Machine Tool Coolant Filter Saves Major Automotive Company over $60,000 Annually, with Payback in Three Months -- A Real World Documented Case Study
Ask Filter Man
generated over $60,000 of annual savings, and a Return on Investment
(ROI) in less than three months on their filter purchase.
The idea was to discard the OEM-equipped replaceable media filters with
a Ronningen-Petter® self-cleaning filters.
The process in question was a group of three machining centers that
machine aluminum transmission parts. The fluid to be filtered--machine
tool coolant--is designed to lubricate, cool, and flush contaminants
away from the part and tool.
The fluid is collected under the machining operation where it is routed
through a set of weirs to separate out the large particulate. A pump
then sends the fluid to a housing containing three large 75-micron
cartridge filters.
The filters needed to be replaced three times per week, generating a
tremendous amount of annual costs to the automotive company. An
in-house filtration audit highlighted the recurring high costs of the
cartridges, cost of disposal, labor for change out, and machining down
time.
Other costs and inconveniences include tool life concerns, the
inability to separate harmful chips from the fluid, all resulting in
borderline product quality and safety concerns.
In their search for a solution for the costly and recurring problem,
the customer selected a Ronningen-Petter Magnetically Coupled Filter
(MCF), which features a permanent self-cleaning slotted filter media,
which effectively removes the harmful aluminum chips and fines from the
coolant.
The automotive company chose the Ronningen-Petter MCF filter for its
spring-loaded cleaning disc design that continuously regenerates the
open area of the filter media.
The engineers responsible for the machining centers requested tighter
filtration, 50 micron, upon installation as a potential opportunity to
increase tool life.
The new Ronningen-Petter MCF filter was installed seamlessly into the
existing space of the removed cartridge filter.
The new Ronningen-Petter MCF permanent self-cleaning filtration
equipment positively affected the machining centers with its ability to
more efficiently manage the full coolant flow and chip loading.
The more efficient cleaning cycle and purge frequency were adjusted to
meet the customer's needs.
Extending the cycle times greatly increased the life of the moving
parts, and allowed for a greater concentration of chips to be
discharged. The purge, or concentrated chip stream, was rerouted three
weeks into the installation back to a large paper band filter for
recycling purposes.
The quality of the filtrate under the Ronningen-Petter MCF filter was
evaluated every shift for the first few weeks to ensure the quality of
the machined parts.
Full evaluation of the economic impact of the MCF installation was
completed following three months of continuous operation.
The final review determined that the "Ronningen-Petter MCF paid for
itself within that three-month evaluation period."