Centralized Filtration System: 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. Transportation of these chips from the point of generation to the scarp yard is a very tedious, time consuming and labourious job. Leaking coolant from these chips also makes the shop floor look dirty. If these chips generated are curly it adds to these problems.

Veeraja provides complete solution of swarf removal from machine bed , common conveying systems, chip crushers and chip briquetting machines.

Features of the solution

  • Made to order solution
  • Sizing and selection of ideal components is done based on type of chips and quantity of chips generated.
  • Integration of all components in respect of mechanical and electrical safety.
  • Built in PLC Controlled electrical and mechanical safety with Auto conveyor Jamming logic.
  • Complete end to end solution

Components

Storage of chips and recovery of precious metal cutting fluid is of primary concern in this industry. Traditionally hydraulic presses are used to recover the fluid by compressing the chips in briquettes or tablets. Read more
Certain application generate long curly chips. They are not only dangerous to handle but require lot of storage space. Such chips also accumulate inside the machine bed which require regular machine downtime for cleaning. Read more
Scraper Conveyer is a simplest device to handle course dirt in bulk. It can be designed in several forms: inserted in a machine tunnel or placed at the bottom of dirty fluid holding tank. It also can be used in combination with a verity of filtration / separation devices. Read more
Scraper Conveyer is a simplest device to handle course dirt in bulk. It can be designed in several forms: inserted in a machine tunnel or placed at the bottom of dirty fluid holding tank. It also can be used in combination with a verity of filtration / separation devices.Read more
Screw conveyors are used for transfer of chips or powder. These are generally useful for controlled movement and disposal. Due to its compact and simple design it can be fitted in spaces not easily accessible. Read more

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Bajaj Auto Ltd

A world class manufacturer in India. They manufacture 2 wheelers and 3 wheelers wide range of products.

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A world class manufacturer in India. They manufacture 2 wheelers and 3 wheelers wide range of products.

Application : Aluminum machining
Process : Machining, Drilling, Tapping, Boring
No of machine : 80 No’s
Fluid : Water based emulsion

Multiple part of a 2 wheeler are made of aluminum die cast. Components are machines, drilled and bored to achieve finished stage. This generates large quantum of chips. Considering the high production requirements multiple machines are working at the same time.

This generates a large quantum of chips. Chips were separated in individual tanks and fluid pumped back to machine. Chips had to be cleaned manually from each tank. This caused significant machine downtime. Customer wanted to reduce this machine down time and if possible completely eliminate it.

Properties of coolant like pH, concentration etc. had to be maintained at each machine. This caused irregularities and required lot of manpower. Due to the space limitation available for individual tanks, filtration level achieved was compromised resulting improper filtration reducing the coolant life and frequent breakdown of machines.

Customer wanted to explore the possibility of adding additional machine in the same shop floor to match the ever increasing production demand

Veeraja proposed a centralized filtration system with large conveyors and mesh drum filters. A layout was prepared with the process planners from Bajaj Auto ltd. Civil trenches were dug in existing machine shop. Advance in civil engineering has made it possible to dig inside the shop floor without disturbing adjacent machines.

Careful coordination with various agencies and technical team Bajaj Auto Ltd ensured that production is hampered the least. A large pit to accommodate a 15000 LPM central filtration which total tank capacity of more than 1,00,000 liters was constructed outside the shop. U shape gutters were fitted in the trenches and a central filtration was installed in the pit. A regularly tracked project execution ensured on time delivery and smooth transition from individual to Centralized filtration system

Individual tanks were removed and dirty fluid outlets of all machines were connected to the U shaped gutters. These carry the fluid and chips to the CFS. Sufficient gradient ensured all is transferred without any blockage and accumulation. Additional flushing nozzles tapped from high pressure supply line are used at regular intervals.

  • Coolant life increased from 3 months to 3 years.
  • New machines were added due to the space saved by removing individual tanks.
  • Manpower was reduced.
  • Lesser breakdown and downtime of machines increased production capacities.
  • Power consumption was reduced by 50%

Industries / Companies Which May Need Centralized Filtration Systems

Our experts will always be happy to help you select proper product / combination of product for your industry application.