In heavy industries like manufacturing, metal forging, and mining, hydraulic equipment is the backbone of operations. But if you manage large hydraulic presses or heavy machinery, you are likely fighting a continuous, invisible battle against two major operational headaches: hydraulic oil degradation and varnish formation.
When traditional filtration methods fail to keep up, the consequences show up directly on your workshop floor: clogged inline filters, stressed pumps, unexpected system stoppages, and skyrocketing oil top-up costs.
A recent global case study from SKF highlights how a major metals producer overcame these exact issues on a massive 30,000-litre forging press hydraulic system. By moving away from conventional filtration and implementing the SKF RecondOil Box, the plant completely stabilised its system, avoided premature pump failures, and captured €80,000 in savings in just five months.
Here is a closer look at how they did it, and how Australian heavy industry can deploy the same technology to reduce varnish formation, cut particle contamination, and significantly reduce hydraulic oil consumption.
The Silent Killer: Why Standard Bypass Filters Fail Against Hydraulic Varnish
Most maintenance teams rely on standard mechanical bypass filters (often around 3 microns) to clean their hydraulic oil. While these are excellent for catching larger, solid debris, they are fundamentally unsuited for tackling nano-particles and the chemical precursors of varnish.
As hydraulic oil is subjected to high pressures, temperatures, and mechanical stress, it begins to oxidise. Microscopic wear particles act as catalysts, accelerating this degradation. The result is varnish: a sticky, tar-like substance that coats internal components, bakes onto valves, restricts oil flow, and insulates heat exchangers. Because these varnish precursors are sub-micron in size, they pass straight through standard filters, continuously accumulating until a sudden component failure shuts down your line.
Case Study: Reviving a 30,000-Litre Forging Press Hydraulic System
A major metals producer in Germany was experiencing severe, recurring hydraulic issues on its large forging press. The system’s 30,000 litres of hydraulic oil had been in service for 8 to 10 years and had become heavily contaminated with dirt, debris, and wear particles.
The symptoms of the system’s degradation were severe:
- Extreme Particle Contamination: The oil cleanliness level sat at ISO 21/16/11, far worse than the plant’s target of 17/15/13.
- High Varnish Potential: Oil analysis revealed MPC (Membrane Patch Colourimetry) values as high as 47, indicating critical varnish formation that was aggressively wearing out system components.
- High Costs and Labour: The existing 3-micron bypass filters simply couldn’t keep up. Technicians were trapped in a constant cycle of replacing blocked filters and conducting emergency pump repairs, while the press consumed roughly 9,000 litres of expensive top-up oil every year.
The Solution: Implementing Continuous Oil Regeneration
To stabilise the system, the plant installed SKF RecondOil Box units. Two RecondOil Boxes, each featuring a four-housing setup, were integrated into the press’s hydraulic layout to feed its separate 15,000-litre backflush and clean tanks.
Unlike traditional mechanical filters, SKF RecondOil utilises Double Separation Technology (DST). This patented chemical-mechanical process separates even the smallest nano-particles and dissolved impurities from the oil, interrupting the degradation process and fundamentally preventing varnish from settling on critical machine parts.
The Results: Drastic Drops in Contamination and Maintenance Costs
Within just five months of continuous operation, the metrics transformed completely:
| Before RecondOil | After RecondOil (5 Months) | |
| Oil Cleanliness (ISO 4406) | 21/16/11 | 16/13/9 (Exceeded plant target) |
| Varnish Potential (MPC) | 47 | 16 (Drastic reduction) |
| Financial Savings | — | € 80,000 saved (€75k oil reduction / €5k labour) |
By dropping the varnish potential and fine particle load, filter life stabilised immediately. The facility completely avoided premature pump failures, reduced maintenance cleanup hours, and dramatically slashed the amount of replacement oil they needed to buy.
The results were so compelling that the manufacturer quickly ordered a second RecondOil unit for its fine press and is now expanding the technology plant-wide across its material manipulators.
What Makes SKF RecondOil Different?
Traditional lubrication management operates on a linear economy: you buy oil, use it, filter out the big dirt particles, watch it degrade, and eventually pay to dispose of it as hazardous waste.
SKF RecondOil introduces a true circular economy for industrial oil. By removing sub-micron particles and reversing varnish precursors, it regenerates the oil continuously, keeping it in a perpetual state of pristine cleanliness. The oil ceases to be a consumable expense and becomes a permanent asset.
For Australian industrial operators, this shifts maintenance from reactive firefighting to a baseline of total reliability, yielding immediate financial and environmental benefits.
Ready to Optimise Your Hydraulic Systems?
If your facility is battling high oil consumption, short filter life, or recurring hydraulic component failures, standard filtration adjustments won’t solve the root cause.
As an SKF authorised partner, Basil VR Greatrex (BVRG) supplies and services the innovative SKF RecondOil system across Australia. Our engineering team can help you transition from traditional, inefficient oil management to a continuous oil regeneration model that protects your machinery, slashes downtime, and permanently reduces your operational costs.
Stop Changing Your Hydraulic Oil. Start Regenerating It.
Download the case study here.