MRO Today - Good & greasy

Good and greasy

Food-grade lubricants help ensure food safety

by John Geyer

When contaminants enter the food production process, the consequences can be dramatic. Recent issues with melamine in pet food and E. coli in spinach are excellent examples. In these cases, the contaminants were implicated in injury and illness leading to product recalls and lawsuits. These incidents highlight the extreme impact contaminants can have on food production, but even less severe contamination can be problematic.

Food producers take extreme care to assure the quality of the ingredients being used in food production. Additionally, producers should take the lead where they can, by limiting potential contamination issues in as many areas as possible. One may not think that plant lubrication could potentially play a role in contamination, but that is not true. Fortunately, this area of risk can be minimized through the use of an NSF H1 approved food-grade lubricant.

It is not uncommon today for a food plant to still be running equipment with lubricants that do not meet NSF International certification standards. In these cases, a company’s ability to reliably produce and deliver a safe food product is in a constant state of jeopardy. One incident in which improper or non-certified lubricants come in contact with food can cause a potential production shutdown, lawsuit or costly recall. This reality places a whole new spin on the concept of lubricant-related reliability.

In order to meet the quality assurance requirements of the food processing industry, many reputable lubricant producers now manufacture food-grade lubricants and greases. These products are designed to provide a better lubrication option for situations where there is a possibility the lubricant could result in incidental contact with the food product being produced.

Food-grade peace of mind
The ability to conduct business without additional concerns about liability, based on the proper selection of lubricants, can deliver plant efficiency. It also provides peace of mind that your products are of the best possible quality because the lubricants used to make them are properly registered and certified for use in their production.

Considering the potential cost of recalls and litigation, not to mention a damaged reputation within a competitive business setting, it is hard to believe many food producers still do not use food grade lubricants in their plants. If a food processor elects to use non-food grade lubricants, the FDA limits contaminant levels to zero.

If there is evidence of lubricant contamination, then the entire batch or product run must be discarded. This is not necessarily the case when NSF H1 food-grade lubricants are used (for example, Chevron FM-based lubricants), since the FDA limits contamination with these lubricants to 10 ppm.

Even though it is paramount that food and beverage processing equipment be designed to limit any lubricant contamination, the possibility cannot be entirely eliminated due to leaks, spills or accidents. Because of the need to curtail contamination from all potential sources — or at the minimum, the effects in case of leakage during the manufacturing process — food-grade lubricants are increasingly valuable in the food, personal care and pharmaceutical industries.

It should be noted that many food producers are today electing to mandate that NSF H1-approved products be the sole lubricants used on the production floors of their facilities.

This concern about controlling contamination can be attributed not only to manufacturers’ desire to guarantee the quality and purity of their products, but also to increasingly stringent governmental regulations, global competition and the consolidation of industries. These production environments present a challenge to control costs, while also increasing plant efficiency and avoiding potentially disastrous shutdowns, litigation and recalls.

The best butter: Selecting food-grade lubricants
In 1999, NSF International launched its voluntary non-food compounds registration program. Products eligible for NSF registration include all compounds used in and around food establishments, including lubricants. Once a lubricant product is validated, NSF International issues a registration letter to the lubricant manufacturer, and adds the product to a directory that can be found on its Web site.

Because this is a voluntary program, manufacturers submit their products for review and certification. It is important to choose a reliable supplier that realizes the importance of this organization. When in doubt about your supplier or their products, review the NSF Web site or ask the supplier for letters of certification denoting NSF approval.

Lubricant products are typically listed under NSF H1, H2 or H3 classifications. These classifications are defined by the NSF in the following manner:

H1 Lubricants with incidental contact: These compounds may be used as a lubricant with incidental food contact on food processing equipment. Common uses include a protective anti-rust film, a release agent on gaskets or seals of tank closures, and a lubricant for machine parts and equipment in locations in which there is potential exposure of the lubricated part to food. The amount used should be the minimum required to accomplish the desired effect on the equipment.

H2 Lubricants with no contact: These compounds may be used as a lubricant, release agent, or anti-rust film on equipment and machine parts or in closed systems (e.g., hydraulic systems) in locations where there is no possibility of the lubricant or lubricated part contacting edible products.

H3 Soluble oils: These products are chemically acceptable for application to hooks, trolleys, and similar equipment to clean and prevent rust. Portions of the equipment that contact edible products must be made clean and free of the mixture before reuse.

While NSF International registration isn’t mandatory, the increased recognition and popularity of food-grade lubricants has led lubrication manufacturers to work closely with NSF to gain a minimum NSF H2 registration for products used in food manufacturing plants. These manufacturers are also striving for an H1 registration for lubricants that are used where incidental contact can potentially occur.

Cross contamination
Some plants may use a mix of food-grade and non-food grade lubricants. When food grade and non-food grade lubricants are stored together in similar areas and containers, the chance of cross-contamination increases greatly, as does the likelihood of incorrect lubricant use for specific pieces of equipment. Efforts should be made to store these products in separate, well-marked areas that clearly distinguish the two types of lubricants. It only takes one incident where an improper lubricant is used to cause a potentially serious financial setback. In fact, if a company is investigated for possible lubricant contamination, and is unable to prove that the contamination came from an H1 food grade lubricant, the consequences can include production shutdowns, fines, product recalls and legal action.

Additionally, the lubricating systems may need flushing and refilling before restarting production. However, if a company can prove the use of an NSF H1 lubricant when incidental contact has occurred, they will likely not face a production shutdown or product recall.

On another note, performance levels offered by some of today’s NSF H1 registered food-grade lubricants can often provide longer service life and better long-term equipment performance due to the use of higher quality, highly refined base oils required to manufacture these unique lubricants. Food production plants operating all their equipment on NSF H1 lubricants eliminate the risk of mis-application and drastically reduce issues associated with incidental lubricant contact.

Reliability best practices
Attention to lubrication systems on food machinery doesn’t stop with making sure a food-grade lubricant is used. Keep your lubrication systems clean and be sure to properly store all lubricants in correctly labeled and sealed containers. Use the same best practices you do with non-food grade lubricants.

Once your lubricant systems are clean, keep them that way by introducing “top-off” oil using specifically designed containers, fill hoses or grease guns clearly marked and dedicated to the fluid or grease being used. This is highly recommended.

Clean storage and transport containers, in conjunction with the placement and use of desiccant breathers on systems that require them, such as hydraulic reservoirs, will help stop the ingression of airborne water and dirt particulates. These practices help create a solid line of defense against unwanted contamination, maximizing your investment in any lubricant, including food grade.

When in doubt, just ask
It is critical in food production and packaging situations to run equipment with lubricants that meet NSF International standards and ensure a quality product for the customer. Through the selection of proper food-grade lubricants, plant managers can conduct business with fewer concerns regarding liability and product recalls.

Maintenance professionals can maximize their lubricant investment by working with suppliers that fully understand their market and offer a full line of food-grade lubricants coupled with reliability-based programs to help maximize production and minimize safety risks.

When in doubt, contact your lubricant supplier directly. That’s why he is there — for you.

John Geyer is an industrial marketing specialist for Chevron Products Company. He can be reached at 724-457-1997; e-mail: jgey@chevron.com.

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