Coolant Management Guide

22
 Coolant Management 3

LUBRICANTS.
TECHNOLOGY.
PEOPLE.
We focus consistently on high-quality
lubricants and related specialties.

We develop innovative and holistic

solutions for a wide variety of
applications.

We value the high level of

commitment of our employees and
their trusting interaction with one
another.

Facts and figures

COMPANY:
FUCHS LUBRICANTS COMPANY, Harvey, IL, USA
FUCHS LUBRICANTS CANADA LTD., Langley BC and Cambridge
ON, Canada
LUBRICANTES FUCHS DE MEXICO SA DE CV
Querétaro, Qro., Mexico

NORTH AMERICAN PLANT LOCATIONS:

Harvey, IL; Kansas City, KS; Huntington, WV;
Langley, BC; Cambridge, ON; Querétaro, Qro., MX

FUCHS has developed, produced and sold lubricants and

related specialties for more than 80 years – for virtually all
areas of application and sectors. With over 100,000 customers
and 57 companies worldwide, the FUCHS Group is the leading
independent supplier of lubricants.

Our knowledgeable North American team works to ensure

the needs of our customers are met. We link inter-disciplinary
expertise between chemists and application specialists to
deliver innovative lubricant solutions to meet the current and
future demands, every single day.
 4

ECOCOOL Water-Miscible Cutting Fluids

Safe, economical and sustainable in use Optimum technical properties

FUCHS water-miscible cutting fluids meet all regulatory FUCHS cutting fluids fulfill the techni­cal requirements and
requirements and offer reliable performance and optimum make machining operations more efficient.
service life. Sustainability and workplace environment is
incoorporated into the products. ECOCOOL products provide:

▪ Optimum cooling and flushing

ECOCOOL cutting fluids are:
▪ Outstanding lubricity
▪ Free of nitrosamine-forming secondary amines
▪ Excellent wear protection
▪ Free of nitrites
▪ Effective corrosion protection
▪ Free of hard complexing agents
▪ Low foaming
▪ Skin compatible
▪ Good material compatibility
▪ Free of heavy metals
▪ Excellent EP properties
▪ Sustainable
▪ Increased productivity
▪ Economical
This means more than just reliability and worker safety. Available throughout the world
ECOCOOL fluids operate with low operating, maintenance, Our fluids are available to our customers on a global basis.
disposal costs and excellent overall cost of ownership. This means that all raw materials must be registered and
comply with chemical regulations in the respective countries.
FUCHS offers water­-miscible cutting fluids under the name
ECOCOOL GLOBAL which can be manufactured anywhere in
the world with the same formulation. This allows users to
pursue globally­harmonized manufacturing processes with
the same fluids.
 Coolant Management 5

Coolant Management - Making an Emulsion

Oil and water do not mix. That’s a very true statement and is Best practice is to premix the concentrate into water prior to
the reason for metalworking fluid formulations to contain introduction into a machine reservoir or tank. This is true for
emulsifiers. Emulsifiers are attracted to both oil and water both the initial fill of a system and also for make-up fluid.
and allow for oil droplets to be suspended in water. The Generally, since fluid loss is mostly evaporation of water, it is
amount and type of emulsifier, type of oil, water quality, best to proportion a much lower concentration for make-up
and especially how the fluid concentrate is mixed with water to avoid increasing system concentration to higher than
determine the size of emulsion droplets as well as the initial recommended levels.
stability.
If the concentrate is added directly to machine reservoirs, it
“OIL” is the best way to remember “Oil In Last.” The is best to add slowly to an area of high agitation as close to
addition of water to a metalworking fluid concentrate can the return line from the machining interface.
lead to an inverted emulsion that is thick and usually
unstable, not to mention an artificially high particle size that
decreases the fluid‘s ability to wet on metal and provide
lubricity. This is especially true in high oil water-miscible
fluids, but can also occur in lower oil semi-synthetic fluids.
Since synthetic fluids form a true solution, less precision is
needed when mixing concentrate into water.

Types of Proportioners
There are two main types of proportioning systems:

▪ Positive displacement mixers, driven by water ▪ Drum proportioners are less costly, and
pressure, mix coolant concentrate and water also mix less precisely than positive
to the desired concentration to a high degree displacement systems.
of accuracy.

With any of these units, it is important to maintain a consistent water pressure and to verify the
resultant concentration on a routine basis.
 6

Coolant Management - Fluid Monitoring

Concentration control is critical for the overall performance of water-miscible metalworking fluids. Low concentrations
can result in poor machinability, increased corrosion and poor product stability. High concentrations can lead to
foaming, misting, smoking and increased dermal and respiratory irritation.

Please consult the Product Information Sheet or contact your FUCHS representative for recommended concentration
ranges.

Refractometers
Handheld or digital refractometers are the most commonly used
method for checking fluid concentration. Perform the following
for proper use:

▪ Clean the lens properly

▪ Routine calibration

▪ Only place emulsion on the lens (no free oil)

▪ Consult the refractometer index or factor to find the accurate

concentration

Titration
Fluid contaminants, especially tramp oils, can make the use of
refractometers inaccurate due to the blurring of the indicator
line. Titration can sometimes add accuracy to concentration
determination. Titration kits and instructions can be obtained
through your FUCHS representative.

pH Measurement
Routine measurement of the pH (acidity / alkalinity) of the fluid
can often identify the presence of contaminants and provide
an indication of emulsion stability as well as presence of
biological activity in the fluid. The pH measurement can be
performed on-site with pH paper or with a portable meter.
Meters should be calibrated weekly for accuracy.

Biological Monitoring
Any fluid that contains water may contain bacteria and fungus
that can degrade the fluid causing poor performance, odors
and high fluid usage. Microbial dip slide tests can detect early
activity and allow for proactive treatment to increase the fluid
life, working conditions and overall product performance.
 Coolant Management 7

Coolant Management - Health and Safety

Machining fluids contain a complex mixture of several potentially hazardous chemicals. The Safety Data Sheet (SDS)
details risks associated with machining fluids, but it is important to remember that these risks are identified for the fluid
concentrate. Many of these risks are greatly minimized when the fluids are diluted with water for use and properly
maintained. Most regulations require exposure to metalworking fluids to be adequately controlled and reduced to a
minimum with all non-essential exposure minimized.

Employers are recommended to: Employees are recommended to:

▪ Assess the risks for workers and decide what ▪ Cooperate with employers and follow all of the
precautions are required training and instructions provided

▪ Prevent exposure to metalworking fluids or at least ▪ Utilize control measures and PPE
ensure exposure is controlled and minimized
▪ Report defective equipment
▪ Monitor exposure and conduct necessary health
▪ Attend and participate in all necessary health
surveillance
surveillance programs
▪ Refer anyone suspected of a work-related illness to
▪ Maintain fluid management procedures and
an occupational health professional to ensure safety
contamination control measures
and control measures are evaluated and maintained,
and that all procedures are observed

▪ Provide workers with sufficient information, training

and instructions for the use of control measures and
PPE equipment required

Reducing Inhalation
Oil mists and vapors can be generated by fast moving equipment and high fluid flow. Mist, vapor, smoke and fumes can
remain in the air for lengthy periods of time before sticking to surfaces or dissipating. These airborne substances may
contain substances that can trigger irritation or other symptoms.

Proper coolant control – minimize flow rates and pressures

Splash guards and enclosures – minimize introduction of

fluid into the air

Ventilation – adequate extraction and air filtration systems

reduce airborne contaminants

Compressed Air – when used to remove coolant and chips

from workpieces and machines, it can create unnecessary
additional mist
 8

Coolant Management - Protection for Skin

Effective Fluid Management

Machining fluids come into contact with skin throughout all

stages of the manufacturing process, especially the hands
and forearms. These fluids can cause skin irritation and other
fluid contaminants can increase the risk of dermal irritation.
This is why it is critical to have effective fluid management
controls in place. The edges of metal swarf, fines and chips
as well as other foreign matter can cause skin abrasions that
lead to increased dermal irritation.

Personal Protective Equipment (PPE)

PPE is designed to minimize fluid contact with the skin. All
PPE should be used in accordance with risk assessments and
regularly examined for tears and holes, cleaned and tested,
and replaced. It is important to wear PPE over dry skin and
avoid contamination when clothing is added or removed.

Hygiene
Good personal hygiene is vital to reduce the risk of dermal
irritation. Barrier creams should be used in conjunction with
proper PPE and only applied to clean, dry skin. Wash
exposed areas frequently and consider applying a
moisturizing lotion or barrier cream afterwards.

Additional information and guidance can be found on the OSHA website:

https://www.osha.gov/SLTC/metalworkingfluids/index.html
 Coolant Management 9

Coolant Management - Contaminants

Compared to other types of lubricants, water-miscible fluids need extra care and attention to insure they’re kept in good
condition. There are many types of contaminants that can have detrimental effects on these fluids with regard to
machining performance, housekeeping, and Health Safety and Environment (HS&E) considerations.

Bacteria and Fungus

One of the most significant causes of reduced fluid
quality and effectiveness is microbial contamination.
Due to water content and quality, airborne compounds,
tramp oils and metal fines; microbials can enter into
these fluids and cause degradation of the fluid, product
instability, odors, corrosion and residues.

There is no way of preventing microbials from entering

these fluids, but they can be controlled. Selection of an Tramp Oil
optimum fluid, keeping correct concentrations, removal Tramp oil is unwanted machine lubricants that have
of contaminants, tank side additives and preventative leaked into the coolant system. This is the most common
system clean outs can all be effective. type of contamination. It can contribute significant
“bacteria food,“ float on the surface and deprive oxygen
FUCHS personnel can advise on the safe use of more to encourage anaerobic biological growth that releases
effective products and / or tank-side additives when hydrogen sulfide odors, and cause emulsion instability.
other control measures have failed. Tramp oils can be reduced by fixing leaks and using
removal devices such as skimmers, weir systems,
centrifuges, coalescing units, filters and other means.

Metal Fines, Chips, and Swarf

Metal debris should be removed from the fluid on a
constant basis when possible. Removal of metal fines
maintains sump capacity for the fluid to cool the tools
and workpiece. Chip or swarf accumulation can increase
biological activity and the formation of insoluble soaps
that cause residue and emulsion instability, dermal
Water Quality irritation, and can be reintroduced into the cutting zone
A water-miscible fluid usually contains 85-98% water, resulting in tool damage and poor part quality. There
therefore water quality greatly impacts fluid are many forms of metal removal including magnetic
performance and life. Very soft water (0-20 ppm) can filters, cartridge, metal, paper or other filters,
cause foaming, while very hard water (>400 ppm) can centrifuges, chip drags, and just simple settling.
contribute to residues, staining and poor emulsion
stability. Many water sources are high in chlorides that
can lead to rust and corrosion issues. Deionization
systems and reverse osmosis systems can be used to
achieve higher water quality. Water sources should be
checked for the presence of undue amounts of microbial
contamination and low (<6.5) or high (>8.0) pH
conditions.
 10

Coolant Management - Removing Contaminants

There are many forms and types of contaminants that can be introduced into a machining fluid system. Leaking machine
oils (tramp oils), metal chips and fines, hard water residues, pre-process metal coating fluids, bacteria and fungus, and
general debris from the work environment. Removal of these contaminants is critical to prolong the life of the machine
fluid as well as to insure the stability of the fluid and its additives for optimum performance.

Removal methods range greatly with regard to design, cost and maintenance required.

Tramp Oil Removal Filtration and Metals Removal

▪ Belt Skimmer ▪ Indexing Paper / Cloth / Fiber

▪ Disk Skimmer ▪ Centrifuges

▪ Decanting Tanks ▪ Magnetic

▪ Coalescers ▪ Cartridge

Belt Skimmer Disk Skimmer Decanting Tanks Coalescers

Magnetic Centrifuges Cartridge

Notes
FUCHS Lubricants

Complete Solutions for all of your

Manufacturing Processes
FUCHS is the world’s largest independent manufacturer of lubricants with
the most extensive program of metalworking fluids. Our comprehensive
portfolio is supported by years of application engineering experience and
customized solutions to benefit your manufacturing processes.

ECOCOOL ECOCUT THERMISOL

MACHINING MACHINING: NEAT QUENCHING
§ High performance § Increased reliability § Low distortion
§ Economical § Economical § Low consumption
§ Outstanding lubricity § Low misting and § Good compatibility
low evaporation

RENOCLEAN RENOLIT RENOLIN

CLEANING LUBRICATION: LUBRICATION: OILS
§ Highly effective GREASES § Compatible
§ Unproblematic § Compatible § Excellent corrosion
processes § Long-term and life- protection
§ Outstanding long lubrication § Optimum wear
emulsification and protection
demulsification

ANTICORIT RENOFORM PLANTOCUT

PROTECTION METAL FORMING MACHINING: NEAT
§ Optimum protection § Cold forming § Non-mineral oil
§ Clean application lubricants for all § Low emission
forming applications § MQL
§ Compatible with
RENOCLEAN metal
cleaners

FUCHS LUBRICANTS CO. FUCHS LUBRICANTS CANADA LTD. FUCHS LUBRICANTS CANADA LTD. LUBRICANTES FUCHS DE
17050 Lathrop Avenue (Eastern Division) (Pacific Division)  MEXICO, S.A. DE C.V.
Harvey, IL 60426 405 Dobbie Drive 19829 99A Avenue Acceso C No. 101
United States Cambridge, Ontario Langley, British Columbia Parque Industrial Jurica
Phone +1 708-333-8900 N1R 5X9 V1M 3G4 76120 Querétaro, Qro.
E-mail: [email protected] Canada Canada Mexico
01/2020

www.fuchs.com/us Phone +1 519-622-2040 Phone +1 604-888-1552 Phone +52 (442) 2 38 91-00

E-mail: [email protected] E-mail: [email protected] E-mail: [email protected]
www.fuchs.com/ca www.fuchs.com/ca www.fuchs.com/mx