Amid a wave of economic uncertainties, there’s one thing metalworking operations can be sure of: even if the wave retreats, another one will come ashore at some point. Such is the cyclical dynamics of economic ecosystems.
This predictable rhythm of financial turbulence underscores the critical need for proactive and long-term strategies to mitigate cost pressures. Fluid reclamation, filtration, and reuse — for coolants, process water, and wastewater — represents a pathway for systematic cost savings.
For financial officers, plant managers, and engineers in metalworking operations, here are some tips to reduce two of your fluid filtration costs.
Identify ALL Coolant Costs
A global supplier of metalworking fluids (MWFs) in Ohio reports that coolant costs represent 1% to 3% of total manufacturing costs. Unfortunately, volatility in the cost of raw materials used to produce coolant, such as petroleum, triggers price increases.
The price per gallon of new coolant purchases is one important consideration. The total cost of ownership (TCO), which extends beyond the coolant itself, is another.
Metalworking operations that use twice as much coolant to achieve the same results inflate costs. However, tool life, decreased machine downtime, frequent sump cleaning, the addition of treatment chemicals, disposal, and environmental compliance lapses also contribute to higher-than-necessary expenses associated with managing MWFs.
How to Establish Coolant Savings
While contracting with a third-party service provider to collect and filter used coolant may be convenient, it increases the financial risk associated with volatile transportation expenses and other aspects of third-party reclamation. Operations that filter and recycle fluids in-house have more control over the costs.
Various technologies, ranging from paper bed filters and solid bowl centrifuges to oil recycling systems, tramp oil separators, and centralized fluid recycling systems, help manufacturers manage their coolant on-site. While the upfront costs of centralized fluid recycling systems are higher than those of less advanced filtration equipment, they are often equipped with less consumable media that needs to be regularly replaced, which helps keep the total cost of ownership (TCO) low.
For instance, The PRAB Guardian™, a centralized coolant recycling system, which includes coalescing media that provides longer-term use (six to 12 months of typical use compared to disposable filtration media) and an automatic air sparging system that decreases maintenance costs, can reduce new fluid purchases up to 75% and decrease fluid disposal costs by approximately 90%.
Machines operating with cleaner coolant also require less frequent maintenance and repairs. The Guardian™ also automates filtration processes, significantly reducing operator intervention and the potential for error. Typical payback for The PRAB Guardian™ is six to nine months.
Assess Process Water and Wastewater Costs
Failing to address process water and wastewater expenses is a financial liability that will increase exponentially in the years ahead. Here’s why:
How to Establish Process Water and Wastewater Savings
Mirroring the advantages of in-house coolant management, implementing in-house process water treatment and wastewater treatment offers metalworking manufacturers another significant avenue for cost reduction.
By treating and recycling process water and wastewater in-house, manufacturers realize four major benefits:
The cost of implementing in-house wastewater treatment technologies can vary widely, depending on the complexity of the system and the volume of wastewater being treated. Several factors contribute to this cost variability, including the required flow rates, the specific characteristics of the wastewater being treated, and the target level of the effluent for the treated water.
Oil-water separation, ultrafiltration, reverse osmosis, vacuum evaporation, and ozone and UV treatment are among the equipment forward-thinking companies are deploying in-house to lower their disposal and water costs. Additionally, automated pH adjustment systems are helping companies meet pH regulations prior to discharge.
Where to Begin
Choosing the most appropriate coolant or industrial water recycling equipment, or a strategic combination of technologies, depends on a careful assessment of the specific types and levels of contaminants present in the fluid, the required flow rates for the operation, and the output goal (reuse in the process, haul away, or discharge).
PRAB offers comprehensive fluid testing that establishes an accurate understanding of the unique characteristics of your mixed solution and its industrial applications. Contact us at PRAB.com to learn more.
