Henkel’s Bonderite duaLCys process exploits synergies between cooling lubricant and cleaners. In this dual process, the cleaning bath is 100% recycled into the cooling lubricant. The process enables a type of pre-cleaning with low foaming at low cleaning temperatures in the machine tool.
Explains Martin Desinger, business development manager for cooling lubricants at Henkel: “Recycling the cleaning solution, instead of disposing of it, and using the synergies between the cleaner and the water-soluble cooling lubricant results in high lubrication performance, superior purity of the parts and excellent corrosion protection.”
The use of Bonderite duaLCys results in cost reductions of up to 40%, due to more efficient use of coolant, water and energy consumption as well as reduced disposal volumes.
To further increase the energy efficiency and sustainability of machine tools, Henkel AG recommends the use of the LDT Dosatron Proportional Pumps for dosing the cooling lubricants.
The Dosatron proportional dosing pump works with a volumetric hydraulic motor that provides continual injection of the liquid or soluble concentrate. It uses water pressure to operate and only requires connection to the water supply. Concentrate for dosing is drawn in independently from the water supply and is mixed with the drive water. The dosing quantity always stays proportional to the water throughput, as per the manually adjusted dosing rate, even if there are flow or pressure fluctuations in the water supply system. Furthermore, the metering accuracy of the pump is not affected by piping lengths, which simplifies its installation. The proportional dosing system combines the functions of a water meter, dosing pump and mixer into a single unit, with a design that does not allow for any dosing errors. Measurements with a diverse selection of customers have resulted in a deviation of +/- 0,05% from the set value.
For the Bonderite duaLCys process, two proportional pumps are connected in series. Feed pumps are used to load cooling lubricant into the machine tool, with the LDT Dosatron dosing pumps then used to ‘re-sharpen’ the coolant mixture and re-fill the recycled solution.
The first proportional pump draws cleaning concentrate into the water stream and mixes it with the water. This water-cleaner solution is then passed through the second proportional pump which further mixes the solution while drawing in the cooling lubricant. The result is a homogenised mixture that is supplied ready for use, volumetrically, to the machine tool to replenish evaporation losses and replace drawn-out lubricant.
These dosing devices can be integrated as individual units into existing systems at the customers' premises. Alternatively, they can be supplied as plug and play packages in the form of complete, non-electric dosing cabinets.
Says Jens Voigt, sales & marketing at LDT Dosiertechnik GmbH: “In addition to individual proportional pumps, the compact dosing cabinets are increasingly being requested and sold beyond the borders of Europe. In January 2017, the first dosing units for Henkel India were delivered and we await further inquiries from domestic and abroad.”
