Cost Reduction for Machine Tool Processing - Hybrid Cutting Fluid Automatic Supply Device
The HCS-100 hybrid cutting fluid automatic replenishment system will enable the Japanese parts processing industry to achieve costs that are on par with those of emerging countries.
Introducing the powerful equipment, the HCS-100 Hybrid Cutting Fluid Automatic Replenishment System, which supports Japan's parts processing industry, renowned for its processing precision worldwide. This hybrid cutting fluid combines the properties of water-soluble cutting fluids and oil-based cutting oils, eliminating most of their drawbacks and showcasing only their advantages, allowing users to automatically generate this dream-like cutting fluid themselves. The conventional cutting fluid, consisting of 10% cutting oil and 90% water, is replaced by a 100% cutting fluid that offers superior performance. With over 50% annual cost reduction, there is no permanent spoilage or odor generation, extended tool life, reduced processing time, no foam generation, no rust formation, no need for additional fluid, and no replenishment work required from operators. Average tank capacity: 300L, dilution ratio: 20 times, number of tanks: 20. The cost difference between conventional equipment and the HCS-100 model results in a reduction of 5.5 million yen annually, totaling 16.6 million yen over three years. All manual replenishment work, new fluid, and additional fluid costs are unnecessary. We also assist companies with the application process for subsidies of 1/2 and 2/3. For more detailed information, please contact U.ENG. We look forward to the continued development of Japan's parts processing industry through cost reductions with this cutting fluid.
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basic information
【Annual Cost】 Number of M/C units: 20 units Average tank capacity: 300L Conventional cutting fluid: New oil purchase (dilution rate 20 times) Cutting fluid replenishment cost: New fluid, labor cost + waste liquid treatment cost (treatment cost + labor cost) Total annual cost: 8.2 million yen Hybrid cutting fluid: New fluid cost (production cost + additive oil cost) + replenishment cost (production cost + additive oil cost + no labor cost) Total annual cost: 2.7 million yen Annual cost difference: 5.5 million yen 【Performance】 ■ Tool lifespan increase: 50% Max ■ Processing speed: 30% Max ■ Processing of non-water-soluble cutting oil materials: Can be processed ■ Foam generation: Does not occur as surfactant addition is unnecessary ■ Rust occurrence on workpieces: No rust generation with automatic and reliable maintenance of ion water with pH above 9 ■ Excellent cleaning ability: Releases factories, walls, floors, machine covers, and others from stickiness ■ Odorless, non-decaying cutting fluid mist: Transforms the entire factory into a healthy air environment without unpleasant odors ■ Automatic management of hybrid cutting fluid: Maintains new fluid performance, preventing decay and performance degradation For pricing and detailed information, please contact 【U.ENG LLC, Uchiyama, TEL: 090-5763-3046】.
Price range
P5
Delivery Time
※Please contact us.
Applications/Examples of results
Number of machines: Approximately 10 to 30 units per machine. Interlocking with the machine-side tank is not required; replenishment will be done with a separately arranged tank liquid level up/down switch and automatic valve. The number of machine-side tanks will be approximately 10 units per block, connected by a common pipe for liquid level management. The replenishment piping to each machine-side tank can be extended and added sequentially.
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Company information
For the metal processing industry, reducing processing costs, minimizing the occurrence of defective parts, and increasing machine operating rates are important challenges. In particular, the chips that accumulate at the bottom of water-soluble cutting fluid tanks are sucked up by pumps, causing pipe blockages, defective products, tool breakage, and decreased machine operating rates. Additionally, the lubricating oil, fine chips, and sludge that float on the surface of the tank can cause the cutting fluid to deteriorate due to bacterial decay and unpleasant odors, drastically reducing its lifespan and increasing processing costs. Our company has been addressing these issues for many years. Users want to collect not only the sludge that accumulates at the bottom of the tank but also the floating sludge. There are complaints about the dewatering of the sludge. Users are troubled by uneven dewatering on the top and bottom surfaces of the recovery basket. Cleaning the basket inside the main unit after sludge recovery is very inconvenient. The FD-1 type sludge cleaner is a product equipped with excellent functions that solve all of these problems, which are not found in conventional products. We highly recommend that you confirm its performance with a demonstration unit.