CASE STUDY – MACHINING & GRINDING
A major global manufacturing subcontractor of innovative braking systems for the automotive industry
was looking to:
- Improve machine performance
- Reduce overall cost
- Reduce waste of machining fluids used in the manufacturing of master cylinders, anti-lock brakes and the electronic stability program, brake calipers and brake forks
To address these needs, Quaker recommended the facility change to 2PAQ technology – in this case, a combination of QUAKERCOOL® W ALCA FF and QUAKERCOOL® OIL HR. Quaker wanted to show that the solution would provide overall cost savings by reducing:
- Waste/waste treatment costs
- Downtime due to foaming issues
- The number of machining and grinding fluids used
As a first step, the manufacturer introduced the combination of QUAKERCOOL® W ALCA FF and QUAKERCOOL® OIL HR for master cylinder production, involving one 20 m3 aluminum central system in one plant. During a period of two years with 2PAQ technology, no biocides were added to the central system – not only did this save money, but also increased worker safety.
Next, the facility introduced the same combination in the machining ABS and ESP department, involving one
100 m3 aluminum central system. The 2PAQ solution enhanced machine performance in the system by improving foaming properties, biostability and lubrication performance as well as offered more robust concentrates. In addition, QUAKERCOOL® W ALCA FF was used at a low concentration for high pressure deburring operations. This eliminated the need for a separate deburring product, and further increased cost savings related to waste treatment (the waste generated by the deburring process was absorbed into the system).