Extended Banbury mixer gearbox lifetime in a tyre factory
A major US-based tyre factory reduced particle contamination in a Banbury mixer gearbox, extending oil life and equipment lifetime while avoiding multiple oil changes.
Customer case written by: Mr. Peter Smyth, C.C.JENSEN Inc. USA
In cooperation with: C.C.JENSEN A/S, Denmark
Application Snapshot
Industry:
Tyre industry
Country:
United States
Oil type:
Mobilgear SHC 636, ISO 680 gear oil
Executive summary
A Banbury mixer gearbox in a tyre factory was operating in a rough environment with high levels of carbon black contamination. This resulted in high particle counts, frequent spare part replacements, and oil changes every two years on a time-based basis.
A CJC® Oil Filter HDU 27/54 with CJC® Filter Inserts GFi 27/27 was installed to continuously remove particles from the ISO 680 gear oil.
After installation, contamination levels were reduced from ISO 22/21/17 to ISO 17/16/13. Oil changes were extended from every two years to more than six years, equipment lifetime was doubled, and three oil changes were avoided, resulting in total savings of 60,000 USD over six years.
Reduced particle contamination
Cleanliness improved from ISO 22/21/17 to ISO 17/16/13 through continuous depth filtration.
Significant maintenance cost reduction
Three oil changes were avoided, saving 60,000 USD over six years with a payback period of two months.
Longer gearbox lifetime
The Banbury mixer lifetime was extended by a factor of 2 due to reduced contamination.
Lower CO₂ emissions from extended oil life
Prevented premature oil changes reduced oil consumption, resulting in approximately 1,500 kg CO₂ reduction annually per machine.
Reducing particle contamination in high-viscosity gear oil
Oil analysis before filtration showed high levels of particle contamination, with cleanliness at ISO 22/21/17. Carbon black particles were the primary contaminant in the Banbury mixer gearbox.
After installation of the CJC® Oil Filter, particle levels were significantly reduced. Cleanliness improved to ISO 17/16/13, and particle counts at >4 µm were reduced from 25,033 to 1,178.
Measurable results and operational impact
The improved oil cleanliness extended oil life by a factor of 3 and equipment lifetime by a factor of 2. Oil changes were extended from a two-year interval to more than six years without oil changes..
“We wanted to reduce the number of oil changes. During the trial period, we selected three companies to test their filtration efficiencies. The CJC® HDU series depth filter far exceeded the other two filter companies and was selected as the filter of choice for our most critical applications.”
– Maintenance Manager
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