Optimising filtration solutions: Enhancing quality and reliability
Published: 22 September, 2023
MacFab Engineering, based in County Monagham, has established itself as a prominent figure in the recycling and refuse compaction industry. With a specialisation in recyclable waste balers and compactors, the company says it has always prioritised delivering top-quality products to its customers.
As MacFab Engineering transitioned from manual to automated machines and took on the task of manufacturing key components in-house, it encountered some challenges. During the development of prototype machines, the hydraulic drive system exhibited irregularities, stemming from the shift from manual hydraulic valves to electronically controlled ones. In search of solutions, MacFab turned to MP Filtri, an expert in addressing oil and system cleanliness.
MP Filtri took an active role in addressing MacFab's challenge. It conducted a thorough site visit to gain detailed insights into MacFab's operations. To pinpoint the root causes, MP Filtri connected an LPA3 particle counter directly onto a prototype machine situated in MacFab's testing area. Analysis of the oil's ISO code exposed contamination levels exceeding its strict limits. MP Filtri introduced a 6-micron absolute filter, leading to a significant improvement in oil cleanliness. This was circulating oil that only included the pump, valve assembly, tank, and hoses.
In addition, MP Filtri and MacFab looked at the valve block's cleaning processes. Once consistent levels of cleanliness were achieved, they proceeded to test a second prototype. The LPA3 was again used to measure oil cleanliness. On start up the ISO code was noticeably cleaner and using a 6-micron filter to clean the machine proved vital. Once the oil was clean and at working temperature, MacFab ran further tests than included moving the ram. The ISO count quickly went above recommended level. It was slow to clean with the 6-micron filter. The only major component not previously tested was the ram and associated hoses.
Through concerted efforts, they improved the cleaning procedure on the ram and retested a batch of machines. These proved to be clean with zero failures in the field.
These notable advancements prompted MacFab to establish stringent cleanliness protocols within its factory.
Each machine is cleaned using a special filter and the cleanliness code is recorded for traceability. It has also manufactured its own oil scrubber unit with an ICM inline particle counter to ensure clean oil is added to all new assemblies.
Each machine now undergoes meticulous cleaning, complete with traceability of cleanliness codes. Furthermore, MacFab designed its own oil scrubber unit, incorporating an ICM inline particle counter to ensure pristine oil in all new assemblies.
To validate cleanliness during the testing phase, MacFab purchased the LPA3 - each machine must succeed in achieving its cleanliness target at final testing before it is dispatched to the customer.
The multifaceted solutions implemented in partnership with MP Filtri have yielded significant results:
• LPA3: This device helps identify issues, pinpointing contaminated components and to what degree, and gauging the effectiveness of the filtration system in maintaining machine cleanliness.
• ICM 4.0: The integration of the ICM 4 within the oil scrubber unit ensures a consistent supply of clean oil for production.
• Hydraulic Filters: MP Filtri's filtration solutions keep MacFab's oil consistently clean in its bulk-storage and on the machines it builds.
The tangible improvements achieved through this collaboration include nearly problem-free hydraulic systems, a significant reduction in warranty claims, streamlined operational processes resulting in substantial time savings, and the preservation of MacFab's reputation as a quality builder in the marketplace.
MacFab Engineering commended MP Filtri for its proactive approach in identifying the root causes of hydraulic contamination. Once identified, the company says MP Filtri were helpful in offering practical solutions and guidance for both R&D and series production. As a result, MacFab confidently recommends MP Filtri to other Original Equipment Manufacturers (OEMs).
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