Improved Coolant Stability and Reduced Oil Contamination at Lake Erie Screw Company
Continuous Belt Skimming Reduced Tramp Oil Accumulation and Extended Coolant Lifetime
Metalworking facilities depend on clean coolant to maintain machining accuracy, protect tooling, and control operating expenses. However, tramp oil contamination can quickly degrade coolant performance, leading to shortened fluid life, increased disposal costs, and unnecessary maintenance in relevant machinery.
The Problem: At Lake Erie Screw, a major Cleveland OH bolt maker, tramp oil contamination in coolant created big problems: when coolant came in contact with hot bolts during the trimming process, clouds of dense, hazy black smoke were created, which seriously affected air quality in the surrounding work environment. Chester Czerski, chief engineer at Lake Erie Screw, noticed that this was occurring because machine coolant was being combined with lubricating oil as it seeped from oiled parts into a common reservoir. As the oily coolant was sprayed on the hot bolts in the trimming operation, the oil smoked, emitting a heavy haze which hung in the air around each piece of equipment. At times, visibility in the area was less than 10 feet.
The Challenge: Tramp Oil Contamination in Coolant Systems
Over time, tramp oil entered the coolant from:
- Machine lubricants and way oils
- Hydraulic system leakage
- Production equipment operation
- Normal machining processes
This contamination created several operational problems:
- Shortened coolant life and effectiveness due to oil buildup
- Poor visibility in the working environment due to smoke
- Increased coolant replacement and disposal costs
- Potential odor and bacterial growth issues
- Increased maintenance requirements for coolant systems
The Solution and Measurable Results: Abanaki Model 4 Oil Grabber Oil Skimmer Improves Coolant Quality
To address these challenges, Lake Erie Screw installed 5 Abanaki Model 4 Oil Grabber Oil Skimmers to serve multiple areas of machining coolant; coolant from grouped machines is piped to a separate reservoir, and the skimmers remove oily waste at a rate of roughly 32 gph. Afterwards, clean coolant can be recycled back to the machines.
The Model 4’s operation is based on the principle that oil is attracted to and will adhere to metal while other liquids (ie coolant) will not. The endless metal belt draws oils up out of the liquid being cleaned, over the head pulley, and past wiper blades which remove oils from both sides of the belt. The oil then drains into a trough connected to a collecting tank or drum.
A unique part of this operation is the head pulley’s ability to drive the belt without interfering with oils present on both sides of the belt. A free-riding tail pulley stabilizes belt operation but permits bends around floating obstructions that might damage permanently secured equipment.
Today, Lake Erie Screw’s plant conditions have improved greatly, with a lower cost coolant undergoing continuous recycling for periods up to 90 days. Present coolants are 95 percent water and five percent soluble oil. Application of the coolant to the heated bolt in the trimming process produces virtually no emissions.
The skimmers continuously remove floating tramp oil from the coolant surface, preventing contamination from accumulating and allowing the coolant to remain effective longer. By separating oil before it can degrade coolant quality, the applications improve coolant and waste oil management throughout the whole operation.
Operational improvements and results included:
- Continuous removal of tramp oil from coolant systems
- Reduced frequency of coolant replacement
- Improved visibility and working conditions
- Improved machining environment and coolant performance
- Reduced maintenance associated with contaminated coolant systems
Quantified results:
- Reduced coolant disposal costs by approximately 75%
- Extended coolant life by approximately three times compared to previous operation
- Improved overall coolant management and machining efficiency
- Reduced waste generation associated with coolant replacement
