Centralized coolant recycling system for metalworking operations — proven to cut new coolant purchases by up to 76% and disposal costs by up to 91%.
Quick answer: The PRAB Guardian is a centralized coolant recycling system that recovers and reuses spent metalworking coolant by removing tramp oil, suspended solids, and bacteria in one integrated process. Guardian systems are proven to reduce new coolant purchases by up to 75% and cut disposal costs by up to 90%, with a typical payback period of 6–9 months. Use the Guardian ROI Calculator to estimate labor and cost savings for your specific operation.
Most coolant recycling systems only solve part of the problem — they filter particulate but leave tramp oil behind, or they remove oil but do nothing for bacteria and concentration drift. The Guardian is built around a simple premise: coolant recovery only works if all three failure points are addressed in one system. That’s the difference between a coolant filtration system that buys you a few extra weeks per sump, and true coolant recovery and reuse that measurably changes what you spend on coolant every year.
The Guardian Coolant Recycling System ROI Calculator is built on the same performance data as PRAB’s published case studies—not a generic industry estimate. It models your specific inputs (current coolant volume, purchase and disposal costs, and labor hours spent on sump maintenance) against the real-world reduction rates the Guardian has delivered in the field to project your savings on new coolant purchases and disposal costs, and your estimated payback period.
Because the underlying reduction rates are based on documented, in-service installations rather than theoretical maximums, the calculator gives plant managers a number they can actually use in a capital budget conversation. Most facilities see a projected payback in the same 6–9 month range PRAB has documented across dozens of Guardian installations — see how Iowa Industrial Hydraulics cut coolant waste 90% with a Guardian 400, or how Cameron International improved profitability after installing a Guardian system.
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Guardian systems use multi-stage filtration that combines magnetic separation and roll media filtration, as appropriate to your requirements. This staged approach removes solids, tramp oil, and emulsified contaminants—extending coolant life and reducing disposal costs.
Guardian succeeds where conventional systems fall short by combining:
This integrated process ensures recycled coolant meets performance requirements for reuse in machining and grinding operations with minimal manual intervention.
Coolant recovery and reuse is the process of removing tramp oil, particulate, and bacteria from spent metalworking coolant so it can go back into production instead of being hauled away as waste. A properly recovered coolant performs at or near new-fluid quality, which is why centralized systems like the Guardian are engineered around particulate filtration, tramp oil separation, and bacteria/concentration control together rather than any one step alone.
A basic coolant filtration system typically addresses particulate only, leaving tramp oil and bacterial growth unresolved — both of which shorten coolant life independently of solids content. A full coolant recycling system, like the Guardian, integrates particulate filtration, tramp oil separation (down to 0.1% or less), and optional ozone-based bacteria control in a single centralized unit, which is why it delivers measurably longer coolant life rather than just cleaner-looking fluid.
Documented Guardian installations have reduced new coolant purchases by up to 75% and disposal costs by up to 90%, with typical payback in 6–9 months. Actual savings depend on current coolant volume, purchase and disposal pricing, and labor hours spent on manual sump maintenance — the Guardian ROI Calculator models these against your specific numbers.
Yes. The Guardian is designed as a centralized system that processes coolant from multiple machines or sumps through a single unit, rather than requiring per-machine filtration. For facilities that need a smaller-footprint or portable option instead, PRAB also offers Mobile Coolant Recycling Systems for spot or multi-location use.
The Guardian doesn’t operate in isolation — coolant concentration control, chip and scrap handling, and wastewater compliance all connect to the same fluid recovery strategy. These resources go deeper on specific pieces of that system:
Successful coolant recycling requires particulate filtration, tramp oil removal, coolant concentration control, and bacteria elimination. The integrated Tramp Oil Separator removes up to 99% of free-floating and lossy emulsifying tramp oil. This process extends coolant life, resulting in up to a 75% reduction in coolant purchases.
The unit mechanically removes tramp oil dispersed throughout the media by a self-cleaning coalescing media compartment. The porous media pack is highly efficient, offering an optimum ratio of coalescent area in open space to pull the maximum amount of tramp oil from the fluid. PRAB’s weir design ensures the highest oil purity for maximum value. The PRAB Guardian is available in three different configurations.
Base
The PRAB Guardian’s base configuration includes the following components:
Standard
The PRAB Guardian’s standard configuration includes all components from the base version, as well as additional elements. Specifically, this package includes a polishing filter assembly rated at 20 microns and a Coolant Manager. Proven to kill up to 99.9% of coolant bacteria, the Coolant Manager is a safe, economical solution that generates and injects Ozone directly into the coolant.
This specific treatment extends coolant life up to 25% and eliminates odors, clogged coolant lines, and slime in sumps. As a result, this decreases the likelihood of employee health issues. Additionally, the coolant manager reduces biocide use and oxidizes bacteria, viruses, cysts, spores, hydrogen sulfate (egg odor), and other contaminants, both organic and inorganic.
Base configuration:
Additional features included in the Standard configuration:
Deluxe
The most robust Guardian package, the deluxe configuration, includes all the features of the standard version, along with additional components. In lieu of an inlet basket strainer, the deluxe uses a Paper Bed Filter with 10-micron-rated media. A dirty coolant transfer system is also implemented.
Base configuration:
Additional features included in the Deluxe configuration:
AC³
A fully automated coolant concentration controller that is compatible with HG1200 units and above, the AC³ will maintain set concentration levels within +/- 0.5% accuracy. The exclusive logic built into the controller allows more or less concentrate to enter the discharge flow of the Guardian system. This comprehensive system provides the necessary intelligence to accurately and automatically inject new concentrate only as needed to maintain optimum ratios and achieve maximum tool life.
| Model | Processing Rate | Dirty/Clean Tank Capacity | Length | Width | Height |
|---|---|---|---|---|---|
| HG400 | 10 gpm | 200/200 gal | 89″ | 73″ | 72.5″ |
| HG600 | 10 gpm | 300/300 gal | 126″ | 74.5″ | 76.6″ |
| HG800 | 15 gpm | 400/400 gal | 154″ | 76.5″ | 78.8″ |
| HG1200 | 15 gpm | 600/600 gal | 168.6″ | 77.5″ | 86.1″ |
| HG1600 | 25 gpm | 800/800 gal | 179.8″ | 90.3″ | 94″ |
| HG2000 | 25 gpm | 1,000/1,000 gal | 174″ | 91.3″ | 101″ |
| HG4000 | 25 gpm | 2,000/2,000 gal | 250″ | 91″ | 148″ |
Product Brochures
Product Brochure: Guardian Coolant Recycling Systems
Product Brochure: Coolant Manager
Product Brochure: Coolant Concentration Control
Product Brochure: Mobile Sump Cleaner
Product Brochure: Sump Cleaner Transport Options
Case Studies
Case Study: Aerospace Components Manufacturer Reduces its Environmental Impact and Cuts New Coolant Purchases by 75%
Case Study: Aerospace Components Manufacturer Turns Its Waste Stream into a Revenue Stream
Case Study: Auto Parts Manufacturer Reduces Coolant Purchase Costs and Eliminates Used Coolant Disposal in First 12 Months
Case Study: Cameron International Improves Profitability, Reduces New Coolant Purchases by Recycling Coolant with Guardian System
Case Study: Cashing in Your Chips
Case Study: Iowa Industrial Hydraulics Reduces Coolant Waste by 90% with Installation of a PRAB Guardian 400
White Paper
White Paper: Avoiding Accidents, Injuries & Illnesses In Metalworking Operations
White Paper: Getting the Most Value from Metal Scrap and Spent Fluids
White Paper: Green Engineering
White Paper: Making Wastewater Compliance Part Of A Profit Strategy
White Paper: Reducing Haul-Away Costs in Metalworking Operations
White Paper: Prioritizing Plant Housekeeping In A Metalworking Operation
Other Downloadable Content
PRAB Fluid Filtration Solutions Product Selection Chart Brochure
PRAB Fluid Filtration Systems and Wastewater Treatment Brochure
PRAB Filtration Spectrum Brochure
PRAB Builds Equipment for the Toughest Jobs in Manufacturing and Metalworking
PRAB completes comprehensive sample testing to establish an accurate understanding of the unique characteristics of your mixed solution and its industrial applications. This test determines the correct centrifuge system design and capacity to optimizes the filtration process within your facility
When you’re ready to get started, contact us or request a material test.
Successful coolant filtration requires three components (1) particulate removal, (2) tramp-oil removal, and (3) coolant concentration control. The Guardian™ Coolant Recycling System incorporates all three elements—not just pieces—for maximum coolant life. This combination makes it the most efficient option for centralized recycling of metalworking cutting fluids. If your current process is labor-intensive, requires a lot of downtime for sump maintenance, or lacks the capacity to handle all the fluid, it’s time for a change. In this video, see how the PRAB Guardian recycles your spent cutting fluids to significantly decrease coolant spend and eliminate tramp-oil issues.
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