At HK Machine, we design and establish world-class grease production plants, one of the most critical manufacturing systems in the lubricant sector. We offer complete turnkey integration from saponification reactors and colloid mills to vacuum deaerators and automatic filling lines. Made in Turkey, installed worldwide.
The key chemical and technical steps converting premium raw ingredients into the final high-performance grease product.
Base oils and thickener soap chemicals are mixed under precise pressure and high temperature inside the main reaction autoclave.
The hot mass is quickly cooled through scraped-surface vertical heat exchangers where anti-wear and antioxidant agents are dosed.
Using precision colloid mills, grease soap fibers are sheared down to micron-level distributions, establishing steady consistency.
Micro-bubbles trapped during mixing are evacuated under high vacuum, enhancing oxidation stability and yielding a glossy product look.
Specialized high-density grease filters eliminate any unreacted thickener lumps, ensuring a 100% smooth, flawless texture.
Servo-driven filling heads package the grease into containers ranging from 400g cartridges to 180kg drums with zero air pocketing.
A grease production plant is a specialized industrial setup where liquid base oils (mineral or synthetic) are chemically reacted with thickener agents (lithium, calcium, sodium, or aluminum soap) at specific temperatures and pressures to form a semi-solid, gel-structured lubricant.
Grease manufacturing requires strict temperature controls, precise shear forces, and a perfectly synchronized step-by-step process flow. Our turnkey installations feature highly automated load-cell feeding, integrated heating, rapid scraped cooling, inline high-speed milling, and degassing systems designed to produce top-grade grease with zero product separation over time.
The HK Machine Advantage: The ultimate benchmark of a premium grease is the uniformity of its soap fiber network. Our proprietary colloid mills and scraped reactors ensure that the target NLGI consistency class (Grade 00 to 6) is met flawlessly and preserved during long-term storage.
We custom-build and project-engineer each grease line to match your targeted market tier, budget, and formulation criteria.
This is where the base oils and saponification chemicals react. Built from heavy-duty pressure vessel steel, it features dual counter-rotating paddle agitations equipped with high-temp Teflon scrapers. This setup guarantees perfect heat distribution and prevents product localized burning.
The core machine responsible for mechanical fiber breakdown. Its micron-adjustable rotor-stator gap ensures the final grease is incredibly smooth, shiny, and highly stable against future oil bleed issues.
Removes micro-air bubbles from the thick grease structure. Unremoved air leads to rapid product oxidation, darkens grease appearance, and ruins filling accuracy. Deaeration guarantees premium surface texture and longer shelf-life.
While reaction requires intense heat, rapid cooling is necessary before adding delicate additives. Our scraped heat-exchanger units reduce processing time by up to 50% compared to traditional jacket cooling systems.
Review our standard plant capacities and design footprints suited for global installations.
Swipe right to view the entire technical specification sheet
| Capacity (Per Batch) | Daily Output (8h Shift) | Heating Source | Mill Mechanism | Automation Level | Min. Required Area |
|---|---|---|---|---|---|
| 500 Kg | 1,000 Kg | Thermal Oil / Electrical | Semi-Automatic Colloid | Push-Button / Semi-Auto | 120 m² |
| 1,000 Kg | 2,000 Kg | Thermal Oil / Boiler | Inline Precision Colloid | Semi-Auto PLC | 180 m² |
| 2,000 Kg | 4,000 Kg | Thermal Oil / Steam | High-Speed Inline Mill | Full PLC & SCADA | 250 m² |
| 5,000 Kg | 10,000 Kg | Thermal Oil Boiler Plant | Dual-Rotor Industrial | SCADA Centered | 400 m² |
| 10,000 Kg | 20,000 Kg | Industrial Oil Boiler | Multi-Stage Homogenizer | Full Entegre DCS | 600 m² |
| All layout options are customized based on your facility's ceiling height and floor plans. | |||||
| Capacity | Core Equipment Package | Control Mode | Est. Price Range | Lead Time |
|---|---|---|---|---|
| 500 Kg / Batch | Open Reactor + Colloid Mill + Manual Packing | Semi-Auto | $45,000 - $75,000 | 45-55 Days |
| 1,000 Kg / Batch | Pressure Autoclave + Mill + Vacuum + Semi-Auto Filler | PLC Control | $85,000 - $135,000 | 55-65 Days |
| 2,000 Kg / Batch | Reactor + Colloid Mill + Deaerator + Scraped Cooling + Auto Filler | PLC & SCADA | $150,000 - $250,000 | 65-75 Days |
| 5,000 Kg / Batch | Multi-Reactor Grid + Automatic Feeders + Master SCADA | Fully Automatic | $270,000 - $450,000+ | 75-90 Days |
| Prices vary based on carbon steel vs. stainless steel selection, filler heads, and onsite pipeline lengths. | ||||
* Prices are EXW. Onsite civil works, local licenses, and base-oil holding tanks are quoted separately.
Building a plant is only half of the challenge; understanding grease chemistry is what guarantees business success. HK Machine offers:
Micron-adjustable colloid mills guarantee zero separation
Scraped heat exchangers reduce energy waste by up to 30%
High-tensile pressure caskets for 20+ years of operational service life
High-vacuum deaeration ensures flawless, glossy grease surface texture
Produce lithium, calcium, or sodium grease grades on the same line
Auto Load-Cell dosing guarantees identical product quality across batches
Complete chemical recipes provided alongside mechanical setups
Rapid global spare parts dispatching and on-location maintenance
Saponification Reactors | Homogenizers | Colloid Mills | Automatic Packing | Turkey
+90 536 037 3281Copyright 2026 HK Machine - Turkey. All Rights Reserved.
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