Below is a detailed breakdown of the method of work and approximate quantities required to produce lubricating oil and grease in a simple production setup.

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1. Production of Lubricating Oil

Method of Work (Step-by-Step Process)

Step 1: Base Oil Preparation

• Select the appropriate base oil (mineral, synthetic, or bio-based).
• Heat the base oil to 50-70°C to reduce viscosity and improve mixing.

Step 2: Additive Blending

• Add additives one by one in a high-speed mixing tank, maintaining a temperature of 60-80°C.
• Common additives and their percentages:
  • Detergents (Calcium/Magnesium Sulfonates) → 1-5%
  • Dispersants (PIBSA) → 3-8%
  • Anti-Wear Agents (ZDDP) → 0.5-2%
  • Viscosity Index Improvers (VIIs) (PMA, OCP) → 5-15%
  • Friction Modifiers (Esters, Molybdenum Compounds) → 0.1-1%
  • Antioxidants (Phenols, Amines) → 0.5-2%
  • Pour Point Depressants (PPD) → 0.2-1%
  • Foam Inhibitors (Silicone-based) → 0.01-0.1%
  • Rust Inhibitors → 0.1-0.5%

Step 3: Homogenization & Filtration

• Mix at 1500-3000 RPM for 30-60 minutes to ensure uniform blending.
• Filter through 5-10 micron filters to remove solid particles.

Step 4: Quality Testing

• Test the blended oil for viscosity, flash point, pour point, oxidation stability, and foaming tendency.
• Adjust formulation if necessary.

Step 5: Packaging

• Transfer the finished oil into storage tanks.
• Package in 1L, 4L, 20L bottles or 200L drums using automatic filling machines.

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Example of a 1000L Lubricating Oil Batch

Component	Percentage (%)	Quantity (Liters)
Base Oil (Group II/III)	80%	800L
Detergents	3%	30L
Dispersants	5%	50L
Viscosity Index Improver	7%	70L
Anti-Wear Agents	1%	10L
Antioxidants	2%	20L
Pour Point Depressant	1%	10L
Other Additives	1%	10L
Total	100%	1000L

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2. Production of Grease

Method of Work (Step-by-Step Process)

Step 1: Soap Formation (for Soap-Based Greases)

• Heat base oil to 80-100°C in a grease reactor.
• Prepare the soap thickener by reacting metal hydroxide (e.g., lithium hydroxide) with a fatty acid (e.g., stearic acid) at 200-220°C.

Step 2: Blending of Thickener and Base Oil

• Slowly add the soap thickener into the heated base oil while stirring.
• Maintain the temperature at 180-220°C and mix for 1-2 hours.

Step 3: Cooling and Additive Addition

• Cool the mixture to 80-100°C and add required additives:
  • Extreme Pressure (EP) Additives → 2-5%
  • Anti-Wear Agents → 1-3%
  • Antioxidants → 0.5-2%
  • Corrosion Inhibitors → 1-3%

Step 4: Homogenization

• Pass the grease through a homogenizer or three-roll mill for fine consistency.
• Ensure a NLGI grade (consistency level) of 00 to 3.

Step 5: Quality Testing

• Test for penetration, drop point, oxidation resistance, and water resistance.

Step 6: Packaging

• Fill into small containers, cartridges, or drums for storage and distribution.

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Example of a 1000kg Grease Batch

Component	Percentage (%)	Quantity (kg)
Base Oil (Mineral/Synthetic)	70%	700kg
Thickener (Lithium Soap)	15%	150kg
Extreme Pressure Additives	3%	30kg
Anti-Wear Additives	2%	20kg
Antioxidants	1%	10kg
Rust Inhibitors	2%	20kg
Total	100%	1000kg

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Basic Production Line Setup

Equipment Needed

Equipment	Purpose
Mixing Tanks	Base oil and additive blending
Heating System	Temperature control
Filtration Unit	Remove impurities
Homogenizer/Milling Machine	Uniform grease texture
Filling Machine	Packaging into bottles, drums, or cartridges
Quality Control Lab	Viscosity, penetration, oxidation stability tests

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Conclusion

• Lubricating oil production involves blending base oils (80-90%) with various additives (10-20%), followed by homogenization and packaging.
• Grease production requires soap formation, blending, homogenization, and milling before packaging.
• A simple production line with mixing tanks, filtration units, heating systems, and testing equipment can efficiently produce high-quality lubricants and greases.