Zero Valve Breakdowns in two years

The Challenge 

Stadco, an automotive stamping specialist with over 30 years of experience, operates high-performance hydraulic presses round 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. 

Customer Savings & Impact 

Delta-Xero cartridge units were installed across the plant, with one to four cartridges per machine depending on oil volume. Within 12 months, the system achieved the following: 

• Zero Valve Breakdowns: No failures caused by press valves have occurred in the two years since installation. 

• Total Varnish Elimination: Achieved a 100% reduction in MPC (varnish) levels. 

• Drastic Particulate Reduction: Recorded a 98.8% reduction in particles > 4 μm and a 96.1% reduction in particles >14 μm 

• Self-Cleaning System: The newly conditioned oil became clean enough to act as a solvent, absorbing and removing historic contamination and varnish from the bottom of the tanks and internal pipework. 

• Operational Efficiency: Cartridge replacement is now only required every 8 to 12 months, eliminating the need for full oil changes. 

Download the complete Stadco hydraulic press reliability case study, including independent laboratory analysis, MPC varnish trend reports, and the technical breakdown of how Delta-Xero turned contaminated oil into a cleaning solution.