Grease retainer upgrade extends decanter life in an ethanol production plant

At Dakota Spirits Distillery, high-speed decanter centrifuges from Alfa Laval are essential for separating solids from stillage after fermentation. However, the demanding environment led to premature bearing wear, frequent maintenance, and unplanned downtime, threatening productivity and increasing costs.​

Challenge

Operating in a high-solids, high-moisture environment, Dakota Spirits’ decanter centrifuges faced accelerated bearing wear due to contamination from process liquids and solids. This resulted in frequent bearing failures, causing unexpected shutdowns which affected productivity.​

Additionally, the need for regular relubrication not only raised labor costs but also introduced risks of over- or under-lubrication, further impacting equipment reliability and plant throughput.​

Solution

Alfa Laval introduced the Grease Retainer upgrade, a retrofit designed to enhance decanter service by improving bearing protection and lubrication retention. ​

This solution offers:​

• Improved sealing to keep grease in and contaminants out​
• Reduced frequency of regreasing, lowering labor and material costs​
• Enhanced bearing life, even under high-temperature and high-solids conditions​
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By implementing this upgrade, Dakota Spirits could protect critical decanter components without the need for full component replacement, ensuring reliable and efficient operation.​

Results

The Grease Retainer upgrade delivered measurable improvements in decanter service and plant performance:​

• Increased overhaul intervals by 30–50%​
• Reduced grease usage per machine by 25–35%​
• Up to 40% fewer bearing-related shutdowns​

These results translated into longer equipment life, reduced maintenance frequency, and lower total cost of ownership, allowing Dakota Spirits to maximise uptime and throughput while minimising operational risks.​

Outlook

In ethanol production, reliability is everything. With a small investment in the Grease Retainer upgrade, Dakota Spirits Distillery protected one of their most critical decanter components – the bearings - against premature wear and failure. This simple upgrade extended the lifespan of their decanters, lowered maintenance costs, and improved overall plant efficiency, demonstrating how a targeted, cost-effective solution can maximise equipment value and operational stability.