Critical Components in Industrial Hydraulics & Production Affected by Air in Oil

Industrial hydraulic and production systems are the backbone of many industries, from mechanical engineering and automation to heavy industry. However, hydraulic oil quality is a key factor in efficiency, lifespan, and operating costs.

Air in oil is an invisible issue that impacts various components throughout the industrial value chain. It reduces the efficiency of hydraulic and lubrication circuits, increases wear in gearboxes and pump systems, and can cause production downtime.

Image

Challenges for Industrial Companies

  • Efficiency & Production Costs: Air in oil lowers lubrication performance, increases friction, and reduces power transmission efficiency, raising pump loads and energy costs while slowing down production processes.
  • Maintenance Strategy & Component Lifespan: Without real-time monitoring, oil changes are based on fixed intervals rather than actual condition. This leads to unnecessary downtime and shortened maintenance cycles, reducing machine longevity.
  • Cavitation & Material Fatigue: Air bubbles and foam cause cavitation in hydraulic systems, accelerate oxidation, and lead to uneven lubrication, significantly increasing wear on bearings, gears, and pumps.

Challenges for Components & Systems

  • Pumps & Hydraulic Systems: Air bubbles in oil reduce flow performance and compressibility, leading to inaccurate power transmission and unstable hydraulic pressure. Foam formation can impair filter performance and increase maintenance costs.
  • Gearboxes & Lubrication Circuits: Air bubbles cause foaming and oil aging in production machinery, leading to deposits that impair heat dissipation, increase mechanical resistance, and reduce energy efficiency.
  • Filter & Tank Systems: Air content in oil affects filtration efficiency and reduces the performance of tank systems. Contaminants and microbubbles accelerate oil aging and degrade lubricant quality.
The SBS Advantage: Increase Efficiency, Reduce Costs, and Optimize Product Design

The SBS Advantage: Increase Efficiency, Reduce Costs, and Optimize Product Design

Air in oil negatively impacts production systems, causes energy losses, and raises operating costs. Conventional measurement methods fail to provide 100% valid and reproducible data.

The Smart Bubble System enables direct air-in-oil measurement, delivering fully validated results on oxidation rates, cavitation points, and lubricant degradation. It provides precise data to optimize operating strategies, maintenance cycles, and product design.

Production Performance & Energy Efficiency

Production Performance & Energy Efficiency

The SBS detects air bubbles and assesses oil aging to minimize friction losses and maximize energy efficiency. Stable lubrication keeps production speeds consistent, reduces performance losses, and prevents downtime caused by lubrication issues.

Reduced Maintenance & Operating Costs

Reduced Maintenance & Operating Costs

Continuous oil monitoring allows for demand-based maintenance cycles. Unnecessary oil changes are eliminated, operating costs are lowered, and machine uptime is maximized. This avoids unplanned downtime and extends maintenance intervals.

Optimized Product Design & Extended Component Life

Optimized Product Design & Extended Component Life

The SBS provides precise insights into air bubble dynamics, helping to optimize product designs. Development cycles are shortened, test phases reduced, and components are specifically designed for durability—resulting in lower development costs and faster market introduction.

Testing & Implementing SBS in Industrial Production

The SBS technology portfolio includes two complementary test setups for analyzing air in oil under real-world conditions—either directly in application or in a controlled laboratory setting.

SBS-ST: Controlled Stationary Measurements

Simulates air content in hydraulic production systems to analyze pressure losses & cavitation.
Ideal for hydraulic manufacturers & maintenance teams to improve energy efficiency & fluid stability.

SBS-ME: In-Line Real-Time Measurements

Direct air-in-oil measurement in production & hydraulic systems to prevent system failures.
Enables predictive maintenance & energy optimization in industrial manufacturing processes.

Industrial Hydraulics & Production

Ready to Optimize Your Production Performance?

The Smart Bubble System helps manufacturers and industrial operators:

  • Maximize machine & system efficiency with precise lubricant analysis
  • Reduce maintenance costs through root cause-based maintenance cycles
  • Extend component lifespan with precise insights into air bubble dynamics
Book a Live Demo
Ready to Optimize Your Production Performance?

Find out more about the Smart Bubble System

The Smart Bubble System was developed to optimize fluid management and lubricant strategies along the value chain. Find out what advantages it brings in your specific case.