Case Study
Dirty Oil Filtration Solution for Old Molding Machines
Location: North India
Product Installed: R- SERIES
Application Background
An established manufacturing company specializing in plastic components faced significant challenges with an aging molding machine. The machine had been in operation for over 15 years and was experiencing problems due to dirty hydraulic oil, which was affecting its performance and leading to increased maintenance costs.
Challenges
The main challenges included:
- Contaminated Oil: The hydraulic oil was contaminated with particles and moisture, resulting in poor lubrication and increased wear on components.
- Frequent Downtime: The machine required regular maintenance and repairs, leading to unplanned downtime and decreased productivity.
- Rising Operational Costs: The costs associated with oil replacement and machine repairs were becoming unsustainable.
Objectives
The goal was to implement an effective dirty oil filtration solution to:
- Restore the hydraulic oil quality.
- Reduce maintenance and operational costs.
- Improve overall machine efficiency.
Cost Savings
The filtration solution resulted in:
- 30% Reduction in Oil Replacement Costs: Cleaner oil meant less frequent replacements.
Decreased - Maintenance Costs: Fewer breakdowns and repairs led to lower overall maintenance expenses.
- Higher Productivity: The machine’s uptime improved, resulting in increased production output
Solution Implementation
Step 1: Initial Assessment:
A thorough Destiny assessment of the hydraulic system was conducted to identify the contamination levels and the type of particles present. The analysis revealed high levels of particulate matter and moisture in the oil
Step 2: Selecting Destiny’ Ultra-fine Oil Filtration Technology
Step 3: Installation
The new filtration system was installed with minimal disruption to production. The installation process included:
Integration with the existing hydraulic system to ensure seamless operation.
Calibration of the system to optimize filtration efficiency.
Staff training on how to operate and maintain the new equipment
Step 4: Monitoring and Maintenance
Regular monitoring of the oil quality was established, along with a maintenance schedule for the filtration system to ensure ongoing performance.
Results
Improved Oil Quality
Post-implementation testing indicated a significant reduction in oil contaminants. The oil cleanliness levels improved from ISO 24/22/18 to ISO 16/14/11, greatly enhancing lubrication properties.
Increased Machine Efficiency
The improved oil quality led to several benefits, including:
Reduced Wear: Components experienced less friction and wear, prolonging their lifespan.
Enhanced Performance: The machine operated more smoothly, with faster response times.
Recommendation
- Routine Maintenance: Establish a regular maintenance schedule for all machinery.
- Ultra-Fine Filtration Systems: Consider modern filtration solutions for aging equipment to enhance performance.
- Staff Training: Provide ongoing training for staff on equipment care and maintenance protocols.
Conclusion
The destiny’s oil filtration solution implemented for the old molding machine successfully addressed contamination issues, leading to improved operational efficiency and significant cost savings.
Extend the life of your old molding machines with our advanced Oil Filtration Solution, specifically engineered for legacy systems like Husky, Engel, Nissei, and other similar brands. Over time, hydraulic oil in older injection molding machines accumulates contaminants, leading to reduced efficiency, increased wear, and unexpected downtime. Our specialized filtration solution removes sludge, varnish, metal particles, and water, restoring oil cleanliness to ISO standards and improving overall machine performance.
Whether you’re running a small operation or a high-volume plant, our Oil Filtration Solution offers a cost-effective, maintenance-friendly way to protect your investment and avoid costly repairs or component replacements. Ideal for aging machines that still have productive life left but require cleaner oil to perform reliably.
If your organization is facing similar challenges with hydraulic systems or aging machinery, contact us for a consultation. We can help identify tailored solutions to optimize your operations and reduce costs.