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Chesterton 715 Spraflex® Gold Applied to Coal Rollers to Extend Lifetime


Case study – Chesterton ILMRO products – Industrial Lubricants

Chesterton - Global Solutions, Local Service



A large coal to liquid fuel plant uses a wire rope driven mechanism to “shunt” rail tank cars for filling. The previous grease combinations were wearing down the ropes and increasing the rate of maintenance and replacement. Chesterton lubricant specialists suggested Chesterton 715 Spraflex® Gold applied every few months. With an increase in lifetime from three years to five, the plant saved over $240,000 per year and their equipment ran more smoothly and efficiently than ever.

Products featured in the case study:

Chesterton 715 Spraflex® Gold.


A large coal to liquid fuel plant uses a wire rope driven mechanism to “shunt” rail tank cars for filling. Previously, a mixture of grease and diesel fuel was used to lubricate the 16 wire ropes. The ropes frequently broke, resulting in four hours downtime for repair each time. The ropes typically had to be replaced every three years at a cost of $115,000 each.

Crane cable lubricants dry out, trap dirt and fail to prevent corrosion after 12 months.


Chesterton 715 Spraflex® Gold applied manually to rollers every 3-4 months. After two years of using Chesterton 715, the plant had not experienced any production delays due to rope breakage.

A side-by-side trail with OEM Lubricant proves the value of Chesterton 715.


The wire rope replacement period has been extended from three years to five years.

Previous Wire Rope Costs (3-yr. life cycle) 16 wire ropes @ $115,000/ea: $1,840,000 $1,840,000/3-yr. life cycle: $ 613,333/yr.)

New Wire Rope Costs (5-yr. life cycle) Current $1,840,000/5 yrs.: $ 368,000/yr.

Savings (5-yr. vs 3-yr. life cycle): $ 248,333/yr. (+ reduced labor costs and downtime)

Cleaned, lubricated, and protected.

About Us

Chesterton global solutions, local service

Chesterton® is a world leader in helping process industry companies and manufacturers improve the reliability and efficiency of their rotating, stationary, and fluid power equipment platforms. We are known across a wide range of industries for our award-winning pump and valve sealing solutions, applications expertise, equipment maintenance and wear-prevention products, and knowledgeable hands-on local service​.

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Case Study – Issued 09/21

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