Lube Oil
Blending Plants

Complete Plant & Technology for Production of Automotive Lubricants, Industrial Lubricants, Synthetic Lubricants, Bio Based Lubricants, Marine Lubricants and Additive Packages

Capacity Ranging From 5MT to 500MT\Day

Lube Oil Blending Plants

Lube Oil Blending is a process of dosing, mixing and filling of a group of base oils with additives in a precise and efficient manner. Depending on the individual requirement of the customer and the product, we offer customized methods for achieving these results. Described below are the various blending systems in use.
  • Automatic Batch Blending
  • Simultaneous Blending
  • In-Line Blending systems
  • Skid Mounted Plants
  • Pigging Units
  • Drum Decanting Units
  • Filling Lines
  • Automation
  • Utilities
  • Lab Instruments

Automatic Batch Blenders

Automatic Batch Blenders are designed for manufacturing simple as well as complex formulations with batch size ranging from 5MT- 200 MT/ shift. The design of these blenders is based on automatic dosing of base oils and additives from storage tanks into blenders mounted on load cells. A Header line provided with automated valves and instruments is provided over each blender. Additives are dosed into the blenders using a drum decanting unit or a batch dosing system. The entire batch is homogeneously mixed and heated if required as per the recipe management system. The batch is recirculated until the required specifications are met.
The finished product is then transferred to holding tanks and packed into small cans or barrels. Pigging systems with residue collecting tanks can be provided if required.
The entire process is automated and PLC controlled with SCADA interface and WIFI enabled remote access system supported by cloud data backup. A MCC is provided for controlling all installed motors and VFD drives. Automated filling lines ,complete with capping, sealing, labelling, printing, palletizing and case packers can be provided. These plants can also be offered in modular systems for ease of installation.

ADVANTAGES

  • High level of blend flexibility.
  • Products can be tailor made to customer orders.
  • Negligible wastage and bottom slop.
  • Quick switchover of batches.
  • Capacity from 5MT- 200 MT/SHIFT

Simultaneous Blending Units

Simultaneous Blending Units are used for blending of large quantities of product in short intervals. All raw materials are pumped from dedicated tanks into the system. SMBs have the advantage of an ILB and flexibility of ABBs. The system consists of a skid mounted unit comprising of flow control valves, meters and instruments. Baseoils and additives are grouped in loops based on the formulations and passed through a family of headers in sequential and controlled ratios. The output from the SMB skid is directed to a storage tank equipped with an agitator to complete the final blend.

A pigging system is then used to clean and redirect traces of previous batches to avoid cross contamination from the pipelines into residual tanks. The product in the residual tank can be used for future batches. The entire process is automated and PLC controlled with SCADA interface with WIFI based remote access system supported by cloud data backup. A MCC is provided for controlling all installed motors and VFD drives.
Automated filling lines, complete with capping, sealing, labelling, printing, palletizing and case packers can be provided.

ADVANTAGES

  • High throughput.
  • Short set up time.
  • Can be coupled with ABB and ILB.
  • Reduced dosing modules and Blend tanks.
  • Capacity from 5MT to 80 MT/HR

In-Line Blending Systems

In-Line Blending systems are used for blending of large batches that require consistent quality which are mostly packed in bulk tankers, storage tanks or totes ready to be shipped. The ILB skids are designed for charging of multiple groups of base oils and additives accurately and simultaneously into a single discharge header provided with a inline static mixer. The system uses a group of VFD controlled pumps, flow meters and automated valves.

Residual fluid in the lines are removed by an automated air purge system which directs the fluid back into the component tanks. The entire process is
automated and PLC controlled with SCADA interface with WIFI enabled remote access system supported by cloud data backup. A MCC is provided for controlling all installed motors and VFD drives.

ADVANTAGES

  • Large Volume Blending.
  • Quick turnaround time.
  • Direct filling into tankers.
  • Consistent quality.
  • Capacity from 25MT to 100 MT/HR.

Skid Mounted Plants

Frigmaires Engineers’ newly developed ABB (Automatic Batch Blending) skid mounted and containerized plants are designed for firms wishing to enter the Lubricant’s Business. They are recommended for installations in remote and logistically challenged areas. These units can be installed indoors, as well as outdoors. A provision for connecting a generator to operate the entire system can be provided as an option to make it independent of the local power supply.

The units are assembled and fully tested at our facility before being delivered in 20 or 40 FT containers with no need for on-site assembly, pipework, electrical wiring or mounting of components. These are simple plug-and-play units. The Base oils are charged directly from flexitanks to be connected to the feed manifold.

The main components of the plant are the Feed Manifold, Feed & Discharge Pumps, Load Cell Mounted Blenders, Additive Dosing Unit, Heating Unit, Online Filters, Piping, Valves, Instrumentation and Filling Station, which are connected and operated through a semiautomatic PLC system with HMI controls.

The end user has to simply connect the base oils from flexitanks to the feed manifold. Each package is provided with basic laboratory testing equipment, a set of spares, maintenance tool kit, a booklet for starting formulations and basic laboratory quality tests. A quick change-over flushing system is also provided for product turnarounds.

This plant is used for production of Automotive Lubricants, Industrial Lubricants, Bio Lubricants and Marine Lubricants.

The main components of the plant are the Feed Manifold, Feed & Discharge Pumps, Load Cell Mounted Blenders, Additive Dosing Unit, Heating Unit, Online Filters, Piping, Valves, Instrumentation and Filling Station, which are connected & operated through a semiautomatic PLC system with HMI controls.
The end user has to simply connect the base oils from flexitanks to the feed manifold. Each package is provided with basic laboratory testing equipment, a set of spares, maintenance tool kit, a booklet for starting formulations and basic laboratory quality tests. A quick change-over flushing system is also provided for product turnarounds.
This plant is used for production of Automotive Lubricants, Industrial Lubricants, Bio Lubricants and Marine Lubricants.

ADVANTAGES

  • Short delivery and installation time.
  • Quick and homogeneous blends.
  • Connects directly to flexitanks.
  • Low investment costs.
  • Reduced on-site erection and hook-up time.
  • Factory tested and manufactured.
  • Single source responsibility, ensuring fewer interfaces for our client to handle.
  • Self-contained operations.
  • Manufactured to CE specifications.

Pigging Units

Pigging Units are installed in pipelines so as to clean the residual products from the pipeline, to avoid contamination. They are smartly designed to reduce the number of pipelines in the plant. The main components of a pigging unit are the launcher, receiver and catcher installed at both ends of the pipe. A valve is provided for controlling the compressed air or gas used for launching the pig, which moves along the length of the line to clear any residual liquid left behind. The pig can be installed or removed from the catcher.

The residual liquid is collected at one end of the pipe and sent to the residual collection tank. The pig is then retracted and ready for the next operation. The pigging lines are integrated with the plant automation and controlled through a PLC. The non piggable lines are to be cleaned manually as per manufacturer’s instructions. The line sizes available range from 1.5 inches up to 6 inches with 2 or 3 way design stations.

ADVANTAGES

  • Reduction in number of lines.
  • Improves quality and yield.
  • Avoids cross contamination of base oils and additives.
  • Reduction in cleaning costs.
  • Reduction of waste.

Drum Decanting Units

Drum Decanting Units are used for dosing and charging of additives in exact quantities from Barrels, Totes or IBCs and transferring them to the respective Blenders or Premix tanks. The main components of these units are the Pump, Lance, Loadcell, Heating unit, Wash Tank, Pigging system and Automation. The Barrels are manually placed on the weighing unit and the system is switched on. From here, the automated recipe program takes over and the exact quantity of additive is discharged.
The weigh table can be tilted to empty the entire drum. On completion, the lance is lifted and shifted to the wash tank where it is cleaned and flushed. The pigging unit is switched on, as required, to clean the line of any residue matter to make the system ready for the next group of additives. The residue is transferred to a residue collection tank and can be reused. Capacities available range from 2 – 5 cumtr / hr. with viscosity up to 2000 cps

ADVANTAGES

  • Large Volume Blending.
  • Quick turnaround time.
  • Direct filling into tankers.
  • Consistent quality.
  • Capacity from 25MT to 100 MT/HR.

Filling Lines

Filling Lines offrered bt us by us range from for Singe Head to 16 Head Filling stations. These are all Linear lines provided with Flow meters for drip free filling. Changeover time is minimum when switching cans. The units are provided with ancillary equipment like Labeling machines, Cap Sealers, Induction Sealers, Printing, Case Packers and Palletizers. Filling lines are either directly connected to the Lines from the Blenders or from the manifold connected to the Holding tanks. An air operated flushing system is provided for each unit. The average filling speed is approx. 5 seconds per head for a 1 Ltr can with an accuracy range of 0. 25%.The Filling section is equipped with its own automation and controlled through a PLC and HMI touch screen.

BARREL FILLING LINES: We offer Single and Multiple Barrel Filling stations. These units are suitable for filling of containers ranging from 50 -210 Ltrs standard barrels and can also be designed for Filling of Totes and IBCs. Microprocessor based with LCD and HMI screens for coarse and fine feed.

The unit can be operated on auto and manual mode. Filling speeds are approx. 30 drums of 200 ltrs/hr. and 60 drums of 20 Ltrs/hr. with an accuracy of 0.05%.

The units include in and out feed conveyors, weight platform with load cells, counter and totalizer, 3 way solenoid operated valve, filling lance, control panel with safety interlocks.

Barrel filling lines are either directly connected to the Lines from the Blenders or from the Manifold connected to the Holding tanks. The Barrel Filling section is equipped with its own automation and controlled through a PLC .

Automation

FE Intel plant automation has been designed to enhance productivity and efficiency. The software has been programmed to manage, record and report all plant activities right from open source recipe management to data tracking and logging. The software can be combined with the plant ERP, Laboratory and Warehousing system to improve quality and manage raw materials .Transfer of various base oils and additive from storage tanks to the individual blenders are automatically controlled from a PLC and SCADA, using Software from Siemens, Allen Bradley or Schneider. The complete blend process is controlled in real time on a distributed control system (DCS).

INTEL CLOUD PLANT MANAGEMENT

Is designed for integrating and capturing data from the PLC/SCADA control Centre installed with our plants. This data is then uploaded to the cloud over Ethernet, Wi-Fi or GSM. The Dashboard installed at the command centre, allows multiple users to monitor the process, machinery and inventory along with various parameters and functions of the plant from anywhere in the world for higher plant efficiency.

This is a web-based application that can be accessed from Internet enabled devices such as laptops, desktops and hand-held devices.

ADVANTAGES

  • Large Volume Blending.
  • Quick turnaround time.
  • Direct filling into tankers.
  • Consistent quality.
  • Capacity from 25MT to 100 MT/HR.
This data is then sent to our Cloud platform that analyses it in real-time for smarter data driven decision making and gives you the ability to control the plant from a command centre
  • Formulation monitoring and management.
  • Production data.
  • Raw material data and management.
  • Breakdowns/ STOP.
  • Plant efficiency.
  • Manufacturing cost.
  • Energy consumption.
  • System failure.
  • Real-time updates on vital system parameters.
  • Uptime and utilization of all equipment.
  • Real-time alerts for deviation from SOPs
  • Preventive maintenance alerts and prescriptive notifications for all equipment.

MOTOR CONTROL CENTRE

All our plants are provided with an motor control centre duly prewired as per standards and installed in IP enclosure.

Utilities

All utilities required for operating the plant are offered by us to keep the client’s scope to the bare minimum.

Hot Oil Unit

Exhaust

Air Compressor

Cooling Tower

Carton Tapping

Drum Handling Unit

Pallet Truck

Holding Tanks

structural work

Base Oil Tanks

Lab Instruments

We supply a complete set of Laboratory instruments to perform quality checks. Please click to download a list of instruments. Basic instruments are supplied for each project we undertake. Additional instruments can be ordered separately as required.

Copper Corrosion Bath Machine

Carton Tapping

Foaming Test Apparatus

Viscosity Bath