Coolant solution refers to the steps or measures  required to address various issues that arise in coolant applications (coolant problems) in the field. Below is a list of the mentioned coolant problems along with their solutions.

1. Chip Issues

• Chips are waste in the form of small metal fragments produced from metalworking processes on CNC machines
• Problems
  • Obstructing coolant flow
  • Clogging filters
  • Breeding ground for bacteria
  • Damaging the finish
  • Increasing conductivity leading to corrosion
• Solutions
  • Coolant filtration
  • Centrifugation/magnet
  • Settling

2. Bacterial Issues

• Bacteria usually reside at the bottom of the tank, stagnant areas, chips, and waste.
• They thrive on minerals in water, tramp oil, coolant concentrate, and food residues.
• Problems
  • Odor, rust
• Solutions
  • Ensure proper preparation of the coolant solution (add water to the container first, then coolant)
  • Use pure water
  • Daily coolant top-up
  • Concentration control
  • Tramp oil control
  • Prevent lubricant contamination
  • Maintain machine cleanliness
  • Complete cleaning (once a year)

3. Fungal Issues

• Fungi grow on the surface of the coolant tank.
• Tend to grow in synthetic coolants.
• Problems
  • Clogging, odor
• Solutions
  • Maintain machine cleanliness
  • Physical handling
  • Fungicide
  • Healthy bacterial population
  • Use DI water

Read more: Bacterial and Fungal Problems in Metalworking Fluids

4. Eczema Issues

• Eczema, also known as dermatitis, causes itchy skin.
• Causes: extreme pH, solvents, dissolved metals, tramp oil, straight oil, protective cream, dirty coolant, biocide
• Problems
  • Itchy skin, health disturbances
• Solutions
  • Avoid direct contact with coolant
  • Avoid using protective cream
  • Relocate allergic operators
  • Maintain optimal coolant concentration
  • Use microbiocide correctly
  • Use proper PPE and tools

5. Tramp Oil Issues

• Tramp oil: machine oil that leaks and mixes with coolant
• Problems
  • Bacterial growth
  • Reduced tool life
  • Filtration obstruction
  • Smoke, oil mist, sticky residue
• Solutions
  • Address oil leaks
  • Use scrounger belts to remove tramp oil
  • Purify coolant through other methods
  • If severe: replace with new coolant

Read more: Tramp Oil: The Causes, Problems, and Solutions

6. Seal Issues

• Seals continuously exposed to coolant can swell.
• Seal durability depends on: seal material, coolant type, workload, installation method.
•  Problems
  • Seals swelling and getting damages

• Solutions
  • Use Viton seals (stronger)
  • Use good quality coolant, consult with Eonchemicals

7. Residue Issues

• Types of residues: thin, soft, hard, sticky, and crystalline
• Problems
  • Can interfere with: dial calipers, gauges, auto tool changers, position sensing scales, precision grinders, cutting tool inserts, transfer line pallets
• Solutions: Use good/appropriate coolant; consult with us

8. Foam Issues

• Foam occurs due to the presence of gas, liquid, and agitation.
• Triggers: air leaks (packing, joints), cascading, cavitation, low coolant level, coolant type, etc.
•  Problems:
  • Dirty floors
  • Safety hazards
  • Wasteful
  • Disrupts cooling and lubrication processes

• Solutions:
  • Address physical causes with physical actions
  • Address chemical causes with antifoam chemicals

Read more: Foaming on Metalworking Fluids and The Solutions

9. Paint Issues

• Regular paint (alkyd type) is generally not resistant to coolant.
• Problems
  • Paint peeling and disrupting the system
• Solutions
  • Use epoxy or polyurethane paint

10. Rust Issues

• Rust can occur due to low pH, parts sticking together, bacteria, contamination, improper grounding.
• Problems
  • Machine damage
  • Unusable parts
• Solutions
  • Use DI water
  • Maintain optimal concentration
  • Use rust preventive
  • Control bacteria
  • Check water content (if using neat oil)
  • Ensure proper grounding
  • Prevent coolant contamination
  • Use coated plastic or cardboard to separate parts
  • Avoid contact between different metals

11. Excessive Usage Issues

• PCauses of excessive usage:
  • Weak concentration control
  • Use of hard water
  • Long intervals between top-ups
  • Low-grade coolant
  • Leaks
  • Poor technical service
• Problems: increased costs
• Solutions: identify the cause and apply the appropriate coolant solution

Summary

• Problems in coolant applications: Chips, bacteria, fungi, eczema, tramp oil, seals, residues, foam, paint, rust, excessive usage.
• All the above problems lead to losses (quality degradation, damage, wastage).
• All problems can be addressed by identifying and eliminating the causes.
• The most common preventive measures are: using DI water and maintaining coolant concentration.

For more information on coolant solutions or coolant/metalworking fluid products, please contact us.