Cutting coolant costs reduced at BAe Filton

Primary considerations when installing the Master Chemical System were to produce significant benefits in terms of reduced replenishment and disposal costs, and improved coolant performance.

"If you ask any of the machine operators, they will tell you the coolant quality is better than ever - you can't get a better testimonial than that.

This is the claim of John Myers, a cell manager at BAE Systems, Airbus in Filton and who was instrumental in planning and overseeing the installation of a Master Chemical turn-key coolant management system servicing the machining operations.

Primary considerations when installing the Master Chemical solution were to produce significant benefits in terms of reduced replenishment and disposal costs along with greatly improved coolant performance.

Prior to opting for the Master Chemical solution, machining cells at Filton used cutting and grinding fluids from three different suppliers which resulted in an unacceptable cost centre, infrequent product management and inconsistency.

As a result of a full assessment, Master Chemical installed the complete distribution, filtration and re-cycling installation supported by a total replenishment and management system with a 5 year maintenance contract.

"There have been occasions when the installation has needed very minor attention in the past year but these were teething problems and we are confident of achieving and exceeding our initial target of a 5% year-on-year savings when compared with conventional coolant replacement," explains John Myers.

"Operator acceptance has been excellent and the combination of reduced cost, improved quality, on-running management and the elimination of problems we were having with corrosion have produced a very satisfactory result," he concludes.

The installation at Filton covers over 100 machine tools, many being 4- and 5-axis machining centres including a new high speed machining cell.

Materials used in manufacture of predominantly aircraft wing components are aluminium and titanium.

Master Chemical installed a Xybex coolant re-cycling system which offers a capability for medium and large machine tools with their own coolant sumps.

The two units will provide makeup coolant and will recycle a sufficient quantity of fluid daily to support up to 9,600 litres of coolant in the machines.

Master Chemical recommended a combination mix of coolant - TRIM VHPE200 and SC880 - that satisfies all of the machining requirements in the operation while overcoming the corrosion problems experienced when billets reacted with the steel beds on the machine tools.

In total the installation contains 108,800 litres of coolant.

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