A Proactive Reliability Strategy for a 1,000-Gallon Hydraulic System
The Challenge
A plastic injection molding facility was managing a serious varnish problem within a 1,100-gallon hydraulic system. Initial laboratory testing returned an MPC value of 72.6, placing the oil well into the critical range.
Because of the system’s size, the objective extended beyond improving a single laboratory result. The customer needed a sustainable approach that could continuously remove varnish and contamination while providing ongoing visibility into lubricant condition.
The Solution
Kimbro installed a Delta Xero system with 0.1-micron filtration to continuously treat the hydraulic oil while the equipment remained in operation.
Kimbro’s in-house laboratory then tracked the system over time using MPC testing, particle counts and viscosity measurements. This ongoing analysis allowed the team to document progress, evaluate the system’s response and support a more proactive approach to lubricant management.
The Results
Laboratory data showed consistent improvement throughout the treatment period:
- MPC declined from 72.6 to 17.9
- Varnish potential was reduced by 75%
- Particles greater than four microns declined by 99.8%
- Particle concentration fell from 535,889 to 1,299 particles per 100 mL
- The final oil sample achieved an ISO cleanliness code of 17/15/11
- Viscosity remained consistent throughout treatment
The Impact
The customer gained more than a cleaner hydraulic system. By combining continuous filtration with ongoing laboratory monitoring, the facility established a proactive strategy for managing lubricant health over time.
Rather than waiting for varnish and contamination to contribute to equipment problems, the customer can continuously manage oil condition and use laboratory data to identify changes early. The result is greater visibility, cleaner oil and a stronger foundation for long-term equipment reliability.
75% reduction in MPC. 99.8% reduction in particles greater than four microns. A proactive approach to long-term reliability.
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