Proven Fluid Filtration Results Across Critical Industries

A landfill gas engine generating plant required frequent engine oil changes to maintain reliable operation.

A ferry operator requested an independent assessment of fuel oil cleanliness from delivery into a bunker barge through to fuel supplied to vessels.

A power generation facility operating a GT26 gas turbine experienced persistent lubrication issues caused by severe varnish formation. Oil analysis showed critically high MPC values, indicating a high risk of varnish-related failures, reduced heat exchanger efficiency, filter blockages, accelerated component wear, and compromised turbine reliability. Previous filtration approaches failed to control varnish levels or stabilise oil condition.  

his case study shows how Delta-Xero tested landfill gas engines, including CAT 3516, CAT 3520, Jenbacher 320 and Jenbacher 420, to prove that silicon levels alone do not accurately show how harmful the contamination really is. It uses POLARIS lab analysis and Micro Patch Ferrography to reveal abrasive wear, varnish and contamination that standard oil analysis can miss. It also shows before/after examples where Delta-Xero reduced abrasive contamination by around 98% and helped extend oil drain intervals.

A long-term independent study was carried out by POLARIS Laboratories Europe to assess whether installing Delta-Xero filtration on a landfill gas engine would negatively affect lubricant condition, additive performance, or expected oil drain intervals.

A Godswill baler, valued at approximately £500,000 and used for processing aluminium and cardboard, suffered five major breakdowns within just six months of installation. Despite being under warranty, the machine experienced two pump failures and three valve failures, resulting in £15,000 in direct repair costs and significant production downtime. Specialist oil analysis revealed that the heavily polluted waste-processing environment was introducing extreme levels of particulate and varnish-like products that conventional maintenance could not identify or remove. 

A 1.5 MW wind turbine gearbox showed persistent contamination risk despite routine oil analysis. To understand the true internal condition of the gearbox, debris captured inside an offline filtration unit was analysed after extended in-service operation. Standard oil samples alone were not showing the full extent of varnish, wear debris, and moisture present within the system.  

A large natural-gas-fired combined-cycle power station operating multiple Siemens gas turbines faced rising operational risk due to oil degradation and varnish buildup. Oil analysis showed valve issues, filter blockages, and elevated varnish levels within the turbine loop systems, increasing the risk of unplanned downtime and threatening contractual energy supply commitments. Existing filtration systems failed to fully control contamination.  

A wind farm operating 117 × GE 1.5 MW wind turbines faced high ongoing costs from regular gearbox oil changes every ~4 years, including oil flushing, downtime, labour, and disposal. Oil analysis showed that standard inline filtration was not sufficient to manage varnish, sludge, moisture, and long-term contamination buildup in aging gearboxes.  

Stadco, an automotive stamping specialist with over 30 years of experience, operates high-performance hydraulic presses around the clock. The facility was plagued by weekly breakdowns caused by oil degradation inherent in industrial-sized presses. Extreme pressure bursts damaged the fluid, creating varnish deposits that clogged sensitive valves worth approximately £20,000 each. Two previous attempts to use alternative filtration systems had failed, and high contamination levels meant that even oil top-ups were ineffective. 

A Bonus 300 kW wind turbine gearbox with over 10 years of operation showed persistent oil discolouration and internal contamination, even after repeated oil changes and flushing. New oil was observed to degrade rapidly, indicating legacy varnish and debris within the gearbox that conventional maintenance could not remove.  

A 2MW wind turbine gearbox had its oil condemned for disposal after 10 years in service. The 320 cSt synthetic gearbox oil showed severe varnish formation, extremely high particle counts, and degraded cleanliness, making reuse impossible under normal maintenance standards. The oil was scheduled for disposal, with full replacement costs unavoidable.