![]() ![]() Thus, the manufacturers who increase the longevity of the coolant are in a better spot to be more profitable in the long run.Ĭastrol provides end-to-end coolant management solutions to help boost the productivity and performance of your coolant. The efficiency with which a business manages coolant can considerably impact bottom lines, particularly in the current market conditions when material costs are ever increasing. ![]() And businesses that want to boost their revenues and profits should definitely consider adopting full-proof coolant management best practices. Hence, effective coolant m anagement is the cornerstone to improving the efficiency and productivity of any metalworking operations. This can be done by using filtration units or vacuums as frequently as possible. Hence, separating the swarf from the fluid is the first measure to achieve this and deal with the related problems. Ideally, a well-maintained coolant contains less than 100ppm/mg per litre of fines. Coolant filtration is essential to maintain the machine's performance and prevent any damage. It also helps decrease the static zone that’s susceptible to contamination. Regularly removing swarf fines from the sump is needed to reduce the risk of corrosion and increase the available sump capacity for the coolant. Timely detection of any defective machine parts or leakages in hoses and seals is vital. Another measure is to regularly clean, maintain and track the machines. Apart from that, tramp oil can be separated using skimmers, tramp oil separators or centrifuges. And one of the best ways to achieve this and avoid any related issues is to ensure a regular circulation of fluid. Ideally, a well-managed machine should have less than 2% tramp oil. If not attended to in time, tramp oil can cause faster fluid degradation, increased corrosion, unstable emulsions and can be hazardous to health. Lower oxygen levels provide a perfect breeding ground for anaerobic bacteria. The accumulated tramp oil on the surface of water-based emulsions leads to oxygen deprivation. The unwanted lube oil that has seeped or leaked into the coolant system is known as tramp oil. One of the leading causes of coolant contamination is tramp oil. Regular clean-outs are recommended to decrease bacterial growth and improve the overall efficiency. One of the best ways to do this is to ensure the right fluid concentration, eliminate tram oil, and remove the swarf to keep the water clean, among others. Tackling these issues requires tracking and managing the level of bacterial growth in the coolant. It can also lead to several other issues like foul odours after the machine shuts down, increased corrosion or rusting, a change in coolant colour, a drop in pH levels or the presence of scum clogging lines or filters. Growth in bacterial breeding can hamper the quality of water-miscible cutting fluids and their technical performance. Bacterias and other microbes require an abundant water supply for breeding, which water-based coolants do offer if not maintained or controlled well. Poorer water quality can also be a result of microbial contamination. Hence, fresh drinking water is preferred whenever possible. Stale water can also have an issue of microbial contamination. To tackle these issues, water softeners, de-ionisation and reverse osmosis systems can be used to improve the water quality. 0-20mm hardness can have a risk of foaming, and the 400ppm and above can lead to various mixing and stability problems in the fluid. Another aspect to consider is the water hardness. The purer the water quality is, the greater the longevity of the coolant. That’s because a soluble emulsion contains anywhere between 85% to 98% water. Poor water quality can adversely affect the performance of the fluid. Practising the following coolant management techniques can also do the trick! But maximising tool life doesn’t necessarily have to be expensive or complicated. The efficiency of a coolant oil can be easily deteriorated by dirt and other contaminants. Compared to other lubricants, coolants require extra care to increase their overall life and effectiveness. But the purity of coolant oil can also impact the overall longevity of tools. The first step to maximise tool life is to purchase high-quality cutting tools. To accomplish this, it is best to practice effective coolant management that will enhance manufacturing efficiency and extend machine and fluid lifespan. This ensures that the performance and quality of the cutting tools is maintained. In order to do this, constant monitoring of coolants is vital. Metalworking operations can be made more productive by making cutting tools more efficient. ![]()
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