our equipment incorporates German-engineered components and thoughtful design that simplifies lubrication and extends service life.

By Path Pack Technical Team