Prevent Costly Downtime: Advanced Monitoring for Hydraulic Systems

Hydraulic and lubricating systems are essential to industrial operations but are constantly threatened by water contamination, particle buildup, and clogged filters. These issues can disrupt operations, cause equipment failure, and lead to costly repairs. Hengst’s advanced solutions, humidity sensors, online particle monitors, and clogging indicators, offer real-time insights to protect your machinery, reduce maintenance costs, and improve overall system performance.

Hengst: Your Trusted Partner in Filtration and Monitoring Excellences

Founded in 1958 in Münster, Germany, Hengst Filtration is a family-owned company that develops innovative filtration and fluid management solutions with more than 3,700 employees at 26 locations worldwide. Hengst supply technologically leading filtration systems for Hydraulic and Industrial applications. Hengst engineer solutions that are used in mining, manufacturing, industrial plants and other critical industries.

The Hidden Costs of Hydraulic System Failures

Hydraulic systems face many hidden risks that increase costs and disrupt operations. Common problems include water contamination, particle buildup, and neglected filter maintenance.

1. Corrosion and Damage to Parts

• Water in oil leads to rust and weakens critical components such as pumps, valves, and cylinders. Over time, this damage results in expensive repairs and equipment downtime.

2. Reduced Lubrication Efficiency

• Contaminated oil thickens into sludge, clogging filters and increasing friction. This reduces lubrication, leading to faster wear and higher energy costs.

3. Unplanned Equipment Breakdowns

• Particles and water contamination can cause cavitation, clogged valves, and overheating, all of which lead to costly repairs and unexpected downtime.

4. Increased Maintenance Costs

• Frequent oil changes, filter replacements, and system repairs are necessary when, contamination is present, raising overall maintenance expenses.

5. Shortened Equipment Life

• Contaminated systems wear out faster, reducing the lifespan of expensive equipment and requiring more frequent replacements.

6. Safety and Environmental Risks

• Leaks caused by water or particle contamination can pose safety hazards and lead to environmental damage, increasing the risk of fines and liability.

How Hengst’s Sensors Solve These Challenges

Humidity Sensors: Real-Time Water Monitoring
Hengst humidity sensors detect even the smallest changes in water content within hydraulic and lubricating oils. Features include:
• Continuous Monitoring: Provides real-time data on moisture levels and oil temperature.
• Quick Detection: Alerts operators to water contamination early.
• Wide Compatibility: Supports analog, digital (IO-Link), and switching systems for flexible integration.

Online Particle Monitors: Precision Cleanliness Tracking
Hengst online particle monitors measure oil cleanliness directly within hydraulic systems, enabling early detection of particle contamination. Benefits include:
• Real-Time Tracking: Continuously assesses particle levels and trends.
• Reliable Under Pressure: Operates at pressures up to 420 bar.
• Standards Compliance: Ensures hydraulic fluids meet ISO 4406:99 cleanliness requirements.

Clogging Indicators: Simplified Filter Maintenance
Hengst clogging indicators alert operators when filters need replacement, ensuring system performance remains optimal. Highlights include:
• Visual and Electronic Alerts: Mechanical-optical indicators and electronic switching elements for real-time monitoring.
• Preventative Maintenance: Avoids pressure loss by identifying clogged filters early.
• Universal Compatibility: Suitable for retrofitting into existing system

Applications Across Industries


Mining Operations
Heavy-duty mining equipment operates in harsh environments with extreme temperature
fluctuations and high humidity. Hengst monitoring tools:

• Detect water contamination and particle buildup to prevent equipment failure
• Maintain system cleanliness, reducing unplanned downtime.
• Prolong the lifespan of hydraulic components like pumps and valves.

Manufacturing Facilities
From assembly lines to CNC machines, manufacturing relies on clean hydraulic systems for
efficiency. Hengst solutions:

• Ensure oil cleanliness to protect critical machinery.
• Prevent contamination that disrupts precision operations.
• Enable predictive maintenance to avoid costly delays in production.

Industrial Applications

Industrial systems like steel production, power plants, and logistics operations depend on
reliable hydraulics. Hengst monitoring products:

• Monitor and optimise high-pressure systems to reduce energy costs.
• Prevent contamination-related failures in critical processes.
• Maintain efficiency in demanding environments with continuous monitoring.

Simple Installation and Operation

Humidity Sensors

  1. Connect the sensor using the G3/4” threaded connection with an Eolastic seal.
  2. Configure the output type (analog, digital, or switching) to integrate with your system.
  3. Begin real-time monitoring of moisture levels and oil temperature.

Online Particle Monitors

  1. Mount the monitor to the system using threaded couplings (M16x2).
  2. Power the device and track particle levels via display or system interface.
  3. Use collected data to maintain cleanliness in compliance with ISO standards

Clogging Indicators

  1. Attach the clogging indicator to the filter housing.
  2. Monitor for mechanical-optical or electronic alerts indicating filter replacement.
  3. Replace filters as needed to maintain system pressure and performance.

Protect Your Hydraulic Systems with Hengst Monitoring Tools

Water contamination, particle buildup, and clogged filters are hidden threats that compromise hydraulic system performance. Hengst’s innovative solutions, including humidity sensors, online particle monitors, and clogging indicators, provide the real-time insights you need to protect your operations, extend equipment life, and reduce downtime.