Automatically monitor emulsions. Detect deviations at an early stage. Reduce the need for manual inspection rounds.

Mabanol Detect is the intelligent sensor technology of the Mabanol Smart Fluid 360 system. The two complementary sensor solutions – Mabanol Detect Premium and Mabanol Detect Level – enable fully automated monitoring of emulsions and other relevant process fluids via data transmission to the web-based Mabanol Connect Dashboard.

Fluctuating concentrations, changes in pH value or an unnoticed drop in the level of the cooling lubricant concentrate can quickly become a problem in metalworking. Mabanol Detect continuously monitors the key parameters of the cooling lubricant directly at the process. Instead of individual inspection rounds and random measurements using a hand-held refractometer or test strips, up-to-date measurement data is available at all times. This enables critical developments to be identified earlier and appropriate measures to be taken in good time.

The result: greater transparency regarding the condition of your emulsion, less manual monitoring effort and greater reliability for your production process.

Would you like to find out how Mabanol Detect can be used in your production process, or would you like a quote? Simply get in touch – we’ll be happy to help.

Concentrations that fluctuate too widely can compromise process stability. With conventional monitoring, for example, the concentration is measured once a week – after which its behaviour may go unmonitored for several hours or even days. Mabanol Detect Premium, on the other hand, monitors the concentration continuously. This means that changes can be detected much earlier.

• For machine operators, this means that corrective action can be taken immediately, before tool damage, process faults or quality defects occur.
• For production managers, this means greater transparency regarding the stability of production processes.

Problems with emulsions do not usually arise suddenly. They develop gradually. Rather than waiting to react until odours, changes in the emulsion or other obvious abnormalities occur, changes in the measured values can be detected at an early stage by using the Mabanol Detect Premium sensor. This enables production departments to move from reactive to proactive emulsion management. Measurement data is thus transformed into process knowledge.

Manual measurements have been carried out in many workshops for years. However, they are time-consuming: locate the machine; take a sample; read the refractometer reading; calculate the coolant concentration using the refractometer factor; determine the pH value; document the results; move on to the next machine.

With ten, twenty or more machines, this effort quickly adds up – it is not uncommon for it to take two hours a week. Mabanol Detect Premium was developed precisely to address this challenge: the relevant values are recorded comprehensively and documented in the Mabanol Connect Dashboard. Time required: 0 minutes.

Even when carried out with care, manual measurements can be affected by various factors:

• Is the refractometer correctly calibrated?
• Was the refractometer reading taken correctly?
• Was the reading taken on the hand-held refractometer multiplied by the refractometer factor?
• Was the correct refractometer factor used to calculate the concentration?
• Was the measurement always taken at the same point?
• Was the measured value recorded correctly?

Mabanol Detect creates a standardised, automated database that significantly improves the comparability of data and prevents measurement deviations caused by the factors mentioned above.

Mabanol Detect sensors are part of the Mabanol Smart Fluid 360 system. Within this system, various components of emulsion management can be linked together:

Mabanol Detect Premium continuously measures the concentration, pH and temperature of the cooling lubricant emulsion.

Mabanol Detect Level monitors the level of the cooling lubricant concentrate or other suitable process fluids.

Yes. Mabanol Detect Premium has been developed for the continuous recording of measurement values. This allows concentration trends to be monitored without the need for manual spot checks.

The measured values are directly displayed on the sensor top. Moreover, the data is transmitted to Mabanol Connect in real time and can be viewed there via a web-based dashboard.

Yes. Mabanol Detect Level measures the fill level of a drum or IBC non-contact using radar technology.

The system automates the continuous monitoring of key parameters (concentration, pH, temperature) and can therefore significantly reduce the workload involved in manual inspection rounds. Which additional manual checks remain necessary at each plant depends on the specific process and other operational requirements.

You would like to automate your emulsion monitoring?

Our application engineering team will support you in designing a suitable emulsion monitoring system – from installing the Mabanol Detect sensors on your machinery through to integrating them into the Mabanol Connect platform.

Monitor your emulsion. Understand processes. Ensure stability.

Contact us now for advice on Mabanol Detect – we’ll be happy to help.