Experiencing These Challenges? Here's why.
Biological contamination of metalworking fluids can significantly reduce the useful life of metalworking fluids and the slow feedback of conventional microbiological tools make it difficult to detect problems before they have caused significant issues. Not only can LuminUltra’s products quantify microbial content in metalworking fluids in minutes, it can also characterize the contamination as a bacterial or fungal issue, thus driving appropriate troubleshooting activities immediately. These benefits greatly reduce the risk of a drain-and-recharge event and prolong the useful life of the fluid product.
The mechanisms of corrosion are not always well understood, but Microbially influenced corrosion is undeniably a significant contributor. Elevated growth within lubricating fluids create an environment that strongly promotes corrosion of both metalworking tools as well as the parts that they produce. A rigorous control program supported by effective monitoring tools such as 2nd Generation ATP monitoring greatly enhances fluid management programs, reduce the risk of MIC, extends the life of metalworking tools, and increases the number of parts that can be made per tool.
For fluid managers, time is money. Return trips to customer sites can now be eliminated by identifying contaminated metalworking fluid on-the-spot, thus enabling same-visit troubleshooting to be done. Fluid managers have typically experienced a 5-10% reduction in fluid management costs resulting in a payback period of 13 months on the investment in our solution.
Microbiological proliferation in metalworking fluids can result in significant health hazards via inhalation as well as severe skin irritation. This can be prevented by a simple monitoring program to optimize fluid treatment programs. The rapid feedback by LuminUltra’s products reveals contaminated fluid on the spot, thus enabling the fluid manager to optimize the treatment program to better manage this threat and minimize health risk.
How can 2nd Generation ATP® monitoring help to mitigate these challenges?
LuminUltra’s solutions provide the first line of defence in metalworking fluid management programs. The results obtained are an invaluable component of continuous improvement programs to decrease costs and reduce risk.
For manufacturing facilities
Detect problems early and prevent problems associated with contaminated metalworking fluids from happening in the first place. An optimized fluid management program not only minimizes health & safety issues, it enables better control and enormous cost savings by reducing operating costs while maximizing tool life and reducing manufacturing problems such as microbially influenced corrosion.
For fluid compounders & managers
Realize a new level of customer service and quality control while protecting your company’s valuable reputation. Microbial growth poses a risk to customer product integrity, infrastructure, and operating budget. Give them peace of mind and confidence in your product through optimized fluid preservation techniques.
How can you realize immediate cost savings?
By providing easily and rapidly measured bioburden test results, 2nd Generation ATP technology can quickly reduce metalworking fluid management costs by ~10%. Through optimizing biocide programs, it can prevent drain and recharge events and also significantly increase tool life as well as the number of parts that can be manufactured per tool.
What is the return on investment?
Assuming the aforementioned 10% reduction in fluid management costs, a payback period of 1 -3 months on the initial investment can be expected. Further indirect benefits are achieved through the reduction in health risks to employees and the savings in time for waiting for microbiological results.
Economic Analysis: Microbiological Control in Metalworking Fluids
ATP monitoring represents a tremendous improvement in fluid management capabilities by enabling assessment and troubleshooting of contamination events during the same visit. This document outlines the economic opportunities that this capability presents.
Recommended Test Kit
Quench-Gone Organic Modified (QGO-M™)
Using a single analysis, Quench–Gone Organic Modified (QGO-M) provides a rapid and interference–free determination of total microbiological concentration in any filterable organic fluid or organic-water mixture. Use this test kit to quantify total bioburden in organics–laden samples for rapid assessment of contamination and in conjunction with additional analyses for a complete process microbiological profile.
The QGO-M test kit is designed for testing Low-Solids Organic and/or Water Mixtures:
- Oilfield Applications
- Fuel & Associated Water
- Metalworking Fluids & Lubricants
- Oily Brines
LuminUltra’s ATP technology as advertised should be considered as the “1st Line of Defense” tool of choice and first primary testing tool for microbial activity. I have had the opportunity to use the ATP method on several projects such as:
– To validate a new process system to reduce bacteria activity;
– Evaluate a drinking water treatment process;
– Demonstrate to a pipeline company with conflicting results using the serial dilution methods the value of using ATP.
Using the field BART testers as the primary confirmation tool, the combination gives a technical consultant the primary information for the customer quickly and accuracy so informed decision can be made and treatment plans can be done quickly and with confidence.