What is oelSmart?
Being oelSmart is all about taking a proactive and whole-system approach to the management of metalworking fluids and associated systems, to make sure they’re working in synergy for optimal performance, productivity and machine operator protection, in a way that is right for you.
Why is synergy important? Well, one small change in any key element (fluid, filtration, mist extraction, or maintenance) can impact overall system costs, productive operating hours, regulatory compliance and product quality.
For instance, did you know that the performance of synthetic fluids is directly affected by your filtration method, or that the right mist extraction system can recycle filtered oils for reuse, that it is a legal requirement for LEV systems to be tested every 14 months, or that can be more economical to clean your system with coolant, rather than machine cleaner!
And oelSmart impacts the bottom line, by getting it right we’ve seen customers:
Resolve HSE notices
Increase tool life by up to 300%
Improve efficiency by 25%
Reduce machining times by 50%
So, how can you be oelSmart?
The good news is, your systems may already be well on the way to being oelSmart. We’re working on some handy tools you can use to assess your current oelSmart level and you’ll soon be able to book a complimentary oelSmart consultation with one of our experienced engineers who will work with you to assess your system’s performance, productivity and worker protection levels, or address specific challenges you might have.
In the meantime, use the information below to consider whether there are areas of your system’s performance which could be giving you more, and refer to our freely accessible oelSmart resources for technical information, H&S guides, troubleshooting, How-To manuals, and downloadable templates for you to use. We’ll be adding more soon, so check back or follow us on LinkedIn to hear about new oelSmart news, tips and resources as they’re released.
An oelSmart approach balances the system elements to create a performance level and cost that suits your processes and budget, and that doesn’t always mean the most expensive option. Our technical team is happy to act as a sounding board and talk through any planned changes you might be considering, or provide advice if you are experiencing any issues related to your fluids, filtration or mist extraction (e.g. workpiece quality variation, machine cleanliness, odour, visible oil mist) - for assistance please get in touch on 01745 814 777
FLUIDS
Providing cooling, lubrication and chip removal, metalworking fluids can directly impact surface finish and quality.
‘The oelSmart buyer’ key considerations:
Process type(s), quality requirements, materials machined, production volumes and speeds, available filtration, dragout levels, viscosity, flash point, budget.
The benefits of getting it right:
oelSmart Performance
Optimal cooling, flushing, releasing and wetting properties resulting in enhanced surface finish and workpiece quality.
oelSmart Productivity
Reduced lifetime coolant spend, faster processing speeds, extended grinding wheel and tool life, machine cleanliness and corrosion prevention, value for money.
oelSmart Protection
Protection for workers and the environment from exposure to potentially harmful substances such as heavy metals and aromatic compounds.
oelSmart Synergy Benefits:
Intelligent fluid additives include inhibitors to prevent cobalt leaching and detergents which protect the machine.
Certain base oils are more suited to electrostatic mist extraction and fine oil filtration.
Manufacturer recommendations are a guarantee that a fluid is proved to give the highest level of performance with their technology.
FILTRATION
Filtration is important for ensuring clean fluids are always available to be delivered to the workpiece.
‘The oelSmart buyer’ key considerations:
Coolant type, materials machined, automation requirements, coolant temperature control needs, in house maintenance availability, budget.
The benefits of getting it right:
oelSmart Performance
Consistently clean oil delivered to the workpiece allowing predictable and repeatable quality levels.
oelSmart Productivity
Extended coolant lifespan. Automation can reduce energy consumption, in house maintenance costs and facilitate 24/7 production.
oelSmart Protection
Removal of contaminants resulting in a reduced risk of worker exposure to substances, such as cobalt, which can present a health hazard.
oelSmart Synergy Benefits:
Effective filtration will extend the coolant’s lifespan.
Effective temperature control during filtration can reduce the oil mist extraction unit’s workload - a coolant with a lower temperature won’t produce as much mist
A well filtered coolant will elongate the service intervals on the mist extraction unit and protect the machine tool.
MIST EXTRACTION
Removing the fine oil mist created by high speed machining keeps the workspace air clean and free from inhalable oil droplets.
‘The oelSmart buyer’ key considerations:
Coolant type (e.g. oil or water based), coolant pressure, aerosol concentration, workroom volume, space available, operational hours, budget.
The benefits of getting it right:
oelSmart Performance
Electrostatic or mechanical, woven or non-woven filter media; the appropriate unit type will result in clean, safe air.
oelSmart Productivity
Reduced energy consumption, oil recycling, cleaner workspace, automation possibilities allow for on-demand extraction.
oelSmart Protection
Workers protected from inhaling oil vapour which cannot be coughed out, workshop surfaces free from sticky oil particles and a reduced risk of fire in the machine.
oelSmart Synergy Benefits:
The constant flow of fresh air from an extraction unit will reduce the temperature inside the machine.
The mist extraction unit can reduce the build up of coolant, which can damage surface coatings, within the machine tool.
Mist extraction units which are capable of recycling collected oil back in to the machining process reduce oil wastage and costs.
MAINTENANCE
Regular servicing impacts the reliability of systems to provide a consistent level of quality and avoid unexpected downtime.
‘The oelSmart buyer’ key considerations:
Overall system performance requirements, H&S regulations, in-house maintenance team, quality and risk management strategy, budget.
The benefits of getting it right:
oelSmart Performance
Appropriate servicing and maintenance contributes significantly to consistent, predictable, system performance.
oelSmart Productivity
Consistent performance and energy efficiency, extended coolant lifespan and downtime prevention through early problem detection and resolution.
oelSmart Protection
Systems provide sustained protection and remain compliant with H&S regulations relating to worker exposure limits and LEV testing.
oelSmart Synergy Benefits:
Correct maintenance of the filtration and mist extraction units ensures sustained performance and system reliability.
Regular maintenance plays a key role in preventing unexpected downtime by detecting issues early.
Certain regulations concerning filtration and mist extraction equipment require regular checks to ensure continued H&S compliance.