Case Studies
Save up to 70% of the Cost of New Oil
A plastics processor in Pennsylvania was using about 2,000 gallons per month of hydraulic oil.
The oil leaked out of the machines and was soaked up with oil dry then disposed of. The new oil was costing the customer over $4.00 per gallon.
We installed combination waste oil storage and purified oil tank. The oil recovery was over 95 percent effective, the savings on Oil Purchases alone were over 60 percent. The elimination of disposal costs is a bonus.
A North Carolina plastic injection molder was using over 5,000 gallons per month of hydraulic oil. The machines leaked badly, all over the plant floor! Two janitors worked full time soaking up the spills with oil dry, and then shoveling the mess into disposal bins.
We worked with the client and showed him ways to contain the spills easily and channel them to in floor sumps. We helped him design a special “wet vac” that would hold 100 gallons, but was still portable enough to move easily around the plant. We re-designed his waste oil storage and provided a 14,000 gallon split storage tank to hold both the dirty oil and the clean oil after it was purified.
The customer ended up with a plant they were proud of. The workers moral is high; the working environment is cleaner and easy to keep clean.
The company is saving almost 100 percent of the oil they use; the disposal bills have gone from a NIGHTMARE to almost nothing. They are saving over $150,000.00 per year in DIRECT SAVINGS.
A plastic processor in the Carolinas was having a severe maintenance problem. The hydraulic pumps in his new machines were wearing out at a tremendous rate and he was also having serious problems with control valves.
We analyzed the oil in his machines and determined that although he was using the filters recommended by the machine manufacturer, the oil was extremely dirty. The dirt and silt levels in the machines were running up to 100 times dirtier than normal. The oil looked visually clear, not dirty.
We instituted a clean up schedule for the machines, we purified all the oil in each machine by hooking up to the reservoir while the machine was operating normally and flushed the oil through our equipment at over 1,000 gallons per hour until all the oil was clean and dry. The worn out and depleted additives were restored at the same time.
The cost for this was LESS than 50 percent of the cost of new oil. There was NO DOWNTIME.
This customer is now on a “preventative maintenance schedule”, where every three months we sample each machine and based on the results, schedule oil purification as needed.
The maintenance cost reported to us by this customer dropped from over $10,000.00 per month, to less than $1,000.00 per month.
A medium sized company in Ontario was faced with a mountain of waste oil drums behind his plant. The Ministry of the Environment was threatening legal action because of the volume of waste oil on the plant site.
We installed storage tanks and processed all the oil from the drums into clean oil storage within three weeks. They now have NO regulatory problems and are saving over 65% of the previous cost of the new oil.
A large heat treating company in Ontario was having trouble disposing of the alkaline cleaning solution off its parts washers. We installed a pre-treatment system that extracted most of the oil from the alkaline solution.
The separated oil is purified by us and returned as quench oil, most of the alkaline cleaner solution is returned to the washers as make up fluid. DOUBLE SAVINGS!
An automotive parts manufacturer in New York State was paying almost $1.00 per gallon to dispose of light metalworking oil from a stamping operation. The volume was in excess of 5,000 gallons per month.
We are purifying the oil on-site and refurbishing the additives for slightly more than just the old disposal cost. The new oil costs in excess of $6.75 per gallon, the savings are well in excess of $200,000.00 per year.
A large automotive parts manufacturer in Ontario had a very expensive computer operated forming press making parts for an assembly plant 200 miles away. This was a “Just In Time” operation working on an 8-hour lead-time.
A Mechanic accidentally dropped a rag into the oil reservoir; it was sucked into the pumps, which shredded it. The rag fragments kept jamming the servo valves and shutting the press down. The machine had a 2,000-gallon oil reservoir.
Our truck arrived three hours after the accident and hooked up immediately. We recirculated the oil through our equipment at over 1,000 gallons per hour for four hours before the machine was restarted.
It ran successfully. We remained hooked up for 24 hours; at which time it was determined that we had removed ALL TRACES of rag fragments from the oil.
This customer was so happy with the performance of our unit that they instituted annual purification of the oil--they have not replaced the oil in this machine for over three years now!
A rubber processor in Ohio was getting water contamination in a very heavy-duty gear reducer driving some extruders. They were concerned that the water would damage the seals on the shafts. Nobody could understand where the water was getting into the reservoir. The machines could not be shut down because of production requirements. The extruders ran a two-shift operation seven days per week.
We cleaned and dried the reservoir twice and were finally asked to come into the plant and try to find out why and how it was being re-contaminated after it happened a third time.
We observed the operation for 24 hours and found that on the midnight shift, the cleaner who worked in this area had the maintenance department electrician reverse the drive on an exhaust fan so that it blew cold roof air into the basement where he worked. The cold air was directed right on to the oil reservoir. The oil cooled rapidly, sucked moist air into the reservoir that condensed into free water. After three nights there was over 10% free water in the oil.
A specialty steel mill in Pennsylvania had the main lube oil system suddenly and mysteriously contaminated with over 5% water. Sabotage was suspected but could not be proved.
The mill had to keep running. A large mobile purification truck was pulled off a routine job and sent to the steel mill. We arrived within 8 hours of the call. The oil system was 12,000 gallons.
We were processing oil by midnight the day of the call and by 7 am the next day had the water content reduced below 0.2%. By noon the oil was CLEAR and BRIGHT, by midnight (after 24 hours processing) the water content was below 100 parts per million!
This steel mill now routinely purifies its main oil systems using our mobile equipment every year now instead of dumping and refilling with new oil.
Savings are in the hundreds of thousands of dollars per year!
A large aluminum extruder in the US Mid-West was using phosphate ester fire resistant fluid in the hydraulic system of a large extrusion machine. It became contaminated with water when a cooling heat exchanger perforated and leaked water into the system. The oil would cost over $15.00 per gallon to replace, there was over 6,000 gallons of contaminated oil in the machine.
Our equipment was on-site and operating within 24 hours of the call and reduced the water to below 200 PPM within 24 hours.
Savings were over $80,000.00 with no production downtime.
A small plastic extruder in Pennsylvania was using about 20 drums of oil per year and when he changed the oil in his machines just disposed of the oil.
He found out about our service and now about once per year, we stop at his plant and purify whatever oil he has accumulated in drums.
He has no disposal cost and saves over 60% of the cost of new oil.
A high-speed steel wire mill in Ontario experienced catastrophic failure of some water seals in its main mill lube system. The mill started shutting down due to low flow indications in the roll bearing lubrication system. The unscheduled shutdowns were causing MAJOR PROBLEMS.
We pulled a large unit off a job in North Carolina and also sent in one of our smaller units to get started on the clean up. The large unit arrived after 16 hours; the small unit had been processing for 10 hours at this time.
The leaking seals on the mill lube bearings were leaking 60 gallon per hour of water into the lube oil; our equipment was removing 60 gallons per hour of water.
We remained hooked up until the next scheduled shut down, when the faulty seals were replaced.
A major steel company in Ontario discovered that the main storage tanks for most of its mill lube systems were contaminated with dirt that had built up over the years. The dirt was being recirculated and was causing bearings problems in some of the mills.
The area was too congested to try and clean the systems using our mobile equipment, so the oil was physically removed so that the sludge layers in the tanks could be cleaned and scraped out.
The oil was purified at our fixed facility in Ontario and returned clean and re-certified by an outside laboratory 4 days later. Each tank held over 6,000 gallons of oil. Savings over 50% of new oil cost.
A large plastic injection molder in Michigan found that 20 of his 30 machines had particle counts well in excess of normal levels.
We were asked to provide clean up services. All 20 machines were cleaned, the additives restored and the cleanliness certified.
Each machine held between 500 and 1,000 gallons of oil. The work was finished in 48 hours.
A steel company in Pennsylvania had its large quench oil system contaminated with water due to a leaking cooler. The oil was changed twice but was still showing water contamination 8 hours after startup.
We were called in to dry the system out and investigate where the water was coming from.
Our unit dried the oil out quickly but moisture was visible in the oil as soon as 2 hours after we finished processing.
Our investigation found an air leak on the suction side of the main pump. This was allowing very wet air from the sub-basement to get into the quench oil. The high humidity was due to steam leaks from a heater next to the pump.
With the oil temperature lower than the dew point of the air, moisture was condensed out of the air and built up in the oil. The pump was pumping about 60% oil and 40% air. The leak was fixed, the oil dried out again. This system has run for two years now with no problem.
Steel company near Philadelphia was using a low viscosity special rolling oil to produce some special grades of cold rolled steel sheet. The oil was very expensive and could only be used for one week before it became too contaminated to use.
Our process cleans the oil that leaks out of the rolling mill, as well as the oil that is changed every week.
The purchases of new oil have dropped by over 80%; the direct savings are in excess of $100,000.00 per year.
A large producer of extruded aluminum in Virginia was using very large quantities of hydraulic oil due to high production rates and low allowances for maintenance.
We installed two 10,000 gallon storage tanks to hold the both dirty oil and the reclaimed oil.
Our reclaimed oil has cleanliness higher than the virgin oil supplied by the major oil company.
This company presently reclaims more than 85% of its hydraulic oil.
Our process Really Works!!
Try us! Give us a call, or send a sample for a “No Charge” analysis.
1-800-263-3939
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