WHY IS ISO 4406 CLEANLINESS
VALIDATION CRITICAL?
The Standard
ISO 4406 quantifies particles larger than 4 µm, 6 µm, and 14 µm.
Beyond the Numbers
It’s not just about counting particles, it’s about understanding asset health through its fluid.
The Risk of Wear
Up to 80% of mechanical failures are associated with contamination in diesel fuel and lubricating oils. Detecting contamination early is the difference between scheduled maintenance and a catastrophic failure.
VISUAL CLEANLINESS COMPARISON ISO 4406 CODES
Diesel 22/20/17 (Average Across Latin America and Africa) vs. Diesel 11/8/7 (Premium Ultra-Clean Fuel)
THE RISK OF SENDING SAMPLES TO THE LABORATORY
THE TIME FACTOR
The laboratory tells you how your oil looked a week ago. The damage happens in real time.
CROSS CONTAMINATION
The simple act of taking a sample in a “clean” bottle and transporting it can alter the result (false positives for contamination).
SAMPLE DEGRADATION
The sample conditions change from the moment it leaves the system until it reaches the laboratory sensor.
THE SOLUTION: ONLINE MONITORING
24/7 VISIBILITY
New FMS measurement equipment enables online monitoring and captures transient events (contamination spikes) that monthly sampling would never detect.
REAL TRENDS
It enables the shift from preventive maintenance to proactive maintenance, acting precisely when the ISO code begins to drift.
LOGISTICAL SAVINGS
Elimination of shipping costs, sample bottles, and man-hours in sample management.
THE INVISIBLE ENEMY: PHANTOM READINGS
LIMITATIONS OF TRADITIONAL LASER TECHNOLOGY
Conventional light extinction counters do not distinguish between solids, air bubbles, or water droplets.
THE ADDITIVE CHALLENGE
Some high-performance oils contain highly concentrated additive packages that traditional laser counters misinterpret as solid particles.
THE BUBBLE
CHAOS
A laser-based particle counter cannot distinguish between an air bubble, a water droplet, and a solid particle.
Result
Alarmingly high ISO 4406 reports that are not real, leading to unnecessary plant shutdowns and unjustified oil changes.
THE NEW ERA: AI AND BUBBLE DISCRIMINATION
ARTIFICIAL VISION TECHNOLOGY
Our equipment uses digital image processing of the fluid. The system separates and counts air bubbles and water droplets from actual solid contaminants.
DIFFERENTIATION TECHNOLOGY
Alarmingly high ISO 4406 reports that are not real, leading to unnecessary plant shutdowns and unjustified oil changes.
PRECISION IN ADDITIVATED OILS
Additives will not affect the actual particle count of the fluid.
UNIQUE IN THE WORLD
We are the only technology capable of discriminating air bubbles and water droplets from solid particles, eliminating false positives.
FMS-MK1000
PORTABLE CONDITION
MONITORING UNIT
The FMS-MK1000 combines the unparalleled capabilities of the OilWear® sensor with an integrated HMI display, providing real-time information directly on the machine.
ROOT CAUSE ANALYSIS
Automatic recognition and classificationof particle shapes.
HMI DISPLAY
Includes all necessary functions to monitor the system, visualize real-time data, and store and export data via USB. It can also be remotely connected for digitized lubricant-based monitoring, ensuring comprehensive tracking of asset condition.
FMS-OW1000
COMPACT ONLINE
CONTAMINATION SENSOR
AI-based machine vision technology and algorithms
Provides fast real-time information about machine condition, enabling early-stage fault decision-making and generating cost savings.
- Particle counting according to ISO 4406 standard
- Particle classification in 6 ranges (>4, >6, >14, >21, >38, >70)
- Air bubble detection and counting
- OLED display with relevant data
- Suitable for pressures up to 150 bar
Pressure kit up to 350 bar
HOW THE SENSOR WORKS
Oilwear® captures digital images of the oil and processes them to:
- Classify particles by size
- Generate cleanliness codes: ISO 4406, NAS 1638, or equivalent
- Count and discriminate air bubbles
- Differentiate additives to avoid false positives
Image storage:
- Last 1,000 measurements
- Last 100 images
AIR AND/OR WATER BUBBLE DISCRIMINATION
The only sensor in the world with discrimination capability.
PARTICLE SIZE CLASSIFICATION ACCORDING TO ISO 4406 AND NAS STANDARDS
ON-SCREEN DATA
BENEFITS
- Classification and counting of particles larger than 4 microns across 6 ranges.
- Provides early insight into machine condition.
- Provides fast and reliable information on fluid contamination.
- Easy installation.
- On-screen data visualization.
- Full integration with SCADA/PC/PLC via digital communications for easy interpretation.
FMS-PB1000
PORTABLE CONDITION
MONITORING UNIT
The FMS-PB1000 is a portable and robust solution that incorporates Atten[2] optical technology for particle counting and particle morphology analysis in lubrication systems.
MEASURED PARAMETERS
- Particle counting according to ISO 4406
- Classification into 6 ranges: >4, >6, >14, >21, >38, and >70 μm
- Air bubble discrimination and counting
- Particle shape analysis (wear diagnosis)
- Lubricant degradation (OD)
- Maximum viscosity: 680 cSt
- Maximum operating pressure: 2.5 bar
EQUIPMENT FEATURES
- Removable battery (3 h) for route inspections.
- Pump for high-viscosity oils (up to ISO VG 680).
- Asset management history.
- Storage of real fluid images.
MAIN PANEL
REAL IMAGE VISUALIZATION
The oil flows into the sensor for continuous analysis, where images are captured.
Fibers can be visually inspected to analyze their origin.
Air bubbles can be observed in the image, which are classified by size and excluded from the particle count.
Images can be enlarged for analysis and measurement purposes.
APPLICATIONS FOR ALL INDUSTRIES
CONVENTIONAL ENERGY
MINING
AUTOMOTIVE
PAPER INDUSTRY
PLASTICS INDUSTRY
SHAPE RECOGNITION
We don’t just count particles we classify them by wear type: fatigue, cutting, sliding, or fibers.
DATA INTELLIGENCE
By understanding particle shape, it provides information that helps identify equipment failure modes.
VISUAL HISTORY
Capability to store the last 100 real fluid images for technical audit purposes.
TOTAL PRECISION
Accurate readings even in highly additive-rich oils. Say goodbye to phantom readings what you see is what it is!
RETURN ON INVESTMENT (ROI)
Fewer unplanned shutdowns and longer oil service life, with accurate and reliable readings.
INDUSTRY 4.0
Equipment ready for digital transformation and AI-based predictive maintenance.