LUBExpert vs Traditional Lubrication Methods: An Effectiveness Comparison

Introduction

Bearing lubrication is one of the oldest maintenance procedures there is. But the way it's actually performed hasn't changed as much as you might think.

Today, plants have a choice: keep lubricating "the old way," or move to modern ultrasonic control methods.

Let's compare these approaches objectively.

Traditional Lubrication Methods

Method 1: Time-Based (Scheduled) Lubrication

This is the most widespread method.

How It Works

• A lubrication interval is set (for example, every 3 months)
• A grease quantity is set (for example, 15 grams)
• The lubrication technician applies grease according to the schedule

Advantages

• Simple to implement
• Low training cost
• Easy to document

Disadvantages

• Ignores actual operating conditions
• Risk of over-lubrication
• Risk of under-lubrication
• No control over the outcome

Method 2: Visual Inspection

Some plants rely on visual inspection.

How It Works

• The technician inspects the bearing
• Condition is assessed visually
• A decision is made on whether lubrication is needed

Advantages

• Requires no equipment
• Fast process

Disadvantages

• Subjective assessment
• Cannot see internal condition
• High probability of error
• Doesn't catch problems at an early stage

Method 3: Run-Time-Based Lubrication

Some plants base lubrication on equipment operating hours.

How It Works

• An interval is set in operating hours (for example, every 1,000 hours)
• Lubrication is performed once the interval is reached

Advantages

• Accounts for usage intensity
• Better than a fixed calendar interval

Disadvantages

• Doesn't account for load
• Doesn't account for environmental conditions
• Doesn't account for the actual state of the lubricant
• Risk of error remains high

Ultrasonic Control with LUBExpert

How It Works

LUBExpert uses ultrasonic diagnostics to control lubrication.

The Process

1. Pre-lubrication measurement — the instrument records the baseline ultrasound level
2. Need analysis — the system determines whether lubrication is required
3. In-process monitoring — real-time tracking of the signal level
4. Stopping at the right moment — the system signals when the optimum is reached
5. Documentation — results are recorded automatically

The Technical Principle

Friction between metal surfaces generates ultrasonic signals:

• High level — insufficient lubrication
• Medium level — optimal lubrication
• Low level — over-lubrication

LUBExpert measures these signals and shows the operator the optimal moment to stop.

Comparative Analysis

Let's compare the methods across key parameters.

Accuracy of the Stopping Point

Method	Accuracy	Description
Scheduled	Low	Fixed quantity with no control
Visual	Very low	Subjective assessment
Run-time-based	Low	Averaged interval
LUBExpert	High	Objective real-time control

Outcome Control

Method	Outcome Control	Description
Scheduled	None	You know what you applied, not the result
Visual	Subjective	Depends on operator experience
Run-time-based	None	No feedback
LUBExpert	Objective	Measurable real-time result

Accounting for Actual Conditions

Method	Condition Awareness	Description
Scheduled	None	Averaged data
Visual	Partial	Only visible signs
Run-time-based	Partial	Only operating time
LUBExpert	Full	Actual bearing condition

Error Risk Reduction

Method	Over-Lubrication Risk	Under-Lubrication Risk
Scheduled	High (40-60%)	Medium (15-25%)
Visual	Very high (60-80%)	High (30-50%)
Run-time-based	High (40-60%)	Medium (15-25%)
LUBExpert	Low (<5%)	Low (<5%)

Economic Comparison

Let's look at the economics.

Implementation Cost

Method	Implementation Cost	Description
Scheduled	Minimal	Training only
Visual	Minimal	Training
Run-time-based	Minimal	Training
LUBExpert	$15,000-30,000	Equipment + training

Annual Costs

A plant with 500 bearings, annual grease consumption of 2,000 kg at $15/kg:

Method	Grease Consumption	Grease Cost	Additional Costs	Total
Scheduled	2,000 kg	$30,000	$5,000	$35,000
Visual	1,800 kg	$27,000	$3,000	$30,000
Run-time-based	1,900 kg	$28,500	$4,000	$32,500
LUBExpert	1,000 kg	$15,000	$2,000	$17,000

Payback Period

Method	Investment	Annual Savings	Payback
Scheduled	$0	$0	—
Visual	$0	$5,000	—
Run-time-based	$0	$2,500	—
LUBExpert	$25,000	$18,000/year	17 months

Advantages of LUBExpert

1. Objective Data

LUBExpert gives you precise numbers, not guesswork.

• You know exactly when to stop
• You see the history of every bearing
• You can analyze trends

2. Reduced Risk

Error risk drops from 40-60% to under 5%.

• Less over-lubrication
• Less under-lubrication
• Fewer bearing failures

3. Savings

Annual savings can range from $10,000-50,000 depending on plant scale.

• 30-50% reduction in grease consumption
• 40-60% increase in bearing service life
• 70-80% reduction in downtime

4. Staff Training

LUBExpert is also a training tool.

• Staff see the result of their actions
• Correct technique is reinforced
• Skill level improves

Conclusion

Traditional lubrication methods have worked for decades. But today we have technology that makes the process precise, efficient, and cost-effective.

LUBExpert doesn't replace the lubrication technician — it gives them a tool for making the right decisions.

Recommendation

If your plant:

• Has more than 100 bearings
• Spends more than $10,000/year on lubrication
• Experiences bearing failures

Then implementing LUBExpert will pay for itself in 6-24 months and deliver savings year after year.

Learn More

• More about LUBExpert — acoustic bearing lubrication system
• More about SDT340 — multi-sensor diagnostic platform
• All ultrasound instruments — full equipment range

Contact Us

If you'd like a comparison done for your plant, contact us for a free consultation and savings calculation.