FEATURE LUBRICANTS & COOLANTS
MAXIMISING PRODUCTIVITY OF plastic component manufacturers
Within most plastic injection moulding applications hydraulic oils play a fundamental role in production while helping to reduce downtime, says Mohamed Mourad of ExxonMobil
D
ue to the competitive nature of the plastics industry companies are
continually looking to maximise productivity while reducing unscheduled downtime and costs. While a small percentage of total maintenance spend, the latest hydraulic oils have the potential to inject additional productivity and performance into operations. Within the majority of plastic injection
moulding applications hydraulic oils play a fundamental role in the production of components while helping to reduce unscheduled downtime and extend oil drain intervals. However, advancements in hydraulic oil technology means plastics manufacturers can select fluids which help produce high quality components and provide outstanding levels of protection along with increased energy efficiency and decreased cycle times. ExxonMobil has developed an award-
winning hydraulic oil which has been proven to help plastic injection moulding operators to increase productivity, reduce unscheduled downtime and improve the energy and cycle efficiency of their machinery. Compared to standard hydraulic oils Mobil DTE 10 Excel can provide up to a 6% improvement in hydraulic system efficiency reduce cycle times and triple oil drain intervals.
NEXT GENERATION HYDRAULIC OILS To help reduce unscheduled downtime contamination control is a key requirement of a hydraulic oil. Contamination may be generated in the system or may ingress from the outside so a hydraulic oil needs to demonstrate excellent oxidation resistance and filterability to avoid lubrication and component failures and frequent oil changes. Further performance requirements include preventing pump damage or failures at equipment start- up and while operating at extremely high temperatures. Laboratory and in-service field demonstrations showed that Mobil DTE 10 Excel has exceptional oil life outlasting standard hydraulic oils by up to three times while maintaining outstanding hydraulic system cleanliness and component protection. In addition, Mobil DTE 10 Excel can help provide
quantifiable increases in hydraulic efficiency compared to standard hydraulic oils. This can translate to reduced power consumption and cycle times, resulting in monetary savings. This is achieved through the oil performing at its optimum volumetric and mechanical efficiency level when the two efficiencies which are inversely proportional to each other are in balance. To ensure this level is maintained throughout the day and avoid late-day sluggishness (PM fade) Mobil DTE 10 Excel’s high viscosity index ensures the performance of the oil is not impacted by the equipment heating up during the day while in operation. In plastic injection moulding equipment a 0.5 second reduction in cycle time can realise up to an 11% increase in productivity.
PERFORMANCE IN THE FIELD Häfner & Krullmann specialises in processing plastics and currently has more than 50 injection moulding machines varying in size from 50 to 2,000 tonnes. One of Europe’s largest manufacturers of plastic spools, the company has realised the importance of hydraulic oils in maximising the productivity of its equipment for many years and was keen to see what performance benefits could be realised through the introduction of Mobil DTE 10 Excel. Following a successful test phase the company decided to convert additional machines. Since then five of the company’s installations have been
filled with the product and for the other machines it has been used for topping up. Following the introduction and initial monitoring Häfner & Krullmann expect to extend oil drain intervals from 40,000 to around 50 to 60,000 operating hours, make an energy saving of 2-3% and double filter life.
MAXIMISING PRODUCTIVITY In order to maximise the productivity of machinery and reduce costs operators should incorporate an oil and equipment condition monitoring programme alongside the use of a high quality hydraulic oil. As part of routine maintenance the ‘health’ of the hydraulic oil and the hydraulic system itself are advised to perform quarterly oil analyses and annual system inspections. Analysis should include a measurement
Advancements in hydraulic oil technology means plastics manufacturers can select fluids which help produce high quality components and provide outstanding levels of protection along with increased energy efficiency
of fluid viscosity, water content, particle count and dissolved metals to determine how well the system is operating. Examining changes in the oil analysis data over time (trending) is necessary to assess the condition of the hydraulic fluid and proactively address undesirable conditions before they become problems. ExxonMobil’s proprietary online Signum
oil analysis programme offers immediate access and direct control of a lubricant sampling programme. In addition, visual system inspections should be conducted regularly to check and document the condition of hydraulic systems. Inspection data can be used to establish the optimum time to perform maintenance on critical hydraulic components such as filters, breathers, valves, hoses, heat exchangers and pumps. Comprehensive leak detection should be performed, especially if excessive hydraulic oil usage is noted during a routine system inspection. By combining the use of high quality
oils and an effective analysis programme plastic companies can achieve a competitive advantage, maximising productivity and reducing the energy consumption of hydraulic machinery.
ExxonMobil T: +420 221 456 426
www.mobilindustrial.com
16 DECEMBER 2015/JANUARY 2016 | FACTORY EQUIPMENT / FACTORYEQUIPMENT
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