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Expanding $10K-1M+ cost-saving “Fast Fifteen”!

Expanding $10K-1M+ cost-saving “Fast Fifteen”!

Schroeder Industries is expanding the courses available through the popular TCO reduction strategy program for OEM and MRO Operations.

Photo of construction worker promoting the Schroeder Industries' Fast Fifteen program with the tagline "give us fifteen - we will give you targeted fluid cleanliness concepts for your machine."

Leetsdale, PA. (March 10, 2021) – Schroeder Industries, a recognized leader in Advanced Fluid Conditioning Solutions®, is continuing the Fast Fifteen program by expanding the course materials offered in 2021.

Schroeder’s Fast Fifteen Program started in May 2020 at the crest of the pandemic.

With most corporations vying for attention during the newly adapted digital age, Schroeder began providing online content (15-minutes or less) proven to help OEM’s and MRO Operations save thousands of dollars.

Organizations have been joining Schroeder’s expert staff for one-on-one reviews and learning ways to:

  • Increase aftermarket revenue stream(s)
  • Reduce oil consumption
  • Optimize hydraulics’ equipment space
  • Enhance component replacements
  • And so much more!

With 29 available courses, there is an opportunity for every type of operation to save thousands of dollars in return for just a 15-minute investment in time.

About Schroeder’s Fast Fifteen?

Schroeder’s Fast Fifteen Program is an all-new training program for OEM’s and MRO Operations. In just 15 minutes time, we will come to a meeting with you and your engineers with the knowledge we have of your company and offer you a suggested fluid cleanliness concept that can save you money and other ROI measurables. Perhaps you could benefit from one of our many aftermarket revenues programs, maybe you’re using and spending way too much money on oil, or maybe you’re noticing a decrease in system availability and an increase in maintenance repair. With our 75 years of expertise, we’re confident that we can help your already impressive operation.

Who is involved?

With 75 years of experience helping the world’s largest OEM and MRO Operations, we’ve learned a thing or two about machine reliability. That is why we have industry experts for machines that run hydraulic and lubricants, fuel and diesel fuel, as well as process water and low-viscosity fluids ready to answer any questions and address concerns you may be experiencing with your plant or fleet equipment.

 

Available Courses:

A list of courses offered through Schroeder's Fast Fifteen program.

 

Initial TCO Reduction Strategy Proposition

When partnered with Schroeder Industries, a customer noticed savings in the form of a quarter more oil service life in their hydraulic turbine, a massive drop in their annual oil usage and a decrease in replacement parts cost.

Sign up below and we’ll schedule a time:

Schroeder Industries' Fast Fifteen Signups

Give us 15 - we will give you targeted fluid cleanliness concepts for your machine. Some of our Fast Fifteen topics include the tools and techniques needed to achieve extended oil drain intervals w/o warranty concerns, how to reduce reservoir sizes by up to 60% through patented air removal designs, how to triple OEM aftermarket revenue programs w/ 100% OES capture, new high efficiency diesel solutions tailored for Tier IV Demands, and more!
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  • Ctrl+ Click to select the course topic(s) you are interested in learning more about.
  • This field is for validation purposes and should be left unchanged.

 

 

 

Overcoming “Phantom” Particle Counting

From: Schroeder Industries’ Filter Systems and Diagnostics (IoT) Product Group

Overcoming “Phantom” Particle Counting


Digital Imaging Picture shows operating software of Schroeder Pro: Total Fluid Health

Imagine this…

  • You have been filtering 30 gallons of your operating fluid in bypass with staged 5- and 1-micron filter elements at a processing rate of five gallons per minute (gpm) (300 gallons per hour (gph)).
  • You have been using a Light Blockage Method (LBM)-based portable particle counter to verify the fluid cleanliness.
    • The starting cleanliness per ISO 4406 2017 was 25/22/15 ISO cleanliness code.
  • After eight (8) hours, the cleanliness has only dropped to 22/20/13 ISO cleanliness code.
    • A difference of about 3 points.
  • You’ve checked that the filter element is not clogged and not in bypass.
    • You even went through the trouble of making sure there was an element actually in the filter!

How could this be possible?

It couldn’t be, right?

What you’re likely experiencing is a classic case of “phantom” particle counting.

 

Demystifying the “Phantoms” in your Fluid

“Phantom” particle counting is a documented problem faced when using LBM portable counters to verify the oil cleanliness class of petroleum-based fluids containing certain insoluble additives.

Silicone-based antifoam agents are common interferents of LBM particle counters.

Fluids used in mobile fluid power systems are typically formulated to contain high antifoam concentrations.

Research has suggested that through differential surface tension, the silicone antifoam additive agents adhere to the inner wall of microscopic, entrained air bubbles, resulting in micelle-like encapsulations of the additive agents that then take on the apparent shape characteristics of a water droplet [1].

The measurement of particle size for micelle-like antifoam agent encapsulations typically range in 4-10µm size range [2].

Once the encapsulations rise to the fluid surface, the agents quickly pierce the air bubble and return back into the fluid.

In a related study of the effects of a variety of non-solid contaminants and additives on LBM particle counting accuracy, it was found that a base stock mixture containing 0.02% (by weight) of a silicone antifoam agent increased the LBM laser particle count by a minimum factor of three [1].

The erroneous particle accounts were particularly evident in the 4µm and 6µm channels of the ISO 4406 2017 cleanliness standard [2, 3] (see also NAS cleanliness standard or SAE AS4059).

 

Limitations of the Light Blockage Method (LBM)

LBM or Light Blockage Method fluid analyzers are useful in many applications.

The principle of the light blockage method is fundamentally simple: fluid flows through a measurement cell containing a light source on one side of the measurement cell, and a receiver (photodetector) on the opposing side of the measurement cell.

The light source becomes partially blocked as the number of particles pass through the measurement cell, creating a light radiation differential—a shadow—corresponding to the circular cross-sectional size of the passing particles.

The operating principle measures particles based on the space between the shadow and the receiving end of the light source.

Because of this fundamental operating principle, LBM portable counters suffer from a key drawback: the lack of and the inability to discern solid contaminates (like metallic composition) from other contaminates like water, air bubbles, “phantom” particles, and so on.

So, how can the “phantom” particles be overcome using oil particle counter sensor technology?

There is an alternative solution to this question: oil particle counting using the Direct Imaging Method.

 

Direct Imaging Method

Direct Imaging particle counting software uses size and shape-recognition technology, based on advanced algorithms, as a dirt classifier to distinguish contaminates.

For example, a Direct Imaging portable information counter can distinguish contaminates into fatigue, cutting and sliding wear with a metallic wear debris sensor and fiber and air bubble categories based on shape characteristics.

It can also recognize water droplets.

The distinction of contaminates allows for a more accurate particle counting by negating non-solid contaminates like entrained air bubbles and water droplets.

Therefore, Direct Imaging particle counting technology can negate the micelle-like antifoaming additive encapsulations as water droplets— “phantom” particles—allowing users to understand the condition of their fluid samples with confidence.

Case Studies 1 and 2 demonstrate how the Schroeder Pro: Total Fluid Health (TFH)–one example of a fluid condition monitoring solution with Direct Imaging particle counting technology–can be used in practical applications to overcome “phantom” particle counting.

 

Case Study 1

An OEM of large off-highway equipment was experiencing continuous oil particle counter inaccuracies at a verification stage of assembly:

  • The rejections due to fluid condition were mounting, causing delayed shipments and significant related costs.
  • The average holding time delay due to rejection was seven days and incurred a holding cost of $1,500, per day, per unit.
  • At the consultation phase of the case study, eight units had been delayed.

The diagnosis was in…

The existing light-blockage-type particle counters were providing inconsistently high and erroneous particle counts.

The ISO 4406 2017 ISO cleanliness code would frequently measure a 23/22/19 size range, despite a strong fluid maintenance and conditioning regime.

Third-party fluid analyzer reports and fluid datasheets suggested that the fluid (synthetic hydraulic fluid) contained a high concentration of a siloxane (silicone derivative) antifoaming additive known to cause “phantom” particle measurements in LBM automatic particle counters.

Schroeder Industries provided an extensive on-site demonstration that proved the advanced Direct Imaging Method technology of the Schroeder Pro: Total Fluid Health (TFH) hydraulic fluid particle counter solution, which measured an average ISO 4406 2017 fluid cleanliness of 15/14/10, allowed the customer to successfully process the fluid of and pass six units during the first day of demonstration.

The two remaining backlogged units passed early on the second day of demonstration.

The realizable savings—evidenced by the demonstration—equated to:

  • Approximately 35% in cost savings and
  • 81% reduction in holding time.

 

Case Study 2

Similar to Case Study 1, an OEM of mobile equipment was measuring unusually high particle counts with their LBM computer particle analyzer after switching to a new hydraulic fluid type with a higher concentration of an antifoaming additive.

Coincidentally, the fluid type was nearly equivalent to that used by the off-highway equipment OEM.

According to the customer, the average oil particle counter of four fluid sample trays of fluid collected from the customer’s well-conditioned bulk fluid storage measured 25/23/20 iso cleanliness code, as shown in table 1.

 

Sample ≥4µm ≥6µm ≥14µm
I 25 23 19
II 25 23 19
III 25 23 21
IV 25 23 19
Average 25 23 20

Table 1 Sample cleanliness results of fluid containing a high concentration of antifoaming additives according to ISO 4406 2017

 

After consulting the customer of the “phantom” oil particle counting issue, Schroeder Industries offered to process fluid samples using a third-party LBM portable counter and the Schroeder Pro: Total Fluid Health (TFH) hydraulic fluid particle counter solution to determine if there was evidence of the phenomenon.

Because of the tell-tale symptoms of particle counting inaccuracies due to “phantom” particle size analysis, the results of the tests shown in table 2 are not surprising; the test results are consistent with typical cleanliness discrepancies produced by “phantom” particles.

 

Sample Processed w/ Third-Party LBM Particle Counter Processed w/ TFH
I – Bulk Fluid Storage Tank 24/23/18 17/16/15
II – Machine Reservoir 23/21/16 18/17/16

Table 2 Comparative sample cleanliness results of fluid containing a high concentration of antifoaming additives according to ISO 4406

 

Keep on Counting…with Direct Digital Technology

It’s no secret that understanding fluid cleanliness is imperative for strategically maintaining fluid-powered and lubricated machines.

Automatic particle counters using the Light Blockage Method (LBM) are generally considered reliable solutions for fluid storage monitoring.

However, LBM particle counters can yield inaccurate measurements while processing fluids that are contaminated by water, entrained air, or high levels of certain additives.

Silicone-based antifoaming agents are common, well-documented additive interferents that become encapsulated within entrained air bubbles that lead to a phenomenon referred to as “phantom” particles.

“Phantom” particles are indiscernible by LBM particle counters due to their fundamental principle of operation.

Research suggests that “phantom” particles can lead to LBM particle counter measurements to be greater than three classes higher than the true cleanliness per ISO 4406 2017.

While they can be filtered out—one possible reason for the slight cleanliness improvement in the hypothetical scenario of the introduction–the additives that can lead to “phantom” particles serve important, specific functions and should not be removed or sacrificed.

An alternative solution to LBM automatic particle counting is the Direct Imaging Method.

The Direct Imaging Method of particle counting uses size and shape-recognition technology in tandem with advanced data-driven algorithms to distinguish solid contaminates into metallic wear debris sensor and fiber categories, and from non-solid contaminants like water droplets and air bubbles.

Because of the apparent water droplet-like shape characteristics of the antifoam encapsulations, Direct Imaging solutions such as the Schroeder Pro: Total Fluid Health (TFH) can indirectly negate the “phantom” particle counts and provide more accurate fluid cleanliness measurements.

 

References:

[1] Michael, P. W., Wanke, T. S., & McCambridge, M. A. (2007). Additive and base oil effects in automatic particle counters. Journal of ASTM International, volume 4 (4).

[2] Ceco, E. (2011). Image analysis in the field of oil contamination monitoring (LiTH-ISY-EX–11/4467—SE) [Master’s Thesis, Linköpings universitet].

[3] Nadasdi, T. (2007, May). Do we really know what we are measuring? Efficiency Plant.

 

For more information on demystifying “Phantom” Particle Counts, please contact us.

Good News for the End of 2020

From: Schroeder Industries’ Fuel Filtration Center of Excellence

New in Bulk Diesel Filtration from Schroeder Industries


Seasons Changing

The changes of the seasons are upon us all. Fall is setting in the Northern Hemisphere. Spring is in bloom in the Southern Hemisphere. Here is how Schroeder Industries is helping with all of your diesel fuel filtration needs.

Introducing the BDFP and BDFPE from Schroeder Industries

2020 has been a challenging year for so many of individuals. Here at Schroeder Industries, we want to share some good news from our side. Today, we are introducing you to our Bulk Diesel Filtration Panel (BDFP) and our BDFPE (Bulk Diesel Filtration Panel Enclosed).

These Schroeder in-line fuel polishing systems are designed with options from the most basic of operation and integration to hands-free automation and programmable functionality. By using the GHPF, GHCF, BDF2 and BDS products as the foundation for the BDPF and BDFPE, we are able to incorporate that same patented water removal technology and high efficiency particulate filtration of the core components detailed in previous posts and trainings.

These turn-key systems can effectively remove both free and emulsified water as well as solid contamination. This prevents the microbial growth from thriving in the stored fuel.

These systems are competitively priced and outperform all of the competitive products in all categories and performance objectives. By having a better performance with a higher throughput, the Schroeder system can offer the best return on investment.

The BDFP and BDFPE ensure reliable protection of the customers’ installations and equipment. These systems can be “private labeled,” thereby generating new revenue otherwise lost today.

Technical Specifications Shown Below: 

Technical Specifications BDFP BDFPEBulk Diesel Filtration Panel

 

 

 

 

 

 

 

 

 

 

 

 

 

How Do They Work?

The BDFP has flow ranges of 14 GPM/ 840 GPH up to 25 GPM /1500 GPH with the electric option. There is an air driven pump option as well at similar flow rates.

This allows for use in applications where electrical service is not readily available.  The BDFP is designed for use in basic diesel fuel transfer, polishing and dispensing applications. The BDFP can be used in all three depending on the plumbing configuration.

Example below is for the BDFPE system rated at 15 GPM / 900 GPH.

 

Enclosed Bulk Diesel Filter Panel Example

 

These systems are available at fixed flow ranges from 5 GPM / 300 GPH up to 25 GPM / 1500 GPH. The enclosure configurations from NEMA 12 to NEMA 4X allow the systems to be used for a wide variety of indoor and outdoor installations.

Through regular fuel polishing, the Schroeder BDFPE can protect vital fuel storage, ensuring a reliable supply of clean stable water-free fuel. Additional options and features include external fuel test points, automatic water drain systems, programmable controls, and standard alerts and alarms ensure safe, functional, reliable operation of the fuel polishing system.

An industry innovation incorporates the use of our field-proven particle counting technology to analyze the cleanliness of the fuel in real-time and use that data to automatically adjust run times to meet pre-programmed target cleanliness levels.

The BDFP and BDFPE systems significantly help expand our overall Fuels product offerings with a key focus on Power Generation-Gensets and high flow HP/kW diesel engines.

For more information about Bulk Diesel Filtration, please contact us.

Crazy John’s Filter Factory

Crazy John’s Filter Factory
Crazy John the elf is a story of a lone Elf of the Shelf making a great adventure to help Santa fix his sleigh

As far as it goes, we tell the tale of snow.
The overworked Customer Service
Not ours of course, they keep us afloat.
We sing of jolly snowmen,
And a reindeer with a nose.
That if you look so slightly,
He claims that it glows.

But deep in the snowy belt,
Lives an elf for whom we don’t talk about.
An elf that wanted nothing more,
Than to be the best filter manufacturer.

Crazy John was his name,
And making Santa filter elements was his game.
One could find, they say,
That Crazy John lived in his Filter Factory.

All through the year, Crazy John worked and worked.
Like a great big ol’ fashion TF1 group.
Crazy John couldn’t stop,
And I’ll tell you why,
It’s because Crazy John knew a guy.

Every year, around the 24th of December,
Crazy John knew it would be a day to remember.
He knew that St. Nicholas would be suspended solid.
Tangled up, sleigh risked being spotted!

So he did what an elf could possibly do.
He worked his fingers through and through.
He knew that if he fit it right,
That perfect Hydraulic filter could keep the sleigh in flight.

But the Saint, himself, could come any day.
The Filter Factory where John slept, worked and play.
So as Crazy John settled down,
A distress call came without a sound.

“John! John!”
The voice did cry,
“I’m test flying
My sleigh
And it
Cannot fly.”
“Oh, John!
Oh, John
He cried
And cried,
“I’ve got to get
To the kids
On Christmas Night.”

Crazy John got up out of kilter,
And worked harder than a Pressure filter.
All came down to a night so dreary,
That behold Santa needed a quick delivery.

“But the filter
Is not ready”
Said John,
And he knew it.

Santa needed a filter for a special type of hydraulic fluid.
The resin was drying, ready for the 25th.
But Santa needed data, no time for a blip.

Crazy John plowed through the snow.
A sight in which he did not know.
And though his bones were a bit shivery,
He set out on a quest to make that day delivery.
Crazy John was parched roughly halfway farther.
But Crazy John forgot his special drinking water.

Nevertheless, it was not the time to distress.
Crazy John’s Filter Element was almost at it’s best.
John had an idea to dry it much quicker.
He’d place it in a Plastic tank in hopes to
Protect it from the bitter.

Alas, he made it to the North Pole, at last.
Now to find St. Nicholas; a challenging task.
Crazy John looked tall scaling every last brick, stone and double wall.
He searched through the ranks;
Searching high and low in Santa’s Storage tanks.

Crazy John popped his head,
In the event that he missed him.
But saw a dark puff,
Black smoke from the hydraulic system.

“Oh John! Oh John!
I’m glad that
You’re here!
We haven’t much time
Christmas is
Almost here!”

Crazy John examined the vessel with care.
And realized the high pressure on the sleigh that stood there.
The Schroeder GZT Crazy John usually worked,
Was not the right solution, no matter how much he twerked.

The presents got heavier as the years went on,
And a typical metal hydraulic tank would not be good for Blitzen or Don.

“There’s not enough
Time for me
To go back.
If only there
Were magic
Still left
In the sack.”

St. Nicholas stopped with a doubt of thank.
He inquired with “Crazy”
About his polyethylene tank.

“What’s that
Crazy contraption
You’ve got there?”

“Why it’s a
TNK7 from
Schroeder Industries,
mon frère.”

“Well, what’s it do,
That tank
You have with you?”

“It’s said to reduce
The weight.
It’s a special
Hydraulic tank.”

It was that moment when a lightbulb went off in Crazy John’s head.

“Santa! That’s It!”
Said John,
In a spit.
“The filters
Not the problem,
It just
Won’t fit!”

So Crazy John pulled out his crazy build on.
He replaced that rusty weighed down Highland.
John retrofitted his tank on top was neither.
That good ol’ GZT and a neat little Air breather.

With a bit of magic and good team building,
St. Nicholas’s sleigh rose up

“For the children!”

Crazy John had a blast on his little vacation,
But starting tomorrow, it was back to
Hydraulic filtration.
Crazy John returned to his Factory alone.
Listened in to hear his silent phone.

Innovation was the reason that saved a good night.
Crazy John began preparing for next year’s flight.

Electric Hydraulic Systems: The Future of Hydraulics

Electric Hydraulic Systems: The Future of Hydraulics

Symbol for an electric drive

Schroeder branded Electric Drive KZ5 Filter Element for Hydraulic Fluid

The mobile hydraulics industry is going through a major transformation – moving towards electric hydraulic systems. Electric hydraulic systems hold the potential to be drastically more energy efficient than the typical hydraulic systems that exist today.

To simplify how this is possible, electric hydraulic motor-pump units only operate when flow and pressure are required to perform the working task at hand.

When there is no flow or pressure required, the electric hydraulic motor-pump unit switches to zero energy-mode, saving the consumption of energy and increasing the system’s efficiency. This is what we call Energy efficiency.

Energy efficiency simply refers to the process of reducing one’s system energy. This can be achieved by lowering the amount of energy consumed to accomplish an equivalent output (e.g. halt of use when not in operation).

Think about some of the newer car models in the market today.

Some of the higher-end models shut down every time the car stops at a stop light. Since the car is in idle at that stop light, why would the car continue to place tension and wear the performing components when they’re not performing their sole duty – to drive?

This theology and way of thinking is slowly creeping into hydraulics too. Experts are now looking at ways to incorporate these (and other) types of electric energy to power hydraulic machines.

This is called electric hydraulics.

With the rising trend of electric drive vehicles and utilizing efficient energy throughputs, there is now a need to reduce power consumption and extend the battery life through increased hydraulic efficiency.

That is where Schroeder’s Electric Drive media can help.

 

Schroeder Electric Drive Media logo for electro-hydraulic systems

The use of Schroeder’s GREEN, Electric Drive (E-Drive) Media filtration technology guarantees safe and reliable equipment operation, all-while conserving the use of energy.

Part of Schroeder’s Energy Saver initiative, filter elements made using the all-new E-Drive Media are characterized by an unusually low pressure drop, making them suitable for low energy requirements compared to conventional hydraulic elements under the same ambient conditions.

E-Drive Media is the clear choice for use in electric hydraulic drive motor-pump units. Use it for conserving energy bills and wherever high viscosity fluids are employed – especially at low temperatures that produce a cold start behavior.

 

Schroeder’s E-Drive Energy Saving Features:

Energy Savings low DP Pressure Drop graph shown in promotion of Schroeder E-Drive Media

  • Retains low resistance of flow to reduce the ΔP across the element.
  • The filter media construction consists of multi-layered, synthetic fiber material with support.
  • Great for cold start conditions where a low pressure drop is required.

 

  Technical Specs:
  • Element Collapse Rating: 145 psid (10 bar)
  • Temperature Range: -22°F to 212°F (-30°C to 100°C)E-Drive Media is part of Schroeder Industries' 2030 Initiative. Sustainable Solutions for OEM & MROs.
  • Flow Direction: Outside to Inside

 

E-Drive Media is currently rated for 8, 10, & 15 µm filtration.

To see if Schroeder’s Energy Saving Initiative E-Drive Media can be the right solution for your electric hydraulic systems, email us at sisales@schroederindustries.com or leave a comment in the blog post below.

Contamination in hydraulic fluid – a myth or reality?

Contamination in hydraulic fluid – a myth or reality?

How often have you been told from an asset manager,

“My oil is clean?” Or how about,

“I don’t see any contamination in my oil,” as a bottle of hydraulic oil is held up to light?

You might have even heard other common adages, such as:

“The oil supplier wouldn’t send me dirty oil.”

“I have a filter on the tank to catch the contamination,” later finding out that the filter element has clogged and the filter in bypass, or that the filter element was missing altogether!

“My reservoir is sealed. How did water get in there?”

And the list goes on and on…

Contamination control is an important part of operating and maintaining hydraulic systems.

It starts with the identification and measurement systems of the different forms of contamination. Once a company has identified the contaminants and source of the contaminate, they can develop a strategy for an efficient, real-world method of controlling and maintaining acceptable contamination levels in a hydraulic system.

The result will be improved fluid condition and consequently extend life expectancy of fluid and equipment resulting in significant cost savings.

Types of Contamination

Types of Contamination include solid contamination, liquid contamination, gaseous contamination, and gel-like contamination

Various types of contamination occur in fluid power systems: solid contaminants, liquid (e.g. water), gaseous (e.g. air) and gel-like contaminants.

Another often-overlooked source for premature fluid degradation and consequent system damage is heat. This is especially important if the tanks size is small and the fluid does not have enough time to properly cool down.

Contamination can cause substantial damage in fluid power systems if they are not removed as quickly as possible. Preventive measures should be taken to reduce the ingress of contaminants in systems.

The contamination that can be most detrimental to a system in operation is one not visible to the naked eye. To put it into perspective, an average healthy human eye can see items down to approximately 40μm (Microns) in size. In comparison, a human hair is 70 to 80μm in size.

Particles that cause problems in high performing, high pressure hydraulic systems are in the range of approximately 5 to 15μm. 1μm is equal to 0.001 mm or 0.000039 Inches.

Particulate contamination in a system is often reports as an ISO (International Organization for Standardization) Code. The objective of the ISO Standards 4406:1999 is to classify quantity of particle contaminants in hydraulic fluids by particle size. Particle counts are determined cumulatively, i.e. > 4 μm, > 6 μm and > 14 μm, and coded for easy comparison. The following table explains how the ISO code is determined for a particular fluid sample:

Graphic depicts the standard ISO Code measurement chart. Showcases how one can read an ISO Code of 23/21/18

Sources of Contamination

 

The source for particulate contamination is often found to be the hydraulic reservoir.

Often the reservoir is filled with fluid without first being cleaned. Dirt can be added during maintenance cycles, the tank is open to the environment and missing or has low quality air breathers installed on the tank.

New fluid coming into the plant (in a drum, tote or truck) is generally dirtier than what a system, and specific components in the system, would require for proper performance and/or adequate life expectancy. Over time, pipe scale/rust, pump wear and dirt on rods/cylinders can add contamination to the fluid.

Particulate contaminants circulating in fluid power systems cause surface degradation through general mechanical wear (abrasion, erosion, and surface fatigue). This wear causes increasing numbers of particles to be formed, the result being that wear increases if the “chain reaction of wear” is not properly contained (by reducing contamination). Gaps grow larger, leakage oil flows increase in size and operating efficiency (e.g. of pumps, cylinders) decreases.

Water contamination in the hydraulic systems can be caused by moisture from ambient air, leakage of cooling systems or process water, leakage of seals and chemical processes such as combustion, oxidation and neutralization. As more water enters the fluid, the fluid will develop a haze to milky/stratified appearance when fully saturated.

Dissolved Water is responsible for:
  • Faster oil oxidation: Accelerates this form of oil degradation, leads to oil acidity, thickening, varnishes, sludge & resins
  • Reduced Fatigue life: Propagation of fatigue cracks in metals
  • Demolition of Ester-based fluids and additives: Reacting with esters – hydrolysis, results in formation of acids, gels, and loss of additives
Free Water causes:
  • Corrosion: Corrosion pits, rough surfaces and release of abrasive flakes into the fluidNegative effects of free water. Images illustrate.
  • Microbial colonization / Bacteria: Odors, acids, slime, and health problems
  • Loss of lubricity: High friction, wear and seizure of components due to additive reduction/depletion seen with high water content
  • Additive depletion: Free water retains polar additives

Design issues in the hydraulic system can contribute to air/gases in hydraulic fluids. If the return line is above the fluid level in the tank, air can be mixed into the fluid. Incorrect motor speeds, unprimed pumps, suction lines too small, suction lifts too high and blocked inlets are among other reasons for air contamination over time.

Air effects:
  • Oil oxidation: Mostly oxygen reacts with oil resulting in premature degradation (oil aging)Negative effects of oxidation. Images illustrate.
  • Varnish formation – lacquer like deposits as shown in photo (oil aging)
  • Cavitation: Formation and collapse of gaseous oil cavities causes decrease in pump efficiency and damage to pumps
  • Micro-Diesel-Effect – Air bubble implosion generating high heat which “burns” the oil surrounding the air bubble
  • Change of viscosity

Hydraulic component clearances are critical and require strategic filtration designs to remove damaging particles.  In hydraulic systems, 70 to 90% of wear and failure is contamination related. Only 10 to 30% can be traced back to misuse, defects or age. Contamination cannot be stopped, only slowed down!

System efficiency can drop by up to 20% before an operator even detects a problem, such as cylinder drift, jerky steering, erratic operation or slower performance. Overall, contamination results in shorter service intervals, higher operating costs and lost productivity.

Next Month:  Effective methods to measure the contamination present in a hydraulic system

Thanksgiving 2020! A message from Gus Schroeder

Thanksgiving 2020! A message from Gus Schroeder, President – Schroeder Industries

A notebook with the words Leadership as well as other ingredients of success when it comes to Leadership. The purpose of this photo is to further exemplify the leadership and strength shown by filtration manufacturers Schroeder Industries.

In the age of transparency, we believe that companies should highlight their strengths (and sometimes weaknesses) especially during a pandemic. Our goal with this post is to shine a light on what we feel we’ve done right and possibly spark ideas for growth, for others, in an otherwise stagnant time.

This email was sent to staff on Monday, November 23. We feel it exhibits strong leadership and pays tribute to a team and not just an individual or select group. This pandemic has really challenged all of us and it really takes all of us to triumph over it.

The email read…

“From: Schroeder, Gus <schroederindustries.com>
Sent: Monday, November 23, 2020 6:02 PM
Subject: Thanksgiving 2020! Thank You

All,

2020 has been a year like no other!

Thank you to everyone for the commitment, the sacrifices and the continued efforts to succeed in a very different and difficult working environment.

I am thankful for our team!   I am thankful for our teams ability to stay as connected and as well-functioning as possible and as I reflect I think its important that we recognize everyone and their role in making this year work.

Thank you….

To the sales/ marketing and product teams who have been upended and challenged in every way.  Selling is an active process where communication is everything. From calls with the team every morning in the beginning to make and change plans, to all new ways of selling, we planned to win as much as possible and we keep doing it.

Thank You To all of you who have been working remotely for the first time in the past 8 monthsThank you! Purchasing, CS and Most of Engineering Thank you! Keep your heads up ! Remain as connected as possible even though you are remote! Talking with people is one way to do that. It’s important for your mental health and it is enjoyable when we solve problems, introduce new ideas and make them come to fruition.

Thank you to all of you who have been in the office, the lab and on the production floor every day! I cannot thank you enough and I am so proud of your efforts, commitment and your ability to be safe at work no matter how much all of us dislike wearing masks, dislike the ever changing rules, and dislike the constant uncertainty that every day brings.

Production, Quality and Production Planning: You are the heart of our team and in times when we were all truly unsure of the environment, you stayed together no matter how frustrating the day became. We have longer to go in this fight but I am truly thankful for all that you have done!

The Lab: I am thankful for the commitment from the lab. In this environment, their work has helped more than ever to deliver additional new business. It has not been easy without getting the immediate answers, the answers that are attainable when we are all here.

Accounting: I want to thank accounting who has maintained constant contact and flexibility with our customers.

Thank you to our HR department!  I cannot remember a year where there was so much pressure on the HR department. They have had to maintain sanity in what has been a less than sane world. I am thankful for your commitment to all of us, to our safety and again we must remember that there will soon be a day when we return to normal.

Finally,  I am thankful that we are in manufacturing! It is a difficult job and the world has changed but we know one thing… Our work has value! We know this because our jobs are essential and we are able to work. We can work because without our efforts, the world will not function for long! Yes we suffered this year, and yes some days in 2020 have tested us all, tested us all in different ways, but we made it in one piece.

We will make it the rest of the way in 2021 and we can have our Thanksgiving dinner knowing that better times will come.  I always say it before the holidays but as we celebrate this holiday, more than ever, BE SAFE, Be smart in your choices and remember that we are going to look back on this time and know that as a team we are doing our best and for everyone’s effort, in that, I am thankful.

Thank you all again & have a Happy Thanksgiving!

Gus Schroeder
President
Schroeder Industries
www.schroederindustries.com

To not show our biases, we believe this email was well thought out and motivational to all employees. What do you think? Leave your comments below.

Schroeder Passes Re-Certification for ISO 9001:2015

Schroeder Passes Re-Certification for ISO 9001:2015

PRI acknowledges Schroeder Industries as ISO 9001:2015 certified.

On Friday, November 6, 2020 at 4:01 PM, we received the good news from our Quality Manager…

“Our Re-Registration Audit…was successful as we were granted conditional approval for re-certification to ISO 9001:2015.”

This [news] came after a several-day long audit given by the Performance Review Institute.

During these audits, our teams in Quality, Engineering, Purchasing, Marketing, and Customer Service have to answer and provide evidence that we are properly implementing and adhering to the ISO Quality Management System (QMS).

And because of the diligent work of the Schroeder team, not just during the audit but from those committed to the quality processes all year round, our ISO Surveillance Audit was successful!

View our latest ISO 9001:2015 certificate online here!

Schroeder Industries now holds the title of ISO 9001:2015 certified until November 30, 2023 – at which time, we will welcome the next phase in the ever-growing world that is quality performance.

International Standardization Organization: The Standardization defines ISO 9001 as "...a number of quality management principles including a strong customer focus, the motivation and implication of top management, the process approach and continual improvement."

We would like to thank the ISO Organization, our entire staff, and our auditor for accommodating us and providing us the tools to navigate as an ISO certified organization through these trying times.

What can we do to help your organization on the road to an ISO certification? Let us know in the comment section below.

What Veterans Mean for American Manufacturing

It happens every year.

While you sip your morning coffee, or watch the morning news, there are soldiers that are starting their mornings a little differently.

Navy day showing combat boats, automatic guns, UAV, drone, warships, handguns, dive boat etc

Then, November 11 comes around and we are reminded of the sacrifices and honor those who chose to risk their lives so we can continue to live ours.

But Veteran’s Day is not the only day an American Manufacturer thinks about the soldiers.

Every day that we wake up and go to our respective work stations, we reflect.

It’s because of the brave individuals that we get to go to work each day and build. We’re building products from American processes for American processes.

We should all take a moment today and consider what we take for granted and how we might not have that privilege if it weren’t for the brave individuals who woke up and decided to sacrifice their lives so that you could drink that cup of coffee grown on American soil, jam out to that American band that takes you back, or type a blog post on a computer built in an American factory.

“We owe you our freedom and without you, we would not have the opportunity to do the work that we do here today! Thank You!” – Gus Schroeder, President.

Do us all a favor and thank a Veteran for us today.

And if you have served, leave a comment below so we can thank you ourselves.

Changing Seasons, Changing Diesel Fuel Blends

From: Schroeder Industries’ Fuel Filtration Center of Excellence

For those of us in the Northern hemisphere, Fall has arrived!

great smoky mountains rail road train ride

For our friends in the Southern hemisphere, October brings the welcoming warmth of Spring and return of the rainy season.

As we transition through the change of seasons, the diesel fuel blends in many regions will soon change as well to accommodate the lower or higher temperatures.

This is a great time to do preventative maintenance, clean, polish, and upgrade fuel systems where needed.

Additionally, many of our customers are reviewing their year-end budgets and may find that they have funds remaining that could be allocated to make those system upgrades and improvements.

With that in mind, it’s critical that fuel-coalescing and particulate removing solutions be integrated into ALL fuel polishing, transfer and clean-out systems.

The GHCF, GHPF, BDS particulate and coalescing filtration, along with the bag filters we offer utilize the same replacement elements across the Fuel Filtration Product Lines. This makes reordering filter elements simpler while providing  better and higher performing systems than our competitors do.

Filter Cart Systems / Mobile Filtration Units

The BDFC Bulk Diesel Filtration Cart provides exceptional single pass or kidney loop filtration with both high efficiency particulate and coalescing filtration integrated into one compact filter cart.

BDFC Gen 3.

The BDFC is ideal for fuel maintenance operations.

It is portable and very easy to use and operate.

Offers flow rate options of  14 gpm (53 l/min) or 25 gpm (95 l/min).

The BDC Bulk Diesel Cart offers higher flow rate options with considerably more dirt holding capacity and throughput for larger operational needs for fuel polishing.

BDC Bulk Diesel Cart

These systems are available in standard flow rated options of 25 gpm (95 l/min) or up to 70 gpm (265 l/min)

The BDC incorporates the BDS particulate and coalescing solution along with a bag pre-filter.

These systems are ideal for environments experiencing microbial growth or blooms or for higher capacity systems where larger throughput and capacity is required.  The three integrated filters combine the economy of a bag element with Schroeder’s high performance synthetic media and our patented water removal technology.

It’s important to note that these systems are all designed to operate on North American electrical standards.

We understand these are not the same globally; therefore, we have designed these systems with slotted mounting holes designed to accommodate NEMA-style motors, which allow for easy adaption of these systems in other parts of the world.

They can be shipped with or without pump and motor groups to enable local sourcing and installation to match regional electrical requirements. We also have the ability to ship these units complete with your local requirements, but this would require a minimum purchase of 10 pcs to accommodate that request.

For more information about diesel fuel cleanliness specs as well as past successes we have had with applications utilizing these products, please contact us.