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Extended Oil Lifetime and Improved Grinding Quality

High levels of fine particle contamination in grinding oil can reduce machining quality, increase wear, and require frequent oil changes. This case shows how continuous fine filtration improves oil cleanliness, extends oil life, and stabilizes production.

Application Snapshot

Factory icon representing industrial application or sector.
Factory icon representing industrial application or sector.
Industry:

Manufacturing / Precision Machining

Country:

Germany

Oil droplet icon representing oil type or lubrication fluid.
Oil type:

Grinding Oil - UNICIT MSA-155-20

Executive summary

During machining, grinding oil in tool grinding machines was continuously contaminated with fine particles smaller than 10 µm. Existing belt filter removed only larger particles, leading to increasing contamination levels over time.


By installing a CJC® Metalworking Fluid Filter for continuous depth filtration, contamination was removed effectively and oil cleanliness was maintained over time. This significantly improved oil cleanliness, eliminated frequent oil changes, and increased the lifetime of both oil and machine components

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water reduction

Extended Oil Lifetime

Oil lifetime increased from 3 months to 18 months

oil recovery

Reduced Wear

Guide rails no longer required replacement after 1.5 years

particle reduction

Particle Reduction

Up to 88% reduction of fine particles within weeks

cost savings

Cost Savings

Reduced oil consumption, maintenance, and replacement costs

Client brief

The operator runs two CNC tool grinding machines, each with an oil volume of 200 liters. High-precision grinding processes require consistently clean oil to ensure stable tolerances and high product quality.

Challenge

During operation, the grinding oil was continuously contaminated with fine particles below 10 µm, which could not be removed by existing belt filters. As a result, contamination levels increased rapidly, requiring oil changes every three months. Oil analyses showed that particle levels increased significantly within a short time, leading to reduced oil quality and increased abrasive wear on guide rails, which had to be replaced regularly.

Solution

A CJC® Metalworking Fluid Filter was installed for continuous off-line filtration. The filtration system uses depth filtration technology with high dirt-holding capacity to continuously remove contamination from the grinding oil. The filtration operates independently of the machine (24/7), ensuring constant oil cleaning during operation and maintaining stable oil conditions.

Table showing annual savings in energy, fuel, engine oil, sludge production, and total operating costs after replacing separators.
Table showing annual savings in energy, fuel, engine oil, sludge production, and total operating costs after replacing separators.

Continuous filtration ensures stable oil quality

The filtration system was tested over a three-month period on oil that had already been in use for three months and was close to requiring replacement.


After the first filtration cycle, the oil became visibly clear again. Within three weeks, particle contamination was reduced by approximately 88%, while water content dropped to just 0.005% (50 ppm).

Even after six months of operation, no oil change was required, demonstrating the effectiveness of continuous fine filtration.

Measurable results and operational impact:

  • Contamination reduced from 0.25% to 0.03%
  • Improved grinding oil cleanliness and stability
  • Oil lifetime extended from 3 to 18 months
  • Lower maintenance requirements
  • Increased operational reliability and machining performance
water trend

BEFORE

Table showcasing the results

AFTER

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