Aluminum Extruder Reclaims Used Hydraulic Oil From Leaking Presses – Saves $450,000 In One Year

New oil purchased for regular consumption which is now being cleaned through a 50 GPM Vacuum Dehydration Oil Purification System.

Hydraulic Oil Contamination Challenges in Aluminum Extrusion Manufacturing

A national leader in the manufacturing of extruded aluminum products in Texas was facing a costly and persistent challenge: hydraulic leaks in four large horizontal aluminum extrusion presses. Each press relies on complex hydraulic systems with high-value pumps and precision valves, making hydraulic oil cleanliness absolutely critical.

The target ISO cleanliness level was 17/15/11, yet maintaining this standard was becoming increasingly difficult due to ongoing oil loss and contamination.

The High Cost of Hydraulic Oil Loss and Equipment Downtime

To keep the extrusion presses operating, the manufacturer was purchasing 1,200–1,500 gallons of new hydraulic oil every week to replace oil lost through leaks. This reactive approach led to escalating oil costs, increased waste, and growing concerns about long-term equipment reliability and sustainability.

Sustainable Hydraulic Oil Reclamation and Filtration Solution

85% of Oil Reused in 2024

The Maintenance Manager envisioned a smarter, more sustainable approach: reclaiming and reusing hydraulic oil instead of continually replacing it. Oil leaking into collection pits was pumped into totes and then processed through a 50 GPM Vacuum Dehydration Oil Purification System (VDOPS).

Restoring ISO Cleanliness Levels with Vacuum Dehydration Technology

The VDOPS removed water, particulates, and dissolved contaminants, consistently restoring the hydraulic oil to at or below the target ISO 17/15/11 cleanliness level. Once purified, the oil was safely returned to the extrusion presses, ensuring continued operation while protecting critical hydraulic components.

Reducing Hydraulic Oil Costs While Extending Equipment Life

By implementing oil reclamation and vacuum dehydration filtration, the aluminum manufacturer significantly reduced new oil purchases, minimized waste, and improved overall hydraulic system reliability, demonstrating how proactive oil cleanliness management can deliver both cost savings and long-term operational benefits.

Measurable Cost Savings and Rapid ROI from Hydraulic Oil Reclamation

Today, the maintenance team filters and reclaims 4–5 totes of used hydraulic oil per week, turning what was once waste into a valuable reusable asset. In 2024 alone, this proactive approach eliminated the need to purchase approximately 30,000 gallons of new hydraulic oil, representing a total cost avoidance of nearly $450,000.

Results: Proven Performance in Hydraulic Oil Filtration and Reclamation

• Significant and ongoing hydraulic oil cost savings by reclaiming oil that continually leaks from extrusion presses

• Reduced dependency on new oil purchases, lowering operational and environmental impact

• Reclaimed and filtered hydraulic oil consistently meets or exceeds OEM cleanliness specifications, achieving ISO 17/15/11

• Improved protection of high-value pumps and precision hydraulic valves, extending equipment life and reliability