QH FLUIDWORKER™ by Quaker Houghton

Innovative, Chemical-free Solution to Bacteria Control

IN PARTNERSHIP WITH

The answer to an age-old manufacturing problem, QH FLUIDWORKER™ tackles bacteria in metalworking ﬂuids with the use of innovative UV technology. With the ability to kill 99.9% of bacterial contaminates, QH FLUIDWORKER™ extends the life of metalworking ﬂuids safely and without the need for harmful chemicals and biocides.

COMPLIANCE

PRODUCTIVE

QH FLUIDWORKER™ ensures environmental and workplace health safety compliance, whilst supporting a more pleasant factory environment.

A ‘plug-and-play’ solution, QH FLUIDWORKER™ is a stand-alone unit with a small physical footprint, able to fit amongst your existing machinery effortlessly, resulting in less downtime and increased efficiency.

COST EFFICIENT

IN BEST PRACTICE

Available in a range of competitive rental rates, QH FLUIDWORKER™ extends the lifespan of process fluids, reduces the vast expenditure on waste disposal and removes dependency on biocides.

QH FLUIDWORKER™ ensures manufacturers are adhering to best practise with the effective, costefficient and HSE compliant treatment and reprocess of production-vital metalworking fluids.

Safe, Innovative and Money Saving With continual changes to biocide legislation, rising costs and availability concerns, manufacturing companies are under increased pressure to find safe and sustainable methods for controlling bacterial contamination within their metalworking fluids. QH FLUIDWORKER™ is a chemical free technology that enables companies to manage their process fluids both cost effectively and safely, whilst creating a safer working environment for employees. Taking the lead in the environmentally safe treatment of metalworking fluids, QH FLUIDWORKER™ makes use of UV-C light to affect the DNA of bacteria found within process fluids and prevent them from replicating. In terms of real-life applications, this means that within hours, bacterial populations can be reduced by 99.9%, without the use of a single biocide. This not only saves manufacturers on the costs of expensive biocides but also on the costs of process fluids and waste disposal, as fluid lifespans are dramatically extended.

Revolutionising the Metalworking Fluid Recycling Process Developed in Sweden by Wallenius Water Innovation, QH FLUIDWORKER™ is a ‘plugand-play’ solution that can be installed with no machine downtime, supporting production process straight away. With rental rates starting from a few hundred Euros per month, QH FLUIDWORKER™ has the ability to support manufacturers immediately, without any costly outlay. Quaker Houghton can also support with the installation and setup of the unit, alongside providing all the production support required through Quaker Houghton’s comprehensive fluid maintenance management programme, Fluid Intelligence. By eliminating the use of damaging biocides, clients stand to reduce their environmental footprint and look after the beating heart of their processes – their employees. Alongside its health and safety benefits, the self-cleaning QH FLUIDWORKER™ will also save clients time. Rather than continually checking up on bacteria levels, the QH FLUIDWORKER™ can simply be turned on and left to operate accordingly.

Equipment Data Description QH FLUIDWORKER™ is based on UV-C technology that keeps bacterial populations in process fluids under control by preventing them from replicating. This secures high productivity and extends the life of the fluid - without exposing employees to potentially allergenic or dangerous. QH FLUIDWORKER™ effectively reduces bacteria in process fluids. The UV rays damage bacteria’s DNA which makes them unable to replicate and results in a rapid reduction in bacterial population, within a few hours 99.9% of the bacteria is decomposed according to our system analysis.

Features & Benefits • Bacteria treatment without the use of

harmful biocides removes the exposure of workers which could lead to severe health impacts if the biocides are improperly handled

• Lower costs - the lifespan of the

process fluids is increased, and biociderelated expenses are avoided

• Self-cleaning technology – minimal maintenance

• Reduces production downtime - fewer

fluid changes are required as bacterial populations are kept under control

• Easy to operate

Application QH FLUIDWORKER™ is compatible with the vast majority of Quaker Houghton’s soluble cutting fluid portfolio. QH FLUIDWORKER™ is the ideal solution for customers with a larger number of metalworking machines with single sumps. It is suitable for 500-1500 litre tanks with water-based process fluid used for metalworking (machining/deformation) or surface treatment (quenching/washing). QH FLUIDWORKER™ is also available for central systems, please ask your local Quaker Houghton representative for more information.

Health & Safety

• Stand-alone unit - can be installed any time, without having any impact on production.

• Kills 99.9% of bacteria within a few

hours, given correct installation and dimensioning

• Reduced environmental footprint -

longer life of the fluid means fewer chemicals in circulation, reduced waste volumes and reduced transport costs associated with this

The equipment is in full compliance with CE-standards.

1340mm

Dimensions & Connections

420mm

360mm

FRONT

Weight excluding packaging: Approx. 48 Kg Exterior Dimensions: 420 x 360Â 1340 mm Lowest possible ceiling height: 2400 mm

Technical Specification SYSTEM

REACTOR

Flow adjustable

2.4 - 5.6 m3/h

Number of UV lamps

Total lamp power

168 - 202 W

Pump power, adjustable

85 - 280 W

Total power consumption

270 - 500 W

Max ambient operating temperature

45OC

Max fluid temperature

45OC

Suitable for tank volume (system and fluid dependent)

0.5 - 1.5m3

Self priming pump

Yes

Lockable on / off switch

Yes

Pressure sensor

Yes

Service timer

Yes

Automatic cleaning system

Yes

On / off via external switch

Emergency stop

Optional inlet filter

Yes

Material reactor, inlet and outlet pipe

Stainless steel EN 1.4301

IP class

Power input

230V 1-phase, 50 Hz

HMI

5â&#x20AC;? colour touch screen

Price and Lease Costs Equipment pricing and leasing costs can be obtained from your Quaker Houghton account manager or Fluid Intelligence BDM.

This document contains information based on data that is believed to be correct. However, the product may not be applicable to all uses and operating environments. No warranty or guarantee is expressed or implied.

Equipment Data QH FLUIDWORKER™ - Mobile Unit To mitigate costs, a new mobile unit has been developed that allows the FluidWorker 100 to be utilised on multiple machines. The equipment can be simply moved from one machine to the next on a scheduled basis, ensuring bacterial contamination is maintained at a minimum level. Not only does this new approach minimise capital investment costs, it gives the customer greater flexibility in addressing bacterial issues.

Design Improvements Other design improvements have been made to the QH FLUIDWORKER™ since its original launch. These additional features have been designed to make the unit more efficient and easier to use. New features include:

• Improved inlet strainer to remove fine contaminants

• Significantly reduce risk of impeller failure

• New mesh design with 1.5mm porosity • Self-cleaning unit available • Hose holder to reduce the risk of leaks and spillages

Industry Case Study As part of a joint innovation project, Quaker Houghton has been working with a major automotive components company in the Czech Republic. This company specializes in the development and manufacturing of hydraulic actuators for clutch and brake systems and were keen to evaluate the QH FLUIDWORKER™ 100 technology to eliminate the need for biocides.

Innovative Bacteria Control Through effective recycling, our customer was able to capture approximately 1000 litres of used metalworking fluid every 24-hours for reuse within their machine tools. Whilst this proactive activity was helping the plant reduce costs, shop floor employee’s were complaining of poor odours and concerns regarding the quality of the coolant. After a detailed investigation by Quaker Houghton, it was established that the processed fluid contained high levels of bacterial contamination that was the root cause of the odour and quality issues. To eliminate this problem plant management had to resort to using using significant amounts of biocides, causing health and safety risks to their employees. To support the plant eliminate the need for biocides a QH FLUIDWORKER™ trial was initiated in December of 2018, to significantly reduce the levels of bacteria. An empty IBC container was filled with 500 litres of contaminated fluid, with an approximate bacteria level of 10^5 CFU/ml.

Before QH FLUIDWORKER™ First Sample 19th December 2018 106 CFU/ml

This container was then connected to a QH FLUIDWORKER™ 100, with the intention of reducing bacterial levels by 90-95% within 24 to 48 hours. To assess the effectiveness of the equipment, dip slide checks were carried out every 3 hours. After 16 hours, it was evident that almost all traces of bacteria had been eliminated from the recycled fluids. This was fantastic news for both the customer and Quaker Houghton. After a number on internal discussions it was agreed that two QH FLUIDWORKER™ 100’s would be introduced to the plant for processing recycled fluid. With these 2 systems in place, the financial, health and environmental benefits were deemed significant by the customer. To ensure optimum, long-term stability, Quaker Houghton also advised that pH and concentration levels should be adjusted approximately 6-12 hours after the start of treatment.

After QH FLUIDWORKER™ Sixth Sample 21st December 2018 103 CFU/ml

Industry Case Study Overview of problem

Application Information

A major Global Automotive manufacturer was experiencing heavy bacterial and fungal infections in their Crank Final Wash, resulting in the entire system being dumped every month. The ongoing problem has created significant production problems and process reliability issues. The system has also had issues with high levels of filter usages due to biofilm residues and contamination build up. Filters have historically been changed every 2 weeks, which involves a significant amount of maintenance time and cost. The issues also present real EHS risks to operators and the general environment around the wash system.

Operation: Crank Final Wash

Project

Wash Model: EcoClean Wash Operation: High Pressure Deburr Product: Castrol Techniclean S-Extra FF Tank Volume: 1000 Litres Concentration: 2% Operating Temperature: 22°C Operating Pressure: 200-300 Bar

Historical Results • Bacterial analysis on the wash system is

alternative to traditional chemical biocides.

conducted weekly. Within a week of a new fluid fill we start to bacteria and fungus developing.

• The QH FLUIDWORKER™ was installed on the

• Within two weeks the result is typically reads

• A QH FLUIDWORKER™ was proposed as an

3rd July 2019

• It was proposed to run the system for a

week and observe what impact this had on reducing bacterial contamination

10 5 or higher.

• After weeks the system is normally over 106 and we start receiving complaints of poor odour.

Overview of Problem Initial Fill Costs: £120 per fill (product and biocide). Savings: £720

filters were replaced every 2 weeks. These have now been extended out to 16 weeks. This has also reduced maintenance department time, which is typically costed at £100 per hour with each change out taking 4 hours. Filter Saving: £16,500 per annum for filters Downtime Saving: £100 x 4 hours x 25 annual changes – 3 changes per annum= £9,700

Dump and Clean Schedule: Typically the system would get dumped every month. Following the introduction of the QH FLUIDWORKER™ this was extended out to every 2 months. Saving: Reduction in downtime equates to £25,000 per annum Filter Usage: The system contains 20 PALL Cartridge filters. Each set costs £750. Prior to the introduction of the FluidWorker 100 these

Biocide Usage: Typically 200 ml of Acticide 14 biocide is used every week. There is no longer a requirement for this biocide. Whilst this isn’t a significant commercial saving, from an EHS perspective this is a significant improvement.

Trial Results

Outcome

The unit was run for an initial 8 hours, with dip slides taken every hour. As the trial progressed it was clear that the level of bacterial contamination was reducing.

The results from this trial have convinced the major automotive manufacturer Dagenham that this technology needs to be extended to all onsite wash system. It has been agreed that two QH FLUIDWORKER™ 300 units will be installed onto a 30,000 litre Lion Head Final Wash system early in 2020.

After 6 hours of running the FluidWorker 100 the fluid went from 106 contamination down to zero bacteria. This was repeated the next day and the same results were observed. The unit was switched off over a weekend period, in this time bacteria once again formed to 106.

9:00

10:00

11:00

If successful it is expected that a saving over £50,000 per annum will be achieved on just extended sump life and reduced biocide usage. The major automotive manufacturer are so enthusiastic about this new innovative UV technology that they have classified this as “Best Practice” and will be promoting this globally to their other manufacturing locations.

12:00

13:00

14:00

6 hours

We are Quaker Houghton.

The global leader in industrial process ﬂuids. If it’s made of metal, if it’s rolled, cut, drawn or cast, Quaker Houghton is there, optimizing processes, reducing costs, advancing safety and sustainability… and driving progress.

Manufacturing facilities

R&D Technology Centres

Offices

15k

Customers

115

Countries served around the world

$1.5

Billion in sales

Employees

Global Headquarters One Quaker Park 901 E. Hector Street Conshohocken, PA 19428-2380 U.S.A +1.610.832.40000

quakerhoughton.com | info@quakerhoughton.com

#8810. 01-02-20