When the only way to reach a lubrication point in winter is on an icy ladder, maintenance stops being “just a technical job”. Every decision carries more weight, and missed lubrication often comes with a price later.
Winter is one of the most critical periods in industrial maintenance. Cold and wet conditions, icy walkways, difficult access to equipment. Machines don’t “slow down” in the cold. They still need regular checks and continuous lubrication, just like the rest of the year.
Winter maintenance is not only a technical topic. It is also a serious safety challenge. In many plants, these are exactly the months when the risk increases that certain maintenance tasks are skipped, shortened, or done with compromises.
Why is winter maintenance critical in industrial environments?
During the cold months, several negative factors affect equipment at the same time:
- low ambient temperatures,
- higher humidity and precipitation,
- icing in outdoor and semi-enclosed areas,
- limited access to lubrication points.
On conveyors, outdoor drives, logistics systems, and in unheated halls, these conditions can lead to failures much faster. In winter maintenance, it is not only the machine that is under heavier load, the maintenance team is too.
Winter maintenance risks in industrial environments
Slips, falls, and high-risk interventions
Many lubrication points are located on ladders, platforms, or hard-to-reach places. What is merely inconvenient in summer can become a serious accident risk in winter. And the same job often has to be done faster, in heavy PPE, with limited freedom of movement.
Skipped or shortened lubrication rounds
One of the most common winter maintenance problems is that certain lubrication points are missed because:
- access is too dangerous,
- weather conditions don’t allow safe intervention,
- the task gets postponed.
These omissions rarely cause an immediate failure, but they can have serious consequences over time.
Lubrication in cold environments and increased bearing load
In cold conditions, lubricant behaviour changes. It gets thicker, it reaches the lubrication point less easily, and starting resistance increases. Bearings see higher loads, especially during start-up.
If missed relubrication is added on top of that, wear accelerates and bearing life can drop significantly.
What happens if lubrication is missed in winter?
Most bearing failures do not develop overnight. The impact of a missed lubrication cycle often shows up later:
- increasing noise,
- rising operating temperature,
- accelerating wear,
- and eventually unplanned downtime.
In practice, failures often appear in spring. At that point it can be hard to trace the root cause, even though the source is frequently the compromises made during winter maintenance.
Planning ahead is the foundation of winter maintenance
Most industrial maintenance professionals agree that a large part of winter problems can be prevented with planning ahead. In summer and autumn you still have:
- safe access,
- dry surfaces,
- time to review critical lubrication points.
This is the time to identify which points become hard to reach in winter, and how to reduce the number of interventions needed during the cold months.
The role of automatic lubrication in winter maintenance
One of the most effective tools for winter maintenance is automatic lubrication. Pre-set, continuous lubricant feed makes it possible to supply a lubrication point without manual intervention.
In practice, this means:
- lubrication doesn’t get missed due to bad weather,
- fewer risky climbs and interventions are required,
- lubricant reaches the bearing evenly, in small doses.
The optimal operating temperature range of Simalube automatic lubricators is –20 °C to +55 °C. This covers most outdoor and unheated industrial applications.
An interesting point is that the system’s electrochemical operation continues even if the lubricator temporarily freezes. As soon as conditions allow, lubricant dispensing continues automatically.
What to consider when choosing an automatic lubrication system for winter
Operating temperature range
Not every lubrication system is suitable for cold environments. Always check the operating temperature range specified by the manufacturer.
Lubricant behaviour in cold conditions
Make sure the lubricant:
- does not separate,
- does not thicken excessively,
- is compatible with the lubricator.
Mechanical protection
In winter, cold is not the only risk. Storms, falling ice, and flying debris can also damage components. In practice, it often makes sense to use:
- metal protective caps against mechanical impact,
- plastic protective caps against moisture and rapid temperature swings.
Extreme cold and the option of remote installation
In cold stores or specific outdoor applications, temperatures can stay below –20 °C. That does not automatically mean you must return to manual lubrication.
Remote installation allows the lubricator to be placed in a protected, warmer location while lubricant is delivered through tubing to the lubrication point. With Simalube IMPULSE connect, this can be up to 4 metres.
Conditions for reliable operation:
- the lubricant is suitable for the extreme temperature,
- it is compatible with the system,
- the lubricator itself stays within the allowed temperature range.
Winter maintenance is not only about protecting machines
In winter maintenance, you are protecting people as well. Fewer outdoor interventions, fewer high-risk tasks, and lower accident risk. Many plants report that automated lubrication solutions noticeably reduce the workload on maintenance teams during winter, while improving equipment reliability.
Key takeaways from winter maintenance
- Winter maintenance comes with higher safety risks.
- Missed lubrication can lead to bearing damage and later downtime.
- Lubrication in cold environments requires extra attention.
- Automatic lubrication reduces the number of risky interventions.
- Planning ahead pays off all year.
Winter maintenance in industrial environments is not an unavoidable inconvenience. It is a task you can manage proactively. By understanding typical risks and using the right lubrication strategy and automated solutions, you can significantly reduce failures and accidents.
Well-prepared winter maintenance not only makes the cold months safer, it also supports reliable operation in the long term.
If Simalube automatic lubrication has raised your interest, feel free to contact us.
As the official Hungarian distributor of Simatec AG, we can support you with automatic lubrication system planning, manufacturing, installation, and maintenance.
FAQ – Frequently asked questions about winter maintenance and automatic lubrication
Why is manual lubrication problematic in winter in industrial environments?
In winter, manual lubrication is often limited by safety conditions rather than technical issues. Slippery surfaces, icy ladders, and difficult access are typical. As a result, lubrication rounds are often shortened or skipped, which can lead to bearing damage and unplanned downtime over time.
Can automatic lubrication be used for every lubrication point?
Not for every point, but it works well in many typical applications. Rolling bearings, linear guides, chain drives, conveyors, and outdoor drives are common examples. Suitability always depends on the environment, the lubricant, and the lubrication demand.
What happens if the automatic lubricator is set up incorrectly?
Just like with manual lubrication, correct dosing matters. Too much or too little lubricant can both cause problems. That is why Simatec offers adjustable systems that can be matched to the application. In practice, once the setting is right, the system works steadily and delivers lubricant in small, consistent doses.
How can you tell if an automatic lubrication system is not working properly?
Modern systems can be checked visually or digitally. Some solutions show status clearly on the unit, while others can be monitored via an app. This helps prevent lubrication points from being left without lubrication for a long time without being noticed.
Does automatic lubrication really work reliably in winter?
Yes, if the system and the lubricant are chosen correctly. For example, Simalube automatic lubricators are designed to operate from –20 °C to +55 °C. Because the system works electrochemically, it remains active even if it freezes temporarily, and it continues dispensing once conditions improve.
What lubricants can be used in an automatic lubrication system?
Not every lubricant is suitable for automatic dosing. The chosen grease or oil must be compatible with the unit, must not separate, and must behave properly within the temperature range. This is especially important in food-grade or special environments. Simalube offers a wide selection of lubricants, so there is usually a suitable option for most applications. If you are unsure, contact us and we’ll help you select the right one.
What about extreme cold, for example in cold stores?
If ambient temperature stays below –20 °C, remote installation can be a solution. The lubricator can be placed in a protected, warmer location while lubricant is delivered through tubing to the lubrication point. This makes automatic lubrication possible even in extreme environments.
Who will design, install, and set up the automatic lubrication system?
This is one of the most common and most important questions. If this topic has raised your interest but you are not sure how to start with planning and installation, feel free to contact our expert colleagues. As Simatec AG’s official partner in Hungary, we support you with sourcing, planning, manufacturing, and maintenance of lubrication systems. That way you don’t just get a device, you get a working solution matched to your environment.
When is automatic lubrication not recommended?
There are cases where manual lubrication remains the better option, for example on equipment that runs very rarely or where lubrication needs are occasional and highly specific. Automatic lubrication is not a universal answer for every situation, but it can reduce many winter maintenance risks significantly.
