New Protein Layer Technology and its use as Additive in ...The 3rd North American Industrial...

The 3rd North American Industrial Lubricants Congress

Chicago, September 20, 2018, Eric Yezdimer

New Protein Layer Technology

and its use as Additive in

Metalworking Fluids

distributed by:

Request Quote or Samples

https://www.tri-iso.com/request-quote.html

GELITA IS A GLOBAL LEADER IN COLLAGEN BASED PROTEIN PRODUCTS

2© 2017 GELITA AG. Any copies need to be authorized by GELITA

USA

Chicago, Illinois PRODUCTION

Sioux City, Iowa PRODUCTION, R&D

MEXICO

LeonPRODUCTION

TolucaPRODUCTION

BRAZIL

MococaPRODUCTION

MaringaPRODUCTION

CotiaPRODUCTION, R&D

FRANCE

Aix-en-ProvenceSALES OFFICE

AUSTRALIA

BeaudesertPRODUCTION

NEW ZEALAND

ChristchurchPRODUCTION

CHINA

ShanghaiSALES OFFICE

LiaoyuanPRODUCTION

PingyangPRODUCTION

SOUTH AFRICA

WestkrugersdorpPRODUCTION

SWEDEN

StidsvigPRODUCTION

GERMANY

EberbachPRODUCTION, R&D

GöppingenPRODUCTION

MemmingenPRODUCTION

MindenPRODUCTION

THE NETHERLANDS

Ter Apelkanaal, NLPRODUCTION

GREAT BRITAIN

Holmes ChapelSALES OFFICE

THAILAND

BangkokSALES OFFICE

MWF are needed in machining

for cooling and reduction of wear

3

Typical ingredients for MWF

• Mineral Oil

• Water

• Emulsifiers• Other additives (e.g. Corrosion

Inhibitors, Extreme Pressure Additives, Anti Wear Additives, Biocides/Fungicides etc.)

© 2018 GELITA AG. Any copies need to be authorized by GELITA

Oil works very good for lubrication

but limits cooling properties

4

Typical issues caused by weak cooling

• Increased Consumption

• Damaged Microstructure

• Reduced tool life• More effort for cleaning due to cracked

oil residues, difficulties in further processing steps (e.g. painting, bonding, phosphating)


Second Skin instead of a Raincoat:

Hydrophilic Protein Layers attract water

5

Advantages of Protein Layer Technology

• Changed surface wetting

• Improved cooling

• Better Surface quality

• Protein can be added as additive to any existing water-miscible product


Choice of Protein is Important

6

Common Proteins Available

in Industrial Quantities

Collagens

Caseins

Whey protein

Soy protein

Pea protein

Initial testing found that collagen based

proteins were more lubricating than

proteins from other sources

Cooling properties appeared very good

Prolines and Hydroxyprolines Stiffen Chains

7

Without Proline With Proline

rotating fixed

Protein ProlinesFrequency

HydroxyprolineFrequency

Collagen 14% 13%

Cassein 8-11% 0%

Whey 6% 0%

Soy 5% 0%

Pea 4% 0%

shear

more coiled less coiled

8

Scheme of Protein Layer Formation on a Surface

Substrate

Surface

Van-der-

Waals

Interaction

Hydrogen

Bonding

Protein

(from Collagen)

Water

molecules

1. Absorbtion

on Surface

2. Interaction

between Proteins

3. Water binding

by Proteins

4. Hydrophilic Layer

EEquilibrium

Moisture

Content

~10%


9

Supplied as 50% aqueous

solution of collagen peptidesContains 1% citric acid and

0.1% potassium sorbate as preservatives

NOVOTEC® CL800

Stock solution 1% dilution

Collagen peptides are very soluble and hard water stable

10

0

20

40

60

80

100

DI-water 400 ppm 800 ppm 1200 ppm

Tran

smit

tan

ce (

%)

450 nm

620 nm

CaCO3

11

Making protein films visible by Fluorescein-Markers


Microscope image of Fluorescein-marked NOVOTEC®

protein molecules (green) bound on a steel surface

Fluorescein isothiocyanate (FITC)

• Under normal conditions the protein layers are fully transparent and not visible for the human eye

• To make them visible under the microscope the Proteins are marked with FITC

Changed Surface Wetting Behavior by Protein Layers

12

without NOVOTEC® 1% NOVOTEC®

1 s

3 s

5 s

7 s

Water on Steel surfaces treated with Protein

Water on Glass surfaces treated with Protein

without NOVOTEC® 1% NOVOTEC®

1 s

4 s

8 s

12 s

0

10

20

30

40

50

60

70

80

0 5 10 15 20

con

tact

an

gle

[°]

time [sec.]

untreatedsteel

treated with1% NOVOTEC

0

10

20

30

0 10 20

con

tact

an

gle

[°]

time [sec.]

untreatedglass

treated with1% NOVOTEC


®

®

Protein Layer provides an Easy to Clean Effect

13

With Protein Layer | Without Protein Layer

treated 1% Novotec CL800

Clean steel plate with a sunflower seed oil drop (dyed for contrast)

Protein Layer provides an Easy to Clean Effect

14

With Protein Layer | Without Protein Layer

treated 1% Novotec CL800

Clean steel plate with a sunflower seed oil drop (dyed for contrast)

15

5 6

Protein Layer provides an Easy to Clean EffectClean steel plate with a sunflower seed oil drop (dyed for contrast)

Benefits of Protein Layers for Metalworking

16

COOLING

LUBRICATION

2% NOVOTEC®

CL800

5% conventional

semisynthetic MWF

5% NOVOTEC®

CL800

5% conventional

semisynthetic MWF


LESS WEAR

CLEAN SURFACES

Protein Layers and Lubrication Performance

17

Cross-Cylinder-Test (XTC)

• Determines friction and wear processes under preselected defined loads

• Records friction and temperature of lubricant

• Parameter: area of abrasion


Performance in Reichert Abrasion Wear TestInfluence of the total concentration (in DI water) of NOVOTEC® CL800 on the area of abrasion

18

Findings

Increasing protein concentration reduces the area of abrasion

The area of abrasion has less residues in the presence of proteins

Level of typical oil based MWF

© 2018 GELITA AG. Any copies need to be authorized by GELITA water 5% semi-syn 5% CL800

Protein Layers and Lubrication Performance

19

Tapping-Torque-Test(TTT)

• Visualizes real evidence of decisive process-parameters during forming and machining

• Forming and cutting operations possible

• Parameter: Torque/Drill depth


20

A: Original MWF Concentrate

B: Product A + 10% NOVOTEC® CL800

C: Product A + 20% NOVOTEC® CL800

Material: Steel 1.4571 (316Ti)

Tool: M4F 3.632 / Speed: 800 RPM

A: Original MWF ConcentrateB: Product A + 10% NOVOTEC® CL800C: Product A + 20% NOVOTEC® CL800

Effect of protein addition to commercial oil-based MWFTapping Torque Measurement of 10% dilution in deionized water


Semi-synthetic MWF

with low additive content

Semi-synthetic MWF

with heavy duty additive package



21

A: Original MWF Concentrate

B: Product A + 10% NOVOTEC® CL800

C: Product A + 20% NOVOTEC® CL800



A: Original MWF ConcentrateB: Product A + 10% NOVOTEC® CL800C: Product A + 20% NOVOTEC® CL800

Effect of protein addition to commercial oil-based MWFTapping Torque Measurement of 10% dilution in deionized water


Semi-synthetic MWF

with low additive content

Semi-synthetic MWF

with heavy duty additive package



22

Material-Protein-Interaction shown for full synthetic MWFTapping Torque Measurement of 5% dilution in deionized water


Full synthetic MWF

Formulations – forming of Steel

Full synthetic MWF

Formulations – forming of Aluminum

A: 5% Full synthetic fluid for aluminumB: 5% Full synthetic for steelC: 5% Test Formulation G18V1 / 25% Protein




Material: Aluminum 3.2315 (6082)


23

Material-Protein-Interaction shown for full synthetic MWFTapping Torque Measurement of 5% dilution in deionized water


Full synthetic MWF

Formulations – forming of Steel

Full synthetic MWF

Formulations – forming of Aluminum





Material: Aluminum 3.2315 (6082)


H2 N

NH

N

NH

HN

N

HN

NH

HN

NH

HN

NH

O

O

O

OO

O

O

OO

O

O

NH

2

NH

OH

O

OHCH

3

O

OH

S

H2 N

HO

O

HO

HN


Hydrogen

Bonding

Van-der-

Waals

Interaction

Hydrogen

Bonding

Charge Distribution and pHOf NOVOTEC® CL800 Proteins

Steel

Aluminum

Basic

Charge

Acidic

ChargeVan-der-

Waals

Interaction

Supplied @

25

Materials:

Piston AlSi12

Piston Surface - Diameter 100 mm

Piston Surface - Diameter 60 mm

Current product 5%

Current product 5%

NOVOTEC® CL800 2%

NOVOTEC® CL800 2%

Recorded Data:

Surface Roughness

Surface Quality

(Resistance to

pressure)

Protein Layers and Surface Integrity


At low cutting speed, chips are

not removed correctly. Broken

flakes melt with the surface.

NOVOTEC® CL800 provides

better cooling and pressure

resistance - thus less welding.


Tested: various operations and materials (turning, milling, tapping) of

Cr-Ni-alloys (1.4301, 1.4571), Cr-Mo-Stahl (1.4112), CuZn39Pb3, AlMg4,5Mn, AlMg3, AlMgSi1

Positive: improved skin tolerance

people with proven allergy against conventional products could use the new product

little foam even at high pressure (20 bar)

no residues anymore although ion exchanger was switched of

better surfaces especially when machining non-ferrous metals

Negative: nothing

Field trial at GuF SondermaschinenNOVOTEC CL800® in KLUTHE HAKUFORM A805 3+ years

switched from synthetic MWF


Tested: turning and milling of steel, stainless steel, aluminum, non-ferrous metal, composites

Positive: improved skin tolerance

less consumption

increased life time of tools

excellent biostability and low demand regarding maintenance

reduced odor

Negative: nothing

Field trial at Heidelberger DruckmaschinenNOVOTEC CL800® in KLUTHE HAKUFORM A805 3+ years

switched from synthetic MWF

Chips are very clean in appearance (reduced carry out)

28


Tested: turning, milling and grinding of aluminum, steel (hard and soft), corrosion-resistant steels, titanium, and plastics

Positive: the work results are very good

works since 3 years on more than 30 machines and is stable even when used not very often

low consumption and dry flakes

parts immediately dry and clean

no emissions

Negative: nothing

Field trial at cwTecNOVOTEC CL800® in Private Label MWF 3+ years

30

Industry Trends Manufacturer (B2B) Consumer (B2C)

Regulatory

(Product Safety)

No REACH

Natural polymer

Natural Product with high

performance

Performance

(Efficiency)

New Additive/ Base Stock(can be incorporated in most water-

miscible metalworking fluids or full

synthetics)

Improved Cooling

Surface Integrity

Easy Cleaning of Parts and

Machines

Eco-friendly

(free-from claims) Clean Label

Skin friendly

Less odor

No or only very low allergenic

potential

Benefits of adding Proteins to MWFsfor NOVOTEC® CL800


31

ACKNOWLEDGMENTS

The GELITA Team:

Matthias Reihmann

Christoph Simon

Berthold Koehler

Nina Offenbecher

Selina Seip

Michael Magenheimer

Peter Reiter

Kyle Hoffman

Special thanks to our partners

and trial participants.

“If I have seen further, it is by standing on

the shoulders of Giants.”

Isaac Netwon, 1675

The 3rd North American Industrial Lubricants Congress

Chicago, September 20, 2018, Eric YezdimerAustralia

Beaudesert

Phone: +61 (7) 55 41 - 35 44

Brazil

Cotia São Paulo

Phone: +55 11 2163-8000

USA

Sioux City, IA

Phone: +1 712 943 5516

South Africa

West Krugersdorp

Phone: +27 11 662 5300

China

Shanghai

Phone: +86 21 6335 3099

Mexico

Lerma

Phone: +52 7 28 285 0101

Germany

Eberbach

Phone: +49 62 71 84-01

New Zealand

Christchurch

Phone: +64 33 84 30 93

Sweden

Stidsvig

Phone: +46 4 35 265 - 00

France

Aix-en-Provence

Phone: +33 4 42 63 28 40

UK

Holmes Chapel

Phone: +44 14 77 53 69 00

www.GELITA.com

[email protected]

THANK YOU distributed by:

Request Quote or Samples

https://www.tri-iso.com/request-quote.html

New Protein Layer Technology and its use as Additive in ...The 3rd North American Industrial...

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