Your Global Industrial FluidcareÂŽ Service Partner
How will the latest HSE guidelines on the use of metalworking fluids affect you? The latest HSE guidance places additional responsibilities on users of metalworking fluids to more effectively manage and maintain their process fluids. This brochure gives an insight into the proposed changes and how Houghton can support customers through a range flexible service programmes, backed up by technical expertise, equipment solutions and training options, to comply with the guidelines whilst still focusing on manufacturing and productivity. At Houghton we work closely with the HSE via our membership of the UK Lubricants Association (metalworking product stewardship group). We feel it is important as the industry leader in metalworking fluids to make sure all our customers are aware of changes in legislation relating to metalworking fluids and provide support with HSE information. To keep customers informed Houghton host seminars, webinars and issue information bulletins on a regualr basis. For further details please contact your Houghton Account Manager.
HSE Compliance
Protect operator health
Reduce operational risk
Latest HSE guidance in 5 simple steps... The guidance objective is to ensure MWFs are effectively managed to minimise risk of occupational health issues in the workplace
• All records of fluid analysis to be kept for at least 5 years
• Store product in a dry bunded area
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• Use industry recognised mixing equipment
Prevention of skin contact and dermatitis by use of suitable PPE
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Prevention of serious health issues by reducing exposure and other control measures eg; LEV, mist monitoring and mist generation
MWF mixing - Recommends use of mixer units and good quality water supply
• Install water treatment equipment to improve quality where required
Guidance outlines the main reasons for maintaining MWFs and the specific areas for control • Concentration -
check at least WEEKLY
• pH - check at least WEEKLY
• Tramp oil - check at least
WEEKLY. Recommended max limit of 2%
• Swarf/fines - Risk assessed based on machining process and keeping to a minimum • Dissolved metals - to be
monitored and controlled as per EH40 listing
• Bacteria - Check at least weekly
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(unless data can justify longer testing regime) New Level for action is now >10⁴ CFUs Biocide use to be a last resort Emphasis on good fluid management and regime of system cleaning (with system cleaner)
• Temperature - check WEEKLY
Guidance emphasises control of MWF mists by • •
Reviewing products, processes, use of LEV, use of suitable PPE
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Initiating effective maintenance programmes for LEV systems – at least every 14 months
No maximum for exposure has been set however levels to be controlled as low as is reasonably practical , including employee health monitoring
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MWF storage in compliance with the Oil Storage Regulations
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Guidance emphasises the legal requirements under COSHH legislation for employers to conduct risk assessments including reducing exposure and good fluid management application processes
All records of exposure to Hazardous Chemicals and employee health records to be kept for 40 years
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Guidance emphasises correct system cleaning with a suitable system cleaner Guidance advises on correct segregation, storage and disposal of waste MWF
Customer Collaboration
Services Houghton believes that it is simply not enough to supply our customers with the best possible metalworking fluids. Working in partnership with you, we can ensure you get the very best value from our fluids, maximising performance over an extended lifetime. In this way you continue to enjoy the benefits delivered by our cutting-edge products for longer with a lower overall cost. Our dedicated Fluidcare engineers are available throughout the UK and Ireland providing excellent Fluid management, supporting your production environment with solutions that meet your specific requirements via service, training, technical support and equipment.
Environmental Compliance
Continuous Improvement
Increased Productivity
Reduced Total Cost of Ownership
Sustainable Solutions
Education and Training
Innovative Chemistry
“We have built such a relationship with
Houghton’s over the last 8 or 9 years now and have come to rely on their expertise, experience, service and top quality products to help maintain our position as a world leading research facility.
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Ashley Godbehere - Factory Manager AMRC Sheffield (Advanced Manufacturing Research Centre)
Peace of mind
Established experienced team
Over 300 UK customers supported
On-site audit of operations
Packages to suit your needs
Implement agreed service levels
STANDARD PACKAGE
ENHANCED PACKAGE
ULTIMATE PACKAGE
WEEKLY
WEEKLY
2 x WEEKLY
Concentration & pH checks for all water based products
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Bacteria & fungal measurment
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Visual tramp oil assesment
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Live visual management for all testing. Coolant charts on all machines updated on each visit
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Houghto-Trend Express - Report issued after each visit
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Temperature monitored and recorded
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Biocide additions made when required
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Houghto-Trend with customer access
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All corrective actions made - additives and product
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Stability test for tramp oil conducted monthly
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Point of application labels on all machines
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Stock control and management
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Regular review meetings will be scheduled as required
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Service frequency
Sustainable service benefits
Houghton Fluidcare Service not only supports HSE compliance but also delivers a number of operational benefits
Increased productivity
Improved product quality
Increased tooling life
Improved site EHS
Reduced operational risk
Reduced operational costs
Reduced tooling costs
Minimised waste
Houghto-Trend™ This state of the art web based solution was developed in-house by Houghton to support our Fluidcare operations. The system is totally auditable and allows users to quickly identify both performance and cost trends for any given system or point of application. 5 KEY BENEFITS
For customers requiring more flexible options to meet the needs of their business, Houghton have recently developed a lighter version of HOUGHTO-TREND™
1 High visibility management of machine and fluid information allowing customers to demonstrate compliance with quality and HSE guidelines
2 Close control minimises cost of maintenance, fluid usage,
waste costs, tooling spend, rework and scrap 3 Real time data handling for you and your colleagues to act quickly based on informed decisions 4 Hosted software eliminates your costs for local deployment or IT system development
5 Supports HSE guidance
HOUGHTO - EXPRESS Simple web based system to record concentration, pH and bacteria results • Coolant and water based fluids testing • Data and action logging • Reports emailed to the customer following visits
NEW LIGHTER VERSION OF HOUGHTO-TREND TM
FEATURES
Live real-time data
Quick, easy access via internet from anywhere
Centralised secure data storage
Fully auditable and traceable
Support HSE data compliance of recording results for 5 years
Customer Test Results 1.6 1.5 1.4 1.3 1.2
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For coolant management, we record all test results for individual machines using Houghto-Trend, generating management reports acceptable to HSE, showing coolant condition at any time and enabling trends to be displayed and reports generated. In terms of lubrication management, Houghton can collate data generated during top-ups and provide reports by application point, highlighting top leakers, cost analysis reports etc.
FUNCTIONS
Scheduling system tasks
Coolant, neat oil and water based fluids testing
Lubrication scheduling & usage
Data and action log
Reports and trend analysis
Houghton Customer Training Solutions Houghton’s team of specialist have over 80 years of experience in the application and formulation of all types of industrial process and metalworking fluids. The team is also widely experienced in the technical service and lubrication requirements of their associated production processes and machine tools. Utilising this experience, Houghton are able to offer a broad range of tailored training packages which transfer knowledge and skills to our customers’ staff. From basic coolant awareness courses through to advanced application and fluid optimisation programs, our technical experts will be able to meet the needs and requirements of your business.
“ Ineducational recent years Houghton’s have provided Cutting Fluid lessons that have been a great help to all
the KTC workforce, helping us understand the benefits that coolant monitoring can bring. The service provided by Houghton’s has been first class and is highly recommended.
Paul Rigden - Knowledge Transfer Worksop Manager AMRC ( Advanced Manufacturing Facility Sheffield)
” Customer training
Principles of lubrications
On-site specialist support
Training Packages 6 steps to achieving metalworking fluid competency...
• How to maintain fluid performance • Monitoring and control • Trouble shooting techniques
HSE Legislation
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Factors effecting cutting performance Chip formation Review of MWF machining and applications Review of Metal machinability and cutting tool technology
Forming, pressing and drawing • Review of processes used • Effect of materials • Review of fluid requirements
Rust Preventives • • • •
What is corrosion How can we prevent it Products and additives used Testing and monitoring
Heat treatment • • • •
What is heat treatment What is a Quenching process Effect of materials on process Products and additives used
Understanding REACH Review of MWF and health implication Discussion on exposure scenarios and prevention Update on current HSE trends and legislation
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Disposal of Metalworking Fluids • Disposal options • Techniques used
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MWF Application Guide
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Introduction to Basic Fluid Management
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Introduction to Metalworking Fluid Technology (MWF) What is metal cutting Primary functions of MWF and fluid types Selection criteria
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Developments in Production Engineering & Metalworking Fluid Technologies • • • • •
Fluid history and development What influences and drives change in Metalworking fluid technology? Current fluid development Current machining techniques Potential Future options for fluid and machining technique development
Houghton Customer Technical Solutions Centre Houghton UK is one of five Centres of Excellence across Europe providing a wide range of analysis and testing to various industrial standards e.g. IP, ISO & ASTM. Our state of the art laboratory is able to provide a range of services to support the safety, quality and performance of our fluids used at our customers’ sites. Our continual investment in new product technologies and our ongoing development of our Houghto-Trend reporting system, which is connected to our on-site labs/offices, ensures the current and future needs of our customers are met.
UK based team of specialist trained chemists providing customer analysis & product development to meet customer requirements
Standard fluid testing
Analytical problem solving
Condition monitoring service & wider analysis
New technology development
Houghton’s technical laboratory can provide a range of analytical testing for the following product ranges;
Metalworking Fluids Offshore Fluids Fluid Power Heat Treatment Rust Preventatives Wash Chemicals Forging Lubricants
Comprehensive range of technical analysis available... Houghton can provide a broad range of test methods to support your production fluid needs
Examples of testing to determine fluid performance and condition
Infra-Red Spectroscopy (FTIR)
Viscosity
• Fluid condition vs. reference material • Quantitative additive depletion • Identification of contaminants including water, oxidation, hard water reaction to products, etc.
Monitoring viscosity is critical and can identify other potential problems: • Lack of lubricant film • Reduced heat dissipation • Incorrect grade in use etc. Too high or too low viscosity values may also indicate: • Fluid contamination • Mechanical or thermal shearing • Oxidation
Total Acid Number (TAN) Total Acid Number is the concentration of acid in an oil: • • • •
Total Base Number is the reserve of alkalinity in the oil TAN determinations are primarily on neat cutting oils, quenchants and machine tool lubricants TBN determinations are mainly for rust preventives A TAN/TBN too high or too low could indicate: - Oil oxidation - Presence of a contaminant, - Incorrect lubricant in use, - Additive depletion
Quick and sophisticated method for determining:
Elemental Analysis • Spectroscopic techniques to quantitatively measure performance additives, contaminants and metallic wear debris • Uses X-Ray Fluorescence (XRF) or Inductively Coupled Plasma (ICP) emission spectroscopy • Determines levels from percentage (XRF) to parts per million (ICP) • A typical oil analysis report will provide reference data for the new oil so additive elements can be distinguished from contaminants • Data can be used to analyse trends rather than any specific elemental level
Microbiological Assessment • Direct requirement of the HSE to assess water-miscible industrial fluids
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Strict guidelines on testing frequency although typical techniques available can be very simple e.g. microbial dipslides Microbial contamination has been linked to serious respiratory health issues and has a detrimental effect on fluid condition Early detection and treatment is essential for the well-being of both operators and fluids Dedicated Microbiology laboratory available to conduct detailed monitoring and investigations
Tribology Performance tests • •
Lubricity/wear performance - Falex - Reichert - Microtap - Mini-Traction Elastomer Compatibility – ISO 6072
Reporting • •
Each sample is given a unique identification number All information recorded in Houghto-Trend web database - Trend analysis - Event changes - Control parameters
Benefits Confirmation of fluid properties relative to specification Confirmation of condition and suitability for continued use Detection of contaminants Advisory advice to extend fluid and equipment life • Optimising manufacturing or treatment processes • Enables predictive maintenance scheduling • Failure prevention for fluid and equipment • Reduces total manufacturing costs • • • •
11,000 samples tested every year covering all product lines
Equipment Solutions To support customers reduce fluid usage, minimise costs and deliver operational efficiencies, our dedicated equipment team have over 30 years of experience in delivering value based solutions. Our equipment offering is designed to support the fluid through its complete life cycle; from storage, to delivery to the point of use, in line fluid treatment and finally to disposal.
EXTERNAL & INTERNAL STORAGE
FLUID MIXING & DISTRIBUTION
FLUID TREATMENT
To ensure compliance with oil storage regulations, Houghton provide a range of internal and external storage containers.
Houghton provide a number of mixing and distribution solutions to meet every budget.
Maintaining fluid cleanliness is essential to the longevity and performance of a metal working fluid.
• Bulk tanks • External storage • Internal bunding • Racking
• Automated delivery systems • Automated return systems • Localised distribution systems • Houghto-mix™ for large machine shops • Smaller mixer systems
• Mobile or fixed tramp oil removal systems • Mobile or fixed fines filtration systems • Batch and full flow systems
MIST FILTRATION
MACHINE CLEANING
WASTE MANAGEMENT SOLUTIONS
Mist and fumes generated during the machining process are a major EHS risk. Houghton can provide full turnkey solutions for the removal of oil mist and dust from the workshop environment.
When metalworking fluids come to the end of their working life, a quick efficient method of removal is required from the machine tool sump, which will provide an effective result to ensure all contamination is removed.
Liquid waste disposal can be both expensive and time consuming to manage. Changes to legislation also mean that tankering effluent off site is becoming more costly year on year.
• Localised & Centralised mist/dust extraction • Replacement filter elements
• Coolant vacuums - Varying sizes & capacities - Traction units available - Power sources – 110V & 240V
• Large Vacuum Evaporator units • Small capacity Evaporation units
Europe Headquarters - Houghton Plc. Beacon Road, Trafford Park, Manchester, M17 1AF, UK www.houghtonintl.com Phone: +44 (0)161 874 5000 • Fax: +44 (0)161 874 5001 • Email: uk.enquiries@houghtonintl.com 20026 17.04 GB