Hydraulic oil maintenance | Sand-lime brick presses

System

Sand-lime brick press type 1200 J

Manufacturer: Dorstener Maschinenfabrik
Oil volume/type: approx. 3,800 liters of SRS Wiolan HLP-D 46 hydraulic oil

Challenge

During the processing of the sand-lime bricks, large quantities of extremely fine particles are produced, which enter the oil system from the environment and contaminate it. With a cleanliness class of 24/22/19 (according to ISO 4406), the oil did not correspond to the purity classes from 20/18/15 (main valve) to 17/15/12 (pilot valve) required by the manufacturer (manufacturer: Bosch Rexroth) for the highly sensitive valve technology of the hydraulic system. Massive jamming, various failures in the proportional valves, and frequent changes in the pressure and cooler filter led to increased maintenance costs and numerous production losses. Despite oil change and filtration of the entire oil volume, as well as installing a new return filter with a filtration degree of 3 μm, the oil was contaminated again within 6 months. The problems with the proportional valves and the short filter life increased again.

Solution

CJC® Offline Filter 27/54 with integrated depth filter insert for continuous oil care in an offline circuit (24/7).

Filter material: 100% natural fibres
Filtration degree:3 μm absolute, 1 μm nominal
Dirt holding capacity: up to 24 kg
Water absorption capacity: > 1.8 l

Result

Despite the immense and permanent dirt input – among other things, due to a severe leak on a hydraulic cylinder – the CJC® Offline Filter reduced the particle content quickly. The content of particles > 4 μm decreased by a total of 99.31%.
Result of significant improvement in oil purity:

• Pressure and return filters (cooler):
  The filter life of both main flow filters has been extended from 2 to 4 to 6 weeks.
  Savings per half-year: approx. 2,250 EUR
• Proportional valves:
  The valve technology works reliably, with no clamping valves. Unplanned downtimes and production losses are avoided.
• Oil purity:
  The oil does not need to be changed again.
  Savings: approx. 3,800 EUR (1 EUR/litre)
  The service life of oil and components is expected to be extended by 3 to 7 times (Source: Noria Corporation)

Due to the convincing results and the high savings potential, the remaining two sand-lime brick presses will also be equipped with CJC® Offline Filters. The payback period of the CJC® Offline Filter is less than one year.

Oil analysis