XADO Manufacturing Solutions
Industry Challenges
- Energy cost control
- OSHA compliance with noise control
- Cost and operational impact of equipment down-time
- Environmental impact of energy usage
- Sanitation requirements of food and beverage manufacturing
XADO Solution
XADO Revitalizant Gels and Greases Can be used on any metal-to-metal contact surface in the manufacturing plants:
Case studies of XADO Products used for manufacturing firms:
- Reduce the friction coefficient by 300%
- Save up to 30% on energy costs
- Smooths pitting from wear and corrosion on metal surfaces by 90%
- Protects parts from future wear and corrosion with a cermet coating that penetrates metal surfaces between 10 and 30 microns
- Provides a minimum 3:1 ROI on energy and repair costs
XADO is nontoxic. All our products have a sanitary permit for usage in the food industry, and a hygienic certificate.
XADO gel is compatible with any mineral or synthetic oil, grease or fuel grade. It is chemically inert with respect to these substances, and does not affect their viscosity. Oil or grease is the vehicle for the revitalizant in getting to the friction surfaces.
Applications
The following are the various types of industrial equipment and machinery that can be treated with XADO Revitalizants and the myriad benefits that accrue from it:
Compressors of all Types
XADO Revitalizant Gel is designed for restoration and repair of all types of compressors, (except the sleeve assembly in oxygen compressors) as well as for bearings running in an oil reservoir.
The revitalizant gel efficiently eliminates wear in compressor and bearings working surfaces and provides reliable protection for friction and roller surfaces operating in hostile environments.
Results of the treatment include:
- Reduction in time for reaching operating pressure
- Raising productivity by up to 30 percent
- Decrease and stabilization of lubricant operating temperature
- Restoration and protection of the friction surfaces from wear
- Restoration of assemblies’ geometry
- Increase of lubricant pressure in compressors
- Decrease in power consumption by up to 36 percent
- Decrease in noise and vibration levels
- Increase in output of piston compressors by 35 percent
- Increase in service life by 1.5 to 2.5 times
Case Study (pdf)
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Reducers and Transmissions
XADO Gel Revitalizants are designed for restoration and repair of all types of industrial, onboard and central reducers, final drives and transmissions of various types and purposes.
Results of the treatment include:
- Recovery of geometry of parts and wear protection
- Wear compensation on contact spots of toothed gear wheels up to 1.6 mm
- Decrease in lubricant operating temperature
- Decrease in electrical consumption by up to 25 percent
- Reduction in oil consumption;
- Decrease in noise and vibration levels
- Increase of service life by 1.8 to 3 times
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Hydraulic Systems
XADO Revitalizants are designed for restoration and repair of hydraulic systems (pumps, hydro-motors and hydro-distributors of all types), and steering wheels in hydraulic actuators of transportation facilities.
Results of the treatment include:
- Recovery of geometry of parts and wear protection
- Increase in the productivity of hydraulic pumps
- Elimination of the hydro-distributor’s flow
- Removal of valve rods wear
- Decrease in vibration acceleration
- Increase of operating pressure and efficiency of hydraulic units
- Decrease in the hydro-motor’s flow
- Increase of service life of hydraulic units by up to 2.5 times
Case Study
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Bearings and Open Gear Trains
XADO Revitalizants are designed for restoration and repair of bearings operating with consistent greases, and oil lubricating bearing assemblies (friction and frictionless).
Bearings and open pinion gears treated by XADO technology results in decrease in play, axle throbbing and radial gaps, and increases the service life of aggressive media by as much as 10 times.
Results of the treatment include:
- Elimination of wear in friction surfaces
- Decrease in radial clearances by up to 0.02 mm
- Decrease of axial clearance of frictionless bearings by up to 0.01mm
- Increase of service life in hostile environments by up to 10 times
- Reduction in noise and vibration levels
Product for open gears operating with oil resevoirs
Product for open gears operating with grease
Product for bearings operating with oil resevoirs
Product for bearings operating with grease
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Open Tooth and Chain Gears
XADO Revitalizants are designed for restoration and repair of open tooth and chain gears with a wear coefficient less than 100 percent.
Results of the treatment include:
- Wear elimination and geometry recovery of rubbing parts
- Increase of service life under harsh conditions by a factor of 5
- Noise level reduction
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Industrial Blowers and Smoke Extractors
XADO Revitalizants are designed for restoration and repair of bearing supports of forming rolls, smoke extractor plants and blow fans.
Overall results of the treatment include:
- Recovery of geometry and wear protection of bearing supports
- Decrease in electrical consumption by up to 14 percent
- Increase of service life in hostile environments and at exposure to high temperatures (up to 400 °C), by as much as 5 times
- Reduction in noise and vibration levels
Results of treatment for forming rolls:
- Decrease in radial clearance and whip of bearing supports
- Increase in service life of bearings at exposure to high temperatures and hostile environments by up to 2.5 times
- Decrease in bearing support vibration levels
Product for bearings operating with grease
Product for bearings operating with oil resevoirs
Product for forming rolls
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Machine Tools and Equipment
Different kinds of machine tools and equipment can be treated and restored using XADO Revitalizants. These include turning machine tools; machine tools of a milling group; surface grinding machines; circular grinding machines; internal grinding machines and coordinate boring machines.
Results of the treatment include:
- Recovery of geometrical parameters of parts
- Increase in the accuracy of machine tools
- Improvement in quality of the surface of treated parts
- Stabilization of operation of machine tools’ hydraulic systems
- Decrease in electrical energy consumption by as much as 20 percent
- Decrease in noise and vibration levels
- Increase in service life by up to 3 times
Product for machines operating on equipment reducers
Product for guides of machines using greases
Product for individual spindle joints and guides of machines operating with oil resevoirs
Product for machines operating on hydraulic systems
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Forging Hammers, Presses and Punches
A wide variety of assemblies and mechanisms in hammers, presses and punches can be treated with XADO revitalizants. These include:
- Compressors of compressed air hammers
- Hydraulic systems of hydraulic hammers and presses
- Ways of forging hammers, presses and title block
- Cylinders of main drives of hammers.
Results of the treatment include:
- Increase of compression in principal motion cylinders of pneumatic hammers
- Increase of compressor’s operating capacity in pneumatic hammers
- Decrease of clearances and recovery of ways of hammers, presses and punches
- Decrease of electrical energy consumption during hammers and presses operation
- Reduction in noise and vibration levels
- Protection against wear and increase in a mechanical presses’ sliding bearing’s service life by up to 2.5 times
Product for compressors & power units
Product for guiding bushings & columns
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Industrial-purpose Diesel Engines
XADO Revitalizants can be used to treat, repair and restore industrial-purpose diesel engines (tractors, diesel locomotives, ships, etc.) with an oil bath volume of more than 30 liters. This includes engines that have turbo-charging.
Results of the treatment include:
- Reconditioning and wear protection of friction parts
- Restoration of geometry of parts
- Saving of fuel at idling by up to 30 percent
- Increase of oil pressure
- Equalization and increasing of compression in cylinders
- Bringing engine power to 100 percent
- Reduction in noise and vibration levels by a factor of up to 10
- Possibility to operate the engine in the case of abnormal oil leakage for up to 300 km/186 miles
- Decrease in CO and CH concentration by a factor of 2 to 10
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High Pressure Fuel Pumps (HPFPS)
XADO Revitalizants can be used to treat, repair and restore high pressure fuel pumps of all kinds. After treatment, the service life of any fuel pump equipment increases by several times. Results of the treatment include:
- Recovery of geometry and protection against wear of rubbing parts of all types of HPFP, injectors and pump-injectors
- Reliable protection against low-quality/adulterated fuel
- Decrease in fuel consumption
- Decrease in noise and vibration levels
- Increase in engine capacity
- Decrease of harmful emissions
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