Food grade lubricant application
in bakery industry
Large bakery plants which are highly automated uses conveyors , material handling
equipments and conveyors . Chain drives are frequently used in bakery plants for rollers ,
conveyors , band drives , blowers and chain for trays , bearings for rotating equipments .
These equipments are always in contact with food raw or finished . Chances are there when
they can contaminate the food items with lubricant if not done properly to avoid this problem
one can put food grade lubricant instead of conventional non- food grade lubricant or oil.
Equipments were we can expect a food contact are mixers , molders , dividers , oven , packing
machines and accessories like oil spray , milk spray ,flour sifters , screw conveyors , sugar
grinders and biscuit grinders .spreading units , conches mixers ,laminators , depositors and
gauge rolls. Compressed air does carry lubricating oil with it .special filters are attached at the
output of the compressor to trap this oil. Oil free compressor are available but a bit costlier
than normal compressor. Seals and gaskets generates leaks and spillages of lubricants .
These equipments need lubrication in intervals for smooth running and proper functioning of
machines .Now due new technology in lubrication and oil industry we can get food grade
lubricants . Here in Indian bakery plants it still to be popular . There are some misconception
about food grade lubricants .
A lubricant qualifies as food grade when, in the event of a contamination, it is present in no
more than 10 mg per kg of the foodstuff in question and must not cause any physiological
hazard or affect the food's odor and taste in any way. Food-grade lubricants, such Shell
Cassida, are special blends of base fluids and additives, and should be approved by the US
FDA and registered by NSF International in the H1 category.
All major food safety management systems recommends using food grade lubricant in food
processing and packaging companies .HACCP,GMPS,BRC,ISO22000,1SO14000,SQF,IFS
Major misconception s and facts about application of food grade in bakery plants.
Legend #1: Contamination by machinery lubricants with food and beverage during
manufacturing doesn't happen.
Fact #1: It happens more often than we think. Most contamination is detected before the
product leaves the plant - but some aren't.
Legend #2: I am pretty sure that the lubricants I use in my plant are all food grade.
Fact #2: Food grade lubricants are made from components approved by the U.S. Food and
Drug Administration (FDA) for incidental contact with food. You can verify whether the
lubricant is food grade or not by asking for a declaration of the formulation from the lubricant
supplier, or by checking whether the product is H1 registered with a third party certifier such
as NSF International.
Food-grade lubricants are readily available in the United States and a growing number of food
and beverage manufacturers are using them. Any food or beverage processor not using food-
grade lubricants is courting a huge risk. The FDA has set a "zero tolerance" for contamination
by non-food grade lubricants and also governs the components that are allowed to make up a
food grade lubricant. The US Department of Agriculture (USDA) formerly approved lubricants
as H1 ("for incidental food contact") and published the list in what was commonly known as the
"White Book." The USDA ceased this activity in 1998. NSF International has since taken over
the "White Book" and now registers lubricants as H1 food grade. You can verify whether the
lubricants in your plant are food grade by checking the list of NSF H1 certified non-food
compounds on www.nsf.org
Legend #3: Food-grade lubricant performance is inferior to traditional lubricants. The
lubricants don't meet the demands of my applications.
Fact # 3: Synthetic food grade lubricants are designed to meet a wide range of applications
and generally outperform traditional food grade mineral oils.
Machinery used in food and beverage processing has many moving parts requiring lubricants
to maintain reliable and efficient operation. Food and beverage contamination can occur from
drips off chains, hydraulic hose failure, oil leaks from seals and gearboxes, or a release of
compressed air containing an oily mist. Using traditional non-food grade industrial oils and
greases is inappropriate in these settings.
Food-grade synthetic lubricants, such as Shell Cassida®, are odorless, tasteless and
generally outperform established mineral oil-based lubricants. They are specially engineered
for high performance remaining effective in the sub-zero cold of freezers and the high heat of
ovens. Their increased oxidation and thermal stability, compared to a traditional mineral or
white oil-based food grade lubricant, can extend equipment life and reduce downtime, which
lowers maintenance costs.
As the FDA restricts the type and concentration of additives allowed to enhance food-grade
lubricant performance, the critical performance factor lies in the lubricant's base oil itself.
Synthetic base oil has superior technical characteristics over traditional white mineral oils.
Synthetic food-grade lubricants are designed for use in food and beverage manufacturing
applications, improving lubrication properties and performance and offering excellent water
resistance. Food-grade lubricants are harmless if accidentally consumed in quantities below
the maximum FDA-prescribed level of 10 ppm (10 parts per million).
Legend #4: Food-grade lubricants cost more than mineral oil products.
Fact #4: Synthetic food-grade lubricants actually cost less in the long run, because they not
only reduce overall maintenance costs, but also can reduce the risk of potential liabilities from
using non-food grade lubricants.
Synthetics do cost more than traditional mineral oils, but the initial cost of the synthetic brings
subsequent returns, against which a food grade mineral oil-based lubricant cannot compete.
Further, damages that could arise from not using H1-approved food-grade lubricants are
immeasurable.
According to the Japanese Institute of Plant Maintenance (JIPM), "up to 65% of mechanical
equipment failures can be attributed to some form of lubrication deficiency."2 Lubrication
failures lead directly to production losses, so a robust lubrication program plays an effective
part in plant management.
Lubrication quality has a significant impact on equipment life. Field experience and case
studies show that food-grade synthetics have a longer product life and need to be replaced
less frequently in machinery. In many instances, results demonstrate up to four times more life
with synthetic oils.
Legend #5: None of my equipment actually requires food-grade lubricants for food safety.
Fact #5: Food grade lubricants should be used wherever there is a chance of incidental
contact with food or beverage products during manufacturing.
Lubricants used in manufacturing facilities can make their way into the food we eat. Oil and
grease droplets can seep from bearings and conveyors, can seamers, bakery ovens and
other critical points of operation.
Plant quality managers and maintenance managers should identify areas of potential lubricant
contamination. Companies can assist by conducting a Lubrication Contamination Control Point
(LCCP) survey, which forms part of the plant Food Safety Plan. For example, a Shell LCCP
Survey is based on Hazard Analysis Critical Control Point (HACCP) principles and examines
where the risks are in a plant, what they are and what can be done about reducing and
managing them.
Food and beverage processing plants must prevent accidental lubricant contamination, which
could potentially harm consumers and damage a company's brand and reputation. Synthetic
food-grade lubricants can help minimize these risks, adding a buffer against contaminating our
food supply.
Source :Shell Oil Co( Facts and Legend )
Major Food grade lubricants brands
- Shell
- Castrol
- Mobil
- FAG
- Rocol
- LPS
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