www.hpmag.co.uk HYDRAULICS & PNEUMATICS October 2026 25 A major automotive manufacturer operating steel presses in the Czech Republic and Slovakia was experiencing recurring valve sticking in its hydraulic systems, alongside pump failures and seal locks. Varnish accumulation was causing problems, but with no oil analysis being carried out, the build-up could go undetected until operational issues emerged. Varnish mitigation systems were already in use, although these required frequent filter-element replacement. When the systems were disconnected, MPC levels rose quickly. MPC testing was subsequently incorporated into the condition monitoring programme, while Fluitec’s DECON was added to the hydraulic systems at a 3% treat rate. Varnish levels then began to decline steadily, and the manufacturer reported that valve sticking ceased. DECON AW was also introduced to help maintain antioxidant levels and control deposit formation. Following the treatment, MPC values decreased significantly and RULER values increased, allowing longer hydraulic oil life. The manufacturer also reported that valves no longer stuck or caused production delays, and that the systems were varnishfree. The project resulted in reported cost savings of $1.3 million, together with oil savings of 2000 gallons (7570 litres). The case demonstrates how incorporating varnish monitoring into an existing condition monitoring programme, alongside treatment of the lubricant, can help address varnish-related problems in hydraulic systems. For this manufacturer, the approach was associated with lower varnish levels, increased RULER (antioxidant) values, longer hydraulic oil life and the elimination of valve sticking that had previously caused production delays. For further information please visit: https://www.fluitec.com Reducing valve sticking in automotive hydraulic presses
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