37 %
Yearly cost savings
The water-miscible coolant Mabanol Cut 264 BF offers the potential to increase productivity and conserve resources by extending emulsion service life and maintenance intervals. In our practical example at a mechanical engineering company, switching to the high-performance coolant Mabanol Cut 264 BF reduced coolant consumption by 29% and maintenance costs by 75%. Find out more insights here!
37 %
Yearly cost savings
3 %
Increase in productivity
29 %
Reduced coolant consumption
75 %
Reduced top-up concentration
75 %
Less maintenance costs
36 %
Less CO2 emissions
Up to 100° dH
Hard water stable
No danger
Of health issues
This testimonial is based on the experience of a single customer. The actual results achieved may depend on the type of machine used and its maintenance, operating and ambient conditions and the lubricant previously used.
Turning, drilling and tapping of free-cutting steel, stainless steel 1.4571 and high-alloy steel (SS1) is carried out on 35 machining centers. The machining centers are divided into the Shapes and CNC value streams and supplied with coolant via 2 central systems, each with a 20 cbm tank. The circulating volume of the value streams amounts to a total of 80 cbm of coolant in the Shapes value stream and 40 cbm of coolant in the CNC value stream.
Until now, a coolant based on amino-octanol and -propanol has been used. According to the GHS classification, this is classified as corrosive with the signal word “Danger”. To prevent the growth of bacteria and fungi, biocides and other additives were added, which resulted in considerable additional costs. The use of the previous coolant posed a risk of health problems for the employees.
With regard to the condition of the machines, constant gumming and sticky residues were documented in the machine rooms. The filter rolls had to be changed weekly. In total, the maintenance effort amounted to 8 hours a day and was associated with high costs. The high cleaning and maintenance effort also led to a decrease in machine productivity.
The search is on for a long-term stable coolant that ensures employee health, avoids the large number of setting agents and increases productivity.
Our lubricant experts have recommended the use of Mabanol Cut 264 BF based on the innovative DCHA emulsifier technology. The resistance of this technology to bacterial growth promises a longer service life without the use of a large number of adjusting agents. In addition, the product is skin-neutral according to a skin certificate.
Furthermore, Mabanol Cut 264 BF is resistant to hard water up to 100° dH during use, so that a permanently good rinsing behavior is offered.
Thanks to the high lubricating performance of Mabanol Cut 264 BF of 55% in total, even wear-intensive processes can be optimised and tool life increased.
Field test procedure
After extensively analysing the current situation and defining the project objectives, the Mabanol Cut 264 BF coolant and the BTB3 machine were selected as a pilot system for a field test by the internal project team in collaboration with our experts. This was followed by employee training by our lubricant experts and machine cleaning of the BTB3.
The field test was accompanied by regular coolant measurements by our lubricant experts. Other machine parameters and health aspects defined in advance were documented by the machine operators. Due to the positive field test results, the new metalworking fluid Mabanol Cut 264 BF was successively rolled out to all machines just 3 months later.
Results
Switching to the coolant Mabanol Cut 264 BF optimises the entire production process in many respects. Firstly, the emulsion service life was significantly increased and the consumption of adjusting agents at the centralised systems was reduced to a minimum. The annual coolant consumption is 29% lower than the previous consumption. The top-up concentration has also been reduced from 3% to 1%. The annual coolant costs are significantly lower, while the costs for biocides and other additives have been almost completely eliminated.
The lower coolant consumption combined with significantly less used emulsion also leads to a reduction in CO2 emissions of approx. 24.6 tonnes per year. This not only lowers procurement costs, but also conserves resources and reduces environmental pollution. The skin-neutral coolant also increases employee health protection.
Furthermore, Mabanol Cut 264 BF has a very good flushing capacity, which leads to a significant increase in machine cleanliness. No more deposits can be detected and the coolant exhibits excellent drainage behaviour. The filter rolls only need to be changed once a year and the daily maintenance work on the centralised systems has been reduced by 75% to 2 hours. This in turn reduces the use of materials and the associated costs and prevents production losses due to downtime caused by cleaning and maintenance work. Machine productivity was thus increased by 3% across the entire production process.
The high performance of Mabanol Cut 264 BF has proven itself across all tools and materials, ensuring the necessary wear protection throughout the entire process. Due to the excellent results at the pilot system, all machines were successively converted to Mabanol Cut 264 BF via the centralised systems. Further process optimisations are planned for the near future, which can be conscientiously implemented thanks to the high performance of Mabanol Cut 264 BF. By extending tool life, machine productivity is expected to increase by a further 3%. Due to the lower oil mist formation, the extraction capacity of the oil mist extraction system can also be reduced and consumption lowered even further. Thanks to the excellent rinsing capacity, it is also possible to extend the machine cleaning intervals from 1 year to 1.5 years.
To summarise, the high-performance coolant Mabanol Cut 264 BF increases employee health, process reliability and productivity, while at the same time helping to conserve resources and reduce environmental pollution.