Mabanol CoolMatic is a fully automatic, compact and intelligent coolant replenishment system with plug-and-play integration. It tackles the day-to-day challenges of managing coolants and ensures maximum process stability at minimal cost.
Mabanol CoolMatic is a fully automatic, compact and intelligent coolant replenishment system with plug-and-play integration. It tackles the day-to-day challenges of managing coolants and ensures maximum process stability at minimal cost.
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Reduction of the refill concentration to 0,5-1%
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Extension of the emulsion service life from 1 to 3 years
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Small investment, big impact – pays for itself in no time
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Simple installation, easy to use, no direct skin contact with the coolant
Coolant refill systems are available in various designs. The choice depends in particular on the following criteria:
Our series of Mabanol CoolMatic coolant refill systems can be flexibly integrated into your existing machinery, whether you are looking for an automation solution for individual machines, a network of machines or a centralised system. The functionality of the Mabanol CoolMatic systems focuses on fully automatic level control with an optimised mixing ratio. This provides a practical and affordable solution, particularly given the high cost pressures and skills shortage in the metalworking industry.
If you have any questions about which Mabanol CoolMatic system is right for your machinery or would like a quote, please don’t hesitate to contact us – we’ll be happy to help.
PRODUCT FILTER TEXT
Measures to prevent fluctuations in coolant concentrations
For each machining process, a recommended concentration for the coolant concentrate is specified to ensure stable and safe machining. In practice, however, the actual concentration often deviates from the recommended target value and fluctuates during the machining process. Fully automated coolant refill using the Mabanol CoolMatic system ensures a constant coolant concentration, as refilling takes place continuously in small quantities, thereby guaranteeing a consistently high tank level with a stable emulsion.
Example:
For a 1,000-litre coolant tank, an average of 300 litres of emulsion must be refilled weekly. The refill process is illustrated and compared below for both manual refilling and the use of the Mabanol CoolMatic automation solution:
Example: manual refilling (current situation)
Traditionally, the weekly refill volume of approximately 300 litres is replenished by a machine operator, for example every Friday. In the meantime, the tank level consequently drops significantly. In doing so, the concentration in the remaining emulsion very likely no longer corresponds to the recommended working concentration, as an over- or under-concentration occurs whilst the level is dropping due to the following causes:
- Microbial contamination: Breakdown of coolant components by bacteria and fungi
- Carry-out: Coolant discharge via swarf and workpieces
- Evaporation: Water evaporation due to high machine heat
- Contamination by tramp oil: Entry of machine oils
At the time of topping up, appropriate countermeasures must be taken to restore the target concentration. This requires calculating the refill concentration, which is often prone to error. The coolant refill calculator from HWU Lubtec (see 2) provides a solution for correctly determining the refill concentration.
Once manual refilling has been carried out, the process described starts again from the beginning. Emulsion and process stability are compromised. In the worst case, the emulsion breaks down prematurely, necessitating an early coolant change. Furthermore, the fluctuating concentration leads to a decline in workpiece quality and an increased rate of defective parts.
Example: Unattended refill using the Mabanol CoolMatic automatic coolant refill system
Unlike manual refilling or other automated solutions, the refill interval for the Mabanol CoolMatic is not time-dependent, but is determined solely by the fill level via a level sensor. The level sensor reacts even to minimal fluctuations in the fill level. The Mabanol CoolMatic therefore continuously refills small quantities of emulsion in the optimum mixing ratio. The tank remains constantly filled, effectively preventing fluctuations in concentration. Furthermore, there is no need for the error-prone calculation of the top-up concentration, as this only needs to be set once during system installation to a low percentage of 0.5–1%.
Continuously calculating the refill concentration is an unavoidable necessity, whether you are refilling the coolant manually or using automated, time-controlled solutions. To help with this, please use the link to the HWU Lubtec refill concentration calculator (see "Features")
Consistent refill concentration with the Mabanol CoolMatic
However, using the Mabanol CoolMatic coolant refill system is even simpler, as it completely eliminates the need to calculate the refill concentration. This not only benefits emulsion and process stability, but also saves you – and your machine operators – a lot of hassle. Thanks to continuous refill in small quantities, the usual fluctuations in coolant concentration in the tank do not occur in the first place, meaning that the refill concentration with the Mabanol CoolMatic can be kept constant at a low percentage of 0.5–1%. This value is set once during system installation on the proportional mixing unit.
Save time and money with the Mabanol CoolMatic
Manually refilling the coolant takes between 5 and 60 minutes per machine each day. However, this task does not contribute to value creation and incurs high costs and labour expenditure. This is a particularly critical issue given skill shortage, as vital staff resources are tied up in the manual refilling process. By using the intervention-free, fully automatic Mabanol CoolMatic coolant refill system, this cost and time factor is eliminated. The machine can run 24/7 in continuous operation. You and your staff can concentrate fully on the core task – the machining of workpieces – and thus increase productivity.
Caculation example - small machine tank (150 L)
The tank of a machining centre with a coolant capacity of 150 litres is typically refilled manually by the machine operator each day with approximately 8–12 litres. This takes around 10–15 minutes (fetching the drum, adjusting the mixer, filling the machine, and returning the drum).
12 minutes/day x 5 days/week = 1 hour per week
Assumed machine hourly rate: €60
€60 x 48 production weeks/year = €2,880
Opportunity costs of €2,880 are incurred every year. These costs are eliminated by using the fully automatic coolant refill system. In addition, an extra 48 hours of production time are gained, which the machine operator previously spent on non-value-adding work.
Calculation example - large machine tank (2,500 L)
The tank of a machining centre with a coolant capacity of 2,500 litres should be refilled several times a day to prevent fluctuations in concentration caused by excessive variations in the liquid level (see 1). The total volume refilled over the course of the day is approximately 200 litres. The process of refilling several times takes a total of approximately 60 minutes.
60 minutes/day x 5 days/week = 5 hours per week
Assumed machine hourly rate: €60
€300 x 48 production weeks/year = €14,400
Opportunity costs of €14,400 are incurred every year. These costs are eliminated by using the fully automatic coolant refill system. In addition, 240 hours of production time are gained, which the machine operator previously spent on non-value-adding work.
Measures to reduce skin irritation caused by coolants
When handling cooling lubricants on a daily basis, you often come into direct contact with them, for example when refilling or cleaning. The aggressive ingredients in some cooling lubricants, such as biocides, can cause severe skin irritation and allergic reactions. To effectively prevent these problems, the following measures should be taken:
- Strict adherence to skin protection and care protocols, including the wearing of personal protective equipment (PPE) such as protective gloves and, where necessary, additional protective clothing
- Switch to a skin-friendly cooling lubricant such as Mabanol Cut E 92 BF & 93 BF (dermatologically tested – skin protection certificates available)
- Automation of coolant replenishment using the Mabanol CoolMatic coolant refill system to avoid direct skin contact
To ensure maximum occupational health and safety, it is recommended that the three measures mentioned above be implemented in combination.
Measures to prevent reverse emulsions
If the water separates from the cooling lubricant during refilling, you have created a reverse emulsion – that is, a water-in-oil emulsion instead of the desired oil-in-water emulsion. The water separates from the lubricant and the emulsion loses its essential lubricating and protective properties. Correctly mixing a cooling lubricant emulsion is therefore essential for emulsion stability and optimum lubrication performance during the machining process.
Please therefore follow the following instructions when mixing a cooling lubricant emulsion:
- Always add the concentrate to the water, not the other way round!
- NEVER refill with pure water, but always with at least a 0.5% emulsion!
- Use a mixing device or an automated solution such as Mabanol CoolMatic
The Mabanol CoolMatic automatic cooling lubricant refill system ensures that the emulsion is always optimally mixed and dispensed.
"The use of Mabanol Cut E 93 BF and the Mabanol CoolMatic refill system has increased our overall productivity by more than 10% and significantly improved health and safety for our staff."
Defence industry company | Germany
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cOverall productivity has increased by more than 10%
88400
Cost reduction in a production hall
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The service life of the emulsion has been increased by 400%, from 3 to 12 months
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Significantly increased service life of the milling heads
Thanks to continuous refill in small quantities, the refill concentration can be maintained at a constant (and low!) level. The refill concentration therefore only needs to be set once, during system installation, on the proportional mixing unit. This prevents calculation errors and ensures maximum process and emulsion stability.
Each unit is fitted with a built-in overflow protection system. The machine tank cannot overflow – ensuring maximum operational safety.
If you have any questions about which Mabanol CoolMatic system is right for your machinery or would like a quote, please don’t hesitate to contact us – we’ll be happy to help.
