Reduce oil consumption

and breakdowns with

CJC® Offline Oil Filtration

EXTEND
oil lifetime by

3-4x

Your guide to effective oil

maintenance in tyre production
 Protect your oil
and your assets

Would you like to extend oil lifetime and

reduce equipment downtime?

Do you need to lower costs for waste oil How does dirty and contaminated
handling and spare parts? oil impact your profitability?
• High oil disposal costs
Are you looking for better ways to improve
• Short life on pumps, valves, gears, etc.
your sustainability profile?
• Downtime and production loss
In this guide for oil maintenance in tyre • Unbudgeted replacement of parts
production, you will discover how CJC® Offline
Oil Filtration can help you to achieve all this,
and more. What if you could save thousands
of liters of hydraulic oil in your
After more than 70 years of supporting
businesses like yours with innovative oil
curing presses?
maintenance solutions, we are your trusted Calculate the value of your oil savings:
partner. Our oil maintenance experts will walk
you through the critical areas, where clean oil
Oil volume disposed Liters *0.75 (example) =
will benefit to your business and operations.
Oil price and disposal fee * ( + ) Price per liter
So say goodbye to unnecessary downtime, Savings
costly repairs, and high oil consumption – and
hello to greater productivity and profitability,
as well as a greener profile.
Imagine what clean oil could do for
your Banbury mixer gearbox and
downstream production!
With CJC® Offline Oil Filtration, you can significantly
reduce your risk of major gearbox breakdown at your
Want to learn more? Banbury mixer, including all related costs from loss of
production.

Calculate how much time you could save:

For more information, please visit:
www.cjc.dk/tyre-manufacturers
Downtime due to:

Oil change hours/year x 0.8

+
In-line filter change hours/year x 0.7

Spare part change

+ hours/year x 0.65

Hours saved = gained uptime

2 CJC® Guide to effective Oil Maintenance in Tyre Production

Oil contamination causes approx.
80% of all oil-related failures
While all contaminants have a direct negative impact How does contaminated oil
on your oil system and components, the main issues are
caused by particles, water, and oil degradation products.
affect your oil system?

Typically, a standard in-line filter processes your oil
in a matter of minutes, which naturally exposes it to
high flow rates. These high flow rates often mean that
in-line filters only filter down to around 10 microns,
letting smaller harmful particles flow through.
Particles (abrasive wear)
When clearance sized hard particles are wedged
between movable metal parts, they destroy the metal
surface further and can result in additional wear.

Pressure pulsations in the oil system can result

in particles being released from the in-line filter,
entering the oil system once again. Furthermore, a
pleated in-line filter will only remove a limited amount
of particles and furthermore allow water to pass
through.
Water (cavitation and pitting)
A CJC® Offline Oil Filter solution processes the oil This occurs in areas where water is present and oil is
volume in a matter of hours. Consequently, the oil compressed; the water implodes, causing the metal
flows at a lower rate, which effectively retains the surfaces to crack and release more particles.
particles in the CJC® Filter Inserts. The reduced oil
flow also enables offline oil filtration to capture
particles as small as 0.8 microns, effectively addressing
the presence of carbon black particles commonly
found in your mixer gearboxes.

In addition, the cellulose depth media in CJC® Filter

Inserts facilitates removal of oil degradation products
(varnish) and the absorption of water, extending lifetime Oil degradation
of your oil. Wear, water, and high temperatures lead to oil
degradation, which is the precursor of varnish. This
Oil system results in sticky deposits on metal surfaces.
hydraulic oil
gear oil
lube oil
etc.

In-line
filter

System
Clean & dry oil is pump
returned to the
oil reservoir

CJC® Offline Fine Filter

(kidney loop)

CJC® Guide to effective Oil Maintenance in Tyre Production 3

 Extending oil lifetime
in mixer gearboxes
It is well known that mixers play a critical role and are often bottlenecks in a
tyre production line. To prevent significant production losses, it is important
to proactively address potential issues that may lead to downtime.

Operating in a rough environment, it is not surprising that mixer gearbox oils

are prone to high particle counts. The mixer gearbox is particularly vulnerable
to carbon black particles, which are commonly found in high quantities. SAVED
Unfortunately, the presence of dirty oil in your gearbox can have detrimental $60,000
effects on its components. Contaminants significantly reduce the lifespan of
important elements such as seals, bushings, and gears. What makes matters
worse is that the most harmful particles are about the same size as the dynamic
tolerance between the moving parts within the oil system. Although standard
in-line filters can capture larger particles, smaller micron particles tend to slip
through. To truly achieve a clean oil system, it becomes crucial to incorporate
offline fine filtration.

Adding offline fine filtration will continuously capture particles in the oil system,
reducing abrasion and extending the life of your mixer gearbox’s components,
greatly enhancing durability and reliability. OIL CHANGE
extended from
2 to 7+
years
Customer case

Company Benefits
Major US-based tyre factory • 3 x longer oil life
• 2 x longer equipment life
Challenge
• Significant maintenance cost reduction
Banbury mixers operate in rough environment, which can
lead to high numbers of carbon black particles in the oil • 60,000 USD savings in extended oil lifetime
system. As a result, the customer experienced frequent spare • 1,500 kg CO₂ reduction annually
part changes and a significantly reduced gearbox lifetime. pr. machine
The customer changed the oil every two years on a time
basis. The mixer had an oil volume equal to $20,000.

Results
After installing a CJC® Fine Filter, contamination levels were
reduced from ISO 22/21/17 to ISO 17/16/13, resulting in
a significant reduction of maintenance costs. The Banbury
mixer lifetime was extended by a factor of 2, and oil changes
were extended from every 2 years on a time basis to more
than 7 years without oil changes. This means that 3 oil
changes could be avoided, each at a value of 20,000 USD.
Following these results, the factory purchased more than
40 CJC® Oil Filters for mixing gearboxes, extrusion gearboxes,
stock prep gearboxes, and bead prep gearboxes.

4 CJC® Guide to effective Oil Maintenance in Tyre Production

 Reducing oil consumption
in curing presses
During the long-term operation of a vulcanizing machine, vibration, wear,
pressure, temperature, and repeated disassembly can often cause oil leakage
at the static sealing parts of the joint surfaces. This can lead to high oil disposal
requirements, resulting in high OPEX costs.

The high temperatures experienced during the vulcanization process can

accelerate oil degradation, while the steam heating process increases the risk SAVED
€47,000
of water entering the hydraulic oil system. This shortens the life of pumps,
valves, and other components.

Water in your oil systems will also cause cavitation, a common problem
that occurs especially in pumps, when water in oil is exposed to vacuum
followed by high pressure. The bubbles vaporize causing quick expansion but
rapidly collapse again causing micro-pitting and damage to the mechanical
components in the oil system. This results in the generation of small metal
particles in the oil system, further contributing to wear on mechanical parts.

With offline oil filtration (kidney loop), you can effectively reuse a significant
portion of your hydraulic oil that would have otherwise been disposed of.
Not only that, but offline oil filtration also helps to maintain the cleanliness of
REDUCED
your oil system by removing water, particles, and oil degradation products. oil consumption by
24,000
This helps you to extend oil lifetime while also ensuring the longevity and
performance of your vulcanizing machine.

liters per year

Customer case

Company Benefits
French tyre manufacturer • Reduced oil consumption by 24,000 liters per year
• 47,000 EUR saved per year on new oil
Challenge
• Reduced carbon footprint
The customer wanted to reduce the costs
related to the purchase of new hydraulic oil.
The oil was heavily contaminated with particles,
sludge, and water from the vulcanization
process, where overheated steam can ingress
into the oil. Due to this, every month about
2,000 liters of oil were wasted, including leaks.

Results
Oil volume recycled per month: 2,000 liters.
The hydraulic oil is now clean and free from
humidity and particles. Oil consumption was
reduced by 24,000 liters per year. The recycled
oil showed oil properties and cleanliness similar
to or better than new oil!

CJC® Guide to effective Oil Maintenance in Tyre Production 5

 The benefits of
offline oil filtration
By implementing a CJC® Offline Oil Filter solution, you can
ensure the removal of harmful particles and the elimination
of water and oil degradation products, leading to cleaner
and more efficient oil systems.

Benefits CJC® Oil Filters can be

• Reduction of the number of oil changes
used on gearboxes and/or
• Increased life of assets thus lower capital investment hydraulic systems for the
• The ability to filter heavy gear oils down to a following machines:
3-micron absolute and a 0.8-micron nominal rating
• Bead and belt steel cord manufacture
• Removal of carbon black, along with other particulates, • Fabric cord manufacture
soft contaminants, water, and acids • Banbury mixer
• Reducing particle counts [ISO code] in critical gearboxes • Fabric ply cutting
and hydraulic systems • Fabric cord calendering
• Varnish removal to assure uptime on • Steel belt calendering
critical equipment • Steel belt cutting
• Bead assembling
• Highest dirt holding capacity on the market,
• Innerliner calendering
giving the lowest cost per kilogram dirt removed • Tread and sidewall extruding
• Tire building
Banbury
mixer • Tire cutting
1 Tyre Plant Overview
Raw materials

Fabric cord
manufacture

Bead
Bead & belt assembling
steel cord
manufacture 4

Steel belt
cu�ng

Steel belt
calendering
Tire curing

Fabric cord 7
3 calendering

Fabric ply
cu�ng Tire building
6
Distribu�on

Tread and sidewall

extruding
5
Innerliner
calendering

6 CJC® Guide to effective Oil Maintenance in Tyre Production

 A solution
for every need
CJC® Oil Filtration solutions

CJC® Fine Filters, HDU CJC® Filter Separators, PTU CJC® Desorbers
Removal of particles, water, Removal of water from oil. Removal of large volumes of water.
and oil degradation products The CJC® Filter separator The CJC® Desorber treats mineral
(varnish) from oils. The CJC® combines depth filtration with oils as well as
Offline Oil Filtration systems water separation, perfect for synthetic fluids,
(kidney loop) have the highest hydraulic and lubrication and even breaks
dirt holding capacity on the oils contaminated stable emulsions.
market, giving the lowest cost with water. The Desorber
per kilogram dirt maintains water
removed. content to very
low levels.

CJC® Filter Inserts

Particles down to 0.8 µm are retained in the

unique CJC® Filter Insert cellulose media.
Water is removed either by absorption
or separation according to oil system
requirements.

Our CJC® Filter Inserts are made of 100%

natural cellulose fibres from sustainable
resources. That means no metal, no plastics,
and no chemicals.

C.C.JENSEN

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 offline oil filters and oil condition
monitoring covers tailor-made solutions for all
system volumes.
Today, the company has over 300 employees, with
200 at our Headquarters and production in Svendborg
and about 100 in our 14 subsidiaries worldwide.
In addition, our CJC® Oil Filters are traded through
more than 40 distributors globally.

CJC® Guide to effective Oil Maintenance in Tyre Production 7

C.C.JENSEN

Contact us
today
Manufacturing
& headquarters
Denmark
C.C.JENSEN A/S
Løvholmen 13
DK – 5700 Svendborg
Denmark

Tel. +45 6321 2014

sales@cjc.dk
www.cjc.dk

Find your local contact at www.cjc.dk/contact

© 2023 C.C.JENSEN A/S | Ver. 001 | 21.11.2023