75%

LESS OIL
RELATED
shutdowns

Reduce oil change

intervals and wear
on crusher components
Guide to effective crusher oil maintenance
 2

Reduce oil change CJC® Filter Inserts,

heavily saturated with
intervals and wear contaminants from dirty oil

on crusher
components
Guide to effective crusher
oil maintenance
Would you like to reduce maintenance-related crusher
shutdowns? How about extending the life of oil and mechanical
spare parts? What if you could improve your sustainable profile
and work conditions?

You can do all of that with one simple solution – offline oil
filtration. The C.C.JENSEN team put this booklet together
to help you understand how offline oil filtration for crushers
could provide an easy path to proactive maintenance,
reduced downtime and increased savings.
In particular, we examine the benefits of clean oil in your
crusher and share some success stories of mining operations
where offline crusher oil filtration has lead to great savings.
How does dirty and contaminated crusher oil
impact your profitability?
• Severely worn components and system failure
• Downtime and lost production
• Unbudgeted replacement of parts
• Frequent oil changes (monthly or quarterly)
• Frequent replacement of in-line oil filters

We hope you'll find some valuable ideas and insights that

you can apply to achieve more efficient crusher operation
at your mine. Imagine if you can avoid
3 out of 4 shutdowns with
offline oil filtration
– how will that impact
your profitability?
Calculate the value of one hour of crusher downtime

Crusher capacity tonnes per hour

Production hours per day * hours per day

/24 hours

Avg. finished product per hour tonnes per hour

*
Avg. sales price per gram $

Grade (grams of a tonne) * gram

Value per tonne $

= One hour of lost production $

 3

Eliminate 3 out of 4
oil changes
Achieve proactive maintenance
75%
LESS OIL
Like many other mining operations, you may want to modernize
your maintenance strategy. Simple and smart solutions such RELATED
as offline oil filtration can enable big gains in your progression shutdowns
to a proactive maintenance model.

It isn’t an uncommon practice to perform crusher service and

repairs on an “as-needed” basis. When unexpected breakdowns
occur, this reactive model can become costly, so many mines
strive to implement a preventive maintenance strategy.

With preventive maintenance (servicing the crusher and

replacing mechanical spare parts at set intervals) you have Offline oil filtration solution
more control of breakdowns, but costly parts are sometimes CJC® Fine Filter HDU 427/108
replaced without need, and production is lost due to scheduled containing 16 x CJC® Filter Inserts
downtime.

From an OPEX perspective, the cheapest way to run a crusher

is to follow a proactive maintenance strategy. With this model,
the focus moves away from maintaining the crusher by replacing
worn out parts. Instead, you monitor and control the factor
which has caused the components to fail – contaminated oil.
Installing offline crusher oil filtration is a proactive step which
businesses can take to improve uptime and the lifespan of
critical mechanical spare parts.

Reducing shutdowns by 87%

Site BEFORE AFTER
Total savings
Copper mine, Chile Type of costs installation installation
per year
of offline oil filtration of offline oil filtration
Challenge
Oil consumption 24,000 litres 4,000 litres 83% reduction
The large dirt and contamination
ingress resulted in oil changes every
Waste oil handling 19,200 USD 4,800 USD 14,400 USD saved
2 months, despite the almost daily
in-line filter changes. Shutdowns
Cost = 10,600 USD/hour 508,800 USD 63,600 USD 445,200 USD saved
Results
Stand still, 6 shutdowns of 8 hours 1 shutdown of 87% less
Since installing offline oil filtration, Oil replacement, each = 48 hours total 6 hours downtime
the client now shuts down just 6 hours Cleaning, Service
annually for a single oil change, resulting
3 cylinders & plates 1 cylinder & plate Market price for
in major oil savings. Spare parts per year
3 main bushings 1 main bushing spare parts saved
 4

Improve sustainability
and your bottom line
With standard, in-line filtration, the oil flows at high
speed through the machine’s internal filter. The entire
How does dirty oil affect
volume of the tank may flow through the internal pressure your crusher's performance?
filter in just a matter of minutes.
Abrasive Wear
An offline oil filter normally processes the crusher’s oil Hard, clearance-sized particles wedged between
in about two hours. This slower, finer filtration results in movable metal parts destroy the metal surface
significantly cleaner oil, reducing the risk of premature and result in additional wear.
oil degradation and oil-related machine failures.

Protect your crusher's internal components

Metal particles, dirt and water cause many problems for
your crusher's oil lubrication system. With the addition of
offline filtration, you can considerably reduce scheduled
and unscheduled downtime.

Cleaner oil in your crusher's system will also reduce wear Oil Degradation
and tear, increase the reliability, and strengthen Wear metals, water and high temperatures lead to
environmentally sound practices. oil degradation resulting in sticky varnish deposits
on metal surfaces.
Improve sustainable practices and your bottom line
Reducing the micron-size particle count in your oil with offline
filtration will significantly reduce your oil consumption over
time. Less oil changes and less handling of oil leads to both
environmental benefits and improved working conditions for
employees. So, micro filtration really can have a macro effect.

A clean and dry system with offline oil filtration

Cavitation & Pitting
Crusher oil system In areas where water is present and oil is compressed,
hydraulic oil
gear oil the water implodes, causing metal surfaces to crack
lube oil
etc.
and release even more particles.

In-line filter

Clean & dry oil

System pump

Clean & dry oil is

returned to the oil
reservoir

CJC® Fine Filter

 5

Extend the life of

mechanical spare parts
with fine filtration 60%
REDUCTION
in spare parts
While standard in-line oil filtration captures larger
particles, it doesn't stop the small micron-size particles
consumption
that are most harmful to your crusher.

As dirty oil flows through your crusher, contaminants greatly

reduce the lifetime of seals, bushings and gears. The most
harmful particles are about the same size as the dynamic
tolerance between the moving parts in the oil system.

The oil film thickness between the critical moving parts

in a crusher are typically between 5 to 0.5 microns in size.
In comparison, a human hair is 70 microns thick. Bigger
particles (15 microns and above) do not have the same Offline oil filtration solution
harmful effect on your equipment because they cannot CJC® Fine Filter HDU 27/54
enter the narrow clearances.

To protect your equipment from the damage caused by

those smaller particles, you need finer filtration than your
in-line solution is capable of providing.

Adding offline oil filtration will continuously remove

water ingress from the system and capture particles,
reducing abrasion and extending the life of your crusher's
internal components.

Reducing in-line filter and mechanical

spare parts consumption
Site
In-line Mechanical Total costs
Yearly costs Oil Copper mine, Chile
Filters Spare Parts annually

Crusher 3,
WITHOUT
2,754 EUR 2,019 EUR 31,411 EUR
36,184 EUR
Challenge
5,824 L 14 pcs 8 pcs The dusty environment caused oil contamination
CJC® Filter
resulting in both unexpected shutdowns and
Crusher 4, WITH 393 EUR 288 EUR 11,779 EUR
12,460 EUR high consumption of in-line filters and mechanical
CJC® Filter 832 L 2 pcs 3 pcs
spare parts.
Yearly savings: 23,724 EUR
Results
In a side-by-side comparison of two identical
86% Oil Savings 62% Mechanical Spare Part Savings
crushers, the system with added offline filtration
saw a savings of 5,000 L of oil per year and an
73% In-line Filter Savings 66% Cost Savings extended lifetime of mechanical spare parts.
 6

Track your
results with an
oil analysis 75%
REDUCTION
in oil
Regular analysis will help you assure the oil in your crusher
is still in good working condition. Additionally, testing will help
consumption
you track the value provided by offline filtration and achieve
the highest level of machine performance and reliability at the
lowest possible cost.

An oil analysis should include:

• Viscosity
• Particle counts
• Moisture/water content in ppm A visible difference
• Acidity level
• Element analysis (wear and additive level) Site
Nickel mine, Finland
Seeing is believing
Initial samples will serve to establish benchmarks and to Challenge
identify the machines with critical levels of contamination. A very high ingress of dirt and contamination in the oil.
Going forward, routine sampling can then be performed
to document that goals are being met, and to detect any Results
abnormal wear that needs to be addressed. Three months after the addition of offline filtration,
component lifetime was extended 4 times and the oil
What can you learn from an oil analysis? was good for further use.
• Is the oil suitable for further use?
• What is the condition of the machine?
• Are seals, breathers and filters operating effectively?

Keep running clean and lean

We hope you can clearly see the benefits of cleaner oil.
If you would like to find out just how much you can save Particles before Particles after Particles after
oil filtration 2 months 3 months
with offline filtration, we would be happy to provide a free, ISO 23/21/11 ISO 16/15/8 ISO 14/12/8
customised savings calculation.

To get your detailed savings

estimate, or to learn more about
solutions for your crusher and other
mining equipment, contact us at
sales@cjc.dk

Offline oil filtration solution

CJC® Fine Filter HDU
427/108
 7
About CJC®
Established in 1953, C.C.JENSEN is a family-owned
international company with headquarters in Denmark.
We offer our customers a unique combination of tradition,
innovation and technical expertise. Our product range of oil
filters covers tailor made solutions for all system volumes.
CJC® HDU Series: Achieve
high-efficiency oil purification
These CJC® Offline Oil Filtration systems with
integrated circulating pumps are perfect for
many applications in the mining industry.
CJC® HDU 27/27 CJC® HDU 27/108
CJC® HDU 27/54 CJC® HDU 427/108
CJC® Filter Inserts: Capture
the contaminants that damage
your machines
CJC® Oil Filters solutions
• High dirt holding capacity
• Low maintenance requirements
• Customisable design, modular
build up
• Highly-qualified technical support
CJC® PTU Series: Remove large
volumes of water from your oil
The CJC® Filter Separators combine depth filtration
with water separation and are used for hydraulic
and lubricating oils contaminated with water.
CJC® PTU3 27/54
CJC® PTU3 2x27/108
With an absolute filtration ratio of 3 µm, CJC® Filter
Inserts attract contaminates to the polar fibres.
Particles down to 0.8 µm are retained in the unique
CJC® Filter Insert cellulose mass. Water is removed
either by absorption or separation according to oil
system requirements.
The CJC® Filter Inserts are produced of 100% natural
cellulose fibres from sustainable resources - no metal,
no plastic, no chemicals.
C.C.JENSEN
- contact us today!
Manufacturing & Løvholmen 13 Tel. +45 6321 2014
DK - 5700 Svendborg sales@cjc.dk
headquarters Denmark www.cjc.dk
C.C.JENSEN A/S

Find your local contact at

www.cjc.dk

© C.C.JENSEN A/S, May 5, 2020