Case Study: Steel Forging Press Extends Equipment and Oil Life By Implementing 50 GPM VDOPS – Prevents Downtime and Saves over $70,000 in Operating Costs
- Victoria Weber
- 13 minutes ago
- 2 min read
A leading steel forging manufacturer that produces high-tensile components for government applications was facing ongoing maintenance issues with one of its largest forging presses. The plant operates a 5,000-ton forging press powered by a 5,000-gallon hydraulic reservoir using biodegradable fire-resistant oil (Fuchs Renosafe 46) to ensure workplace safety and environmental compliance.
The Challenge: Elevated Water and Particulate Contamination
The customer began experiencing elevated water and particulate contamination in the hydraulic oil caused by condensation from adiabatic expansion and humidity. This contamination was ruining their four hydraulic pumps, valued at $5,500.00 each, and increased maintenance costs, while also threatening the reliability of critical forging operations. The customer needed a reliable, on-site oil purification solution to remove both water and particulates effectively.
Our Solution: Deploying the VDOPS Oil Purification System
To address these issues, Oil Filtration Systems provided a 50 GPM Vacuum Dehydration Oil Purification System (VDOPS) to treat the hydraulic oil in service.
Our certified field technicians were on-site to assist with system operation, setup, and troubleshooting. During the process, it was determined that the reservoir also required an internal cleaning to remove sludge and deposits contributing to recontamination. Once cleaned, the VDOPS unit ran continuously to remove water, and fine particulate matter from the fluid.
Results: Oil Restored to Cleanliness Targets
The results were clear and measurable. Laboratory analysis showed dramatic improvement in oil cleanliness:
Initial Contamination Level: ISO 25/25/21
Final Contamination Level: ISO 16/15/11 (over 512x cleaner!!!)
Initial Water: 544 ppm
Final Water: 46 ppm (over 11x drier!!!)
This represented a major reduction in both particulate and moisture levels, restoring the hydraulic fluid to within acceptable operating limits and protecting critical components from further wear or failure. They had been changing pumps three times a year, at $22,000.00 per change ($66,000.00 annually).
The customer was highly satisfied with the outcome, stating:
“This machine is great! We would like to purchase one for full-time use.”
The VDOPS unit continues to operate at their facility, providing ongoing protection and helping extend the life of hydraulic components while maintaining system reliability.
Proven Hydraulic Oil Purification for Industrial Applications
By removing both free and dissolved water as well as fine particulates, the Oil Filtration Systems VDOPS enables manufacturers to protect critical equipment, extend oil life, and reduce maintenance costs, all while supporting sustainability through the reuse of biodegradable hydraulic fluids.
Contact Oil Filtration Systems to learn more about our VDOPS units and how they can help improve oil cleanliness hydraulic, or heavy industrial applications.