Project Description

Hydraulic Oil Care | Sand-Lime Brick Press

Application Study

System

Sand-lime brick press type 1200 J
Manufacturer: Dorstener Maschinenfabrik
Oil volume / type: approx. 3,800 Litres, SRS Wiolan HLP-D 46

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.

Sand-lime brick press with CJC offline filter
Sand-lime brick press, particle input, hydraulic oil maintenance

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 fibers (cellulose)
Filtration degree:3 μm absolute, 1 μm nominal
Dirt holding capacity: up to 24 kg
Water absorption capacity: > 1.8 l

Light metal casting, die casting machines

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.

Improving the CO2 balance

Further advantages:

Longer oil change intervals lead to high savings and, at the same time, protect the environment and resources:

  • less fresh oil
  • less waste oil and CO2
    approx. 9,880 kg per saved oil change and sand-lime brick press *)
*) The thermal disposal of waste oil produces approx. 2.6 kg of CO2 per 1 litre.

Oil analysis

Particle content according to ISO 4406
Number of particles in 100 ml oil

Particle content, ISO 4406, Maintain hydraulic oil, Sand-lime brick press
Fine filtration with CJC® Offline Filter
Zero sample Oil Sample No. 1 Oil Sample No. 2 Oil Sample No. 3 Oil Sample No. 4 Oil Sample No. 5
Particles
> 4 μm
13.8 million 9.7 million 6.7 million 2.7 million 387.122 95.238
ISO Code
4406 *)
24/22/13 24/20/12 23/18/14 22/15/11 19/17/14 17/16/3

*) Information on the determination of cleanliness classes available on request.

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Download Application study
Maintaining hydraulic oil, sand-lime brick presses