Applications
The processing of swarf that comes out of automatic lathes operating with neat oil, brings many advantages to companies. The leading advantage is the reclaim of very precious neat oil. The following advantages can be listed as; ease of storage of swarf, the visibility of work pieces hidden in swarf, keeping the workshop and environment clean.
In order to enjoy these benefits, the bundles of lathe swarf needs to be shredded first. Kazcıoğlu Automotive shreds the swarf before feeding into ECOCUT-TECH ECT-600 Centrifuge. By means of reclaiming the oil, the company saves on the neat oil bill, while adds value to itself by effective swarf management.
Operating in the automotive parts sector, Sio Automotive, decided to use separate systems for the steel and aluminum swarf. It is unavoidable to have some debris of swarf within the swarf processing systems and it is not possible to completely clean these systems. When this situation taken into account, decision on separate systems for different metal types makes more sense.
In this application, the swarf collected in swarf carts are fed into the hopper of the shredder feeding conveyor by the lift. The swarf that comes out of the shredder feeding conveyor and the shredder, is fed into the centrifuge by a steel belt conveyor, and the processed swarf is carried into containers with a discharge conveyor. A PLC run pump transfers the reclaimed coolant into barrels.
Food packaging machines manufacturer based in the UK, decided to employ an ECOCUT-TECH EPC3-L1 Briquetting Press supported with a Swarf Cart Loading Lift, in order to manage the aluminum swarf that comes out of intensive machining processes.
The swarf collected in carts can easily be transferred into a hopper large enough to be fed by a lift.
The screws installed in the hopper transfers the swarf to the press, which then compacted under high hydraulic force to form briquettes, discharged into carts.
The reclaimed coolant by briquetting is transferred to a filtering station with a PLC controlled pump, which then re-conditioned and fed into machining centers.
This application consists of two identical lines each of which has the ability to load the swarf collected in carts from two different levels.
Swarf Cart Lifts - Lower Floor
Swarf Cart Lifts - Upper Floor
The swarf carts are tipped over automatically into the shredder feeding screw conveyor hopper.
Swarf Cart Lift At Tip Over Position
The swarf fed into the hopper of the shredder feeder is pushed towards the shredder blades.
Shredder and The Shredder Feeding Screw Conveyor
Shredder Blades
The shredded swarf and the small sized pieces fall underneath the shredder feeder are collected and conveyed to the centrifuge with a steel belt conveyor. The de-oiling begins on the steel belt by means of oozing. The oozing coolant is collected in the tank that is attached to the body of the conveyor and transferred via a pump controlled by a level sensor to the main coolant collection tank.
Steel Belt Conveyor With Oozing Coolant Collection Tank
A swarf screen driven by a vibration motor is used to separate the solid parts that might be present in the swraf conveyed by the steel belt conveyor to the centrifuge. In order to reclaim the coolant, the swarf that passes through the screen is fed into the centrifuge. The reclaimed coolant flows into the main coolant collection tank through a different channel than the swarf discharge channel.
Centrifuge, Main Coolant Collection Tank and The Swarf Screen
The processed swarf discharged from the centrifuge is conveyed to the silo loading scraper conveyor by another scraper conveyor.
Centrifuge Discharge Scraper Conveyors
Silo Loading Scraper Conveyors
The hatches located underneath the silo loading scraper conveyor distribute the processed swarf into silos following the commands of the automation system.
Silo Loading Hatch (Silo Loading Scraper Conveyor View from Below)
Swarf Silos
The swarf collected in the swarf silos is discharged into the transportation vehicle through the silo discharge hatches and complete the journey through the system.
The Discharge Hatches of the Swarf Silos
Each and every step of the operation is run fully automatically by the PLC system. With the help of the touch screen on the main control panel, all the components of the system can be operated manually, the status of the system can be monitored, parametrical settings of the system can be done and fault reports can be viewed.
The Main Control Panel
İyiokur Metal, a producer of brass rods, bars, profiles and manifold profiles, is processing the brass swarf they buy in with an ECOCUT-TECH ECT-600 centrifuge, which decreases the losses at the smelting furnaces and the negative effects to the environment.
Oznur Pres is the producer of faucets, and valves under the brand name NSK. The company lately realized an improvement in de-oiling the brass swarf in order to re-use the oil recovered. To process 2 tons of brass swarf daily, Oznur Pres choose ECOCUT-TECH, and improved the savings by lower residual oil levels and workmanship costs.
The machining of brass produces high levels of sub-millimeter particles, most of which decreases the quality of recycled oil. Thanks to the filtering techniques developed by Karenpro, the particles in the recycled oil is kept under 200 μm level.
Our client is working as a sub-contractor in the Oyak Renault factory gearbox workshop, separating the cutting oil (synthetic oils are used) from the swarf in order to re-use the lubricant. ATIKSAN is undertaking the processing of 3 tons per day of swarf to retrieve 230 liters (more than a barrel) of synthetic oil which then be re-used in the workshop. Our client increased the productivity of the system by 15% after replacing their horizontal centrifuge with vertical ECOCUT-TECH Swarf De-oiling Centrifuge. The factory officers underlined the productivity increase by saying "the processed swarf is now more dry".
