Lubsolutions Benelux BV in Gorinchem specializes in metalworking fluids and industrial lubricants and includes Fuchs' professional products in its program. According to director Dennes Lagendijk, a higher production efficiency can be achieved at many metal companies by better selection and coordination of all coolants and lubricants used in production. But not only that, because, according to Lagendijk, "good housekeeping" is at least as important in this context.
Partly because of the relatively high labor costs in our country, our manufacturing industry must produce at an optimum profit in order to remain internationally competitive. This can be achieved, for example, by more unmanned/manual production, but also by putting a heavier load on machines. This, without sacrificing service life, for example by applying high performance lubricants. The use of better tools, the introduction of tool life and vibration measurements and, last but not least, the application of high-quality metalworking fluids that are well matched to the machine and the tool increase overall efficiency.
In doing so, it is not only important that these liquids are used in the correct application and concentration, but above all that they are properly maintained. So we are talking about "good housekeeping" which includes much more than checking the concentration with a refractometer from time to time.
So what exactly does "good housekeeping" mean? "Unlike in the past, that concept has become quite comprehensive these days," Lagendijk explains. "Whereas in the past regular checks for bacterial growth, leakage oil, foaming and certain chemical values were sufficient, nowadays it is also very important to keep the liquid as clean as possible. So in this context we also speak of 'Good housekeeping' 2.0. Particularly machinists who work for demanding sectors such as semicon, optical industry and medtech do recognize this. More and more often, parts must be delivered very clean, with Grade 2 of exception increasingly becoming the norm. To raise awareness in this context, we also provide in-site training on clean working. Because remember, the cleaner the fluid stays, the cleaner the workpiece stays and the easier and better it is to deliver it in accordance with the required cleanliness class."
"In addition, of course, the fluid itself must also be kept in optimum chemical and biological condition," Lagendijk continued. "This not only for cost-effective and accurate machining, but also to extend the tool life of the fluid. Sometimes companies add products in the interim to inhibit bacterial growth and foaming, for example. This is neither wise nor necessary. We can take periodic liquid samples and analyze them for bacteria and the pH and BRIX values and adjust them if necessary. The latter two measurements, by the way, are also done in an automated emulsion refill system such as our L-smart system. This keeps the metalworking fluid in machine tanks in optimal condition, resulting in long service life, higher machine efficiency and lower fluid purchase and disposal costs. With the L-smart system, all measurement results are also stored in memory for later analysis and possible traceability consultation."
"Another very important phenomenon that greatly affects the service life, effectiveness and cleanliness of metalworking fluids is leakage oil," Lagendijk emphasizes. "Through the slideway lubrication, oil or grease enters the fluid. As oil and grease float on the fluid, the fluid present in the machine reservoir is sealed off from the outside air, resulting in bacterial and fungal growth. Not only does this impair the proper functioning of the fluid which has a major impact on both contamination and machining results, it also significantly reduces tool life. The use of a good oil separator combined with filtration keeps the fluid free of oil and other contaminants, which can mean a world of difference in terms of machine performance, workpiece cleanliness, fluid run time and operator health risk."
Another thing companies still need to pay close attention to is the composition of metalworking fluids. "Not every fluid is allowed from critical customers
used in the semicon or aerospace sectors, for example. Fuchs' newly developed Ecocool Global 1000 may. Also important is that these latest fluid generations do not contain boric acid, formaldehyde and MEA, making them people- and environment-friendly without compromising operational and economic properties."
Is it true that a professional, high-quality liquid normally lasts for many years? "Yes it is true. But there is a but to that," Lagendijk emphasizes. "Sometimes the wrong fluid is used for the type of material being machined. It also matters whether you are milling, turning or grinding. So proper selection based on machine, tool and material to be machined is crucial. In addition, you must monitor the fluid well, keep it as clean as possible and refill the machine reservoir in a timely manner with fluid prepared in the correct ratio. As mentioned, we can play an important supporting and advisory role here. Machine cleaning, lubrication maintenance, fluid monitoring and inventory management are among our standard services in this context. Only when everything is right do you achieve maximum machining results at the lowest possible Total Cost of Ownership (TCO)."