Improving the Testing Facilities for Oil Separation in Grease Samples by Developing the Preter (Pressure Digital Timer) Device

Abstract

Oil Separation testing is the determination of base oil separation from grease during storage at a constant temperature with a pressure of 0.25 psi for 24 hours using an oil separation device. Oil separation testing is a critical parameter in grease product specifications to meet the company's established quality standards. The high %RSD impacts include customer complaints caused by product sedimentation due to oil and soap separation in grease, which clogs suction pumps with solid soap. Customer complaint data from 2024 confirmed these losses, encompassing product replacement costs, return transportation costs, and failed product rework costs. From an internal perspective, during the 24-hour testing process, pressure frequently drops because water in the tube cannot withstand excess pressure and spills out, forcing analysts to periodically refill the tube. This requires analysts to remain on standby for 24 hours, generating overtime costs totaling 5,460 hours from January to October 2024. This research focused on improving the %RSD value through the development of the PRETER tool, consisting of two main components: a Safety Valve as an automatic pressure controller and a Panel Box as a time controller and power supply. Testing involved seven different analysts. Results showed a %RSD of 1.41% for conventional grease and 3.57% for complex grease, both below 5%, proving that the PRETER tool effectively improves testing precision, streamlines the work process, and eliminates the need for 24-hour monitoring.