case study: PFAS-Free lifetime lubrication for pipe pressing tongs
The pressing of pipes is a highly sensitive process where consistently high quality and operational reliability are essential. Our customer approached us with the challenge of developing a PFAS-free anti-friction coating for guide bolts used in pipe pressing tongs — a solution capable of delivering reliable lifetime lubrication under demanding mechanical conditions.
To meet these requirements, we developed and implemented GLISS-COAT® green GP-708, an innovative PFAS-free anti-friction coating specifically designed for high mechanical resistance, corrosion protection, and automated assembly processes.
The project combined our expertise in anti-friction technology, corrosion-inhibiting surface coatings, and advanced low-friction additives to create a sustainable and future-proof solution.
initial situation and challenge
The original production process relied on manually greasing the guide bolts of the press jaws. This approach created several challenges:
- Low assembly frequency due to manual handling
- Increased risk of assembly errors
- Inconsistent lubrication quality
- Repeated maintenance requirements during product lifetime
- High failure risk caused by insufficient lubrication
- No feasible option for automated greasing
At the same time, upcoming European PFAS regulations required the development of an environmentally friendly alternative without compromising technical performance.
The customer’s goal was therefore clear:
Develop a PFAS-free anti-friction coating with high resistance to mechanical stress that provides reliable lifetime lubrication throughout the entire service life of the product.
objectives
The project focused on achieving the following technical and operational targets:
- PFAS-free anti-friction coating
- Lifetime lubrication without grease
- High resistance to mechanical stress
- Poka Yoke-compatible assembly process
- High assembly processing frequency
- Temperature resistance from -40 °C to +50 °C
- Excellent corrosion resistance
- Reduced maintenance requirements
- Compliance with future European PFAS regulations
our solution: GLISS-COAT® green
Based on intensive technical discussions and requirement analysis with the customer, we developed and implemented GLISS-COAT® green GP-708.
GLISS-COAT® green systems are environmentally friendly, water-based anti-friction coatings that are free from PFAS and heavy metals. The systems are already compliant with current RoHS and REACH requirements and provide a future-proof solution regarding upcoming PFAS restrictions in Europe.
The coating system was specifically engineered for lifetime lubrication applications and offers:
- Outstanding anti-friction performance
- Excellent wear and corrosion resistance
- Low coefficient of friction through advanced additive technology
- Elimination of manual greasing
- Noise and wear reduction without using grease
- Stable performance under demanding operating conditions
Our expertise in anti-friction and corrosion-inhibiting surface technologies enabled the successful integration of state-of-the-art friction-reducing pigments and additives into a robust coating system suitable for industrial-scale production.
results and achievements
The implementation of GLISS-COAT® green GP-708 delivered significant technical and economic improvements.
Before
- Low assembly frequency
- Manual greasing required
- Higher probability of assembly errors
- Repeated maintenance during service life
- Increased risk of lubrication failure
After
- Fully grease-free process
- Lifetime lubrication achieved
- Poka Yoke-supported assembly
- Automated assembly process enabled
- Higher assembly frequency
- Reduced production time
- Lower failure rate
- Increased service life of the pressing tool
Key Benefits
- Substitution of grease
- PFAS-free lifetime lubrication
- Excellent corrosion protection
- Automation of the assembly process
- Reduced maintenance requirements
- Increased productivity and profitability
- Environmentally friendly coating technology
- Compliance with upcoming European PFAS regulation
conclusion & outlook
The project demonstrates how innovative surface technology can simultaneously improve sustainability, production efficiency, and product performance.
By replacing manual greasing with a PFAS-free lifetime lubrication coating, the customer achieved:
- Overall cost reduction
- Increased productivity
- Improved process reliability
- Reduced failure rates
- Maintenance-free operation over the product lifetime
- Enhanced end-user experience
- Future-proof compliance with environmental regulations
With GLISS-COAT® green, manufacturers can already prepare today for tomorrow’s PFAS regulations while improving operational efficiency and product quality.
about Aalberts surface technologies in solingen
Aalberts surface technologies in Solingen is a specialist in advanced surface refinement solutions for industrial components. With extensive expertise in anti-friction coatings, corrosion protection, and functional surface technologies, we support customers in developing high-performance and sustainable solutions for demanding industrial applications.
