Reliable gearbox validation with accurate oil cleanliness monitoring in bubbly conditions.
This case study shows how Hyster Yale Material Handling improved gearbox validation by solving unreliable oil cleanliness testing caused by air bubbles.
Incotech Ltd integrated the Atten[2] OilWear S sensor into a test bench, enabling real-time monitoring and accurate separation of bubbles from contaminants.
This resulted in faster testing, reliable measurements, simpler system design, and improved confidence in gearbox quality before assembly.
Article Highlights:
Hyster Yale Material Handling faced inconsistent gearbox testing due to air bubbles affecting oil cleanliness measurements.
Traditional particle counters struggled in low-pressure, aerated oil conditions.
Incotech Ltd integrated the Atten[2] OilWear S sensor into a custom test bench.
Real-time monitoring enabled accurate differentiation between air bubbles and contamination particles.
Eliminated the need for complex high-pressure systems to suppress bubbles.
Reduced testing time and improved repeatability of results.
Increased confidence in gearbox quality before assembly.
Scalable solution for other applications with foamy or aerated oil systems.
Key Takeaway:
Atten[2] OilWear S sensor enables accurate, real-time oil cleanliness measurement even in bubbly, low-pressure conditions—helping Hyster Yale Material Handling achieve faster, more consistent, and reliable gearbox validation without complex system modifications.
Join us for an insightful webinar focused on Mining 4.0 and how advanced condition monitoring is transforming the way mining operations protect critical machinery, reduce failures, and maximize uptime.
As mining operations continue to push for higher productivity, safety, and cost efficiency, unplanned downtime remains one of the industry’s biggest challenges. Harsh operating conditions, aging assets, and increasing production demands make reliability more critical than ever.
Agenda:
• Overview of the current mining process • Identifying critical machinery • Why monitoring is key for uptime optimization • Success stories: Real-world impact
Date and Time:
Wednesday, 4 March 2026
07:00 AND 11:00 PM CET
To better support our global audience, we will host three live sessions:
APAC (English): 7:00 AM (Spain time) – Speaker: Eneko
EMEA (English): 11:00 AM (Spain time) – Speaker: Bruno
Discover how to advance your career in oil analysis and lubrication management with Yellotec’s specialised training and Noria-certified courses. Build practical skills, improve diagnostics, and strengthen equipment reliability through a structured path to excellence.
In the world of machinery lubrication and oil analysis, standing still is not an option. As equipment becomes more complex and reliability expectations increase, the demand for skilled Oil Analysts and Oil Technicians continues to grow. Advancing your expertise doesn’t just benefit your career — it directly impacts maintenance performance, asset longevity, and operational efficiency.
Whether you are building foundational knowledge or refining advanced diagnostic capabilities, continuous learning is the key to remaining relevant and effective in your role.
The 3-Step Path to Oil Analysis Excellence
1. Oil Analysis Series
COMPREHENSIVE FOUNDATION
Build your expertise from the ground up with a comprehensive training programme designed to equip professionals with the knowledge and practical skills required to implement and manage effective oil analysis programmes.
This stage ensures you develop the technical confidence needed to apply best practices in real-world environments.
2. Certified Training from Noria Corporation
BECOME A CERTIFIED OIL ANALYST / TECHNICIAN
Take your expertise to the next level by preparing for internationally recognized certification exams associated with:
International Council for Machinery Lubrication (ICML)
Certification validates your knowledge, strengthens your credibility, and positions you as a trusted reliability professional. It demonstrates not only theoretical understanding but applied competence in lubrication and oil analysis practices.
3. Skills Boosting Training
KNOWLEDGE SUPPORT FROM NORIA
Learning does not stop after certification. Continue strengthening your expertise with access to Noria Corporation’s expansive collection of world-class lubrication practices, research, and professional development tools.
Gain knowledge support through:
Noria Publications
Noria Online Training
Access to LPD (Lubrication Program Development resources)
This ongoing development ensures you remain current, competitive, and aligned with global best practices in lubrication and reliability.
Why Advancing Your Skills Matters
Oil analysis is far more than interpreting lab results. It is about understanding machine health, identifying early warning signs, and making informed maintenance decisions that prevent costly failures.
By advancing your knowledge and practical ability, you can:
Deliver more accurate and confident diagnostics
Strengthen preventive and predictive maintenance strategies
Improve overall equipment reliability
Reduce unplanned downtime and associated costs
Add measurable value to your organization
The difference between a competent technician and a trusted reliability professional often lies in structured training and certification.
Your Structured Path to Excellence
Yellotec’s Path to Excellence has been designed specifically for Oil Analysts and Oil Technicians who are serious about professional growth. The programme combines specialized, practical training with internationally recognized certification through Noria Corporation.
This approach ensures you don’t just gain theoretical knowledge — you develop practical skills you can apply immediately in the field.
Through this structured pathway, you will:
Strengthen your understanding of lubrication fundamentals
Improve sampling techniques and contamination control practices
Enhance your ability to interpret oil analysis results
Apply best practices in lubrication management
Build confidence in making data-driven maintenance decisions
Globally Recognized Certification
Certification validates your knowledge and demonstrates your commitment to professional excellence. Noria certifications are widely respected within the lubrication and reliability industry, providing a benchmark for competency and technical expertise.
Earning certification not only boosts your credibility but also positions you for greater responsibility and career progression.
From Technician to Trusted Expert
The Path to Oil Analysis Excellence is designed to equip you with the skills, knowledge, and practical experience required to excel in oil analysis and lubrication management. It supports professionals at various stages of their careers — whether you are strengthening your foundation or preparing to step into a more strategic reliability role.
Investing in your development is an investment in better diagnostics, smarter maintenance strategies, and more reliable assets.
Enroll today and take your Oil Analysis expertise to the next level.
We Provide Comprehensive Transformer Oil Testing & Support to Monitor Insulation Health, Detect Faults Early, and Ensure Operational Reliability.
Protect Your Assets – Extend Transformer Life – Prevent Costly Failures
Transformer oil testing is a critical pillar of effective asset management, providing early insight into the health, reliability, and remaining life of high-value electrical equipment. At Yellotec, transformer oil analysis is not just a laboratory service — it is a strategic reliability solution designed to help asset owners prevent failures before they occur.
Through our ISO-accredited laboratory, Yellotec delivers precise, trustworthy results that support confident decision-making. With fast turnaround times and expert diagnostics, potential faults such as insulation degradation, contamination, or thermal stress can be identified early, allowing corrective action long before they escalate into costly, unplanned outages. This proactive approach enables cost-effective preventive maintenance, helping organisations optimise maintenance budgets while maximising equipment availability
Our Key Services Include:
Professional On-Site or In-Lab Sampling
Expert collection of representative oil samples to international standards – safe, clean, and compliant.
Dielectric Dissipation Factor (Tan Delta) / Power Factor
Furan Analysis – Paper insulation aging & remaining life estimation
Color, Appearance, Resistivity, PCB Content & More
Get clear, actionable reports with expert interpretation and trending recommendations.
1-Day Practical Training Workshop “Understanding Transformer Oil Analysis
Hands-on session for your maintenance team:
How to interpret test results
Key parameters & fault indicators
Best practices for sampling & trending
Real-world case studies Empower your staff to make informed decisions and maximize transformer reliability.
Benefits Highlight
Why Choose Us?
Extend asset life & reduce replacement costs
ISO-accredited laboratory precision
Fast turnaround times
Expert diagnostics to avoid unplanned outages
Cost-effective preventive maintenance
By integrating transformer oil testing into a structured maintenance strategy, Yellotec helps clients extend asset life, reduce the risk of catastrophic failure, and ultimately lower replacement and lifecycle costs — ensuring electrical assets continue to perform safely, efficiently, and reliably for longer.
Ready to Safeguard Your Transformers? Contact us today for sampling kits, quotes, analysis packages, or to book your 1-Day Training!
Discover How Excess Lubrication Leads to Higher Costs, Equipment Damage, and Unplanned Downtime.
In this Atten2 Original Case Study, over-lubrication is shown to be just as damaging as insufficient lubrication, disrupting optimal machine operation.
Excess lubricant leads to leaks, contamination, increased energy consumption, heat buildup, seal damage, and even electric motor failures—resulting in unplanned downtime, higher maintenance costs, and environmental risks.
Over-lubrication is as damaging as under-lubrication, leading to premature equipment failure.
Excess lubricant increases pressure, causing seal damage, leaks, and contamination ingress.
Higher energy consumption occurs as lubrication moves away from optimal operating conditions.
Dirt and contaminants accumulate when surplus lubricant is exposed to the environment.
Heat buildup and oil degradation accelerate wear and reduce lubricant effectiveness.
Electric motors are at risk, as excess grease can enter windings and cause overheating or failure.
Unplanned downtime and environmental costs rise due to leaks, cleanup, and maintenance issues.
Key Takeaway:
An excess of industrial lubricants, just like too little lubrication—can seriously harm machinery by disrupting optimal lubrication conditions, leading to leaks, increased energy use, contamination, accelerated wear, and even equipment failure. This highlights the importance of precise lubrication control and monitoring to maintain machine performance, reduce breakdowns, and avoid environmental and operational costs.
Yellotec is excited to be part of the Mining and Technical Exhibitions (MTE) taking place throughout the year. As a trusted partner to industries across Southern Africa, Yellotec invites visitors to stop by our stand for live product demonstrations and practical insights into Reliability and Online Condition Monitoring—shared by experienced industry professionals who understand real-world operational challenges.
We look forward to connecting with you at MTE this year:
Expert Insights into Machine Health and Reliability
At the heart of Yellotec’s offering is a solution-oriented approach to improving machine health and reliability. Our focus is on helping organizations reduce unplanned downtime, extend asset life, and make smarter maintenance decisions through proven, condition-based maintenance strategies.
At the MTE Expos, visitors will have the opportunity to explore a wide range of advanced technologies, including:
Online Vibration Analysis
Handheld Vibration Solutions
Laser Shaft Alignment
Thermal Imaging
Online Oil Analysis
Motion Amplification
Electric Motor Testing
Ultrasound Technologies
These solutions work together to provide early fault detection, actionable insights, and greater visibility into asset performance.
Powered by Leading Global Brands
Yellotec proudly represents some of the world’s most respected reliability and condition monitoring brands. These include Fluke Reliability, Teledyne FLIR, RDI Technologies Inc., UE Systems, Mobius Institute, Noria Corporation, Atten2 Deep Monitoring Solutions, PCB Piezotronics, Gill Sensors & Controls, and many more. By combining best-in-class technologies with local expertise, Yellotec delivers reliable, fit-for-purpose solutions tailored to demanding industrial environments.
Visit Yellotec at MTE
Whether you are looking to modernize your maintenance strategy, implement online condition monitoring, or gain expert advice on reliability best practices, Yellotec’s stand at the MTE Expos is the place to be. Come and engage with our team, see the technology in action, and discover how smarter maintenance can drive safer, more efficient operations.
Insights on Improving Wind Turbine Uptime Through Proactive Condition Monitoring
In today’s fast-paced renewable energy sector, wind power operators face constant pressure to boost efficiency and minimize downtime. On November 21, 2025, Atten2, in collaboration with United Wind Force (UWF), hosted an insightful webinar titled “Maximizing Wind Asset Performance.”
The session explored innovative strategies for managing onshore and offshore wind assets more effectively, with a spotlight on how advanced monitoring technologies can help operators reduce lost wind power and optimize turbine performance.
Below are the key takeaways and insights.
The Core Challenge: Lost Power and Limited Visibility
Wind operators increasingly deal with:
Lost revenue from turbine downtime
Competition in the spare parts market
Difficulty accessing trustworthy condition data
With 67% of spares now non-OEM, owners are shifting away from rigid OEM models toward flexible, proactive maintenance strategies.
UWF’s Role: A Bridge Across the Aftermarket
UWF supports more than 47,500 turbines across Europe and Latin America by connecting turbine owners, OEMs, Independent Service Providers, and parts distributors.
Their supply mix highlights a diverse, responsive network:
54% direct
33% OEM
14% ISP
UWF partners with major industry players such as Vestas, Siemens Gamesa, GE Renewable Energy, Eickhoff, AMSOIL and more.
What this delivers: Faster access to parts, deeper technical expertise, and reduced downtime — all helping operators fight lost wind power.
Atten2’s Contribution: Turning Oil Data into Decisions
Atten2 specialises in real-time oil condition monitoring, with more than 3,000 installed sensors and over two decades of development.
Their monitoring philosophy is clear: Seeing transforms uncertainty into knowledge — and knowledge into better decisions.
Their flagship wind solution is the Wind Oil Sensor (WOS).
Wind Oil Sensor (WOS): Early Warning for Critical Components
The WOS, powered by Atten2’s OilWear® S technology (SHAPE SERIES), is an online sensor detecting particles and bubbles >4 microns in hydraulic fluids and lubricants. It converts raw fluid data into actionable insights on wear, contamination, and degradation, actively protecting gearboxes, hydraulic pitch systems, and yaw mechanisms.
Key Features:
Particle Counting & Classification: ISO 4406, six size ranges (>4–>70 microns), supports NAS 1638.
Advanced Analysis: Identifies wear type (fatigue, sliding, cutting) for particles >20 microns and discriminates bubbles.
Oil Health Monitoring: Tracks degradation (%OD)
Fluid Image storing: Supply images of oil being monitored.
Data-Driven Decisions: Stores 10,000 tests, 100 images, with temperature monitoring.
Real-World Application Cases
Two case studies demonstrated how Atten2’s sensors enable proactive, data-driven maintenance.
Case 1: Gearbox Damage Monitoring
Background: A ZF GPV442 gearbox showed advanced macropitting (ISO 15243 Category 4) confirmed via boroscope.
Monitoring: RSMK tracked oil cleanliness over 93 days (Aug 22–Oct 11) at full turbine power.
Findings: Stable particle levels indicated no further damage progression, later verified by boroscope images.
Outcome: Combined online monitoring and periodic inspections ensured safe operation and informed planning.
Case 2: Particle Counting in Gearbox Testing
For a major wind gearbox manufacturer, long flushing and testing periods were a challenge.
Benefits: Faster testing, improved filtration performance, and reduced operational strain.
Objective: Achieve ISO 4406 cleanliness of 16/14/11.
Solution: Atten2’s particle counters outperformed competitors (HYDAC, Laser), with significantly lower counts during testing.
The webinar made it clear that the future of wind asset performance lies in preventing issues before they cause downtime. Real-time visibility into turbine condition enables operators to plan maintenance confidently, protect key components, and keep turbines producing power. Ultimately, reducing lost wind power is less about reacting to failures and more about using accurate data to stay ahead of them — improving uptime, reliability, and overall return on investment.
Atten2’s Additional Solutions:
OilWear: Real-time particle quantity and quality measurement.SMK: OilWear tech integrated into filter carts.RSMK: High-speed version for test benches and labs.OilCMS: Offline suitcase for particle analysis.OilHealth Probe: Monitors fluid degradation.OilMoisture: Measures water content in PPM.OilHealth Probe MAX & OilStreak: Advanced degradation and moisture monitoring via bypass installation.
Yellotec to Showcase Cutting-Edge Reliability and Condition Monitoring Solutions at Electra Mining Africa 2026
Yellotec is proud to announce that we will be exhibiting at Electra Mining Africa 2026, taking place from 7–11 September 2026 at the Johannesburg Expo Centre, Nasrec. Recognized as Africa’s largest mining, electrical, automation, manufacturing, power, and transport trade show, Electra Mining is the perfect platform to connect with industry professionals and demonstrate the latest advancements in reliability and condition monitoring technologies.
At Yellotec, we continue to lead the way in providing world-class solutions that help industries operate more efficiently, safely, and sustainably. From predictive maintenance technologies and laser shaft alignment to infrared thermography, motion amplification, and vibration analysis, our solutions are engineered to empower maintenance teams and reliability professionals to make smarter, data-driven decisions.
Visitors to our stand can expect live demonstrations, hands-on product experiences, and technical insights from our experts. We’ll be showcasing the latest innovations from our global partners, including Prüftechnik, Teledyne FLIR, RDI Technologies, HIKMICRO, all aimed at optimizing plant performance and minimizing unplanned downtime.
Achieve Lubrication Excellence with Noria’s Proven Ascend™ Methodology
Reaching lubrication excellence is no longer a vague or unreachable ideal. With Noria’s Ascend™ methodology, organizations gain a clear, structured path to optimizing their lubrication practices. More than just a definition, Ascend™ is a strategic tool that guides teams through evaluating, designing, and executing a transformation plan—becoming the compass that leads the way to world-class lubrication.
The journey begins by benchmarking current practices against Noria’s Optimum Reference State (ORS) to identify gaps and opportunities. From there, organizations can build a high-impact roadmap, ensuring resources are focused where they deliver the greatest ROI. By aligning improvements with lubricant lifecycle logic and reliability goals, and by measuring progress consistently, teams can sustain meaningful change and drive long-term performance.
Ascend Assessment
Get a customised roadmap for quick wins and long-term success, along with training, KPIs, and a detailed report to help you cost-justify improvements.
Engineering Design
Noria experts survey your lubricated assets, collecting all the data needed to deliver comprehensive procedures along with lubricant and hardware recommendations.
Program Implementation
Noria facilitates the vendor selection and procurement process to outfit your program with equipment and hardware you need to achieve your reliability and maintenance goals.
Optimizing Lubrication Management with Advanced Predictive Maintenance.
Previously, traditional predictive maintenance tools failed to detect early bushing damage in a primary crusher, resulting in a catastrophic $1,000,000 failure. To enhance their lubrication management, the customer integrated Atten[2]’s OilWear S sensors after a thorough assessment of predictive maintenance technologies.
Before this, lubrication cycles took over a week, requiring sampling, lab analysis, and decision-making. With the new sensors, real-time monitoring now streamlines maintenance, reduces downtime, and improves equipment health.
Short time interval from start of damage to catastrophic machine failure
Damage difficult to detect with conventional monitoring technology
Possible mistakes during oil sampling
Long response time of the lab
SOLUTION:
Given this customer’s needs, Atten[2] recommended the installation of OilWear S sensors. The ISO code display and real-time particle shape classification enabled quick decision-making:
The lubrication management cycle went from one week to one or two days, reducing risks in sampling, reducing lab and labour costs, and thus increasing machine lifetime.
The sensors also optimized asset management and prevented a catastrophic failure that would have shut down the mine production.
SEQUENCE OF FAULT DETECTION
May 20th, 2021
“Baseline” of primary crusher operation was set to an ISO code 22/20/19, as seen in the box, the average data before the failure began.
May 22nd, 2021
At the precise moment when the values showed a notable deviation, increasing beyond the normal ISO code (24/23/21), an increase in sliding wear was detected.
Armed with this information and mindful of the previous catastrophic bushing failure, the operator conducted on-site inspections, leading to the discovery of a fault in one of the bushing.
* Note: The increase in fatigue wear (natural wear) is not in itself an abnormality that requires attention!
May 23th, 2021
The graph shows a sustained upward trend in the ISO code (25/24/22). Similarly, the classification of particulate matter indicates a continuous increase in cutting and sliding particles.
To stabilize the crusher’s performance, several corrective actions were implemented, including partial lubricant changes, enhanced lubrication practices (such as lifting and balancing the bushing with additional oil supply), reducing the machine’s operating speed, and maintaining frequent filter replacements.
June 06th, 2021
Thanks to continuous monitoring, an issue with a bushing was detected, associated with the presence of cutting and sliding particles deviating from normal operating parameters. Without Atten[2]’s imaging technology and shape analysis, detecting this damage in time would have been impossible or very difficult. The ability to provide reliable measurement results even with high oil viscosity and strong bubble formation in lower ISO classes, compared to con-ventional particle counters, is another key advantage that enables early damage detection under harsh conditions as given here with this particular crusher.
Prompt actions were taken to rectify the situation, allowing production to proceed as planned. On June 6th, 2021, corrective measures were implemented during the scheduled plant shutdown, replacing the bushing. After the crusher’s startup process, it returned to its established ‘normal line’ of operation, indicated by the ISO code (22/20/19). During the monitoring period, a bell-shaped curve in fatigue particles was noted, a typical phenomenon linked to the machine’s startup phase.
CUSTOMER ́S BENEFITS
An unexpected failure in this type of machine significantly impacts the mine’s operation, leading to substantial production losses. Atten2 technology played a crucial role in early fault diagnosis, allowing timely decisions and actions to prevent a catastrophic breakdown. This proactive approach not only extended the machine’s lifespan until the next planned shutdown but also helped the mine avoid potential failure-related costs amounting to USD$1,000,000.
This same event occurred years ago at the primary crusher, resulting in the customer reporting losses and expenses of approximately one million dollars. This includes direct costs of production hours and expenses associated with the shutdown.
![Atten2 RSMK [Rugged Smart Monitoring Kit]_OA](https://www.yellotec.co.za/wp-content/uploads/2025/04/Atten2-RSMK-Rugged-Smart-Monitoring-Kit_OA-1024x1024.png)
