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Behind the scenes at PAS Grantham Ltd in the heart of Lincolnshire in the UK, Tim Wainwright is hard at work on the shop floor, as he has been for the last 32 years. In this fascinating insight into the potato products production line, Tim reveals the secrets behind the company's significant cost savings and increased reliability.

The potato was first cultivated over 4,000 years ago in Peru. Today, thanks to companies like PAS Grantham Ltd (McCain), the potato is one of the world’s most widely eaten and enjoyed foods. For instance, it's said that the average American eats 140 pounds (63.5 kilograms) of potatoes a year, the average German eats more than 200 pounds (90.7 kilograms) a year, and the average person in the UK consumes 220 pounds (100 kilograms) of potatoes a year.

PAS Grantham Ltd (McCain) produces a nutritious and delicious assortment of products, including oven chips, home fries, French fries, low-fat French fries, and have also entered into the mini pizza market.

Its foods are made with quality in mind. Not only does it carefully select its ingredients, it also adheres to a strict manufacturing process. This manufacturing process helps the company increase equipment reliability and productivity, and decrease operating costs.

Tim Wainwright, Mechanical Engineer at PAS Grantham Ltd (McCain) for the past 32 years, says that the greases it uses in its machinery play a big role in the manufacturing protocol, and in the company’s ability to increase productivity and decrease operating costs.

PAS Grantham Ltd’s (McCain’s) Total Preventative Maintenance programme is a cornerstone of its business and Tim constantly searches for products that will enhance its capabilities to achieve quality improvement throughout the plant.

*The lubricant trial * The production lines at PAS Grantham Ltd (McCain) run 24 hours a day, at least five days a week – sometimes even seven days a week. If a machine goes down, it can result in the entire line being shut down.

“When the line goes down, it costs us £900 an hour – that’s the figure we use as our benchmark,” says Tim. “Productivity is everything, and proper lubrication plays an integral role. We're always looking for lubricants that will perform, protect and save us money by reducing downtime and increasing operational efficiencies.”

Four years ago, Petro-Canada account manager James Ross suggested that PAS Grantham put “food safe” Purity FG Synthetic Grease to the test.

In 2004, Tim ran a six-month trial using Petro-Canada’s Purity FG2 Synthetic Grease – an advanced food-grade grease specially formulated for the toughest food processing applications. He compared it to his existing product to see which grease provided better protection of gears, bearings and equipment. Tim also compared the difference in cost between the two products.

The results and the switch “Lubrication improvements were noticeable. There was a decrease in actual volume used vs what we were using before, and our reliability was enhanced,” explains Tim. “Petro-Canada’s account manager James Ross ensured we achieved excellent efficiency results by ensuring that we had the right products for all of our applications.”

“After this six-month trial of Purity FG2 Synthetic Grease, we quickly realised the benefits of the product. There wasn’t any need to do any further trials. We went ahead and switched to a full line of Purity products, including Purity FG2 Grease, Purity FG00 Grease and Purity FG AW Hydraulic Fluid 68.”

Purity FG2 is now used on the company's standard conveyors, Purity FG2 Synthetic on its steam peelers and fryers, Purity FG AW Hydraulic Fluid 68 on its freezer chains, and Purity FG00 on the auto lube systems. Purity FG Gear and Hydraulic Fluids are also used throughout the PAS Grantham plants.

*The products and savings * Purity FG Greases provide outstanding lubrication and pump-ability over a wide range of temperatures, exceptional equipment protection and resistance to water washout and water jet spray loss. Purity FG2 Synthetic Grease also maintains consistency and lubrication in the presence of demanding cleaning processes.

Purity FG AW Hydraulic Fluid 68 is an advanced food-grade lubricant formulated to deliver enhanced, long-lasting protection. It resists oxidative breakdown better than leading speciality food-grade hydraulic fluids, and minimises the formation of sludge and varnish to ensure smooth and reliable operation. This can result in longer fluid life and reduced downtime.

“Purity FG food-grade lubricants provide us with improved reliability and cost savings,” adds Tim Wainwright.

Petro-Canada’s food-grade approvals are extensive, including, but not limited to, H1 registered by NSF International, certified by Star K for use in the preparation of kosher food, certified Halal by IFANCA. Selected products also fit perfectly in HACCP (Hazard Analysis and Critical Control Point) and GMP (Good Manufacturing Practice) plans.