The Synonym for Oil CareThe tool for predictive maintenance

www.cjc.de

Fine Filter Systems for applicationsin the industry sector

|2 3|

ApplicationsCJC™ Fine Filter systems - one solution for many applications

Machining• Lathes• Grinding machines• Cutting machines• Milling machines

Waste /Recycling industry• Scrap shears• Baling presses• Crushers• Extruder drives• Shredders• (Un)Loaders, Cranes

Forming• Drop forging hammer / -presses• Rolling mills• Upsetting machines• Rotary swaging machines• Round bending machines• Flanging machines• Wire-drawing machines

Steel works• Coal mills• Blast furnaces• Slag granulation• Converters• Casting plants• Rolling mills• Band steel production• Manipulators• Shearing and slitting lines• Straightening machines• Welding machines• Balancing and bending systems• Feeders and feed units• Steering and servo-systems• Conveyor belts• Transformers• Turbines• Spreaders and scrapers

Storage tanks /Reservoirs• Oil reservoirs• Intermediate bulk containers

Test benches• Component test benches• Endurance test benches

Mobile machinery• Earth-moving machines• Tunnel boring machines• Agricultural machines • Road building machines • Street sweepers• Industrial trucks• Cranes• (Un)Loaders

Further applications• Hydraulic roller coasters• Hydraulic flight simulators• Hydraulic control systems• Vacuum pumps• Labelling machines

ApplicationsCJC™ Fine Filter systems - one solution for many applications

Quenching• Annealing ovens• Closed quench oil baths• Open quench oil baths• Wash water• Reconditioning of skimmed oil

Automotive industry • Hydraulic presses• Die casting machines• Injection moulding machines• Machine tools• Wash systems• Quench oil baths / furnaces• Conveyor belts

Pressing • Press brakes• Screw presses• Excenter presses• Wedge presses• Vulcanising presses• Chamber filter presses• Flanging presses

Compressors• Screw compressors• Piston compressors• Turbo compressors

Paper industry• Paper machines• Calenders• Refiners• Packing machines• Turbines

Casting• Casting machines• Trimming presses

Timber industry• Block band saws• Saw mills• Round timber feeder lines, sorters, conveyors

Thermal oil systems• Food industry• Pharmaceutical industry

Engines /Generators• Gas engines• Diesel engines• Generators

Cement works • Crushers• Raw mills• Coal mills• Cement mills • Rotary kilns• Cement mixers• Concrete mills

Plastic industry• Injection moulding machines• Blow moulding machines• Extruder machines

- for more than 65 years!Karberg & Hennemann, Your Partner for Oil and Fluid Maintenance

|4 5|

ParticlesParticle contamination of the oil can only be reduced, not avoided. The contaminants enter the system from the environment (e.g. through venting, oil refilling or repairs), but they are also generated inside the system (abrasion). Every particle in the system can generate more contamination (sand blasting effect).

Grooving through abrasion

(bearing ring)

ErosionSmall particles in a high velocity oil flow come in contact with metal surfaces and edges, breaking off more particles (sand blasting effect).

AbrasionHard particles jammed between moving parts destroy the surfaces (abrasive wear).

WaterIt is very difficult to avoid water contamination in the oil. Humid air enters the system via air vents and is absorbed by the oil. Varying temperatures enhance this process. Cooling water leakages and similar water ingress are also common sources of oil contamination.

Corrosion(shaft)

CavitationWater droplets in the oil evaporate under high pressure, implode and rip particles off the metal surfaces.

CorrosionWater or chemical contaminants in the oil cause rust or chemical reactions, which deteriorate the component surfaces.

Oil ageing (formation of resins, varnish, sludge and acids)Degradation products resulting from oil ageing occur in both lubrication and hydraulic systems. This is mainly influenced by oxidation (oxygen), hydrolysis (water) and pyrolysis (thermal decay at high temperatures). In most cases, all of these three factors combined are at play. The degradation products lead to formation of sludge and / or resin-like deposits. Additionally, an acidification of the fluid occurs during oil ageing process.

Varnish(valve)

Oil degradation productsThe resin-like degradation products are deposited on the metal surfaces and form a sticky layer to which particles adhere. The created sand paper effect accelerates wear and tear.

Particles, Water and Oil Ageing80 % of all breakdowns in hydraulic and lubrication systems are the result of contaminated system fluids

Cellulose - The Ideal Filter MaterialCJC™ Depth Filter inserts simultaneously remove particles, water and

oil degradation products

WasserCellulose fibres absorb water by capil-lary attraction. Even if only a few ppm of water are in the oil, the fibres dry the oil.

Capacity: several litres

Oil ageing / OxidationOxidation products, resins, varnish and sludge residues deposit permanently, with a combination of adsorption and absorption, on the polar sites of the cel- lulose fibres. Cellulose fibres have an in-ner surface of 120 to 150 m² per 1 gram.

Capacity: several kilogrammes

Particles Solid particles are permanently retained between the cellulose fibres. 75 % of the insert volume forms a structure of cavi-ties. Each insert has a filtration degree of 3 µm absolute and 1 µm nominal.Especially developed CJC™ Fine Filter inserts offer a filtration degree in the submicron range.

Capacity: several kilogrammes

Depth filtration - extremely high dirt holding capacity and long filter lifetimeCJC™ Fine Filter inserts are depth filters, i.e. compared to surface filters contaminants are retained in the depth of the filter material. This implies an enormously high dirt holding capacity and extremely long filter lifetime. Due to the slow pace of the oil flow – only possible in an own circuit (offline filtration) – and the extremely long filter paths of a depth filter, CJC™ Fine Filter inserts are particu-larly effective. The longer the fluid has contact with the filter material, the more effective is the fine filtration. The filter efficiency is basically a function of the fluid’s contact with the filter material.

Cross-section of a used CJC™ Depth Filter insert

Flow direction

clea

n oi

l

Cross-section of a CJC™ Depth Filter insert - The oil flows through the CJC™ Depth Filter insert radially from the outside to the inside

until these are also filtered out.

Only clean oil is able to loosen already deposited particles and degradation products in the oil system and to hold them in suspension

See product sheets for fu

rther information.

Download: www.cjc.de/p

rodukte

For each application a suitable solutionWith more than 20 various types of filter inserts we offer the optimal solution for each application.

• Mineral oils and synthetic pressure fluids and lubricants up to ISO VG 460 / 40 °C, also biodegradable oils• Aqueous oils and fluids • Oils and fluids with extremely high dirt ingress• Oils and fluids with high potential to generate acids, e.g. HFD fluids, gas engine oils• Oils and fluids with high water content that has to be minimised in short time, e.g. insulating oils• Oils and fluids with high potential to generate acids or high water content and simultaneous contamination with particles and oil degradation products

|6 7|

Offline Oil MaintenanceIndependent of the machine's operation for highest possible oil cleanliness

Easy installation:The oil is drawn and returned at the system tank.

Your AdvantagesReduce costs, increase machine reliability and avoid oil changes

The constant high oil cleanliness level permanently achieved by offline fine filtration prolongs the lifetime of system components and oil by a factor of 2 up to >10 and more!

Small investment, large effectGood for you - good for our environment!

Less maintenance, increased productivity • Approx. 60 % lower maintenance costs • Less wear and tear and therefore less unscheduled downtimes and production losses • Improvement of the process stability • Longer lifetime for system components and oil  • Longer lifetime for filter elements of inline filters

Lower energy consumption  • Less frictional loss • Less pressure build-up by system pump necessary u as for pressure filters, a lower filtration degree can be selected u as due to the longer lifetime, the filter elements of pressure filters are saturated much slower

Short amortisation time • > 75 % of the installed CJC™ Fine Filter systems have a payback time of less than one year of operation

Protect the environment • As a result of the longer lifetime of oil and components the energy and resources consumption necessary for production and disposal of spare parts and operating material (new oil etc.) decrease  • Improvement of the carbon footprint by oil conditioning u Thermal disposal of waste oil causes approx. 2.6 kg of the harmful greenhouse gas CO2 per 1 litre • Filter material consists to 100 % of renewable raw material • No additional impact on the environment during disposal of the filter material u CJC™ Fine Filter inserts can be disposed of according to the (German) Waste Product Key 150202 and thus, they also comply with the requirements of DIN EN ISO 4001:2005 "Environmental Management System" and the life-cycle resource management

Profit from the advantages of the CJC™ Fine Filter systems!

Oil system

Tank

Highest possible oil cleanliness can only be ensured by continuous offline fine filtration -in conjunction with the inline filter.

Inline filtration in comparison with offline filtration

Offline filter

• Particles, water and oil ageing products are simultaneously reduced to a minimum• Fine filtration to a range of < 1 µm (submicron range)• Continuous fine filtration (24/7), independent of the operation of the machine• Oil is drawn from the lowest point of the system tank, meaning the highly-contaminated oil in the bottom of the tank (sediments) is filtered too - the clean oil is returned to the tank close to the suction point of the main system pump• Its own pump enables an application-specific adjustment of the pump flow • Efficient fine and depth filtration due to the long contact time between filter material and fluid • For filter replacement it is not necessary to stop the machine • No high pressures, flow rates or pressure surges and the related problems• Extremely high dirt holding capacity and long lifetime of the filter elements

Pressure filter (inline)

• Housings and filter elements are expensive, because they have to be designed for max. system pressure• High energy costs (the higher the filtration degree, the higher the costs)• High operation pressures and high flow rates lead to an extreme load (material fatigue, damage of the pore structure)• Release of already filtered particles due to highly fluctuating pressure surges• Short contact time between fluid and filter material due to the high flow rate• Low dirt holding capacity• Frequent filter replacements • Dependent on the operation of the machine• Only solid particles are filtered out, no protection against cavitation, corrosion and oil ageing

Return filter (inline)

• Big filter sizes in some cases necessary, because the return flow rate is often bigger than pump flow rate• Short contact time between fluid and filter material due to the high flow rate• Dependent on the operation of the machine• Only solid particles are filtered out; no protection against cavitation, corrosion and oil ageing

Suction filter (inline)

• Only protection against large solid particles • No protection against caviation, corrosion, oil ageing and wear caused by fine particles • Oil is drawn from the surface; contaminants in the oil sump are not captured• Big filter sizes necessary• Dependent on the operation of the machine

Bypass filter (inline)

• Only a part of the inline fluid flow is filtered• Dependent on the operation of the machine

|8 9|

CJC™ Fine Filter unitsInstallation sizes and modular build-up

Further CJC™ Oil Maintenance SystemsEspecially for oils and fluids with very high content of free or dissolved water

For optimal dimensioning customised for your fluid system, please contact us!Fluid volume, viscosity, type and amount of dirt ingress, operating temperature and other parameters influence the dimensioning.

Principle: Fine and depth filtrationApplied for following contaminants:• Particles• Water• Oil ageing products (resins, varnish, sludge)• Acid compounds

Design size 15/25

Design size 727/108

140 cm110 cm

161,

6 cm

Design size 427/108

159,

7 cm

120 cm85 cm

Filter capacity

Dirt Water

≈ 1,1 kg ≈ 0,5 l

Ø 15 cm

25 c

m62 c

m

36,3 cm31,5 cm

Design size 27/-

Filter capacity

Size Dirt Water

27/108 ≈ 8 kg ≈ 4,8 l

27/81 ≈ 6 kg ≈ 3,6 l

27/54 ≈ 4 kg ≈ 2,4 l

27/27 ≈ 2 kg ≈ 1,2 l

27 c

m54

cm

81 c

m108

cm

Ø 27 cm

70 cm

50 cm

81 |

109

,5 |

135

| 1

63,5

,5 c

m

Design size 38/100

Filter capacity

Dirt Water

≈ 15 kg ≈ 7,2 l

Ø 38 cm

100

cm146,

9 cm

75 cm

57 cm

Filter capacity

Dirt Water

≈ 56 kg ≈ 33,6 l

Filter capacity

Dirt Water

≈ 32 kg ≈ 19,2 l

CJC™ Filter SeparatorsFine and depth filtration in combination with a coalescer-filter for removal of larger amounts of free water from oils and fuels.

Applied for the following contaminants:• Free water • Particles• Oil degradation products (resins, varnish, sludge)

PrincipleThe coalescing principle is ideal for the separation of free water from mineral and synthetic oils with a good demulsification time (< 20 minutes). For optimal coalescer efficiency the solid and soft contaminants contained in the oil (particles and oil ageing products) have to be removed by fine filtration before the coalescing process starts. Contaminations negatively influence the demulsification capability, clog the coalescer and reduce the coalescer efficiency. In a subsequent coalescer filter, the water droplets are carried by the laminar oil flow through the coalescing element and attach to the coalescer fibres due to the larger adhesion forces. The flow pushes them along the coalescer fibres and lets them coalesce with other droplets at the intersections. Finally, due to gravity and the higher density, the larger droplets are released and separated in a discharge area.

CJC™ Desorber Desorption for removal of larger amounts of dissolved water from mineral, synthetic and high-viscosity oils - even from stable emulsions and oils with a density > 1.

Applied for the following contaminants:• Free and dissolved water• Particles (only in combination with a CJC™ Fine Filter unit)• Oil degradation products (only in combination with a CJC™ Fine Filter unit)

PrincipleWith desorption it is possible to separate both free water and dissolved water from the oil unaffected by additive packages and viscosity. Mineral and synthetic fluids with a poor demulsification time (> 20 minutes) and stable emulsions can be dried – even with very high water content - up to 30 % (300.000 ppm).The desorption process is based on the principle that heated air can effec-tively hold large quantities of water. In the desorber, the warm oil is met by a counter flow of cold, dry air. The air, heated very quickly by the warm oil, absorbs any water present until saturation is reached. During the subsequent air cooling process the water condenses and the dry air is used again for dry-ing of the following oil flow.Desorption removes only H2O. In the case that the oil is contaminated with particles and oil ageing products too, it is possible to connect a CJC™ Fine Filter unit upstream of the CJC™ Desorber.

CJC™ Depth filter

See product sheets for technical data.Download: www.cjc.de/produkte

Ø 27 cm

108

cm

Ø 27 cm

108

cmCJC™ Fine Filter insert

CJC™ Coalescer-filter

Flow switch and solenoid valve

|10 11|

Analyse and evaluate oils

Particle Content and Oil Cleanliness Water Content and Varnish-PotentialAnalyse and evaluate oils

Classification according to ISO 4406 (International Organization for Standardization)The ISO 4406/1999 method for coding the level of contamination of solid particles is a classificationsystem that converts the numbers of counted particles into an ISO class (oil cleanliness level). According to ISO 4407, counts at 5 and 15 µm from the manual particle counting areequivalent to the counts at 6 and 14 µm when using an automatic particle counter calibrated inaccordance with ISO 11171.

Automatic particle countFrom a 100 ml sample of the fluid to be examined, the quantity of particles > 4 μm, > 6 μm and> 14 μm is determined. The quantities of particles are then categorised in class codes, indicating the oil cleanliness level. Example - ISO Code 19/17/14(typical for new oil): 250,000 up to 500,000 particles ≥ 4 μm,64,000 up to 130,000 particles ≥ 6 μm and8,000 up to 16,000 particles ≥ 14 μmare contained in 100 ml of the tested oil.

Microscopic analysis Only the quantity of particles ≥ 5 μm and ≥ 15 μm is determined.

Example - ISO Code 17/14(typical for new oil): 64,000 up to 130,000 particles ≥ 5 μm and8,000 up to 16,000 particles ≥ 15 μmare contained in 100 ml of the tested oil.

Amount of particles > specified sizemore than up to ISO Code

8,000,000 16,000,000 24

4,000,000 8,000,000 23

2,000,000 4,000,000 22

1,000,000 2,000,000 21

500,000 1,000,000 20

250,000 500,000 19

130,000 250,000 18

64,000 130,000 17

32,000 64,000 16

16,000 32,000 15

8,000 16,000 14

4,000 8,000 13

2,000 4,000 12

1,000 2,000 11

500 1,000 10

250 500 9

130 250 8

64 130 7(Extract from the currently valid ISO 4406 standard.)

Categorising cleanliness levelsDepending on the application, specified oil cleanliness levels for oil systems (ISO 4406) are recommended. The adjacent table shows these minimum requirements in an overview. (Source: Noria Corporation)

The service life of hydraulic and lubrication system components varies distinctly according to the cleanliness level (ISO 4406).

19 / 17 / 14

mediumcontaminatede.g. new oil*

low and mediumpressure systems

75 % ofservice life

22 / 20 / 17

heavilycontaminated

not useablein oil systems

50 % ofservice life

17 / 15 / 12

lightlycontaminated

hydraulic andlubrication systems

100 % of service life

16 / 14 / 11

clean

servo and highpressure systems

150 % of service life

14 / 12 / 10

very clean

all oil systems

200 % ofservice life

*) Up to 0.05 % of insolubles are permissible in new oil. (DIN 51 524, Part 2)

ISO 11/10/6

ISO 13/12/7

ISO 18/17/15

ISO 20/18/13

ISO 15/13/8

ISO 24/23/20

Photos of test membranesof various contamination degrees

MPC-Test (Membrane Patch Colorimetry)50 ml of the oil to be tested and 50 ml filtered heptane are mixed and vacuum-filtered through the test membrane. The colorimet-ric analysis is conducted after the subsequent drying of the membrane. The residuals on the membrane are analysed by the spec-tral sensor. The deposits absorb or reflect the light completely or partially. The differences between sent and reflected light as well as the colour intensity in the respective spectral range allow an MPC value to be calculated. The higher the MPC value, the heavier the colour change on the membrane and the greater the potential of the oil to generate deposits.

0 - 10 11 - 25 26 - 30 31 - 45 46 - 50 51 - 55 56 - 60NORMAL MONITOR CRITICAL O u NEED FOR ACTION

Normal oil ageing Critical value for formation of deposits

is achieved soon

Many soft contaminants,

start of deposits on sleeve bearings and cooler spots in the lubrication system

Extremely high amount of soft contaminants,

formation of deposits in bearings, valves

or tanks

Additive degradation, oxidation, high oil temperatures and long use of the oil

can generate further particles, which

deposit

Additive degradation and oxidation well

advanced, deposits in bearings, valves and

tanks

Oil no longeruseable, deposits in the whole system

MPC value 2 MPC value 35MPC value 19 MPC value 41 MPC value 49 MPC value 60MPC value 53

Karl-Fischer-Titration With the Karl-Fischer-Titration it is possible to determine the water content in oils. Basis for water determination is the reaction of iodine with water in a dissolution. Two different methods exist:

Volumetry:This method is used for detection of larger amounts of water in oil. The measuring ranges from 0.01 % up to100 % water in oil.

Coulometry:This method is used for exact detection of smallest amounts of water in oils. The measuring ranges from0.001 % up to 5 % water in oil.

Hydraulic oil samples with various water content.From left: 0.01 % - 0.03 % - 0.06 % - 0.1 % - 0.2 % - 2 % water in oil

Further im portant analysis options:• Viscosity determination• Acid content: Detection of neutralisation number or base number• Element analysis• Particle Quantifier index

Read more about the topics ofclassification systems, oil analysis andcorrect oil sampling in our brochure "Ratgeber Öl".Download: www.cjc.de

to sustainably reduce the content of particles, water and oil degradation products to a minimum!Ensuring a longer lifetime for machine, system components and oil is a must

|12

Hydraulic Oil - Application Examples

13|

Lubrication Oil - Application ExamplesMinimise downtime and failures, reduce maintenance costs and prolong oil lifetime Reduce costs by fine filtration instead of oil changes and

simultaneously optimize protection against wear

Asset Manager: „I hadn't thought that we would achieve such a clear result! We will use the CJC Fine Filters also for our othersites so that those compressors will also be supplied with clean oil.“

Problem: Water and particlesRing rolling machine1,500 litres hydraulic oil HLP-D 68

Chief of technical services: „The achieved oil cleanliness is notable. We have tried out a lot of filters but only with the filters from CJC did we reach the desired oil cleanliness. In the meantime we have retrofitted four further machines in our production with CJC offline filters.”

Problem: ParticlesCompressor4,200 litres lubrication oil, type Shell Turbo T 46, ISO VG 46

ISO Code 4406 )*

Water,ppm

New oil reference 18/16/13 < 1,000

Without CJC™ notmeasurable 3,900

AFTER 6 days offine filtration with CJC™ 18/16/14 200

AFTER 7.5 months offine filtration with CJC™ 14/13/9 117

*) Further information on cleanliness classes see page 10

Particle content according to ISO 4406

Num

ber o

f par

ticle

s in

100

ml

Problem: Oil ageing, water and particlesWire-drawing machines500 litres lubrication oil, type Fuchs Ratak TRP 170 / 2.300, 400 cSt

Maintenance Manager: „ [...] The CJC Filter has given us some very satisfactory results. It is a very beneficial installation that provides us with clean oil, something crucial for good lubrication.Our final product, the stainless-steel wire, has also been improved and is no longer stained by oxidation of the lubricant. [...] It's for this reason that we have installed offline fine filters in 13 systems.”

WITHOUTCJC™ offline fine filter

AFTERapprox. 4 months

with CJC™ fine filter

Particles > 1 µm 2.819 % * 0.241 % *

Particles > 2 µm 2.747 % * 0.0 % *

Water 22,000 ppm 874 ppm

Membrane color black white* Weight of the particles in the oil in percent

ISO Code *)

New oil 20/18/13

WITH CJC™ Fine Filter 15/14/10

WITHOUT CJC™ Fine Filter 21/19/15

WITH CJC™ Fine Filter 16/15/12*) Further information on cleanliness classes see page 10.

Submerged pump of a hydraulic press withresin- and varnish-like deposits (oil ageing)

Maintenance Manager: „The installation of CJC Filters at ourhydraulic presses was an excellent decision. From now onCJC Filters are part of the technical specification, and all new machines are fitted with CJC as original equipment.”

Withinline filter

filtration degree 8 µm

WithCJC™ offline fine filterfiltration degree 3 µm

Particles > 4 µm 1,443,178 6,774

Particles > 6 µm 298,680 2,204

Particles > 14 µm 17,893 356

ISO Code *) 21/19/15 13/12/9*) Further information on cleanliness classes see page 10.

Problem: Oil ageing and particles60 hydraulic presses (80 up to 500 tons)Average 1,500 litres hydraulic oil

0

200.000

400.000

600.000

800.000

1.000.000

1.200.000

> 4 µm

> 6 µm

> 14 µm

After 9 days withCJC™ fine filtrationCompressor not in

operation

New oil(initial sample)

After 2.5 month withoutCJC™ fine filtration

Compressor inoperation

After 1.5 months withCJC™ fine filtration

Compressor inoperation

1,200,000

1,000,000

800,000

600,000

400,000

200,000

0

Please feel free to contact us or visit our website for more information!In total more than 100 application studies from different industries verify the success of CJC™.

• Ingressing condensed water regularly led to an extremely high water content of 2,900 up to 3,900 ppm and an accelerated oil ageing process.• Additionally, the contamination with solid particles was so high that the oil cleanliness class could not be detected by particle counter.• The already installed offline filter could not achieve the recommended oil cleanliness for hydraulic systems.

Result after fine filtration with CJC™• Permanent low water content after start-up of the CJC™ Fine Filter system: After 6 days: 200 ppm After 7.5 months: 117 ppm• Oil cleanliness level improved with finally ISO Code 14/13/9 - significantly cleaner than new oil• Optimum protection against abrasive and corrosive wear and tear as well as cavitation

• Oil system was heavily contaminated with particles and oil degradation products - despite an inline filter with a filtration degree of 8 µm.• Increased wear and tear due to abrasive particles and resin- and varnish-like deposits on the system components • Enormous maintenance costs caused by daily oil related failures

Result after fine filtration with CJC™• Particle content was decreased by > 99 % within shortest time and due to the simultaneous removal of oil degradation products, the potential to generate deposits was reduced to a minimum.

• The drastic drop of oil related failures and downtimes led to an appreciable reduction of costs and to significantly higher machine reliability and productivity.

• Due to the operating conditions the oil contaminates within a very short period of time.• Oil cleanliness of the new oil is already poor - despite filtration before filling it into the tank and flushing of the whole oil system (filter of the oil supplier was used).

Result after fine filtration with CJC™• Only continuous offline fine filtration ensures a permanently high oil cleanliness level (see results on the right).• As a result of the prolonged oil lifetime, costs and time are saved (costs per compressor and oil change: approx. 25,000 EUR).

• Due to the production process the oil is heavily contaminated with particles and water.• Additionally, the thermal stress of the oil during the drawing process causes formation of oil degradation products. • Resin- and varnish-like deposits adhere to the final product, blocking the wire nozzles in the soldering machines and considerably reducing the useful life of the lubricant.

Result after fine filtration with CJC™• The formation of deposits on the surface of the wire is avoided as a consequence of the contamination removal.• Due to the permanent high oil cleanliness the oil lifetime has been prolonged drastically.

|14

Gear Oil - Application Examples

15|

Other Oils and Fluids Improve processes and increase productivity Avoid unnecassary oil changes and thus, protect resources and environment

Problem: ParticlesCement mill2,000 litres gear oil, type Addinol Eco Gear 320 M

Manager metalworking shop: „The extensive oil analyses fromOELCHECK have convinced us. They clearly show the improvement of the oil cleanliness. Because of the excellent results the gearboxes of the other four cement mills as well as of the raw mill were also equipped with CJC Offline Filters.”

Problem: Particles and oil ageingCasting machine7,000 litres HFC fluid, type Houghto Safe 620

Particle content according to ISO 4406

0

2.000.000

4.000.000

6.000.000

8.000.000

10.000.000

12.000.000

14.000.000

16.000.000

18.000.000

Initial Sample After 6 days After 18 days After 46 days

Partikelgehalt nach ISO 4406

> 4 µm

> 6 µm

Num

ber o

f par

ticle

s in

100

ml

Oil samples - membrane filter test

BEFORE fine filtration,Test membrane: 0.8 µm

AFTER 8 days of fine filtrationTest membrane: 0.8 µm

Oil samples - membrane filter test

BEFORE fine filtration,Test membrane: 0.8 µm

AFTER 18 days fine filtrationTest membrane: 0.8 µm

Particle content according to ISO 4406

Num

ber o

f par

ticle

s in

100

ml

0

5.000

10.000

15.000

20.000

25.000

30.000

35.000

Initial sample After 8 days fine filtration

> 2 µm> 5 µm> 15 µm

Due to the brilliant results, all three die casting machines were equipped with CJC Offline Filters.In future, CJC Fine Filters are part of the technical specifications.

Problem: Oil ageing, water and particlesGear box hot rolling mill, steel workGear oil

Oil samples - membrane filter test

BEFORE fine filtration,Test membrane: 0.8 µm

AFTER fine filtrationTest membrane: 0.8 µm

Water content

30,000

25,000

20,000

15,000

10,000

5,000

0

35,000

16,000,000

14,000,000

12,000,000

10,000,000

8,000,000

6,000,000

0

18,000,000

4,000,000

2,000,000

CJC™ offers the optimal oil maintenance systems for any problem! In the industry, marine or mining sector, in power plants or in wind turbines

0%

5%

10%

15%

20%

25%

30%

35%

40%

24.07. 08.08. 15.08. 08.10. 31.10. 31.01. 19.03.

Water content in %

• Although the oil was changed 2 years ago, the oil was heavily contaminated especially with metal particles and swarf. • Oil cleanliness 25/22/16 (ISO 4406).• The use of such an extremely contaminated oil reduces the lifetime of components by 50 %. (Source: Noria Corporation)

Result after fine filtration with CJC™• Particle content reduced by 50 % within the first 6 days and by 99 % within 18 days.• Oil cleanliness improved to 17/15/11 (ISO 4406) - cleaner than new oil. • Optimum protection against abrasive wear and tear as well as longer oil change intervals reduce costs and preserve the environment.

• Gear box breakdowns, high component wear and short oil lifetime caused by an enormous amount of dirt and water in the oil.• Water content approx. 35.5 %.• Water accelerates oil ageing and therefore the oil was not only contaminated with solid particles, but also with reaction products caused by the oil ageing.

Result after fine filtration with CJC™• Since the installation of the CJC™ Oil Maintenance system no oil related breakdowns and production downtime occured.• Spare part and maintenance costs were significantly reduced.• Water content was reduced to 0.01 %. • After fine filtration particle content was measurable, oil cleanliness 18/15 (ISO 4406) was achieved.• Simultaneously, the amount of soft contaminants was immensely reduced (Compare membrane colours).

• Comparatively frequent failures at casting machine no. 5 due to the poor fluid condition. • HFC fluid was loaded with solid particles (metal particles etc.) and especially with oil degradation products - so-called soft contaminants - from oxidation and degradation processes.

Result after fine filtration with CJC™• Within 8 days the number of particles > 2 µm decreased by 86 % - abrasive wear and tear was minimised.

• Simultaneously, also the amount of soft contaminants was visibly reduced (compare membrane colours). • Significantly less failures, less production downtime and less maintenance resulting in decreasing costs and increasing process reliability and productivity. • Additionally, the customer profits from the longer lifetime for fluid and system components.

Problem: Particles and asphaltenesIPSEN discontinuous chamber furnace2,400 litres mineral oil based quenching oil

Maintenance Manager: „We have clearly seen the efficiency of the CJC Fine Filter on the quenched parts. This result hasconvinced us.“ Hardened parts:

on the left with unfiltered, on the right with filteredquenching bath

Oil samples - membrane filter test

BEFORE fine filtration,Test membrane: 0.45 µm

AFTER fine filtrationTest membrane: 0.45 µm

• Black deposits on the small hardened parts (valve covers).• Despite extensive after-treatment not removable.• High scrap quantity due to these optical defects.

Result after fine filtration with CJC™• After only 1 1/2 weeks the surfaces of the hardened parts were significantly cleaner without black deposits.• No sand blasting during after-treatment necessary.• Minimised scrap. • Work amount and costs considerably reduced.

- worldwide

MPIe | 03.18

CJC™ worldwideCJC™ Fine Filter systems are available worldwide through subsidiaries and distributors.Find your nearest distributor on our website www.cjc.de - or give us a call!

HistoryFounded in 1928 and located in Hamburg, we develop and manufacture CJC™ Fine Filter technology since 1951. With substantial know-how and in-house analysis and test facilities we are experts when it comes to the maintenance of oils and fuels.

QualityCompetent advice and individual solutions, even for the most difficult filtration problems of our customers - that is our daily claim. The certification of our company according to DIN EN ISO 9001:2015 provides us with assurance and motivation.

Karberg & Hennemann GmbH & Co. KGMarlowring 5 | D - 22525 Hamburg | GermanyPhone: +49 (0)40 855 04 79 - 0 | Fax: +49 (0)40 855 04 79 - 20filtration@cjc.de | www.cjc.de