High-Viscosity Grease Packaging for Steel Mill Equipment

Challenge

A lubricant manufacturer developed a high-temperature grease formulated for bearings operating in steel mill equipment. The grease contained molybdenum disulfide and solid lubricant additives designed to maintain boundary lubrication under high loads and elevated temperatures.

The product required packaging in several industrial formats including:

• 14 oz grease tubes
• 5 lb cans
• 35 lb pails
• 400 lb drums

The formulation had extremely high viscosity and a dense additive package. During packaging, improper handling could cause additive separation, resulting in inconsistent performance in the field.

Solution

Altaris Industrial implemented a packaging process designed specifically for high-viscosity lubricants. The production setup included:

• heated transfer lines to maintain consistent viscosity
• piston-driven filling systems capable of handling dense materials
• controlled mixing prior to filling to maintain additive suspension
• calibrated fill systems to ensure accurate weights

Results

• consistent packaging across multiple container formats
• maintained additive distribution in final product
• successful launch of a new industrial grease product line
• reduced material waste during packaging operations