Cutting sludge recovery case: Cleaning once every 2-3 months has been reduced to once every six months!
The magnet separator method creates a difference in "sludge recovery capability" / The accumulation of sludge in the coolant tank of the machining center has drastically decreased!
Responding to on-site voices with implementation power! Cleaning costs cut by half. ◇ Introduction Background 〇 Fine sludge accumulates in the coolant tank of the machining center. 〇 The conveyor for chip discharge alone cannot completely remove the fine sludge from the cast iron processing process. 〇 Within three months, sludge accumulated to about half of the tank, which is approximately 400mm deep, requiring the line to be stopped each time for tank cleaning, among other issues. ◆ Implementation Effects ● After one and a half years of implementation, the amount of chip accumulation in the six months following installation is less than that in the three months prior to installation. ● Cleaning, which used to be done every three months, can now be done once every six months. ● In addition to labor and cleaning costs, coolant fluid costs have been reduced from approximately 400,000 yen annually to half, at 200,000 yen, after implementation, among other savings.
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◆ Standard (Fine Particle) Type (K/F) ◆ Secondary Filtration and Shaving Processing Compatible Type (KS/FS) ◆ High Filtration Precision Type (KD/FD) ◆ High Filtration Precision / Secondary Filtration and Shaving Processing Compatible Type (KSD/FSD) ◆ High Flow Rate Processing Type (K/F) (Details) ◇ Secondary Filtration Type (KS/KSD) - Recovers over 90% (by weight) of the mud-like sludge generated during machining of castings, which is below 100μ. ◇ Shaving Processing Compatible Type (KS/KSD) - Reduces chip clogging in the squeezing roller through P rollers and specially arranged magnetic drums. - Significantly reduces the amount of cutting oil used by decreasing oil carryover.
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Applications/Examples of results
◆ Coolant Treatment for "Grinding Processing" 1. Significant improvement in the recovery of grinding sludge from accumulated deposits in the grinding tank. 2. The in-house coolant purification system combined with fine magnets places less burden on the machine and improves yield rates. 3. The burden of tedious maintenance tasks has been greatly reduced, contributing to eco-friendliness. 4. The lifespan of the magnetic drum in grinding processing has increased, drastically reducing operational costs. 5. Maintenance such as coolant liquid replacement and cleaning in grinding processing has significantly decreased. ◆ Coolant Treatment for "Cutting Processing" 1. The lifespan of cutting fluid in cast machining centers has doubled. 2. The accumulation of sludge in the coolant tank of the machining center has drastically decreased. 3. Secondary filtration in cutting processing contributes to the recovery of particulate sludge. ◆ Coolant Treatment for "Shaving Processing" 1. Zero oil removal in shaving processing, contributing to the extension of pump lifespan.
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In manufacturing sites, we have extensive experience in using solutions for inbound and outbound inspection, pallet management, and access control management utilizing RF tags, as well as LORAWAN-related solutions and the development of smartphone and tablet applications. Additionally, we introduce the "FINE MAG" series from Sumitomo Heavy Industries Fine Tech, which has been implemented in many companies for "coolant sludge recovery devices." We offer a wide range of services, including software development, system equipment, and devices.
