Carbide Cutting Tools Manufacture
Company Name: Pro Cut Tooling Ltd
Location: Hull (UK)
Eclipse Product Installed: Filtramag FM2.5
Industry: Machine Tools
Process Type: Tool Cutting/Grinding
Pro Cut Tooling are a leading manufacturer and refurbisher of carbide cutting tools for woodworking, metal and plastic cutting. The plant operates 24 hours per day. Previous filtration was a 20 micron paper filter on the Walter Helitronic and low intensity magnetic rods fitted into the coolant oil holding tanks on the ANCA machines.
Pro Cut were faced with the challenge of entering the market for tools produced with a “mirror” finish. These high precision tools cost the same to manufacture but can command up to 4 times the selling price of standard finish tools.
Previous filtration was inadequate as anything smaller than 20 micron on the Walter machine continued to be circulated. On the ANCA machines the magnetic rods were ineffective. The low intensity magnets were ineffective with carbide which has only 20% magnetic permeability compared to mild steel. The rods were also positioned in the tank so that most carbide particles bypassed them. It was impossible to achieve the “mirror” finish as re-circulated carbide particles were damaging the surface of the tools.
Carbide particles were also causing other problems, each machine had to be stopped for 2 hours weekly to clean away carbide deposits from the polishing heads and cutting tools. In addition, filters on a demister on the Walter machine required changing on a weekly basis as they became blocked by carbide particles, the cost for this was £30 ($46.8) each time.
Due to the volume of carbide particles each holding tank had to be cleaned out every 6 months resulting in a full day of downtime.
Filtramags were fitted to work in conjunction with the existing filtration. Each Filtramag extracts 2 Kg (4.4lbs) of carbide waste each week providing Pro Cut with some major operating benefits.
- Pro Cut achieved the mirror finish required to sell into high precision applications
- Cleaning of the machine is only required once a month instead of weekly
- De-mister filters no longer require changing saving £30 ($46.8) per week
- The estimated coolant life has been extended from 2 to 5 years; it costs £1400 ($2184) per machine to replace coolant
- The holding tank now needs to be cleaned every 18 months instead of 6 months
"We were delighted with the service provided by Eclipse Magnetics; from the initial site survey through to delivery."
"I cannot begin to tell you how much it has helped our operation, the magnetic filtration unit has been a real problem solver it has surpassed all our expectations. Its cured a 30 year plague!"
"This technology is economical, reliable and efficient. I believe that magnetic filtration technology is the future."
"Magnetic filtration has dramatically cleaned up our fluids and improved the surface finish we can offer. It extracts around 50Kg per day of ferrous waste."
"We chose Eclipse Magnetics to supply our housed grid because they are a respected and well-established brand. They offered us a very competitive price, and the process of ordering and installation was straightforward and reliable."
“We are delighted with the Automag installation; it’s solved all the problems we were having previously with downtime and maintenance costs. The filter means that we are able to use recycled water, which is saving us £1000 per week!”
"Here at Qualflow, we base our business on a philosophy of make the product simple to use, reliable and cost-effective. Eclipse Magnetics’ neodymium magnets offer the strongest magnetic performance, and are nickel plated, making them a cost effective.."
"The Ultralift Plus magnetic lifter from Eclipse Magnetics is the perfect solution for the pick-up and transportation of the ultrasonic calibration blocks in our facility"
"The result is an aesthetically pleasing system, which is effective in trapping metal contaminants and is easy to clean..."