Manufacturing

Effective filtration of industrial manufacturing fluids is critical to facility operations and product quality. OEI designs magnetic filtration solutions optimized for CNC machining, parts washing, hydraulics, process water systems and engines.

Feature Case Study

ROI: Eliminated Valve Failures

Annual Cost Savings of $25,200

Company
Ingresoll

Location
Calgary, Ab Canada / 2013

Equipment:
Rand High Pressure Air Compressor

Application:
Lube Oil

Challenge:
Moisture in the air system was causing corrosion
of the carbon-steel piping was producing high levels of contamination in the system.
The contamination was prematurely damaging the solenoid valve rubber seals. The damage forced the valves to remain open resulting in the need to replace them monthly. The valve failures were inhibiting production. In an effort to reduce unscheduled downtime and the monthly expense of replacing the valves, the maintenance team removed them all together.

Solution:
Install an OEI magnetic filter y-strainer before the solenoid valves to remove the sub-micron wear particles that were damaging the seals.

Result:

The photo shows contamination removed from the system after two weeks. The air flow is now clean, and the valves were re-installed. A similar amount of contamination is removed every three weeks during cleaning. If left in the system, these contaminants would continue to cause premature valve failure.

The annual savings realized from eliminating the replacement of 3 valves each month ($700/valve) can be equated to $25,000. This does not include the cost savings realized from preventing unscheduled downtime.


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Manufacturing

RESULTS

Gildermiester Milling Machine Cooling Fluid Filtration

The challenge was to prevent metal filings from filling the cooling system to avoid overheating and shutdown. The traditional filtration in the Gildermeister machine’s cooling system was not providing effective filtration and, therefore, the machine’s radiator was filling with metal filings. As a result, the machine was running at temperatures from 32-34 degrees Celsius (shut down would occur at 35 degrees). This was causing frequent unscheduled downtime for cooling system maintenance.

Lube Oil Reservoir Filtration

The challenge was to improve the Mobil 220 lube oil cleanliness to prevent unscheduled downtime and extend equipment life.

Ariston Parts Washer Quality Control

The challenge was to reduce contamination in the parts washing fluid to meet quality control cleanliness levels for painting.

Finishing Line Pneumatic Control Valve Protection

The challenge was to reduce downtime due to pneumatic control valves failing every four to six weeks. This is a common occurrence in pneumatic systems due to pressurized air producing wear contamination under 10 microns. Rust and slag are also produced in pressurized air environments which results in the plugging off of seals and pneumatic system components.

Ingressol High-Pressure Air Compressor

Moisture in the air system was causing corrosion of the carbon-steel piping was producing high levels of contamination in the system. The contamination was prematurely damaging the solenoid valve rubber seals. The damage forced the valves to remain open resulting in the need to replace them monthly. The valve failures were inhibiting production. In an effort to reduce unscheduled downtime and the monthly expense of replacing the valves, the maintenance team removed them all together.

Improving SACMIs Cooling Cutting Fluid with Quality Filtration

The challenge was to clean cooling/cutting oil contaminated with wear particles, to prevent wear on system components. 

Improving Cleaning Capability of Linermar’s Hotsy Parts Washer

The challenge was to reduce fine ferrous contamination, under 10 microns in size, which was missed by 40 micron nominal filter bag. Linemar’s specifications for parts cleanliness were not met, and the secondary washer was considered. 

Husky’s Injection Molding System Protection

The traditional drum filtration system was ineffective in filtering the cooling/cutting fluid thereby reducing the fluid’s operational life. The contaminated fluid caused premature wear  on the cutting dies, decreasing the system pump life. The challenge was to remove ferrous contaminant from the fluids to submicron particle levels. 

Improving Linex Parts Washer Cleanliness

The challenge was to remove ferrous contamination from the washing fluid because products were consistently rejected due to lack of cleanliness, even though the parts are passed through three washing systems. 

Evraz Coolant Flush Water Mechanical Seals

The mill pump flush water was not adequately filtered; wear contamination in the system was causing premature failure of mechanical seals.

Mitsuboshi Belting Calendaring Hot Water System

The challenge was to improve water quality to sustain consistent heating of the calendar roll’s internal chamber to ensure quality rubber for transmission belt production.
Corrosion in the hot water pipes was causing inconsistent heat transfer within the calendar roll’s internal chamber. The uneven temperature on the surface was causing poor quality rubber profile and finishing of the manufactured transmission belts.

OEI magnetic filters are designed for 95+% efficiency: they are optimized for fluid viscosity, flow volume, flow rate, temperature, mobility, and mounting requirements.

Use of the OEI Data Form will provide the necessary specifications for OEI to
determine which product is right for you.

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