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Sustainability is the primary objective

Sustainability is the primary objective

by | May 27, 2021 | Customer Cases

Sustainability is the primary objective Biral Headquarters in Münsingen, Switzerland The situation facing Biral AG, the leading Swiss pump manufacturer, in its production hall was anything but optimal, with an unstable emulsion and unsatisfactory coolant service life the least of the company’s problems. The greatest concern was the skin irritation suffered by three employees. Analysing the various manufacturing processes and switching to the optimal Blaser metalworking fluid transformed production into a sustainable process. Even more importantly, skin problems are now a thing of the past. View of the shopfloor Biral AG, headquartered in Münsingen, was founded in 1919. From the outset, the company built up its reputation as a manufacturer of state-of-the-art pumps for building services, municipal applications and industry. The 165 employees are committed to the goal of producing the best pumps around. The manufacturing process involves a comprehensive mate-rials mix. The pump housings are made from grey cast iron. Bronze is machined for various components, while aluminium and steel are also produced. Grey cast iron machining accounts for the majority (around 80%) of the production processes at Biral AG. Aluminium and steel make up around 15%, and there is one machine for working bronze. “It is not easy to handle such a diverse mixture of materials,” explains Martin Haas, application engineer at Blaser Swisslube, Switzerland. It was no surprise, therefore, that the situation in the pump manufacturer’s production hall was anything but optimal. The service life of the coolant being used was unsatisfactory, and the emulsion had to be adjusted at regular intervals by add-ing additives. Three employees complained of skin irritation caused by the unstable metalworking fluid. Faced with these problems, Biral staff were reminded of a metalworking fluid seminar at Blaser Swisslube. Biral contacted Blaser in search of a sustainable solution. Liquid Tool Blaser’s experts scrutinised all aspects of the situation in the production hall. “In combination with materials, tools and processes, the right metalworking fluid becomes a Liquid Tool. Our objective was to get the skin irritation under control and sustainably improve Biral’s processes by choosing the right product,” says Haas. The analysis focused in particular on the materials mix. We identified green discolouration, often found when working bronze. We therefore had to find a product that was also appropriate for...
Sustainable production thanks to the Liquid Tool

Sustainable production thanks to the Liquid Tool

by | May 27, 2021 | Customer Cases

Sustainable production thanks to the Liquid Tool Headquarters in Triengen, Switzerland Trisa AG, a leading global supplier of oral, hair and personal care products, faced problems in its production: it was using an unstable coolant that had to be changed every two to three months, discolored and left stains on non-ferrous metals and aluminum. Following thorough analysis by the specialists from Blaser Swisslube, the turning and milling processes were converted to the Vasco 5000 coolant. The results were gratifying: emulsion sump life was quadrupled, the process was stabilized and discoloration was eliminated. Trisa employs around 1,100 people in its entire group. The employee- and family-run company was founded in 1887 and has been in the hands of the Pfenniger family for four generations. While 50,000 toothbrushes were produced each year in the 1950s, this number has now risen to over one million a day. In 2018, consolidated sales amounted to 219.6 million Swiss francs. Trisa is based in Triengen in the canton of Lucerne. Andreas Meier, Head of Production at Trisa, contacted Blaser Swisslube in 2018. He was unhappy with the coolant situation in his company and was considering switching to Blaser Swisslube products. Following a change in its formulation, the coolant used had been unstable for some time. Additives had to be added constantly, but the emulsion sump life was still only around two to three months. In addition, there was staining on copper alloys and aluminum. This meant that tools had to be cleaned before machining. In short: process security in production was unreliable. The objectives were clearly identified at the start of cooperation: firstly, a stable, sustainable process needed to be achieved, secondly, both coolant discoloration and staining on metals needed to be eliminated. A Blaser application engineer visited the production site to get a precise picture of the situation in production. Different materials are processed, such as various grades of steel, copper alloys, aluminum and plastics. A variety of operations are used, such as milling, turning and grinding. “We also checked the water quality and found that only soft water is available. All of these factors influence the choice of the right coolant,” explains Marco Frey. The Blaser application technician recommended the use of Vasco 5000 for milling and turning. This coolant is based on renewable raw materials and is free from mineral oils. “The natural polarity of the oil...
Metalworking fluid helps to reduce tool wear by more than 20%

Metalworking fluid helps to reduce tool wear by more than 20%

by | May 27, 2021 | Customer Cases

Metalworking fluid helps reduce tool wear by more than 20% Satisfied customer at AMI Industries When AMI Industries, a precision manufacturer in Tainan, Taiwan, purchased a new machining centre, the German machine manufacturer recommended the use of Blaser Swisslube metalworking fluids. After discussions with the Blaser experts, the decision makers at AMI Industries concluded to start with a test phase. They set ambitious targets: extending the tool life, reducing the tool and production costs, improving the surface quality. With the holistic approach of Blaser Swisslube and a change to the metalworking fluid B-Cool 755, all these goals were achieved. AMI Industries Inc. is specialized in precision machining of complex components for the aerospace, automotive, medical, computer, hydraulic, optical, and pneumatic industries. The company was established in 2008 and is located in Liuying Technology Park in Tainan, Taiwan. The AMI Industries machinery park features the most modern multi-axis processing machines for turning, milling and drilling. When AMI Industries purchased a new machining centre, the engineers of the German machine manufacturer recommended the use of Blaser Swisslube metalworking fluids. AMI Industries contacted Blaser to find the ideal coolant solution. After first talks, it was soon clear that there was optimization potential in the whole production processes. “Our main goal was to extend the tool life, reduce the tool and production costs as well as improve the surface quality of the machined parts,” explains Mr. Jian Yao Huang, Manager Aerospace Business Division of AMI Industries. Dennis Wu, Blaser Customer Service Manager in Taiwan, recounts: “Besides a better cooling performance, a better surface quality and reduced cycle time, we also aimed for an improved dimensional accuracy.” In order to suggest an ideal metalworking fluid, the Blaser experts needed to evaluate the production processes, the machines, materials and tools thoroughly. This Blaser-specific integrated approach ensures that the metalworking fluid becomes a “Liquid Tool”, positively influencing parameters such as tool life, surface quality, and production costs. Produced precision part Test phase with B-Cool 755 AMI Industries and Blaser Swisslube agreed to conduct a first test on a vertical lathe in the production of aerospace engine parts out of Inconel 718. After careful consideration, Dennis Wu suggested the use of B-Cool 755. B-Cool is a water-miscible,...
Synthetic cutting fluid keeps shop cleaner

Synthetic cutting fluid keeps shop cleaner

by | May 27, 2021 | Customer Cases

Synthetic cutting fluid keeps shop cleaner without sacrificing performance The move to a new facility presented the opportunity to change the CNC machines over to a new metalworking fluid to improve air quality and cleanliness at Wells Manufacturing in Houston. Sometimes synthetic metalworking fluids end up negatively impacting tool life when used with tough materials. Wells Manufacturing overcame that issue when it converted to a new product from Blaser Swisslube. While preparing to physically relocate 14 milling and turning machines to his new building in Houston, Texas, owner James Wells decided it was the right time to examine every process at Wells Manufacturing for potential optimization. He had just invested in a new, larger facility with bright lights and shiny new epoxy floors intended to represent the culture of quality at Wells Manufacturing. But it wasn’t until he had to clean out his machines for the move that he thought about the metalworking fluids going into them. After a decade of filling the sumps with the same product, he recognized an opportunity to try something new in hopes of further improving the new shop environment. Mr. Wells met with John Hinders, the area manager for Blaser Swisslube, to discuss his options. “I suggested that Mr. Wells should try converting to one of our new products, Synergy 735. I thought it would improve the air quality and smell in the shop, and possibly improve tool life as well,” Mr. Hinders says. Owner James Wells shows Carsten Witthuser, general manager of Blaser Americas, precision-machined parts made at Wells Manufacturing of materials including nickel-based alloys, hardened steels and stainless steels. A synthetic solution Wells Manufacturing produces parts for many different industries, and that comes with a wide variety of materials including nickel-based alloys, hardened steels, stainless steels (including 13 chrome) and more. This makes Synergy 735 a particularly good fit for Wells Manufacturing because the metalworking fluid is specially developed for mixed production, Mr. Hinders says. Introduced by Blaser in 2018, Synergy is a completely clear, water-miscible metalworking fluid with a neutral odor. Despite the cleaner formula, the main concern at Wells Manufacturing was how a synthetic product would perform — and impact tool life — when used for machining tougher materials. In 2018, Mr. Wells decided to test the new metalworking fluid in one of his Doosan machines. It didn’t hurt that he had...
Optimum coolant ensures skin compatibility and increases productivity

Optimum coolant ensures skin compatibility and increases productivity

by | May 27, 2021 | Customer Cases

Optimum coolant ensures skin compatibility and increases productivity Serious skin problems among machine operators and the resulting high level of sick leave gave those responsible at Weber-Hydraulik GmbH considerable cause for concern. The culprit was the use of unstable coolant. Working with the experts from Blaser Swisslube, they switched the coolants B-Cool 755 and Synergy 915, which allowed the company to kill two birds with one stone: Skin problems are a thing of the past, while coolant life has increased more than fivefold and costs have been reduced by 75 percent. Weber-Hydraulik GmbH is an international expert in custom-made and reliable hydraulic solutions. For more than 80 years, the innovative Swabian family-owned company, based in Güglingen, Germany, has been offering sophisticated, application-specific system solutions according to customer requirements. They develop highquality cylinders, control blocks, steering and suspension systems, valves and aggregates for mobile machinery, commercial vehicles and machine tools as well as rescue equipment and components for renewable energy. Founded in 1939, the company is 100 percent family owned and has a turnover of around 300 million euros with more than 1,700 employees. The Weber-Hydraulik Group has seven locations worldwide. The company offers a wide range of manufacturing processes at the Güglingen, Germany location which includes both soft and hard machining as well as electroplating. Four years ago, an unstable coolant caused problems in the production plant in Güglingen. The sump life of the emulsion was very short at three to five months. The biggest challenge, however, was the serious skin problems among the machine operators, which led to a high level of sick leave. The works council and management were informed and the search for a reliable coolant partner began. The Güglingen, Germany location of Weber-Hydraulik GmbH offers a wide range of manufacturing processeswhich includes both soft and hard machining as well as electroplating. Holistic approach Seek, and ye shall find: After initial discussions with the coolant experts from Blaser Swisslube, our Regional Sales Manager, Jochen Rühle, examined the production processes at Weber-Hydraulik. “Numerous factors play a role in selecting the optimal coolant solution, ranging from the manufacturing processes through the processed materials to the water used. If the coolant is ideally matched for all conditions, it becomes a...
New cutting oil for maximized workplace safety and productivity

New cutting oil for maximized workplace safety and productivity

by | May 27, 2021 | Customer Cases

New cutting oil for maximized workplace safety and productivity © Intoolges The Catalan high precision manufacturer Joan Bonastre Group opened recently a new production plant in Barcelona. The modern building has the shape of a ship. After the Catalan high precision manufacturer Joan Bonastre S.A. opened a new production plant, the technicians identified a number of problems in the workshop: Smoke development and a strong odor. Additionally, the tool life and the surface quality were worthy of improvement. Together with the metalworking fluid specialists of Blaser Swisslube, the right tool was found to solve all these problems: A change to the Blaser cutting oil Blasomill GT 15 maximized both the workplace safety and the productivity. The Bonastre Group, based in Barcelona, consists of the Joan Bonastre S.A. and the Bonastre Biomed S.L. The family owned business has a long tradition dating back to 1958. The synergy between the manufacturing and engineering departments, the broad network of specialized suppliers and the more than 60 years of experience allowed Bonastre Group to establish itself as a leading manufacturer of all kinds of parts for medical devices and industrial products. The company is known as a benchmark for quality in advanced machining and high precision, offering added value and full service to its customers. Bonastre Group works with and for their clients, in personalized and confidential way, complying with the requirements and standards required. The company is certified with UNE 166002 as well as with ISO 9001 and ISO 13485, and in 2021 ISO 14001. Just recently, the high-tech company inaugurated a new production plant. © Intoolges The Bonastre family in the new production hall, where industrial products are manufactured. Already for several years prior to the opening of the new plant, Mr. Vicente Giner, CEO of Intoolges, the Spanish Blaser Swisslube business partner, has been in close contact with the Bonastre Group engineers, introducing the Blaser Swisslube product and the extensive concept of a Liquid Tool: When the metalworking fluid or cutting oil is tailored to the needs, processes, materials and surroundings, it can become a Liquid Tool and considerably improve the productivity and efficiency of the whole process. A new solution for the new production plant The production in the new plant started with neat oils from another manufacturer – but soon it became clear that a different solution was needed. Mr. Joan Jordi Bonastre,...