01 / The challenge
The valves kept sticking. The oil condition was going unchecked.
A major automobile manufacturer was losing production time when the valves on its hydraulic steel presses stuck. Varnish had accumulated in the systems, and the absence of oil testing meant the problem repeatedly caught the maintenance team by surprise. Pump failures and seal locking added to the maintenance burden.
Existing varnish removal equipment consumed large numbers of filter elements. Once the equipment was disconnected, varnish-potential readings rose again. The team needed a way to control deposits and follow the oil condition before valve movement disrupted production.
02 / The approach
Combine deposit treatment with oil condition checks.
Make varnish potential visible
The team added membrane patch colorimetry, or MPC, to its condition monitoring program. MPC measures varnish potential in oil, giving the team a way to follow the deposit problem through treatment.
Treat deposits in the hydraulic system
Fluitec DECON™ was added at a 3% concentration for this application. Varnish levels began to decline steadily, and the valves stopped sticking.
Support continued deposit control
DECON™ AW was also added to help maintain antioxidant levels and control further deposit formation. The approach addressed the condition of the hydraulic oil alongside the immediate valve problem.
03 / The outcome
The valves stopped sticking and the oil condition improved.
The treatment stopped the sticking valves and the production delays they caused. MPC results declined, while RULER results, which track antioxidant levels, increased. Fluitec describes the system as free of varnish after treatment and reports an oil saving of 2,000 gallons, or 7,570 litres.
- Valve operation
- Sticking stopped
- Production
- Delays caused by sticking valves eliminated
- Oil condition
- MPC declined; RULER values increased
- Reported oil saving
- 2,000 gallons / 7,570 litres
04 / Applying the findings
Follow the valve behaviour and the oil together.
Recurring valve sticking gives the maintenance team a reason to examine the fluid as well as the component. Record when sticking occurs, which valves are affected and what changes after maintenance. Pair that history with oil analysis that addresses varnish potential and lubricant condition.
The next decision is which treatment fits the actual problem. Hydraulic oil filtration addresses contamination; deposit treatment and additive replenishment require a review of the lubricant, equipment requirements and test results. After treatment, follow both the oil trend and the return of reliable valve movement.
Our guide to hydraulic oil varnish and sticking servo valves explains how deposits affect press response and what to check before replacing another valve.