Real-Time Fluid Monitoring
Real-time fluid monitoring provides improved metalworking system control
With seemingly unceasing pressure to comply with environmental legislation, today’s manufacturing world is more complex than ever. While improving performance and driving cost efficiencies are naturally central to success in manufacturing, striving to meet new standards often creates an additional cost which most businesses could well do without.
Castrol however, believes it has created the perfect solution in the development of Castrol SystemRT. The exclusive fluid monitoring system for large metalworking systems – introduced in 2006 – has already been proven to improve manufacturing performance while at the same time both cutting waste and reducing costs.
It achieves this by dispensing with the current time-consuming practice of analysing fluid samples at off-site laboratories in favour of real-time in-house monitoring of chemical profiles which can be used instantly to make corrections to fluid management, preventing costly damage to machinery and extending fluid life.
Without good metalworking fluid control there is potential for multiple issues to arise. These include continual fluctuations in system concentration; reduced concentration which can lead to reduced tool life, corrosion protection and ultimately reduced fluid life. In addition, elevated concentration may result in increased product usage, dermal irritation, and residue build-up.
Put simply, an uncontrolled fluid system results in higher costs and increased risk.
With seemingly unceasing pressure to comply with environmental legislation, today’s manufacturing world is more complex than ever. While improving performance and driving cost efficiencies are naturally central to success in manufacturing, striving to meet new standards often creates an additional cost which most businesses could well do without.
Castrol however, believes it has created the perfect solution in the development of Castrol SystemRT. The exclusive fluid monitoring system for large metalworking systems – introduced in 2006 – has already been proven to improve manufacturing performance while at the same time both cutting waste and reducing costs.
It achieves this by dispensing with the current time-consuming practice of analysing fluid samples at off-site laboratories in favour of real-time in-house monitoring of chemical profiles which can be used instantly to make corrections to fluid management, preventing costly damage to machinery and extending fluid life.
Without good metalworking fluid control there is potential for multiple issues to arise. These include continual fluctuations in system concentration; reduced concentration which can lead to reduced tool life, corrosion protection and ultimately reduced fluid life. In addition, elevated concentration may result in increased product usage, dermal irritation, and residue build-up.
Put simply, an uncontrolled fluid system results in higher costs and increased risk.
Real-time fluid monitoring
The real-time fluid monitoring and analysis capabilities of Castrol SystemRT offer manufacturers an easy-to-use and reliable way of achieving consistent system stability and operational performance on their very own premises.
Capable of testing most water-based metalworking fluids, Castrol SystemRT has already made a positive impact on overall manufacturing efficiency and costs for customers worldwide.
Its trending data helps the user improve fluid control, thus reducing the variability in concentration. One major automotive customer in Europe enrolled in a Castrol SystemCare programme (a management programme for Castrol metalworking fluids), using Castrol SystemRT to obtain actionable concentration readings. The use of daily readings and responsive corrective action allowed the customer to stabilise its systems with more timely additions of concentrate. The effect of improved concentration control reduced annual concentration additions on one central system by 4,000 litres, amounting to a 15% reduction and a significant overall cost saving.
The real-time fluid monitoring and analysis capabilities of Castrol SystemRT offer manufacturers an easy-to-use and reliable way of achieving consistent system stability and operational performance on their very own premises.
Capable of testing most water-based metalworking fluids, Castrol SystemRT has already made a positive impact on overall manufacturing efficiency and costs for customers worldwide.
Its trending data helps the user improve fluid control, thus reducing the variability in concentration. One major automotive customer in Europe enrolled in a Castrol SystemCare programme (a management programme for Castrol metalworking fluids), using Castrol SystemRT to obtain actionable concentration readings. The use of daily readings and responsive corrective action allowed the customer to stabilise its systems with more timely additions of concentrate. The effect of improved concentration control reduced annual concentration additions on one central system by 4,000 litres, amounting to a 15% reduction and a significant overall cost saving.
Biological benefit
Castrol SystemRT also provides the ability to measure biological activity in real-time – a unique benefit over standard biological analysis which takes several days to deliver results, meaning any required actions cannot be addressed immediately thereby increasing the risk of losing system control.
The immediate, actionable results of Castrol SystemRT allow operators to proactively control their systems’ biological growth and maintain consistent fluid parameters to prevent future metalworking fluid issues.
This technology proved vital to a major industrial customer in Europe as its team was able to use the additional functionality of real-time data to tightly control the company’s metalworking fluid parameters.
As a result, biological activity was detected up to five days sooner than previous testing would have allowed. In addition, more effective administering made possible by improved system control led to a 33% reduction in biocide usage.
These results, however, are by no means unusual as similar reductions in biocide have been realised by customers using Castrol System all around the world.
Castrol SystemRT also provides the ability to measure biological activity in real-time – a unique benefit over standard biological analysis which takes several days to deliver results, meaning any required actions cannot be addressed immediately thereby increasing the risk of losing system control.
The immediate, actionable results of Castrol SystemRT allow operators to proactively control their systems’ biological growth and maintain consistent fluid parameters to prevent future metalworking fluid issues.
This technology proved vital to a major industrial customer in Europe as its team was able to use the additional functionality of real-time data to tightly control the company’s metalworking fluid parameters.
As a result, biological activity was detected up to five days sooner than previous testing would have allowed. In addition, more effective administering made possible by improved system control led to a 33% reduction in biocide usage.
These results, however, are by no means unusual as similar reductions in biocide have been realised by customers using Castrol System all around the world.
Environmental and health benefits
Perhaps the most significant benefit of the improved system control that Castrol SystemRT provides is that overall metalworking fluid and chemical usage can be substantially reduced. A tightly controlled metalworking fluid system not only extends fluid life, it also reduces overall manufacturing waste which leads to savings in waste processing costs as well as helping companies to meet their environmental objectives.
Furthermore, controlled systems require fewer tank-side additives, thus reducing operator chemical exposure. Well-managed metalworking systems have also been proven to reduce the opportunity for biological growth, which in turn reduces the need for biocides and the safety risks associated with handling them.
In short, Castrol SystemRT is a prime example of Castrol’s ongoing commitment to providing its customers with the most advanced solutions available – all of which are developed with a strong respect for the environment. The new proactive approach to maintaining metalworking central systems provided by Castrol SystemRT offers a comprehensive range of unrivalled benefits which manufacturers should seek to embrace and use to their advantage as quickly as possible.
Perhaps the most significant benefit of the improved system control that Castrol SystemRT provides is that overall metalworking fluid and chemical usage can be substantially reduced. A tightly controlled metalworking fluid system not only extends fluid life, it also reduces overall manufacturing waste which leads to savings in waste processing costs as well as helping companies to meet their environmental objectives.
Furthermore, controlled systems require fewer tank-side additives, thus reducing operator chemical exposure. Well-managed metalworking systems have also been proven to reduce the opportunity for biological growth, which in turn reduces the need for biocides and the safety risks associated with handling them.
In short, Castrol SystemRT is a prime example of Castrol’s ongoing commitment to providing its customers with the most advanced solutions available – all of which are developed with a strong respect for the environment. The new proactive approach to maintaining metalworking central systems provided by Castrol SystemRT offers a comprehensive range of unrivalled benefits which manufacturers should seek to embrace and use to their advantage as quickly as possible.
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