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.
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.
Group I ‘Lightly Refined’ Oils were once the most common class of hydraulic fluid.
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 & III ‘Hydrocracked’ or ‘Synthetic’ oils are replacing Group I oils as a more eco-friendly alternative.
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.
Effects of Electrostatic Discharge on Hydraulic Systems
Electrostatic discharge and static cause a variety of serious issues in hydraulic systems, including:
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
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!
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!
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.
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%!
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:
The Head Space Dehydrator assembly pulls ambient air into the chamber through a series of particulate breathers.
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.
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!
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.
Liquid contamination in your hydraulic reservoir can cause a variety of serious problems, some irreversible.
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.
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!
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
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
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!
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!
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?
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
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.
Contact the experts at Schroeder Industries
Interested in the new GPT filter? Contact our filtration experts for more information!
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.
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
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:
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:
Schroeder’s tank optimization services are backed by expertly crafted reservoirs and filters. Learn more about these premium products:
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)
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.
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?
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:
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 downtimebefore 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
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.
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!
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!
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:
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:
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:
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!
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.
This article is based on a webinar conducted by Aaron Keck, a product manager in Schroeder Industries’ Fuel Filtration group. This insightful presentation is informed by Aaron’s 13 years of experience in the Diesel Power and Fluid Power Industries.
Growing global energy demands are ‘fueling’ technological advancements in engines and driving the adoption of alternative energy sources. The ripple effect of this evolution has major implications for the filtration industry.
Given the speed of advancement and diversification of fuel sources, and the increasing desire for environmentally responsible energy consumption, what do the futures of diesel and fuel filtration look like?
Despite the growth of alternative fuel technology, all signs point to a continual refinement of diesel technology in tandem with developments in CNG, hydrogen, and electric power. The diversity of technology and fuel sources provide many avenues for new innovations.
1. The Diesel Engine is Here to Stay
Electric engine technology has advanced by leaps and bounds, but industry sources indicate that all electric vehicles are still far off in many applications, from military to commercial.
A variety of factors contributes to the practicality of diesel engines over electric engines in the near term for various applications, including:
Limited electric infrastructure. Reliable electric power requires an expansive, efficient power grid. Especially for remote applications such as mining, the infrastructure to sustain such operations does not currently exist.
Lower energy density of current battery technology. Pound for pound, current battery technology can’t match the energy density of diesel fuel, which is critical for consistent, reliable, long duty cycles.
Reliability concerns. There’s a reason diesel is often a primary backup source for critical operations, processes, and services: Diesel’s proven reliability. In renewable, hybrid power generation systems, diesel is frequently integrated to make up for production shortfalls and periods of high demand.
A long runway for advancement in diesel technology still exists, even as electric and alternative energy technology adoption grows.
As liquid diesel engines evolve, filtration technology must adapt to enable efficient, clean operation. Major considerations include:
The sensitivity of new fuel system designs. Protecting system components from contamination is increasingly vital as components become more sensitive and precise. Eliminating as much contamination as possible is necessary for increasing component life, maintaining efficiency, and reducing emissions.
Changing fuel chemistry. The adoption of biodiesel, diesel blends, and other sustainable fuel sources demands additional considerations in filter material selection. Choosing appropriate metals, coatings, and elastomers ensures that filtration components will not react adversely to changes in fuel chemistry. Rapid prototyping and modular testing are essential for keeping pace with chemical changes.
Maintaining system efficiency to reduce emissions. Legislation and broader concerns regarding emissions and carbon footprints calls for filtration solutions that maximize system efficiency, increases energy efficiency, and reduce emissions.
In the October 2022 Outlook for Energy Report from Exxon Mobil, there was an emphasis on the long-term reduced reliance on oil and shifting demand towards a variety of alternative fuel sources.
There are three key drivers of this trend:
Technology. As alternative fuel technology becomes more viable, affordable, and widespread, adoption increases.
Policy. Legislation and environmental agreements on the global and national level, such as the 2015 Paris Agreement and the 2022 U.S. Inflation Reduction Act, provide incentives and regulations that drive alternative energy adoption and control emissions.
Consumer Preference. Consumers are increasingly interested in alternative energy sources in their transportation and utilities. A Consumer Report survey conducted in 2018 found that 76% of U.S. residents agree that increasing renewable energy is a worthwhile goal. With technological innovation and government incentives increasing alternative energy accessibility, consumers may be more encouraged to support entities utilizing alternative energy sources or consider adopting alternative energy in their own lives.
While oil will remain a large source of global energy over the next 30 years, the growing shift to alternative fuel sources will drive new technology and demand new tailored filtration solutions.
Compressed natural gas, or CNG, is one of the mostly widely used alternative fuel sources for lower emissions and requires specialized filtration solutions. Three major, interconnected applications for CNG filtration come with their own considerations:
CNG Dispensing. Commercial last-mile delivery and hub-and-spoke distribution models, which increasingly run on CNG for carbon footprint reduction, are driving an increase in CNG fueling stations.
Filtration solutions for this expanding infrastructure must maintain a low pressure drop while ensuring optimal filtration to provide consistently clean fuel to these fleets in a timely manner.
Virtual Pipelines. For plants and operations far from existing natural gas pipelines, compressors are used to load CNG onto trailers, which are taken to remote industrial sites. This system is referred to as a ‘virtual pipeline.’
Reducing pressure drop is vital for reducing the energy consumption of these compressors and extending service intervals. Utilizing the latest gas filtration media in a layered, pleated construction, lower pressure drop and higher efficiency can be achieved versus traditional filtration setups typical to these applications.
Oil & Gas. Dual-fuel technology, in which an engine is designed to operate on diesel and CNG, is regaining traction in the oil & gas industry and continues to evolve.
The intensity of oil & gas work environments calls for especially robust filtration solutions which maintain a low pressure drop and are small enough to maximize available space and accommodate two fuel systems. In many cases, appropriate surface treatments and the use of stainless-steel materials where possible are also required to prevent degradation in potentially corrosive environments.
4. Hydrogen Filtration and Transitional Technology Between Liquid Fuel and Electric-Powered Engines
In the quest for electrification, hydrogen power is a critical stepping stone. Emitting only water vapor and small amounts of nitrous oxide, hydrogen power is a benchmark for eco-friendly alternative fuels.
In the spring of 2023, Cummins Inc. rocked the industry with the reveal of a fuel-agnostic 15L engine capable of running on hydrogen. This development illustrates that fuel-diversity is an attainable first step in transitioning away from liquid fueled engines and moving us closer to the infrastructure needed to support more alternative energy sources like hydrogen.
As with any fuel, filtration plays a key role in the performance of hydrogen-powered equipment and fuel cells at every stage:
Manufacturing. Filtration plays a key role in the manufacturing process, as component cleanliness of fuel cells and battery technology, to compressed gas storage tanks require extremely clean environments to ensure safe and reliable operation in the field.
Generation. From the electrolysis process needed to produce the hydrogen, to the compression and storage of the hydrogen, the same requirements of removing contaminants during the handling and storage of the fuel parallel that of compressed gas.
Refueling. Refueling points also require a level of filtration to ensure that the hydrogen introduced into a fuel cell maintains a high purity.
Charging. The stationary equipment used to charge battery electric equipment, or the fuel cell electric equipment use some level of filtration for both the air used in the fuel cell, as well as the hydrogen fuel being consumed.
Developing hydrogen filtration solutions requires special considerations:
Hydrogen embrittlement. Solid metals will deteriorate in the presence of hydrogen, so material selection is extremely important for extending the integrity of filters and elements.
Hydrogen molecule size. Hydrogen is an exceptionally small molecule compared to other filtered fuels. To secure the system and prevent leaks, seal designs need to be carefully selected and appropriate elastomers used to ensure a consistent, leak-free, and serviceable sealing surface.
Appropriate filter elements. Traditional filter medias used for other liquids and gasses will not withstand the design requirements of hydrogen compression, transfer, storage, or dispensing. Stainless steel is a common choice for hydrogen elements to avoid electrostatic discharge. To prevent fiber migration into highly sensitive, high-pressure hydrogen system components, compressed metal fibers are a common choice for filter media.
Hydrogen presents an exciting, yet challenging avenue for expansion in the filtration industry where we will continue to push the limits of filtration and material science.
The future of fuels and fuel filtration will not be defined by a clear linear advancement towards renewable fuel sources.
Just as physical currency still exists alongside electronic payments and banking, our energy needs will continue to be satisfied by a range of fuel sources, including diesel and alternative fuels. Advancements in diesel and liquid fuel technologies must continue alongside alternative fuel developments.
Schroeder Industries: Your Source for Advanced Fuel Filtration
Schroeder Industries continues our 75+ year tradition of evolution and innovation, monitoring industry trends and developing advanced filtration solutions for virtually every application. Our solutions are engineered with consideration for ongoing technological advancements and changes in the diesel and alternative fuel landscape.
Looking for premium fuel filtration solutions for your diesel, hydrogen, or CNG application? Let the experts at Schroeder help you!
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