how motorex swisscool tresor pmceurolineusa.com/images/tresor_pmc.pdf · 2018. 6. 4. · motorex...
TRANSCRIPT
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How MOTOREX
SWISSCOOL TRESOR PMC® hunts down bacteria the natural way...
FIRSTA WORLD!
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Ladybugs (the Coccinellidae family of beetles) eat up 50 greenfly a day. These useful beetles are also bred for use in biological pest control. TRESOR PMC® has taken its cue from this model provided by nature.
The Green RevolutionFIGHTING BACTERIA WITH PRECIOUS METAL:
Water-miscible cooling lubricants are a crucially important element of demanding metal machining processes. In nature, life cannot exist without water – but the water, mineral oil and emulsifiers used in machine tools can turn them into ideal incubators for bacteria and fungi. Up to now, chemicals such as boron, amines, fungicides or bactericides have had to be regularly used to check this persistent growth. The need for such “chemical bludgeons” is now over! MOTOREX presents a world first: SWISSCOOL TRESOR PMC® (Precious Metal Catalyst) – the first cooling lubricant concentrate that impedes and sustainably limits bacterial growth using bioactive precious metals.
MOTOREX TRESOR PMC®
REPORT
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Drilling, milling, turning and grinding – machining
operations that send swarf flying everywhere call for
heavy-duty cooling and lubrication. Cooling lubricant is
flooded over the tool and workpiece. Water mixed with
finely dispersed droplets of oil forms an emulsion that
effectively cools and reduces friction. These emulsions
also contain additives that ensure optimum cutting
performance and high-quality surface finishes.
Ingress of foulants carried by raw materials, leakage oil
and other impurities promotes the growth of micro-
organisms in the emulsion circuit. This results in noxious
odors, corrosion, sediment and deposits, etc., that neces-
sitate changing the coolant fluid. Up until now, the only
truly effective means of countering such coolant degra-
dation were stabilizers that pose hazards for humans
and the environment. This is why the use of such proble-
matic substances has become the subject of broad deba-
te worldwide and faces growing, justifiable challenges
from the workplace in particular.
HOW PMC® TECHNOLOGY WORKSWhen the coolant circuit of a machine tool is filled with
MOTOREX TRESOR PMC®, a precious metal catalyst – the
patented BacCrack® from MOTOREX – hunts down and
eradicates bacteria. Tiny particulates of precious metal
that are invisible to the naked eye float suspended in the
cooling lubricant flow. Bacteria that these particulates
encounter along the way are promptly destroyed by
catalytic action. Thanks to these ever-present, finely dis-
persed precious metal catalysts, undesirable bacteria
populations never have a chance. Machine operators
can breathe a deep of sigh of relief. And because precious
metal always remains a precious metal, its catalytic
effect does not weaken over time, a feature that signi-
ficantly lengthens coolant life.
INTENSIVE RESEARCH AND DEVELOPMENTChemists and engineers at MOTOREX, working in col-
laboration with external biologists and led by the ex pe -
rienced MOTOREX industrial specialist Dr. Stefan Maric,
invested numerous man-years to achieve this exciting
new development. Beginning with the initial idea and
Many areas of science and technology, including human medicine, use the antibacterial effect of precious metals: with TRESOR PMC®, MOTOREX has succeeded in inte-grating this technology into an innovative cooling lubricant with long-term action.
MOTOREX TRESOR PMC® – the green drum and what it holds take metal machining to new dimensions!
TRESOR PMC® IN PICTURES
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continuing through development and comprehensive
field testing all the way to the finished product, every
aspect of this new development was examined and all
relevant perspectives were closely scrutinized, from
strict occupational health regulations and ecological
sustainability to the demands for high-tech perfor-
mance in machine tools. The formula for MOTOREX
TRESOR PMC® contains no substances that are hazard-
ous to humans or the environment. Not only is this cool-
ing lubricant entirely
• boron-free
• amine-free, and
• chlorine-free
• free of problematic substances,
it has also been ranked in the product category least haz-
ardous to water quality, Water Hazard Class 1. This in-
novative formula already satisfies the even more strin-
gent EU biocide regulations scheduled to come into force
as of 2014.
GROUNDBREAKING PERFORMANCE AS WELLOne of the specifications driving development work was
that absolutely no compromise could be made in manu-
facturing performance. Field testing more than con-
firmed that this innovative product guarantees very
high cutting performance and very long tool life, and
thus stands entirely on a par with MOTOREX’s other,
well-known SWISSCOOL products. Its performance is
further enhanced by the generally low concentrations
The results of bacterial colonization tests conducted on cooling lubricants are clearly visible in the culture growth medium: weak (TRESOR PMC®) and heavy bacterial colonization (conventional cooling lubricant).
With its innovative TRESOR PMC® (Precious Metal Catalyst) cooling lubricant concentrate, MOTOREX has achieved a world first in the metalworking industry. The emulsion underwent years of exhaustive testing, and has won over leading experts and shop-floor machinists alike.
required, the resultant beneficially low rate of concen-
tration adjustment, and improved tool life. What is
more, cost-effectiveness is sustainably improved thanks
to significantly lower lubricant consumption, a reduced
maintenance requirement and the fact that supplemen-
tary chemical additives are no longer needed.
COMPREHENSIVE FIELD TESTING WITH CUSTOMERSFollowing successful field testing in 2007, entire manu-
facturing centers belonging to innovative customers in
Switzerland and abroad were filled with TRESOR PMC®.
It goes without saying that, by that point in time, TRESOR
PMC® had already successfully passed all clinical tests
and met all the objectives specified by its developers.
The number of systems using TRESOR PMC® grew quick-
ly, as even our most discerning customers were immedi-
ately convinced by the innovative concept. Demand
swiftly increased worldwide.
NEWLY ERECTED PRODUCTION FACILITIESThe sophisticated product formula of TRESOR PMC® re-
quires specialized installations and carefully monitored
processes. MOTOREX invested in new production facili-
ties with online monitoring capabilities which are used
exclusively to produce TRESOR PMC®. This serves to
ensure reliable, industrial-scale production of large
quantities and reproducible process programming. •
REPORT CONTINUED
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BG
When machining this stainless-steel component, Lars Schmäder, head of the machining workshop at Enz Technik AG in Giswil, noticed marked improvements on several machining parameters when working with TRESOR PMC®:
IMPROVED PERFOR-MANCE VALUES WITH TRESOR PMC®
AVERAGE CONCENTRATION
LONG-TERM STABILITY
HARD WATER STABILITY Suitable for use with water of any hardness.“We work with hard water from the municipal mains system and nevertheless achieve excellent emulsion stability with no calcium soap formation. What is more, we have been able to reduce cooling lubricant concentration from 15 to 7% with no loss of quality, even in very demanding machining processes!”Bernhard Münger, head of the machining department, Ernst Roser AG, Berne
SKIN COMPATIBILITY Free of boric acids, amines and free of problematic substances.“Ever since I started working with the innovative TRESOR PMC® cooling lubricant, my skin problems have disappeared – this is a fabulous improvement!”Anna Petrovic, employee, Wandfluh Hydraulics & Electronics, Frutigen
TRESOR PMC® IS A HIT WITH CUSTOMERS The MOTOREX Research and Development project team documented all day-to-day production parameters from real-life use by customers and industry specialists, including cooling, filtration, concentration adjustment rates, occupational exposure to germs and machine hygiene. The results were extremely gratifying. Here are just a few testimonials from the extensive positive feedback:
TOOL LIFE High long-term stability and substantially extended tool life.“Precision drilling of camshaft bearing bores is an acid test by which we can measure the quality of a cooling lubricant. Many cooling lubricants fail the test owing to their lack of lubricating effect. TRESOR PMC® scored double points in this regard, because not only did it perform the task outstandingly, it succeeded in doing so at an extremely low concentration level of 6%.”Dirk Sellmer, head of testing and development, MAPAL Dr. Kress KG, Aalen, Germany
COST-EFFECTIVENESS Very good flow characteristics.“We succeeded in lowering our concentration adjustment rate, and with it consumption by our 9,000-liter system, from 1.5 to 0.8%. The lubricant runs off the workpiece and swarf very well.”Jürg Haltiner, owner of Rätia Mechanik AG, Felsberg
PERFORMANCE Excellent cutting performance.“After introducing TRESOR PMC®, the service life of the indexable inserts improved by an incredible 20% compared to the predecessor product. The cooling lubricant also came through a three-week shutdown over the holiday season problem-free. We were also able to sustainably reduce cooling lubricant concentration levels.“Lars Schmäder, head of the machining workshop, Enz Technik AG, Giswil
THE FUTURE IS NOW Technology harboring good future perspectives.“I see good future opportunities for a cooling lubricant such as TRESOR PMC®, which is free of problematic substances and inhibits germ growth by natural means. This has been proved in comprehensive tests at reference production sites. I have already amply alluded to the possible risks posed by biocides in use today, and the cost factor for such products that necessitate back-end moni-toring and processing is the object of increasingly critical focus.”Michael Rocker, chemical engineer, Berufsgenossenschaft Metall Nord Süd (BGM), Mainz, Germany
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MOTOREX magazine: What confirmed triggers of skin
disorders are associated with the use of coolants?
Michael Rocker: Skin disorders caused by coolants – contact
eczemas, as they are known – are generally multifactorial in
nature. Depending on the damaging factors in each case, we
refer to allergic, toxic, irritant or degenerative changes in the
skin, and mixed forms are common. The period between first
contact with the coolant and the appearance of a skin disorder
can range from a week to 30 years.
Allergic contact eczemas are characterized by the fact that
the skin reaction persists throughout life, in many cases forc-
ing the sufferer to give up their job if the allergen cannot be
avoided. Common allergens such as nickel, cobalt or chro-
mium ions enter coolants from the workpiece. In such cases
substitution is generally not possible. Other relevant aller-
gens are biocidal substances such as formaldehyde deposits
or isothiazolinones. In this case, action can usually be taken
by replacing the triggering allergen.
Toxic irritant contact eczemas develop as a result of skin con-
tact with substances with powerful effects, e.g. machine-
cleaning or system-cleaning agents, or coolant or biocide con-
centrates. This type of disorder can be avoided by wearing
suitable gloves (which must be specified in the safety data
sheet).
Degenerative contact eczemas occur as a result of many
years of contact with cutting oils or cooling emulsions or so-
lutions. They develop through the slow but constant drying
and defatting of the skin and the disruption of the equilibrium
at the skin surface. This destruction can be avoided by opti-
mized skin protection measures (skin protectant plus skincare
product). However, care must be taken to ensure that coolant
specifications such as working concentration and pH meet
the manufacturers’ recommendations.
Interview with Michael Rocker, chemist, Berufsgenossenschaft Metall Nord Süd (BGM), Mainz, Germany,in the MOTOREX magazine.
Berufsgenossenschaft Metall Nord SüdPrevention DivisionHealth Protection DepartementWilhelm-Theodor-Römheld-Strasse 15 D-55130 Mainz www.bg-metall.de
NEW PERSPECTIVESCOOLANTS OF THE FUTURE OPEN UP
What are the costs incurred by industry in Europe each year
as a result of productivity losses due to skin disorders?
A wide variety of figures are bandied about, and I only have a
rough overview for Germany from the standpoint of the acci-
dent insurance companies. Reliable figures are difficult to
establish due to the mixture of direct costs (e.g. for treatment
or retraining) and indirect costs (sick leave, production losses)
that is involved. A survey conducted for the years 2002 – 2004
has produced direct cost figures of between 600 million and
2 billion euros a year and estimated indirect costs some five
times higher, giving an estimated cost figure of 3 to 10 billion
euros a year for Germany.
Extrapolating this estimate to Europe produces a sum well
into the double-digit billions. That’s reason enough to replace
skin-damaging substances wherever technically feasible.
How do you view the future development of biocide-
containing coolants?
This is a complex issue. The current standard practice is to
pre-preserve coolant lubricants or to subsequently add bio-
cides. The possible risks have already been described. Coolant
lubricants that are naturally biocide-free and physical decon-
tamination systems are also known. Minimum-quantity lu-
brication and dry machining are other options that avoid bio-
cides. My guess is that users will continue to give preference
to biocide-containing coolant lubricants for the foreseeable
future because of the need to suppress microbiological degra-
dation. Innovation will always be needed when negative
aspects such as skin or respiratory disorders get out of control.
What will future regulations mean for industrial companies
and operators?
I would feel happier if I could predict the expected positive
implications of REACH and GHS. Basically, manufacturers will
be increasingly responsible for investigating the harmful ef-
fects of their chemicals on humans and the environment. This
will initially focus on raw materials, then spread to finished
products for industry, skilled trades and private users. Com-
munication between the various manufacturers will also be
regulated.
The next step is to identify which particular application-spe-
cific conditions, such as intensive skin contact, aerosol forma-
tion during open use or risks associated with transport, lead
to which particular requirements in terms of protective
measures. The outcome of such an analysis might mean that
certain applications need to be restricted or even banned al-
together in individual cases, for example if they are carcino-
genic or environmentally hazardous.
BG
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This will be a protracted process, and REACH will not be
fully implemented before 2018. But at least then there
should no longer be any applications where we do not
know the extent of the risk to employees, and we will be
able to optimize protective measures. I am assuming that
the standard of occupational safety will be higher and that
there will be no unpleasant surprises because constitu-
ents that have been used for many years but have not
been adequately investigated “suddenly” prove to be es-
pecially dangerous.
The aim of GHS is to set global standards, i.e. even those
manufacturers that have not primarily been affected by
REACH to date will be compelled to classify and label their
products.
How do you view the future prospects for a product such
as MOTOREX TRESOR PMC® 100, which is free of boron
and amines and that limits microbial growth by other
means?
Assuming that the technical performance and service
lives have been confirmed in reference facilities, I think
that its prospects are very good and that it will probably
be used increasingly. I have already talked enough about
the possible risks associated with biocides, but the focus
for future products will increasingly be on the cost factor.
Although the current discussions about boric acid are not
based on particularly firm ground, they influence buyers
– albeit unconsciously – nevertheless.
What about the current position concerning coolants
containing boric acid with regard to the Biocides
Directive in 2014?
Looking ahead is always an uncertain business. Boric acid
is not currently listed as a biocidal substance in the Bio-
cides Directive, so while this situation continues (because
its anticorrosive effect remains the prime consideration),
the requirements of REACH will continue to apply. Discus-
sions within the EU are currently focusing on whether
boric acid should undergo the authorization procedure,
which would again entail additional costs. There is also a
risk that certain applications will not pass the authoriza-
tion procedure, or to put it plainly, will be banned. That’s
why the future for boric acid will be uncertain, even
though not a single case of illness has been documented
to date and the latest studies indicate that even highly
exposed workers in the boric acid manufacturing industry
are not affected by disease.
Why are all the relevant ingredients of coolant lubri-
cants listed meticulously in the safety data sheets and
labeled, whereas in real-life, biocides are sometimes
handled naively? For example, TRGS (Technical Rules
for Hazardous Substances) 611 stipulates that pH,
concentration, nitrite and temperature have to be
measured every week. However, the biocidal content,
after additions, is a parameter associated with a high
degree of risk but is hardly documented at all.
What do you think about this?
The main problem is that the requirements arising from
the legal areas of “placing on the market” and “activities”,
i.e. use, differ widely. For the purposes of placing on the
market, the properties of the traded product are consid-
ered, this is usually labeled and therefore subject to the
requirements of the Preparations Directive (from 2015:
GHS). Manufacturers implement these obligations, com-
pliance is (relatively) easy to monitor and violations are
subject to substantial fines.
Differing levels of risk apply to the use of products, depen-
ding on each case on the working concentration, i.e. the
degree of dilution. So we have individual company-spe-
cific or production-specific scenarios. Certain individuals
are responsible for establishing (i.e. estimating in many
cases) the level of risk during use, and that’s where the
problem touched on in your question arises. Large fac-
tories have suitable individuals (e.g. safety engineers,
works doctors, foremen) with the appropriate expertise to
implement the requirements, yet the smaller a company
is, the more difficult it is to identify problems and come up
with a suitable solution.
Monitoring compliance with the latest rules or regu lations
also becomes more difficult with decreasing company
size. It is no secret that some companies have not been
visited by accident insurance companies or regional au-
thorities for a decade or more (and they are certainly not
unhappy about this).
This problem can be resolved only by clarifying the risks,
informing the relevant company personnel (line man-
agers and specialists) about their responsibility, developing
appropriate protective measures in the form of informa-
tion sheets and seminars and, in particular, encouraging
them to create a healthy working environment.
Finally, I should like to look specifically at biocides. As a
result of the EU Biocides Directive, more products than
ever before now have to be investigated and authorized
and the fact that users sometimes handle biocides more
carelessly than they should has been taken into account.
There is now a need to make users aware that biocides are
dangerous or potentially dangerous products, depending
on the specific application, and to familiarize them with
the risks of corrosive burns, poisoning or chronic skin dis-
orders. The rules are strict enough, users just need to take
them seriously and adopt them in practice. This they can
do with the aid not only of the manufacturers, but also of
accident insurance companies and the authorities. • www.motorex.com
“Prospects are very good”
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HE LOVES DIFFICULT CUSTOMERS. IT’S MORE FUN TO EXCEED THEIR EXPECTATIONS.
Just how much Fischer’s products are in demand is clear from the moment you visit the company’s website: apart from English, French and German, there are also versions in Chinese and Japanese. No wonder: the precision spindles developed by Technical Director Thomas Frisch are among the best in the industry. Striving to attain international standards: that’s something MOTOREX also stands for. And why we are precisely the right partner for Fischer. Find out more about how our oils are helping com-panies from a wide range of industries establish leading positions for themselves: www.motorex.com
Thomas Frisch, Technical Director Fischer AG Precision Spindles
WHY DO YOU THINK HE SWEARS BY US?