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IntelliStick Inc. recently completed a multi-month pilot program to evaluate its industrial intrusion and oil condition system in the challenging environment of paper mills. The program was conducted in conjunction with the Energy, Engineering and Maintenance Task Force of the Recycled Paperboard Technical Association. Intrusion Detection & Oil Condition Monitoring:A Paper Industry Pilot Programby Dan Edney, PhD & Sam Jones, IntelliStick Inc. Technical Contributions by: RPTA Energy, Engineering & Maintenance Task Force Pilot Program Participants
EXECUTIVE SUMMARYA Pilot Program by IntelliStick Inc. and the Energy, Engineering and Maintenance Task Force of the Recycled Paperboard Technical Association evaluated the IntelliStick Intrusion & Oil Condition system in paper mill environments. For a period of five months in 2009, a total of five instruments were employed in three mills. The instruments were installed on two bearing lubrication systems, a pulper gearbox, and two generator engine oil reservoirs.
This IntelliStick Pilot Program Report concludes that the IntelliStick system reliably detects water intrusion, in addition to oil condition and temperature, in real time using a single sensor. The sensor must be installed in a location where the water is emulsified to detect it—water that has settled out away from the sensor location is not detected.
The Intellistick system is relativily inexpensive and easy to install. The information provided by the IntelliStick system has less detail than oil lab reports. Although IntelliStick is not seen as a replacement for lab analysis, it provides the advantage of real-time immediacy. This program also identified a limitation in the communications; accordingly Intellistick has added a 4-20mA communications option to better integrate with plant monitoring systems.
This evaluation concludes that the system is cost-effective in providing information for condition-based maintenance programs, helping protect critical equipment and assure maximum up-time. Since the completion of the trial, all of the participating mills have purchased more units.
A copy of the full report is available as a pdf document. You may also contact IntelliStick Sales at 888-812-5988, ext 224 or by e-mail at
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for a free copy of the report.
About IntelliStick IntelliStick is a real-time electronic intrusion and oil condition monitor for oil management and maintenance in industrial manufacturing and plant process operations, as well as in diesel and gasoline vehicles, heavy equipment, trucks. IntelliStick products are based on a patented technology developed military and use a single sensor to continuously monitor oil wear package depletion, oil and detect intrusion. About RPTA The Recycled Paperboard Technical Association (RPTA) is a nonprofit association that brings together the expertise of more than 100 paper mills worldwide that manufacture products from at least 90 percent recovered fiber. RPTA is dedicated to the improvement of the recycled paperboard industry. Source |
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 Doubling oil life is good for business & the environment
Perry Mecum doesn’t intend to be among the 73% of drivers who change their oil too frequently. That’s bad for the environment – unnecessarily using and disposing of thousands of gallons of oil – and it’s not smart business either. One quart of motor oil can pollute 250,000 gallons of drinking water. With toxic chemicals and heavy metals, the Environmental Protection Agency classifies it as a major source of contamination. Although safe ways of recycling or disposing of oil are increasingly available, an easier and greener solution is to simply reduce the amount of oil used.
YOU NEVER KNOW WHAT YOU’RE GETTING
The typical oil change interval for Perry Mecum’s 2006 Freightliner with a Detroit Diesel Series 60 engine is 30,000 miles. Before he got an IntelliStick Oil Condition Monitor, Perry had been following this advice, but he didn’t like being tied to an interval-based maintenance program. The problem was that he never knew the true condition of his oil.
KEEPING HIS TRUCKS RUNNING IN TOP CONDITION
As an independent contractor for FedEx Ground and the owner of Mecum Trucking, Perry has the freedom to set his own maintenance schedule. He maximizes the return on his investment by keeping his trucks running in top condition and extending their lives as long as possible.
NOT TOO SOON, NOT TOO LATE
If he changes the oil too soon, Perry wastes time and money and puts an unnecessary strain on the environment. Perry said he’s aware of the money-saving aspect, but that he wants to be a good steward of the planet, too. But, Perry knows that if he waits too long, he could seriously damage his engine – which would cost even more time and money. This put Perry in a lose-lose situation of having to guess what was best for his truck.
INTELLISTICK: A BETTER WAY TO MAKE MAINTENANCE DECISIONS
Tim Grooms at Engine Technologies in Gastonia, NC, told Perry about IntelliStick, an “intelligent dipstick” that tells him his truck’s true oil condition. Perry said that in the trucking industry with its tight margins, you have to save money wherever you can, and every week that his trucks run safely on the same oil helps his bottom line. Plus, Perry knows that IntelliStick is monitoring for water or coolant intrusion, and that if it is detected in his engine, he can take action immediately — saving him from a $15,000 engine overhaul.
PERRY STAYS FOCUSED ON PROPER MAINTENANCE
It’s no coincidence that Perry has over 1.5 million accident-free miles under his belt. He’s been a driver for 20 years and knows that if he takes care of his trucks, they’ll take care of him. Perry and his drivers at Mecum Trucking carefully inspect each truck, making sure it’s ready to make the weekly trek from Charlotte, NC, to Rialto, CA, and back. This attention to detail earned Perry the highest score in the pre-trip inspection portion of the 2008 North Carolina State Truck Driving Competition. The judges create certain “defects” in the truck, like leaving a latch undone or hiding a foreign object in the chassis, and the driver must identify them. Perry starts in one corner and methodically works his way around the truck – calling out each one as he spots it. It’s the same system that he uses to inspect his own trucks. And now with IntelliStick, Perry knows what’s going on inside his engine.
EASY TO INSTALL, EASY TO USE
IntelliStick is easy to install and easy to use. Each week, Perry’s data is wirelessly uploaded. The IntelliStick software creates a “Kauffman Curve,” a graph showing the good additives being used and harmful oxidation.
SAFELY EXTENDING OIL LIFE
After running 30,000 miles with IntelliStick, Perry’s oil had used additives, but it hadn’t started to oxidize. Perry knew that he could continue to safely run his truck on the same oil. Perry replaced the oil filters and topped-off with one gallon of fresh oil. This registered on the IntelliStick and showed Perry that his engine was still protected. At 45,000 miles, the IntelliStick showed Perry that his oil still had usable life. He sent an oil sample to the local CAT lab and the results affirmed the IntelliStick data – and Perry was confident that he could still safely continue on the same oil. Within a few weeks, Perry passed 50,000 miles, extending his previous oil change interval and saving over $200 that he would have spent on each oil change. By safely reducing the number of oil changes, Perry estimates he’s saving about $880 a year for each truck equipped with IntelliStick, and he is helping the environment as well. Everyone’s situation is different, but no one should rely on guesswork. An IntelliStick onboard delivers real-time information. Condition-based maintenance is not too soon or too late—it’s smart, cost-effective business that’s environmentally friendly.
For additional product information call 1-888-812-5988 Ext 221 or email
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