Making the most of the mix

This has been achieved through implementation of metalworking fluid best practice and waste management techniques.

With 18 CNC machining and turning centres onsite at its main manufacturing facility in Adlington, Cheshire, and with business growing significantly, Proseal recognised a need to better manage its metalworking fluids. Working closely with Cardev-Motorex, Proseal now has a workable solution that delivers in all areas of concern and also provides a financial benefit to the business.

Key to solving the problem was the use of coolant recycling. The used coolant is now processed in a Cardev coolant cleaning system, which restores it back to as new condition allowing it to be re-used in the machine shop. The process involves initial treatment of the old coolant, which is stored in a dirty oil tank, with Ozone infused compressed air in order to control any bacterial activity within the fluid. The next stage is to filter it down to 5µm and remove any tramp oil. Once cleaned the coolant is transferred to the clean oil tank where it is held ready to be distributed to any machine via a pipe network.

The cleaning system is also linked to a Cardev Smart Mix system, which mixes fresh coolant to the correct concentration automatically. These two systems work in tandem, with recycled coolant being used as a priority and new coolant only being mixed when no recycled product is available, further reducing consumable costs.

By maximising the use of recycled coolant along with the added benefits of longer life, improved surface finish and low top up rates of the Motorex Swisscool 7755 Aero metalworking fluid, Paul Wilson, Proseal’s CNC manager indicates that the company has reduced its consumption of neat metalworking fluid by around 50% as a result of recycling and optimising the fluid used.

“The coolant recycling has become an invaluable system to us as a business,” he says, “and the benefits both environmentally and financially speak for themselves. We have reduced transportation cost, disposal costs, and ongoing costs as we are purchasing less neat metalworking fluid concentrate. As an example, we used to send two to three barrels of old coolant each week for disposal; this requirement has virtually disappeared as we now recycle the vast majority of our coolant. Even when we emptied five sumps recently for a machine move, we were able to re-use the coolant thanks to the Cardev system.

“In addition, the Motorex Swisscool 7755 Aero fluid is perfect for the mix of work we do. The vast majority is aluminium, but we are called on to machine stainless steel as well, so we needed a coolant that would work well with both. With the Motorex product we have witnessed lower top up rates, reduced evaporation and extended sump life so that we only empty and clean the sump once a year. Improved surface finish and the working environment is also improved.”

Managing the partnership with Proseal is Cardev-Motorex sales manager Alan Dalton: “Proseal is a perfect example of a customer embracing the total solution for metalworking fluids and recycling,” he affirms.

“We are supplying a total cradle to grave service for all of their metalworking fluid, lubricants and hydraulic oils. Our role starts from the initial fill of the machine’s coolant system with high quality Motorex metalworking fluids, through sump and coolant supply and lubrication system maintenance to recycling of used coolant and swarf.

“The Cardev fluid management systems that we have in place ensure that every stage of the process is covered and, as the figures are proving, the financial investment made can be quickly repaid, while at the same time the company’s environmental targets are also being met.”

ETL Fluid Experts www.etlfluidexperts.com