Alpet Madeni Yağları
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• Mineral Oil and Antifreeze • Grease • ISO Standards

What is grease?

Grease is a type of lubricant preferred usually in vertical mounting applications, where contamination should be prevented, and mineral oil cannot provide sufficient and economic lubricating. It is especially used in systems where there are swing bearings.
Greases are composed of three basic components; base oil, thickener and chemical additives.
Grease’s main component is the base oil with a percentage ranging between 80-95%. Mineral or synthetic base oils can be selected. Since the part of the grease that gives the lubrication feature is the base oil, selection is made according to the required lubrication feature.
The most preferred substances as thickeners are calcium, lithium, aluminum soaps, clay and polyurethane. Thickeners serve almost as a sponge that will hold the base oil inside.
Chemical additives add additional properties to greases, such as those found in mineral oils. The most commonly used chemical additives in grease formulations are oxidation and rust inhibitors, polymers, corrosion inhibitors, extreme pressure additives, friction reducing additives.


Where and how do we produce?

With the Grease Production Facility which was put into operation at the end of 2014, Atak Madeni Yag started grease production Cigli Ataturk Organized Industrial Zone. The facility, which has a capacity of 6,000 MT of grease production per year, is the first grease production facility in Turkey equipped with automatic filling line. Unlike other grease production facilities in Turkey, manual applications are avoided and an automation system is preferred instead so that the production processes can be managed in a safer and controllable way. 
Product quality in all processes, from raw material acceptance stage until completion of product filling stage, is examined by means of laboratory analyses. At Atak Grease Production Facility, which is operated in accordance with EN ISO 9001 Quality Management and EN ISO 14001 Environmental Management standards, the grease production processes are carried out as follows:
The raw materials to be used are determined according to the production order and transferred from the stock tank to the production tank by means of the relevant base oil automation system.
After the addition of the thickener, the temperature is adjusted so that the saponification reaction takes place and a homogenous mixing is provided at the desired temperature.
Quality Control Laboratory takes the first production sample and measures the penetration for consistency determination, which also reflects the grease flow and dispersion characteristic and expressed by NLGI grade.
The production department, depending on the penetration result provided by the Quality Control Laboratory, adjusts the NLGI grade. NLGI grades are indicated as 00, 0, 1, 2, 3, 4, 5, 6. The grease with a NLGI 00 grade is the most liquid grease and as the grade number increases the grease appearance changes from soft to hard.
The mixing process performed in the production tank with mixers is not enough for grease’s fibrous structure to become homogenous. Unlike many grease production plants in Turkey, Atak Madeni Yag uses in the production a milling unit to homogenize the grease fibers. At the end of this production process, despite the fact that it extends the production duration and increases the production costs, a grease product consisting of same-size fibers can be obtained. With the grease applications, it has been observed that any grease treated in the milling unit is brighter and smoother, does not cause blockage in the filters of the users’ machines, and ensures a high-level customer satisfaction.
Grease, which is obtained in a homogeneous fibrous structure after being treated in the milling unit, is sampled and subjected once again to tests by the Quality Control Laboratory.
After being approved by the laboratory, chemical additives, such as oxidation and rust inhibitors, extreme pressure (EP) additives, anti-wear agents, which enable the grease to have superior properties, are added. Afterwards, also paint is added and mixed with grease.
As soon as the production process is completed, the Quality Control Laboratory gets the final production sample, examines the product standards with accredited devices and checks whether the produced grease is appropriate for filling process or not. The product is subjected to corrective processes until the compliance is achieved. After it is determined that all control parameters are within acceptable range, filling process is started.
Before every filling process, filling lines are necessarily washed to eliminate any contamination risk and warmed up so that grease can easily mode through the lines.
Before filling grease in packages, Quality Control Laboratory takes the first filling sample and examines whether there is any contamination or not. At this stage, not only the chemical properties but also the physical parameters of the grease such as appearance and consistency are examined.
The filling process can be initiated only if the product is in compliance with the international standards and approved by the laboratory and the product is then filled in tins, HDPE, etc. packages by fully automated filling system in amounts such as 0.9 kg, 4 kg, 15 kg, 16 kg, 50 g, 180 kg depending on user demands.
With the production date and the lot number data indicated on every product filled, information on which laboratory analyses has been the product subjected to, with which formulation it has been produced and which raw materials have been used during production processes can be provided. At the same time, with the examinations on product packages, it is possible to confirm whether there is a leakage on any final product or not and to put up the final products for sale in compliance with the appearance and packaging standards.


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