Summary of Industrial Reports

There are 65 summaries of industrial reports on the performance of Militec-1 as a metal conditioner below. For many of the summaries, we have the full report attached as a PDF file, if you would like to read them.

Overview

The high value of Militec-1 for industrial maintenance has been proven over and over by many well-known industrial companies. The savings derived from Militec-1 use are many times greater than the cost of the product. Militec-1 is the only oil additive/metal conditioner that has successfully penetrated the industrial market. Even more importantly, Militec-1 has been proven to be completely safe in metal-to-metal friction environments and to reduce mechanical wear. Not one report has come from industry that shows a detrimental effect or negative outcome.

There are many ways that Militec-1 can be used. It is compatible with all motor oils, gear oils, hydraulic fluids and greases. It uses these as a vehicle to get to the metal surface, which it penetrates (into the micropores) and starts to bond when the temperature of the metal reaches 66°C to 71°C. It can also be put directly onto metal surfaces such as in machine shop applications and on bearing surfaces before grease is packed.

Bonding means that there is a physical reaction between the Militec-1 and the metal by which Militec-1 becomes part of the metal itself, not just a coating on top of the metal. Scientific testing of treated metal surfaces ( see report ) shows that Militec-1 significantly increases the stiffness of the surface (not the hardness of the metal). Militec-1 does not remain in the oil when used at the recommended ratios. That is why Militec-1 should be added in addition to the normal amount of primary lubricant. Once the Militec-1 has treated all heated metal surfaces, any remaining Militec- 1 will remain in the oil and serve no useful purpose.

Militec-1 is highly concentrated and only a small amount is needed. For light load applications, about 30ml per litre of primary lubricant will suffice. For moderate loads, the ratio is about 45ml (just over 4%) per litre and for heavy loads/extreme conditions, the best mix is around 60ml per litre (6 %). For hydraulic systems, only 250ml of Militec- 1 is needed for each 19ltrs of hydraulic fluid. For very large engines, 60ml of Militec-1 is best for each litre of engine displacement.

Because Militec-1 will bond to all heated surfaces (over 66°C), the first application, at the above recommended ratios, is generally at least twice the amount needed for subsequent applications. Any treated metal surface area not experiencing wear will not react with additional Militec-1 applications. Thus the subsequent applications need only be enough to treat the surface areas that have been worn although mechanical wear should be substantially reduced.

The interval between Militec-1 applications will vary depending on the amount of metalto- metal contact/pressure. Since a layer of metal (which contains the bonded Militec-1) has to be worn off, the amount of time this will take varies. While some intervals may be as short as 350 hours or 24,000 kilometres, only one application of Militec-1 has been proven effective in some cases for 3,000 hours and more despite numerous oil changes. The best way to tell when more Militec-1 is needed is to monitor the piece of equipment over time and determine when the effects of Militec-1 are no longer evident. Among the things that can be monitored are temperature, vibration, sound, energy consumption and wear. Some companies use a measure of metal wear particles (at each oil change) to determine when more Militec-1 is needed. When the metal particle count is back to where it was when Militec-1 was added, it is time for more

Militec-1

Militec-1 was assessed in accordance with OSHA CFR 1910.1200 and determined not to be hazardous. Safety precautions are those typical for hydrocarbon lubricants: keep away from open flames; keep out of reach of children; keep container closed when not in use; store in original container; keep off foodstuffs; avoid eye contact; avoid repeated and/or prolonged skin contact; wash thoroughly after handling; avoid breathing oil mists.

The flash point of Militec-1 is 210°C and the auto-ignition temperature is 379°C. See Militec-1 Spec Sheet. Once it has bonded with the metal, it has the characteristics of metal rather than fluid. It has been seen to work at +1090°C and -73°C. Consult the Militec-1 MSDS for more detail. There is a caution to observe when using Militec-1 in some industrial equipment. When the equipment manu- facturer specifies, "non-detergent oil only", and there is a significant build up of sludge in that quipment, or there is polycarbonate used for a window or filter bowl, Militec-1 should not be used. While these conditions are rare, they do occur. Militec-1 has a slight detergency and will loosen the sludge. However, if there is no sludge, Militec-1 can be used. Many Militec ustomers change their polycarbonate filter bowls to metal or glass so they can use Militec-1 to obtain its benefit without the concern of causing cracks in the polycarbonate.

Diesel Engines

A large oil refinery in Texas has been monitoring Militec-1 applications for about a year and has found that Militec-1 can be effective in reducing wear by more than 95% in Caterpillar 3408 diesels (988B Loaders used in the coke pits) for more than 3,000 hours. A Texas company has had a similar experience in rock quarries in which Caterpillar 3412 diesels have reduced wear by more than 95% for more than 2,000 hours.

A lumber mill in New Hampshire found Militec-1 could save one day of fuel per week in its stationary Caterpillar diesels used to power the plant. Other companies that have monitored fuel use in stationary diesels have found savings to average around 10%. See detailed report.

A power plant in Maryland found that it did not need to use a supplemental power source to start up twin Cummins diesels in very cold weather or when the engine was still hot shortly after being shut down. See detailed report.

A U.S. Navy maintenance facility reported that turbo-charged Detroit Diesels were not damaged when shut down hot if Militec-1 had been applied. This finding was confirmed by dynamometer tests at the maintenance facility. Nor was there damage when the engines were accelerated at start up. See detailed report.

The Norton Sandblasting Equipment Company in Virginia tested the decibel level of a 6- cylinder Fiat/Iveco diesel engine before and after Militec-1 was applied. Inside the cab, the noise level went from 88 dB to 77 dB while outside, 5 feet from the driver's door, it went from 88 dB to 78 dB. The company also recorded a savings of 10% in fuel. See detailed report.

At Mattson Terminals, Militec-1 was used for the newly rebuilt engines of 6 Stradocaster container movers. It was added to the crankcases of these Mitsubishi engines at a ratio of 2 oz. per quart of oil. After over 1500 hours of operations and five oil change intervals (with no more Militec-1 added), wear metal analyses have shown negligible wear metals throughout this period. The company recently treated its fleet of Cummins diesel trucks and reported an average drop of 15oF in engine operating temperature.

The owner-operator of an eighteen-wheel hauling truck applied 2 oz. of Militec-1 per quart of primary engine oil about 11 months ago. The engine was a turbocharged 425 Caterpillar diesel and ran fairly hot, around 195oF. He added 2-1/2 quarts of Militec-1 to his engine oil reservoir which held 10 gallons. The oil already had about 5000 miles on it (he uses 8000-mile oil change intervals). The next day, he was pleased and amazed that his engine temperature was down to 182oF, a drop of 13oF (7%). After 11 months and 20,000 miles, the temperature still ranges between 180oF and 185oF although he changed his oil twice and no more Militec-1 added. The owner recently retreated his engine after 25,000 miles and this time he also treated his transmission and rear end differential. He reports smoother operation.

The French National Railroad Company tested Militec-1 in a 3,200 hp engine for 3 1/2 hours after a baseline was established. The test was to measure any reduction in temperature at critical spots on metal surfaces of the connecting rods and socket pins. The temperature of the connecting rods decreased an average of 6oC and for the socket pins the decrease was 4oC. See detailed report.

At R&A Bender, Inc. in Scotland, Pennsylvania, a Komatsu bulldozer's in-line, 6- cylinder, 140 hp, 6D125 diesel engine showed a decline in copper wear particles from 335 ppm to 44 ppm after 6 months and to 3 ppm after 15 months of Militec-1 use. Iron wear particles decreased by 42% and lead wear particles decreased by 81%. See detailed report.

A Brazilian bus company had one bus engine (Mercedes Benz model 1420) tha t was estimated to have only 5,000 Km. left at best before a rebuild was required. Oil consumption was 1 liter every 246 Km. Militec-1 was added at a 6% ratio to the oil. After 25,000 Km., 50,000 Km. and 75,000 Km. Militec-1 was again added. At the end of 90,000 Km. they inspected the engine and found the cylinder walls and pistons to be completely polished without a scratch. They estimated the engine can go at least another 150,000 Km. and oil consumption was down to 1 liter every 567 Km. Militec-1 is now in their entire fleet of 225 buses and they say that engine rebuilds are now a thing of the past. See detailed report.

At Singh's Engineering Works in Trinidad (a maintenance facility for most of the island's major contractors) Militec-1 was installed in 10 Nissan V8 diesels. Among the ten, bearing failures had occurred every 4 months on average costing about $20,000 per year for engine replacement. In one year of Militec-1 use, one bearing failure occurred (bearing was already damaged before Militec-1 was applied) and there was no resulting damage to the crankshaft or other engine parts. The main bearings were replaced and the engine has worked perfectly for nearly a year. In another 12-15 Nissan V8s, among which bearing failures occurred every 1-2 months, Militec-1 has now been used for six months without a failure. In 8 D6 and 7 D8 Caterpillar tractors, Militec-1 has reduced maintenance problems to zero for eight months. See detailed report.

A Mass Transit Administration in the mid-Atlantic states tested MILITEC-1 in seven Flexible Transit Buses. They provided the following report: Summary: The MTA has tested an internal engine metal treatment product called "MILITEC-1". The product appears to reduce wear by 63%. The annual cost of application is $22,400.00, less than the cost of two replacement engines. Results: There was a reduction in wear metals in all engines. The level of wear metals increased as the treated surface wore and reduced again when the buses were redoped. The field tests confirmed MILITEC's claims. If a six year life is assumed 72 engines wear out each year. Accordingly 63% of 72 is 45 engines. Only 2 of these need to be saved by the use of MILITEC to recover more than the cost. Recommendation: The Quality Assurance Department recommends that MILITEC be used in the fleet system-wide. See detailed report.

The captain of a charter fishing boat reported that he installed Militec-1 in his twin J&T Detroit Diesel engines and transmissions starting at 1,800 hours. Subsequently, he found an average fuel economy improvement of 8.6%, and a drop of 8oF in the transmissions and 7oF in the engines. The engines' compression, factory new, is 475 psi. These engines normally need a rebuild at 3,000 hours as the compression usually falls to 450 psi by then. At 5,883 hours, 9 of the 12 cylinders tested at 475 psi while the other 3 cylinders were 468-470 psi. See detailed report.

The manager of a bus company in Brazil wrote of his activities marketing Militec-1: To date, we have approximately 40 clients in this field, all of them with fleets of not less than 100 units, of which some of them are using MILITEC-1 since March, 1994. All, with no exceptions, are satisfied with the results and benefits obtained from the product. Some urban bus firms have reported a cost/benefit result of up to 1:6. For instance, motors that normally last 380,000 kilometers [237,500 miles] (urban vehicles), today they are doubling their useful life and we do not know yet if some will not pass it and triple it. We are finding the same positive results in gearboxes, differentials, bearings, etc. Some companies extended oil change intervals from 10,000 to 20,000 kilometers and, depending on the driver, a savings in fuel (in some cases 3-7%). We likewise experienced a significant reduction in pollutant emissions from vehicles treated with MILITEC-1. The units treated with our product gain power, operate smoother and with lower temperatures. They are also protected in case of deficient lubrication (including extreme cases of contamination or oil loss). Mechanics love how clean the parts are when working on buses treated with MILITEC-1, because the product does not permit carbon to adhere to the metal, which normally they can clean only by working hard and using chemicals and steel brushes. We saw parts like pistons and cylinders totally clean and polished, without
scratches or other signs of wear. See detailed report.

The Venezuelan Navy tested Militec-1 in a Detroit Diesel 8V71 engine. They compared results using different operational conditions including running the engine 9 hours without Militec-1, 20 hours with Militec-1 and ten minutes without oil. They came to the following conclusions: (A) By using Militec-1, engine water temperature was lowered by 10oF to 13oF (5.5oC); (B) The engine oil always remained at normal temperature and viscosity, within operational parameters; (C) The oil analysis showed no abnormal wear; (D) Connecting rods, block and crankshaft did not show damage after the engine was run for 10 minutes without oil; (E) Militec-1 effectively protects engine parts, lowering the friction between metal surfaces.

Industrial Motors

The Municipal Water Department of a large Midwest city had a history of a major breakdown of its motors generally once a week. For a full year after Militec-1 was applied, not one major breakdown occurred and 10 to 12 new motors that would have been installed were kept on the shelf.

The distribution center of a major children's clothing retailer has been using Militec-1 in their motors that run their conveyors. They have found that the motor oil maintains its viability twice as long. Prior to using Militec-1, they changed the oil once a year. Now they need change it only once every two years.

Transmissions/Gearboxes

The SPECO Corporation in Springfield, Ohio, tested Militec-1 in a differential type planetary gearbox with an output speed of less than one RPM. This creates one of the worst combinations possible from a lubrication stand-point in that there are very heavy loads with very little velocity to help generate a lubricant film. In testing the dynamic efficiency of the gearbox with moly grease and then with Militec-1, they found a 6.2% improvement in efficiency and a 59% reduction in power required to turn the unit without a resistant load. See detailed report.

Volkswagen do Brasil S/A had a failure of a wormgear in their exhaust manifold drilling machine. This was an old piece of equipment in which the wormgear had become misaligned and this caused premature wear on the bronze gear. It was repaired using the same gear and worm shaft as new parts were not available. In a workbench test, the unit seized up after 40 minutes. It was again repaired (in the same manner as after the first failure) but this time Militec-1 was added at 20% of the total oil volume. In both workbench testing (3 hours) and field use on the production line, the wormgear has operated without interruption. Volkswagen do Brasil S/A has approved of Militec-1 for use in all machines for the Water Cooled Engines and Axles Manufacture unit. See detailed report.

A printing plant in North Carolina has seven gearboxes which, historically, would break down one each month, costing the company 2 1/2 to 3 hours of repair work and down time as well as $150 in parts. Only 1 1/2 ounces of Militec-1 was added to each gearbox one time only. At the end of FOUR YEARS, not one gearbox had broken down. The major saving was 120 to 144 hours of down time. See detailed report.

A power plant in Maryland had increased the capacity of its coal belt without having the right parts to increase equally the capacity of the fluid drive that helped drive the belt. The fluid drive soon overheated and the oil, losing its viscosity, poured out of through the seals while the operator stood there pouring new oil in. Finally, 16 ounces of Militec-1 were added. Within minutes, the oil temperature returned to normal, the oil's viscosity also returned to normal and the leakage stopped. The fluid drive continued to operate for months without the right parts being installed. See detailed report.

A major U.S. auto manufacturer had a similar situation at one of its plants. A gear drive unit broke down during a production run and there were no spare parts to make the repair. The vendor was called and could only supply a set of gears that were close to what was needed. The un-matched set was assembled into the drive unit with new bearings and seals. When the unit was put into operation it immediately became so hot it could not be touched (about 175oF to 190oF). It was taken off line and let cool. Militec-1 was added and the unit put back on line. With Militec-1, the unit stayed at about 115oF to 120oF and a week later was down to about 95oF to 100oF. When the right gear set arrived, it was put on a shelf. See detailed report.

The War Eagle Construction and Mining Company in West Virginia has a Lee Norse 245 Continuous Miner with 2 ripper boxes that historically have run so hot they could not be touched without burning a hand or finger. The oil deteriorated so rapidly that after only two weeks the smell of the oil would be so strong and disagreeable the oil would have to be changed. Militec-1 was added and, from that time six months ago, the operating temperature has remained so low a hand can be placed on either ripper with no discomfort. At a beverage cannery plant, Militec-1 has been used extensively in the plant's equipment for over 14 months. Amperage draw reductions in the plant's gearboxes have ranged from 1.5 to 6.0 amps throughout this period. The maintenance engineer also reported that there have been no mechanical breakdowns of any Militec-1 treated equipment.

In forklift transmissions of a large supermarket chain in North Carolina wear was a big problem as these Crown forklifts model 30RDTT have a motor mounted in a vertical position on the gearbox making lubrication difficult. There is a tremendous load applied to the gears and metal is thereby pressed hard against metal. The wear can be seen as the metal shavings from the wear are attracted to a magnetized drain plug. After Militec-1 was added, the wear particles were only about half the normal amount. This company has a continuous history of Militec-1 in these transmissions over a period of 4 years. See detailed report.

A Falk Speed Reducer of the Jade Energy company has been powered by a 200-hp moto
but was rated for only 150 hp. It consistently operated with an oil temperature of 165oF and had a current draw of 150 amperes. After Militec-1 was added, and for approximately 3,000 hours without an oil change or repair work, the current draw was 141 amps (a 6% reduction) and the temperature was 145oF (a 12% reduction). See detailed report.

At a major oil refinery, Militec-1 has been tested and used for over 6 months. In one large essential gear unit that was noticeably grinding and ready for major overhaul, an unscheduled maintenance to replace the parts would have caused expensive refinery down time. Instead, Militec-1 was applied and the wearing parts stopped grinding (and wearing), affording continuing use of the gear unit. It was later repaired during a scheduled plant shutdown. The plant now treats all of its heavy industrial gear units, pumps, shaft bearings and compressors with Militec-1. See detailed report.

At a grain and flour mill, Militec-1 was first tested in the company's grain mill gearboxes which were old and showing wear. Initial use of Militec-1 afforded a 10oF temperature drop in these units.

At Trombini Papel e Emblagens S/A in Brazil, a speed reducer (1985 SAUER MF 406 SSE), run by a General Electric motor of 400 CV and 1750 RPM was monitored with a Vibrameter device and showed a vibration reduction of 20% horizontally, 32% vertically, and 21% axially.With respect to the power consumption, there was an average reduction during this period of 10,044 kWh/month, at a cost of R$0.07 (approximately US$ 0.07) kWh/month (11/95), yielding a reduction of R$703.00/month. See detailed report.

Subject: Allison transmissions. Silvio Gryboski of Nossa Senhora do Carmo bus company in Brazil reports that he has not yet opened any of the automatic transmissions in use since he first applied MILITEC-1 in December '94. This is because he has not experienced any problems whatsoever and this made him feel confident enough to postpone the usual 150,000 km preventive maintenance revision (which includes the opening of the transmission), to be done at 250,000 km. Some of the transmissions are actually running at 220,000 km without problems. Silvio also told me that jumpy gear shifting is a thing of the past, since he uses MILITEC-1. The mechanical gearbox preventive maintenance has been extended to 150,000 km instead of the usual 100,000 km "BM" (Before MILITEC-1). This means extended oil life and labor/parts savings.

The parts of already opened transmissions were unusually clean (no deposits), showed a considerable reduction of wear and they could be closed with none or very few replacement parts. This is in other ways confirmed by continuous smooth gear shifting operations, even at 180,000 km without changing any vital original parts. See detailed report.

A mid-Atlantic power generating station with 16 gas turbines uses a sliding clutch to start up the turbines. The gas turbines are started up an average of about 20 times per year. Twelve of the sliding clutches are made by Allison while the other four are made by Twin Kisk. The clutches historically would experience a failure every 5th or 6th start (more than 50 failures a year for the 16 clutches combined) despite trying many oils and greases. In the five years since Militec-1 use began, only one failure has occurred and that was unrelated to lubrication. Overall, more than 250 failures were avoided over the five year period. See detailed report.

Bearing Sets

A 450-ton steam locomotive, built in 1944, and operating at speeds of us to 75 mph, experiences some of the most extreme operating conditions. Last season while operating in the Chicago area, it developed a hot bearing. After cleaning it and other bearings, Militec-1 was added. The result was a decrease in bearing temperature of 25 to 30 degrees. The locomotive bearings are running at cooler temperatures and significantly less grease is used. As a result, the locomotive is greased fewer times allowing the use of those man-hours in other areas. Click here to see pdf file.

The Hampden Coal Co. in West Virginia has a raw coal vibrator/crusher that had a 3-year history of requiring bearing changes every four months at a cost of $3,000 per set, plus 4 to 6 hours of down time. Militec-1 was added and, after nine months without any change of bearings, the equipment was checked and the oil plug was found lying on the ground. The maintenance personnel did not know how long the oil had been out, but watched as the vibrator/crusher continued to operate without oil. The plug was replaced and new oil added but no additional Militec-1 was installed. The machine was still operating 12 months later without need of a change of bearings.

At a subsidiary of the A.T. Massey Coal Company, the take-up roller of a coal belt seized up, threatening to halt production. Militec-1 was quickly applied to the hot (about 300oF) bearings and the roller. This provided sufficient lubrication for the roller to turn. The roller continued to operate for another 6 1/2 hours after which the bearings were removed. The extreme wear that occurred before Militec-1 was added was very apparent. Militec-1 allowed the bearings to function despite their terrible condition.

Similarly, at a large food processing plant, the bearing in an induced draft boiler fan was nearing the end of its 2-3 year life. A vibration analysis showed the bearing had a severe outer race defect and could last no longer than 2 more weeks. Militec-1 was added and the vibration showing the defect disappeared. After 5 months, the vibration returned and Militec-1 was again added. Again the vibration disappeared but returned in 5 months. Militec-1 was added once again and the vibration again disappeared. After 4 months, while the vibration had not returned, the bearing was taken out and the severe outer race defect was there to be seen. The bearing went 14 months when it should have failed within 2 weeks. See detailed report.

At a large food-processing mill, the plant manager first used Militec-1 in the small oil reservoirs of several large fan shaft bearings and gear drives. Average oil temperature measurements were:

• Before Militec 141oF
• With Militec 121oF
• Heat Reduction 20oF = 14.2 %

The company usually replaces the bearings (which cost about $300.00 each) on a yearly basis. Of 8 shaft bearings running with Militec-1, 7 are still in operation with no servicing and no replacement 15 months later. One bearing had to be replaced because it was damaged by one of the fans throwing a weight, putting too much off balance stress on the bearing assembly.
A parts painter for General Motors, Ford, and Chrysler has a motorized conveyor chain to which hooks are attached. The parts hang from the hooks and pass through a number of sprays, rinses, heat treatments, etc. The system uses ball bearings to run along a metal beam above the chain. The bearings are open and are subjected to the harsh conditions of each stage. They and the chain are lubricated by a Rapid Luve system that uses a pneumatic oil spray triggered by an electric eye. The plant operates 16 hours per day, 5 days per week but the conveyor system had to operate 24 hours a day, 7 days a week to build up lubrication for the workday. Still, breakdowns were frequent. When Militec-1 was added to the spray, the lubrication system had to operate only 4 hours per day and breakdowns have been reduced by about 90 percent. See detailed report.

At a waste recycling plant in New Jersey with 30 conveyors made by Hustler Conveyor Co., the average number of bearing sets per conveyor is eight. These 240 sets of bearings have required greasing at least once a day, occupying one maintenance worker full time. The biggest problems were the bearings outdoors and in the pits as access was difficult. The company found that with Militec EP-2 grease, the bearings needed greasing only one time per week. After more than 2 months of using Militec, the bearings and shafts showed no deterioration despite the infrequent greasing. See detailed report.

At a food processing plant in the South, their 80 vertical shaft fans together needed 50 lbs. of grease each month and experienced an average of 3 failures per month. The top bearing would often lose its grease protection causing the failure. When Militec EP-2 grease was used, only 5 lbs. of grease per month was needed. After 9 months of Militec use, it was reported that there were no failures throughout the 9 months. Twenty-seven failures have so far been avoided. See detailed report.

At the Pallet Outlet in Biglerville, PA, their Clary "Sidewinder" high speed horizontal band saws have four spherical bearings which support a 1 1/2" diameter shaft. These bearings historically have failed at about 1,000 hours. With Militec EP-2 grease, the bearings have already lasted 2,000 hours and have saved the company about $3,112.00. See detailed report.

A large blood bank operates 13 blood centrifuges. Each centrifuge has a main shaft and bearings to which buckets are attached. When maintenance was done on the shaft and bearings, the cloth used to wipe the metal surfaces, showed a black residue with a lot of shiny metal particles indicating considerable wear. The bearings are made of a steel alloy that is used to withstand the high speed of the centrifuge (4,000 RPM). Despite this, the heat from the bearing surface penetrates the bucket and causes stress cracks. There are a total of 78 buckets; six on each of the 13 centrifuges. A bucket is replaced when stress cracks appear and the number of replacements has historically averaged 2 to 3 per month. Militec-1 was applied to the bearing and shaft surfaces six months ago. Since that time, only one bucket has needed to be replaced due to stress cracks. That bucket was already old when Militec-1 was applied and had little life left. When the shafts and bearings of the buckets are now wiped clean, the cloth shows only a brownish colour from dirt and dust and the shiny wear particles are barely visible, showing almost no wear.

At a polymer products manufacturer in Pennsylvania, Militec-1 was used on the 4" steel roller bearings of a plastic powder mixer. A pump supplies heavy oil into the bearing casing where the oil is continually dripped onto the bearings to keep them lubricated. The pump failed and the maintenance staff did not notice the failure for 16 hours until a rotor broke in the mixer (unrelated to the lubrication problem) and happened to examine the bearings. They found the bearings had not been lubricated for 16 hours and should have failed after only several hours without oil. The bearings were still in excellent condition with no significant wear and no sign of overheating. The replacement cost for the bearings would have been $1,920 plus 12 hours of very critical downtime.

A power generating station in the Mid-Atlantic states uses Militec-1 to machine bearing journals in gas turbines. A dummy bearing assembly is put on the No.1 bearing area. Before Militec-1, STP was used to lubricate the dummy bearing. It would heat up and throw the alignment of the cutter off. Time was lost while it cooled down. Occasionally the Babbit material would melt and the bearing would need to be rebuilt. It took 4 men to bar the rotor over. With Militec-1, the bearing never got hot again, a small air motor could turn the rotor, which solved a safety problem for the 4 men, and the quality of the cut was improved for a better finish on the journal. See detailed report.

Air Compressors

The Pulitzer Community Newspapers Inc. in Chicago has a Gardner-Denver 50-hp Compressor that operates in a poorly ventilated area. The compressor was operating 24 hours per day in the printing plant. Without Militec-1, after 7-8 weeks of operation, the oil temperature regularly rose 35oF, the oil's total base number (TBN) dropped 60%, and metal wear reached 14-27 parts per million (ppm). With Militec-1 added to the oil, after 8 weeks, the oil temperature was at the same level as the first week without Militec-1, the TBN dropped only 15%, and metal wear showed 0 ppm. The company was able to triple the interval between oil changes. In a second compressor in the same plant (which had been operating about one year), the amperage draw before adding Militec-1 was 125 amps. Within two to three minutes after adding Militec-1 to the oil, the amperage started to drop. After 12 minutes, the amperage had fallen to 105 amps where it leveled off.

In a 40-hp rotary vane compressor at Universal Plastics in Pennsylvania, prior to adding Militec-1 to the oil, the current draw was between 105 and 106 amps. Records of current draw during 2,376 hours of operation with Militec-1 showed an average drop of 5 amps. Prior to adding Militec-1, the compressor had experienced shutdowns in hot weather due to high oil temperature. With Militec-1 there were no shutdowns during hot weather since less friction caused less heat. See detailed report.

A 70-hp Ingersoll-Rand Type 40 reciprocating compressor at the Henry County Plywood Corporation in Virginia, before adding Militec-1, was pulling 92 amps, 460v at full load. After adding Militec-1 to the crankcase, the amperage gradually decreased and stabilized at 80-81 amps, a reduction of greater than 10%. See detailed report.

In a 450-hp Joy Turbo-Air centrifugal 3-stage compressor at a large food processing plant in Mississippi, amp and vibration measurements were taken prior to adding Militec-1, then monitored after adding Militec-1. A steady decrease of amps was noted over the first three hours before they levelled off. Since then, after over 3,800 hours of operation, the decrease from the baseline (both just prior to Militec-1 application and historically) has been between 4.1% and 5.0%. Historically, the input shaft vibration range was .7 to .8 mils. With Militec-1, the reading has stayed in the .6 range. See detailed report.

For two Fuller 200 hp C150 Duplex compressors used to pump dry cement powder onto shore from a 450-ft vessel docked outside of Chicago, 8 ounces of Militec-1 were added to each of 4 oilers once. That oil was passed through the system over the next 8 hours. Readings over the next 39 days showed an average amp drop of 12 to 13 percent throughout the period compared to before Militec-1 was added. Temperature readings using an infrared gun showed that treated bearings under load dropped ten percent in temperature while untreated bearings under load rose six percent over the 39 days. See detailed report.

A subsidiary of AIRCO Industries began testing Militec-1 five months ago at an industrial liquid nitrogen and dry ice facility. One pint of Militec-1 was added to the 5- gallon reservoir of a 1952 425 hp Worthington CO2 compressor, which was drawing 61 amps. Within six minutes, the amperage draw was measured at 58 amps. (a 4.9% reduction). Two weeks later, 2 more pints of Militec-1 were added and amperage reading was measured at 51 amps where it has remained for the last eleven months (over 2000 hrs.). This 10-amp drop represents a 16.4 % reduction in energy consumption.

A large marine stevedore company began using Militec-1 about 3 months ago. One quart of Militec-1 was added to 7 gallons of compressor oil in a 1000 hp Detroit Diesel compressor which runs the company's sand blasting equipment (8 - 12 hrs/day). The machine normally runs hot (around 180oF). Within 5 minutes, the temperature dropped to 175oF, where it has remained throughout 600 hrs of operation and 3 oil changes. A company in Michigan has a Gardner Denver rotary air compressor (Model EDEQJ 50- horsepower) that had 2235 hours of running time when Militec-1 was installed. They found a 16 percent savings in electricity when the amps dropped from 125 to 105. See detailed report.

A power generating station in the Mid-Atlantic states has 4 Worthington air compressors that service its gas turbines. Critical parts on the compressors historically would wear out between 10 and 12 months while catastrophic failures often occurred before this time when oil leaked out or water leaked in. Rebuilds were therefore frequent and costly. Three years ago, a routine schedule was started adding 5 ounces of Militec-1 each 6 months. For 3 years there has been no failure despite oil leaks and water intrusion. The $170 spent on Militec-1 has saved an estimated $12,000 to $18,000 in equipment replacement and labor. See detailed report.

The same power generating station has 16 fuel atomizers, installed in 1968, for its gas turbines. One started to fail 3 1/2 years ago when a ticking was heard and the rest were also nearing the end of their lives. Replacement parts are no longer available. One ounce of Militec-1 has been added to the oil of each compressor every 6 months. The ticking disappeared and all have operated without problems since then. The $175 worth of Militec-1 to date is suspending the need to invest over $22,000 in new equipment. See detailed report.

Pumps

One of the largest U.S. chemical companies operates a large fertilizer plant at which there was a long history of pump failures, averaging almost one per day among their 120 centrifugal pumps. These are end-case, ANSI pumps made by Duriron Pump Co. The maintenance supervisor who maintained the pumps started using Militec-1 in them 3 1/2 years ago. He gives Militec-1 half the credit for innovative techniques that brought the failure rate down from about 20 per month to one per month. See detailed report.

Refrigeration Systems

Freon Compressors: Militec-1 has been used between six months and one year in a variety of refrigeration environments. Specifically, Militec-1 has been applied to Copeland and Carrier refrigeration compressors and has worked successfully with R-12, R-22, and R-502 refrigerants. There have been no indications of lubrication problems while Militec-1 has been in use.

Air Conditioners

American Air Company, Inc. tested Militec-1 in the Mitsushita rotary compressor used in their marine Sea Breeze air conditioners. After a baseline was established and Militec-1 added, there was an amp drop from 11.2 to 9.4 while the unit dropped in temperature from 230oF to 194oF. The temperature differential of the treated air was 20oF while 16oF to 18oF had been the norm. They also removed the R-22 to see if it would lock up in the normal two to three minutes. It ran for two hours without the R-22 before they stopped it and reintroduced the R-22. During those two hours it only reached 249oF while it is rated for a maximum of 266oF. See detailed report.

In 3 federal government agencies, their common maintenance contractor put 24 ounces of Militec-1 in fifty 100-ton reciprocating, semi-hermetic compressors. These are used to cool mainframe computer rooms and operate 24 hours per day 365 days per year. Another contractor (a university) monitored these 50 units over a period of 5 months. Before using Militec-1, the amps were generally from the upper 180s to the lower 190s. With Militec-1, the amps were upper 170s to lower 180s. This resulted in an average energy savings of $8.20 per unit per day. Over the 5 months, the energy savings for all 50 units amounted to over $62,000 with only $1,500 spent for Militec-1. See detailed report.

The Howmet Company in Virginia tested Militec-1 in their 25-ton air conditioning unit. Prior to adding Militec-1, this unit was capable of lowering ambient temperature by only 20oF to 25oF. After adding Militec-1, the temperature on one side of the coil was 94oF and 59oF on the other side; a drop of 35oF across the coil. This represented a significant increase in the unit's efficiency. See detailed report. At a hospital in Chicago, Militec-1 was tested and then used in 12,500 BTU air conditioners. A test unit was operated and carefully monitored for two days prior to adding Militec-1. It was then treated with Militec-1 and again monitored for two days. With Militec-1 there was an amp drop of 7%. In addition, the temperature change across the coils increased from 20oF to 28oF, which showed that the air conditioner was able to remove more heat from the air. See detailed report.

Hydraulic Systems

A major laboratory in the U.S. that tests bridge components for their capacity to withstand heavy load (fatigue testing), needs to apply heavy pressure onto these components. It does so using jacks that can apply from 10,000 to 220,000 lbs. The jacking system is controlled by servo valves that can vary the pressure the jacks apply. The system uses a special hydraulic fluid supplied by Mobil Corp. A constant fluid pressure of 3,000 psi is maintained 24 hours per day. This high pressure historically has kept the temperature of the fluid at approximately 180oF using a 300- gallon sump and cooling towers. When 64 ounces of Militec-1 were added to the hydraulic fluid, the temperature decreased to between 165oF and 170oF and it has stayed at that level for the past 1,000 hours.

At a large soil engineering firm, Militec-1 has been used in the company's car fleet, pumps and hydraulic and rotary drilling rigs for over 15 months. One Deitrich D-20 skid rig was sent to Guam for a two-month drilling job. Two extra hydraulic motors were sent as back ups because the driller on the job had a reputation of burning out the motors after only 15 hours of heavy drilling operations. The company's head mechanic reported later that the original 'Militec'd' motor had lasted throughout the whole job over 70 hours of operation and the two spares did not need to be used.

Sprockets and Chains

A packaging company in North Carolina has not had a wear problem with their sprockets and gears in packaging equipment but has had difficulty preventing the seizure or "freezing up" of the equipment which costs valuable downtime. In a recent case, a servomotor mounted on the main motor moves a series of sprockets that in turn move slip rings. The sprockets were seizing up several times a day and regular lubrication could not solve the problem for more than a day at best. Militec-1 was applied once and no sprockets have seized up in over a month. See detailed report.

A Pennsylvania company, that operates a woodworking machine with two 40-ft. chains, was rebuilding the chain twice a year due to wear of the bushings and hinge pins. When the bushings and hinges were replaced, an Arbor press was used to press the pins into the bushings. However, the fitting was too tight to complete the job with the Arbor press and a hammer and block were required to fully seat the pins. When they started dipping the parts in Militec-1, they found the pins would easily seat using just the Arbor press. Also, after six months of lubricating with Militec-1, they found no significant wear and no need for a rebuild. See detailed report.

Machine Shop Applications

Allied Signal Aerospace in California has reported that Militec-1 saved them over $137,000 in possible lost shipments when they used it as a lubricant with a standard 10- 24 high speed steel (HSS) Heli-coil tap on 49-53 Rc hardened steel. Before using Militec- 1, they were unsuccessful in tapping these hardened parts using an industry approved tapping lubricant. They would not have been able to tap the parts in time to ship them to their customers. Militec-1 made the job feasible within the allowable timeframe. See detailed report.

At the William E. Adams Machine Shop in Columbia, Maryland, Mr. Adams found the small taps he used were difficult to burn out of the hole so he would lose that machined item. Since tapping is usually the last step in machining an item, the prior work would be lost. He would have to start on a new piece. This was very common before he started using Militec - 1. In the six years he has been using Militec - 1, he can't remember losing even one item to a broken tap. See detailed report. A Shore Intermediate Maintenance Activity of the U.S. Navy in California found that drill bits lasted 5 times longer when dressed with Militec-1.
Air Tools At a major automotive assembly plant in Flint, Michigan, using Chicago Pneumatic Air
Tools, a baseline was established for the drill motor of a C.P. 2480-067 Nut Runner with a quick-change chuck. It showed the motor was running at 6,700 RPM, which is exactly as it is rated. The torque was measured at 4.1 Newton meters which is also equal to its rating.

Approximately one-eighth of an ounce of Militec-1 was then introduced into the motor through an air inlet of the tool. The motor was run for about 3 minutes and a second set of measurements was made. The RPMs jumped to 7,200 (7.5% increase) and the torque rose to 5.1 Newton meters, which is a jump of 24.4%. A Die Grinder (C.P. 9107) had been operating at 24,000 RPM, but after treatment with Militec-1 the RPMs increased to 28,000 (16.6% increase).

Compactors

A large construction company treated 35 Rammax compactors with Militec-1 about 10 months ago. This type of equipment was picked because of the severe beating it takes in the trenches. They sit out in the rain and the operators often tilt them sideways and let them run out of oil. Normally, these compactors require rebuilding after one month of operation because of these conditions. The head of maintenance was pleased to report that there have been no breakdowns of the Militec-1 treated compactors in over 9 1/2 months of operation.

Sealed Valves

A manufacturer of hermetically sealed valves designed to accurately regulate the flow of steam, hot water or chilled water through coils or heat exchangers reported excessive friction despite the use of Teflon grease. The valve turns at a very low speed and the wear has been minimal but the friction reduces energy efficiency. The friction was stainless steel rubbing against carbon steel. The critical metal components (armature, canister and pole pieces) were wiped with a cloth saturated with Militec-1. They were put into a standard oven and baked at 180oF for 20 minutes, then cooled and installed. Friction force was measured by precision scales as a response to a pneumatic signal. The reduction of friction force was between 30% and 33%. Militec EP-2 grease has replaced the Teflon grease to provide continuous metal conditioning over time. See detailed report.

Stone Cutting & Drilling

The Sae Jin Stone Co., Ltd. in Korea, while using Militec-1 in all of their mining, transport and processing equipment, provided a special report on Militec-1 for diamondtipped drill bits ($55 each) and saw blades ($500-$700 each) used for drilling and cutting marble. The bits and blades are heated first in an oven to 176oF and then immersed in Militec-1 which is kept at 140oF. (The Militec-1 is in a bowl that is immersed in heated water) The life of the drill bits was extended from 420-450 holes to 550-620 holes. The life of the saw blades was extended by a minimum of 50% to as much as 67%. See detailed report.

Pressure Washers At a vehicle service center in Accra, Ghana, a pressure washer developed a big crack in the cylinder head gasket. Replacement parts were not available and water was continually flowing into the motor oil. By changing oil and adding Militec-1 3 times a day, they were able to keep the washer operating. However, on one extremely busy day they had no time
to change the oil. That day, over a period of 12 hours, they washed 72 vehicles including trucks and tankers. There was no breakdown and the washer was able to remain in service subsequent days until the parts arrived. See detailed report.

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