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FILLING
The filling of packed products is divided into five sections according to the type of fill. The large drum section has seven filling points and each line has the capacity to fill between 35 to 45 drums per hour depending on the viscosity of the oils being filled. This section also fills the one cubic metre containers. The Sealed Can machine is used to fill 500 ml tins of motorcar oil, which is sold on most forecourts. The Multi-purpose filling machine fills 500ml plastics containers and is run on a twenty - four hour shift basis owing to the high demand of this pack type. Both the Blendcor five litre and Castrol five litre lines are high volume low variety fillers. Most of these packs end up in chain stores and garages. The Twenty Litre lines are used to fill plastics buckets. These lines produce an average of 3000 buckets per day. Most these products are destined for the motor and light industrial sector. An Overall Equipment Effectiveness (OEE) monitor electronically measures each of the above Filling machines. This program measures the productivity of the lines and acts as a troubleshooting guide for maintenance or poor performance.

BLENDING
Blending is a process of bringing together various resources (ingredients) nominated by the blend formulation under specified conditions to produce a specific grade of lubricating oil. The three processes are the addition of resources that make up the blend composition, the heating of the resources to reduce viscosity and the mixing of the resources to make the blend homogenous. This is followed by testing the blend to confirm that the right quantities of all the resources were used. Two Automatic Batch and a Simultaneous Metering System (SMS) are used for blending. The three blenders are automatically controlled by the Lubecell Software (Cellier Program) The Blending section operates on a shift cycle to meet production demands and each shift is lead by a shift foreman, who is responsible for all operational aspects of the shift. The equipment in this section consists mainly of pigged transfer lines, valves, volume and mass measuring devices, pumps and tanks. In order to ensure a safe operation and to obtain maximum efficiency, all of the associated equipment is maintained in good condition. Running maintenance of the various equipment is the responsibility of the teams and the Foreman.

GREASE
The process of Grease manufacture undergoes two stages, viz: the saponification process (soap making) and the grease completion stage. Soaps can be saponified in the autoclave and kettle, generally all Lithium based soaps are saponified in the autoclave and all Calcium and Clay based soaps are saponified in the kettle. In the autoclave an acid and base is reacted with the addition of water as the catalyst to make soap. Temperature is controlled by the use of hot oil, which passes through a jacketed internal element. During saponification an exothermic reaction takes place, an increase in temperature / pressure with the aid of heating and the use of a screw mixer aids the completion of the reaction. Controlling of the vent valves is critical for the correct formation of soap and it also minimises soap carryover that will affect the environment and quality. The soap is then stirred and dropped into a kettle when the saponification process is completed. In the kettle the soap is processed into grease, this process occurs when the soap is cooled (water is used to cool the grease, water passes through an external jacket attached to the kettle). This stage is known as crystallization and it is at this stage the grease fibres are formed. The grease is cooled to 100 deg and the performance additives are added. The product is mixed and circulated through a homogeniser (in the homogeniser all the undissolved additives are “broken down” and dispersed evenly in the product). The product is tested and when passed by the laboratory it is filled into various pack sizes.