Optimising lubrication for hydraulic systems

22 April, 2025

Water contamination, specifically, is one of the most damaging threats to hydraulic fluid. Even small amounts of water can lead to
rust and corrosion, degrading the fluid’s ability to lubricate effectively. It can also cause the fluid to become emulsified, forming a mixture that loses its lubricating properties. Water can enter the system through condensation, faulty seals, or even the atmosphere, so it’s important to regularly check for moisture. Special dewatering systems or water-absorbing filters can help
remove any excess water before it causes damage. In addition, performing regular water content testing ensures that the fluid
remains in optimal condition.

Even with the best maintenance routines, there comes a time when the fluid must be replaced. Over time, hydraulic fluids break
down due to oxidation, contamination, and the stresses placed on them. As the fluid degrades, its lubricating properties are
compromised, leading to increased friction and wear. Replacing the fluid at the right intervals ensures that the system continues to
operate smoothly and that the components are properly lubricated. For some systems, condition-based monitoring is used to assess the exact right time for fluid replacement, based on factors like acidity levels, viscosity, and contamination.

Regular fluid replacement

Regular fluid replacement goes hand-in-hand with maintaining the filtration system. Filters are essential in removing particles from
the fluid and keeping the system free from damaging debris. Clogged filters can reduce the effectiveness of lubrication, and in
some cases, they can even cause a complete failure of the system. Checking filters regularly, and replacing them when needed,
ensures that contaminants are kept to a minimum and that the fluid continues to lubricate the system effectively.

The type of hydraulic fluid used is another consideration that can affect lubrication. Some fluids contain additives, such as anti-wear agents, that help protect against friction and wear in the system. Others may be designed to withstand higher temperatures or have better resistance to contamination. Choosing the right fluid for the specific system and environment can significantly improve performance and reduce maintenance needs. For example, biodegradable fluids are becoming more popular in industries where environmental concerns are a priority, while synthetic oils offer enhanced lubrication in extreme conditions.

In the UK, industries are increasingly aware of the importance of hydraulic fluid maintenance, particularly in sectors like manufacturing, construction, and agriculture. Proper lubrication isn’t just about keeping the system running smoothly; it’s about preventing unnecessary wear, reducing downtime, and protecting expensive equipment from failure. A proactive maintenance plan that includes regular fluid checks, contamination control, and timely fluid replacement can save companies significant amounts of money in the long run.

To ensure hydraulic systems remain reliable and efficient, operators need to focus on more than just the basic functionality
of the machinery. Maintaining the lubrication system through careful fluid management is an investment that pays off in the
form of reduced repair costs, fewer breakdowns, and better overall performance. By monitoring fluid quality, controlling
contamination, and replacing fluid at the appropriate intervals, businesses can maximise the life of their hydraulic systems and
ensure smooth operations for years to come.