CASE STUDY I
Date: March 1997
The global CNC industry takes an step ahead towards effective coolant
management program with the use of Coolant Wizard Senior. This initiative economized
the cost of coolant consumption by reducing coolant purchases by 90%.
Coolant Used: Trim-sol, soluble oil and water miscible metal working
Problem: Coolant became rancid overnight, generating the need to
clean sumps frequently and dispose the coolant, thus increasing wastage &
Conventional Controls: Adding biocide and cleaning of machine sumps
on regular basis
Use of Coolant Wizard reconditioning system was in initiated in March 1996
and has been in use since then by different machine sumps to manage the
coolant. CNC Industries operate 24 x 7 and so does the Coolant Wizard. The
system processes each and every sump and when the last sump is done, it
starts over with the first machine again. A company that makes use of 10
machines having an average of 50 to 60 gallon sumps, the process time for
each sump would be 1 hr and 40 mins to 2 hours. One of the prime advantages
observed was that there has been no significant requirement of maintenance
of Coolant Wizard and the final filter elements lasted over a year.
Operator/ manpower involvement in the entire process is not more than 15
minutes per shift.
Before implementing the coolant management program the companies under
observation were buying 1 to 1.5 drums of coolant concentrate every month
and were having the spent coolant hauled away at a significantly high price,
and the entire process becoming an expensive affair, which also involved
huge wastage. But the Coolant Wizard, coolant purchase and disposed have
reduced down by almost 90% a year.
CASE STUDY - II
Date: March 1997
The Coolant Wizard System reduces coolant costs by 66% leading to cost
efficiency and effective waste minimization
Coolant Used: Blaser Swisslube 4000 CF soluble oil, water miscible
or metal working fluid.
Problem: Coolant purchases were excessive due to disposal and
Conventional Controls: Discarding a portion of coolant and adding
newly mixed coolant to reduce the tramp oil entrainment problem.
The company under observation machines stainless steel aircraft landing
gear parts, in addition to nickel and cobalt based alloys. The company has
more than 30 machines with sumps that range from 40 to 100 gallons each. It
installed the Coolant Wizard system in May of 1996, along with coalescing
and skimming unit, for effective reduction of tramp oil entrainment. The
unit operates the Coolant Wizard system for 20 hours a day and also
maintains a regular schedule to recondition all machine sumps. There has
been almost no maintenance of the Coolant Wizard system and use of minimal
consumables is also noted. Bacteria and fungus levels are reduced and
The purchase and disposal is notably reduced by over 66%, leading to a
three month return on investment. The quality of the coolant has been more
consistent, thus leading to better machining operations. Enhanced tool life
along with faster and deeper cuts is the present reality.
CASE STUDY - III
Date: June 1997
X-Rite resolves the increasing dermatitis problem, while reducing machine
downtime required to clean sumps. Coolant cost and disposal was
significantly reduced by 50% with the use of Coolant Wizard.
Coolant Used: AMACO semi-synthetic, water miscible metal working
Problem: Complains of odor and skin irritation by operators.
Downtime to clean the sumps was hampering production and the cost associated
with coolant was increasing.
Conventional Control: Adding biocides, dumping sumps and then
cleaning machines to eliminate odors.
X-Rite installed Coolant Wizard and trained its employees, establishing a
metal working coolant management program. The sumps were monitored every day
for concentration, adjustments to the fluid to maintain the level of
concentration and an overall housekeeping. The use of Coolant Wizard System
reduced the skin irritation, order was eliminated and the cost efficiency
increased. The Coolant Wizard is now use, two times a week on the machines,
on two shifts, while the operator involvement and filter element usage is
nearly zero, presently.
The fluid management program achieved the objectives and Coolant Wizard is
the only system that could suffice the needs of X-Rite in terms of size,
ease of operation and cost. Consequently, the cost involved in purchase of
coolant concentrate and in the disposal of spent coolant, costing a
roung$50.00 per drum, was reduced by more than 50%.