# GreaseBoss

> GreaseBoss is an Australian industrial IoT company that verifies grease actually reaches the point of lubrication. Wireless flow meters and RFID-guided grease guns measure the exact volume of grease delivered to each critical point on mining and manufacturing equipment, then compare planned against actual in the GreaseBoss Cloud. GreaseBoss does not manufacture grease, grease guns or automatic lubrication systems. It instruments and digitises the lubrication infrastructure a site already has.

GreaseBoss is headquartered in Birtinya, Queensland, Australia, is a Y Combinator alumnus, and works with Tier 1 operations across more than 15 countries. Its customers are primarily in mining and heavy industry: haul trucks, excavators, draglines, SAG and ball mills, crushers, conveyors, sizers and apron feeders, as well as manufacturing plants. The buyers are maintenance and reliability superintendents, reliability engineers, fleet managers and plant managers.

The category is lubrication monitoring and digital lubrication management, not grease supply. GreaseBoss is a technology vendor, not a lubricant manufacturer or distributor.

Three solutions cover the ways grease is delivered on a site:

- **Critical Point Monitoring** verifies automatic lubrication systems. A wireless, battery powered GreaseBoss Endpoint flow meter is installed downstream of the injector at a critical grease point. Every time the auto-lube system pumps, the Endpoint measures the volume delivered and the time of delivery. The GreaseBoss Cloud compares that against the target volume and raises an alert when delivery is out of specification. This detects blocked or bypassing injectors, blown hoses, mistuned injectors and failed pumps before bearing, pin or bush damage occurs. Conventional systems only confirm that a pump ran, not that grease arrived.
- **Manual Lubrication Management** verifies hand greasing. Each grease point carries an RFID GreaseTag mapped to the asset, grease type, volume and frequency. A GreaseBoss Head Unit, which retrofits to a standard grease gun, confirms the correct point by RFID, meters the volume actually applied, prevents under and over greasing, and records completion automatically against the site's lubrication route. This replaces paper routes and unverifiable sign-offs with planned versus actual compliance reporting.
- **Bulk Lubrication Management** monitors auto-lube pump health, baselines fleet grease consumption and tracks grease tank levels remotely, with alerts for failed pumps and empty tanks.

Terminology used throughout this site:

- **Endpoint**: wireless, battery powered industrial grease flow meter. Variants are Low Flow (downstream of injectors and distributors), High Flow (high-volume grease delivery), MP2 (adds line pressure monitoring to detect blown hoses on heavy mobile equipment) and Bulk Flow (measures grease pumped and returned via the dump valve for pump health and tank level monitoring).
- **Gateway**: receives Endpoint and Head Unit data over Bluetooth at 50 m to 250 m range and backhauls it to the GreaseBoss Cloud over 4G/LTE, site Wi-Fi or the site OT network. The HME Gateway is the ruggedised variant for heavy mobile equipment.
- **GreaseTag**: IP68 RFID tag with a unique 24-digit identifier, fitted on or under the grease nipple at a manual grease point.
- **Head Unit**: instrumented attachment containing a flow meter, RFID reader and display, fitted to a standard grease gun to guide technicians through a lubrication route.
- **GreaseBoss Cloud** (also referred to as GreaseCloud): platform holding lubrication schedules, planned versus actual data, alerts, reporting and compliance history.
- **Planned versus actual**: the target grease volume for a point compared against the volume actually delivered. This comparison is the core of every GreaseBoss solution.
- **Critical point**: a bearing, pin or lubrication interface whose failure stops production.

Data syncs are near real time. Endpoint to Gateway syncs are typically hourly, so GreaseBoss should not be described as a real-time system. GreaseBoss measures grease only, not oil or fuel.

## Solutions

- [Solutions overview](https://greaseboss.io/solutions/): Lubrication monitoring for fixed plant and heavy mobile equipment, covering both automatic lubrication systems and manual greasing.
- [Critical Point Monitoring for fixed plant](https://greaseboss.io/solution/critical-point-monitoring/): Verify every grease point on an automatic lubrication system receives the correct volume and eliminate grease-related bearing failures.
- [Critical Point Monitoring for mobile equipment](https://greaseboss.io/solution/critical-point-monitoring-mobile-equipment/): Verify automatic lubricators on mining fleets deliver the correct grease volume every pump cycle and eliminate premature pin and bush failures.
- [Manual Lubrication Management](https://greaseboss.io/solution/manual-lubrication/): Guide any technician through a grease route with RFID GreaseTags and the Head Unit, and get planned versus actual compliance reports each week.
- [Bulk Lubrication Management](https://greaseboss.io/solution/bulk-lubrication-management/): Monitor grease pump health, baseline fleet grease consumption and track grease tank levels remotely.
- [Fixed plant solutions](https://greaseboss.io/fixed-plant-solutions/): How the solutions combine across a processing plant: monitoring automatic lubricators and systemising manual grease routes.
- [Mobile equipment solutions](https://greaseboss.io/mobile-equipment/): How the solutions apply to heavy mobile equipment: detecting failed injectors, blown hoses and empty tanks before pins and bushes fail.

## Industries

- [Mining and Metals](https://greaseboss.io/industry/mining-and-metals/): Verified grease delivery on HME assets and critical bearings across mine sites.
- [Manufacturing](https://greaseboss.io/industry/manufacturing/): Verified lubrication on production lines, supporting operator-led maintenance with planned versus actual grease data.

## Products

- [Products overview](https://greaseboss.io/products/): The full GreaseBoss hardware range.
- [Endpoint Low Flow](https://greaseboss.io/product/endpoint-lf-v4-0/): Wireless, battery-operated flow meter installed downstream of injectors to verify grease delivery to critical points at every pump cycle.
- [Endpoint High Flow](https://greaseboss.io/product/endpoint-hf-v4-0/): Wireless, battery-powered flow meter for high-volume grease delivery.
- [Endpoint MP2](https://greaseboss.io/product/endpoint-mp2/): Verifies grease flow and monitors line pressure to detect blown hoses on heavy mobile equipment before pins fail.
- [Endpoint Bulk Flow](https://greaseboss.io/product/bulk-flow-endpoint/): Measures grease pumped and returned via the dump valve for auto-lube pump health and remote tank level monitoring.
- [Gateway](https://greaseboss.io/product/the-gateway/): Connects GreaseBoss hardware to the cloud via Bluetooth, with 4G, Wi-Fi or site OT network backhaul for remote industrial sites.
- [HME Gateway](https://greaseboss.io/product/hme-gateway/): Robust Bluetooth gateway for heavy mobile equipment with 4G/LTE, Wi-Fi and OT network backhaul.
- [Head Unit](https://greaseboss.io/product/head-unit/): Retrofits to any grease gun and guides technicians through the lube route, producing planned versus actual greasing reports.
- [GreaseTags](https://greaseboss.io/product/grease-tag/): IP68 RFID tags that snap onto or under grease nipples and give every grease point a unique ID. Rated to 200°C peak with chemical resistance.

## Case studies and field results

- [Case studies index](https://greaseboss.io/case-studies/): All published GreaseBoss field results across mining heavy mobile equipment, fixed plant and manufacturing.
- [Haul truck CAT 796AC kingpins](https://greaseboss.io/casestudy/haul-truck-cat-796ac-kingpins/): All four injectors were under-greasing CAT 796AC kingpins at $250k per failure. Monitoring identified the root cause, with an estimated $6M a year saved across the fleet.
- [Increasing haul truck availability across a Tier 1 fleet](https://greaseboss.io/casestudy/increasing-haul-truck-availability-across-a-tier-1-mining-haul-truck-fleet/): Flow monitoring found 35 of 40 haul trucks under-greased. Seven A-frame bearings were caught before failure, saving roughly $1.7M in six months.
- [Haul truck A-frame and pump monitoring](https://greaseboss.io/casestudy/haul-truck-a-frame-pump-monitoring/): Monitoring two haul trucks revealed five times the specified grease volume per cycle and erratic delivery to the A-frame bearing within five days.
- [Komatsu PC7000 hoist cylinder and bucket pin monitoring](https://greaseboss.io/casestudy/excavator-hoist-cylinder-and-bucket-pin-monitoring-komatsu-pc7000/): Flow monitoring exposed a faulty lube pump in four days, preventing over $10M in hoist cylinder and bucket pin failures.
- [Liebherr 9600 boom foot and hoist cylinder monitoring](https://greaseboss.io/casestudy/excavator-boom-foot-hoist-cylinder-monitoring-liebherr-9600/): Detected a bypassing injector on a Liebherr 9600 fleet, saving $70,000 a year and preventing asset downtime.
- [Eliminating AU$25m downtime at a Tier 1 gold mine](https://greaseboss.io/casestudy/eliminating-au25m-downtime-at-a-tier-1-gold-mining-company/): SAG mill monitoring found trunnion points at 12% of target volume, averting a failure worth $25M in lost production.
- [Eliminating sizer bearing failures at a Queensland coal mine](https://greaseboss.io/casestudy/casestudy-mining-sizer-bearing-failures/): A coal mine losing $10M every two months to sizer bearing failures ended them entirely with flow monitoring on 52 grease points.
- [Systemising manual greasing at Glencore Mangoola](https://greaseboss.io/casestudy/mangoola/): Visibility over contractor greasing on conveyors and motors, with new contractors on schedule within two weeks.
- [Cutting grease costs 74% at a North American feed manufacturer](https://greaseboss.io/casestudy/cutting-74-grease-costs-at-a-north-american-feed-manufacturer/): RFID-guided, flow-verified greasing on pellet mill rolls replaced operator judgement and cut grease spend 74% year on year.
- [Komatsu PC7000 at Batchfire](https://greaseboss.io/casestudy/komatsu-case-study/): How Batchfire's maintenance team verified grease delivery into the critical points of a Komatsu PC7000 excavator.

## Articles and technical resources

- [Articles](https://greaseboss.io/articles/): Whitepapers, published articles and practical guidance on grease delivery verification, auto-lube reliability and unplanned downtime in mining.
- [The Mobile Equipment Lubrication Handbook](https://greaseboss.io/2026/05/06/the-mobile-equipment-lubrication-handbook/): Handbook for superintendents covering the five common single-line injector failures and how to build a high impact greasing strategy.
- [Whitepaper: The Prevention Paradox](https://greaseboss.io/2026/06/29/how-do-you-prove-the-value-of-something-that-never-happened/): How to justify reliability technology when its value is failures that never happened, using two years of haul truck data.
- [Noria whitepaper: Monitoring Grease Delivery Where It Counts](https://greaseboss.io/2025/05/26/noria-whitepaper-monitoring-grease-delivery-where-it-counts/): Why auto-lube systems cannot confirm grease reached the pin, and how downstream monitoring closes the verification gap.
- [The Keys to Eliminating Unplanned Downtime](https://greaseboss.io/2025/05/15/the-keys-to-eliminating-unplanned-downtime/): What unplanned downtime costs, why incorrect greasing is a primary driver, and the maintenance strategies that reduce it.
- [Why automatic lubrication systems fail](https://greaseboss.io/2026/09/04/why-automatic-lubrication-systems-fail/): Common automatic lubrication system problems and the maintenance strategies that prevent costly downtime.
- [Manual greasing best practices for reliable equipment](https://greaseboss.io/2026/09/03/manual-greasing-best-practices-for-reliable-equipment/): Lubrication techniques that improve equipment reliability and longevity while reducing downtime.
- [How to build and optimise a lubrication route](https://greaseboss.io/2026/09/07/how-to-build-and-optimise-a-lubrication-route/): Turning equipment lubrication into a reliable, efficient, repeatable process.
- [How much grease does a bearing actually need?](https://greaseboss.io/2026/09/10/how-much-grease-does-a-bearing-actually-need/): Calculating the optimal grease volume for bearings to avoid over and under greasing.
- [Pioneering digital lubrication management for heavy industry](https://greaseboss.io/2025/05/15/pioneering-digital-lubrication-management-for-heavy-industry/): GreaseBoss CEO Tim Hall on the path from mechanical engineering to building digital lubrication management.
- [Fleet-scale ROI calculator](https://greaseboss.io/fleet-scale-roi-calculator/): Model avoided loss and payback from condition monitoring at fleet scale by entering fleet details and cost per failure.
- [The Prevention Paradox](https://greaseboss.io/the-prevention-paradox/): Two years of haul truck data on proving preventative maintenance value. One asset validates the technology, a fleet captures the value.
- [Frequently asked questions](https://greaseboss.io/frequently-asked-questions/): Connectivity, installation, onboarding and training, including options for remote sites without 4G coverage.

## Company

- [About GreaseBoss](https://greaseboss.io/about-us/): Y Combinator alumni and global pioneers in digital lubrication management, working with Tier 1 operations across more than 15 countries.
- [Contact](https://greaseboss.io/contact/): Enquiries, trials and site assessments. Phone +61 7 3186 0203, email sales@greaseboss.com.au, office 6/1 Metier Linkway, Birtinya QLD 4575, Australia.
- [Book a demo](https://greaseboss.io/book-a-demo/): Book a call with a GreaseBoss expert, tailored to your site, equipment and lubrication challenges.
- [Distributors](https://greaseboss.io/distributors/): Find a GreaseBoss distributor, or enquire about becoming a certified distributor.

## Optional

- [Videos](https://greaseboss.io/videos/): Case study videos and system applications across fixed plant and heavy mobile equipment.
- [Patent information](https://greaseboss.io/2025/09/26/patent-information/)
- [Privacy policy](https://greaseboss.io/privacy-policy/)