How to properly replace and use coolant?

Water-based coolant is one of the standard equipment of every professional production facility. Why? First of all, because it streamlines the entire production process, which translates into faster completion and increased efficiency. The use of coolant, however, must be done in the right conditions and with all the rules for proper operation. Otherwise, its effectiveness will be very limited.

First, however, it is worth looking at the composition of the coolant. This will help you understand the rules of use or the need for replacement. Water-soluble coolant is nothing more than a mixture of water and emulsifying oil. After combining, the preparation is characterized by excellent cooling properties (thanks to water) and lubricating properties (thanks to oil). In addition, various types of additives are added to the coolant in order to obtain the best performance when it is applied to a particular material. These can be, for example, biocides, dyes, emulsion stabilizers, collision inhibitors and many other packages. In this way use of coolant becomes more effective and simpler.

What affects coolant consumption?

Lack of knowledge of the nature of the substance and little experience can cause it to wear out quickly. Then there is nothing else to do but replace coolant. However, it can be counteracted. Of course, only to a certain, albeit significant, degree. It must not be forgotten that there are no permanent solutions. After some time, the coolant will need to be replaced anyway. However, this may be much later than usual.

So what is the most common cause of rapid wear and tear? This is largely due to poor quality water. Another common problem is poor preparation of the system for replacement, which results from little experience. It also happens that for the same reason the agent is not properly selected for the workpiece, and this translates into faster wear of the coolant or one of its additives.

Effects of improper use of coolants

Wearing and replacing the coolant comes with some difficulties. They can harm the efficiency of the production line and even the workers themselves. Therefore, it is necessary to regularly check the condition of the substance and strictly adhere to the rules of operation. Otherwise, it may go to:

– corrosion of some elements of the machine tool,

– problems with tools,

– decrease in emulsion durability,

– limitations of lubricating properties.

The examples above are for machines only. Unfortunately, the safety of people operating the devices is also at risk. The appearance of a specific, unpleasant odor after a few days of downtime is just the beginning of trouble. It can even cause respiratory allergies and skin problems for machine tool operators. Therefore, complete exhaustion of the substance should be avoided when using coolant.

How to prevent problems?

There are several ways to avoid the difficulties caused by coolant misuse. Particularly important in this regard is the proper preparation of machine tool systems for replacement. How to do it? It is enough to thoroughly clean the tank and the installation with a detergent and disinfectant. You can also use a pressure washer for this, and at the end rinse the whole thing with hot water with the addition of a delicate cleaning detergent. If there is an old emulsion in the system, it is worth removing it with a 2-3% solution of fresh emulsion. In more severe cases, you still need to use fungicides and bactericides. In terms of the number of doses of the preparations used, follow the instructions on the packaging.

Another way is to simply care for the emulsion combined with monitoring its condition. This consists of:

– supplementing losses with a specialized mixer,

– maintaining the proper coolant concentration,

– control of pH and the level of biological contamination (you can use pH-meters and commonly available bacterial tests),

– regular cleaning of the inside of the installation,

as well as checking any other parameters using appropriate measurement tools. Thanks to this, you can quickly react to any changes that may occur that could result in coolant consumption at the least appropriate moment. How often should this be done? It all depends on how coolant usage is in your facility. It is assumed that inspections should take place at least once a day.

Can coolant life be extended?

Absolutely possible. Just follow the above good practices. You can also do more. It is enough to equip the plant with regenerating devicese coolant and filter units. They are best used in combination with mechanical removal of impurities and irradiation with ultraviolet radiation. Then the effects will exceed all expectations. It is estimated that in this way you can extend the time of using the coolant up to several times. Unfortunately, this involves quite a serious investment, because devices of this type are not the cheapest. Small and medium-sized companies more often decide to outsource coolant regeneration services.

Which coolants to choose?

Unfortunately, there is no universal coolant. Therefore, it is necessary to carefully match the product to the needs and specifications of the machines. Of course, there are preparations with a very wide range of applications. They are worth recommending, although they will never be as effective as substances intended for a given material. Effective use of coolant should therefore take into account the type of machining process and the raw material used.

If you are unsure about the above, you can always contact the specialists. People experienced in the industry will be able to help you choose the right product and even give tips on the correct use of coolants. Therefore, it is worth taking advantage of their knowledge.

We especially recommend contacting our representatives. Melkib specialists will be happy to answer any question and help you choose the right coolant.