The most frequently overlooked issue in all of metalworking fluid management is distribution of the coolant.  Most shops in America have drums of coolant sitting and leaking in various places around the shop to provide easy access by people who know nothing about the chemical they are handling or how to manage its use in their machine.  As a result, they commonly put MWF in the wrong machines, in the wrong amount, at the wrong time, and in the wrong way.  While doing so they spill it, slip in it, and bath in it.

WHY?

Portable distribution is the easiest of all coolant issues to justify.  It's a no brainer for anybody with more than 30 machines.  If you have 80 or more machines, you can easily justify a Coolant Cart similar to the one pictured above.

The following memorandum evaluates the practical aspects of utilizing a Coolant Dispensing Vehicle in a medium to large manufacturing facility.  This opportunity is compared with the option of installation of a permanent plumbed, central distribution system.  Also included is a general outline used to facilitate a mutual understanding of the basic elements of metalworking fluid management.  If it looks like too much to read, skip down to the picture at the bottom and you'll get the idea.

Portable Distribution System Analysis

Strategies

Two strategies are considered improvements in the efficiency of operations for comparison:

1. Installation of a Central Distribution System.
2. Purchase of a Coolant Cart.

Either of these strategies will improve operations at most facilities.  The strategies are mutually exclusive of each other, in that implementation of either one negates the positive economic value of the other.  This results from partial commonality of utility between the two strategies.  Therefore, it is a "one or the other" analysis.  Both strategies address the same principal issues: Delivery of new coolant to machines.  Without a system for delivery, it is necessary to maintain a larger inventory of new product, maintain drums of the chemical throughout the facility, and suffer numerous other fundamental inefficiencies.

Central Distribution System

A central distribution system has the advantage of allowing the operator to add premixed coolant to his machine at any time, without requiring assistance from a MWF Staff member.

Advantages:

1. Elimination of requirement to call and wait for service to top off a coolant tank.
2. Elimination of manual transportation of coolant to machines.
3. Elimination of shop drum storage.
4. No requirement for special training by machine operators.

Disadvantages:

1. Does not eliminate or facilitate the inspection requirement by an MWF staff member.
2. Does not eliminate transportation requirement of used coolant.
3. Installation prohibits variation in coolant selection for individual machines.
4. Installation prohibits variation in coolant concentration for individual machines.
5. Requires facility-wide overhead plumbing.
6. Coolant may spoil in low-circulating branches of plumbing.
7. High initial cost.

Coolant Cart

The Coolant Cart is designed to operate in conjunction with a MWF Management System of scheduled maintenance, but is still effective even without a system.  Within the framework of a maintenance plan, the Coolant Cart is the nucleus of the service program.  With the Coolant Cart, the employee in charge can visit a large number of machines and satisfy all of the requirements of an inspection, including topping of tanks.

Advantages:

1. By mobilizing the inspection service, MWF Staff member can provide inspection service to a large number of machines in a single shift.
2. Machine filling is completed coincidental with the inspection service.
3. Digital read-outs allow accurate adjustments to concentrations and data collection of coolant usage per machine.
4. Elimination of requirement to call and wait for service to top off a coolant tank.
5. Elimination of manual transportation of coolant to machines.
6. Elimination of shop drum storage.
7. No requirement for special training by machine operators.
8. Elimination of all machine operator participation in coolant maintenance.
9. Coolant products can be varied to accommodate specific machining requirements.
10. Coolant concentrations can be varied to accommodate specific machining requirements.
11. All coolant storage tanks can be located together, outside of the shop, in a single location.

Disadvantages:

1. Cart chambers should be filled at the beginning of each shift, and possibly refilled during the shift (frequency depends on the use of concentrated coolant).
2. Cart must be recharged at the end of the day.  Batteries are typically good for 2 shifts.
3. Does not eliminate transportation requirement of used coolant.

Features:

1. Self-contained, customized electronics eliminate the need for hooking-up to shop electrical outlets or shop air for power.
2. Digital instrumentation provides precision read-out of volume of coolant dispensed.
3. Fully electric operation protects shop air quality and provides quiet operation.
4. Push button controls provide for simple operation.
5. On-board battery charger with retractable cord for added convenience.
6. Electronic "lock-out" of cart motor while pumps are running.
7. Instrumentation monitors cart battery system.
8. Design permits distribution of multiple fluids without cross-contamination.
9. Stainless steel construction eliminates corrosion and paint peeling.
10. Cart design may include tanks for concentrated coolant and/or premixed coolant.
11. Optionally, a pre-mixer can be mounted on the cart.

Recommendation

The obvious recommendation is the purchase of a Coolant Cart as superior in overall utility, flexibility, efficiency, quality control and capital cost over the option of a distribution system.  The estimated cost for a Coolant Cart is about $17,200 depending on the number of chambers and pumps required.  A central distribution system will typically cost several times that amount, provide less utility, and lock your facility in on the choice and use of a single coolant product.  A Coolant Cart is in use at Dresser Industries and the entire MWF maintenance system is built around the device.  It provides a safe and reliable means for maintaining the coolant on a large number of machines.  In addition to better quality coolant throughout the shop, the entire facility will appear cleaner and safer with the removal of all of the coolant drums and decanting stations.  Other than a Coolant Cart, only a recycling system offers greater savings, and recycling equipment can be used much more efficiently in a scheduled program which includes a Coolant Cart.

The Coolant Cart TM

The Coolant Cart is an entirely self-contained, stainless steel unit
that can be configured to dispense a multitude of fluids

The Coolant Cart is designed to operate in conjunction with a MWF Management System of scheduled maintenance, but is still effective even without a system.  Within the framework of a maintenance plan, the Coolant Cart is the nucleus of the service program.  Digital readouts totalize coolant dispensed for fast and accurate adjustment to machines with various capacities and for any difference between the measured concentration and the target concentration.  Customized electronics allow completely independent operation without the need for connection to air or electrical service.  With the Coolant Cart, the MWF employee can visit a large number of machines and satisfy all of the requirements of an service inspection, including topping of tanks. 

   Improve the quality of your MWF service and appearance

     of the shop.

   Eliminates storage of all MWF drums in your facility 

     (free real estate).

   Eliminates leaks, spills, safety hazards, misuse, and waste.

If you don't buy one from us, build your own.  It's not that difficult and you will save a ton of money.  You don't have to trust us on this, call the EHS Department at Security DBS division of Halliburton.  Ask them if you can borrow theirs for a month and see what they say.

*Notice to readers: This is the only product promoted by the publisher... so we may be just a little prejudice :)

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