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SFR (GB) Ltd Bodymaker Presentation Beverage & Food Can Manufacturing

SFR (GB) Ltd Bodymaker Presentation Beverage & Food Can Manufacturing. BODYMAKER PROBLEM. Poor oil condition High oil consumption High filter use High main ram seal pack use Main ram seal pack failure High lee jet use High amount of lee jets requiring cleaning Increased maintenance cost

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SFR (GB) Ltd Bodymaker Presentation Beverage & Food Can Manufacturing

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  1. SFR (GB) Ltd Bodymaker Presentation Beverage & Food Can Manufacturing

  2. BODYMAKER PROBLEM • Poor oil condition • High oil consumption • High filter use • High main ram seal pack use • Main ram seal pack failure • High lee jet use • High amount of lee jets requiring cleaning • Increased maintenance cost • Increased wastage in production • Increased downtime • Difficulty in controlling Tramp oil levels • Host oil low in the additives required to control contamination

  3. CAUSE OF PROBLEM • Overall Bodymaker design makes the control of contamination very difficult • Current filtration is poor and unable to effectively deal with high levels of contaminants (Micron size often 25 microns on existing filter.) • Coolant is entering oil reservoir via main ram seal pack • Oil is entering coolant via main ram seal pack • Main ram seal pack is not compatible with coolant • High levels of condensation being formed in Bodymaker

  4. Results of SFR Programme on Beverage Can site Examples of Bodymakers not treated after ingress of water and condensation

  5. Results of SFR Programme on Beverage Can site Example of seal pack failure in Bodymaker

  6. Results of SFR Programme on Beverage Can site Bodymakers after SFR programme

  7. SOLUTION • New main ram seal pack • Introduce off line filtration @ 3 micron to remove contamination • Introduce desorber filtration unit to remove water caused by coolant ingress and condensation • Apply specific oil technology to existing Bodymaker oil to clean Bodymaker and assist in controlling both water & particle contamination • Introduce oil analysis to measure results

  8. Bodymaker 7 – Three-Month Trial Summary Water As you can see from the results the water content as be maintained at a level of approx 200 PPM. The target performance for this type of oil is approx 300 PPM. The desorber unit when it was attached immediately reduced the level of water contamination from 5000 PPM to 220 PPM in 48 hours. The average content of water in Bodymaker seven for the preceding three years has been over 4000 PPM compared with the 200PPM during the three months the desorber unit as been applied. According to SKF and Exxon this will be increasing the life of the equipment components by a factor of SIX. Dirt Contamination (ISO 4406) The ISO 4406 reading for Bodymaker seven during the trail has been a consistent 15/12. The ISO standard for this type of oil is 16/13 which means that your oil currently exceeds the standard. The average level of contamination over the previous three years as been 20/17. When following the ISO standard this should equate to a life expectancy increase of the equipment of a factor of FOUR. At 20/17 your oil will be handling in excess of 5,000 PPM of contaminates; at 15/12 it is a little over 200 PPM. A significant achievement in this type of equipment.

  9. Results of SFR Programme on Beverage Can site

  10. Results of SFR Programme on Beverage Can site Improvements in TAN of oil

  11. Results of SFR Programme on Beverage Can site Volume of water removed

  12. Results of SFR Programme on Beverage Can site

  13. Results of SFR Programme on Beverage Can site Total Cost for Year One - $66,043.80  Savings for Year One - $293,110.56  Pay Back – Three Months

  14. Results of SFR Programme on Beverage Can site

  15. CHANGES IN MAINTENANCE COST

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