A company amalgamation prompted a critical reappraisal of cutting fluid policy to tackle problems arising from bacteria and fungi, and tramp oil contamination.

Prior to the merger of his two companies, TRI-Tech Engineering and  Micron Wykes Engineering, to create T G Engineering, Graham England was using up to 20 barrels of cutting fluid per year across the two sites and a total of 14 machine tools. This was made up of two different products from one supplier.

Contaminants were promoting the growth of bacteria and fungi in the cutting fluid causing degradation and premature failure of the sump, resulting in up to 30 - 45 cleanouts per year. In addition, tramp oil contamination was caused by the total loss slideway lubrication system which unfortunately is incorporated in the majority of modern machine tools.

In crude terms, the design of today’s machine tools can often encourage tramp oil contamination and poor cutting fluid life.

Other problems encountered were caused by hard water in the area. Water conditions in the vicinity are 250 - 270ppm CaCO3 resulting in hard water soap deposits and other associated issues such as corrosion smells and splitting.

England comments: ‘Following the amalgamation of the two companies I wanted to improve the overall efficiency of the resulting company and part of this was an urgent need to reduce our cutting fluid costs, particularly those resulting from machine downtime through short sump life and associated disposal costs.

'Ideally, one high performance global product capable of dealing with the various types of materials we work with, supplied by a single-source manufacturer who could offer us the service, back-up and support we required whilst at the same time satisfying COSHH and health and safety concerns, would allow us to improve our overall productivity and running costs.’

He looked at various options before choosing products from the ROCOL TRI-Logic system. ROCOL’s research and development team devised this synergistic system of cutting fluid, slideway lubricant and tapping fluid which work together to maximise metalworking fluid life and performance.

There are various cutting fluids and lubricants in the range depending on materials used and environmental conditions such as water hardness. All TRI-Logic metalworking fluids have been formulated to resist degradation in the sump and the system has been shown to significantly increase sump life, in most cases to at least a minimum of 12 months.

ROCOL advised on the suitability of each product and the decision was taken to invest in the TRI-Logic ALX maximum life cutting fluid for roll tapping, TRI-Logic VG68 patented slideway lubricant and TRI-Logic RTD tapping fluid that fortifies cutting fluid.

TRI-Logic ALX is proven to give superior finish and tool-life across all materials and machines and does not stain aluminium. TRI-Logic VG68 slideway lubricant incorporates special additives which prevent the oil being degraded by bacteria and fungi when it drains into the cutting fluid system.The final element of the TRI-Logic system is TRI-Logic RTD tapping fluid. When used in conjunction with water mix cutting fluid, tapping fluid creates yet another source of contamination when it is washed from tool and workpiece into the cutting fluid.

In order to avoid providing an additional food source for bacteria and fungi, TRI-Logic RTD has been formulated using 'biologically hard' raw materials. TRI-Logic RTD builds on the well established RTD technology, providing excellent tool life and surface finish.

T G Engineering took advantage of ROCOL’s Ultracare programme. Customers on the Ultracare programme receive regular visits from a ROCOL service engineer who monitors the condition of the fluid. In addition, operator training in best practice of metalworking management is offered and a metalworking fluid folder is provided to record full details of fluid checks and action taken.

By offering customers the Ultracare programme it is possible for users to save up to 40 per cent in metalworking fluid spend from a reduction in fluid usage, tool wear, downtime and labour costs and disposal. England continues: ‘I have been delighted with the professional service ROCOL has provided right from the start of our relationship and the results achieved have been fantastic. Initial purchase costs were reduced by approximately eight per cent per litre and with the regular and reliable ROCOL Ultracare service implemented, we have ensured maximum value and minimal costs.

‘In the first two years of use we reduced our fluid consumption for the 14 machines to approximately 10 - 12 barrels per annum, a saving of around £4000 per annum. In the third year T G Engineering amalgamated with another company, ENCO Engineering of Christchurch and that increased the total number of CNC machines to 20. However, we still only require 15 barrels of fluid compared to the 20 barrels we had been using on the original 14 machines; this provides another saving of around £1500 per annum. Downtime and waste volume costs are down resulting in improved efficiency. We have saved on average two clean-outs per machine per year, an approximate saving of between £2000 and £3000.

'In addition a number of our machines are still running on the original fill. The machine shop is pleasant and odour free thus satisfying any health and safety concerns and a recent poll indicated that our shop-floor users were happy, which all aids productivity.’

Graham England concludes: ‘Utilising the ROCOL TRI-Logic system in conjunction with the Ultracare service programme has dramatically reduced our costs, reduced our wastage and improved working conditions. Machine up-time has increased as well as our production output. We are able to concentrate on our core business without having to worry about cutting fluids.’

Rocol

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