Eclipse Magnetics Filtration Solution Stabilises EDM Drilling and Heat Treatment Performance at HepcoMotion

Application Background

HepcoMotion is a global engineering company specialising in linear motion and automation components used in manufacturing, guidance, and transfer applications. Headquartered in Tiverton, Devon, the company operates internationally with offices across Europe and Korea, supplying precision-engineered components to a wide range of industrial sectors.

It manufactures and distributes linear guides, curved rail and track systems, driven track systems, linear actuators, and gantry systems. The production of these components relies on tightly controlled processes, including induction and flame hardening and EDM drilling, where the cleanliness of quench and deionised water systems is critical to maintaining consistent quality and reliable machine performance.

Our Client’s Filtration Challenges

HepcoMotion had managed contamination in its quench and deionised water systems using conventional filtration methods such as paper filters and cartridge filters. Despite regular maintenance, contamination remained an ongoing issue that affected both process stability and operating costs.

Contaminants in the deionised water were causing electrical sparking during EDM drilling, which resulted in inconsistent machining performance, increased scrap, and rework. At the same time, contamination within the quench system reduced the effectiveness of the hardening process, leading to inconsistent hardness across components and an increased risk of premature wear.

These issues required frequent intervention, with machine cleanouts typically carried out on a monthly basis, sometimes more often. Each machine required multiple cartridge filters, and cleanouts resulted in approximately two hours of downtime per machine, involving two maintenance engineers.

The combined effect of downtime, consumable costs, and inconsistent quality had a direct impact on machine availability and production efficiency. Scrap and rework also extended lead times, which in turn affected HepcoMotion’s ability to maintain optimal service levels for its customers.

How Magnetic Filtration Provided the Best Solution

To address these challenges, HepcoMotion installed an Eclipse Magnetics MicroMag on a trial basis. The objective was to determine whether magnetic separation could provide a more effective and lower-maintenance solution for removing fine ferrous contamination from both quench and deionised water systems.

The MicroMag is a compact magnetic filter that operates by generating a high-intensity magnetic field to capture and retain ferrous contaminants circulating within a system. By continuously removing fine magnetite and iron particles from the fluid, it helps maintain system efficiency, protect critical components, and reduce long-term wear.

Improvements were immediate following installation. The magnetic filter began capturing fine ferrous contaminants at the point of flow, preventing their recirculation within the process fluids. The effectiveness of the system was verified in operation, leading HepcoMotion to adopt this filtration method as a long-term solution.

Since installing the MicroMag, HepcoMotion has achieved a significant reduction in maintenance requirements and process disruption. Machine cleanouts, which were previously required on a monthly basis, are now typically carried out every three months. In addition, cartridge filters have not required replacement for over six months since the magnetic filtration system was installed.

The reduction in contamination has led to improved stability in EDM drilling, resulting in fewer instances of sparking and a corresponding reduction in scrap and rework. Hardening processes have also become more consistent, improving overall product quality and reducing variability across components. Machine reliability has improved, and unplanned downtime has been reduced, increasing overall equipment availability.

The estimated annual saving achieved through reduced maintenance, labour, and consumable costs has reached approximately £600. With these savings, the return on investment for the Micromag is estimated at around 12 months.

Operators now carry out a simple weekly routine to remove collected contaminants from the magnetic filter, which has significantly reduced day-to-day maintenance effort compared with previous filtration methods.

The introduction of magnetic filtration has also supported the company’s environmental and sustainability objectives, delivering both environmental and economic benefits.

Reduced contamination has extended the life of both quench and deionised water, resulting in fewer fluid changes and lower disposal requirements and the elimination of disposable filter cartridges has reduced waste generation, while collected ferrous material is sent directly for metal recycling.

Client Testimonial

Matt Winiarski, Maintenance Manager at HepcoMotion, said: “Before installing the MicroMag, contamination in both our quench and deionised water systems was a constant maintenance headache. We were carrying out monthly cleanouts, replacing cartridge filters regularly, and still seeing inconsistent hardening results and sparking during EDM drilling.

Since adopting magnetic filtration, contaminants are removed immediately, downtime has been significantly reduced, and we’ve achieved far more consistent process performance. We haven’t needed to change cartridge filters in over six months, cleanouts are now only required every three months, and overall maintenance effort has dropped considerably.

The installation was quick, the results were immediate, and the return on investment is clear. It’s a simple, effective filtration solution that delivers real operational and environmental benefits.”