Centralized Filtration System: Overview

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.

Below is the list of all the reasons why you should opt for a Centralized Filtration System in comparison to a stand alone filtration system.

Saving in electrical power / connected load:

  • 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

Increase in Coolant life:

  • 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.

Increase utilisation of shop floor area:

  • 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.

Increase utilisation of 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.

CFS for Aluminium Machining

Aluminum is vastly used in automobile components. Various operations like drilling tapping on such components generate large quantum of chips.

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CFS for Steel Machining

Steel because of its ductile and tensile strength is widely used in auto component industry. But steel machining generally generates long curly chips.

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CFS for Cast Iron Machining

Cast Iron is used for most major engine components and motion transmission. Various operations like drilling tapping and turning on such components generate large quantum of chips.

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Grinding

Grinding process is used to generate better surface finish on components. Along with the removal of metal particle, the grinding wheel is also consumed.

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Honing

Honing is a very material removal process used to generate better surface finish on components.

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Swarf Handling Systems

Swarf is generated in any type of material removing process. The swarf generated in machining is typically is of high volume and weight.

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Dirty Fluid Transfer

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.

Instrumentation

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

Industrial Centralized Filtration System Benefits

How CFS Helps At Different Levels In Your Organization?

Save 25% Shop Floor Utilisation & Increase Production By 25%

How CFS Will Help Reduce Machine Maintenance & Manpower Costs?

Centralized Filtration System For Long Term Benefits & Increased ROI

How Production Managers Can Achieve Production Targets With No Machine Breakdown?

How Veeraja's Centralised Filtration System Technologies Help Purchase Manager?