Lubricants for

continuous extrusion

Your specialist for extruder gearbox oils

Lubrication is our World

 Content Page

Oiling your productivity 3

The chemistry’s right 4

Specialized to fulfill maximum requirements

Klübersynth GH 6 oils 5
Klübersynth GEM 4 N oils 6
Klübersynth UH1 6 oils 7
Klüberoil GEM 1 N mineral oils 8

Solutions for your productivity

Testing is part of our service 9
Your partner in development 9

Quality pays
Saving potential for extruder gearboxes – example 10
Your benefit 11

There for you – around the world 12

Product overview 12

Request for Information 14

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Oiling your productivity
Continuous profit with continuous profiles through continuous productivity

Whether operating continuously,
24 hours a day, 365 days a year, or
subjected to daily start-up, demands
on plastic extruders are constantly
increasing. Thanks to the implementa-
tion of optimized gear drives and
screws, extruder throughput has dou-
bled over the last few years. Operating
conditions for the entire drive and lubri-
cation regime have changed in line with
these new demands: Torque, tempera-
tures and loads have increased as
machine design has become more
compact, thus increasing the require-
ments made on gear oils. Mineral oils
are now reaching the limits of their
capabilities, and because a reliable
lubricant film needs to be formed under
a wide range of service conditions, syn-
thetic oils are coming into their own.
We can support you in selecting the
correct gear oil for your drive, as your
choice of lubricant will affect the long-
term operational reliability, up-time
and profitability of your machinery.
Synthetic gear oils, such as
Klübersynth GEM 4 N, Klübersynth
UH1 6 and Klübersynth GH 6 offer a
significant number of advantages over
standard mineral oils.

Benefits:

❑ Increased efficiency through ❑ Extended oil change intervals

reduced coefficient of friction (15,000–25,000 h)

❑ Reduced energy consumption ❑ Increased oil service life

and associated costs (3–5 times)

❑ Reduced operating and ❑ Minimal oil consumption and

maintenance costs associated costs, together with
the consequent reduction in
❑ Reduced wear and prolonged used oil quantities and disposal
machine service life costs

We also provide consulting service and technical

support for product changeover. Bringing you:

Optimized performance, productivity and profitability.

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 The chemistry’s right

Synthetic gear oils, such as polyglycols

and polyalphaolefins, which are the
base oils of our Klübersynth product
lines, should offer similar compatibility
with seals, viewing glasses and gear
housing paints as well-established
mineral oils.

As part of the Freudenberg Group,

Klüber Lubrication cooperates closely
with Freudenberg Seal and Vibration
Technology, the market leader for
extruder gear seals. Therefore, Klüber
special lubricants offer good compati-
bility with NBR and FKM sealing mate-
rials, and test data to back it up.

Gear oil approvals from various gear

manufacturers and the long-standing
experience of gear operators are proof
that our chemistry is right.

In our laboratories, we can also check

the compatibility of our special oils
with the seals, interior paint and
viewing glasses of your extruder
gearboxes.

Klüber chemistry supports your

productivity.

The quality of the base materials we use

is not tied to any one manufacturer, which

ensures that all our high-performance
gear oils, greases and other special
lubricants contain base materials with the
highest quality characteristics. This is an
additional benefit for you.

4
Specialized
to fulfill maximum requirements
Extruder gear oils need to fulfill continuously rising demands. We have developed
synthetic gear oils to meet these exceptionally high requirements and are dedi-
cated to being your specialist partner for maximum demands.

Klübersynth GH 6 oils –
take performance to the limit

These synthetic high-performance ❑ High efficiency reduces opera-

extruder gear oils, based on polyglycol
oil, offer the following excellent perfor-
mance characteristics:
❑ Higher load-carrying capacity
improves wear protection and
operational reliability under high
loads. In the enhanced FZG Four
Square Gear Oil Test (A/16.6/140),
these oils achieve a scuffing load
stage >12 and a specific change in
weight < 0.2 mg/kWh. Klübersynth
GH 6 oils also offer excellent
micro-pitting resistance.
ting costs and prolongs the ser-
vice life of your machines. Lower
wear, reduced energy consumption
and costs.
❑ Oil change intervals of up to
5 years or 25,000 service hours
are achieved due to specific addi-
tives which improve the oxidation
stability and ageing resistance of
the oil. This results in lower oil
consumption and disposal costs
while increasing operating effi-
ciency and cost effectiveness.

❑ A consistent lubricant film is

formed under full load at tempe- ❑ Good compatibility with NBR
ratures up to 160 °C due to the and FKM sealing materials.
high viscosity index of the poly-
glycol base oil. This ensures
trouble-free production even under
severe operating conditions.

We recommend checking compatibility of the materials used with the selected lubricants,
especially prior to series production.

5
 Klübersynth GEM 4 N oils –
rapid changeover to synthetic technology

Based on synthetic polyalphaolefin

oils, this product line offers some of
the well-proven characteristics of min-
eral oils, while providing the added
benefit of synthetic chemistry.
Klübersynth GEM 4 N oils are miscible
with mineral oil products and, there-
fore, are the perfect choice for a quick
changeover from mineral to synthetic
gear oils:

❑ Special additives extend oil

change intervals to up to 3 years
or 15,000 service hours. Your
advantages: less downtime, lower
maintenance expense, less oil con-
sumption and reduced disposal
costs.

❑ Better wear protection and ope-

rational reliability through opti-
mum load-carrying capacity.
In the enhanced FZG Four Square
Gear Oil Test (A/16.6/140), these
oils achieve a scuffing load stage
>12 and a specific change in
weight ≤ 0.2 mg/kWh.
Klübersynth GEM 4 N oils also
offer high micro-pitting resistance.

❑ Trouble-free operation under full

load and high temperatures due
to a high viscosity index.

❑ Reduced operating costs

through optimized efficiency.
Lower energy consumption, more
cost effectiveness and longer
machine service life.

❑ Good compatibility with NBR

and FKM sealing materials.

We recommend checking compatibility of the materials used with the selected lubricants,
especially prior to series production.

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 Klübersynth UH1 6 oils –
designed for the food industry

Klübersynth UH1 6 is not only an

excellent gear oil for extruders operat-
ing under high loads: This product line
is based on a special polyglycol oil and
offers you all important food industry
approvals and homologations. They
comply with the German law governing
foodstuffs and associated ancillaries
(LMBG, §5 para 1/1) and meet the
requirements set forth in the guidelines
of sec. 21 CFR 178.3570 of FDA regu-
lations. Klübersynth UH 6 oils are NSF
H1 registered so you can manufacture
your products safely for any type of
customer whilst retaining all the advan-
tages of synthetic lubricating oils:

❑ Oil change intervals are 3 times

longer thanks to the high ageing
and oxidation resistance of these
oils. The benefits are extended ser-
vice life and lower maintenance
costs.

❑ Less wear and longer machine

service life thanks to trouble-free
operation, even under full load. In
the enhanced FZG Four Square
Gear Oil Test (A/16.6/90), these oils
meet the requirements of load
carrying capacity > 12 and a speci-
fic loss of weight < 0.2 mg/KWh.

❑ Reduced operating costs due to

improved efficiency. Lower
energy and oil consumption plus
reduced disposal costs while
ensuring higher cost effectiveness
and extended machine life.

❑ Good compatibility with NBR

and FKM sealing materials.

We recommend checking compatibility of the materials used with the selected lubricants,
especially prior to series production.

7
 Klüberoil GEM 1 N mineral oils –
proven quality

While mineral oil performance cannot

be compared with synthetic oils, there
are still significant performance differ-
ences among the various mineral oils.
Our Klüberoil GEM 1 N oils are top-
quality products based on the careful
selection of ingredients and over 75
years of experience in the formulation
of special lubricants, offering excellent
protection against corrosion, wear,
oxidation and ageing:

❑ Klüberoil GEM 1 N oils offer

good wear and corrosion
protection achieving a scuffing
load stage > 12 (A/8.3/90) in the
FZG Square Gear Oil Test and a
high micro-pitting resistance.
They also meet the API GL4
requirements.

❑ These oils offer good compatibi-

lity with all non-ferrous metals,
sealing materials and most com-
monly used gearbox paints.

❑ Klüberoil GEM 1 N oils extend

the service life of your gearbox
bearings. Long-term tests on the
FAG FE8 test rig indicate the
excellent properties of these well-
proven high-performance and
multi-purpose oils.

We recommend checking compatibility of the materials used with the selected lubricants,
especially prior to series production.

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Solutions
for your productivity
Under maximum operating conditions, 24 hours a day – 7 days a week,
production and operational reliability are issues of top priority. Machine down-
time can lead to considerable costs. Synthetic high-performance extruder gear
oils, particularly polyglycols such as Klübersynth GH 6 and UH1 6, offer
significant advantages in preventative maintenance:

❑ Lower friction

❑ Increased efficiency

❑ Less wear

❑ Higher operational reliability

❑ Reduced machine down-time

❑ Extended machine lifetime

Friction-free productivity.

Testing is part of Your partner in

our service development

When oil change intervals are five
times longer than you’re used to, it’s
reassuring to conduct regular used-oil
analysis. You’ll see the proof in test
results. This service is available to
customers using either our synthetic
or mineral based products.
We offer our development partnership
to machinery manufacturers. With over
75 years experience in the research,
development and application of lubri-
cants, we can provide in-depth know-
how and the use of more than 100 test
rigs. When possible, we test our lubri-
cants on OEM original equipment and,
when required, are able to design cus-
tomized test rigs.

Our objective? Developing a high

performing lubricant that fulfills all of
your expectations and creating a long-
lasting partnership with you.

9
 Quality pays

The investment in synthetic oils pays off due to their

extended oil change intervals. Cost effectiveness is
enhanced by lower oil and energy consumption, reduced
disposal costs, less wear and extended machine lifetime.

Saving potential for extruder gearboxes –

example

Saving potential for extruder gearboxes – example

Worm size: 90 single-screw extruder

Oil sump temperature: approx. 70 °C
Drive capacity: 93 KW
Operating time per annum: 6500 h
Machine lifetime: 15 years
Oil filling: 50 l
Electricity: 0.07 €/KWh

Mineral oil Polyglycol

Lubricant purchasing costs 2 €/l 7 €/l

Efficiency 98.0 98.5
Power loss 181,000 kWh 136,000 kWh
Oil changes during 15 4
machine lifetime
Total oil quantity during 750 l 200 l
machine lifetime

Costs of oil 1,500 € 1,400 €

Costs of energy losses 12,670 € 9,520 €
Costs of oil changes 3,750 € 1,000 €
Cost savings with 6,000 €
polyglycol oil

The calculation does not account for increased up-time and productivity of the
machines.

Your investment is worthwhile.

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Your benefit

Savings on your extruder gearboxes

with Klüber Lubrication special gear oils

Energy costs
–> lower energy consumption

Oil costs
–> prolonged oil change
intervals
–> lower maintenance costs

Maintenance
costs –> extended machine life due
to lower wear
–> reduced maintenance costs

Operational
costs –> less down-time of machinery
particularly with 24 hour
operation, 7 days a week
–> lower running costs

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 There for you –
around the world
As a lubrication specialist for all industries, Klüber Lubrica-
tion operates worldwide. Our global network of production
and sales companies ensures that we are nearby for opti-
mum customer care and service.

On the reverse of this brochure you will find a contact

partner for your region, eager to answer your questions
on lubrication.

You will find additional, comprehensive information in

our product information leaflets, which you can order under
+49 89 78 76-0. Or visit us on our website
www.klueber.com.

Product overview
Extruder gear oils

Product name of Oiltype ISO VG Remarks

Klüber gear oil DIN 51519

Klüberoil GEM 1 N Mineral oil 100 to 680 Standard high-performance

gear oil

Klübersynth GEM 4 N Polyalphaolefin 100 to 680 Synthetic high-performance

gear oil for extended service
life

Klübersynth GH 6 Polyglycol 100 to 1000 Synthetic gear oil with excellent per-
formance characteristics for high
loads and extremely long service life

Klübersynth UH1 6 Polyglycol 150 to 680 To fulfill additional requirements made

by the food and pharmaceutical industry

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 w t h e

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Synthetic extruder gear oils from the specialist source:

Klüber Lubrication.
Some run 24 hours a day, 365 days a year, others are brought up from zero to full speed day after day:
at any rate, extruders operate under increasingly demanding conditions – yours won’t be an exception.
For a higher output and optimised operation, we offer innovative, synthetic special gear oils. Low friction
coefficients lead to higher machine power combined with less wear and energy consumption. Oil change
intervals can be extended three to five fold, service lives increased and operating costs reduced. We also
offer oil analyses as part of our standard service. So make sure the worm turns for you. Call us.

Klüber Lubrication München KG · Geisenhausenerstraße 7 · 81379 München · Germany

A company of the Freudenberg Group
Tel. +49-89-78 76 404 · Fax +49-89-78 76 333 · www.klueber.com
 Request for Information

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14

Would you like
more detailed information
on our product range?
Do you need
Material Safety Data Sheets
on any of the above products?
You can order
using the form overleaf or our
website www.klueber.com.
Publisher and Copyright:
Klüber Lubrication München KG
Reprints, total or in part, are permitted
if source is indicated and voucher copy
is forwarded.
9.40 e
Edition 03.05
The data in this technical brochure is
based on our general experience and
knowledge at the time of printing and
is intended to give information of
possible applications to a reader with
technical experience. It constitutes
neither an assurance of product
properties nor does it release the
user from the obligation of performing
preliminary tests with the selected
prodcut. We recommend contacting
our Technical Consulting Staff to
discuss your specific application.
If required and possible we will
be pleased to provide a sample
for testing.
Klüber products are continually im-
proved. Therefore, Klüber Lubrication
reserves the right to change all the
technical data in this technical
brochure at any time without
notice.
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