Case Study 2

Kalyani Maxion Wheels: “RBC Media the technique for filtration of Water based Glycol”

Background:
Kalyani Maxion Wheels, founded in 1996 in Pune, India, is a leading manufacturer wheels with a capacity to produce 1.3 million Commercial Vehicle steel wheels and 4 million Light Vehicles steel wheels annually. Low-pressure die-casting technology is deployed for producing these alloy wheels.

The process involved high-temperature operations, necessitating a hydraulic fluid capable of withstanding extreme heat while ensuring precise movements of equipment. After careful evaluation, water-based fluid identified as a potential solution. Kalyani Maxion Wheels opted for a water-based fluid, specifically formulated with glycols, for their hydraulic system; due to it’s non-flammability in the event of unforeseen incidents, environmental friendliness, and ability of effective heat dissipation in the high-temperature operating environment of the aluminum alloy Die Casting foundry. The fluid's ability to efficiently convey heat away from hydraulic equipment contributed to improved operational reliability and reduced risk of overheating-related issues.

Challenge:
As new challenge emerged, as the offline, Electrostatic Oil Cleaning machines deployed earlier, frequently tripped, as it could not sustain the inherent water content, in the water-based glycol media. Water being a good conductor of electricity, stands contrast, to the fundamental principle of Electrostatics which is essential for functioning of any Electrostatic Oil Cleaning Principle.

SMCEPune Hydraulics and Filtration approached the client with the all-new mechanical depth filtration technique deploying graded density Resin Bonded Cellulose media. The desired, results of filtration were accomplished and the machine continues to operate and consistently filter the water based glycol media to deliver the desired oil cleanliness.

Disclaimer: The online oil contamination counters of any make and model, does not indicate the correct count of cleanliness levels, as the inherent presence water in the media itself is considered as contamination by the particle sensors deployed in these online particle counters. Such tests can only be ascertained through Gravimetric analysis.

This application stands testimony to WIDE COMPATABIITY of RBC elements to wide variety fluid filtration.

Our sincere gratitude to the management of Kalyani Maion Wheels for trusting SMCEPune Hydraulics & Filtration.

Case Study 4

HUSCO Hydraulic - Filtration Results Class Apart on our Single Stage RBC Media

HUSCO Pune is into manufacturing of valves used in construction vehicles like excavator etc. These valves are used to control the precise movement/operations of vehicles. These valves are tested on the hydraulic test bench at client’s plant, for which the hydraulic oil used shall be of high cleanliness level i.e., of NAS 1638 class 5 or above. The Electrostatic Liquid Cleaner was in use at client’s plant, with which it is impossible to achieve such high cleanliness level. HUSCO Hydraulic was in search of a suitable Oil Filtration System for achieving this cleanliness of oil of NAS 1638 Class 5.

SMCEPune Hydraukics & Filtration, proposed them a newly developed MICROCARE Oil Filtration Trolley deploying a Media Filtration technology. A mechanical filtration unit was developed deploying a Resin Bonded Cellulose (RBC) Media.

The RBC Media is Depth Filtration Media. It is closely bonded, eliminates fine contaminants and have a high dirt holding capacity. Thus, it is compatible to achieve high cleanliness level.

The photos are of an onsite demo of Single Stage Filtration Unit with Resin Bonded Cellulose (RBC) Media at HUSCO Hydraulics. This unit achieved a result of Class 14/12/03 as per ISO 4406 after 24 hours of operation. The result is equivalent to NAS 1638 class 3 and at par with the client’s requirement. It was validated over a client’s owned, HYDAC online contamination sensor CS 2000 available at their quality lab.

This application stands testimony to the EFFECTIVENESS of filtration through RBC elements in challenging Industry Environments.

Our sincere gratitude to management of HUSCO Hydraulics to have reposed faith in our proposed filtration unit.