Electrostatic hydraulic oil filtration in injection molding operationsReduction of hydraulic faults by means of electrostatic oil cleaning
In the main plant of a medium-sized plastics processing company, it was sought to reduce the costs for changing hydraulic oil on the injection molding machines. After consulting with the oil supplier, a trial was initially started with inexpensive used oil. As the origin of the oil could not be traced in all cases and the oil treatment was unclear, this approach was not pursued further.
Problem:
Despite regular oil changes, hydraulic faults occurred approximately twice a year (pump failure or valve defect).
Due to the malfunctions that occurred, no savings could be made in the operation of the injection molding machines. Instead, more and more money was spent on repairs and oil changes.
Solution: FRIESS EFR hydraulic oil filter
In November 2003, a trial was started with the FRIESS EFC electrostatic hydraulic filter model D8. The first successes were achieved after a very short cleaning time. Maintenance staff and machine operators unanimously reported that the injection molding machines ran more quietly and smoothly after about 1/3 of the planned cleaning time.
The oil sample analyses at the end of the cleaning time confirmed these statements and showed excellent cleanliness codes between NAS 3 and NAS 5.
The convenient menu-guided user interface greatly simplified the commissioning of the oil cleaning system.
The data of the individual injection molding machines, such as oil type and oil volume, were already programmed before commissioning. After connecting the hydraulic hoses, only the machine number was called up on the display.
As the oil type and oil volume are stored in the control system, the cleaning time is automatically calculated and displayed. This means that the operator immediately knows when cleaning on the respective machine is complete and the EFC hydraulic oil filter can be moved to the next injection molding machine.
This meant that various machines could be cleaned straight away and the good results were repeated.
Result:
In the first year after the introduction of the electrostatic hydraulic oil filters, the number of hydraulic faults was reduced from two to zero. The consumption of machine filters was reduced by 75 %.
No more oil changes have been carried out since the introduction of electrostatic oil cleaning. Only leaks have been replaced.
The oil analyses carried out on all machines showed perfect values within the tolerances specified by the manufacturer with excellent oil cleanliness.
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- Previously, the oil had to be changed after a few months. After the introduction of FRIESS electrostatic oil cleaning, the service life is now several years.
- Consumption of machine filters has been reduced by 75%.
- No more hydraulic faults.