Why Oil Compatibility Should Be Checked Before Switching Lubricant Types

Lubricants are often called the lifeblood of machinery because they reduce friction, control wear, and keep moving parts working smoothly. But changing from one lubricant to another is not as simple as draining the old oil and adding new oil. What if the two lubricants do not work well together? Incompatible oils can cause performance problems, increase wear, and even lead to costly machine failures. 

This is the reason why it is always good to know about the compatibility of oils before changing the type of lubrication. Fubex Lubricants is here to provide you with top-notch lubricants for your engine. Fast delivery, matched price, and no-hassle returns guaranteed. Not sure what kind of oil to choose? Contact us today at +971 50 544 9614.

Awais I., Sales Director, says: “Checking oil compatibility before switching lubricant types helps prevent wear, performance issues, and costly repairs. Choosing the right lubricant protects equipment, improves reliability, and extends machine life.” 

Keep reading to explore the key compatibility risks and learn how to make safer lubricant changes.

Causes of Lubricant Incompatibility

Many manufacturers do not know exactly which cutting fluids, oils, or lubricants are being used in their machines. An Intelligence survey found that only 42% of companies had the correct lubrication procedures in place. Also, 63% of respondents said they did not provide training to employees about oils and lubricants.

Because of this, different and incompatible lubricants can sometimes be mixed by mistake. This can affect machine performance and may cause lubrication problems.

Some other causes for incompatibility of lubricants may be:

• New Supplier of Lubricant: The new supplier may supply the lubricant in a new formulation or type.
• Change in Specification of Machine: The machine may need a new lubricant because of the change in its specifications and requirements.

• New Rebuilt Machines: There is a possibility that some lubricant or rust-prevention products could be inside the machines when they are received.
• Insufficient Draining of Previous Lubricant: Some amount of the previous lubricant would have stayed inside the machine, mixing with the new lubricant.
• Incorrect Lubrication Instruction: Failure to refer to the lubricant manufacturer’s instructions may cause problems in using lubricant oil.

Dangers of Lubricant Incompatibility

Even highly skilled maintenance staff can be subject to lubricant incompatibility. Mixing different lubricants with varying characteristics and additives will result in reactions that lead to lubricant issues within the machinery.

There are cases where acidic elements of one lubricant react with the alkaline additives of another, thus changing their effectiveness and reducing the protection of mechanical parts.

Lubricant incompatibility can lead to corrosion, machine damage, acid formation, and oil carbonization. These problems can reduce machine efficiency and may result in costly repairs or downtime.

Why Do Operators Change Lubricants?

There are various reasons why operators may decide to change the lubricant in their machinery. Some of the most common reasons include improving the efficiency of the machinery, as an appropriate lubricant will reduce friction and extend its life.

Environmental issues can be one of the factors leading to the choice of another lubricant. Nowadays, many companies prefer more environmentally friendly lubricants.

Compatibility is another important reason. If the existing lubricant does not suitably interact with other parts of the machine, the change in lubricant will aid in preventing damage.

In addition, cost reduction can also be another reason for the change. The lubricant that lasts longer and needs minimum maintenance will result in lower operation costs.

Advancement in the field of lubricant technology also results in better lubrication and greater protection under extreme conditions.

The equipment modification can also lead to a need for another type of lubricant. Overall, the decision to change lubricants depends on several factors, including machine performance, environmental impact, compatibility, cost, new technology, and equipment requirements. However, changing lubricants can also have risks if it is not done correctly.

Understanding Oils and Greases 

Whether to use oil or grease will be dictated by the machine, its functionality, and its environment. Oil lubricant decreases friction and dissipates heat while grease remains static and is used for protection from dirt, dust, and moisture.

Base oils are the key elements in any lubricant composition. These characteristics are determining the viscosity, thermal stability, and lubrication properties. There are three main kinds of base oils: mineral oils, synthetic oils, and vegetable oils.

Mineral oils are derived from petroleum products and are commonly used due to their low price and compatibility with a wide range of materials. Synthetic oils (PAO and esters) are characterized by higher stability under high temperatures and good heat resistance.

Base oils are the key ingredient in lubricants. They influence the viscosity, heat stability, and lubrication properties of lubricants. Mineral oils, synthetic oils, and vegetable oils can be distinguished. Mineral oils are extracted from petroleum and are commonly used due to their low cost and compatibility with many materials.

Synthetic oils (PAO and esters) have better stability and heat resistance and can be used at high temperatures. Vegetable oils are more eco-friendly but may not resist oxidation as well as mineral or synthetic oils.

Grease contains a thickener that helps it stay in place. Common thickeners include lithium, calcium, and polyurea.

Lithium greases are popular for general use. Calcium greases provide good water resistance, while polyurea greases perform well at high temperatures. However, each type should be checked for compatibility before mixing with another grease.

What to Consider When Mixing Lubricants

There are some issues associated with mixing incompatible lubricants. It is important to check base oils, grease thickeners and additives before mixing them.

Different base oils can have issues when being mixed together. This can result in a separation and affect the efficiency of the lubricant. Always make sure the base oils are compatible before you mix them.

Mixing greases with different thickeners can change the consistency and affect the ability of grease to work. There should be a compatibility test before mixing the greases.

There are additives included into the lubricant that will improve the properties of the lubricant. Additives from different lubricants can negatively interact and reduce their efficiency.

What Happens When Incompatible Lubricants Are Mixed?

Mixing lubricants that are not compatible can cause serious problems for machines. Some common issues include:

• Incompatible Thickener: Using an incompatible grease results in the grease losing its oil. This is referred to as oil bleeding. The grease becomes sticky and gums up, and loses the property of lubricating, resulting in faster wear and tear of machinery.
• Different Viscosity: Viscosity refers to how easy it is for the oil to flow. Mixing oils of different viscosities will result in the modification of the oil’s behavior. This might limit lubrication and add to the stresses of the machine components.
• Separation and Leakage: There are certain base oils that do not have compatibility at all. Separation occurs and the oil causes damage to the seals and leaking occurs.
• Additive Interaction: Lubricants contain additives that improve their performance and protect machine parts. When different additives are mixed, they may react with each other and become less effective. This can reduce protection and increase wear.

How to Test Lubricant Compatibility 

Prior to the blending of two different types of greases, there is a need to determine their compatibility. There are many useful compatibility charts that can help users in determining grease compatibility, but they need to consult the actual greases that they intend to blend.

There are many trusted manufacturers of heavy duty greases who can offer compatibility information on different grease combinations and advice in selecting and changing over to different greases.

Grease compatibility can be complex, so standardized testing methods are used to evaluate how different lubricating greases perform when mixed. The test looks at important properties such as dropping point, mechanical stability, and consistency. It also checks how these properties change after the grease mixture is heated.

Final Takeaways

Before changing to another type of lubricating oil, one should be very careful and consider testing its compatibility to avoid damage to the machine and possible high costs of repair in the future.

By selecting an appropriate lubricant and adhering to compatibility standards, you will be able to enhance performance and increase the longevity of your machines. Protect your equipment with the right lubricant. Choose Fubex Lubricants for reliable performance and better machine protection.

FAQs

Q1: What should you know about lubricant compatibility?

Before changing or adding a lubricant, check whether it is compatible with the lubricant already in the machine. In some cases, a laboratory compatibility test may be needed to prevent damage or poor performance. Common issues include mixing PAG oils with mineral oils, ash-forming oils with ashless oils, or replacing one type of grease or fluid with an incompatible product.

Q2: What should you do if lubricants have been mixed?

Should the wrong lubricants come into contact, the machine should be stopped to avoid damaging the machine. Consult the manufacturer on the type of lubricants required, remove the wrong one, and in case of need, clean the machine with the correct type of oil.