Blog | POLARIS Laboratories®

Seeing the Unseen: Advancing Microscope Wear Analysis

At POLARIS Laboratories®, precision and innovation drive everything we do, especially when it comes to helping customers understand what’s happening inside their equipment. We’ve recently expanded our analysis capabilities with the addition of the Olympus DSX1000 Digital Microscope, a powerful tool that enhances our ability to detect, analyze, and document wear debris consistently across all our global laboratories – something you won’t get with other laboratories.

Elevating Microscopic Analysis Capabilities

The Olympus DSX1000 delivers unmatched magnification, clarity, and automation, allowing our data analysts and reliability experts to visualize the smallest wear particles with extraordinary detail. With up to 9,637x magnification, this technology captures what traditional microscopes can miss and gives customers a more complete picture of component wear and overall fluid cleanliness.

The advanced microscope allows for consistent, high-resolution imaging across every sample we test and analyze. This automation not only speeds up analysis time but also ensures repeatability and accuracy, both critical factors when trending wear patterns or investigating abnormal test results.

Connected Technology & Global Consistency

Thanks to its PRECiV unified imaging software, the DSX1000 seamlessly connects every POLARIS Laboratories® location worldwide. Samples can be scanned with the microscope at our headquarters laboratory in Indianapolis and reviewed and interpreted by reliability analysts at any of our seven global laboratories. This feature enables remote collaboration, faster training, and a consistent interpretation of results across the globe.

This connectivity also supports global standardization in testing methods like Analytical Ferrography, Micropatch, and Photomicrograph Analysis. Customers benefit from the same advanced imaging, precision, and reliability, no matter which lab processes their samples.

Beyond the Numbers: Telling the Story

While fluid analysis provides the data, microscopic analysis tells the story. The DSX1000’s multiple observation modes, like Brightfield, Oblique, Darkfield, Mixed, and Polarization, help analysts reviewing the images distinguish between particle types, identify ferrous wear, and investigate sources and failure modes. This level of detail allows for more accurate root cause analysis (RCA), helping customers make confident maintenance decisions based on clear, visual evidence.

The result? Earlier detection of wear, more reliable diagnostics, and greater confidence in making critical decisions.

Raising the Bar for Reliability

By integrating this advanced microscope technology into our global operations, POLARIS Laboratories® continues to lead the industry in delivering data you can trust and insights you can act on. The DSX1000 doesn’t just enhance our testing capabilities, it strengthens the connection between the laboratory and your maintenance team, helping you protect assets, extend component life, and improve overall equipment reliability.

Published November 13, 2025

Detect Equipment Wear Sooner with Ferrous Debris Analysis

In the world of heavy-duty equipment, small issues can quickly become big problems. A worn bearing or damaged gear doesn’t just cause mechanical headaches , it can lead to costly downtime, safety risks, and unexpected repairs. That’s why early detection of wear is one of the most valuable tools in any maintenance strategy.

One of the most effective ways to spot wear early is through ferrous debris analysis. This is a key part of fluid testing that helps you understand what’s happening inside your equipment long before performance declines.

What is Ferrous Debris?

Ferrous debris refers to the tiny metal particles (typically iron and steel) that are generated when internal components begin to wear. These particles are carried in the lubricant and can tell a detailed story about what’s happening inside an engine, gearbox, or hydraulic system.

While some wear is normal, a sharp increase in ferrous debris is often one of the first signs that something is going wrong. Identifying these particles early helps maintenance teams take corrective action before the wear turns into failure.

Why Testing Matters

Routine oil analysis provides an overview of fluid health and contamination, but ferrous debris testing focuses specifically on wear; the earliest and most direct indicator of mechanical distress. By trending ferrous data over time, maintenance professionals can spot abnormal wear patterns and schedule repairs before they become emergencies.

The Next Generation of Wear Detection: FerroQ

Traditionally, laboratories have used Particle Quantifier (PQ) testing to measure the amount of ferrous material in a lubricant sample. While effective, PQ testing can have limitations when dealing with complex samples or heavy contamination.

That’s why POLARIS Laboratories® has implemented the FerroQ method across all laboratory locations. FerroQ is an advanced approach to ferrous debris analysis that delivers more accurate, consistent, and repeatable results — giving you a clearer picture of equipment condition. Learn more about the switch here.

With FerroQ, you get:

Improved precision for detecting even small changes in wear levels
Faster, more reliable trending for better long-term insight
Consistent results across all POLARIS Laboratories® locations

This consistency ensures that wherever you send your samples, you’ll receive the same high-quality data, making it easier to monitor trends and take action with confidence.

Turning Insight into Action

Ferrous debris analysis doesn’t just measure metal content — it helps identify the type of wear occurring. When combined with techniques like Analytical Ferrography, maintenance teams can determine whether particles are from normal rubbing, cutting wear, or fatigue failure.

This level of insight allows you to move from reactive maintenance to a truly proactive, data-driven approach — extending equipment life, improving reliability, and maximizing return on investment.

The Bottom Line

When every hour of uptime matters, early detection makes all the difference. With advanced ferrous debris testing like FerroQ, you can identify wear before it becomes damage — keeping your equipment running stronger, longer.

Ready to detect wear sooner? Contact us today!

Published October 24, 2025

Get More from Your Lubricants: How Oil Analysis Can Optimize Drain Intervals

In today’s market, lubricant supply challenges are pushing maintenance teams to rethink how they manage oil drain intervals. From additive shortages and rising demand to logistical delays, getting the lubricant you need when you need it isn’t as easy as it used to be.

How can you get the most of the lubricants?

The answer lies in oil analysis.

Routine oil analysis is a powerful tool for extending and optimizing drain intervals without risking equipment reliability. Instead of relying solely on preventive maintenance (PM) schedules or disposing of used oil without checking its remaining life, consider switching to a condition-based monitoring (CBM) strategy. With CBM, sample results guide your maintenance actions, allowing you to safely push drain intervals further while monitoring for wear, contamination and fluid health.

Lubricants can often be safely used beyond OEM-recommended intervals, but only when supported by testing and analysis. A routine fluid analysis program evaluates the oil’s physical properties, identifies signs of wear and determines if the fluid can still perform effectively. POLARIS Laboratories® offers customers an Extended Drain Comments Program where our team of support analysts help you determine how to reach optimal lubricant usage.

At a time when it’s needed the most, oil analysis can reduce costs, minimize waste and lower maintenance spend.

For more insight into optimizing drain intervals and getting more from your lubricants, check out this infographic:

Contact your Account Manager or Customer Experience (service@eoilreports.com) to learn more about participating in the Extended Drains Program at POLARIS Laboratories®.

Coming Soon: Ferrous Debris Analysis with FerroQ

Out with PQ, in with FerroQ.

Starting September 11, 2025, POLARIS Laboratories® will transition all of our laboratory facilities from the PQ™ (Particle Quantifier) test method to the more advanced FerroQ™ instrument for ferrous debris analysis. This upgrade applies to both oil and grease sample testing and marks a significant improvement in how wear-related ferrous debris is measured, interpreted and reported.

To learn more about different types of wear, ferrous debris and tests performed to measure it, watch the webinar Ferrous Debris 101: What Your Lubricant is Telling You:

Enhanced Ferrous Debris Analysis with FerroQ

Instead of results reported in PQ Index (a unitless number), results will be reported in parts per million (ppm) on analysis reports delivered to customers. This change delivers greater accuracy, improved trendability and more reliable data for identifying wear and making informed maintenance decisions.

Why the change?

The FerroQ™ method provides a clearer, more quantifiable picture of ferrous contamination, making it easier to detect early-stage wear and better predict component failure. It also enhances consistency across sample reports and allows for easier integration with maintenance data systems.

For more technical information related to ferrous debris, testing limitations and particle debris measurement, read the blog Assessing Methods to Analyze Particles: PQ vs FerroQ or view the Technical Bulletin PQ vs FerroQ.

As your fluid analysis laboratory and reliability partner, our goal is to help you make smarter data-driven decisions based on the most reliable results and the FerroQ™ is the next step forward. Customers can expect to receive additional communication when the change goes into effect in the coming months.

If you have any questions, please contact service@eoilreports.com.

2025 Reliability Summit

Catch Pesky Particle Contamination

Did you know 80% of failures in hydraulic systems can be traced back to contamination? Particle contamination is the most common, most detrimental type of contamination, can come from many different sources and can include dirt, metal, soot and rust.

How do these pesky particles enter your system?

Sources contributing to particle contamination can include:

Lubricant additives
Sample bottle cleanliness
Poor oil sampling procedures
Air entrainment
Use of improper reservoir covers
Transport, distribution and transferring of new lubricants

Due to the wide range of potential sources and cause of particle contamination, it’s important to identify it before it can cause issues including:

Increased wear and tear on bearings, gears and seals
Lubricant degradation
Clogged filters causing fluid flow restriction
Pitting, scoring or cracking in critical components
System malfunction (jammed valves and surface erosion)
Overheating

Performing Particle Count Testing

If you have pesky particle contaminates within your system, chances are standard testing with Inductively Coupled Plasma (ICP) won’t catch the real problem. ICP can only fully analyze a particle at approximately 10 µm in diameter and gives no indication of the morphology or distribution of the particles.

Particle count is one of the best available tools for measuring system cleanliness. This test is suitable for most (but not all) fluid types and systems and can count particles as small as ≥ 4 µm and can lead maintenance professionals to identify the source of the contamination and assess the damage that has occurred to the component.

Evaluating the use case, objectives, and system type are key to determining whether particle count and other tests may provide the most valuable data. Particle count is crucial to maintaining the performance and longevity of sensitive components with small clearances.

It is recommended to perform particle count testing to determine the number and size of particles in these components:

Hydraulics
Compressors
Turbines
Circulating systems
Automatic transmissions
Natural gas engines
Robotics
Injection molding machines
Bearing and gear systems

Should you be performing Particle Count to address system contamination? View the HORIZON Technical Bulletin Particle Count: When to Use it and Why

Explore different test methods for counting particles in the HORIZON Technical Bulletin Particle Count Test Techniques

Ready to improve system cleanliness and address those pesky particles?

Contact your Account Manager or Customer Experience at service@eoilreports.com or call +1 317-808-3750.

Published January 7, 2025

Diesel Exhaust Fluid (DEF) Testing is Now Available

POLARIS Laboratories® is excited to offer our customers testing and analysis for Diesel Exhaust Fluid (DEF).

DEF, also known as AUS 32 and marketed as AdBlue, is a water and urea mixture that is non-toxic, colorless and non-flammable. The aqueous urea solution is comprised of 32.5% urea and 67.5% deionized water.

Testing for DEF will include:

Elemental analysis
Visual examination
% Urea
pH
Specific Conductance

Because DEF manufacturers perform specification testing following the ISO 22241 guidelines, POLARIS Laboratories® will not provide this testing.

Testing your DEF can identify concerns of contamination that can result in a decrease in engine performance capabilities. The above tests will provide a comprehensive check for contamination within the DEF in-service fluid. Including comprehensive testing will provide awareness and indicate actions required to maintain the engines’ proper performance.

As DEF is consumed by the engine, the fluid in the tank on the equipment will eventually be depleted and new fluid will be added. Addressing identified contamination concerns early will avoid potential future issues in the system.

Reach out to our team today to add DEF testing to your fluid analysis program.

Go Digital with Your Condition Monitoring

As the industry continues to grow in the digital landscape, POLARIS Laboratories® is always looking for ways to maximize customers’ access to technology. With tools such as Component ID Tags, QR-Code-Only Sample Labels and the HORIZON® mobile app, our customers can digitally customize how they manage their fluid analysis programs.

QR-Code Only Sample Labels

QR-Code Only Sample Labels contain a unique barcode number linked to a specific fluid sample, made to easily apply to the surface of the sample bottle. By transitioning to QR-Code Only Sample Labels, customers can reduce the costs of kits while simultaneously improving the overall carbon footprint.

Start using QR-Code Only Samples and:

Eliminate handwritten submissions
Minimize paper waste
Accelerate result time
Manage previous submission information
Save on costs of kits

Introducing Our New Mascot: Beecon, the ReliaBee

In celebration of POLARIS Laboratories’ 25th Anniversary and the significant advancements driven by our dedicated team members and valued customers; we are proud to unveil our new mascot. Meet Beecon, the Reliabee!

Putting the B in Reliability

Beecon represents our steadfast commitment to excellence, collaboration and dedication in assisting our customers achieve peak equipment reliability through fluid analysis. At POLARIS Laboratories®, we strive to provide accurate, reliable and timely results, personalized customer experience, expert recommendations and collaborative insights.

A Beecon Towards Value

Much like our guiding POLARIS star, the name Beecon symbolizes both aiding navigation and orienting position or location. From the very beginning, POLARIS Laboratories has prioritized delivering state-of-the-art navigational data management and integration technology solutions aimed at ensuring our users achieve total equipment reliability. Through HORIZON®, our customers gain access to a robust suite of information and tools that help them take their maintenance program management capabilities to the next level.

Sample Data as Sweet as Honey

Actionable maintenance recommendations, expert analysis and accuracy of test results are integral to the operational efficiency at POLARIS Laboratories®, reflecting the meticulous processes observed within a beehive. Much like bees maintain hive health through careful oversight and teamwork, our customers rely on us to help them improve operational efficiency, predict maintenance and optimize fluid drain intervals safely. POLARIS Laboratories® is the “Beecon” on our customers’ reliability journey, guiding them with precision and clarity.

Welcome, Beecon the ReliaBee

At POLARIS Laboratories®, we value the dedication of our teams, ensuring smooth and efficient operations. Our commitment to engaging customers in effective maintenance strategies reflects our core values. Beecon exemplifies the reliability, performance and excellence that define POLARIS Laboratories®.

Published July 9, 2024

Staying Cool for the Summer: How to Utilize Coolants During Hot Temps

With the summer months coming, assessing your cooling system is more important than ever to prevent equipment overheating.

As the outside temperatures rise during the summer months, equipment concerns come into focus. Engine metallurgy and lubrication relies on a specific temperature range while in-service. Anything outside of this range will result in reduced efficiency and prolonged exposure to high internal temperatures will increase component wear and lubricant stress. The viscosity of the lubricant is crucial for providing a fluid film to avoid metal to metal contact. Overheating will cause the lubricant’s viscosity to become too thin for proper protection. This affects lubrication, resulting in friction, wear and shortening the lubricant’s capabilities to provide proper protection to the system.

The Functions of a Cooling System

The cooling system becomes a driving reminder to the importance of regulating the engine temperature. The cooling system must be able to circulate coolant, remove heat from the system and dissipate the heat. To keep overall internal temperatures stable during outside temperature shifts, the cooling system must function correctly. However, if one of the functions cannot perform properly, this will cause a snowball effect of concerns.

The effects of temperature, pressure, flow on the cooling system operation, will noticeably impact equipment health. Corrosion in the cooling system occurs at a slower rate than engine wear; however, up to 40% of preventable engine failures are traced back to the cooling system. Concerns with the lubricant and engine performance may be a sign of cooling system issues.

Click here to read more on the effects on the cooling system

The Importance of Coolants

Coolant in the cooling system plays a critical role in the ability to transfer heat and prevent corrosion protecting the overall system health. Overheating is a common concern due to coolant property issues. Increased summer heat might also increase unexpected failures. The frequently acknowledged coolant properties that are reduce corrosion in the cooling system and lubricant concerns are:

• Glycol Concentration
• pH
• Corrosion Protection Inhibitors
• Concerns of Contamination
• Degradation Acids

Maintaining Coolant Systems for Improved Longevity

Coolant chemistry reactions occur due to mechanical issues, coolant property concerns or contamination of the system. Warmer temperatures should not keep your equipment out of service or increase lubrication costs. Maintaining your cooling system can be a simple task to avoid resulting in a neglected system. Understanding coolant and equipment demands is key to proper maintenance in the field. With consistent maintenance, the coolant and equipment health can provide adequate functions to protect and remove heat from the component parts as needed.

A proper fluid analysis program should include assessing all fluids in the equipment. Your fluid analysis program will remove maintenance guesswork for whether the equipment components are appropriately supported and protected or not. With trend analysis, you can reliably catch concerns and are able to act on the recommendations and address the issue before further damaging your equipment. Reach out to our team today to see how we can help see your fluid analysis program succeed and achieve your ROI.

Contact Us Today

Published June 25, 2024