Fluid Management Inc
Fluid Management Inc
3255 Spring Street NE
Minneapolis, MN 55413
Phone: (888) 227-8808
Email: info@coolantrecycle.com

Case Studies

Coolant Management Case Study 1

The site where this coolant management program was incorporated is a Southeast manufacturer of machined metal components. This company uses both CNC and manual mills, lathes, grinders, and saws. Their annual expenditure for coolant was $150,000; disposal cost for spent coolant was $70,000. Approximately twelve hours a week were spent removing spoiled coolant and putting in new coolant. This activity was conducted on an as needed basis during regular production hours resulting in about 630 hours of lost production time annually. Machine cleaning was minimal to reduce lost production time.

Fluid Management was contracted to manage the coolant at this facility to enable the customer to focus on their core competency. The Fluid Management program consisted of monitoring the coolant conditions at sump side and determining a machine cleanout schedule based on chemical analysis of individual machines. When coolant conditions warranted it the coolant was removed from the system and recycled. While the recycling was taking place the machine sump system had the chips removed and was then cleaned using a coolant friendly detergent. This process cleaned the tank, pumps, screens, and conveyor. Upon completion of the cleaning the recycled coolant was mixed with fresh coolant and brought to the correct mixture level for this machine. Machine sump maintenance was conducted during non-production time thereby eliminating lost production time.

The first year results were a reduction in coolant purchases from $150,000 to $50,000. The $70,000 disposal cost was eliminated, as all coolant was recycled, including coolant from the chips. The 630 hours of lost production was also eliminated as all machine maintenance was conducted during non-production hours. With machine time at $150 per hour an annual savings of $95,000 was achieved. Savings from scrap and rework were estimated at $500,000. Reduced tooling purchases were estimated at $150,000.

Savings summary

$ 70,000     Haul away of used coolant eliminated
$100,000    Reduced coolant purchases
$ 95,000     Machine cleanouts during non-production
$500,000    Reduction in scrap and rework
$150,000    Reduced tooling costs
$915,000  Total eliminated costs
$145,000    FMI Program costs (subtract)
$770,000  Annual savings
 
 
 
 

Case Study 2

A manufacturer in the upstate of SC has approximately sixteen machines and was using operators and maintenance personnel to clean them during normal production hours. Due to cost and storage of the spent coolant they were only cleaning their machines twice a year and disposing of the coolant. They were also disposing of run-off coolant from the chip hoppers every other month. According to their own numbers, it was costing them about twenty thousand dollars in down time, disposal costs, and coolant purchases.
We implemented an on-site coolant recycling and machine cleaning program for this facility, servicing the machines twice as often, at a savings of about eight thousand dollars.
The screw machines presented a unique challenge. Previously they had to clean these machines out annually and pay for disposal. Regulations required them to wait for delivery of the new oil until the old oil was disposed of. As a result, the machines were out of service for a week. The down time was costly and as a result the customer only cleaned these machines once a year. With our program we were able to clean all three screw machines and recycle the oil in one day. Because of the reduced down time the customer was able to increase the cleaning frequency to three times per year. The increased frequency resulted in decreased tool usage and improved surface finishes.
 

Contact Fluid Management Inc. for a discussion about how your company can start saving money on unnecessary fluid purchasing and coolant disposal.  Minneapolis, MN 612-378-2580 or click here to email us.

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