CASE STUDY
Real installs. Real problems. The product we actually shipped.
Every project below was supplied or refurbished by DS Filtration. Names withheld at customer request — happy to make introductions on request.
Oil/Water Separator install
Trade-waste compliance for a Victorian engineering workshop
Problem
Workshop discharging compressor condensate to a trade-waste pit was flagged for hydrocarbon levels above local council limits.
Solution
Specified and supplied a Sepura-class oil/water separator sized to the existing 75 kW compressor station, with a zero-loss electronic drain replacing the failing timer drain on the receiver.
Outcome
Discharge water now within trade-waste limits. Service kits stocked locally — annual changeover handled in under an hour.
Filter housing rollout
Ten-line filter upgrade for a food packaging plant
Problem
Existing aluminium filter housings were past service life, with documented oil carry-over risk into a food-contact packaging line.
Solution
Supplied a full set of compressed air filters with coalescing + activated carbon stages, plus differential pressure indicators on every housing for compliance.
Outcome
Line passed its next ISO 8573-1 audit at Class 2 air, with documented filter change schedule supplied for the QA file.
Cross-reference supply
Cross-reference program for a national compressor service contractor
Problem
Contractor servicing a mixed Atlas Copco / Donaldson / Hankison fleet was juggling three OEM accounts and 6-week part lead times.
Solution
Built a stocked cross-reference list of the contractor's top 40 element part numbers, held in Boronia and dispatched on PO.
Outcome
Single supplier, single PO, parts dispatched same day on stocked items. Contractor reports faster service callouts and better service margin per visit.
Refrigerated dryer replacement
Dryer replacement at a regional manufacturing site
Problem
Existing refrigerated dryer was running on a phased-out refrigerant and tripping intermittently, dropping +3°C dew point under summer load.
Solution
Supplied a cycling refrigerated dryer matched to compressor cfm, with R-513A refrigerant and integrated zero-loss drain.
Outcome
Stable +3°C pressure dew point. Site reports lower dryer power draw under part-load conditions through cycling control.
Desiccant dryer install
−40°C dew point for an instrument-air application
Problem
Plant control instruments were specifying ISO 8573-1 Class 2 water, which the existing refrigerated dryer could not deliver.
Solution
Supplied a heatless adsorption dryer with twin-tower design plus pre/after-filtration package and a dew-point monitor.
Outcome
Documented −40°C pressure dew point at the instrument header, audit-ready dew-point log.
Ultrasonic refurbishment
Filter housing refurbishment instead of replacement
Problem
Customer had eight large aluminium filter housings caked with oil residue. Replacement cost > $30,000 with 8-week OEM lead.
Solution
Ultrasonic cleaning of all eight housings at our Boronia facility, with inspection report on each.
Outcome
Housings returned to service in under one week at a fraction of replacement cost. Inspection report kept on file for the next audit.
