Case Study - Improved Rollercoaster Lubrication

In this case study, we will explore the problem that Six Flags Over Georgia Adventure  and its supervisor of maintenance, John Kuschyk, faced for their 3,600-foot-long roller coaster, The Great American Scream Machine.
 
Prior to their 1998 season, Kuschyk began searching for a more cost-effective and readily available lubricant that would continue to meet Six Flags’ high-performance requirements and their application. They took the issues they were facing to their supplier contact. Based on their application and what was needed, MOLYKOTE® BG-20 High-Performance Synthetic Grease was recommended.

Problem: Costly Maintenance

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The constant lubrication required to ensure safety and a fast, smooth ride was becoming costly. The process at the time was to soak the wheel bearings of the 11-year-old roller coaster in an oil bath to keep them lubricated. This method resulted in the oil caps flying off occasionally, allowing oil to escape the bearings.

Another method Kuschyk utilized was sealing the caps and replacing the oil with grease manually via pump or gun through fittings and bearings located in the wheels’ hubs. With this method, the grease needed to be replaced every seven to ten days to replace any grease that had leaked out during that time. This method became costly since the grease used for this application was very expensive, according to Kuschyk. An alternative grease that was more readily available and cost-effective while meeting Six Flags’ performance regulations needed to be researched.

The Solution: MOLYKOTE® BG-20 High-Performance Synthetic Grease

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Why Molykote BG-20 Grease?

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Made of synthetic polyol ester (POE), MOLYKOTE® BG-20, an NLGI Grade 2 grease, is ideal for lubricating and protecting bearings under medium to heavy loads. While under heavy loads, most roller coasters have an average of 4,000 rotations per minute (RPM). At high rotational speeds, along with environmental exposure, the grease must withstand a broad temperature range. MOLYKOTE® BG-20 Grease can perform in temperatures between −45°C to 180°C (−50°F to 360°F), making it the perfect grease to withstand the hot summer days, cold rainy nights, and everything in between.

With its long-term lubrication properties (due to low oxidation and oil evaporation) and broad operating temperature, MOLYKOTE® BG-20 High-Performance Synthetic Grease is an ideal choice for roller coaster applications.