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Gear Oil Flow Meter DN100: Maintaining Steady Flow in Industrial Shredders
Quick Answer
A DN100 oval gear flow meter measures high viscosity gear oil with low pressure loss and no straight pipe runs. It gives steady 4-20 mA HART output even when shredder gearbox oil flow changes slowly. Most plants in Thailand, Vietnam, and Mexico pick this meter because it ignores pulsation and works reliably with oil above 100 cP.
Why Industrial Shredders Need a Reliable Gear Oil Meter
Industrial shredders chew through scrap metal, plastic bales, and rubber tyres. The gearbox oil must flow all the time. If flow stops for 30 seconds, bearing temperatures climb fast. A DN100 oval gear flow meter sits on the lube oil supply line and sends a signal straight to the control room. You see actual flow in litres per minute and total volume in litres. One scrap metal yard in Malaysia runs two shredders. Each shredder gearbox takes ISO VG 320 gear oil. The operator watches the flow meter display near the PLC panel. When flow dips under 12 L/min, the system triggers an alarm. That simple check saves a gearbox rebuild every year.
Why DN100 Size Makes Sense
DN100 matches the oil pump capacity in mid to large shredders. Flow rates often sit between 40 and 200 L/min. A larger diameter body keeps the pressure drop below 0.3 bar at 150 L/min. This matters because the oil pump does not need to push harder. Lower back pressure means less wear on pump seals. The oval gear pair inside the meter turns slowly and smoothly. No sudden pulses appear on the output. You get a steady 4-20 mA signal. Many plants add a local display with totaliser so the maintenance team can read oil consumption per shift.
Handling High Viscosity Gear Oil
Gear oil in shredders often has viscosity between 220 and 460 cSt at 40 °C. The DN100 oval gear meter measures this without linearity drift. Oval gear meters actually get more accurate when oil is thicker. The clearance between rotors and measuring chamber stays liquid filled. No slip. Typical accuracy reaches 0.5 % of reading. Repeatability is 0.1 %. In a cold start situation, the oil can be 1000 cP. The meter body is cast iron or stainless steel with PTFE gears to reduce friction. A heater jacket option keeps the oil fluid if the shredder operates outdoors in Poland or Canada. This meter works with a standard oil temperature of up to 150 °C.
Installing the Meter Without Stopping Production
Most engineers skip long installation guides. In practice, the DN100 oval gear flow meter fits between two flanges. No need for straight pipe runs. You put it right before the gearbox oil inlet or after the filter. A simple bypass loop allows meter service while the shredder keeps running. The flow direction arrow on the body tells you which way oil flows. Connect the wires to a 24 V DC supply and the 4-20 mA HART loop. Done. In ATEX Zone 1 areas we supply the meter with Ex ia IIC T6 certification. A paint and solvent shredding facility in Indonesia uses the ATEX version because fine metal dust is always in the air.
Which Output Signal for Your PLC
Standard output is 4-20 mA with HART. This works with Siemens, Allen Bradley, and Mitsubishi PLCs. Many plants in the Middle East still use Modbus RTU via RS485. Silver Automation Instruments configures the meter with Modbus on request. The local display shows flow rate an
Real Numbers from a Shredder Site
Last year a customer in Vietnam asked us to replace a turbine flow meter that kept jamming on heavy oil. They shred aluminium profiles and generate fine chips. The turbine meter bearing got sticky within two weeks. We sent a DN100 oval gear meter with cast iron body and PTFE internals. Installation took 40 minutes. After six months, the meter still shows the same stable flow within ±0.5 L/min. The maintenance manager told us he does not touch that meter at all. He just reads the total volume once a month for oil consumption records. That kind of field feedback tells you more than a datasheet.
Material Choices and Wetted Parts
The measuring chamber needs to resist gear oil additives, small metal particles, and moisture. We offer cast iron body with aluminium rotors for standard gear oil. For aggressive or high temperature oil, choose a stainless steel body with PPS rotors and PTFE seals. The bearing material is tungsten carbide or graphite carbon. These bearings stay accurate after years of continuous flow. A magnetic pickup sends the pulse signal. No dynamic seal between the wet section and the electronics. This design eliminates leak points. In a shredder environment full of dust and vibrations, that sealed design makes the difference.
Frequently Asked Questions
Can the meter measure gear oil with small metal particles?
Yes. A magnetic filter installed before the meter catches ferrous particles. We recommend a filter mesh of 200 microns. The oval gear rotors still operate even if a few soft particles pass through.
What flow range can the DN100 meter handle?
Typically 20 to 250 L/min for oil viscosity above 100 cP. The exact range depends on viscosity and back pressure. Send us your flow data for a sizing check.
Is ATEX certification available for shredder rooms with dust hazard?
Yes. Zone 1 II 2G Ex ia IIC T6 certification is standard for our oval gear meters. We ship to cement, wood, and metal shredder sites worldwide with the ATEX documents.
Do we need a straight pipe run before the meter?
No. Oval gear meters do not need straight runs or flow straighteners. Install it directly in the pipe line with a bypass for maintenance.
How do we get a price for a DN100 gear oil meter?
Send us your pressure (bar), temperature (°C), pipe size (DN), and flow range. Also mention the oil type and viscosity. Email us at the address on flow-meter.com.au. Our team replies within one working day for Southeast Asia, Oceania, and the Middle East.
Next Step for Your Shredder Lube Oil System
Silver Automation Instruments supplies DN100 oval gear flow meters to shredder plants in Malaysia, Thailand, Indonesia, Vietnam, Mexico, and Poland. We stock cast iron and stainless steel bodies. You get the meter, a local display, ATEX certs, and a HART signal all in one shipment. See our oval gear flow meter for heavy oil on flow-meter.com.au. Send your actual process data and we will return a quotation with a performance curve for your exact oil grade. No generic estimates. Just numbers that match your shredder.
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