In quarry operations, maintaining heavy equipment is critical to productivity, yet some routine maintenance tasks remain surprisingly labour-intensive. One such challenge is refilling centralised lubrication systems, a process that typically relies on either manual grease guns or disposable grease cartridges. While effective, both methods can be time-consuming, physically demanding and costly when managing large fleets of machinery.

To address this issue, German companies Lutz Pumpen and Woerner have launched an innovative filling solution designed to simplify the maintenance of centralised lubrication systems in quarries and other heavy-duty applications. Marketed as LubeDrive by Lutz Pumpen and Power Fill Pro by Woerner, the new tool is the world’s first eccentric screw pump powered by a standard cordless drill, offering operators a faster, more ergonomic and cost-effective way to handle grease refilling.

The new pump was showcased at Steinexpo, the international trade fair for the raw materials and construction industry, where visitors can see solutions developed specifically for the demanding operating conditions faced by quarry operators.

Developed through a collaboration between the two Wertheim-based companies, the solution combines Woerner’s expertise in centralised lubrication systems with Lutz Pumpens’ pump technology know-how.

Andreas Frank 

A Smarter Approach to Quarry Lubrication

When operators need to fill the central lubrication systems of construction machinery in a quarry, there are two established methods: using 400-gram grease cartridges and refilling with grease guns.

“However, both methods have drawbacks: Manual grease guns are time-consuming. In addition, they can lead to strain on the arms, shoulders, and hands. Grease cartridges, on the other hand, are often more expensive to purchase, store, and dispose of than larger containers,” says Andreas Frank, sales manager at Eugen Woerner GmbH & Co. KG, a manufacturer of central lubrication systems based in Wertheim. “We have therefore been searching for a long time for a more efficient and ergonomic solution for our customers,” he adds.

The resulting product brings together Woerner’s expertise in automatic central lubrication systems and Lutz Pumpens’ know-how in pump technology.

“This is the world’s first eccentric screw pump that can be powered by a standard cordless screwdriver,” explains Andreas Rössler, sales manager at Lutz Pumpen.

Designed to work with standard NLGI 2 grease, the system enables operators to fill centralised lubrication systems directly from grease containers. The pump unit is secured in the container using an adjustable lid, connected by hose to the lubrication system and powered using a standard cordless drill.

“Refilling is quick, ergonomic, and requires no separate drive unit,” Rössler adds.

Andreas Rössler

Lower Costs Through Bulk Grease Handling

Beyond simplifying the maintenance process, the system offers the potential for significant cost savings. By allowing operators to switch from 400-gram cartridges to grease containers weighing up to 180 kg, it enables them to benefit from bulk purchasing while reducing storage, procurement and disposal costs.

“When operators use 400-gram grease cartridges to fill central lubrication systems, they often cannot take advantage of the purchasing benefits offered by larger containers of grease,” says Rössler. “At the same time, the relatively small cartridges increase the effort involved in procurement, storage, and disposal, especially when multiple machines are involved.”

“Depending on the lubricant and purchasing terms, costs for procurement, storage, and disposal can be reduced by up to 40 percent,” he adds.

Faster Refilling, Higher Productivity

Efficiency gains are equally significant. According to the companies, the filling tool can deliver grease at rates of up to 2 kg per minute directly into the reservoir of the central lubrication system, dramatically reducing maintenance time.

“The LubeDrive and PowerFill deliver lubricating grease at a rate of up to 2 kg/min directly into the reservoir of the central lubrication system,” says Frank. “This allows filling operations to be completed much more quickly.”

A practical example illustrates the potential impact. Assuming ten machines each require 2 kg of grease during maintenance, a manual grease gun with a flow rate of 0.25 kg/min would require approximately 80 minutes to complete the task.

“With the LubeDrive, the actual filling time is reduced to about 10 minutes. This saves 70 minutes on refilling alone, making the maintenance process significantly more efficient,” Frank says.

LubeDrive is quick, ergonomic, and requires no separate drive unit

Reducing Physical Strain

The solution also speaks to a growing focus on worker wellbeing and ergonomics across heavy industry. Manually dispensing grease, particularly high-viscosity lubricants or in cold operating conditions, can place considerable strain on maintenance personnel.

“However, manually dispensing lubricating grease requires a great deal of effort, especially when dealing with thick greases or at low temperatures,” says Frank.

Such repetitive tasks can affect employees’ hands, arms and shoulders, especially in operations involving large numbers of machines.

“The LubeDrive, on the other hand, handles grease delivery with virtually no physical effort,” he adds.

Even for operators who continue to use manual grease guns, the system offers productivity benefits by rapidly replenishing the equipment.

“At full flow rate, a standard grease gun is filled and ready for use in 10 to 15 seconds,” Frank adds.

As quarry operators continue to seek ways to improve equipment uptime, reduce maintenance costs and enhance workplace safety, innovations such as LubeDrive and Power Fill Pro highlight how relatively simple engineering solutions can deliver meaningful improvements across everyday maintenance operations.