Recovery of Cutting Oil in 48 Machining Centers
A centralized system supplying 48 machining centers was experiencing serious issues: high levels of water and particle contamination were creating an unstable emulsion, forcing the cutting fluid to be disposed of frequently. The installation of a CJC® D30 Desorber with pre-filtration reduced the water content to below 300 ppm and drastically minimized particle levels, making it possible to reuse the cutting oil.
Resumen de la aplicación
Industry:
Industry
Country:
Germany
Type of oil:
Cutting oil, Zeller + Gmelin Multicut Basic 20 Extra
Executive Summary
The 48 machining centers drain their cutting oil into collection trays and mobile carts. From there, the oil is stored in IBC containers, with approximately 2–4 tank deposits per month. The recovered oil arrives heavily contaminated with water and particles originating from the machining processes. The water content ranged from 1,000 to 8,000 ppm. Due to the limited separation capacity, a stable water-in-oil emulsion formed, giving the fluid a milky and cloudy appearance.
The objective was twofold: to reduce the water content to below 300 ppm while simultaneously decreasing particle contamination, enabling the oil to be returned to the machining centers in a cost-effective manner. For the filtration trials, a CJC® D30 Desorber was installed in combination with a CJC® 27/81 Fine Filter.
Drastic Reduction in Water Content
In just 18 hours, the water content was reduced from 1,000-1,300 ppm to approximately 160-270 ppm, thereby stabilizing the cutting oil.
Complete Recovery of the Cutting Oil
The treated oil became clear and transparent, making it possible to return it to the machining centers for reuse.
Minimized Particle Contamination
Solid particle contamination was reduced by 84-95%, improving both the cleanliness of the oil and the operational reliability of the system.
Reduced Waste Volume and Lower Operating Costs
Up to 38,400 liters per year can be reused, reducing cutting oil consumption and lowering overall costs by approximately 30%.
Measured Improvement in Fluid Condition
After 18 hours of operation, equivalent to six circulation cycles, the water content decreased from 1,000–1,300 ppm to approximately 160–270 ppm.
At the same time, particle contamination was significantly reduced, and the appearance of the cutting oil changed dramatically: from milky and cloudy to clear and transparent. The analyses were conducted by independent laboratories to verify the results.
Results and Operational Impact
Within 18 hours, the cutting oil regained a clear and transparent appearance. The water content was reduced to below 300 ppm, and particle levels decreased significantly.
Based on these satisfactory results, the operator implemented automated timer-controlled operation for the treatment process. An 18-hour cycle proved to be the optimum treatment time for complete recovery of the cutting oil.
.webp)
Let our experts help you
Get a tailored assessment of your oil condition
and keep your equipment running reliably
