Company Name: Steering suspension parts
Location: North India
Product Installed: Coolant Sump Cleaner
Background
A leading manufacturer of precision automotive components based in Pune, India, operates a large-scale facility with several centerless grinding machines. These machines are critical for achieving the precise tolerances and surface finishes required for components like valve lifters, rocker arms, and fuel injection parts. The company uses water-based coolant to maintain grinding efficiency and prevent overheating of both the workpiece and the grinding wheels.
Problem Identification
Over time, the grinding operations resulted in significant accumulation of fine metal swarf, sludge, and tramp oil in the coolant sump of the centerless grinding machines. This contamination led to multiple operational issues.
- Reduced coolant life, requiring frequent disposal and replacement every 10-15 days.
- Clogging of coolant nozzles and pipes, disrupting flow and increasing maintenance.
- Bacterial growth, leading to foul odor and potential health concerns for operators.
- Increased tool wear, affecting production accuracy and raising tooling costs.
- Frequent downtime for cleaning sumps manually, impacting production schedules.
Destiny’s Team Investigation
A thorough investigation was conducted to pinpoint the root causes of the dirty hydraulic oil issue. Key findings included:
1. Site Visit & Trial Run
- An on-site trial was conducted to demonstrate the sump cleaner’s effectiveness. The trial involved cleaning the sump of a centerless grinding machine that had been running continuously for two weeks and had accumulated a thick sludge layer
2. Sump Cleaning Operation
The Coolant Sump Cleaner was connected to the sump tank.
In less than 15 minutes, the machine extracted nearly 100 liters of dirty coolant and sludge.
The in-line filtration and oil separation systems processed the coolant, and reusable fluid was pumped back into the machine.
Sludge and swarf were collected in a removable mesh basket for easy disposal.
Consequences
- Accumulation of fine grinding dust and metal swarf
- Bacterial growth in the coolant sump
- Foul odor and reduction in coolant life
- Frequent machine downtime for manual sump cleaning
Solutions Implemented
After understanding the client’s challenges, our team recommended the use of a portable Coolant Sump Cleaner, specifically designed for metalworking fluid management in machine shops. The chosen unit featured:
High suction power to pull contaminated coolant, sludge, and swarf.
Dual-tank system (dirty and clean tanks) for separating contaminants from reusable coolant.
In-line filtration system to remove fine particles up to 50 microns.
Oil skimmer attachment to eliminate tramp oil.
Stainless steel construction for durability and easy cleaning.
Results
Within two weeks of using the Coolant Sump Cleaner, the client experienced significant improvements:
✅ Extended Coolant Life
Coolant life increased from 10–15 days to nearly 45 days, drastically reducing fluid consumption and disposal costs.
✅ Improved Machine Efficiency
Coolant flow was uninterrupted, and nozzles remained clean. Machine uptime increased due to fewer clogs and reduced need for emergency cleaning.
✅ Reduced Tool Wear
Grinding wheel life improved by 20–25% thanks to cleaner coolant, leading to better part finishes and fewer tool replacements.
✅ Reduced Manual Labor
Manual sump cleaning, which previously took 3–4 hours per machine, was replaced by a 15–20 minute automated process, freeing up labor for other productive tasks.
✅ Health & Safety Benefits
The coolant maintained a better pH and showed lower bacterial growth. Operators reported reduced odor and better working conditions around the machines.
✅ Return on Investment (ROI)
The initial investment in the sump cleaner was recovered in less than 6 months through savings in coolant usage, downtime, and maintenance costs.
BEFORE
AFTER
AFTER
Destiny’s Coolant filtration Systems Installation
Outcome / Benefits After Installation
| Parameters | Before Installation | After Installation |
|---|---|---|
Coolant Life |
10-15 days |
45-60 days |
Machine Downtime (Monthly) |
4-5 hours |
< 1 hour |
Surface Finish Consistency |
Inconsistent |
Highly consistent |
Maintenance Frequency | Weekly | Monthly |
Coolant Disposal Costs |
High |
Reduced by 60% |
Customer Feedback
The coolant sump cleaner has completely changed our maintenance routine. Not only has it improved coolant life and surface finish, but we’re also saving significantly on downtime and disposal costs.
Say goodbye to contamination and hello to a cleaner, more productive system