High-volume subcontract machining saves energy

Rodmatic Hytek based in Reading has committed to reduce its carbon footprint by 20 per cent in 2007 following a full environmental survey carried out by the Carbon Trust.

The high-volume subcontract machining operation of Rodmatic Multico, and its high-technology division Rodmatic Hytek based in Reading has committed to reduce its carbon footprint by 20 per cent in 2007 following a full environmental survey carried out by the Carbon Trust.

Said managing director Brian Steatham: "We have looked very carefully at what can be achieved and there is definitely a payback to the business by being ecologically minded as well as contributing to improving the environment.

What is important is that a policy has to be built into the strategy being pursued by the company and serious consideration paid to any effects or influence when looking at improvements and investment." In the last 12 months Rodmatic has installed a new automated swarf handling and oil reclamation system in support of its 37 multi-spindle automatic lathes in the Multico division, purchased a new Freddy sumpsuck for more effectively cleaning out the machines on a regular basis, installed a new air compressor to replace two existing units and re-laid the 18,000 ft2 factory floor with a non-slip coating.

Following a total investment of around GBP120,000, the Arboga Darenth swarf handling and oil reclamation has already saved GBP60,000 in under a year and almost halved the purchase requirement of new coolant.

It has also contributed to extended tool life and enabled two people to be redeployed that were engauged in the swarf handling area that operated 24 hours/day.

A Hydrovane HV 37 RS rotary air compressor is already saving a third of its GBP15,000 purchase price on power alone and the on-demand air supply system has contributed eight per cent to Rodmatic's carbon footprint reduction.

In addition, with the inclusion of a refrigerated dryer unit, clean and dry air has eliminated the need for filters around the factory, reduced maintenance requirements and helped to reduce levels of noise.

With the new Freddy Ecovac 200 Mark II - 5 sumpsuck, two machines are now cleaned out each day against a rota which has provided an immediate improvement in coolant flow, pump problems have been eliminated on machines and by using good filtration, up to 98 per cent of swarf is removed from the neat oil, leading to improvements in tool life and enhanced quality.

The company has four large coolant vats and with the new swarf handling and coolant reclamation policy the tank holding virgin oil has been able to be locked and the company priority is to use reclaimed coolant.

Swarf from the machines is dumped into a hopper and any bar ends/scrap components automatically ejected.

The swarf is crushed and spun and the reclaimed oil passed over a magnadrum separator to take out any small particles.

It is finally filtered in a micro filter before being pumped into the storage tanks.

Says Brian Steatham: "With the price of oil so volatile and constantly on the rise, we have reduced our need to purchase which helps the profitability of the business.".

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