Off-line filter - high-speed transfer press
Viscous oil and machine downtimes? Off-line filters can avoid and prevent machine downtimes!
Project/Customer
SILGAN METAL PACKAGING MEISSEN GMBH is a leading European manufacturer of metal packaging for the food, chemical, fish and decorative sectors. Some of these products are manufactured on high-speed presses at one-second intervals. To ensure that the guides of the punching and forming tools, for example, are optimally lubricated, a viscous oil (Bremer & Leguil Rivolta F.L. 500 500 c St.) is fed from an open reservoir to the individual lubrication points via very finely adjustable valves. Due to the process, a large number of small and sometimes large particles are introduced into the hydraulic/lubrication circuit. These cannot be filtered out 100% by the existing filtration system. In the past, machine downtimes have repeatedly occurred due to clogged and defective lubrication valves. To reduce this type of machine downtime, the customer was looking for a suitable off-line filter.
Procedure
After discussing the initial details on the phone, we made an appointment on site. After inspecting the system, we took an oil sample and analyzed it with our partner Oelcheck. The purity class of the oil was not suitable for use in conjunction with the fine lubrication valves. It can be assumed that this cleanliness class (25/22/14) could lead to further machine downtimes.
As the general overhaul was due at the end of the year, we decided to take another oil sample at this time and install the Greenoil bypass filter system WP1-P1-100 with a 5µm filter element.
Result
After overhauling and cleaning the machine, a significant improvement in oil quality has already been achieved (17/16/13). Particular attention should be paid to the particle sizes 21µm, 38µm and 70µm. These were presumably introduced during the overhaul and the number of these particles was significantly higher than during the first sampling.
After just 3 months, we were able to improve the purity of the oil to 16/14/11 in accordance with ISO 4406. The filter system will be in continuous operation (24/7) in future. We will support the customer with further oil samples and continue to monitor the process.
Good to know…
In projects where oil cleanliness is involved, it is particularly important to know what type of contamination is being discussed and in which range of cleanliness classes you are currently in and/or whether there are any other issues that need to be taken into account. It is therefore essential for us to demonstrate this with oil samples in order to select a suitable off-line filter on this basis and to record and monitor its success in the course of further customer and system support.
The costs of the bypass filter and the associated installation are amortized within the first 1-2 years as a machine standstill can very quickly become very expensive!