Industrial Overview


We Offer the Perfect Proactive Maintenance Solution

What is Crisis Work?

Plainly stated, the growing cost of maintenance is a serious business problem. According to DuPont, “maintenance is the largest single controllable expenditure in a plant: in many companies it often exceeds annual net profit.” One major U.S. automotive manufacturer has a maintenance staff of between 15,000 and 18,000, all plants combined. They say, “85% to 90% is crisis work” (breakdown). While preventive maintenance, when well implemented, has been shown to produce savings in excess of 25 percent, beyond that its benefit quickly approaches a point of diminishing return. According to a Forbes Magazine study, one out of every three dollars spent on preventive maintenance is wasted. A major overhaul facility reports “60 percent of hydraulic pumps sent in for rebuild had nothing wrong with them.” These inefficiencies are the result of maintenance performed in accordance with a schedule (guess work) as opposed to the machine’s true condition and need.

Let us help you cut down on maintenance costs and crisis work which we have shown has saved millions of dollars with the companies that we have been involved with.

What is Proactive?

Proactive maintenance is a cost saving trend toward a maintenance program that targets the root causes of machine wear and failure. Proactive methods are currently saving industries of all sizes thousands, even millions of dollars on machine maintenance every year. By 1 micron Filtration and 100% water removal, the sand blasting effects of dirty oil under pressure, is eliminated. Increase life of pumps, seals, etc.

Laboratory and field tests show that more than any other factor, fluid contamination is the number one culprit of equipment failure. Even the most microscopic particles can eventually grind a machine to a halt. No discipline has previously taken a micro view on machine damage, concentrating on the causes instead of the symptoms of wear. Proactive maintenance is that discipline, and it is quickly being recognized worldwide as the single most important means of achieving savings unsurpassed by conventional maintenance techniques. Proactive maintenance is presented as an important means to cure failure root causes and extend machine life.

Fluid contamination control through the installation and management of improved filtration systems for all lube, gear, hydraulic and turbine oils has been established as an essential method to implementing proactive maintenance. Substantial savings are based on case studies involving the installation of improved filtration applications.

Numerous examples of 10-fold maintenance cost improvements are given. Extend the life of your plant equipment, and save money doing it! Heat, moisture, air and particles literally rob fluids and lubricants of life. But with rigid contamination control practices, these fluids and lubricants can last indefinitely which, in turn, prolongs the life of the machine’s components and keeps the machine running at the highest level of efficiency. Plus, the costs to begin a proactive contamination control program are quickly absorbed in maintenance cost savings.

Proactive “Life Extension” Maintenance

Proactive maintenance has now received worldwide attention as the single most important means of achieving savings unsurpassed by conventional maintenance techniques. The approach supplants the maintenance philosophy of “failure reactive” with “failure proactive” by avoiding the underlying conditions that lead to machine faults and degradation. Unlike predictive/preventive maintenance, proactive maintenance commissions’ corrective actions aimed at failure root causes, not just symptoms. Its central theme is to extend the life of mechanical machinery as opposed to (1) making repairs when often nothing is broken, (2) accommodating failure as routine and normal, or (3) preempting crises failure maintenance in favor of scheduled failure maintenance.
While the root causes of failure are many, or at least presumed to be, it is generally accepted that 10 percent of the causes of failure are responsible for 90 percent of the occurrences. Most often, the symptoms of failure mask the root cause or they are presumed themselves to be the cause. For example, a sudden bearing failure is often blamed on poor quality or a bad lubricant. The root cause, on the other hand, is often contamination in the lubricant (bad filter) or faulty installation of the bearing.

When a machine is well designed and well manufactured, the causes of failure can generally be reduced to machine misapplication or contamination. And, among these two, contamination is clearly the most common and serious failure culprit. A great deal of laboratory proof and field confirmation now are available to support this fact. Therefore, the logical first-approach to proactive maintenance is the implementation of rigorous contamination control programs for lubrication fluids, hydraulic fluids, coolants, air, and fuel. The appropriateness and veracity of this maintenance strategy is emphasized below:

A. According to the bearings division of TRW, “contamination is the number one cause of bearing damage that leads to premature removal.”

B. Machine Design Magazine reports that “less than 10 percent of all rolling-element bearings reach the fatigue limit because contamination usually causes wear or spalling failure far earlier.”

C. According to Caterpillar, “dirt and contamination are by far the number one cause of hydraulic system failures.” J. I. Case states that “one thing holds true about hydraulic systems: the systems must be kept clean — spotlessly clean — in order to achieve the productivity they’re capable of.”

D. Protractive studies by the U.S. Navy show that the cost of contamination on marine and aviation equipment per operating hour exceeds 60 percent of the cost of fuel per hour on the same equipment.

E. Massachusetts Institute of Technology states, “six to seven percent of the gross national product ($240 Billion) is required just to repair the damage caused by mechanical wear.” Wear occurs as a result of contamination.

F. Oklahoma State University reports that when fluid is maintained 10 times cleaner hydraulic pump life can be extended by 50 times.

For more detail, please download this PDF article.

 PT Pamapersada Nusantara

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Sudiarso Prasetio – PT Pamapersada Nusantara History

 In 2000, Denton introduced his products and solutions to Mr. Sudiarso Prasetio the President and Director of PT Pamapersada Mining, Indonesia (PAMA). PAMA Mining, the largest independent mining contractor in the world, has saved hundreds of millions of dollars in equipment, fuel, and maintenance costs, and drastically reduced their Carbon Footprint since implementing the Filtagreen™ Complete Proactive Maintenance System.
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The Indonesia-based company went from getting an average of 12,000 hours of operation out of their equipment to getting over 40,000 hours –and still growing– without a single major overhaul or breakdown.

“We … committed to reduce our green house gas emission by improving our fuel consumption efficiency. PAMA is the first [mining] contractor in the world–and … the first among Indonesian-based companies–[to have] received the Green House Gas Emission Reduction Certification.

– Sudiarso Prasetio: The Legend’s Insight

vehicles-trucks-driving-on-highway

Large trucks (such as delivery trucks and school buses) account for 7 percent of all vehicles on U.S. highways, yet consume more than 25 percent of all oil used on the road.

Unlike passenger vehicles, which have been subject to fuel economy standards since the 1970’s, medium- and heavy-duty trucks have only recently faced similar measures. The first-ever greenhouse gas and fuel economy standards for trucks were finalized in 2011 and take effect in 2014.

The MY 2014–2018 medium- and heavy-duty vehicle standards will:

• Reduce annual oil consumption by 390,000 barrels per day in 2030, roughly equivalent to the amount of oil we import each year from Iraq (EIA 2013a)

• Cut carbon dioxide equivalent pollution by 270 million metric tons (EPA and NHTSA 2011a)—equal to the emissions from more than 4 million of today’s

Now truckers can save an average of $42,000 on Fuel and Oil Costs PER 1,000,000 MILES and in some circumstances, as much as $100,000 over that same distance

  • 1st Year Savings Per 120,000 Miles
    approximately $4,576+
  • 2nd Year Savings Per 120,000 Miles
    approximately $5,218+

Interested in learning more? Call and to a Sales Representative today at 877-464-5728

MONEY BACK GUARANTEE
if not satisfied with results

Bonus: Save the Environment

OCEAN POLLUTION – GLOBAL SHIPPING & THE CRUISE INDUSTRY

Ships transport 90 percent of the world’s consumer goods, including computers, cars, shoes, clothes and toys. People and the environment pay a high price for these cheap goods in the form of cancers, breathing problems and premature death from inhaling air toxics in ship engine exhaust. Ships burn tons of fuel per hour, generating 3 to 4 percent percent or more of human-generated global warming gases—more than commercial aviation. Container and cruise ships also pollute the oceans and coastlines by dumping sewage, dirty graywater, and garbage directly overboard. Because the shipping industry is under-regulated, these environmental and public health impacts will escalate tremendously as global trade triples over the next two decades—until new air pollution and no-discharge laws are enacted by national and international bodies.

EMISSIONS AND BUNKER FUEL

  • Ships generate 15 to 30 percent of the world’s smog-forming emissions.
  • Bunker fuel burned by ships is 1,000 times dirtier than highway diesel used by trucks and buses.
  • A single ship coming into harbor produces the smog-forming emissions of 350,000 new cars.
  • Ship engines are far dirtier than on-road engines due to lack of regulation.
  • The International Maritime Organization has lagged far behind in revising outdated regulations for ship emissions.

HUMAN HEALTH

  • Ship exhaust contains harmful air toxics that cause cancer, respiratory illness and premature death.
  • Ship air pollution often disproportionately harms low-income and people of color who live near ports.
  • More than one in 10 children has asthma in the world’s biggest port cities.

CLIMATE CHANGE

  • Ships burn tons of fuel per hour, generating large volumes of global warming gases and black carbon that contribute to climate change.
  • Researches are finding that the black soot from ship smokestacks settle on polar ice sheets and help cause melting.
  • The world’s shipping fleet generates about four percent of the world’s carbon dioxide emissions.
  • The shipping industry burns 300 million tons of bunker fuel per year.

BEARINGS & GEAR PROBLEMS SOLVED

Since 1993 a product now known as EFFICIAMAX® NANO Metal Surface Modifier has improved performance in a large range of equipment – increasing the performance of engines, gearboxes and differentials and extending operating lifespans by several times normal. This Metal Surface Modifier prevents wear and breakdowns and is the solution to many problems common to wind turbine bearings and gears.

Despite advances in technology, wind turbine gearbox failures continue to occur. Bearing and gear experts understand that even in a properly designed and lubricated gearbox, heavy torque operations can cause oil-film breakdown. Even as gearbox lubrication has been improved, extreme load conditions compress the oils within the gearbox and abate the lubrication. The oil just itself is not enough to prevent loading, skidding, shearing or even fracturing of the bearing rollers.

EFFICIAMAX® NANO Metal Surface Modifier is a Metal Surface Modifier that significantly reduces friction between the surfaces of the bearings as explained below. This molecular technology is delivered to the ferrous metal surfaces by way of the oil, but is not an oil additive. When applied,

EFFICIAMAX® NANO Metal Surface Modifier completely fills the microscopic pores of ferrous metal and creates a strong ionic bond. The resulting surface is smooth and has a greatly strengthened surface hardness. Friction is virtually eliminated.

Experimental data shows a 2.5GPa, metal surface treated with EFFICIAMAX® NANO Metal Surface Modifier restructured to a hardness of 12.4GPa. Once EFFICIAMAX® NANO Metal Surface Modifier is applied, the friction coefficient is reduced 4.67 times down to 0.003, with an increased microhardness of over 5 times that of the untreated hosting metal.

EFFICIAMAX® NANO Metal Surface Modifier is the solution to countermand skidding, and also to prevent micro-pitting (sometimes known as “greying,” “micro spalling” or “frosting”). This material prevents microscopic metal particles from being shed and contaminating the oil. If the gearbox is equipped with a  standard inline OEM filter, typically only particles down to 15µ (microns) to 30µ  in size are removed. Particles in oil or hydraulic fluid start causing wear at 4µ, and among the most problematic contaminants within gearboxes are those between 4µ to 12µ.

When pitting and shearing continuously occur within wind turbines, the freed particles smaller than 12µ consistently contaminate the gearbox oil and cause further wear and tear on the bearings and gears until complete failure occurs, often well before the end of the unit’s life expectancy.

Because Filtagreen®‘s EFFICIAMAX® NANO Metal Surface Modifier resurfaces the ferrous metals within gearbox, the amount of microscopic particles that are shed is significantly decreased, preventing the breakdown described above.

OEM filters if supplied are ineffective at removing water in the oil. Water in the oil can make micro-pitting worse by causing hydrogen embrittlement of the surface. However, surfaces that are restructured with EFFICIAMAX® NANO Metal Surface Modifier no longer react with molecules of water or oxygen, and hence are not subject to chemical corrosion or oxidation.

Since 1997, the Founder of FILTAGREEN® International, Denton E. Thiede, has been providing solutions to heavy equipment operators all over the world; especially to the mining industry, which operates in some of the harshest environments on planet earth.  FILTAGREEN® International has successfully cleaned and extended the operating lifespan of engine oil, hydraulic oil, gearbox oil and many other oils. In turn, this has also extended the life of engines, gearboxes, axles, bearings, differentials, etc. to several times their normal life expectancy, saving equipment owners millions of dollars over the years and therefore adding to their profits. The same technology can be applied to the manufacturers and operators in the wind turbine industry.

More To Come