MEGAlife Maintenance-Free Roller & Conveyor Chains

Less Lubricant. Longer Service Life. Reduced Maintenance.

MEGAlife maintenance-free roller and conveyor chains are designed for applications where long service life and reduced maintenance requirements are important. Their special joint design enables operation, when used as intended and within the specified operating limits, without scheduled relubrication of the chain joint during the intended service life.

At iwis, “maintenance-free” means that no scheduled relubrication of the chain
joint is required during the intended service life, provided the chain is used as
intended and within the specified operating limits.
However, inspections and other maintenance measures, as well as wear-related replacement, are still required.

Compared with standard chains that require regular relubrication, this can significantly reduce the amount of lubricant required. At least 75% lower lubricant requirement under comparable operating conditions.* The dry chain surface can also help reduce the risk of contamination caused by escaping chain lubricant.

Coated individual components provide additional corrosion protection. Suitability for corrosive environments depends on the MEGAlife version and the respective operating conditions. MEGAlife II is not suitable for corrosive environments.

Design of the MEGAlife Roller Chain

High wear resistance and low maintenance requirements are important criteria for high-performance drive and conveyor chains. MEGAlife chains have been specially developed for applications where additional relubrication is not possible or is only possible to a limited extent. The combination of high-performance sintered bushings, wear-optimised pins and coated individual components reduces friction and wear in the chain joint.

Under the intended operating conditions, no additional relubrication is required. This can significantly reduce maintenance requirements compared with standard chains that require regular relubrication. Depending on the application and operating conditions, MEGAlife chains are supplied dry or with a defined initial lubrication.

Oil-impregnated high-performance sintered bushings
Pins ML-1: Wear-resistant and friction-optimised pin surface
Seamless rollers with corrosion-protected surface and optimised geometry

To the interactive chain graphic

MEGAlife – Your Benefits in Operation

Depending on the application and operating conditions, maintenance-free MEGAlife chains can achieve a service life up to three times longer than standard roller chains. Combined with the reduced need for relubrication, longer operating and replacement intervals can help reduce maintenance requirements and maintenance-related downtime. Over the service life, this can also have a positive impact on operating costs.

Key Benefits at a Glance

Up to three times longer service life* compared with standard roller chains – depending on the application and operating conditions
Reduced lubricant requirements: under comparable operating conditions, less than 25% of the lubricant quantity required for standard chains that need regular relubrication
No scheduled relubrication of the chain joint required during the intended service life*
Depending on the application and operating conditions, MEGAlife chains are available with a dry outer surface or with a defined initial lubrication.
Improved corrosion protection through coated individual components
Low maintenance requirements and potentially longer replacement intervals

*Provided the chain is used as intended and within the specified operating limits. Inspections, other maintenance activities and wear-related replacement remain necessary.

MEGAlife I and II: The Right Version for Your Application

MEGAlife is available in two versions tailored to different application requirements: MEGAlife I for versatile chain applications with low maintenance requirements and MEGAlife II for high-speed chain drives and applications with high loads.

MEGAlife I: MEGAlife I – Up to 3 m/s

Suitable for chain applications without additional relubrication at speeds of up to 3 m/s*
No additional relubrication required under defined operating conditions
Easy to disassemble – “easy break”
Reduced lubricant requirements due to the low quantity of lubricant required
For corrosive environmental conditions, additional initial lubrication is recommended
Compatible with iwis standard conveyor chains through the use of the same original iwis attachments
Available in a wide range of versions, including transfer chains, accumulation chains and grip chains, as well as other configurations

* Operating limits and suitability depend on the respective operating and application conditions.

MEGAlife II: High Speeds and Loads

Developed for high-speed chain drives with v > 3 m/s and/or high loads
No additional relubrication required under defined operating conditions
High wear resistance due to a special thermochemical treatment of the pins for high surface hardness
Designed for long operating periods and low maintenance requirements
Matched pins and sintered bushings for optimised wear behaviour
Not suitable for corrosive environmental conditions
Particularly suitable for use as a drive chain
Developed for demanding applications with high requirements for speed and load capacity

MEGAlife I vs. MEGAlife II

Feature	MEGAlife I	MEGAlife II
Chain speed	Up to 3 m/s*	> 3 m/s and/or high loads
Relubrication	No scheduled relubrication under defined conditions	No scheduled relubrication under defined conditions
Corrosive environments	Initial lubrication recommended	Not suitable
Typical focus	Versatile drive and conveyor applications	High-speed and high-load drive applications
Versions	Transfer, accumulation and grip chains, among others	Particularly suitable as drive chain

Technical Performance

MEGAlife – Developed for Long Operating Periods and Low Maintenance Requirements

MEGAlife chains are characterised by high fatigue and breaking strength as well as optimised wear behaviour. Thanks to their high precision and load capacity, they are suitable for a wide range of demanding drive and conveyor applications. Under the intended operating conditions, no additional relubrication is required over the intended product life cycle. The chains are designed for operating temperatures from –40 °C to +150 °C.

The technical properties are achieved through the interaction of high-performance sintered bushings, wear-resistant pins and specially coated components. The matched components reduce friction and wear in the chain joint and help keep wear elongation low over long operating periods. As a result, maintenance requirements can be reduced compared with standard roller chains – depending on the application and operating conditions.

Optimised wear behaviour – even at high speeds
High fatigue and breaking strength
Precise parallel and synchronous running
High positioning accuracy
High corrosion protection through coated individual components
Easy disassembly

Wide Range of Applications and Industries

MEGAlife maintenance-free roller and conveyor chains are particularly suitable for industrial applications where scheduled relubrication is difficult, undesirable or only possible to a limited extent. Typical applications can be found in the packaging and food industries, conveyor technology, printing and paper processing, textile machinery, electronics and PCB manufacturing, wood, glass and ceramics processing, as well as medical technology.

Their dry outer surface, high wear resistance and reduced relubrication requirements make MEGAlife chains particularly suitable for systems with difficult maintenance access, high cleanliness requirements or long operating intervals.

The special joint design enables operation without additional relubrication under the intended operating conditions. Combined with their optimised wear behaviour, MEGAlife chains can help reduce maintenance requirements and maintenance-related downtime as well as extend replacement intervals. As a result, ongoing operating costs can also be reduced – depending on the application and operating conditions.

To the MEGAlife product catalog