The metalworking industry is ever-growing, especially in the USA with such a robust economy in 2019 – 2020. With industry growth, most manufacturing engineers try to have systems in place that perform efficiently on all their metal working processes. These last several years, a small percentage of manufacturers discovered a lubrication process called minimum quantity lubrication that’s superior to the traditional flood cooling process which uses toxic metalworking fluids (MWFs).
Minimum quantity lubrication, or MQL is more efficient in virtually every step of a manufacturing process. For the most part, manufacturers see sustainability and efficiency as a product of high cost and hesitate switching to a process they’re not familiar with. But with a Minimum Quantity Lubrication (MQL) setup, sustainability can actually mean lower costs with higher productivity. So, the vast majority of manufacturers could improve their entire process, if only they would be open to change.
How manufacturers’ fear of change is costing them time and money?
So, Why are only a small percentage of manufacturers actually investing in innovative production technologies such as MQL? This is a question that deserves some consideration.
Why, even with laws and regulations that could benefit them using a more eco-friendly solution, are the majority of manufacturers not taking steps to improve their production practices? Isn’t it their responsibility to ensure the environment isn’t compromised in their manufacturing processes?
Maybe… some manufacturers fear new technologies? Or, are a lot of the “old guard” folks just not comfortable with change?
In all honesty, we feel that biggest reason a large percentage of these manufacturers haven’t made the transition yet is because of one simple phrase; “If it aint broke… don’t fix it.” Well, there is some truth to that statement. After all, flood cooling and using toxic MWFs does assist the metal working process and allow the worker to quench the heat of the tool and the workpiece. But that would be just like saying; my horse and carriage gets me from point A to point B, so why should I use an automobile instead?
This may be a slightly exaggerated example, but true nonetheless!
Minimum Quantity Lubrication facts that prove it to be superior to flood cooling
The Minimum Quantity Lubrication flow rate is much lower than traditional metalworking fluid systems – the flooding technique. With MQL, only a small amount of lubricant is used. This lubricant is mixed with air and delivered manually or automatically to specific points of the tool and workpiece that need lubrication. Also, because of the molecular composition of the micro-lubricants formulated by MagLube, there is a magnetic type effect at work, causing the microscopic amount of lubricant to adhere or bond exactly where it’s delivered. This reduces the friction dramatically during that process, resulting in higher quality end products, produced with a less expensive process.
By converting to MQL, it reduces or even eliminates wet and soaked equipment and the formation of bacteria to the equipment due to flood cooling. Consequently, the workers won’t be exposed to harmful MWFs. Still, the benefits don’t’ stop there. Manufacturers can save a lot with MQL. Instead of purchasing gallon after gallon of lubricant, each drop will now be utilized for the equipment’s performance while also reducing friction during the cut. This friction reduction will Always result in a higher quality end product!
Because of our carefully formulated lubricants, and our custom designed systems, MagLube MQL debunks the notion that more is always better. Sometimes, a small amount applied properly is way better than “more is better”. Just read what the customers say about switching to MagLube’s systems.
Converting to MQL will have your facility reaping the benefits
Metal workers and manufacturers who already adopted the precise air-lube stream technology of MQL are enjoying the benefits. One major perk here that can’t be ignored is the reduced impact of the production to the environment. MQL uses vegetable-based materials that are safer for both humans and the environment. We could write an entire post on just this aspect of MagLube’s custom micro-lubrication systems, but knowing that your workers can now work in an environment, free from the toxic adverse health risks of MWFs should be enough reason to consider how MQL can transform your business.
Moreover, production becomes even more eco-friendly with MQL. The cutting fluids that need to be disposed of when using flooding techniques are reduced dramatically. We could claim they’re completely eliminated. MQL now overshadows the haphazard toxic flooding that many manufacturers are still practicing.
If more companies would be willing to adopt MQL, the “dirty” image of manufacturing could be reversed.
MagLube MQL produces a better product quality
Like briefly mentioned before, another benefit from adopting MQL in metalworking is that the metal chips produced are dry. Aside from reducing post production cleanup costs, these near-dry chips are much easier to recycle. This is the reason why dry cutting and Minimum Quantity Lubrication are grabbing the attention of responsible manufacturers that are wanting to streamline their metal working process, save time and money and provide workers a cleaner… more eco-friendly working environment.
Many manufacturers hesitate converting from what they’re already used to. Because the fact is if we are to breakdown the cost of wet manufacturing and dry manufacturing through MQL, the results are surprising to most, but to us, exactly what we and our customers have come to expect. MQL yields more profit, higher quality work pieces, less environmental damage and promotes a safer work environment.
So why are manufacturers not using MQL?
With all these mentioned benefits, we can’t help but wonder why only a small percentage of metal manufacturers are switching to MQL.
All of these questions of “why” still remain unanswered. But any questions of the validity and efficiency of MQL have been answered. We now have years of data and proof to backup MQL systems. Minimum Quantity Lubrication (MQL) setup has been proven to be beneficial in all aspects of metal working and production. If manufacturers won’t take strides in adopting this new technology, they most likely have resisted many other changes in technology over the years. Eventually we’d like to see every manufacturer that’s using any type machining that requires lubrication to at least explore what MagLube custom MQL systems can do for their overall process and bottom line. We’re always ready to show everyone the facts about minimum quantity lubrication!
At MagLube, we have the ability to custom design any MQL system for any machining application. This is what we do for ongoing customers and clients. To explore how our lubricants and systems may benefit your company, we’ve also put together several packages that can be used as a portable solution. This will allow your company to inexpensively test how MQL performs for you. Check out our MQL packages here.