With strong demand for highly innovative metalworking fluids, forward-thinking formulators are helping manufacturers meet the challenges by discovering the right chemical components and blending them in the optimal formulation.

In today’s competitive manufacturing environment, metalworking companies are continually searching for that next competitive advantage that will give them the edge – using new materials, adopting advanced manufacturing processes, attaining higher speed/feed rates, and more. While meeting new goals for quality and productivity, manufacturers are, at the same time, under pressure to lower total operating costs and the impact on the environment. That’s a tall order, but the right fluid can help. That’s why the demand for highly innovative metalworking fluids is stronger than ever.

Forward-thinking formulators are helping manufacturers meet the challenges by discovering the right chemical components and blending them in the optimal formulation, to find the best product fit to the customer needs. They must know the key drivers of their customers’ businesses and deliver. Not just on one or two, but on all of them – high productivity, low environmental impact, reduced cost and bio-stability, just to name a few.

1. Developing a Less Hazardous Metalworking Fluid

Environmental drivers: Government and corporate restrictions; and Consumption and waste reduction

Quaker formulators have the expertise to reshape processes and formulations to meet or exceed today’s environmental and safety standards and to help customers reduce wastewater and emissions. In addition, innovation in processes and formulations can extend the life of fluids and reduce consumption.

For example, by applying mineral oil-free, unique lubrication concepts to fluid design, we’ve been able to reduce system concentrations while at the same time providing superior machining performance. These innovative emulsion characteristics and properties can have a direct impact on the amount of fluid used per part produced. The amount of fluid used can typically be reduced 15-20% as compared to traditional metalworking fluids.

The reduction in fluid used per part produced also reduces the total water consumption of plant operations. This is a significant benefit in areas where water consumption is of great concern. Besides improving the lubrication at the machine tool/part interface, these new, novel emulsion packages have been proven to be very effective in defending against tramp oils and are very compatible with waste minimization technologies such as coolant recycling programs that reduce the total cost of ownership.

2. Developing Extremely Versatile Multifunctional Fluids.

Versatility drivers: Inventory; Logistics; Training; and Environmental reporting

A manufacturer’s ideal would be to have one fluid for their entire facility. Reducing the number of products on the plant floor reduces inventory costs, logistics costs, operator training and environmental reporting. The invention of new technologies allows for unique emulsion and lubrication combinations to effectively machine a number of alloys in various manufacturing processes. Results have shown very tangible reductions in tooling costs, up to 20-40% tool life improvement, as well as enhanced part quality. These mineral oil-free technologies are extremely versatile and can be utilised in heavy-duty applications such as tapping and reaming.

These new combinations have been tested on various materials from titanium and aluminium as well as machining ferrous applications. These product platforms are extremely versatile fluids and an excellent choice for large central systems to individual sumps and total machine shop applications.

3. Going Beyond Bio-Stability

Biostability drivers: Bacteria; pH; and Contaminants

Since the invention of emulsifying oil in water to create water-soluble coolants, controlling the biological growth of bacteria and fungus has always been a concern. The challenge with controlling biological growth is to create an effective bio-resistant control system that remains effective over the life of the fluid with normal maintenance procedures.

Controlling the pH of a coolant system has always been the primary method for controlling bacteria and fungus because elevated pH creates an inhospitable environment for bacteria and fungus to grow and multiply. Although maintaining pH is a very effective first defense in bio-control, other outside plant factors, such as dirt, air, and system carry-over, may inoculate the system with bacteria and fungus that require the use of bio-control material to eliminate the biological contamination and growth.

Typical industry bio-resistant testing for validation of coolant technology is a test in which the coolant is inoculated with bacteria and is tested for growth over an eight-week period. Quaker has gone beyond standard bio testing by extending the bio evaluation. We have utilized actual plant bacterium as inoculant in Quaker bio resistant tests. These improved and versatile bio-resistant packages have resulted in products that have passed these more stringent microbiological challenge tests. Quaker’s unique bio-resistant package is designed to resist degradation from tramp oil and other plant coolant contaminants.

Cold Temperatures, Frozen Product...No Problem!

As the winter season approaches and temperatures fall below 32°F (0°C), fluid products can be susceptible to freezing while in transit from our manufacturing location to your facility. Expediting freight and using a heated truck if at all available, are both expensive options. Shipment deliveries can also be delayed due to cold temperatures since some trucking companies will refuse to accept a shipment if the container has a “DO NOT FREEZE” label on it.

If this is a primary concern during the harsh winter months, consider one of many metal removal fluids Quaker offers that will withstand being frozen. Designed to retain its consistency, a portfolio of products can be thawed and ready to use with no impact on product performance.

Build Your Skills...

Dump, Clean and, Recharge (DCR) applies to single sumps or central systems in which the time has come to replace the fluid whether it is a coolant, cleaner, stamping fluid, or another water soluble product. A DCR needs to be conducted properly and in a timely fashion so that resources are not wasted.

A DCR is performed so that a stable situation can be achieved with the fluid being dumped. The reasons could stem from the following:

The fluid is too dirty with fines, tramp oil, or other debris
The system has a leak or mechanical issues
The microbiological level has reached a critical level that cannot be handled by the post addition of the necessary biocides; and
A change to a different product type is required to improve the operation.