Category Archive: Uncategorized

Superior Solutions for Compressed Natural Gas Filtration



Compressed Natural Gas, or CNG, is one of the best known and most widely used alternative fuel options currently available. As CNG and CNG-powered technology proliferates, as with any fuel, filtration is necessary to ensure optimal fuel quality and operational efficiency.

In this post, we explore:

  • The projected growth of CNG
  • Examples of CNG applications
  • The unique considerations of CNG filtration
  • The products that Schroeder Industries has engineered for excellence in the realm of CNG filtration

CNG Surge: Compressed Natural Gas Market Projected to Grow

According to a June 2023 report from The Business Research Company, Compressed Natural Gas Global Market Report 2023, the global CNG market was valued at 147.16 billion USD in 2022. By 2027, the market is expected to grow 83.5%, for a total estimated value of 269 billion USD.

CNG is one of the major players in alternative fuels for several reasons, including:


CNG burns cleaner than traditional gasoline and diesel fuel. CNG engines reduce greenhouse gas emissions by up to 20% and cut toxic emissions overall, including up to 97% reduction in carbon monoxide versus gasoline.

Natural gas is one of the most widely abundant and relatively cheap alternative fuels, making it cost effective to produce and utilize.

It also delivers comparable torque and power to traditional diesel engines, making it viable for intensive work such as construction and mining.

CNG can largely utilize existing technology such as vehicle designs and transportation infrastructure, making transitions and retrofits more straightforward compared to other alternative fuel sources, such as electric power.


Part of this growth in the compressed natural gas market is being driven by CNG fueling and other related applications, including power generation and fueling CNG-powered vehicles for commercial fleets. Delivery vehicles, refuse collection trucks, and other commercial vehicles are seeing increased adoption of CNG. Compressed gas dispensing stations and virtual pipelines are expanding to satisfy the growing need for CNG fuel.

In order to ensure optimal performance of both CNG dispensing units and the vehicles that utilize it, CNG must be filtered to remove damaging contamination such as water vapor, residual oils, and solid particulates.


CNG Filtration 101



  • Water Vapor: Water vapor is found in all compressed gases and air. When under pressure, the water vapor becomes more concentrated.
  • Oil: Oil can leach into the compressed gas via lubrication in the compressor system. Hydrocarbon contamination is also present even in gas drawn through oil-free compressors.
  • Solid Particulates: Compressed gas systems can also ingest particles of rust, dirt, and other solid contaminants, just like a liquid fuel application.


  • Reduced Desiccant/Dehydrator Absorption: Compressed gas systems include dehydrating components, but high contamination levels can more quickly overwhelm these dehydrators.
  • System Component Wear: Sensitive system components, fuel injectors, and seals can be abraded and damaged overtime by contaminants, leading to costly repairs and replacements.
  • Reduced Efficiency Overall: Worn components reduce operational efficiency and increase maintenance-related downtime for CNG-powered equipment.
  • And More!


  • Account For Different Gas Types. Filter housings size selection must consider not only the system flow but also the type of gas as well as the operating pressure and temperature of the system.  
  • Account For Smaller Gas Molecules. Gas molecules are much smaller than liquid fuel molecules, so material selection and porosity are a major consideration in filter construction. A gas filter must be exceptionally well-sealed and utilize low porosity materials. Ductile iron and aluminum are common material choices for CNG filters.
  • Tackle Ultra-Fine Particulates. Contamination in compressed air is often under 1 micron in size, which is substantially smaller than typical contamination in liquid fuels. Gas filters must be capable of trapping tiny particulates without compromising the differential pressure in the compressor system.

CNG Filtration Solutions from Schroeder Industries: Engineered for Excellence




Schroeder Industries offers comprehensive solutions for CNG filtration and filling stations, from generation to dispensing.


Learn more about our CGF Series for CNG filtration, as well as our premium replacement elements!


Compressed Gas Filters

Schroeder’s premier filtration series for compressed air and compressed gases like CNG

  • CGF filter series provides cost-effective, robust filtration solutions for a broad range of applications.
  • Unlike other compressed gas filters, the CGF series utilizes pleated microglass media construction for more reliable performance and greater capacity.
CGF50CGF8CGF1.5
up to
5,000 psi
up to
800 psi
up to
150 psi

Compressed Gas Filter Panel

The CGFP50 provides twice the filtration power for your bulk filtration needs!

  • High Pressure Compressed Gas Polishing Panel for dispensing & transfer filtration
  • Uses two stages of the Schroeder CGF50 Compressed Gas Filters to remove particles and aerosols of oil and water.
  • Stainless Steel valves, connections, and tubing with flareless crimp connections are used for longevity and durability.

Replacement Elements

Premium replacement filter elements for the CGF series and more!

  • Replacement element kits designed for competitor housings in common sizes and media grade equivalents.
  • Currently available in 4C, 10C, and WS media grade equivalents, using pleated microglass media for extended service life with exceptional performance.
  • The element kits include the replacement bowl seals, designed to fit the competitor housings in the full range of sizes.

CGF Series: Beyond CNG

The versatile CGF Series also offers exceptional performance in other compressed gas applications besides just CNG!

  • Air Dryer Pre-Filtration
  • Paint Sprayer Booths
  • Air Cylinder / Air Valve Protection
  • And More!


Contact-Blog-CNG Filtration + CGF Series

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‘Shockingly’ Effective Anti-Static Filter Elements: Anti-Stat Premium


Struggles With Static

Over the last decade, users of hydraulic systems noticed a sharp increase in unusual failures and contamination within their equipment, including:

  • Burned and discolored filter elements
  • Rapid oil degradation
  • Prematurely worn, damaged components
  • Electrical arcing outside of the system

The culprit? Electrostatic discharge, also known as ESD, was becoming more frequent within hydraulic equipment. Static buildup is already a known issue, but why was it suddenly happening more often, and to greater extremes?


Behind the ‘Electrifying’ Increase in ESD

Fundamentally, static discharge in a hydraulic system is caused by friction—just like how shuffling across carpet in thick socks allows you to lightly zap someone else with static electricity. Oil may be a lubricant, but there is still some friction between hydraulic fluid and the filter media it passes through, and thus, static buildup can occur.


GIF animation showing visible electrostatic discharge in a filter element during hydraulic operations

In a system with highly conductive hydraulic fluid or oil, this static buildup is more easily absorbed and evenly distributed. This prevents the worst effects of electrostatic discharge. However, environmental standards driving changes in oil composition meant that low conductivity oil was becoming more widespread.


Diagram showing Group I versus Group II and Group III oils. Under Group 1 oils, bullets read: High conductivity, more toxic, less static/ESD, Under Group II and Group III oils, bullets read: Low conductivity, more eco-friendly, more static/ESD.

  • These oils contained aromatics and heavy metals. Due to the presence of heavy metals, Group I oils have high electrical conductivity.
  • However, the heavy metals within Group 1 oils are mostly toxic. Due to this toxicity and the potential threat to the environment, Group 1 oils do not comply with newer, international environmental standards.

  • Group II and III oils contain no toxins or carcinogens, as the toxic heavy metals have been removed.
  • Due to the lack of heavy metals, these oils have much lower electrical conductivity than Group 1 oils.


Between 2012 and 2020, the global market share of Group 1 oils fell by half, from 51% to roughly 26% of hydraulic oils in use. This trend is expected to continue. While moving away from Group I oils is much better for the environment, the proliferation of low conductivity oils led to more electrostatic discharge in hydraulic systems.


Chart comparing Global API Group Oil Market Share between 2012 and 2020. Group I oils decreased from 51% of market share to 26%.

Effects of Electrostatic Discharge on Hydraulic Systems

Electrostatic discharge and static cause a variety of serious issues in hydraulic systems, including:

Image of filter element scorched by ESD/electrostatic discharge
  • Damaged elements. Scorched, degraded filter elements are a hallmark of static buildup in a hydraulic system.
  • Increased contamination. When damaged, filter elements become unable to filter out contamination as intended, and the filter element itself may become a source of contamination as it degrades.
  • Reduced oil and component life. The increase in contamination and compromised filtration drastically reduces oil life and increases component wear.
  • Formation of sludge and varnish. As oil rapidly degrades, varnish is deposited in the system, affecting system function.
  • Fire risk. High amounts of ESD can potentially cause deflagration, or combustion of gas within the hydraulic reservoir.
  • Arcing and discharge outside of the system. In extreme cases, the electrostatic discharge can become so intense that it becomes an electrocution hazard to workers, as well as damaging to surrounding equipment.

Anti-Static Solutions from Schroeder Industries

Anti-Stat Premium and Anti-Stat Media from Schroeder industries are engineered to combat static buildup while providing robust filtration. Because levels of ESD can vary based on factors like fluid type and temperature, two levels of protection are available.

Both offer virtually the same efficiency as Schroeder’s standard, exceptionally powerful microglass media. For superior protection from both typical particulate contamination and the effects of electrostatic discharge, look no further!

NEW: Anti-Stat Premium


Anti-Stat Premium: Supercharged Static-Busting Capabilities For Extreme ESD

  • Specially formulated media dissipates electric charges before they can begin damaging your system
  • Eliminates all static buildup at the source
  • Effective for even the most critical cases of ESD, tackling conductivity values lower than 100 pS/m

Anti-Stat Media


Anti-Stat Media: Reliable, High-Performance Solution For Low to Moderate ESD

  • Specially formulated media dissipates electric charges before they can begin damaging your system
  • Cost-effective option for mid-range ESD scenarios
  • Effective for conductivity values higher than 100 pS/m

Schroeder Anti-Stat: Proven Performance

See how these customers benefited from the static-suppressing characteristics of Anti-Stat Media!


When a paper mill was experiencing a shortened filter element life of just 30 days, Schroeder Industries stepped in to extend the filter life, reduce oil waste, and reduce unscheduled downtime.

A Schroeder expert immediately identified the signs of static discharge in the hydraulic system. As the elements were burned and degraded by the electrostatic buildup, they failed prematurely, forcing the customer to swap out elements much sooner than usual.

Switching to Anti-Stat Media took the shock out of their system, extending their filter life and leading to substantial savings!


Oil Service Life Increased +3 Years


Annual Oil Usage Decreased -951 Gallons


$24.8K Annual Filter & Oil Cost Savings


An automotive plant contacted Schroeder Industries when, after switching to a new hydraulic oil, their oil lifespan dropped by as much as 80%.

The customer’s new oil blend was zinc and ash-free, meaning its conductivity was lower than their previous hydraulic oil. As we’ve discussed, the lower a hydraulic fluid’s conductivity, the more likely static buildup is to occur!

Burn marks and varnish on the customer’s used elements confirmed that electrostatic discharge was building up in the customer’s system. By switching to Anti-Stat Media, the customer was able to get the most out of their oil and more!


Oil Service Life Increased +4 Years


+2.6K Gallons of Oil Saved Per Press, Per Year


+31.7K Gallons of Oil Saved Annually


In Need of Anti-Stat? Ask the Experts!

Contact-Blog-Anti-Stat Premium Introduction

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Schroeder’s AFTF: For Superior, Stabilized In-Tank Filtration & Deaeration



Introducing the latest in Schroeder Industries’ line of powerful in-tank filters!

Using the same cutting edge technology as the Schroeder AFT, the new AFTF provides all the best qualities of Air Fusion Technology with stabilized, fixed-head porting.

Air contamination can be devastating within a hydraulic system, so having an in-tank filter that specializes in advanced deaeration can prevent substantial downtime, repairs, operational inefficiency, and more!


AFTF Benefits and Specifications

Here’s just some of what makes the AFTF one of the most powerful deaerating in-tank hydraulic filters available:


  • Exceptional deaeration capabilities. Air Fusion Technology reduces fluid velocity and encourages bubble coalescence for substantially more effecting deaeration than other in-tank filters currently available.
  • Fixed head allows for a breather attachment. The stabilized porting allows the addition of an external breather, further increasing the deaeration potential.
  • Provides filtration even in bypass. The specialized bypass valve in the head of the filter allows the filter to function even while in bypass for greater filtration efficiency.
  • Potential for reservoir downsizing. The deaeration of the Air Fusion Technology is so efficient that it may be possible to downsize your hydraulic reservoir by up to 60%!


Filter Housing Specifications

Flow Rating:40 gpm (151 L/min)
Max. Operating Pressure:100 psi (7 bar)
Min. Yield Pressure:350 psi (24 bar)
Rated Fatigue Pressure:100 psi (7 bar)
Temp Range:-20°F to 225°F (-29°C to 107°C)
Bypass Setting:Cracking: 25 psi (1.7 bar)
Element Change Clearance:4LK = 5.28” [134mm]
8LK = 8.62” [219mm]
12LK = 11.96” [304mm]
16LK = 15.30” [389mm]
Element Case:12 elements

Features:

  • Patent Pending In-tank filter design
  • Lightweight and as part of a tank optimization package can reduce reservoir size
  • Lock & Key Quality Protected, OEM-specific interfaces available
  • Superior de-aeration performance
  • Fixed head connection. Lines stay connected during element changeouts

Markets Served:

  • Automotive
  • Agriculture
  • Defense
  • Forestry
  • Industrial
  • Marine
  • Mining Technology
  • Mobile Vehicles
  • Oil & Gas
  • Railroads
  • Refuse


Find out if the AFTF is right for your application!

Contact-Blog-AFTF Introduction

  • Max. file size: 256 MB.

Head Space Dehydrator: Stop Water Contamination Before It Happens!



Most hydraulic reservoirs in major industries including pulp & paper, primary metals, and more feature a pocket of open space between the fluid level and the top of the reservoir. This open space, known as head space, fills with moisture as humid air ingresses via faulty seals, vents, and other entry points.

As the moisture builds in the head space, water condenses at the top of the reservoir, eventually coalescing and falling into the oil.

This water contamination can cause a range of serious problems which can impact your equipment’s efficiency and may require repairs, including:

  • Rust
  • Cavitation
  • Sensor failures
  • Reduced oil lubricity

How Schroeder’s Head Space Dehydrator Helps:

Dewatering units such as the Triton Dehydration Stations are excellent for targeting water contamination when oil has already become saturated, but preventing contamination before it reaches critical levels is ideal.

The new Head Space Dehydrator is designed to combat moisture in the head space of a hydraulic reservoir before it contaminates the oil. This unit is permanently installed on a hydraulic reservoir so that humidity inside the reservoir can be managed continuously.

Here’s how it works:

  1. The Head Space Dehydrator assembly pulls ambient air into the chamber through a series of particulate breathers.
  2. The clean, dry air is then blown through the head space above the fluid level, displacing and venting the moist internal air though existing ventilation points.
  3. As the moist air is displaced, the opportunity for water contamination via condensation is reduced.


Specifications:

Flow Rating:Max flow rate 282 cfm (7985 lpm)
Blower:1/2HP blower with 220-275/380-480V-60Hz-3 phase motor
Breathers:Uses 4 breathers which include -0.5 psi (-0.035 bar) differential pressure indicators

Features & Benefits

  • Cost effective, reliable solution for water ingression
  • Improved oil cleanliness
  • Increased lifespan of oil and components

Markets & Applications

Ideal for industrial applications where water contamination may be introduced to the reservoir head space, particularly:

  • Steel & Primary Metals
  • Pulp & Paper Production
  • Bulk Storage
  • and more!

Ask the experts at Schroeder what the HSD can do for your application!

Contact-Blog-HSD Introduction

  • Max. file size: 256 MB.

Triton Dehydrators: The Ultimate in Mass Transfer Dewatering Filtration

Banner image reading "Triton Dehydration Station" with a subheading reading "ask the experts"

Water Contamination Can Damage Your Hydraulic System

Water contamination in hydraulic systems is a common problem, which can severely reduce the life of hydraulic systems and fluids. If your hydraulic fluid appears milky when sampled, it’s likely that your system is experiencing high levels of water contamination.

Water ingression can occur in two primary ways:

  • Ambient humidity, which can ingress into the reservoir headspace and condense into the oil. Humidity can vary depending on the location and season, so pay attention to the conditions your equipment operates in and monitor your fluid condition accordingly.
  • Pre-contamination of new fluid due to poor storage. Be sure to examine any new fluid for water contamination before introducing it into your hydraulic reservoir.

You can expect the following if water contamination isn’t controlled:

  • Due to its chemical composition and density differing from oil, water can affect compressibility, impacting operational efficiency.
  • Water reduces oil lubricity and can lead to varnish buildup.
  • Water can also cause corrosion and oxidization in the system. Cavitation and damage to metal surfaces in the system may lead to costly replacements and increased downtime.

Trust the Experts in Water Removal & Dewatering Filtration

Schroeder Industries offers various products for targeting water contamination in hydraulic systems, backed by our vast expertise in fluid conditioning solutions. Our Triton Dehydrators, the TDSA and TDSE, bring proven performance across a wide range of applications where oil dehydration is needed.

Image of TDSA Triton Dehydration Station

The Triton Dehydration Station® series uses patented mass transfer dewatering technology to eliminate 100% of free water and up to 90% of dissolved water.

  • Ambient air is conditioned to increase its water holding capability before injecting to the reaction chamber.
  • Fluid is equally distributed and cascaded down through reticulated media and the conditioned air stream.
  • Water is transformed to water vapor and is expelled from the unit as moist air/stream.

View the specifications of our TDSA and TDSE units below!


Image of TDSA Triton Dehydration Station

Features:

  • Patented mass transfer technology uses ambient air to optimize and control dewatering rates
  • High Dewatering Rates and particulate removal in one system
  • 2.4kW heater option for unheated reservoirs
  • Simple Controls; RUN/DRAIN modes
  • Reduce fluid recycling cost
  • No expensive vacuum pump to service and replace
  • Compact, efficient footprint
  • Remove free and dissolved water
  • Highly effective in low and high humidity environments

Specifications:

Dimensions:45.2”(H) x 36.7″(W) x 20.3”(D)
Dry Mass:295 lbs (134 kg)
Inlet Connections:1″ SAE
Outlet Connections:1″ SAE
Flow Rate:120 gallons/hour or 2.0 gpm (7.6 L/min)
Permissible Inlet Pressure Range:-5.8 psig (-0.4 bar) to 32 psia (2.2 bar)
Max. Permissible Outlet Pressure:75 psig (5 bar)
Fluid Service Temperature:100° F to 150°F (40°C to 65.5°C)
Fluid Viscosity:70- 1000 SUS (13 – 215 cSt), Explosion-proof: 500 SUS maximum
Power Supply:110 VAC, 60 Hz, 12 amp
Attainable Water Content:< 50 ppm
Heater Options:220V/ 60hz/ 1 Phase, 460V/ 60hz/ 3 Phase
Relative Humidity Display:Standard, 0-99% Range
Construction:Reaction Vessel: Stainless Steel
Seals: Viton®
Protection Class:NEMA 2
Image of TDSE Triton Dehydration Station

Features:

  • Patented mass transfer technology uses ambient air to optimize and control dewatering rates
  • High Dewatering Rates and particulate removal in one system
  • Simple Controls – maintenance, operation and troubleshooting instructions are available in the Human Machine Interface (HMI) Touch Screen
  • Reduce fluid recycling cost
  • No expensive vacuum pump to service and replace
  • Compact, efficient footprint
  • Remove free and dissolved water
  • Highly effective in low and high humidity environments

Specifications:

Dimensions:32”W x 59”L x 70.25” H
Dry Mass:1000 lbs (453 kg)
Inlet Connections:1-1/2” MJIC
Outlet Connections:1-1/2” MJIC
Flow Rate:15 gpm Standard, (other options available)
Inlet Pressure:Atmospheric
Outlet Pressure:to 125 psi (8.62 bar
Fluid Service Temperature:50° F to 175°F (10°C to 79°C)
Fluid Viscosity:70-2000 SUS (13 -539 cSt), 2500 with heater
Power Supply:460 V/3/60 Hz, 13 amps
460 V/3/60 Hz, 28 amps w/heater
575 V/3/60 Hz, 10.5 amps
575 V/3/60 Hz, 23 amps w/heater
Attainable Water Content:< 50 ppm
Relative Humidity Display:Standard, 0-99% Range
Construction:Standard, 0-99% Range
Base Frame: Carbon Steel
Vessel: Stainless Steel
Seals: Viton®
Protection Class:NEMA 2

Schroeder Success: See How This Customer Saved!

Don’t just take our word on the effectiveness of the Triton Dehydration Station® series. Review the case study below to see how a real customer benefited from these advanced dehydrators!

Image of TDSA Triton Dehydration Station with automotive manufactured parts in the background

When an automotive parts manufacturer found high water levels in the hydraulics of a critical hydraulic press in their facility, they needed a solution quickly.

With the very close timetables of automotive part production, any downtime could be devastating to their operations—but solving their water contamination issues required an unobtrusive fix, too.

With a rental TDSE from Schroeder Industries, the customer was able to resolve their contamination issues, reduce their oil consumption, and maintain uptime without unduly interrupting operations.

In fact, the performance of the TDSE was so impressive that the customer ultimately purchased their own TDSA to maintain fluid quality and ensure continued high performance!


Ask the experts at Schroeder Industries if a Triton Dehydration Station could be right for your application!


Contact-Blog-Triton Dehydrators

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Introducing the GPT: Superior Filtration for Cold Start Conditions

Header image featuring GPT filter images on an oil splash background. Text reads: Schroeder GPT. Protect your system from bypass contamination with this innovative filter. Contact the experts.

Schroeder Industries works tirelessly to provide innovative, effective filtration solutions. The GPT is a new hydraulic filter engineered to resolve a common problem with similar filters on the market: contamination from the bypass.



What makes the GPT the ideal hydraulic filter for cold start conditions?

Image of GPT filter with a splash of oil.

When a hydraulic machine is shut down and the fluid stops flowing, contaminants will settle loosely onto the filter.

In cold start conditions, when the viscosity of the hydraulic fluid increases, the high differential pressure will force the filter into bypass. Until the machine and fluid warms up, thus lowering the  viscosity, the fluid will bypass the filter and enter the hydraulic system directly.

Competitive filters currently available in the market have the bypass located low or within the element, where contaminants have settled during shutdown. If the system starts in bypass, all of that dirt is forced into the system without being filtered, flooding the system with harmful contaminants.

Unlike these other filters, the GPT bypass is located up top, in the diverter cap. This keeps the contaminants settled in the bottom of the filter from entering the system through the bypass.


Flow Rating:Up to 175 GPM (662 L/min) FOR 150 SUS (32 cSt) Fluids
Max. Operating Pressure:150 PSI (10.3 bar)
Min. Yield Pressure:Consult Factory
Rated Fatigue Pressure:89 psi (6 bar)
Temp. Range:-20° F to 225° F (-29° C to 107° C)
Bypass Setting:Cracking: 35 PSI (2.4 bar)
Ported Head and Cap:Die Cast Aluminum
Element End Caps:Nylon
Weight:7 LBS. (3.18 kg)
Element Change Clearance:20.0” (508 mm)

Features:

  • Filter bypass in cap vs base, provides cleaner cold start
  • Patent-pending in-tank design
  • Lock & Key Quality Protection
  • Reusable diverter cap offers environmental advantages
  • Fast, easy change-out solution
  • A variety of media options and micron ratings

Markets Served:

  • Automotive
  • Agriculture
  • Defense
  • Forestry
  • Industrial
  • Marine
  • Mining Technology
  • Mobile Vehicles
  • Oil & Gas
  • Railroads
  • Refuse

Diagram showing the GPT filter reusable diverter cap, separated from the filter element.

Reusable diverter cap reduces landfill waste for a more sustainable filter design.

An unfortunate reality of filtration is the disposal of used elements, which contributes to the waste stream.

Keeping with the principles of our Energy Sustainability Initiative, Schroeder Industries is always looking for more sustainable angles in our product designs.

Our engineers saw the opportunity to reduce waste in our GPT design by developing a reusable diverter cap. Typical filters discard the diverter cap along with the filter element, but the reusable GPT design reduces the amount of waste material being disposed of.

With the GPT, element changeouts are fast and easy, and the Lock & Key Quality Protection ensures that only the highest-quality elements are being used.


Banner reading: Learn more about the GPT and assembly process! View data sheet.

Contact the experts at Schroeder Industries

Interested in the new GPT filter? Contact our filtration experts for more information!

Contact-Blog-GPT Introduction

  • Max. file size: 256 MB.

Enhance Hydraulic Equipment Through Tank Optimization

How can tank optimization benefit you? Ask the experts.

Rising oil and fuel costs, trends towards electrification, and overall concerns about sustainability across virtually every industry are driving an increased push for improved efficiency in the designs of hydraulic equipment.

Schroeder Industries family of hydraulic tanks, TNK Series

One area where great opportunities for improvement lie is with the hydraulic tank. Due to inefficient designs, many machines operate with oversized hydraulic tanks containing more oil than needed.

Many benefits can be realized through tank optimization, including:

  • Increased energy efficiency
  • Overall machine weight savings
  • Steel and oil savings per machine
  • CO2 emission reduction
  • Tank downsizing
  • Additional machine space for other features

Read on to learn more about the benefits of optimizing your hydraulic reservoir, and how Schroeder Industries can help:


What Is Tank Optimization?

The goal of hydraulic tank optimization is to reduce the reservoir size and thus reduce its fluid volume. Two main factors determine how much a tank can be optimized:

  • Volume Utilization. In a suboptimal reservoir design, ‘dead zones’ can appear, where fluid stagnates and is not effectively utilized by the system. In a properly designed tank, every cubic inch of the hydraulic fluid should circulate within the reservoir. Dead zones can be detected by digital simulations, and are a strong indicator that tank optimization is needed.
  • Fluid Velocity. Fluid velocity impacts how well a tank can de-aerate, or release trapped air from within the fluid, and prevent new air from entering the fluid due to splashing. Increased air contamination causes a variety of issues within hydraulic systems, decreasing operating efficiency and component lifespan. Fluid velocity can be reduced through improved in-tank filtration and adjusting the structure of the hydraulic tank itself.

The Benefits of Hydraulic Tank Optimization

Here’s some of the ways optimizing a hydraulic tank design can benefit both OEMs and end users:

  • Cost Savings. Downsizing a reservoir with tank optimization means less steel and oil are needed upon initial construction, reducing up front manufacturing expenses for OEMs. Additional savings are passed on to end users, who will need less hydraulic oil to run the equipment over its lifetime.
  • Improved Energy Efficiency. A smaller reservoir with reduced fluid volume reduces the overall weight of the equipment, translating to improved energy efficiency. Lower fluid volume also reduces warmup time in cold start conditions. Any improvements in energy efficiency are especially important for electric-powered equipment, which relies on more limited battery power.
  • Increased Machine Space. A smaller hydraulic reservoir can allow overall downsizing of the equipment or make way for additional improvements to the design. Larger batteries or fuel tanks, cooling units and other beneficial modifications can be made when space is freed up within the machine.
  • Sustainability Benefits. Tank optimization reduces the carbon footprint of an operation in several ways:

    1. By downsizing a reservoir, less hydraulic oil must be produced and then disposed of, reducing the emissions from both the initial manufacturing of the oil and lowering the amount of waste oil per machine.

    2. The carbon footprint of initial construction is also mitigated by the reduction in materials needed to create the reservoir itself.

    3. Improvements in fuel efficiency for diesel and other fossil fuel-powered equipment reduces CO2 and other harmful emissions overall.

    4. Finally, the increase in energy efficiency and available machine space can open up avenues for electrifying equipment, or improving the performance of electric-powered machines, which are at the forefront of sustainable equipment.

The benefits of optimizing your tanks are clear, and the filtration experts at Schroeder Industries can help you get the most out of your reservoir.


Tank Optimization Services from Schroeder Industries

Rendering of flow simulation using a TNK.

Schroeder Industries is leveraging our extensive experience in hydraulic system filtration components towards tank optimization. Through cutting-edge flow simulations, our experts can identify dead zones and inefficiencies in hydraulic tank designs and work with your company to develop a solution that suits your specific application.

The benefits of optimizing your hydraulic tank are more than just theory. In the following case study, learn how one OEM saw substantial savings with Schroeder’s tank optimization services:


Closeup image of stump grinding machine with TNK12 in the foreground

An OEM customer producing stump grinding machines for the forestry industry came to Schroeder Industries searching for updated filtration solutions.

An engineering analysis of their fabricated tanks found that not only were they heavy and prone to weld cracks: The volume utilization was subpar.

Further testing concluded that the existing Schroeder TNK12 would provide equivalent deaeration performance to the customer’s current tanks with a 40% reduction in tank volume.

This resulted in substantial savings on both oil and tank production cost in their stump grinder manufacturing:

Oil reduced per unit: 8 gallons
Oil Reduced annually: 4,000 gallons
Cost savings: $28,000 USD
Labor cost per TNK: $30 USD
TNKs used annually: 500
Labor cost savings: $15,000 USD

TNK Series and Air Fusion Technology

Schroeder’s tank optimization services are backed by expertly crafted reservoirs and filters. Learn more about these premium products:

Schroeder Industries TNK7 with Air Fusion Technology AFT filter.

Lightweight tanks, heavyweight performance! The Schroeder Industries series of rotomolded HDPE tanks are lighter than traditional steel tanks, but built to take a beating in the field with no risk of corrosion. Available in five performance optimized sizes, with custom options available, there’s almost certainly a TNK for your application.

Engineered with baffling that improves deaeration and cools returning oil by creating settling zones, these tanks are designed to assist in the ever-important degassing of hydraulic fluid.

Specifications:

Tank Materials:High Density Polyethylene (HDPE)
Tank Volumes:4 gal (15L)
7 gal (26L)
12 gal (45L)
18 gal (70L)
25 gal (100L)
Operating Temperature:High Density Polyethylene (HDPE) 20°F to 180°F (-29°C to 82°C)

Nylon (PA)
32°F to 240°F (0°C to 116°C)
Max. Return Flow:TNK4: 25 gpm
TNK7: 35 gpm (135 L/min)
TNK12: 40 gpm (150 L/min)
TNK18: 40 gpm (150 L/min)
TNK25: 75 gpm (284 L/min)
TNK Weight:TNK4 (AFT4): 11.5 lbs (5.2 kg)
TNK4 (AFT8): 11.5 lbs (5.2 kg)
TNK7: 16 lbs (7.3 kg)
TNK12: 21 lbs (9.7 kg)
TNK18: 33 lbs (15 kg)
TNK25: 45 lbs (20 kg)
Schroeder Industries Air Fusion Technology AFT filter

Schroeder’s secret weapon in the quest for tank downsizing is the AFT. This next-gen in-tank filter offers superior deaeration, engineered to reduce fluid turbidity and enhance degassing, reducing the amount of air entering the hydraulic system.

With this powerful filter, see up to 60% reduction in reservoir size! With the AFT, our goal is to create a smaller, more efficient hydraulic system to help our customers get the most out of their fuel source.

Specifications:

Flow Rating:40 gpm (151 L/min)
Max. Operating Pressure:100 psi (7 bar)
Min. Yield Pressure:350 psi (24 bar)
Rated Fatigue Pressure:100 psi (7 bar)
Temp Range:-20°F to 225°F
(-29°C to 107°C)

Ask The Experts How Your Tank Can Be Optimized!

If you could be getting more out of your reservoir and in-tank filtration, Schroeder Industries can help.

Tank Optimization Request Form-Tank Optimization Blog

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AutoFilt® RF9: Superior Process Filtration for Hydroforming


Header graphic with text reading: Superior Filtration for Hydroforming. How can your business benefit from the AutoFilt® RF9? Ask the Experts.

What is hydroforming?

Hydroforming is a specialized deep draw manufacturing process used to create a wide variety of metal components and is especially popular within the automotive industry.

In the sheet hydroforming process, highly pressurized water is applied into a mold, and the water pressure forces the metal to conform to the shape of the die.

Diagram showing the hydroforming process.

Compared to conventional stamping methods, hydroformed parts can be created in more complex shapes with greater efficiency, thinner metal sheets, and high-quality surface finish.


Why is process filtration so important for hydroforming applications?

Like any process water application, contamination can greatly affect the lifespan and performance of the high-pressure hydroforming press.

To protect vital downstream components like high pressure pumps and manifolds from wear and tear, high-quality process filtration is a must for any hydroforming system. If left unchecked, contamination can wear out machine components, reducing operational efficiency and forcing expensive repairs and costly downtime. Additionally, defective/scrap material output can increase.

The process filtration experts at Schroeder Industries understand the impact that high-quality filtration has on a business. We can find a Schroeder solution for virtually any process filtration application, including hydroforming:


Why is an AutoFilt® RF9 from Schroeder Industries the best choice for your hydroforming application?

Image of the AutoFilt® RF9 filter with a water splash in the background.

The AutoFilt® RF9 is Schroeder’s first choice for filtration in hydroforming applications. Already, the RF9 has seen great repeat success in the hydroforming division at one of the world’s largest automotive frame manufacturing plants.

Here’s what makes the RF9 so effective:

  • Super fine filtration with minimal pressure loss. When filtering process fluid or water for a high pressure application, it’s critical to both achieve the lowest micron filtration levels as possible while minimizing pressure loss. The RF9 is capable of filtering down to 5 microns in a standard hydroforming setup.
  • Eliminates costly, disposable cartridges. The automatic back-flushing mechanism within the RF9 cleans the re-usable filter elements in under a minute, with minimal interruption to the filtration process.
  • Low-maintenance and service-friendly. Elements are held securely in the RF9, but are easy to access and require no special tools or torque to change out.
  • Customizable with options like bypass filters, external heaters, backwash waste treatment units, and more.

Connection Sizes:DN 32 to DN 350
Flow Rates:1000 m3/h (4400 GPM)
Pmin / Pmax:2.0 bar / 16.0 bar (29-232 PSI)
Max. Operating Temperature:180° C (356° F)
Filtration Ratings:3 to 500 μm
Filter Elements:– Chemicron® metal fibre
– Dutch weave
– Square mesh
Filter Housing Materials:EN-GJS-400-15 / DIN EN 1563 / AD-2000 W3/2
Material of Internal Parts and Filter Elements:– Internal parts: steel and cast iron
– Filter elements: stainless steel
Control Parameters:Electronic or PLC control unit

The AutoFilt® RF9 is defined by its globally unique, patented hydropneumatic back-flushing technology with secure media separation.

Features

  • Back-flushing driven by external air system, rather than using system differential pressure
  • Large filter surface for its compact size
  • Low-maintenance, service-friendly design
  • Suitable for fuels, cooling lubricants, lubricating oils
  • External heater possible
  • Optional: bypass filter
  • Optional: Backwash Treatment Unit for back-flush volume treatment

Advantages

  • No mixing with the compressed air
  • Adjustable back-flushing intensity
  • Efficient hydraulic cleaning
  • High cleaning efficiency
  • No reduction in pressure during back-flushing
  • Low compressed air consumption
  • Low pressure drops
  • Intelligent control system

Let the experts at Schroeder Industries help find the perfect solution for your process application!

Backed by over 75 years of innovation, industry experience, and proven successes, Schroeder Industries can work with you to find the optimal solution for your filtration needs. Let us know how we can help you:

Contact-Blog-RF9 Hydroforming

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Every Successful Filtration Plan Starts With Superior Oil Analysis



Clean Oil is the Key to Productivity

Is your hydraulic equipment experiencing more downtime than usual? Are you noticing that your equipment is operating less efficiently?

If your operation is paying a price for the inconsistent performance of your vital equipment, high contamination is most likely to blame.

Hydraulic fluid contamination from a variety of sources is by far the most common cause of system inefficiency and failures. In fact, approximately 80% of all hydraulic equipment failures can be directly attributed to the effects of fluid contamination!

Consistently clean hydraulic oil is vital to every operation that relies on hydraulic equipment. Additionally, systems that rely on process water or run on diesel fuel are also vulnerable to the effects of contamination. Proactive measures to analyze fluid and prevent contamination provide significant benefits to cost and productivity:

  • Prevent costly equipment failures and downtime before they happen by detecting and treating contaminated fluid.
  • Save money on repairs by protecting system components from contamination and extending their lifespan.
  • Get the most out of your hydraulic oil by detecting and treating contamination before the oil’s life is exhausted. As oil prices continue to rise and hydraulic oil supply lines remain unstable, it’s important to conserve the oil you have!
  • Increase fuel efficiency not just by filtering your fuel source, but by improving overall system efficiency when you reduce contamination-related wear. Clean fuel and efficient operation reduces fuel consumption, cuts carbon emissions, and saves your operation money.

Struggling with Fluid Contamination? Fluid and Oil Analysis Services by Schroeder Industries Can Help!

Backed by over 75 years of innovation, Schroeder Industries is a leader in developing filtration products and technology that detect, analyze and remediate contamination to protect hydraulic systems and other vital equipment.

When contamination is attacking your equipment, the first step towards an effective filtration plan is a thorough analysis of the affected fluid, be it oil, fuel, or water.

Our fluid health experts will test your samples and create a detailed report, identifying the type and potential sources of contamination in your system and giving recommendations on how to best protect your equipment.

Schroeder offers a variety of premium testing kits, including:

Offering a comprehensive look at your hydraulic fluid or water glycol condition, our bottle sampling Bottled Fluid Analysis Test Kits provide vital insights into your fluid health.

Use Filter Debris Analysis (FDA) Test Kits alongside traditional oil analysis methods to analyze wear particles and discover the root cause of premature equipment wear & failures.

Diesel analysis can identify potential causes for fuel filter plugging, smoking, loss of power, poor injector performance, malfunctioning throttle position sensors and sticking valves. Testing also confirms a diesel fuel’s sulfur content, biodiesel content and compliance with manufacturer specifications and standards for cleanliness that could affect equipment warranty requirements.

The WaterTest Kit (WTK) is used for quantitative analysis of the absolute water content in mineral-oil-based lubricating and hydraulic fluids. Use to perform quick, on-site analysis of water contamination and supplement on-site laboratories.


Monitor Contamination with Schroeder’s State-of-the-Art Fluid Care Portal


Regular testing is vital for monitoring trends in your fluid health and preventing problems before they arise. However, tracking results over time for many pieces of equipment takes time and hassle.

As part of our testing and analysis services, Schroeder Industries is now offering a smart digital solution for detecting trends in the quality of your hydraulic oil, diesel fuel, process water, and more.

The Fluid Care Portal is a new, powerful digital tool for easily tracking the health of your equipment’s fluid as you test over time:

  • All your data is in one place, versus scattered over spreadsheets or various paper reports.
  • Easily monitor trends in fluid testing data over time, allowing you to detect and resolve contamination issues before they begin impacting your bottom line.
  • Monitor as many equipment assets as you need. Whatever the size of your operation, the Fluid Care Portal allows you to individually monitor the testing results for each piece of equipment.
  • Receive alerts when ISO Code, Water Content, or other parameters are exceeded. In the Fluid Care Portal, users can set target limit profiles for various parameters, creating customized criteria for your most critical components

Schroeder Filtration Services

Once a proper diesel, fluid or oil analysis has unlocked the source and quantity of contamination, filtration is the next step.

If you aren’t prepared for the upfront cost of purchasing filtration equipment, Schroeder Industries makes our state-of-the-art equipment available through our Rental Program and Filtration Management as a Service. Learn more about how these services can benefit your operation!

Schroeder Rental Equipment Program

Enjoy the benefits of Schroeder Industries’ exceptional filtration equipment without a large capital investment. Superior filtration extends oil life and increases machine reliability and energy efficiency.

Filtration Management as a Service (FMaaS)

With this turnkey service, Schroeder Industries will plan, execute, and manage your filtration strategy and filtration equipment, allowing you to focus on running your business with peace of mind!


Take the First Step in your New Filtration Plan

Our fluid care experts can help you determine the right test kit for your needs and provide vital insight into the health of your fuel, process water, or hydraulic oil. Contact us today!

Oil Analysis Request Form

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Save Oil Through Filtration and Reduce Your Carbon Footprint


An operation’s carbon footprint is influenced by many factors, and making a business more sustainable requires a combination of solutions. One often overlooked way to increase sustainability is through optimal oil filtration.

All hydraulic oil, turbine oil, and other lubricants have a lifespan, as contamination and the breakdown of chemical compounds degrade oil over time. If contamination is left unchecked, oil reaches the end of its usability much faster.

Waste oil is challenging to dispose of properly, and high oil turnover increases demand for the very energy-intensive production of new oil. Much of the hydraulic oil and engine oil in use today is disposed of before its usable life is up.

Every gallon of oil that is conserved by extending the lifespan of existing oil directly contributes to a reduced carbon footprint. So, how do you get the most out of your oil?

Utilizing offline filter systems and high-quality filter elements is proven to extend the lifespan of oil significantly by removing contaminants and slowing the degradation of the oil.

Check out the following case studies where Schroeder Industries products saved a significant amount of oil or extended its service life:

Offline Filter System Saves Manufacturer 2,600+ Gallons of Oil Per Year

A plastic parts manufacturer in the automotive industry experienced frequent failures and downtime in their 16 injection molding machines. Like the majority of hydraulic system failures, high contamination load was identified as the cause. Without a quality control program for the machine oil, the customer changed oil frequently before its usable life was up.

Schroeder Industries stepped in, providing the customer a customized offline filtration system designed to tackle the high contamination:



Contamination-Related Downtime Reduced 54%


2,600+ Gallons of Oil Saved Per Year


$616,916 Cost Savings Per Year


Specialized Anti-Static Filter Elements Increase Oil Life by 3 Years at Paper Mill

When a paper mill was experiencing a shortened filter element life of just 30 days, Schroeder Industries stepped in to extend the filter life, reduce oil waste, and reduce unscheduled downtime.

An expert investigation revealed the culprit affecting the filter elements: static discharge. Static charges can build up in a hydraulic system due to friction between the fluid and system components. In this case, the static was burning and damaging the elements, causing them to prematurely fail.

By switching to Schroeder’s ASP® Anti-Stat Pleat Media, the electrostatic discharge no longer caused significant problems for the customer. Here are just some of the benefits from this filter element switch:



Filter Life Increased +5 Months


Oil Service Life Increased +3 Years


$12.2K Oil Cost Savings Per Year


Varnish Mitigation Unit (VMU) Increases Oil Life by 3.5 Years, Saves Nearly 1,000 Gallons Per Year at Waste Incineration Facility

Operations at a waste incineration plant were constantly disrupted by constant turbine problems on startup.

A survey of 22 machines revealed the issues were the result of varnish buildup in the control block, caused by usage of incorrect oil in certain machines and an inexpensive, ineffective return line filter element. Varnish is a byproduct of aging oil, and is accelerated by contamination, temperature extremes, and other factors.

Schroeder Industries implemented a VMU to continually filter the turbine oil and tackle harmful varnish buildup. This not only reduced downtime and increased productivity, it also helped the customer in the following ways:



Oil Service Life Increased +3.5 Years


986 Gallons of Oil Saved Per Year


$12.1K Oil Cost Savings Per Year


Schroeder Industries’ Energy Sustainability Initiative

The Energy Sustainability Initiative is Schroeder Industries’ mission to provide fluid power filtration solutions that contribute to a cleaner world and help organizations reach their sustainability goals.

Conserving oil is just one of the ways the products from Schroeder Industries are helping move the world forward towards a more sustainable future. Learn more!


Contact the Experts at Schroeder Industries

If you are experiencing issues such as increased machine downtime, frequent repairs, shortened filter life, and more, the experts at Schroeder Industries can help solve them! Our customers have seen proven increases in oil life and oil-related savings.

Contact-Blog-Save Oil Through Filtration

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