Advantages of the Bonderite duaLCys process vs. the standard process The Bonderite duaLCys process meets numerous market needs. It provides: • Process cost reduction by providing low operating concentration and reduced drag out of product;
• Reduced water consumption and waste generation; • Improved working conditions resulting from use of safer, more predictable solutions;
• Energy savings from operating the washer bath at reduced temperature.
In a typical standard process, with a 100m3 central lubrication
system, machining requires an initial fill with an aqueous solution containing 6-15% of a lubricant. This requires a topping up with approx. 2.0% emulsion. Every two to five years, the contents need to be disposed of and the system cleaned.
The system suffers from high drag-out, of around 200 liters concentrate per day. The cleaning bath requires an initial fill with 2% cleaner, which needs to be disposed of approx. every 4-6 weeks. The cleaning bath operates mostly at a temperature of 45°C. (see Fig.1)
Wastage is much lower in a similarly-sized Bonderite duaLCys process, which means that costs are lower too. The initial fill is made with water containing just 2-5% lubricant and 2-5% cleaner, and the topping up is done with a 0.4% solution, which means in our example only a 32-40 Liter concentrate a day (depending if you are recycling or not). As with the standard process, disposal and cleaning is carried out every 2 to 5 years. In the cleaning bath, the initial fill is the same as with the standard system, but everything is recycled back into the lubricant bath, so no disposal is required at all. In addition, also, the bath can operate at a much lower temperature — just 20°C — that obviously means reduced energy costs.
Sustainability and the Bonderite duaLCys process Through its sustainability strategy, Henkel contributes both to sustainable development and to its own economic success. As a leader in sustainable solutions, Henkel aims to pioneer new
solutions for sustainable development while continuing to shape its business responsibly and further increase its economic success.
The Bonderite duaLCys process demonstrates sustainability on numerous levels. The high-lubricity coolant increases tool life and lasts longer itself; the chemistry behind the process is safe to use, it helps customers consume less and reduce waste; routine storage and handling of waste is eliminated completely; the parts cleaner operates at low temperatures; no bactericides are required in lubricant of cleaning fluid; and routine addition of extra additives is no longer required.
Summary Henkel’s Bonderite duaLCys process is an innovative 2-component process which produces less product, waste, water and energy consumption. By utilizing this process, metal working companies can achieve cost savings of up to 40%. Henkel has the strong capability to globally coordinate the roll out and transfer of the technology to any location around the world.
Figure 2. Cost saving of up to 40 % are possible by adopting the Bonderite duaLCys process. Reasons are a lower product- consumption, better bath- life-time, reduced waste and water consumption and plus possible energy savings and tool-life-time increase.
LINK
www.henkel.com
Figure 1. The Bonderite duaLCys process. With the Bonderite duaLCys process, the customers recycle the cleaner bath into the lubricant bath. It enables up to 40% cost savings as illustrated in the same example with a 100m³ central system.
LUBE MAGAZINE NO.139 JUNE 2017
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