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KH Article - How Motion and Shell Transformed Gearbox Performance

KH Article - Page Banner - How Motion and Shell Transformed Gearbox Performance How Motion and Shell Transformed Gearbox Performance A routine audit uncovered a lubrication issue that was quietly eroding a pipe manufacturer’s gearboxes – and chewing through their maintenance budget. With the support of Shell’s Omala S2 GX 220 and Motion’s product support team, the business was able to double oil change intervals, cut downtime, and regain control over critical assets. KH Article - Page Banner Desktop - How Motion and Shell Transformed Gearbox Performance KH Article Tile - How Motion and Shell Transformed Gearbox Performance KH Article - Text Block 1 - How Motion and Shell Transformed Gearbox Performance White The problem hiding in plain sight When a major Australian pipe manufacturer asked Motion to conduct an on-site audit of its fixed plant, the issues were immediately apparent. Excessive wear. Costly oil change routines. A lubricant that simply wasn’t up to the demands of continuous, heavy-duty gearbox operation. “Our customer was spending 3–4 days each year changing out nearly 1000L of oil,” explains Mark Brocherie, Business Manager at Motion. “And this was a logistical challenge in terms of handling, disposing and replacing the gearbox oil. We needed a lubricant that could handle heavy, continuous use without breaking down or requiring constant replacement, and Shell Omala S2 GX 220 was a perfect fit.” KH Article - Text Block 2 - How Motion and Shell Transformed Gearbox Performance White The solution that went the distance Shell Omala S2 GX 220 is a heavy-duty industrial gear oil designed for the very conditions the customer was facing: high loads, sustained runtime, and no tolerance for performance drop-off. Its advanced additive system resists oxidation, combats corrosion and micro-pitting, and delivers thermal stability under punishing conditions. “This Shell oil is particularly effective in prolonging the interval between oil changes,” Brocherie says. “By switching to this product, this specific customer was able to move from a yearly changeover to intervals of two or even three years.” For a site previously stuck in an annual cycle of labour-intensive maintenance, the benefits of stretching out service intervals were immediate – and measurable. KH Article - Text Image Block 1 - How Motion and Shell Transformed Gearbox Performance Image Left KH Article - Image 1 - How Motion and Shell Transformed Gearbox Performance More than a product – a complete solution What made the project successful, however, wasn’t just the lubricant itself. It was the broader service Motion delivered around it: auditing, product selection, technical support, supplier engagement, and implementation – all integrated through a single point of contact. This was a classic example of Motion’s model in action – combining deep application knowledge with national supply capability and frontline engineering support. “Our product support team was fantastic, eagerly looking to solve the underlying issues and provide peace of mind to our customer’s critical operation,” says Brocherie. It’s a service offering that goes beyond transactional product supply – bringing together Motion’s experience across power transmission, condition monitoring and lubrication engineering to drive longer-term plant performance. KH Article - Text Block 3 - How Motion and Shell Transformed Gearbox Performance White From early gains to long-term results According to Brocherie, the transition to Shell’s lubricants was seamless, with noticeable impact from the outset. The oil held up under lab testing, simplified the site’s maintenance planning, and improved performance stability over time. “The customer could see results from early on,” he says. “Their oil sampling results confirmed that it retained its integrity over the long haul, and the service life was immediately apparent.” The new regime has reduced the risk of unexpected downtime, while freeing up labour previously dedicated to oil management. With less intervention needed, plant reliability has quietly increased. Cutting consumption, cost and complexity Shifting to Omala S2 GX 220 didn’t just stretch oil life – it delivered significant commercial upside. The customer achieved a 40% reduction in oil consumption costs, while also cutting the labour, waste, and risk associated with routine oil changes. Instead of reacting to wear, the site is now proactively managing it – with the support of Motion’s team and the proven performance of Shell’s premium lubricant range. “Now, instead of changing the oil every year, this specific customer is looking at a two-to-three-year schedule,” Brocherie adds. “That’s doubling the oil’s life for this customer, and significantly reducing stress on the gearboxes, all while cutting costs.”

 

Disclaimer:  Motion Asia Pacific Pty Ltd has prepared this for your general information and to use as a general reference. The results mentioned in this case study are specific to this customer and their unique operational conditions. Actual results may vary depending on the use and circumstances. Please refer to the Shell Omala S2 GX 220 Technical Data Sheet for full specifications.

A routine audit uncovered a lubrication issue that was quietly eroding a pipe manufacturer’s gearboxes – and chewing through their maintenance budget.

How Motion and Shell Transformed Gearbox Performance

KH Article - Comprehensive Bearing Inspection

KH Flipbook Embed - Comprehensive Bearing Inspection <iframe src="https://player.flipsnack.com?hash=Nzc3NUFDQThCN0ErN3AzNGo5OXh1Mw==" width="100%" height="900" seamless="seamless" scrolling="no" frameBorder="0" allowFullScreen allow="autoplay; clipboard-read; clipboard-write"></iframe>

A scientific facility’s satellite dish, operational for decades, relies on precision movements supported by its azimuth rollers and elevation bearings.

Comprehensive Bearing Inspection for a Scientific Facility | Motion

Comprehensive Bearing Inspection for a Scientific Facility

A change in perception: Building a case for raw edge belts in iron ore

Page Banner - A change in perception: Building a case for raw edge belts in iron ore A change in perception: Building a case for raw edge belts in iron ore KH Article Tile - A change in perception: Building a case for raw edge belts in iron ore Text Block 1 - A change in perception: Building a case for raw edge belts in iron ore White Throughout his years of experience as Power Transmission Engineer with CBC Australia, Tony Voiklis had come to conclude that raw edge, or cogged, v-belts were not ideal for applications in harsh environments. That perception took a 180-degree turn when he learned about the superior performance of the Carlisle ®  Power-Wedge ®  Cog-Belt ®  by  Timken. As manager of power transmission applications in South Australia and Northern Territory for Industrial Solutions Australia – the largest distributor of power transmission products in Australia and  CBC ’s parent company – Tony often engages with sales teams across the Industrial Solutions Australia business network to provide them with product training.


The solution Tony says he often recommended to his customers and sales teams for drive belts in harsh conditions was to upgrade to heavy-duty or wrapped v-belts. While this ensured longevity under harsh conditions, these belts could be substantially dearer in cost compared to the raw edge Carlisle Power-Wedge Cog-Belt.


“Our experience with other brands of raw edge cogged belts was that when contaminated with dust and dirt in harsh applications, such as those in mines and quarries, these belts heated up quickly, which made the rubber material hard and brittle. This further increased risk of premature belt failure and created other problems such as the belts slipping excessively,” says Tony.


“But that’s not the case with the Carlisle Power-Wedge Cog-Belt by Timken,” he adds.


In 2015, the renowned U.S. belt manufacturer and one of CBC’s premium partners, Timken, acquired the Carlisle belt business – changing the brand name to Carlisle Belts by Timken. This gave Tony an opportunity to travel to the U.S. two years ago and inspect the Carlisle belt manufacturing plant in Springfield, Missouri, along with other CBC power transmission engineers. Quote Block 1 - A change in perception: Building a case for raw edge belts in iron ore "It’s the unique manufacturing process that Timken has in place, combined with the high-quality materials they use in production that makes their raw edge belts resistant to harsh conditions." Tony Voiklis Text Block 2 - A change in perception: Building a case for raw edge belts in iron ore White That is when Tony says he learned more about what made the Carlisle Power-Wedge Cog-Belt different from its competitors. “It’s the unique manufacturing process that Timken has in place, combined with the high-quality materials they use in production that makes their raw edge belts resistant to harsh conditions,” he says. “Even though the basic material used in manufacturing a Power-Wedge ®  Cog-Belt is the same as what is used in many other raw edge belts, which is EPDM (Ethylene Propylene Diene Monomer) synthetic rubber, the Power-Wedge Cog-Belt has a higher temperature rating that helps them withstand up to 121ºC without cracking or stretching. They are also manufactured with high quality polyester cords and are rigorously tested as part of the production. This means all of the Power-Wedge ®  Cog-Belt family, including the SPZX, SPAX, SPBX and SPCX are built to resist hardening and glazing in harsh environments,” he further adds. More importantly, Tony says the change in his perception came from learning that much of Timken’s business for raw-edge belts in the U.S. was concentrated around the agricultural industry. As a major supplier of belts to original equipment manufacturers in the agricultural industry, Tony says Timken’s Carlisle belts have already proven their superior performance in tough agricultural environments. “If the belts are good for agriculture, they are good for mining,” says Tony. “Conditions in agricultural industry are very similar to those in mining in terms of the belt drives being exposed to heavy dust and dirt. The Carlisle Power-Wedge Cog-Belt by Timken has consistently proven its performance in the agriculture industry, both in Australia and globally.” With his renewed confidence in the performance of Carlisle ®  raw edge belts with the Power-Wedge Cog-Belt, Tony Voiklis says he has already started re-educating his sales team about what sets Carlisle belts apart. “I would encourage all experienced salespeople and maintenance specialists to give the Carlisle Power-Wedge Cog-Belt by Timken a chance and talk
to CBC or BSC experts about whether or not they may be the suitable choice for their application.” Text Image Block 1 - A change in perception: Building a case for raw edge belts in iron ore Image Right KH Article Image 1 - A change in perception: Building a case for raw edge belts in iron ore Celebrating 100 years of the raw edge v-belt Celebrating 100 years of the raw edge v-belt In 1921, Warren G. Harding became the 29th President of the United States, insulin was discovered, baseball’s World Series was broadcast on radio for the first time, and the predecessors of Timken Belts invented the raw edge v-belt.
Early v-belts were made of leather or balata and fabric, glued or riveted together. The materials evolved to natural rubber with a fabric covering, but the harsh demands of industry pushed for a better belt. The solution put forward by Carlisle® belts by Timken was a raw edge die cut v-belt. This revolutionary multiple ply neutral axis raw edge v-belt was a huge success. The new raw edge v-belt was soon transmitting power on automobiles, industrial machines, business equipment and household appliances. The gripping power of raw edge sidewalls increases energy efficiency and reduces vibration for extended component life. The raw edge construction also allows more cord width for increased horsepower capacity compared to wrapped v-belts.
 In 1921, Warren G. Harding became the 29th President of the United States, insulin was discovered, baseball’s World Series was broadcast on radio for the first time, and the predecessors of Timken Belts invented the raw edge v-belt. Early v-belts were made of leather or balata and fabric, glued or riveted together. The materials evolved to natural rubber with a fabric covering, but the harsh demands of industry pushed for a better belt. The solution put forward by Carlisle® belts by Timken was a raw edge die cut v-belt. This revolutionary multiple ply neutral axis raw edge v-belt was a huge success. The new raw edge v-belt was soon transmitting power on automobiles, industrial machines, business equipment and household appliances. The gripping power of raw edge sidewalls increases energy efficiency and reduces vibration for extended component life. The raw edge construction also allows more cord width for increased horsepower capacity compared to wrapped v-belts. Black Get the latest from Motion Get the latest from Motion Get exclusive offers and content, information about news and upcoming events and so much more. 13971266 KH Sign Up Form - Default Image KH Sign Up Form - SVG Separator

A change in perception: Building a case for raw edge

Throughout his years of experience as Power Transmission Engineer with CBC Australia, ...