Manufacturing Case Studies

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Gearbox


INEOS: Flender Gearbox Filtration

Problem:

INEOS workers discovered large amounts of ferrous contaminants in the lube oil of the Flender gearboxes at the Chemical Plant. This ferrous contamination from the lube oil can cause premature wear and component failure in the gearboxes.

Results After OEI Filtration:

There was a significant (over 50%) reduction of FE in the lube oil over the tested period. The more contaminants that were removed, the longer the service hours of the lubricant lasted for gearboxes.

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West Fraser Sawmills: Wagner Log Loader (3408 CAT Engine)

Problem:

After an oil analysis, the company’s 3408 engine was diagnosed needing an engine rebuild. This was due to excessive contamination in the lube oil. Traditional filtration is unable to remove this contamination causing premature component failure.

Results After OEI Filtration:

The engine rebuild was cancelled! The ADD-Vantage 9000 removed the wear contamination to sub-micron levels and significantly reduced the wear cycle. “The amount of both non-ferrous and ferrous wear contamination the ADD-Vantage 9000 filter took out was amazing.” states Pat Napier. The original engine is still in service after 20 months running two shifts per day with no engine issues.

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Division of ThyssenKrupp: Steel Mill hydraulic filtration

Problem:

Traditional filtration failed to maintain hydraulic fluid ISO cleanliness levels. Failure to do so, resulted in premature wear of the hydraulic system components, which caused production loss and unnecessary maintenance costs.

Results After OEI Filtration:

After 5 days, the Magnetic Filter Rod was inspected and a substantial amount of ferrous material was removed. “These are huge INNSE milling machines that are very old. After this result we will be putting Scrubbers on a number of our machines,” stated an SDF Engineer.

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Hydraulic and Pneumatic


PT. Tjiwi Kimia Pulp & Paper Mill: Hydraulic Pump

Problem:
The slurry pump and its components have been subject to premature wear due to excessive amount of bale wire contaminating the pulp slurry mix. The current magnetic filtration system was unable to remove the majority of this wire.
Result After OEI Filtration:

A significant amount of ferrous wire contamination was captured by the OEI magnetic filter rod in the pulp slurry mixture after only eight hours in operation. The production manager has since requested OEI magnetic filter rods to replace magnetic filtration systems to help protect the integrity of the equipment in other areas of the plant.

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Medisystems Europe SPA: Hydraulic Oil Filtration for Hydrualic Pumps

Problem:

Premature failing of pump components due to the high level of ferrous contamination were unable to collect. To complete the production run they would have to leave the failing pump in service. The OEM filters would not allow them to maintain production because they were unable to remove the large volume of fine wear contamination.

Result After OEI Filtration:

They were able to complete the production run without shutting down or replacing the pump. “Without the ADD-Vantage 9000 protecting the pump and the hydraulic oil, there would have surely been a catastrophic failure and high expenses in lost production”. – Alex Priori

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Select Packaging: Air Compressor Filtration

Problem:

High levels of ferrous contamination resulting from corrosion on the carbon steel piping due to moisture in the air system. Traditional filtration was unable to remove below 30 microns. This contamination was prematurely damaging the rubber seats of their solenoid valves and forcing them to remain open to a point where they were replacing them on a monthly basis. This became costly causing them to remove the valves, reducing the efficiency of the system and causing unplanned downtime.

 

Results After OEI Filtration:

The air flow now clean and the valves arere-installed in the system. A similar amount of contamination is removed every three weeks during cleaning.
After 6 months, the savings realized from eliminating valve replacement (3 x $700/per month) can be equated to $25,200/year. The savings of increased up-time are not included.

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Coolant and Water


Mituboshi Belting: Hot Water Filtration of Calendaring System

Problem:

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.

Results After OEI Filtration:

A higher level of cleanliness of the water has resulted in more uniform flow and heat transfer within the calendaring system.
Benefits: Reduced need for chemical flushing, higher quality of finished product, and increased reliability and uptime.

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Linamar: Parts Washer Filtration

Problem:

Products were being rejected due to high un-cleanliness level, even though the parts are passed through three washing systems.

Results After OEI Filtration:

“It is amazing how much contamination was taken out of the system. Before the unit was installed the milligrams was 22 on the patch and now they implemented the OEI Magnetic scrubber unit it reduced the milligrams to 9 on the patch. Less than half of what it was,” stated Linex Engineer Supervisor. Since installing the OEI scrubber we have extended the element life from every 3 weeks to over 2 months and have eliminated product rejection due to cleanliness.

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Indorama: High Heat Transfer Fluid

Problem:

Indorama faced excessive downtime periods due to leaks caused by the premature wear of gaskets, pump packing/seals and piping, caused by fine metal contamination created by corrosion and erosion of the carbon steel piping. Traditional strainer screens are unable to filter out the metal contamination because traditional filtration media is unable to operate at such high temperatures.

Results After OEI Filtration:

The test proved successful as the OEI Magnetic Filter Rod reduced the high levels of ferrous contamination in the system to below required lab levels. The downtime associated with the premature wear of the pipe and components has been reduced over 60%, and the clean transfer fluid is now able to operate at optimum ability. The Magnetic Filter Rods are still operating today at full field strength.

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Food


Mayora Indah: Candy Manufacturer Filtration

Problem:

High levels of finished product being rejected due to ferrous contamination.

Result After OEI Filtration:

“Since installing the OEI Magnetic Filter our product rejection from metal contamination has been reduced considerably. Our product quality and production has increased significantly. We have installed 6 more Magnetic Filter Rods and are very appreciative of your product,” factory engineer.

OEI Magnetic Filters are also installed to clean product purchased from other vendors. This helps quality control with inspections.

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Mayora Indah: Cookie Manufacturer Filtration

Problem:

Concern with the quality of base chocolate ingredients related to an increase in product rejection due to metal contamination.

Result After OEI Filtration:

After viewing the results from this funnel scrubber company officials have stated, “We will continue to install OEI magnetic filters in all production processes throughout our facility.” Removing these contaminants from the product will increase the quality and insure production values are increased.

Photo B shows the contamination collected after one week of operation on all three magnetic filters.

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Bonduelle: Fresh Produce Conveyor Belt Filtration

Problem:

Fresh produce (beans) are transported along the conveyor to the canning or freezing processes. Traditional ceramic magnetic filtration was unable to effectively remove ferrous contamination such nails and wire, as well as non-ferrous contamination causing production losses.

Result After OEI Filtration:

After a year and a half in service Bonduelle’s Quality Control Manager is very pleased at the results derived from the OEI Magnetic Filter. Some of the retained contamination can be seen in their report in Photo B.

Bonduelle is expanding the implementation of OEI’s Magnetic Filtration technology throughout their plant.

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Coal Powered Boiler Filtration at Coffee Plant

Problem:

Excessive amounts of ferrous metal contamination ranging from microscopic particles to steel, wire, nails, etc., were found in the furnace of the coal powered boiler unit. This contamination was degrading the quality of the coal utilized in the furnace by breaking it apart. It also resulted in lost time due to costly unscheduled maintenance and repairs to the furnace.

Result After OEI Filtration:

Utility Manager Mr. Satrio Aji was very impressed with the results of the OEI magnetic filter rod. Since employing OEI’s technology, they have experienced an improvement with the quality of the coal, fewer unscheduled downtimes and a cost savings in maintenance and repairs.

Photo A shows the substantial amount of ferrous contamination captured by OEI’s magnetic filter rod after only one week in operation.

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Tobacco Processing Plant Product Quality Enhanced

Problem:

Excessive amounts of ferrous metal contamination found in the tobacco processing plant after the conventional magnetic filter system failed to remove the contamination to meet standards.

Result After OEI Filtration:

Jimmy, the Maintenance Manager, was so impressed with how the OEI Magnetic Filter Rod outperformed their conventional magnetic bar system, that they have now completely replaced their old filtration system with OEI’s Magnetic Filter Rods.

Photo A shows the substantial amount of ferrous and non-ferrous (by static adhesion) contamination captured by OEI’s magnetic filter rod after only one week in operation.

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Magnetic Funnel Scrubbers in Operation for over 10+ Years

Problem:

In May of 2005, Pinnacle Foods’ (formerly Dial Corporation) food processing facility in Fort Madison, Iowa installed One Eye Industries’ Magnetic Funnel Scrubbers on a trial basis in their facility. The units were installed on two multi-product lines (3” & 4”) having many different product densities and viscosities along with varied particulate sizes.

Result After OEI Filtration:

“Almost 5 years after installing the OEI Magnetic Funnel Scrubbers I am pleased to state they are still in operation with the original magnetic filters. They are tested on a regular schedule and have not lost any strength. OEI’s magnetic filters have lived up to their claims and as we update our facility OEI products will be installed”

– Bill Thomas, Maintenance Team Manager, Pinnacle Foods.

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