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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,...
Three times longer sump life significantly saves costs

Three times longer sump life significantly saves costs

by | May 27, 2021 | Customer Cases

Three times longer sump life significantly saves costs Headquarters of IG EVEARTH located in Kariya city, Aichi Japan, the area famous for its automotive industry Unstable coolant and unpleasant odors in the shop were the main concerns of the manufacturing team from IG EVEARTH when visiting the Blaser Swisslube stand at JIMTOF. After a thorough analysis of the situation, the experts at Blaser recommended switching to Synergy 915, which not only solved the air quality problems but also reduced coolant costs and downtime for maintenance. IG EVEARTH manufactures high quality mold components for automotive The company IG EVEARTH was established in 1960. Its business is based on two main pillars: metal molding for automobile parts and manufacturing parts for prototypes in development. The company’s corporate mission is to satisfy customers and employees through high-tech manufacturing of automobile parts. The perfect metalworking fluid should be a first step in this process. Getting to the bottom of the unpleasant smell Mr. Masato Yoshino, a director at IG EVEARTH, says: “We were very aware of the problem of the nasty smell that our previous coolant emitted in our workshops.” When Mr. Yoshino visited JIMTOF 2018 with young leaders and associates from the manufacturing department, he made a point to visit the Blaser booth to talk about this problem. A few days later, an applications expert from Blaser visited IG EVEARTH and joined a project team together with one of the manufacturing team leaders who visited JIMTOF. The next step was to conduct a comprehensive analysis of the situation on the shop floor. This included review of the relevant CNC machines and materials, as well as specific cutting conditions and unique environmental factors like water quality. This information was considered together with IG EVEARTH’s specific improvement goals. After a thorough review, the team decided to test Synergy 915 coolant on two machines, one machining center and one lathe, in the headquarter production facility. The importance of a stable concentration Blaser also held a seminar on coolant maintenance for employees of IG EVEARTH. It was during training that the experts from Blaser learned the machine operators and technicians initially believed that the more concentrated the coolant was, the more stable it would be. However it is not necessarily a good thing for the coolant to be highly concentrated, and a high level of concentrate in the sump increases...
Holistic approach optimizes processes and tool life

Holistic approach optimizes processes and tool life

by | May 27, 2021 | Customer Cases

Holistic approach optimizes processes and tool life Tools and instruments of the highest precision and durability are manufactured at the headquarters in Wasen andSumiswald (Copyright PB Swiss Tools). Swiss tool and instrument manufacturer, PB Swiss Tools, and Blaser Swisslube agreed on a collaboration with ambitious goals in early 2019. By taking a holistic approach under the “Liquid Tool” banner and promoting a change of coolant, the aim was to optimize processes, increase tool life and reduce production costs. A test phase proved very successful, achieving the ambitious goals that had been set. Since then, the collaboration has been expanded to include further production processes. What started with the production of nose rings for taming oxen in the village blacksmith’s shop in Wasen in Switzerland’s Emmental region, evolved over the years into a global and innovative company synonymous with tools and medical instruments that are unrivalled for their precision and durability: PB Swiss Tools. The tool manufacturer’s history can be traced all the way back to 1878. It has been manufacturing tools since 1940, and medical products since 2013. Today, specialists in more than 80 countries choose PB Swiss Tools when their work needs to meet the highest quality standards. 180 employees in Wasen and Sumiswald manufacture 12 million tools and instruments each year. More than two thirds of these are exported all over the world. These tools and medical instruments from the Swiss Emmental are distributed to over 80 countriesworldwide, equipping production lines in a wide variety of areas, and provide valuable service in operatingtheaters (Copyright PB Swiss Tool) Blaser brand ambassador, Titan Gilroy, and coolant Synergy 735 caught the attention of PB Swiss Tools representatives at the Prodex exhibition in Basel in 2019. PB Swiss Tools Production Manager, Patrick Gehrig, was particularly interested in the holistic approach taken by Blaser Swisslube, increasing productivity and optimizing costs through the use of the Liquid Tool. “A visit to PB Swiss Tools’ shop floor was arranged to discuss potential collaboration,” explains Hans-Peter Dubach, application engineer at Blaser Swisslube. This visit was entirely consistent with the overall approach adopted by Blaser Swisslube: In addition to talks and discussions, all the production details were closely examined. Hans-Peter Dubach explains: “This includes an analysis of the water quality, the tools and machines used,...
High-performance grinding oil improves quality and economic efficiency

High-performance grinding oil improves quality and economic efficiency

by | May 27, 2021 | Customer Cases

High-performance grinding oil improves quality and economic efficiency Left to right: Roland Brouczek (Berner + Straller), Hugo Limmer, Linus Erlacher (Werkzeugschleiferei Hugo Limmer) and Martin Reichhart (Blaser Swisslube GmbH Germany) at the Rollomatic 620XS (Photography: Sonja Sindlhauser) In 2017, Werkzeugschleiferei Hugo Limmer, which specializes in the production of high-precision cutting and machining tools, started an initial test phase using Blaser’s Blasogrind GTC 7 grinding oil. The goals were ambitious: faster grinding processes, fewer dressing intervals and machine idle times, better process security, fewer rejects, better surfaces and optimum human compatibility. Blasogrind passed the test with flying colors, and all goals were achieved. Machine efficiency was increased by 15 percent. Werkzeugschleiferei Hugo Limmer was established in 2000 and is based in the quiet town of Waakirchen in Bavaria, not far from the shores of Lake Tegernsee. The company focuses on the production of high-precision cutting, drilling, milling and special tools, and on sharpening services for the mechanical engineering, aerospace and medical technology industries. Staff at the tool grinding shop have many years of experience and manufacture within very tight tolerances. Implementing such high-precision grinding processes reliably and efficiently calls for a suitable high-performance grinding oil. Looking for a coolant solution tailored to its production processes, company founder Hugo Limmer and the responsible industrial engineer Linus Erlacher contacted the specialists at Berner + Straller GmbH in Munich, the official business partner of Blaser Swisslube in Bavaria, Saxony and Thuringia. The experts from Berner + Straller and Blaser examined the grinding processes, looking for ways to optimize operations. The first machine was filled with Blaser GTC 7 in March 2017, and further machines were gradually switched over in the following years. Linus Erlacher inspects a cutting edge on the Zoller measuring machine (Photography: Sonja Sindlhauser) Ambitious targets At the start of the cooperation, a comprehensive analysis of the current situation was carried out and goals were defined. The new metalworking fluid needed to be almost odorless, as well as offering optimum human compatibility and low misting. “At the same time, we wanted to continuously improve productivity and quality, to get the most out of the available resources and in this way to add economic value,”...