FLUID INTELLIGENCE - Quaker Houghton Customer Solutions Centre · majority of Houghton’s soluble...

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E QUIPMENT

The answer to an age-old manufacturing problem, FluidWorker tackles bacteria in metalworking fluids with the use of innovative UV technology. With the ability to kill 99.9% of bacterial contaminates, FluidWorker extends the life of metalworking fluids safely and without the need for harmful chemicals and biocides.

Safe, Innovative and Money SavingWith continual changes to biocide legislation, rising costs and availability concerns, manufacturing companies are under increased pressure to find safe and sustainable methods for controlling bacterial contamination within their metalworking fluids. FluidWorker is a chemical free technology that enables companies to manage their process fluids both cost effectively and safely, whilst creating a safer working environment for employees.

Taking the lead in the environmentally safe treatment of metalworking fluids, FluidWorker makes use of UV-C light to affect the DNA of bacteria found within process fluids and prevent them from replicating.

In terms of real-life applications, this means that within hours, bacterial populations can be reduced by 99.9%, without the use of a single biocide. This not only saves manufacturers on the costs of expensive biocides but also on the costs of process fluids and waste disposal, as fluid lifespans are dramatically extended.

Here to Revolutionise the Metalworking Fluid Recycling Process Developed in Sweden by Wallenius Water Innovation, FluidWorker is a ‘plug-and-play’ solution that can be installed with no machine downtime, supporting production process straight away.

With rental rates starting from £155 per month*, FluidWorker has the ability to support manufacturers immediately, without any costly outlay.

Houghton can also support with the installation and setup of the unit, alongside providing all the production support required through Houghton’s comprehensive fluid maintenance management programme, Fluid Intelligence.

By eradicating the use of damaging biocides, clients stand to reduce their environmental footprint and look after the beating heart of their processes – their employees.

Alongside its health and safety benefits, the self-cleaning FluidWorker will also save clients time. Rather than continually checking up on bacteria levels, the FluidWorker can simply be turned on and left to monitor accordingly.

*Please find various rental packages on the last page of this brochure.

CHEMICAL-FREE SOLUTION TO BACTERIA CONTROL

COMPLIANCEFluidWorker ensures environmental and workplace health safety compliance, whilst supporting a more pleasant factory environment.

PRODUCTIVEA ‘plug-and-play’ solution, FluidWorker is a stand-alone unit with a small physical footprint, able to fit amongst your existing machinery effortlessly, resulting in less downtime and increased efficiency.

COST EFFICIENTAvailable in a range of competitive rental rates, FluidWorker extends the lifespan of process fluids, reduces the vast expenditure on waste disposal and removes dependency on biocides.

IN BEST PRACTICEFluidWorker ensures manufacturers are adhering to best practise with the effective, cost-efficient and HSE compliant treatment and reprocess of production-vital metalworking fluids.

YOUR TRUSTED AND ESSENTIAL STRATEGIC PARTNERS.

FLUID INTELL IGENCE

INDUSTRY REFER ENCES

01

Innovative Bacteria ControlThrough effective recycling, our customer was able to capture approximately 1000 litres of used metalworking fluid every 24-hours for reuse within their machine tools. Whilst this proactive activity was helping the plant reduce costs, shop floor employee’s were complaining of poor odours and concerns regarding the quality of the coolant. After a detailed investigation by Houghton, it was established that the processed fluid contained high levels of bacterial contamination that was the root cause of the odour and quality issues. To eliminate this problem plant management had to resort to using using significant amounts of biocides, causing health and safety risks to their employees.

To support the plant eliminate the need for biocides a FluidWorker trial was initiated in December of 2018, to significantly reduce the levels of bacteria. An empty IBC container was filled with 500 litres of contaminated fluid, with an approximate bacteria level of 10^5 CFU/ml.

This container was then connected to a FluidWorker 100, with the intention of reducing bacterial concentrating by 90-95% within 24 to 48 hours. To assess the effectiveness of the equipment dip slide checks were carried out every 3 hours. After 16 hours, it was evident that almost all traces of bacteria had been eliminated from the recycled fluids. This was fantastic news for both the customer and Houghton.

After a number on internal discussions it was agreed that 2 two FluidWorker 100’s would be introduced to the plant for processing recycled fluid. With these 2 systems in place, the financial, health and environmental benefits were deemed significant by the customer.

To ensure optimum, long-term bio-stability, Houghton also advised that pH and concentration levels should be adjusted approximately 6-12 hours after the start of treatment.

After FluidWorker Sixth Sample 21st December 2018 103 CFU/ml

Before FluidWorker First Sample 19th December 2018 106 CFU/ml

As part of a joint innovation project, Houghton has been working with a major automotive components company based in the Czech Republic. This company specializes in the development and manufacturing of hydraulic actuators for clutch and brake systems and were keen to evaluate the FluidWorker 100 technology to eliminate the need for biocides.

Simple & SafeWith a variety of old and complex (circa 1998) metalworking systems working within the customer facility, the medical manufacturer was finding processes laborious, time-consuming and production limiting, with fluids needing to be changed and production halted during this process for up to one week at a time.

Working closely alongside the client, Houghton was tasked with improving the working environment within the facility, as well as reducing the risk of unplanned fluid change-outs – both of which was causing significant impacts on their workforce and bottom line.

With the customer already utilising our Hocut 3380 within their facility, Houghton and Wallenius Water conducted numerous pre-trials over an 11-month period, including various fluid analysis exercises, including absorbance, scaling and stress, alongside a pre-test installation with a smaller FluidWorker.

Houghton’s global client specialises in the manufacture and supply of innovative medical devices and orthopaedic and neurosurgery products, with a broad portfolio of products.

After initial inspection, it was also proposed that a bespoke docking station also be implemented in the facility to accommodate a varying bacterial load within a portable and flexible production environment.

After numerous trials, two FluidWorker 300’s were installed into the customers facility on the purpose-built docking unit. A stand-alone, plug-in unit, installation was quick and seamless – not heavily disrupting production.

Post-installation, the FluidWorker presented various benefits to production, including a more bio-stable fluid, quicker fluid recovery and less biocide usage – all of which supports the customers environmental endeavours.

The FluidWorker also achieved the desired result of fewer change-outs, saving the facility essential production time and money.

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E QUIPMENT D AT A

DescriptionFluidWorker is based on UV-C technology that keeps bacterial populations in process fluids under control by preventing them replicating. This secures high productivity and extends the life of the fluid - without exposing employees to allergenic substances or carcinogens.

FluidWorker effectively reduces bacteria in process fluids. The Fluid is irradiated with UV-C, which alters the bacteria’s DNA and makes it unable to replicate. The reduction in bacterial population is often very fast, within a few hours 99.9% of the bacteria is decomposed given dimensioning according to our system analysis.

Features & Benefits \ Bacteria treatment without the use of

harmful biocides can prevent workers being exposed to eczema, allergies, respiratory problems, sterility and even cancer

\ Lower costs - the lifespan of the process fluids is increased, and biocide-related expenses are avoided

\ Self-cleaning technology – minimal maintenance

\ Reduces production downtime - fewer fluid changes are required as bacterial populations are kept under control

\ Easy to operate

\ Stand-alone unit - can be installed any time, without having any impact on production.

\ Kills 99.9% of bacteria within a few hours, given correct installation and dimensioning

\ Reduced environmental footprint - longer life of the fluid means fewer chemicals in circulation, reduced waste volumes and reduced transport costs associated with this

ApplicationFluidWorker is compatible with the vast majority of Houghton’s soluble cutting fluid portfolio.

FluidWorker is the ideal solution for customers with a larger number of metalworking machines with single sumps. It is suitable for 500-1500 litre tanks with water-based process fluid used for metalworking (machining/deformation) or surface treatment (quenching/washing). FluidWorker is also available for central systems, please ask your local Houghton representative for more information.

Health & SafetyThe equipment is in full compliance with CE-standards.

FluidWorker effectively reduces bacteria in process fluids, securing high productivity and extended fluid life - without exposing employees to allergenic substances or carcinogens.

Dimensions & Connections

Technical Specification

SYSTEM

Flow adjustable 2.4 - 5.6 m3/h

Number of UV lamps 1

Total lamp power 168 - 202 W

Pump power, adjustable 85 - 280 W

Total power consumption 270 - 500 W

Max ambient operating temperature 45OC

Max fluid temperature 45OC

Suitable for tank volume (system and fluid dependent)

0.5 - 1.5m3

Self priming pump Yes

Lockable on / off switch Yes

Pressure sensor Yes

Service timer Yes

Automatic cleaning system Yes

On / off via external switch Emergency stop

Optional inlet filter Yes

REACTOR

Material reactor, inlet and outlet pipe Stainless steel EN 1.4301

IP class 21

Power input 230V 1-phase, 50 Hz

HMI 5” colour touch screen

This document contains information based on data that is believed to be correct. However, the product may not be applicable to all uses and operating environments. No warranty or guarantee is expressed or implied.


S I DE

360mm

1340

mm

FR ONT

420mm

FLUIDWORKER LEASE COSTS

PERIOD COST NOTES

36 months €175.00 monthly

Annual service and bulb inclusive


Annual service and bulb inclusive


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Weight excluding packaging: Approx. 48 Kg

Exterior Dimensions: 420 x 360 1340 mm

Lowest possible ceiling height: 2400 mm

FLUID INTELLIGENCE - Quaker Houghton Customer Solutions Centre · majority of Houghton’s soluble...

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