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Honing Oil Life Extended Beyond 12 Months

Offline filtration eliminated frequent oil changes and avoided €11,500 in annual oil purchasing costs.

Case study written by:

Charles Van de Velde

Application Snapshot

Industry:

Industry - Precision Manufacturing

Oil type:

HONING OIL (Sunnen KG3X)

Executive Summary

A manufacturer of high-precision ceramic and stainless-steel pumps for the pharmaceutical industry was experiencing frequent honing oil replacement due to contamination generated during the honing process. The honing machine operated with a 350-litre oil reservoir, and depending on production levels, the oil typically required replacement every three to six months. To maintain oil cleanliness and extend oil service life, a C.C.JENSEN HDU 27/108 offline fine filtration unit was installed on the honing oil reservoir.


The unit continuously removes fine contamination generated during operation, helping preserve oil quality and reduce the need for oil replacement. After more than twelve months of operation, no oil replacement has been required. The customer avoided approximately €11,500 in oil purchasing costs during the first year while reducing oil consumption, waste oil generation and maintenance associated with frequent oil changes.

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Extended Oil Life

Oil life increased from 3-6 months to over 12 months.

Reduced Oil Consumption

Significantly fewer oil changes required.

Avoided Oil Purchasing Costs

€11,500 saved during the first 12 months.

Lower Environmental Footprint

Reduced waste oil generation and lubricant consumption.

Client brief

The customer manufactures high-precision ceramic and stainless-steel pumps for the pharmaceutical industry. The honing process operates with a 350-litre oil reservoir. Depending on production levels, contamination generated during honing typically required the oil to be replaced every three to six months. Annual honing oil costs were approximately €11,500.

Challenge

The honing process continuously generates fine contamination that accumulates in the oil over time. As contamination levels increase, oil quality deteriorates and the lubricant must be replaced to maintain process performance and product quality. With oil replacement intervals as short as three months under some production conditions, the customer faced recurring lubricant costs, maintenance requirements and waste oil disposal. The objective was to extend oil service life while maintaining the oil in a condition suitable for continued operation.

Solution

A C.C.JENSEN HDU 27/108 offline fine filtration unit was installed on the 350-litre honing oil reservoir. The filtration system continuously removes fine contamination generated during the honing process, maintaining oil cleanliness and preventing contamination from accumulating to levels that would otherwise require oil replacement. By continuously cleaning the oil during operation, the filtration unit helps preserve lubricant quality and significantly extend oil service life.

Measurable Results

Following installation of the C.C.JENSEN HDU 27/108 filtration unit, the customer has operated for more than twelve months without requiring an oil change. The previous oil replacement interval of three to six months was extended beyond twelve months, with the oil still in operation at the time of reporting.


This resulted in approximately €11,500 of avoided oil purchasing costs during the first twelve months while also reducing maintenance activities and waste oil generation.

Key Results:

  • Oil life extended from 3–6 months to >12 months
  • No oil replacement required after more than 12 months
  • €11,500 in oil purchasing costs avoided
  • Reduced oil consumption
  • Reduced waste oil generation
  • Reduced maintenance associated with oil changes

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