25+
Years Experience
"No excuses. Just results."
FLAC Guard operates at the control point of one of the most dominant failure drivers in heavy mining equipment: contamination. We manage fluid cleanliness as a measurable reliability variable across engine lubrication, transmission circuits, hydraulic systems, pump drives and fuel systems — to control contamination, stabilise wear, improve predictability and protect production.
Filtration is not the objective. Reliability stability is. We do not "fit filters" — we engineer circuit integration through documented pick-up and return routing protocols, pressure validation standards, flow verification after servicing, and machine-specific configuration mapping.
Systems operate at 1 micron nominal and 3 micron absolute, reducing particle population density within the critical wear band and directly influencing component life curves.
Documented pick-up & return routing protocols, pressure validation, flow verification, and machine-specific configuration mapping. Installation integrity is treated as a reliability control measure.
ISO 4406 cleanliness trending, ASTM-aligned wear metal analysis, viscosity stability, TAN/TBN tracking, oxidation progression and water detection. Oil is treated as a diagnostic data stream.
Structured fleet monitoring linking asset-level cleanliness, filter lifecycle tracking, service-interval compliance, wear-metal progression, failure correlation mapping and contamination deviation alerts.
From refinery to equipment, the risk grows with every transfer. In high-load mining environments, sub-micron contamination accelerates abrasive wear, bearing distress, injector scoring and hydraulic pump degradation — and the most destructive particles are far smaller than the human eye can see.
Injector clearance is 300× smaller than a grain of sand — and FLAC Guard filters to that level.
Cleaner fluid means dramatically longer component life. FLAC Guard routinely achieves ISO 14/11 — placing fleets firmly in the "Excellent" band.
Moving from ISO 18/15 to 16/13 reduces particles by 98% and extends component life by up to 1.5×. FLAC Guard delivers a documented hydraulic cleanliness of ISO 14/12/9 in the field.
Without protection, abrasive contamination circulates through pumps, valves and cylinders — driving accelerated wear and eventual catastrophic failure. With FLAC Guard installed, contamination is captured and controlled before it ever reaches your precision components — trapping up to 1 kg of dirt in a single fuel cartridge within two weeks.
Validated across mining, heavy transport and industrial fleet operations — cleaner fluids deliver a compounding dividend across fuel, lubrication and maintenance, simultaneously.
The cost of filtration is predictable. The cost of component failure is not — and it is always higher.
Leading equipment manufacturers specify fluid cleanliness targets that FLAC Guard meets or exceeds as standard — delivering ISO 14/11 against every requirement.
Installing FLAC Guard satisfies OEM fluid cleanliness conditions and preserves your warranty entitlements — while extending component life well beyond standard service intervals.
"When the world's largest mining companies choose a filtration system, they validate it against the harshest conditions on earth. FLAC Guard passes."
From iron ore to diamonds, from OEM partnerships to independent mine sites, FLAC Guard's contamination control programmes have delivered consistent, measurable and independently verified improvements — including 7+ years at Geita Gold Mine.
Oil cleanliness held to 500-hour standards while running 1,000 hours continuously — allowing the mine to double its fleet at the same service cost and labour complement. Haul-truck availability rose from 90% to 95%.
Breakdown-related maintenance cost reduced from ZAR 23 million to ZAR 11 million in year one, ZAR 5 million in year two, and ZAR 4 million in year three using the FLAC Guard programme.
DP1500 with a C11 engine after 1,580 hours without an oil change: copper improved 188×, iron 4.3×, lead 11×. Service intervals extended 250 → 1,000 hours, with 78% oil saving and 2× machine life.
Barloworld officially advise clients that the best service provider is the FLAC Guard programme, recommending additional filtration on each engine with continuous support and backup data from FLAC Guard experts.
| Client | Key Metric | Result |
|---|---|---|
| Kumba Iron Ore | Fleet availability | 90% → 95% |
| Kumba Iron Ore | Service intervals | 500 → 1,000 hours |
| Trans Hex Group | Breakdown costs (3 years) | ZAR 23m → ZAR 4m |
| De Beers Voorspoed | Oil cost savings | 78% reduction |
| De Beers Voorspoed | Machine life extension | 2× longer |
| Barloworld | OEM endorsement | "Best Service Provider" |
Engineering authority and intellectual property are held at our South African headquarters, while our offices in Tanzania and Zambia deliver on-the-ground mining execution, service integration and fleet reliability support under controlled governance standards.
Configuration standards, tribology methodology, installation governance, R&D oversight and fleet analytics integration.
On-site contamination control, fleet service delivery and Geita Gold Mine operations — 7+ years of continuous support.
Regional fleet reliability programmes, contamination control services and copper-belt mining support.
Engineering governance is centralised. Execution is regionally embedded. Standards are controlled. FLAC Guard South Africa holds the engineering authority and IP for all configuration standards, while regional offices execute under controlled governance — ensuring consistency, quality and reliability across every operation.
Whether you operate a single mine site or manage a fleet across multiple territories, FLAC Guard delivers the contamination control, tribology intelligence and predictive data linkage to protect your production and stabilise your maintenance costs.