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Dry Cooling Method To Replace Metalworking Fluids

Dry Cooling Method to Replace Metalworking Fluids

There is now a proven green and clean method to cool and lubricate workpieces and cutting tools in the machine tool industry. Article by Oy ECE EcoCooling
Engineering Ltd.

Metalworking fluids are no longer needed to cool and lubricate workpieces and cutting tools in the machine tool industry. Instead, there is now a proven green and clean method that uses only ionized and cooled air and has none of the environmental hazards and costs related to oil-based fluids. 

EcoCooling is the result of long-term, interdisciplinary R&D from the same team that developed the optical technology behind Amazon’s ground-breaking family of front-lit Kindle devices. 

Now, the group of scientists, engineers and experienced businesspeople from various disciplines has developed a dry, clean and environmentally friendly method to cool and lubricate metal workpieces without using any emulsions.

“Workshops have wanted to get rid of the fluids and many have tried to find a solution to the problem, but with poor results,” says Leo Hatjasalo, co-founder and CEO of EcoCooling. “Now, we have the answer to this demand, since EcoCooling can be used when cutting and carving everything from high tensile steels and titanium alloys to plastics.” 

Big Market

The global market for metalworking fluids is estimated at about $12 billion this year. It is growing steadily, with estimates that the global market for machine tools is expected to grow from $120 billion to $150 billion in five years’ time. The growth is driven, for example, by the accelerating need for components in the aerospace, automotive and transport sectors.

”EcoCooling is not only a way to cut down the costs of emulsions, but also a way to boost productivity, minimize maintenance costs and improve occupational health and safety,” Hatjasalo says. ”Since the chips are not contaminated by the metalworking fluids, they can also be fully recycled without cleaning.”

The EcoCooling unit is very compact in size, and the system can also be easily retrofitted to older machine tools. The unit does not need any service and has been proved to prolong the lifetime of the cutting tools significantly.

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Blaser Swisslube Hosts Live Webinars

Blaser Swisslube Hosts Live Webinars

Blaser Swisslube is offering in-depth live webinars (blaser.com/webinars) for the coming weeks and months on topics such as coolant maintenance, microbiology and the underestimated leverage effect of the metalworking fluid on total costs.

Since physical meetings are hardly possible at the moment, Blaser Swisslube has quickly changed to online company tours and trainings. Anybody interested in the power of the metalworking fluid can therefore easily refresh their knowledge and learn new things.

“From basics to expertise, from analysis to monitoring and maintenance, our machining experts and chemists help you fully capitalise on the potential of your machines and tools and turn your metalworking fluid into a key success factor – a Liquid Tool”, explains CEO Marc Blaser the background of Blaser’s current training series.

Blaser Swisslube started on April 2, 2020 with internal online courses, so that employees can use the challenging time for their further training. In the first five weeks, the in-house Blaser College held in total 176 live sessions, which were attended by over 3200 employees as well as business partners and customers from all over the world. Moreover, since April 30, Blaser has been offering live events for the entire machining world. In the first of a series of webinars, attended by over 1000 people,

Chief Technology Officer Bernhard Gerber provided a look behind the scenes at the headquarters in Switzerland. He talked to machining experts and chemists from Blaser’s technology center and laboratory about the strong leverage effect of the metalworking fluid on crucial performance indicators such as tool life, cycle time, work piece quality and machinist satisfaction, as well as about the importance of regular monitoring and maintenance.

Since Blaser Swisslube has had positive experiences with its online trainings, they will remain an integral part of the training offer after the corona crisis. “We will focus on online and live trainings to provide our customers and partners with in-depth knowledge and experience,” concludes Marc Blaser.

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How A Metalworking Fluid Can Be Critical Success Factor

How A Metalworking Fluid Can Be Critical Success Factor

What prompted Yida Precision Engineering to switch to a new coolant fluid for its 17 machines? Read on to find out. Article by Blaser Swisslube.

Established in 2006, Yida Precision Engineering is an ISO-certified company operating from a 6,000 square feet facility and supporting customers with cost-effective, time-sensitive and quality assured precision engineering solutions.

The Singapore-based company employs around 50 people and serves industries such as the oil and gas, aerospace, semiconductor, as well as consumer electronics. Yida Precision Engineering always thrives for continuous improvement and serves their customers in the best possible way.

In an effort to achieve improvements in the workshop, including cleaner machines and better maintenance, Steven Boh, sales executive at Yida Precision, was keen to know more about Blaser Synergy 735.

Trials and results

Johnny Chia of Blaser Swisslube Singapore visited Yida Precision. “At the customer site, we first evaluated the given parameters such as water quality, materials to be machined, and the processes. Then, we recommended the appropriate coolant solution,” he explained.

Convinced that the new Synergy 735 is the perfect match for Yida Precision, Blaser experts convinced Boh, a long-time customer of Blaser’s, for a trial.

And so, the first machine was filled. For a period of four weeks, Boh and his team tested the new coolant in-depth.

“Synergy 735 convinced us with easy maintenance, and better tool life even for exotic alloys. Better surface finishing and better visibility trump up. As the colour of the coolant is transparent, we have a better view of the operation,” explained Boh.

But that is not all. He also saved money due to the lower concentration of Synergy 735. Thanks to the ideal formulation of Synergy 735, the coolant ensures long-term cleanliness of the machine. On top of that, the operators also profit from a cleaner workshop.

“With the new coolant solution, we were able to improve our competitiveness towards players from other countries,” said Boh. After the test-run, he switched all of his 17 machines to the new synthetic coolant, which features longer tool life and ensures a cleaner workshop.

Not only did Synergy 735 proved itself, but the continuous amazing customer service from Blaser Swisslube did as well. Blaser not only helped in regards to the coolant, but also provided Yida Precision valuable advice when it comes to machining strategy and programming.

Productivity, economic efficiency and machining quality are factors that critically depend on the choice and the quality of the metalworking fluid. “With our profound know-how and experience, customized services and excellent products, we help our customers to fully capitalize on the potential of machines and tools and to turn the metalworking fluid into a key success factor – a Liquid Tool,” said Marc Blaser, CEO of Blaser Swisslube.

 

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Blaser Swisslube Discusses How Liquid Tool Achieves The Milestone

Blaser Swisslube Discusses How Liquid Tool Achieves the Milestone

In an interview with Asia Pacific Metalworking Equipment Magazine (APMEN), Punit Gupta, Head of West Asia (India & SEA) at Blaser Swisslube, talks about the challenges and opportunities in the metalworking fluid market, a 20-year milestone project and his outlook for the metalworking fluid industry. Article by Stephen Las Marias.

Blaser Swisslube is one of the leading companies in the metalworking fluid sector. Founded in 1936, the independent and family owned Swiss company has since grown from a small business into a technologically leading global player, having a presence in 60 countries worldwide.

Out of total association of 15 years with Blaser Swisslube India, past 11 years, Punit Gupta has been the managing director of Blaser Swisslube in India. Starting January this year, he was given the responsibility to run the Southeast Asia market as well. In this interview with Asia Pacific Metalworking Equipment Magazine (APMEN), Mr. Gupta talks about the challenges and opportunities in the metalworking fluid market, a 20-year milestone project, and his outlook for the metalworking fluid industry.

WHAT OPPORTUNITIES ARE YOU SEEING IN INDIA AND SOUTHEAST ASIA, OR WEST ASIA, AS YOU CALL IT?

Punit Gupta

Punit Gupta

Punit Gupta (PG): As a whole, it is an interesting and developing market. The Indian market is largely dominated by the automotive industry with over 50 percent of the overall manufacturing share. However, interesting developments are also happening in aerospace and medical. More and more companies are setting up their manufacturing hub there—but I believe, looking into the future, automotive will still grow together with other sectors.

We hold a very good market share in India. In fact, we are the pioneer in providing technological solutions to our customers. We have around 2,000 customers—varying from small customers to very large automotive OES (original equipment suppliers)—and it gives me satisfaction that so many customers trust us and grow together with us.

When I look at Southeast Asia, I see very interesting markets. In Vietnam, there are a lot of investments happening in manufacturing from South Korea, Japan, and China. This country is growing rapidly. For the first Vietnamese car company, VinFast, we got a project. We have a couple of active business partners working here, who are very committed. Meanwhile, in the other Southeast Asia markets, like Malaysia, Singapore and Thailand, there is still a lot of potential.

Looking at the larger picture of West Asia, I would say there are a plethora of opportunities and we have a long way to go.

WHAT ABOUT THE CHALLENGES IN THE MARKET?

PG: If I talk from a customer point of view, the big challenge is competitiveness. In the aspect of globalisation, customers face competition from all across the globe. We now live in a Global village. And for that, they must prepare for a higher degree of competitiveness.

Today, manufacturers are constantly grappling with challenges of high productivity, uncompromising quality, cost-effectiveness and tighter deadlines to meet the ever-changing consumer demands.

The Liquid Tool from Blaser helps increasing the competitiveness of our customers. It brings transparency and a holistic view on overall returns on their investments. Productivity, economic efficiency and machining quality in the manufacturing process depend decisively on the choice of the right coolant. Hence, Blaser Swisslube endeavors to holistically analyse its customers’ processes to proffer them unique solutions for their challenges. This could mean reduced scrap rate or longer tool life and much more, based on the optimal coolant solution.

YOU’VE BEEN IN THE INDUSTRY FOR QUITE SOME TIME NOW. FROM A COOLANT STANDPOINT, HOW HAVE YOU SEEN THE INDUSTRY CHANGED OVER THE PAST DECADE OR SO?

PG: One point is the importance of the human health and the environment. This means a contribution to a greener planet. We see in many countries still a lack of regulation or awareness. Chemicals which are classified as not safe for human health and environment in Europe, are still in use in other markets. We from Blaser offer formulations, which do not harm the human health or the environment. This is one of our credos since 1936.

Second, customers have started to look at coolants as a valuable item. Around 15 years ago, customers had an opposite attitude towards coolants. Today, it has changed a lot. Their expectations are also changing. They are expecting benefit in terms of productivity and competitiveness.

So, overall awareness is increasing, and the market is maturing. And I foresee that in the next five to 10 years, this is one of the big jobs that we at Blaser Swisslube have to do: educate the customers more and more and contribute as a technology leader.

TELL US MORE ABOUT THE MILESTONE THAT YOU HAVE ACHIEVED RECENTLY.

PG: We have a unique technology, which we call Blasocut Bioconcept. The uniqueness of this technology is that the coolants are free from bactericide—they are one of the safest coolants in the world.

There have been many products based on the Blasocut Bioconcept. In India, we have one central system that has completed 20 years of sump life without a change. One of my colleagues from Switzerland travelled in 1998 to fill up this central system. At that time, Blaser India wasn’t even born.

The technology from our side plus the care from the customer’s side resulted in a system that is running for 20 years without a need to change the coolant in the central system. And this has been a big milestone for the company—Tata Motors—a very well-known company in car manufacturing.

WHAT’S THE IMPORTANCE OF THAT MILESTONE?

PG: There are many interesting facts to this achievement. One is the stability of the process. Second, if you look at the contribution in terms of the environment— there is the coolant disposal load, which we have been able to avoid. Furthermore, as we don’t use bactericide, we avoided the use of tons of bactericides for the whole manufacturing. Overall the contribution of the last 20 years to the greener planet is priceless.

WHAT OTHER INNOVATIONS HAS THE COMPANY DONE WHEN IT COMES TO COOLANTS?

PG: I would say Blaser is known for bringing out a lot of latest technologies and innovations in the market. This year, we have launched a unique and interesting formulation in water-miscible coolant, Synergy 735. This is a fully synthetic coolant—the first in the market—that has a neutral pH and it can work very nicely on aluminum as well as titanium alloys.

The coolant is very friendly on the skin and shows a very high performance. Plus, zero foam. Even at 70- to 80-bar pressure the coolant stays stable. We launched Synergy 735 in the US, then Europe, and now in Asia. Titan Gilroy, TITANS of CNC, is a huge fan of Synergy 735. According to his statement, it’s the best coolant he has ever used.

WHAT IS YOUR OUTLOOK FOR THE METALWORKING INDUSTRY?

PG: The current economic situation in the manufacturing industry, especially in India and Southeast Asia, is challenging. For instance, production levels are down in India’s automotive segment for over the past five to six months now. In Southeast Asia, we see challenges towards semiconductor and HDD manufacturing. But these are temporary issues. Therefore, I am positive. The market will bounce back. So, in terms of the overall growth, the opportunities in the markets, as well as our business in this whole region looks optimistic in my eyes. Our Liquid Tool is the absolute right fit for these markets and allows our customers to exploit more and more from their machines.

WHAT’S NEXT FOR BLASER SWISSLUBE?

PG: Well, working with more and more customers! We have to make our customers happy by improving their productivity and if they are happy, then we are happy too.

 

SIDEBAR

20 Years of Sump Life – And Still Going Strong!

Tata Motors is a market leader and pioneer in making commercial vehicles in India. In 1998, the company decided to enter the passenger car market with its Indica car. For their car production, Tata was investing in high-performance technology for aluminium machining for its plant in Pune. Among their main requirements were a high-performance material removal with a very good coolant system. After thorough research, Tata decided to start a partnership with Blaser Swisslube. This defined the beginning of Blaser Swisslube in India, followed by the founding of a subsidiary, Blaser Swisslube India, in 2001.

Hans Niederhaueser

Hans Niederhaueser

At the beginning of this partnership, Hans Niederhaueser (now retired sales manager) from Blaser Swisslube Switzerland came to India to personally fill the central system. “I still remember how it all started. I flew to India in May 1998 to fill the central system with 80,000 litres of our Blasocut 4000 Strong. I am very happy to see that the emulsion is still stable and running smoothly for 20 years now. By avoiding a huge quantity of coolant disposal from the last 20 years, the contribution to the greener planet is priceless,” says Niederhaueser.

The Blasocut Bio-Concept for a Greener Planet

Blasocut 4000 Strong is a coolant out of the Blasocut line. Featuring excellent human and environmental compatibility, the Blasocut technology has been able to contribute to the robust process of machining, providing high productivity and better machining quality.

In today’s manufacturing world, it has become a global requirement for all manufacturing industries to contribute towards a greener planet. There is a high level of awareness about the ill effects brought in by many factors of industrialisation. Sustainable technologies like the Blaser Swisslube Bio-Concept work in perfect harmony with nature. With the Blasocut Bio-Concept, emulsions need no tank side addition of bactericides. They stay inherently biologically stable and have a unique way of maintaining the long-term bio-stability of metalworking fluid emulsions.

The Bio-Concept uses an age-old law of nature whereby bacteria normally colonise aqueous media immediately. To keep the emulsions stable, deliberately foster this by creating ideal conditions for harmless primary bacteria, which are also present in drinking water, to build up a naturally stable biotope, where undesirable bacteria have no chance of propagating.

“At Tata Motors in Pune, the emulsion Blasocut 4000 Strong is still running great. Our specialists are checking and monitoring the emulsion on a regular basis to control the vital parameters like pH, emulsion concentration and many more. We offer each customer a tailored monitoring plan for their central systems. Customers like Tata not only want a cutting fluid, but also are looking for a competent and dependable partner to help organise and optimise their machine processes. With our committed team, we provide this partnership. The collaboration of 20 years is a result of trust and strong commitment from both sides, to deliver the best to the industry, environment and safety,” says Punit Gupta, Managing Director of Blaser Swisslube India and Southeast Asia.

 
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Metalworking Fluid Market To Hit US$14.5 Billion By 2025

Metalworking Fluid Market To Hit US$14.5 Billion By 2025

The global metalworking fluid market size is forecasted to reach US$14.5 billion by 2025, with a CAGR of 4.4 percent, according to findings by Grand View Research.

Metalworking fluids are used to reduce heat, friction and to remove metal particles in industrial machining and grinding operations. There are many formulations from removal fluids to water-based fluid and may be a complex mixture of oils and other additives.

Increase application of metalworking fluids in heavy machinery and automotive industries due to increase in production capacity are driving the growth for metalworking fluids. The automotive industry end-use segment will likely see a CAGR of 5.3 percent revenue by 2025. Furthermore, Asia Pacific has the greatest consumption of metal working fluid owing to the large number of suppliers and distributors. With substantial growth in the manufacturing sector for emerging economies, for example, rising production of aluminium in China, the demand for metalworking fluids is set to rise.

Major players in the market include Houghton, BP, Quaker, FUCHS, Yushiro Chemical, ExxonMobil, Henkel, Chevron, Blaser, PETROFER, Master Chemical, Buhmwoo Chemical, JX MOE, Dow, Francool, Talent, Sinopec, Oemeta, Milacron, Amer, Peisun, Boer technology.

 

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