How Does Whitmore Envirolube XE Extreme Prevent Open Gear Wear?
Whitmore Envirolube XE Extreme is a non-asphaltic, high-viscosity open gear lubricant engineered to address heavy wear and surface scuffing in severely loaded machinery. The fluid works by creating a protective physical and chemical layer between mating gear teeth. When heavy-duty equipment like ball mills and kilns operate, microscopic metal peaks (known as asperities) on the gear surfaces can weld together under extreme pressure. This welding and subsequent tearing is known as scuffing wear.
Instead of relying on heavy metals or asphalt, Whitmore Envirolube XE Extreme uses a combination of high-viscosity petroleum distillate, synthetic polymers, resins, and a specialized friction-reducing additive package. This formula establishes a resilient cushion that prevents micro-welding. Under high loads, rather than shearing off or tearing metal, the mating pressure pushes these asperities down. This action gradually smooths the gear contact surfaces over time without removing excess parent metal, effectively healing existing wear damage and restoring a smoother operating surface.
What Does FZG and Four-Ball Wear Testing Reveal About Performance?
Standardized laboratory testing highlights how Whitmore Envirolube XE Extreme performs compared to standard open gear lubricants. Under FZG testing (specifically ISO 14635-3, using settings A/2.8/50 and A/2.76/50), which evaluates wear protection by measuring mass loss across sequential load stages, the product demonstrated significant performance advantages:
- Mass Loss Reduction: After passing 12 standard load stages, Whitmore Envirolube XE Extreme recorded a mass loss of only 9.2 milligrams, compared to competitor products that lost 21 milligrams, 32 milligrams, and 51 milligrams.
- Specific Mass Loss: Its specific mass loss after Stage 12 was measured at just 0.067 milligrams per kilowatt-hour (mg/kWh), a substantial reduction compared to competitor rates ranging from 0.1390 to 0.1800 mg/kWh.
- Extended Wear Test: During a 30-hour extended wear test conducted at load Stage 10, the product limited mass loss to 20 milligrams, while competitive products suffered losses as high as 78 milligrams. This extreme protection preserves the original manufacturing crosshatch pattern on gear teeth, preventing the polishing and scuffing common to typical formulations.
- Extreme Pressure Protection: ASTM D-2783 testing confirmed a Four Ball EP Weld Point of 800 kg, and ASTM D-4172 testing achieved a Four Ball Wear scar width of 0.50 mm.
Why is a Non-Asphaltic Open Gear Lubricant Easier to Maintain?
Traditional open gear lubricants historically relied on asphaltic binders to maintain viscosity on exposed gears. However, asphaltic lubricants dry, bake, and harden over time when exposed to the environment and heat, making maintenance cleanup extremely difficult and labor-intensive. Whitmore Envirolube XE Extreme circumvents this issue by using a synthetic polymer and resin base that contains no asphalt or chlorinated paraffins.
The primary benefit of this formulation is that the spent lubricant remains soft. It flows naturally from gear guards and can be removed without specialty chemical cleaners or scraping. Additionally, the resulting brown coating remains transparent enough on the gear teeth to allow maintenance personnel to perform periodic inspections using a strobe light while the machinery is operating. From an environmental standpoint, the spent product is TCLP-safe, passing the EPA Toxicity Characteristic Leaching Procedure, meaning it is not classified as a characteristic hazardous waste.
How Do You Properly Apply Whitmore Envirolube XE Extreme?
This lubricant is designed to meet the rigorous physical and chemical requirements of major OEMs, including Falk, Metso Minerals, and FL Smidth. For optimal gear protection, it can be applied using several standard delivery systems, depending on the plant configuration and climate conditions:
- Sump Systems: Suitable for direct immersion and distribution via oiler wheels.
- Automatic Spray Systems: Fully compatible with intermittent spray systems using airless spray systems or automatic drip tubes and spray nozzles.
- Lubrication Frequency: For large, heavily loaded Ball Mill gears, an intermittent spray frequency of 15 to 20 minutes is recommended.
- Viscosity Grades: Available in Medium (completed product viscosity of 1,080 cSt @ 40°C) and Heavy (completed product viscosity of 4,000 cSt @ 40°C) grades to match temperature demands. Low-temperature pumpability tests using a Lincoln Ventmeter at 400 psi indicate the Medium grade remains pumpable down to 5°F (-15°C), while the Heavy grade is rated to 20°F (-7°C).
Summary
- 66% Wear Reduction: Third-party FZG testing confirmed that Whitmore Envirolube XE Extreme reduces overall friction and wear by up to 66% compared to conventional options.
- Zero-Wear Visuals: After a 30-hour Extended Wear Test, gears lubricated with Envirolube XE Extreme preserved their original manufacturing crosshatch patterns without polishing or scuffing.
- No Asphalt Hardening: Formulated with synthetic polymers and resins instead of asphalt, ensuring the spent product remains soft, flows from gear guards, and simplifies cleanup.
- High-Pressure Capabilities: Standardized tests verify a 800 kg weld point (ASTM D-2783) and a 0.50 mm scar width (ASTM D-4172).
- OEM Compliance: Exceeds application specifications for heavily loaded ball mills and kilns manufactured by Falk, Metso Minerals, and FL Smidth.
Step-by-step
- Select either the Medium or Heavy viscosity grade based on operating ambient temperature and pumpability requirements down to 5°F (-15°C) or 20°F (-7°C).
- Configure the automatic lubrication system using either drip tubes, spray nozzles, or airless spray equipment.
- Set the intermittent lubrication timer frequency to spray the gears every 15 to 20 minutes for large, heavily loaded Ball Mill configurations.
- Monitor the physical gear teeth under a strobe light through the transparent, brown lubricant coating to check for alignment and surface smoothing.
- Collect and dispose of soft, non-hardened spent lubricant flowing from the gear guard, noting its TCLP-safe, non-hazardous classification.
Products discussed in this episode
- ENVIROLUBE XE 680 DRUM Open Gear Lubricants
- Envirolube XE Extreme Heavy Open Gear Lubricants
- WHITMORE Envirolube XE Extreme Medium Open Gear Lubricants
- ENVIROLUBE XE MEDIUM PAIL Open Gear Lubricants
- ENVIROLUBE XE MEDIUM KEG Open Gear Lubricants
- WHITMORE ENVIROLUBE XE MEDIUM DRUM Open Gear Lubricants
- ENVIROLUBE XE HEAVY Liner KEG Open Gear Lubricants
- ENVIROLUBE XE HEAVY PAIL Open Gear Lubricants
- WHITMORE ENVIROLUBE XE HEAVY KEG Open Gear Lubricants
- ENVIROLUBE XE HEAVY DRUM Open Gear Lubricants
- ENVIROLUBE MED TCLP-SAFE W/LI KEG Open Gear Lubricants
- WHITMORE ENVIROLUBE MED TCLP-SAFE PAIL Open Gear Lubricants
- ENVIROLUBE MED TCLP-SAFE KEG Open Gear Lubricants
- ENVIROLUBE MED TCLP-SAFE DRUM Open Gear Lubricants
- WHITMORE ENVIROLUBE MED TCLP-SAFE TOTE Open Gear Lubricants
- ENVIROLUBE LIGHT TCLP-SAFE PAIL Open Gear Lubricants
- ENVIROLUBE LIGHT TCLP-SAFE KEG Open Gear Lubricants
- WHITMORE ENVIROLUBE LIGHT TCLP-SAFE DRUM Open Gear Lubricants
- ENVIROLUBE HVY TCLP-SAFE w/LI Keg Open Gear Lubricants
- ENVIROLUBE HEAVY TCLP-SAFE PAIL Open Gear Lubricants
- WHITMORE ENVIROLUBE HEAVY TCLP-SAFE KEG Open Gear Lubricants
- ENVIROLUBE HEAVY TCLP-SAFE DRUM Open Gear Lubricants
- ENVIROLUBE HEAVY TCLP-SAFE P2 Open Gear Lubricants
- WHITMORE ENVIROLUBE HEAVY TCLP-SAFE TOTE Open Gear Lubricants
- ENVIROLUBE EXTREME MEDIUM KEG Open Gear Lubricants
Browse all Whitmore products on PE Energy Industrial Supply.
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