Forward Thinking: New approaches to coolants are dramatically reducing resource use.

Stimulated by the need to meet the challenges of sustainable production, there is a wave of new thinking, technologies, and processes influencing manufacturers. One such concept is Resource-Efficient Manufacturing (REM) doing more with less and finding viable reuse and recycling technologies to conserve materials. These REM innovations are helping large-scale manufacturers meet stringent environmental targets and are increasing their competitiveness. The metalworking fluid industry is already playing an essential role in REM by providing smart, sustainable solutions towards resource efficiency. One global leader in metalworking fluids, Quaker Chemical, is putting sustainable chemistry into action by helping customers on issues of energy efficiency, waste reduction, safety, and durability through new approaches to coolant and cleaner use.

In traditional coolant/cleaner use, dedicated fluids are used for each purpose and disposed after one use. The approach Quaker devised is called 2PAQ. It includes a compatible, two-part coolant/cleaner that is used for a wide variety of operations. The fluid, when used as cleaner, can be repurposed in the cutting fluid tanks for top-ups therefore it is used twice. Ilievski says, The result can be as much as a 90% reduction in waste generation. This is dramatic, especially for customers with CNC units connected to large 100,000 or 200,000 liter centralized systems. The 2PAQ approach has helped Quakers customers be both eco-efficient and economically efficient. First, by reducing wastewater quantities, 2PAQ customers improve their environmental compliance. Second, the customers will see savings in a number of sources: Water consumption is minimized because the cleaners are reused for the makeup of the top-up emulsions. Energy and wastewater treatment costs are reduced because significantly lower quantities need to be treated. Capital investments in wastewater treatment equipment can be reduced or eliminated.

Rethinking Coolant and Cleaner Use

Incremental improvements in machining operations costs and sustainability can be obtained through conventional controls, such as closely monitoring and upgrading to more bio-stable coolants to extend sump life. But to achieve dramatic ecological and economic benefits, a completely new way of working is needed. Product Manager, Laurent Ilievski*, talks about how Quaker developed a new approach to coolants and cleaners. Most manufacturers operate on largely linear use of materials they employ a process where they inventory dedicated coolants and cleaners, they use them, and then dispose of them. We knew to get the resource reductions our customers were looking for, we would have rethink that whole process and change it from start to finish.

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Ilievski adds, One of our customers was planning to install a larger evaporator. Once 2PAQ was in place, they not only stopped running their evaporator the equivalent of three months in a year saving the related electrical expenses they eliminated the need for a new evaporator. Furthermore, 2PAQ has been shown to enhance machining performance especially in the foaming behavior and stability of the emulsion. Ilievski continues, This same customer, who uses a boron-free version of 2PAQ, added tank-side additives just once during the last year. And this was for maintenance purposes during the summer break. Thats a very significant improvement for them.

Proven Results
Quaker 2PAQ is running in 37 central systems globally some for nearly five years in the automotive and heavy equipment manufacturing industries as well as their component suppliers for brakes, engines, gears and more. Customers have achieved dramatic annual savings.

Here is one example:

A major global manufacturing subcontractor of innovative braking systems for the automotive industry was looking to improve machine performance, reduce overall cost, and reduce waste of machining fluids. Quaker implemented 2PAQ in four central systems in the customers facility. The change brought a quantified savings of 54,000 euros (approximately $73,800) in fluid related costs to the largest of the central systems.

The Essentials of 2PAQ

The 2PAQ concept is based on the versatility of its chemical components and a new way of working. A two-component fluid replaces many (sometimes 20 or more) dedicated fluids that a manufacturer uses for machining operations. 2PAQ is formulated in different solution ratios of the alkaline and oil phases mixed into water to prepare emulsions to meet a wide variety of different coolant/cleaner needs. For example, for operations that require higher levels of lubrication, the oil phase is used at a higher ratio to provide a more robust, high-performance micro-emulsion for machining cast iron, steel, and aluminum alloys. 2PAQs versatility also allows it to be used as a process cleaner. When the cleaner solution becomes saturated, instead of being disposed of, it is added to the coolant tank to aid with volume control (top-up).

Documented Annual Cost Savings

Waste Treatment: 35,000 to 38,000 Biocide Additions: 1,000 Top-Ups: 18,000

Courtesy of Ecofluide Filtration Equipment

With the versatility of 2PAQ, QUAKERCOOL Oil HR and QUAKERCOOL W ALCA are used for a wide variety of applications. The cleaner is recirculated into the coolant tank to be used again.

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An interview with 2PAQ Product Manager, Laurent Ilievski. Converting to the 2PAQ technology. Q: What does that the conversion to 2PAQ entail? A: Generally there are limited investments needed to make the conversion to 2PAQ. Many customers are already equipped with large centralized systems and the associated equipment. However, some may need to invest in equipment to recirculate the cleaners into the central systems. Q: Can customers top off their existing system with 2PAQ products or do they have to run down or drain the current system? A: You dont have to drain the system or waste what is in inventory as long as the existing material is chemically compatible. Quaker can help run tests to ensure the current products are compatible with 2PAQ. So far, we havent experienced any compatibility issues with a customers current systems. Q: How do customers learn how to create solution ratios for the different phases and for different applications, metal types, etc.? A: Creating the proper ratio is not difficult and the process is not really different from choosing an appropriate coolant. Quakers technical team works together with the customer providing training and support to ensure the proper makeup of the emulsion. Our technical team is generally on-site for all our customers managing large centralized systems and lab tests are available, when needed.

Quaker Chemical Corporation is a leading global provider of process chemicals, chemical specialties, services, and technical expertise to a wide range of industries including steel, aluminum, automotive, mining, aerospace, tube and pipe, coatings and construction materials. Quakers products, technical solutions, and chemical management services enhance customers processes, improve product quality, and lower costs. Quakers headquarters is located near Philadelphia in Conshohocken, Pennsylvania. * Laurent Ilievski works at Quaker European Operations in France. He is a global expert on cutting and grinding fluids with 20 years experience in that field. For more information call +31 (0)297 544644 or visit quakerchem.com.

What is Resource Efficient Manufacturing (REM)? It is a strategy that seeks to reduce the environmental footprint of an industry by doing more with less and finding viable reuse and recycling technologies to conserve material inputs. REM is about good ecology and it is good for business, as well. Numerous studies show the positive correlation between resource efficiency and competitiveness. REM has become a key strategy for companies to save money and reduce the environmental impact of their operations. The REM concept is well established in the EU where companies are given targets by government regulatory groups. It is taking root among large-scale manufacturers across the globe.

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