Save Money On Your Metalworking Fluid

Getting Real About Hidden Operating Costs

It seems like every time I turn on the TV, open a newspaper, log onto the internet, or switch on the radio I hear more bad news about the economy. There is no way around it: we are living in difficult times. Personally and professionally it has become absolutely crucial to conserve resources and minimize costs. For individuals this might mean cutting out obviously unnecessary things like cable television, eating out, and vacations but for companies it can be harder to identify hidden and avoidable costs. Recognizing and improving on these areas is the first step that any business, whether large or small, should take because it is the cheapest, easiest, and fastest way to cut overhead.

In the metalworking industry optimizing machine and operator productivity is now more important than ever before. A simple way to make sure that you are minimizing costs while maximizing profits is with your cutting fluid but currently most companies lose between 5 and 20% of their productivity to mismanagement of their cutting fluid.

The numbers:
$130.00
$6,600.00
$29,400.00
$31,200.00
$60,600.00

Machine downtime costs, on average, $130 an hour and frequent cutting fluid changeovers.
Tools are expensive: a band-saw blade is between $30 and $60, broaches run around $100, end mills cost up to $150, drills between $30 and $100.

A gallon of cutting fluid will run you $0.50 - $2.00 depending on the fluid and concentration; disposing of that same gallon of used cutting fluid costs between $0.50 and $2.50 depending on state.

To fill and empty out a 100 gallon sump every two months costs roughly $660.00 – $2,940.00 just for one sump, if you have ten machines you are looking at $6,600.00 to $29,400.00 for cutting fluid and disposal alone.

Now take into account the $15,600.00 to $31,200.00 it will cost to have 10 machines down for two to four hours every two months and the cost of broken tools and wasted parts, which can easily be in the tens of thousands of dollars.

To me those are some pretty scary figures. Time and time again it has been shown that by simply using the right coolant for your operation, running at the correct concentration, removing tramp oil every week, and dosing once a month with an antimicrobial additive the amount of money that can be saved is staggering.

Many coolant manufacturers are happy to help you assess your current situation and offer cost saving advice and recommendations. Talk to your coolant representative and see what changes you can make to start seeing big savings.

Check out the Daily Coolant Checklist and 10 Point Coolant Inspection in the Help section for ideas on maintaining your coolant. For help from a metalworking expert from Rustlick email info@rocolnorthamerica.com.

You are visiting the blog of ITW ROCOL North America, manufacturer of Accu-Lube, Rustlick, SafeTap, and Daraclean. For more information please visit their website at www.rocolnorthamerica.com.

Treating Bacteria and Fungus in Metalworking Fluids

Bacteria and fungus are two major causes of metalworking fluid failure; they impair the effectiveness of the cutting fluid and are harmful to operators. Treatment and prevention is not difficult but it does require consistent maintenance.

Some cutting fluids are more susceptible to microbial problems than others. Water-Soluble Oils typically have the most problems simply because they have the highest oil content of all the different types of cutting fluid. Also as formulas advance and sump life increases the chances for product loss also increases. Even if you don’t currently have problems with bacteria or fungus, if the sump life of your coolant is four months or more it is a good idea to get into the habit of dosing your sump with a bactericide once a month.

Preventative Dosing:
For prevention a good rule of thumb is dosing in the morning on the first Friday of the month.

Treatment Dosing:
If you already have a problem with bacteria and/or fungus use the following dosing schedule to first eliminate your problem. Once the problem is under control continue preventative dosing.

Problems with bacteria only: Use 1 oz of Grotan† for every 5 gallons of cutting fluid (take the capacity of your sump in gallons and divide by 5 to get your dose in ounces). For other bactericides see manufacturer’s guidelines.

Problems with bacteria and fungus: Use 1 oz of Triadine 20† for every 5 gallons of cutting fluid (take the capacity of your sump in gallons and divide by 5 to get your dose in ounces). For other bactericides/fungicides see manufacturer’s guidelines.

30 gallon sump = 6 oz of Grotan/Triadine 20
50 gallon sump = 10 oz of Grotan/Triadine 20
100 gallon sump = 20 oz of Grotan/Triadine 20

Dosing schedule:
Always use full doses.

*Use additional doses for major contamination problems.

† These Rustlick products are available through MSC Industrial Supply, Grainger, and DGI Supply along with a wide number of regional distributors. For more information on where you can find these products contact info@rocolnorthameria.com.

You are visiting the blog of ITW ROCOL North America, manufacturer of Accu-Lube, Rustlick, SafeTap, and Daraclean. For more information please visit their website at www.rocolnorthamerica.com.

How to Use a Refractometer

A refractometer is an investment that pays for itself almost instantly. Properly maintained cutting fluid concentration prevents wasting coolant, protects machines and tools, reduces disposal, and produces better parts. Measuring your coolant concentration with a refractometer takes less than a minute and the payoffs are huge, make sure that your operators know how to use and read a refractometer.

Basics:

When light passes through a prism it is separated into different wavelengths of light (red, orange, yellow, green, blue, indigo, violet). A refractometer works in much the same way except it is the coolant concentration that causes light to “refract,” or separate as it passes through the sample. The higher the coolant concentration, the greater the separation and the higher the refractometer reading.

Taking a reading:

Step 1: Place 1 to 2 drops of cutting fluid, onto the prism glass and close the plate cover. (If you are measuring the current concentration of a sump it is helpful to fill a paper cup with the used cutting fluid and let it sit for 10 minutes so that the tramp oils and fines separate out. After 10 minutes poke a small hole in the middle of the cup and use the stream of coolant to take your reading.)

Step 2: Look through the eyepiece and view the scale. The top portion of the scale appears blue and the bottom part appears white. Take your reading at the intersection of these two colors.

 

It is important to note that each coolant has its own unique concentration readings. One coolant may have a refractometer reading of 9.2°Bx at 10% concentration (10:1) while another coolant may read 3.3°Bx at the same concentration. Water-soluble oils typically have the highest refractometer scales and synthetic coolants typically have the lowest. Make sure to check with your coolant manufacturer for the correct scale for your coolant.

You are visiting the blog of ITW ROCOL North America. For more information please visit their website at www.rocolnorthamerica.com.

 

Winter Tip # 4

A Better Solution

For shops with minimal heating during the winter months it is possible to keep your coolant from freezing without resorting to harmful measures like adding antifreeze. You don’t have to heat your entire facility to keep cutting fluid from freezing, just the sump.

The most effective way to do this is with heat tape. Heat tape (or heating cables) is commonly used to prevent water pipes and gutters from freezing; heat tape intended for gutter use are typically a little heavier-duty than the type for water pipes and therefore work better on large sumps.

To install heat tape simply wrap the tape around the outside of your sump using electrical tape to hold it in place. Continue wrapping the sump in two inch increments until all four sides are covered. Cover the heat-tape wrapped sump with insulation, MAKE SURE that the insulation you use is heat and water resistant, Thermwell Foam and Foil Duct Insulation (12″ W x 15′ L x 1/8″ thick, available at Lowe’s) is the perfect size for this job. BE CAREFUL because not all heat tapes are intended to be used with insulation so make sure that you read the instructions on the tape carefully so that you don’t accidentally start a fire.

Ace Hardware, The Home Depot, and Lowe’s carry a number of different types of water-pipe heat tape but gutter heat tape isn’t as readily available at these stores so your best bet is an online search.

You are visiting the blog of ITW ROCOL North America. For more information please visit their website at www.rocolnorthamerica.com.

Winter Tip # 3

Antifreeze: Don’t even think about it!

Click here for more information.

Every winter I run into the same question, “Is it safe to add antifreeze to my coolant?” And every year my answer is the same, “NO!” Coolant is expensive, machines are really expensive and adding antifreeze to your sump will ruin both. Don’t do it.

Ethyl glycol (EG) is the main ingredient in most automotive antifreezes because of its low freezing point. When antifreeze is mixed with cutting fluid, especially water-soluble oils and semi-synthetics, the EG causes the cutting fluid to separate, eliminating all of the beneficial properties of the fluid. Your cutting fluid won’t freeze but your machine and parts will rust and you will burn through your tools.

For a better solution see Winter Tip # 4 above.

You are visiting the blog of ITW ROCOL North America. For more information please visit their website at www.rocolnorthamerica.com.

Winter Tip # 2

Anyone who has machined with water-based cutting fluid for a number of years will tell you that skin irritation can be a major concern, especially during the winter months when the air is dryer and skin is more prone to dehydration. A machinist might go all summer without experiencing any problems then suddenly, with the onset of winter, develop a severe case of dermatitis. The most common reaction is to blame the fluid but more often than not it isn’t the product that has changed, it’s the working conditions.

The following steps will help you to treat and prevent winter-induced skin irritation.

1. Maintain proper coolant concentration
2. Wash hands frequently with a mild soap
3. Practice good work and personal hygiene, launder clothes after exposure to fluid
4. Use work gloves or waterproof barrier creams

Many operators dislike working with gloves or barrier creams but having a protective layer between your skin and the fluid can be the single best way to prevent short-term and long-term skin damage. The gloves should be PVC coated and fit snugly, having several different sizes available is an easy way to encourage use. The barrier cream should be water and solvent resistant and readily available in a number of locations, particularly the wash station and restrooms. These can take some getting used to but the long term benefits are defiantly there.

Most importantly remember that skin irritation is a medical problem that if not treated properly can lead to bigger problems later on. All cases should be reported to medical personnel and properly investigated.

You are visiting the blog of ITW ROCOL North America. For more information please visit their website at www.rocolnorthamerica.com.

Diluting Your Coolant

One of the easiest ways to save money on your cutting fluids is to make sure that you are running at the correct concentration. Not all operations require a rich coolant; in fact most jobs can be run between 20:1 (5%) and 30:1 (3%). Consult your coolant manufacture’s Technical Service Department for more information on determining the optimal concentration for your operation and then follow the mixing instructions below.

 

Always premix your coolant BEFORE adding it to the sump. Always pour coolant concentrate into water when mixing. Remember O.I.L. = Oil In Last.

 

For easy mixing add the indicated amount below to 4 gallons of water, a 5 gallon pail makes a perfect mixing container.

 

Measurements are given in gallons, cups, and liters.

 

Rustlick coolant customers can use the Make-Up Coolant Calculator located in the Help section above to automatically calculate exact dilution ratios and mixing instructions.

 

You are visiting the blog of ITW ROCOL North America. For more information please visit their website at www.rocolnorthamerica.com.

Tell Us What to Blog About

We want to hear from you… The purpose of this blog is to address topics, concerns, and problems that are important to you as manufacturers, operators, supervisors, engineers, and the industry in general. So we want you to tell us what to write about; whether you are an old hand or new to the industry it’s your operations that we want to focus on. Topics can include anything to do with metalworking lubrication, so put your thinking caps on and see if you can stump our experts. (It won’t be easy!) Suggestions can be posted here or you can email us at info@rocolnorthamerica.com.

You are visiting the blog of ITW ROCOL North America. For more information please visit their website at www.rocolnorthamerica.com.

MQL for Beginners

Click here to view Getting Started With Minimum Quantity Lubrication

Minimum Quantity Lubrication is a concept that has been around for decades but it only in the past five years that it has really begun to gain popularity with mainstream operations. This is due in part to advances in the technology and increasing awareness of environmentally-safe practices. However there are many people in the industry who don’t understand the basic principles of MQL.

Todd Schuett of Creative Evolution, in conjunction with Modern Machine Shop, has put together a video that does a great job of highlighting the basic points of MQL.

You are visiting the blog of ITW ROCOL North America. For more information please visit their website at www.rocolnorthamerica.com.

Winter Tip # 1

Chances are that the cutting fluid in your sump is 90-95% water, which means that it will freeze around 32°F (0°C), the same temperature as water, and because water-mix cutting fluid contains so much water it expands when it freezes.

If you use water-mix cutting fluids make sure that you keep your facilities ABOVE 50°F (10°C) or you risk freezing your coolant and causing very expensive internal damage to your machines.

You are visiting the blog of ITW ROCOL North America. For more information please visit their website at www.rocolnorthamerica.com.