ALFIE 500 coolant cleaning
For the metalworking industry, coolants are a major expense. Some are obvious: Replacing them – a messy and time consuming task. Disposing of them – a continually rising expense in the face of today’s environmental regulations.
Any Machine shop with more than a couple of machine tools can benefit from what the Alfie 500 has to offer – the ability to clean and recycle coolants and cutting fluids almost indefinitely and save enough.
within Alfie 500 working the first 12 months of operation to pay back the capital cost of the machine in full. Just take a look at the example set out below and you’ll rapidly appreciate what the Alfie 500 could do for you.
within Alfie 500 workingthe first 12 months of operation to pay back the capital cost of the machine in full. Just take a look at the example set out below and you’l rapidly appreciate what the Alfie 500 could do for you
Typical payback example
A typical engineering machine shop has 15 CNC machines, each with a coolant sump capacity of 500 litres. Due to coolant issues they are being emptied and refilled twice per year. The disposal cost of the coolant is £ 0.12/litre, system cleaner concentrate is £ 3.00/litre and new coolant concentrate is £ 3.50/litre.
- A. DISPOSAL COST (7500L X £ 0.12/L) £ 900
- B. SYSTEM CLEANER AT 2% (7500L X £0.06/L) £ 450
- C. NEW COOLANT FILL AT 6% CONCENTRATION (7500 X £0.21/L) £ 1,575
- D. DOWNTIME AT £50/HOUR (2 HOURS PER MACHINE) £ 1,500
- TOTAL COST (ASSUMING 2 CHANGES PER YEAR: 2 X £4,200) £ 8,850/YEAR
In addition to this typical cost you also have the cost of tramp oil and particles in the coolant causing additional tool wear costs. For example, according to The Institute of Advanced Manufacturing Sciences,Inc, we know that just 3% tramp oil can cause 15% reduction in tool life !. Back to our typical machine shop – the estimated tooling cost per year is £25,000 so a 15% saving is significant.
A. TOOLING COST REDUCTION PER YEAR (15% OF £25,000) £3750/YEAR
B. TOTAL SAVINGS BY USING ALFIE 500 £12,600/YEAR
GIVING A PAYBACK IN JUST A FEW MONTHS!
It doesn’t stop there!, other additional benefits/savings include:
- A. LESS COOLANT DRAGOUT £????
- B. INCREASED TOOL LIFE DUE TO FINE PARTICLE REMOVAL £????
- C. CLEANER MACHINES/WORK – LOWER MAINTENANCE £????
- D. IMPROVED OPERATOR HEALTH AND SAFETY £????
But dirty coolants also incur other less obvious but no less expensive costs. For example, tramp oil and solid particles in coolants can cause increased tool wear, quality problems during later processing and health problems for your personnel.
Benefits of the Alfie 500 include:
- Low fluid replacement/disposal costs.
- Longer tool lifetime.
- Cleaner components.
- Improved end-product quality.
- Less downtime for service since the separator is installed in bypass flow.
- Fewer man-hours required for maintenance of service fluids.
- Healthier work environment.
- Reduced impact on the environment.
Longer coolant life
Thanks to high-speed separation technology made simple and affordable, the Alfie 500 coolant recycling prolongs coolant lifetime by between three and five times. This reduces coolant disposal costs. It also lowers the costs associated with production stops to buy and replace coolant and to clean tanks since the separator can operate during production and when the equipment is idle. These cost-savings make investment in this separator a wise choice and one that, in most cases, pays for itself in less than a year.
Better product quality
Clean coolant contributes directly to overall product quality. The Alfie 500 keeps coolant clean by using just a single step to remove tramp oil and most metal particles down to 1 micron. This significantly reduces tool wear, results in fewer rejects and dramatically improves product quality. Since these contaminants no longer adhere to tool and component surfaces, processing precision is maintained and clean up simplified.
Healthier work environment
What’s more, using this coolant cleaner eliminates the unpleasant odors that can result when hydrogen sulfide gas forms from anaerobic bacteria that grows on the tramp oil in the tanks. The separator draws the tramp oil off the coolant and pumps it into a collection tank. This minimises the risk that machine operators develop allergies or skin problems from contact with the oils.
Ready to go
The Alfie 500 has got large wheels, so it will travel-even across uneven workshop floors. Its compact design occupies about a half square meter of floor space, making it easy to move through tight spaces to any location, including hard-to-access sumps. This versatility enables you to service just one tank, or several. The system handles coolant volumes of up to 15 m3 (7,500 gallons)-no small feat for a compact separator.
This high-speed separator comes with an added benefit: it requires no supervision whatsoever. In fact, it is so easy to operate that it practically runs itself. Just plug it in, connect the hoses at the machine’s bypass flow and press the start button. A PLC-based control system conveniently displays all functions on a control panel using easy-to-read symbols and clear text.
Truly the most effective cleaning method
High-speed centrifugal separation is the most effective way to clean all types of process fluids. Using the force of gravity to separate contaminated fluids in a settling tank is both time-consuming and largely ineffective. Heavy particles slowly settle to the tank bottom, while the lighter fluids rise to the top-and in between there’s a mixture that remains unseparated.In contrast, a centrifugal separator generally applies a force that is 5,000 times greater than the force of gravity to the process fluid to increase separation efficiency. The disc stack further enhances separation efficiency by providing a larger surface to which particles can adhere and directing lighter particles toward the bowl periphery. This makes centrifugal separation truly the most robust and efficient cleaning method for cleaning process fluids.