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Given all the complications involved with labelling of biocides under the BPR, some companies are considering separating out the biocide from their MWF concentrate and adding it separately to the sump. For large central systems, this could be a practical approach, but for small to medium machine shops with numerous single sump machines, this would require careful on-site management.
Boron Chemistry The introduction of boron-based long life technology in the 1980’s was a step change to increasing the sump life of MWFs. This chemistry was based on the reaction products of boric acid with alkanolamines. Subsequently in Europe, boric acid has been classified as a Category 1B reproductive toxin. Whilst boron is not present in MWFs as boric acid, many end-users prefer boron-free products in response to concerns about the future of this chemistry. Again, the formulator has responded to these requests by providing “Boron-free” long life fluids.
Controlling Micro-organisms The HSE has mandated the introduction of bacteria dip slide testing for end-users in response to the outbreak of respiratory disease linked with exposure to inhalation of micro-organisms in MWF mists. This requires end-users to monitor and control the levels of bacteria in their fluids which relies in part on the ability of the MWF to control bacteria and in part on the end-user to control the MWF adequately. With the BPR impacting on the availability of biocides, this is making the formulator develop new products using new biocide combinations to meet end-user expectations and future regulatory requirements.
End-User Challenges To compete in the global market the engineering industry is developing new manufacturing technologies, such as additive machining and using modern production materials, like composites and high-performance metal alloys. In many cases, this presents new opportunities for the additive suppliers and formulators to develop new MWFs.
The demand for higher productivity has resulted in OEM’s producing standard machine tools with higher spindle speeds and through spindle coolant tooling. This increases the pressures on aqueous MWFs (typically referred to as coolants) to be lower foaming.
12 LUBE MAGAZINE NO.146 AUGUST 2018
Fortunately, there have been many developments in lower foaming surfactants and detergents to improve these aspects.
With neat cutting oils, the development of environmentally friendly synthetic ester products can reduce the fire risks associated with modern high-speed machining operations, due to their higher flash points and lower volatility when compared against their traditional mineral oil counterparts. Ultimately, end-users will have to meet the challenges of more regulation and implementing better control measures to minimise the exposure of machine operators to mists and the potential hazards associated with inhaling bacteria, endotoxins (linked with micro-organism cell membranes), heavy metals and chemical substances such as tramp oil. This is encouraging end-users to become more H&S conscious and use local exhaust ventilation (LEV). This is also stimulating the UKLA MWFPSG, in conjunction with the HSE, to develop better monitoring techniques to help end-users control these potential hazards.
Changing Times Currently UK formulators are providing MWFs which are compliant with EU regulations. After March 2019, formulators will be responsive to the introduction of a new UK regulatory system. Dramatic changes are not expected in the short term, but with the passage of time, formulators may have to react to different priorities set by UK authorities.
As always, manufacturers will be conscious of keeping their production costs down in a very competitive global market, minimising their waste costs and improving their environmental profile. Similarly, formulators of MWFs will still need to develop new products which meet these demands, though in future within a UK regulatory framework.
Acknowledgements:
MacDermid Ltd Health & Safety, Compliance Department
LINK
www.macdermid.com
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