There are many costs to be aware of when running a machine shop, such as the total cost of managing and owning coolant. Managing these costs is a key to maintaining profitability.
Notably, the costs of fluids and fluid recycling have drastically increased in recent years. That is why paying close attention to how coolant is managed in your shop is essential.
Ensuring proper handling practices are implemented within your operations extends your coolant life and reduces the overall cost of ownership.
Coolant as a Living Tool
Many shops believe that managing coolant is a waste of time or that the coolant’s technology will allow it to ‘take care of itself.’
While it is true that technology has greatly improved the performance and longevity of coolant, it is essential to rely on proper handling practices rather than the coolant’s technology. This is because even though it is a liquid, coolant must be treated like any other tool in the shop.
Like any tool that must be repaired, maintained, and upgraded – your coolant is no exception. In fact, it must be cared for as if it were a living tool.
6 Best Practices for Handling and Managing Coolant
The best way to recycle your coolant is to take care of it. Proper handling practices can allow you to develop a strong in-house fluid management system. This is key to increasing your coolant’s life in the sumps.
1. Using a Coolant Mixer
Coolant mixers help extend the life of your coolant by keeping your coolant consistent and stable. Improperly mixed coolant can cause performance and even hygiene issues. A mixer accurately mixes the coolant, allowing you to maintain your coolant properly.
2. Monitoring Concentration
Maintaining proper concentration levels in your coolant will extend its life and improve its performance. If the coolant’s concentration is too high, this wastes coolant and can even create foam.
On the other hand, if the coolant’s concentration is too low, this spoils the coolant and causes foul odours. That is why an essential part of handling your coolant is monitoring its concentration levels.
The proper use of a refractometer plays an important part in this. Regularly using a refractometer to track the concentration of your coolant helps you protect your coolant life and quality. This has a major impact on your operation’s performance.
3. Minimize Tramp Oil
Tramp oil is a contaminant that negatively affects the life and performance of your coolant. It can damage tools, decrease production efficiency, and even create an unsafe work environment. This is because it can give employees skin rashes.
Investing in devices like a surface oil skimmer is key to minimizing tramp oil.
4. Top Off Machines Regularly
Regularly topping off your machines with coolant helps you save money. Since the water in your coolant evaporates, the coolant’s concentration gradually increases. That is why more coolant must be added.
Regularly topping off your machines lets you top off at a lower percentage of coolant. When you don’t top off regularly, you spend more money adding a higher percentage of new coolant to your sumps.
5. Maintaining Your Sump
Since contaminates are also in the machine, not just the coolant, dumping and refilling the coolant is not enough. Thoroughly cleaning the sump is a necessity. That is why cleaning your sump every 8-12 months is recommended.
However, when cleaning their machines, some shops choose to recycle their fluids completely. Throwing out all the used coolant is not always required. In some cases, reusing some of the old coolant and replacing it with new coolant is possible.
Completing a fluid analysis will determine what percentage of the old coolant can be reused, allowing you to reduce your recycling costs and carbon footprint.
6. Run a Rinse Cycle
A rinse cycle consists of filling the machine with a mild concentration of the new coolant. This rinses out contaminants, allowing you to maintain a cleaner coolant for longer.
Even brand-new machines need a rinse cycle. This is because, as previously mentioned, contaminants are also found in the machine.
See the comparison images provided by Blaser Swisslube to see the differences a rinse cycle can make.
Ask us about Blaser’s Seven Points of Success for more details on proper handling practices.
Negative Effects of Improper Handling
Unnecessary Costs
Hidden costs build up over time due to poor coolant management.
For example, think about the costs that rack up when coolant must be disposed every 6 months. There is the initial disposal fee, the costs that come with washing and prepping the machine, and the costs of putting in the new coolant.
These are only a few examples of costs shops face when disposing of coolant. In reality, the list of costs goes on and on.
The table below compares a typical machine shop with ten machines. It compares the differences in the costs of disposing every six months versus every 12 months.
| Sump Life (For a 2,500 Litre Shop) | EVERY 6 MONTHS | EVERY 12 MONTHS |
| Total Amount of Coolant to Recycle in a 12 Month Period | 5,000 Litres | 2,500 Litres |
| Recycling Cost (At $1.50 per Litre) | $7,500 per year | $3,750 per year |
| Time to Clean Machines (4 hours per machine x 10 machines) | 80 hours per year | 40 hours per year |
| Cost to Clean Machine in $ (Hours x $100 per Hour Rate) | $8,000 per year | $4,000 per year |
| Total Cost per Year | $15,500 per year in costs | $7,750 per year in costs |
Notably, this table does not include the cost of recharging after disposal, which can be significant.
With proper management, coolant can stay in the machine for over a year or much more. As shown in the table, costs are heavily reduced once the coolant’s life is extended.
Increased Likelihood of Tool Damage
Poor management of the coolant’s concentration could lead to tool damage and even lower tool life.
When the coolant’s concentration drops too low, foam is created. This causes corrosion, which heavily impacts the tool and the operation.
In fact, the damaged tool or machine could even cause workpiece inaccuracies. This increases the likelihood of scrap.
Manage Your Coolant to Maximize Productivity and Cut Costs
Coolant is a fundamental part of machining used in various operations, from turning to grinding. Your choice of coolant and handling practices have a major impact on the performance and life of your tools and machines.
Upholding proper coolant handling practices is important to reducing costs and extending your coolant life, but so is using the right kind of coolant.
Using premium coolant can reduce costs, extend coolant life, and even improve productivity and economic efficiency. For example, the B-Cool MC 600 from Blaser Swisslube is a universal and economical formulation that offers stable and safe processes. It is a high-performance metalworking fluid that focuses on making production reliable.
Additionally, proper maintenance of premium coolant will allow its technology to really stand out and operate at its full potential.
Are you currently maximizing your sump life? Do you want to know if your shop implements proper and effective handling practices? Contact the Triumph Tool team today for help! We’ll work with you to find the most fitting solution for your application.
References
Blaser Swisslube B-Cool MC 600