A Centralized Filtration System is basically a Common Filtration System for a group of machines. Hence a centralised filtration can cater to a small group of machines or the complete shop. It is generally a combination of various Coolant Filtration System Products and Accessories.
A Centralized Filtration System is the most effective and efficient ideology in Coolant Filtration System and Cutting Oil Filtration System.
A Centralized Filtration System has huge benefits over a Individual Filtration System.
Working of CFS
In a CFS the dirty fluid from the machines has to transfer to the system. The image shown is of CFS for Cast Iron machining with underground gutter.
Underground Gutter
U shaped gutters are placed along the machine below the shop floor level. Dirty fluid from the machine drops in these gutters. These gutters are inclined to give a gradient towards the centralized filtration system. Inclination is calculated based on the dirt coming from the machine.
A. Grids of civil trenches are made inside the shop floor.
B. Metallic U shaped gutter are placed inside these trenches.
C. Dirty fluid from machines drops into these gutters instead of those messy tanks. These gutters placed in such a way that the fluid along with the chips flows towards the CFS.
D. Enough slope is provided to the gutters to facilitate the flow of coolant along with the chips. Both these metallic gutter and the civil trenches have covers that means all the dirty fluid is below the shop floor away from eye contact but can be accessed easily.
E. ThisThis grid of gutter joins into a main gutter which in turn connects to the CFS.
F. The CFS is placed in a pit where the filtration system, clean tanks and pumps are placed. This is where it is filtered to the required quality.
G. The pumps supply the fluid through pipes which are laid next to the gutters inside the trenches.
If underground gutter construction is not possible, dirty fluid transfer can be done in another way
A. Transfer Tanks
Tanks with pumps and electrical control panel are placed near machines. Dirty fluid from machine drops in these tanks. The pumps transfer the dirty fluid into overhead dirty fluid return piping. The pump is tuned ON/OFF with help of the panel.
B. Overhead Piping
Dirty fluid from transfertank is pumped into overhead pipes. The piping is sized and positioned to facilitate the easy flow of dirty fluid. Pulse Jet system can be used to reduce the piping size by generating the required flowvelocity..
Reasons Why You Should Opt For A Centralizeddd Filtration System?
A stand alone filtration system has seperate pumps for bed flushing , tool flushing , spindle cooling etc. Hence the connected load for each machine is very high. All these requirements can be catered using a single pressure fluid line. A Centralized Filtration System has common pumps which pressurize a grid of piping which runs in your shop. Tapping is taken from the same pipe line for various requirements. This reduces the number of pumps required.
In a Centralized Filtration System a pump with larger flow capacity is used. These pumps have higher efficiency compared to smaller capacity pumps used in stand alone system. Hence the power required to pump the total flow is much lower as compared to the sum total of power required of stand alone tanks.
A total power reduction of 25% can be achieved.
Additional facilities like a VFD ( variable frequency drive ) can also be easily incorporated to reduce the power consumption even further
A stand alone system has to kept near the machine. Hence it occupies a large shop floor area. In order to reduce the area some aspects of filtration are typically compromised.
Smaller size means lesser through put time ( allowable time ) for filtration. The fluid has to pass through the filter faster. This increases the flow velocity which drastically reduces the filtration efficiency.
Due to small size multiple stages of filtration is not possible which puts load on the finer filter reducing its efficiency.
As the finer particles are not filtered properly, they start accumulating in the system. After a certain threshold level an operator is forced the coolant / cutting oil as the contamination starts affecting the surface of the job. Traditional it has been observed that a stand alone has to be cleaned after every 3-6 months.
As the centralised system can be kept away and also outside the shop floor area, the size can be made suitable to provide sufficient through put time. Also a multi stage filtration and seperation is provided. The increases the bath life drastically to 45-60 months.
A stand alone system has to be placed near the machine and consumes valuable shop floor area. It takes almost the same space or more than the machine tool.
This area if saved can be used for direct production activities increasing the productivity.
Space also has to be provided for easy access and maintainence of these stand alone filtration systems.
A Centralized Filtration System can be placed in non-productive area like utility hangers or even outside the shop. Hence you not only save on the foot print area of the stand alone filtration system but also the area kept vacant.
Through our various projects we have seen a 25% saving in shop floor utilisation. This means you can increase your production by 25% in the same available shop floor area.
Huge manpower is required for the cleaning and maintainence of indivisual stand alone system. As each system has its multiple pumps , conveyours , filter units etc.
Parameters like coolant concentration , pressure , temperature , filter media replacement has to done on each stand alone system.
SComparitively such activities are needed to be done at a single point of the Centralized Filtration System. Typically we have seen a 80% reduction in the manpower associated in these activities.
In a Centralized Filtration System the dirty fluid from the machines has to transfer to the system. The transfer can done in various ways:
Underground gutters: U shaped gutters are placed along the machine below the shop floor level. Dirty fluid from the machine drops in these gutters. These gutters are inclined to give a gradient towards the centralized filtration system. Inclination is calculated based on the dirt coming from the machine.
Transfer Tanks:Tanks with pumps and electrical control panel are placed near machines. Dirty fluid from machine drops in these tanks. The pumps transfer the dirty fluid into overhead dirty fluid return piping. The pump is tuned ON/OFF with help of the panel.
Overhead Piping: Dirty fluid from transfer tank is pumped into overhead pipes. The piping is sized and positioned to facilitate the easy flow of dirty fluid. Pulse Jet system can be used to reduce the piping size by generating the required flow velocity.
In a Centralized Filtration System various instrumentation and electronic systems are used to further increase the effeciency and make it user friendly. Some of these facilities alongwith its benefits are listed below:
VFD Control: Pumps are provided with VFD control. This reduces the pump rpm when the flow requirement is less. This reduces the input power requirement and hence saves on the power consumption. This is very useful during low production volumes.
Maintainence automation: Automation featurers can be added to make system more user friendly. These include:
Fault signal communication via SMS
Flow meter
Auto concentration checking and Top up
Auto Temperature control
These features are commercially viable in a Centralized Filtration System than a stand alone Coolant Filtration System
Aluminium Machining
Gearbox Cover Drilling | Pressure Die Cast
Component Machining | Gravitaon Die
Cast Machining
We installed Veeraja's Filtration System (vacuum filter, scraper conveyor, upflow drum) for honing machine. Initially we tried on one machine & with satisfactory results implemented on 3 machines. The results were fantastic. The filtration level was very good, sorted out issues on honing tool jamming issues, size variation due to improper filtration. Appreciate Veeraja teams support for appropriate, cost effective solution, understanding our pain & resolving the same.
Mr. Prasad Shirodkar
Plant Head, Gabriel India Limited.
We installed Veeraja's Centralized Filtration System (vacuum filter, scraper conveyor, upflow drum) for grinding line and deep hole drilling a few years ago. We were convinced that results would be positive and am glad to announce that our projections were correct. Productivity increased through recycling, lowering electricity bills and improved cycle times on processes. Great investment, great ROI
Mr. Nikhil Patani
GM, BD & Projects, Precision Camshafts Ltd.
We installed Veeraja's Centralized Filtration System (vacuum filter, scraper conveyor, upflow drum) for grinding and machining. Our productivity inproved substantially, lowering power supply cost and improved cycle times on processes. Working with Veeraja Industries was a pleasant experience. Very happy. Keep up the good work Veeraja Industries. Profitable investment for our business division.
Mr. Ajitkumar Jain
Manufacturing Head - Rings Plant, Anand I-Power Limited
I have complete confidence in solutions from Veeraja Industries. Veeraja Industries has unmatched application experience in metalworking fluid filtration industry. Also they offer the widest range of technologies to choose from. Low operations cost is another important benefit the user gets. I strongly recommend filtration solutions from Veeraja Industries.
Mr. Hemantkumar Tambade
Managing Director, NHB Ball & Roller Ltd
Working with Veeraja Industries was a pleasant experience. Work was completed on time and within our stipulated budget range. Happy overall.
Mr. Kalpesh Mehta
When we were setting up one of our plants, the Management decided to Install Centralised Filtration System for Process media like Coolant, Honing / Lapping Oil. We reviewed lot of providers but ultimately entrusted Veeraja Industries to engineer Centralised Filtration System. We were convinced that results would be positive by Productivity increase through recycling of Coolant, Honing / Lapping Oils, lowering electricity bills and improved cycle times on processes due to Clean Coolant, Honing / Lapping Oils. Great investment, great ROI. Profitable investment for any business division as the functional results are wonderful.
Mr. Virendra Tikhe
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