EUROTEC COMPRESSOR OIL 46 ENHANCES RELIABILITY AND EFFICIENCY IN ROMANIAN INJECTION MOLDING PLANT

Industry: Manufacturing – Plastics

Location: Romania

Client: Tier-2 Automotive Supplier with 5 Rotary Screw Compressors

Related Product: Eurotec Compressor Oil 46

Client Background

A prominent plastic parts manufacturer in Ploiești, Romania, operates five rotary screw compressors

critical to maintaining stable air supply for over 40 injection molding machines. The compressors run 24/7,

with zero tolerance for pressure loss, and any unplanned shutdowns directly affect production output for

Tier-1 automotive contracts.

Operational Challenge

The facility was experiencing frequent disruptions and maintenance escalations stemming from lubricant

degradation in the compressors:

• Discharge temperatures reached up to 98°C, risking oil breakdown
• Sticky valves and varnish buildup disrupted air/oil separator performance
• Oil oxidation caused rapid viscosity increase and sludge accumulation
• Air delivery losses led to production slowdowns and higher scrap rates
• Drain intervals were limited to 2,000 hours, with no predictability in oil life

Solution

After evaluating compressor operating conditions and oil analysis reports, Eurotec recommended

transitioning to Eurotec Compressor Oil 46, engineered for high-efficiency air systems with:

• Oxidation life >6,000 hours (ASTM D943)
• Low-volatility base oils that resist carbon formation and sludge• Excellent varnish control, ensuring clean valve and separator operation
• Strong rust/corrosion protection and anti-foam properties

A detailed flushing and oil conversion protocol was developed, including MPC testing to monitor varnish

potential and offline filtration upgrades.

Implementation Process

• All five compressors were flushed and filled with Eurotec Compressor Oil 46
• Air/oil separators and coalescing filters were replaced
• Monthly oil analysis began, tracking viscosity, TAN, ISO cleanliness code, and varnish potential
• Compressors were thermographically inspected pre- and post-implementation

Measured Results (12-Month Operational Review)

• Discharge temperatures reduced by 12–14°C, improving oil life and system stability
• Zero varnish or sticky valve incidents observed over 12 months
• Drain interval extended to 4,500 hours, cutting lubricant consumption by 50%
• Annual energy cost savings of €3,700, due to reduced compressor load and improved air efficiency
• Production downtime from compressor failures reduced to zero

Customer Statement

"This has been our most stable year yet. No shutdowns, no varnish, and significantly less time spent

dealing with compressor issues. We now run with confidence."