What Are the Health Risks Linked to Machine Coolant?

Machine coolant, also known as metalworking fluid, plays an essential role in machining by reducing heat, improving tool life and supporting a better surface finish. However, if coolant is not properly managed, it can pose health risks to machine operators and maintenance teams. From skin irritation to respiratory conditions, understanding these risks is vital for creating a safer working environment and keeping coolant systems performing effectively.

Skin Disorders

When skin comes in direct contact with coolant it can cause an array of skin conditions such as contact dermatitis. These conditions can be worsened by dirty coolant and high concentration levels. If dirty coolant enters cuts and abrasions on the skin this can result in swelling and blisters. Maintaining good hygiene by washing hands regularly helps lessen the negative effects.

Long Term Health Effects

Constant exposure to coolant mist can lead to respiratory problems including asthma and Occupational Hypersensitivity Pneumonitis. OCP is an allergic reaction in the lungs that causes a fever, cough and shortness of breath. Symptoms to check for lung disease are regular chest infections, difficulty breathing, coughing and weight loss. In the past there was also a higher risk of developing skin, lung and pancreas cancer due to unrefined mineral oils.

Working with water-based fluids also carries a risk of operators developing Legionnaires Disease, a serious and potentially fatal lung condition caused by Legionella bacteria growing in the fluid.

How to Keep Coolant Cleaner for Longer

If your metalworking fluid changes colour this can indicate bacterial growth or tramp oil. Foul smelling fluid also indicates bacteria which can be inhaled in the mist causing operators to become ill. Treating the fluid with biocides can help, but sometimes it may be best to replace the coolant.

Metal chips and tramp oil in the metalworking fluid is a sign your filtration system is not working sufficiently. Adding a magnetic filter to the machine improves the removal of fine ferrous particles from the cutting fluid. Oil skimmers can also be added to remove tramp oil.

Refractometers can measure the concentration levels of the cutting fluid, and a dip slide test can be carried out to see how bacteria grows which is then compared to a reference chart.

Health & safety Requirements

As an employer it is important you minimise the risks associated with metalworking fluid to maintain a healthy workforce. Installing Local Exhaust Ventilation (LEV) systems and splash guards on CNC machines help to limit exposure to harmful coolant mist. Ensure operators are supplied with the correct PPE to do their jobs safely; this includes nitrile gloves and safety goggles. Encourage your workforce to regularly was hands and arms to remove any irritants.

The HSE website has handy guides for complying with the Control of Substances Hazardous to Health Regulations 2002.

Regular checks, maintenance and cleaning not only prolong the life of the cutting fluid, but it also prevents harmful bacteria from growing in the coolant and making operators unwell. It is also important to check the performance of your extraction systems.

Matching the fluid to the application and using mist suppressants also help prevent negative effects on operators. Adequate filtration methods will also contribute to a healthier workforce.

Conclusion

Keeping machine coolant clean and well maintained is not only important for machining performance, but also for protecting operator health. By monitoring concentration levels, controlling bacteria, removing tramp oil and fine metal particles, and following HSE guidance, employers can reduce exposure risks and help prevent avoidable illness. With the right filtration, maintenance routine and safety measures in place, coolant can remain cleaner for longer and contribute to a safer, more productive workshop.

Why choose Eclipse Magnetics for your magnetic filtration requirements?

Eclipse Magnetics has over 100 years of experience in the creation of high-performance magnetic systems. As a world leader we supply critical equipment to some of the leading names in the most demanding industries.

We have a track record of producing high-quality products backed by a commitment to excellent customer service. Our market leading products are guided by our technical application teams who have a wealth of experience. All manufacturing is carried out under an ISO 9001 certified quality management system.