Coolant filtration: savings and sustainability from VOMAT
Climate protection: the challenges for society and industry are enormous. Balancing the need for resource-conserving production, sustainability, climate and environmental protection with economic efficiency, while generating profits is challenging. Many production plants still have the potential to reduce their ecological footprint and one way for metalworkers to improve their environmental impact is by choosing a coolant filtration method which contributes to more sustainable production.
“ Political commitment or the setting of goals is not enough. What is needed now is a solid action plan and the right market-based incentives to switch to alternative and climate-friendly technologies. Today many of our customers in the tool industry already want to grind their tools in the most resource-efficient way possible. In sales or planning meetings, they are increasingly asking whether our filter systems can contribute to sustainability in production in addition to being highly efficient and contributing to quality. The answer is yes; the VOMAT units can significantly reduce resource requirements, making a positive impact on both the environment, and ongoing consumable and energy spend.”
VOMAT’s full-flow ultra-fine filtration technology provides permanently clean oil of the highest quality (NAS 7). Demand-oriented filtration and backwashing ensures reduced load on the filter components and reduces energy consumption
Optimisation for efficiency
In tool grinding, the filtration system provides the grinding process with lubrication and cooling at a pre-defined purity and volume flow. The heart of this system is the filtration of the cooling lubricant. Optimally filtered cooling lubricants have many positive influences on the manufacturing of cutting tools. In particular, they make the grinding process more economical and contribute to achieving high quality finished tools. Coolant lubricants which no longer need to be changed as often not only help to reduce maintenance time, but also lower the costs of fluid purchase, storage, recycling and energy consumption.
VOMAT manufactures filtration solutions from small stand-alone units to large-scale industrial central systems, which separate 100 percent of dirty and clean oil in full flow by means of durable high-performance pre-coat filters. The purity achieved is 3-5microns (NAS 7 standard). State-of-the-art filter, cooling and disposal technology, including HSS pre-filter systems for mixed processing if required, ensure economic and ecological effectiveness. In addition, VOMAT filters are low-maintenance and, due to their compact design, take up little valuable production floor space.
Adapted filtration performance to the production process
In VOMAT systems, the filter flow and backwash cycles are automatically controlled. This extends the service life of the filter elements and saves energy and costs. Many conventional systems on the market permanently filter at full filtration capacity, even if this is not required. VOMAT systems on the other hand, adapt to the production process. If, for example, the grinding machine runs at a slower speed, only the required amount of coolant is filtered. If a VOMAT central system provides filtration for several grinding machines, and some are not in operation, the filter capacity automatically adapts to the machining volume. At the same time, less cooling capacity is required. This reduces the energy consumption even further.
The machine supply pumps correspond specifically to the VOMAT units in both capacity and performance. The cleaner the grinding oil, the longer it can remain in the system and can provide better protection for machine pumps and lines
During cleaning in full-flow mode, the demand-oriented backwash cycle provides further advantages: with VOMAT filters, the backwash cycles are triggered by the degree of filter cartridge contamination. Once the relevant values are reached, the backwashing process begins, during which each filter is backwashed individually and with a time delay. The other filters ensure a continuous supply of clean oil. In the disposal unit, the dirty oil is separated from the sludge and then fed into the dirty oil tank. This fully automatic control of the filtration system keeps energy and operating costs low. In addition, VOMAT technology controls the temperature of the coolant during the grinding process within a range of ± 0.2 K, providing accurate workpiece quality whilst also extended the lifespan of the grinding oil. VOMAT offers various design options for cooling systems, such as pallet- mounted units for easy removal and re-assembly on-site without service personnel, and auxiliary units with an external condenser for cooling. Another option is a cold water-operated cooling unit with a closed loop piping system, such as the VOMAT’s modular and expandable KWS 250 chiller, complete with circulating pump and Eaton controls. The cooling capacity is 250 kW for brine operation with a control accuracy of +/-1.0 K. This particular unit does not require a buffer storage tank, can be installed in industrial outdoor areas, and offers excellent energy efficiency while maintaining high-precision temperature control.
VOMAT’s modular and expandable KWS 250 chiller is an excellent example of technology designed for accurate temperature control (+/-1.0 K), whilst achieving a high rate of energy efficiency
During cleaning in full-flow mode, the demand-oriented backwash cycle provides further advantages: with VOMAT filters, the backwash cycles are triggered by the degree of filter cartridge contamination. Once the relevant values are reached, the backwashing process begins, during which each filter is backwashed individually and with a time delay. The other filters ensure a continuous supply of clean oil. In the disposal unit, the dirty oil is separated from the sludge and then fed into the dirty oil tank. This fully automatic control of the filtration system keeps energy and operating costs low. In addition, VOMAT technology controls the temperature of the coolant during the grinding process within a range of ± 0.2 K, providing accurate workpiece quality whilst also extended the lifespan of the grinding oil. VOMAT offers various design options for cooling systems, such as pallet- mounted units for easy removal and re-assembly on-site without service personnel, and auxiliary units with an external condenser for cooling. Another option is a cold water-operated cooling unit with a closed loop piping system, such as the VOMAT’s modular and expandable KWS 250 chiller, complete with circulating pump and Eaton controls. The cooling capacity is 250 kW for brine operation with a control accuracy of +/-1.0 K. This particular unit does not require a buffer storage tank, can be installed in industrial outdoor areas, and offers excellent energy efficiency while maintaining high-precision temperature control.
Efficient recycling of valuable materials: getting the most out of your coolant
Offering not only advanced high-performance filters which clean coolants extremely well and ensure energy efficiency but also an inbuilt automatic sedimentation system also allows for sustainable recycling. Thanks to the proprietary design features of the VOMAT system, the grinding sludge has a residual moisture content of only 5 to 10 percent after settling. The filter system can continue to operate during the removal and disposal of recyclable material and the sludge is deposited directly into transport containers provided by the recycling company, ready for collection. In addition, coolant contamination from filter aids such as cellulose or residues of paper bands is eliminated with the VOMAT technology which not only saves money, but also resources and the environment.
VOMAT ultra-fine filtration units can be used for tool grinding machines processing carbide, HSS, or for a mix of the two and are available in various sizes to meet customer requirements. Standard flow rates are 70 litres/minute, 120 to 420 litres/minute and 480 to 960 litres/minute. In addition, customer-specific system configurations can be built to the required capacities for centralised systems. Both central and standalone units can be adapted to customer-specific or changing requirements by means of various expansion modules, such as special cooling concepts, machine pumps, additional tanks and recycling options.
“Our systems manage the balancing act between productivity and environmentally friendly production. Sustainability comes from all aspects of the manufacturing process and the bottom line is that VOMAT technology saves many resources such as machines, working time, space, energy and raw materials.”
As Vomat’s official UK agents, we are best placed to advise on any planned investment in a Vomat unit. Our technical expertise and understanding of the systems mean we can ensure the correct specification and configuration to work with your processes and machines, to avoid potential issues such as system overloading long term, or an incorrect installation.
To discuss your requirements, contact out technical team on 01745 814 777 or via sales@oelheld.co.uk
This article was published in September 2021’s edition of Grinding & Surface Finishing.
Read the whole publication, including features on all the topics listed below HERE
EMO Milano 2021 preview
Aerospace Report
Production Grinding
Grinding Wheels & Discs
Deburring
Measurement
Polishing & Lapping
Tell & Profile Grinding
Component Cleaning
Metal Finishing
