2023.09.15 UV, Work environment, Trends, FluidWorker 150, Automation, Sustainability

Automation replaces critical manual work that nobody wants to do

Despite recent decades of automation and robotization in the machine industry, cutting fluids are still handled manually and inefficiently. New solutions are now available, and the result is increased productivity, lower costs, and an improved work environment.

Cutting fluids are used to cool, lubricate, and transport chips during machining of metal parts. Until today the industry has been forced to accept two major challenges:

  • The fluids are consumed due to evaporation and drag-out via chips/workpiece and must be maintained at the correct quality, concentration, and fluid level
  • Most cutting fluids contain toxic chemicals that can cause health issues

Cutting fluids are important for efficient machining

Cutting fluids consist of 90-95% water and is an attractive environment for bacteria. Traditionally, various types of toxic chemicals (biocides) have been added, but the chemical legislation in Europe (REACH) gradually limits the use of harmful substances. In the last decade, the industry has struggled to find ways to ensure both long-lasting fluids and a good work environment effectively.

Effective machining requires high-quality cutting fluid, which is a mixture of concentrate and water. In order to work optimally, a range of ±1% concentration is typically required. Due to the constant evaporation and consumption, it has been difficult to manually maintain the specified value so there is an urgent need to find precise and automated control solutions.

Studies show that handling cutting fluids constitutes 8-16% of the total production cost. It is often a hidden cost with unclear ownership.

Long-lasting fluid without adding biocides

FluidWorker 150 is now used by more and more industries for automatic control while getting a long fluid lifespan without toxic additives. The automatic control function ensures correct concentration and fluid level, without any manual work. Fluid degradation by bacterial growth is significantly reduced by UV treatment. With FluidWorker 150 installed, operators can focus on production.

A proven solution

FluidWorker is a mature and well-proven product. It helps European industries to be competitive as well as attractive workplaces. The main benefits with FluidWorker 150 are:

  • Reduced consumption of cutting fluid
  • Improved production quality
  • Less unwanted manual work

The result is a longer lifespan of tools and machines, and a better work environment with less risk of allergies and respiratory problems. Companies that want to manage their environmental impact appreciate a lower climate footprint by reducing the amount of chemicals, waste, and transport.

To conclude, there are many reasons for metalworking industries to introduce automated fluid management. Studies also support this by showing a high financial return.

Ulf Arbeus
Ulf Arbeus

Ulf är VD för Wallenius Water Innovation och har mer än 15 års erfarenhet av företagsledande befattningar inom miljöinriktad verkstadsindustri, med huvudsaklig inriktning mot produktutveckling och innovation. Ulf is managing director for Wallenius Water Innovation and has more than 15 years’ experience of management positions in environmentally-oriented industries, mainly within product development and innovations. Ulf ist Geschäftsführer von Wallenius Water Innovation und verfügt über mehr als 15 Jahre Erfahrung in Führungspositionen in umweltorientierten Branchen, insbesondere im Bereich Produktentwicklung und Innovationen.


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