Lubricants & Reclamation
Aluminum Profile Extrusion Line
Aluminum Profile Extrusion Oil Purification
Key outcomes
- No cartridge replacement required: using centrifugal separation technology, no filter cartridge replacement needed, significantly reducing consumable costs
- Aluminum powder recovery rate approximately 98%: efficiently separates fine aluminum powder from the fluid, achieving resource recovery
- Improve profile surface quality: reduce profile surface scratches caused by particles in the oil, improving yield rate
Case Study
Stage 1 · Customer Problem
Aluminum Profile Extrusion Pain Points
A large-scale aluminum profile manufacturer in the Northeast region operates aluminum profile extrusion and wire drawing processes, where lubricant (drawing oil / extrusion oil) plays a key role in lubrication and cooling. During processing, large quantities of fine aluminum powder are generated and mix into the lubricant, causing the following issues:
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Product Surface Defects
Aluminum powder particles suspended in the fluid accumulate at the extrusion die, causing "pitting," "scratches," or reduced surface finish on aluminum profiles, increasing the defect rate.
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High Filter Cartridge Consumption
Due to high aluminum powder content, traditional bag or cartridge filter units clog within hours, requiring frequent shutdowns for filter bag replacement, with high consumable and labor costs.
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Accelerated Oil Aging
Aluminum powder has a catalytic effect, accelerating oil oxidation and deterioration, causing the fluid to turn black and develop odors, shortening the oil change cycle.
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Equipment Wear
Aluminum powder-laden fluid recirculates, exacerbating wear on hydraulic pumps and extrusion dies, increasing maintenance and component replacement costs.
Stage 2 · Fuel Analysis · NEW
Contaminated Drawing Oil Profile
Analysis of the in-service drawing oil before treatment revealed the following key indicators:
| Parameter | Value | Assessment |
|---|
| ISO Cleanliness Code | ~24/22/19 | Poor — far exceeds target for extrusion lubricant |
| Solid Content (Al powder) | High | Severe — drives clogging and catalytic aging |
| Minimum Particle Size | Down to 1 μm (sub-micron) | Beyond bag/cartridge capture range |
| Oil Appearance | Blackened, odorous | Advanced oxidative deterioration |
| Viscosity | Affected by contamination | Reduced lubrication performance |
Note: ISO cleanliness ~24/22/19 indicates heavy particulate contamination from aluminum powder; sub-micron particles are beyond the effective capture range of traditional bag or cartridge filters.
Stage 3 · Solution
JY-N95 Fully Automatic Centrifuge
A JY-N95 fully automatic centrifuge was deployed on the production line, replacing traditional intercept filtration with consumable-free centrifugal separation:
Separation Principle
Centrifugal force (density difference)
Min Separation Size
1 μm (sub-micron)
Separation Efficiency
~98%
Discharge Mode
Fully automatic
Filter Media
None (consumable-free)
Operation Mode
Continuous, high-load
Recovered Material
Aluminum sludge (scrap metal)
Utilizing centrifugal force generated by high-speed rotation, heavy aluminum powder is separated from light fluid based on density difference, with no filter cartridge needed. When accumulated aluminum powder reaches the set level, the system automatically discharges oil-containing aluminum sludge without manual intervention. The discharged sludge is classified as general industrial solid waste; due to the combustible nature of aluminum powder, the storage area should be ventilated and kept away from fire sources.
Stage 4 · Results
Operational Outcomes
Export
Surface Finish Standard
| Metric | Before (Bag Filters) | After (JY-N95) | Improvement |
|---|
| ISO Cleanliness | ~24/22/19 | Markedly improved | Sub-micron capture to 1 μm |
| Cartridge cost | High (frequent replacement) | Zero (consumable-free) | 100% consumable elimination |
| Profile surface quality | Pitting, scratches, high defect rate | Export-standard finish | Yield rate improved |
| Oil service life | Shortened (catalytic aging) | Extended (powder removed) | Oil change cycle prolonged |
| Aluminum sludge | N/A (lost in waste) | Recovered as scrap metal | Resource recovery |
The JY-N95 centrifuge transformed the workshop's fluid management approach. The direct benefit was a significant reduction in filter bag procurement costs, as no cartridge replacement is required. The treated drawing oil showed markedly improved clarity, and the aluminum profile surface finish reached export standards, improving the yield rate. The separated aluminum sludge could be recovered as scrap metal, and the equipment operated stably with low maintenance costs.
Stage 5 · Lessons Learned · NEW
Key Takeaways
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Centrifugal Separation Eliminates Consumables
For high-solid-content fluids like aluminum-laden drawing oil, centrifugal separation based on density difference removes the need for filter cartridges entirely, eliminating consumable costs and reducing waste.
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Aluminum Sludge Combustibility
Discharged aluminum sludge is combustible; the storage area must be ventilated and kept away from fire sources. Follow environmental requirements for collection and disposal as general industrial solid waste.
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Automatic Discharge Maintains Efficiency
Fully automatic discharge at set accumulation levels ensures continuous operation without manual intervention; regular monitoring of discharge cycles helps maintain optimal separation efficiency over time.
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Customer feedback
We previously spent considerable amounts on filter bags, and workers found replacing them each shift to be dirty and tiring. The JY-N95 centrifuge solved both problems simultaneously. It automatically separates aluminum powder, keeps the fluid clean, and requires basically no manual intervention. Our aluminum profile surface quality has noticeably improved.
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