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Downtime Is Not a Maintenance Problem  – It’s a Lubrication Strategy Problem

Across high-output plants – from automotive powertrain lines to heavy manufacturing conveyors – unplanned downtime remains the costliest drag on productivity. Industry research from Plant Engineering Magazine reports that bearing-related issues account for up to 45% of all unscheduled shutdowns, with the financial impact averaging $260,000 per hour in lost production, labor and scrap.

While equipment design and operational load play their roles, the silent variable behind most bearing failures is lubrication – either the wrong grease, degraded grease, or inconsistent relubrication schedules. This is where MOBIL POLYREX EM, a premium polyurea-based electric motor grease, has proven transformational.

Deployed globally by leading manufacturers, POLYREX EM helps stabilize operating temperatures, extend bearing life and significantly reduce maintenance interventions. More than a lubricant, it has become a strategic enabler of uptime, directly linked to energy efficiency and asset reliability KPIs across multi-site operations.

1. The Technical Foundation: What Makes POLYREX EM Different

MOBIL POLYREX EM was formulated to outperform conventional greases in thermal endurance, oxidation stability and water resistance – three decisive factors in motor reliability. Its unique polyurea thickener system provides a fiber-reinforced matrix that locks in base oil, resists oxidation and forms a durable lubricating film under high load and speed.

Interpretation:

MOBIL POLYREX EM maintains film integrity beyond 260°C, ensuring operational stability even in the high ambient environments typical of automotive body shops and heavy manufacturing lines. Its superior oxidation resistance reduces grease hardening and oil separation, translating into 40–50% longer regreasing intervals and fewer lubrication-related shutdowns.

2. Proven Reliability: Real-World Impact Across Global Operations

Case Study 1 – Automotive Powertrain Manufacturing (Germany)

A Tier 1 automotive supplier operating over 450 electric motors across robotic assembly lines faced frequent bearing replacements and overheating issues. After switching to MOBIL POLYREX EM, results over an 18-month cycle included:

• 52% reduction in bearing-related downtime

• Energy savings of 1.8%, verified through vibration and thermal monitoring

• Bearing life extension from 9 months to 18 months on average

These improvements directly supported the facility’s ISO 9001 and IATF 16949 compliance goals for process stability and energy management.

Case Study 2 – Steel Fabrication & Heavy Equipment Facility (India)

In a high-dust, high-heat environment where bearing failures were common, POLYREX EM was used across conveyor and dust collector drives. Results included:

• 1.6× increase in bearing service life (aligned with ISO 281:2007 standards)

• 72% reduction in water ingress failures

• 30% decrease in annual grease consumption, saving approximately USD 75,000

The plant subsequently standardized MOBIL POLYREX EM for all continuous-duty motors, aligning it with global asset management practices under ISO 55000.

3. Engineering Behind the Performance

a. Polyurea Thickener Chemistry

Unlike lithium thickeners, polyurea structures resist oxidation catalysts. This allows long-term stability without metal ion degradation, ensuring clean operation in electric motor bearings conforming to NEMA MG-1 specifications.

b. Base Oil Design and Viscosity Control

The grease’s synthetic base oil (ISO VG 100) supports bearing DN values up to 400,000, ideal for high-speed, high-temperature applications. This dual compatibility reduces the need for multiple grease types across plant assets.

c. Shear and Oxidation Resistance

In ASTM D3336 high-speed bearing life tests, MOBIL POLYREX EM achieved an L10 life exceeding 1,000 hours at 177°C – two to three times longer than typical lithium greases. The benefit is predictable performance under both sustained load and start-stop cycles, common in automated lines.

4. Implementation Strategy: From Trial to Standardization

Global manufacturers deploy POLYREX EM through a structured rollout, ensuring both compatibility and measurable ROI.

Step 1: Compatibility & Baseline Testing 

Run ASTM D6185 compatibility checks to verify transition readiness and prevent cross-contamination with existing greases.

Step 2: Controlled Phase-In

Begin with electric motors in critical zones (assembly robots, blowers, conveyors). Log bearing temperature and vibration data.

Step 3: Data Benchmarking & Optimization

Monitor lubricant consumption, bearing temperature and motor amperage over 8–12 weeks. Adjust regreasing intervals based on performance stabilization.

Step 4: Global Standardization

Integrate POLYREX EM into corporate lubrication SOPs and reliability frameworks. Align documentation with ISO 55001 asset management and TPM pillar metrics.

This process not only eliminates unplanned downtime but also converts lubrication into a quantifiable performance discipline within plant reliability systems.

Key Takeaway:

MOBIL POLYREX EM demonstrates 2–3× longer oxidation life (ASTM D3336), operates reliably up to 260°C and reduces bearing-related downtime by over 50% in both automotive and heavy manufacturing applications.