Lubricants are vital for reducing friction, dissipating heat and preventing wear and corrosion in industrial machinery; however, lubricants’ effectiveness is compromised when they are contaminated with particles, water and other impurities. Ensuring the quality and cleanliness of lubricants is crucial for maintaining optimal equipment performance and longevity.
Many people assume that new oil is synonymous with clean oil, but is this always the case? Brace yourself for the fascinating and gritty truth about new oil.
Myth #1: Sealed Containers Guarantee Purity
Many operators and maintenance professionals believe that new oil is inherently clean and free from contaminants. After all, it comes directly from the manufacturer and undergoes rigorous quality control measures, right? While it is true that new oil typically meets certain cleanliness standards, it is essential to recognize that it is not immune to contamination.
New oil may contain microscopic particulate matter, moisture and trace metals from the manufacturing and packaging process, and it can pick up additional contaminants during transportation, storage and handling prior to being installed in your equipment.
“Oil manufacturing involves complex machinery and vast storage tanks, requiring a watchful eye on quality control.” –AMSOIL Industrial Sr. Tribologist Kevin Dinwiddie
Myth #2: Storage is Sterile
Large drums and bulk tanks might appear impenetrable, but they are not immune to contamination. Temperature changes can cause air, moisture and dust to seep in, and sediment will settle to the bottom, waiting to be sucked into your expensive equipment.
Myth #3: Filtering Fixes Everything
While filtration can remove particles that cause wear, it adds another step to the oil-handling process, introducing potential contamination points and increasing the risk of human error. Filtration is not a one-stop solution and needs to be incorporated into a complete lubrication program.
The Impact of Contaminated Oil
Contaminants degrade an oil’s performance and diminish its lubricating properties. Contaminated oil has a detrimental effect on industrial equipment, leading to increased friction, accelerated wear, reduced efficiency and potential breakdowns. In fact, up to 80% of equipment failures are attributed to contaminated lubricants, underscoring the importance of proactive contamination control measures.
Assuming that new oil is inherently clean can be a costly misconception for industrial manufacturing operations. For instance, contamination-induced problems like silt lock can cause hydraulic equipment to stick in place or behave erratically, leading to production problems and even potential injuries. Even a small amount of dirt in a large drum of oil can significantly impact the performance and expected service life of hydraulic oil and hydraulic equipment.
Implementing Best Practices
Regular oil analysis is essential to ensure the cleanliness and quality of lubricants, regardless of whether they are new or in service. Oil analysis involves sampling lubricants and analyzing them for various parameters, such as particle count, water content, viscosity and chemical composition. By monitoring the condition of lubricants through oil analysis, maintenance professionals can identify potential issues, such as contamination, degradation or abnormal wear patterns, before they escalate into costly problems. This proactive approach allows for timely intervention, optimizing equipment reliability and performance.
Ensuring oil cleanliness starts with testing new oil when it arrives — before it goes into a machine. Best practices include proper storage, handling and dispensing procedures to minimize the risk of contamination during the lubricant’s lifecycle. Filtration also plays a vital role in ensuring oil cleanliness by removing contaminants from both new and in-service oils, which can significantly prolong equipment life and reduce maintenance costs. Some facilities take a more proactive approach, using separation systems to bring hydraulic oil to an exceptionally clean state prior to installation.
Regardless, the cleanliness of the oil when delivered determines the amount of time and effort required by your maintenance crew, which directly correlates to your operational costs.
The Solution
Prioritizing lubricant cleanliness is essential for maximizing equipment reliability and minimizing costly downtime in industrial manufacturing operations. New oil may meet certain cleanliness standards, but it is not immune to contamination and can harbor impurities that compromise equipment performance.
By understanding the importance of best practices for lubricant management, including proactive contamination control measures and oil analysis, industrial manufacturers can ensure the cleanliness and quality of lubricants throughout their lifecycle.
Here are some actionable steps to consider before installing fresh oil into your machines:
Source: Choose AMSOIL Industrial for stringent and verifiable quality control.
Inspection: Visually check oil for any signs of discoloration or sediment.
Storage: Keep oil in controlled environments to minimize temperature fluctuations and moisture exposure.
Filtration: Invest in high-quality filtration systems and adhere to proper maintenance schedules.
Oil Maintenance Program: Clearly define systems and procedures that minimize the risk of oil contamination at every contact point.
Embracing these practices transforms oil management from a potentially risky proposition into a powerful tool for optimal machinery performance. AMSOIL Industrial technical experts are dedicated to helping you identify ways to extend equipment life, reduce downtime and improve productivity in your industrial operations, starting with cleaner oil.