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American Grown Renewable Resource
Performance Biolubes manufactures a complete line of bio-based
metalworking
lubricants for use in metal cutting, grinding, forming,
lubricating and quench applications.
Performance Biolubes products
provide our customers with huge
productivity improvements due to their
increased lubricity and film strength
which extend tool life, improve
finishes and allow cutting tools to cut faster.
We also eliminate smoke
and dermatitas problems. Our products are made
from USA grown seed
crops. Most of Performance Biolubes products earn a MSDS "0" health rating.
Performance BioLubes ---
Youtube Features
Click on the Movies and see some video from folks who have used this product.
Hear what they have to say...
Majeski Machine 34410 Rosati Drive Livonia, Michigan 48150
A Gear Manufacturer in Livonia Michigan
has found a money saving way to go GREEN!
“This product is its own best advertising.
We got 3 times the tool life out of our hobs after filling our machine
with NU Cut Plus (Soy- Based Cutting Oil) from Sterling Tool.
Before adding NuCut Plus, we had to change stations on our hobs twice a day.
Now, we change stations every other day.
Consequently, we are sharpening and recoating hobs less often,
saving us time and money.
Production has significantly increased due to the lack of downtime
and I can confidently run my other shifts without worrying that
they will run out of good hobs.
I would recommend this high performance cutting oil to anyone.
Amazing results from a renewable resource that is grown in the USA!
Ted Grutza
Majeski Machine
Success Story
Another reason to Go Green
Bio-Based Lubricants
Product: NuCut Plus Bio-Based Cutting Oil
Process: Gear Shaper / Tool Sharpening
Savings: $24,000.00
Background
The world’s leading international manufacturer of
agricultural, construction, forestry, and lawn and turf
care equipment was seeking ways to improve productivity,
reduce cost and improve the environmental
sustainability of their operations.
Situation
The Company desired to reduce the maintenance
cost of cutting tools, specifically the High Speed
Helical Shaper Cutter. The operation was using
Henkel Circlene FG20 petroleum-based metalworking fluid.
It required 60 minutes to re-sharpen the dull tool
at a cost of $34.80 per tool.
Solution Recharged the system with
NuCut Plus Soy-Based Cutting Oil.
Benefits NuCut Plus dramatically extended tool life.
The number of pieces cut between tool changes
increased from 29 to 44 pieces, a 52% increase.
NuCut Plus reduced grinding time from 60 minutes
to 35 minutes, a 25 minute reduction. This represented
a savings of 42%. NuCut Plus improved the tool performance
because the tool held its cutting edge, performed better,
reduced sharpening error and improved finish.
NuCut Plus is Soy-Based so the company was able to
use a product manufactured from a renewable resource.
It is biodegradable so it is friendly to the environment.
Annual Savings Current Cost: $51,956
Savings: $24,800
Percentage Saving: 47.7%
Payback Period: 2 Months
Your company can see these same cost reductions
by using this Bio-Based Technology. Give us a call.
Toll Free 1-866-929-7200
Another SuccessStory
Product
NuCut Plus Cutting/Grinding Oil
Application
Form Grinding heated treated high carbon steel with
CBN plated wheels
Background
Manufacturer of proprietary power transmission parts
struggled with heat checking in hardened parts after
grinding forms with CBN plated grinding wheels.
Situation
Customer has ground forms in heat treated high
carbon steel parts for many years. A typical plated grinding wheel
ground 2000parts before it required stripping and re-plating.
he quality control department has identified small cracks in
parts after the grinding process, causing increased scrap, lost
production time, increased inspection, and additional administrative efforts.
The grinding fluid used was a Blaser petroleum-based oil.
Solution
Customer replaced their petroleum-based grinding oil
with Performance Biolubes’ NuCut Plus Bio-based Cutting/Grinding Oil.
Benefits
When grinding with NuCut Plus, the grinding process
no longer causes the customers parts to crack.
This is due of reduced heat from improved lubrication
of the grinding wheel. Also, this improved lubrication
allows the CBN plated grinding wheels to last over 6000 parts
before requiring re-plating. The customer is able to
increase feed rates while reducing smoke
produced by the grinding process.
Your company can see these same cost reductions
by using this Bio-Based Technology.
Give us a call. 248-524-0100
Cost Savings Grinding wheel expense is reduced$60,000 annually.
Reduced quality control efforts save approximately $30,000.
Reduced production time saves $200,000 per year.
These savings total $290,000 per year.
Additional savings comes from reduced scrap and administrative time.
Another Success
Story
Bio-Based Metal Cutting Fluid
Product Bio-Cool
XXL Plus Water Soluble Coolant
Process Finish
Turning
Application
Machining the face of a
carbon steel automotive part
with a .7 (metric) micro-finish requirement.
Background
A first tier automotive
supplier was having trouble
maintaining a .7 micro-finish on a finish turning
operation.
Tools were being changed
when surface finish deteriorated
after about 60 parts. Feed rates were held to .0055
per revolution
to maintain finish.
Situation
Customer needed to
improve tool life while keeping
finish within tolerances. They had tested various cutting tools
and
settled on a Tungaloy wiper style insert
to obtain the best surface finish.
Solution
Customer added five
gallons of Performance Biolubes’
Bio-Cool XXL Plus coolant concentrate to the
current
semi-synthetic coolant in their 100 gallon sump.
Benefits
Finish improved to a 3.5
micro-finish.
Tool life increased to
130 parts per edge.
After these results were solidified,
the Performance
Biolubes Representative suggested
that the customer increase their feed
rate.
With XXL Plus, the customer was
able to increase
feed rate from .0055 per rev. to .014 per rev.
Your
company can see these same cost reductions
by using this Bio-Based
Technology.
Give us
a call.
248-524-0100
Cost Savings
Insert cost is $7.42 each with 6
cutting edges.
At $1.24 per edge, tool
cost per part was $.021 for 60 parts
and is now $.009 per part for 130 parts.
The customer manufactured these
parts on two machines
with an $80 burden rate per machine. Together,
the two machines produced 3000 parts
per day in sixteen hours.
The total
burden cost was .853 per part.
There
were 50 five minute tool changes.
After adding Bio-Cool XXL, tool changes were
reduced
to 23 per day, a reduction of 2.25 hours in tool change time.
The increase in feed rate reduced
machining time by 10 seconds
per part times 3000 parts per day totals a
reduction of 8.3 hours
in machining time.Total cost reduction using
Bio-Cool XXL Plus
is .293 per part. The
annual cost savings is $219,750.
This
does not include the reduction in scrap parts,
reworks or reduction in costs of
reduced quality control
and administration efforts.
Bio-Based Metal Cutting Fluid
Product
Bio-Cool
XXL Plus Water Soluble Coolant
Application
Heavy wall carbon steel tube cutoff
on a Modern Cutoff Machine.
Background
Second tier supplier to a
large bearing manufacturer
has a contract to cutoff 85,000 pieces per week of a
carbon steel tube running 24 hours per day, 7 days a week.
They selected a Modern Cutoff machine and
tooled it
with Ingersoll blade style indexable carbide cutoff tools.
Situation
Customer tested various
tools and determined that
they could achieve 700 parts per edge consistently
with an
eleven second cycle time.
Customer asked his distributor
representative if there was anything else
they could do
to improve tool life or cycle time.
Solution
Customer added 2-1/2
gallons of Performance Biolubes’
Bio-Cool XXL Plus coolant concentrate to the
current semi-synthetic
coolant in their 50 gallon sump to see if the biobased
product
would help with tool life.
Benefits
The customer stated that
he knew immediately that his
tool life would improve because the surface finish
in the
cut area was much better and that usually translates
to better tool
life. As it turned out, their tool life
improved
dramatically. The customer
now gets more than 1400 parts per tool,
a 100 percent improvement.
Your
company can see these same cost reductions
by using this Bio-Based
Technology.
Give us
a call.
248-524-0100
Cost Savings
Insert cost is $16.20 each with 2
cutting edges.
At $8.10 per edge, tool
cost per part was $.023 for 700 parts
and is now $.0115 per part for 1400
parts.
Tool cost savings is $24,589 per
year.
With an eleven second cycle time,
tool changes were
every two hours and took five minutes each.
Performance Biolubes coolant reduced tool
changes
by one half. With an $80 per hour burden rate,
the savings
from reduced tool change time was $14,000 annually.
Total annual savings from using
Performance Biolubes coolant is $38,589.
Other Benefits
Performance Biolubes’ Bio-Cool
coolant is a truly “Green” product,
made from USA
grown seed crops.
There are no known
cases of dermatitis from this product,
and most users say that they have
eliminated dry skin cracking
that occurred when working with petroleum-based
coolants.
The vapors from Bio-Cool are
not hazardous.
Disposal is not hazmat
unless the used product contains
other hazmat classified materials such as
heavy metals from machining.
An in-depth veiw of Elm Cost Savings at a Screw Machine House:
Soy Metal Working Fluid
Miller Products Company Osceola, Iowa
Bill Frosch billf@millerproductsco.com 641-342-2103
Number of employee: 40 Industry:
Metal Fabrication Process:
Machining Waste Reduced:
Oil Substance: Cutting fluid
Miller Products realized a 20-30% increase
in productivity and cut retooling costs 50%
by switching to soy metal working fluid.
Miller Products Company
1015 N. Main, Dept. TR
Osceola, IA 50213
http://www.millerproductsco.com
Miller Products Company, a manufacturer of
screw machine products and turned parts
located in Osceola, Iowa, began testing soy
neat oil in Spring 2006. The company is a leading
manufacturer of trailer pins with worldwide distribution.
Bill Frosch, Plant Engineer, was interested in trying soy
metal working fluids because he felt that it is important
to close the loop as a supplier to agribusiness. He was
pleasantly surprised to find that the soy product’s performance
was superior to petroleum straight oil.
Miller Products realized a 20-30% increase in
productivity and cut retooling costs in half by
switching to soy metal working fluid.
Miller Products machining capacities range in size
from 1/4" to 3-1/2" diameter bar stock. Miller Products
features multiple spindle, CNC and single spindle screw
Machines with complete secondary operations including
in-house zinc plating, centerless grinding and vertical CNC.
Contract screw machine products are available in long and
short runs. Stock items include: lock pins, hitch pins, snap
lock pins & bent pins. Founded in 1936, Miller Products has
been a reliable employer and a good community steward.
The company was interested in the positive environmental
image as an immeasurable benefit of pollution prevention.
The company has been ISO9000 certified for many years
and was interested in capitalizing on an increasingly precious
public relations commodity: green street credit.
Small Business Placement Description Soy metal working fluid
replaced straight petroleum oil in several test machines.
As the test period proceeded, additional machine stations were
converted to soy oil. The shop has a central reservoir system
so the test machines were isolated to ensure that no soy neat
oil was mixed into the central system and no petroleum make
up oil was added to the test stations. The machines were single
and multi-spindle stations. An immediate increase in tool life
(or reduction in retooling) was identified.
The product placed was Environmental Lubricants Manufacturing, Inc.
(ELM) SoyEasy UNI-Cut™, a universal cutting,way,and hydraulic fluid.
Formulated with the best- optimized USA-grown natural seed oils
and select additives, it surpasses the lubricity and performance
of conventional metalworking fluids.1 As the test period continued,
the machine feed rates were increased at each station.
A minimum increase in feed of 20% was verified with some
machines increased to 30% higher productivity than when
using petroleum oils. Overall an average of 25% increase in
feed rate (productivity) was realized. Additionally, a noticeable
reduction in the number of retooling events for each station
was documented. Previously, using petroleum neat oil, each
spindle had to be retooled twice per day for about 15 minutes
of downtime. Using soy oil the frequency was cut in half, resulting
in only one retooling event per day. This reduction in retooling
further increased productivity as well as cut the cost of retooling
by 50%, potentially saving over $66,000 per year.
Environmental Lubricants Manufacturing, Inc is the leading
provider of bio-based lubricants and greases in the United States.
These products are based on exclusive biotech-based technology,
formulated with renewable, biodegradable USA-grown vegetable oils.
These lubricants, greases, and metalworking fluids are
environmentally friendly and meet or exceed industry standards.
5 http://www.elmusa.com/
The reduction in retooling cut the cost of retooling by 50%,
saving over $66,000 per year.
Following the test period, Miller Products Company decided
to make a full conversion to soy oil based on the a 20-30% increase
in productivity and 50% reduction in retooling costs. The cost
for complete shop conversion was $23,000. The petroleum oil
could have been consumed but the plant manager was anxious
to complete the conversion to soy to realize the increased
productivity and reduced tooling costs as soon as possible.
Technology Description (P2 Application) Metal working fluids
basically come in two types: water-soluble coolants and
neat (straight) oil. Neat oil is required for difficult processes
that require the highest level of lubricity. Neat oil is the most
expensive metal working fluid due to the high volume of
product used. Therefore, is only used in shops only when
specialty work requires it.
The use of soy oil for metalworking began as an alternative
to conventional products (petroleum-based, synthetics and
semi-synthetics). Soy oil, like many other ag-based oils, exhibits
superior lubricity in many industrial applications. Additionally,
many companies are interested in biodegradable products,
especially those developed from renewable resources that
help agribusiness.
Specifically, soy oils have the following advantages over
conventional products:
1) produce less smoke and mist for reduced inhalation problems
2) contain no chlorine or sulfur
3) reduce or eliminate dermatitis issues
4) reduce retooling costs
5) increase productivity (or feed) rates.
Several steps are necessary to convert metal ores into
useful metal products. These steps are conducted by
businesses in the metal working industries; specifically
classified by Standard Industrial Classification
(SIC) Codes 3400-3499.2 The fabricated metal industry
shapes products from stock material through one or more
machining processes. Metals may be shaped by using
heat-treating or cold pressure methods. Cold pressure
methods shape the work piece by applying direct
physical pressure to cold metal. Shaping operations include
shearing (e.g. punching), forming (e.g. spinning or drawing),
and machining processes. Machining operations require the
use of machining tools to refine the shape of the work piece
by removing small amounts of material. Examples of machining
processes include drilling, milling, turning, planning, sawing and
grinding. Machining processes use various products in the
processes such as cutting fluids, lubricants, hydraulic fluids,
cooling or quench oils, and possibly cleaning solutions.
Machining involves high-pressure, metal on metal moving
contacts between tool and work piece. To reduce the heat
and friction caused by these operations, metal working
fluids (MWFs) are circulated over the work surfaces.
These fluids are used to:
- Control and reduce the temperature of tools and work surfaces;
- Reduce friction and vibration by acting as a lubricant;
- Wash away chips and metal debris;
- Improve the quality of the machined surface; and
- Inhibit corrosion and rust on newly exposed surfaces. Environmental, Health, and Regulatory Background
(Environmental Benefits) Neat oils contain additives
to improve performance and inhibit rust and corrosion.
Traditionally, petroleum products contain wetting agents
to increase lubricity as well as extreme pressure additives
such as sulfur and chlorine.3 These additives enhance the
anti-welding properties and improve lubrication. However,
neat oils have poor heat dissipating properties and therefore,
increase fire risk. They may also create smoke in the shop
that results in a poor work environment. Petroleum oils can
cause folliculitis and oil acne by blocking skin or hair follicles.
4 Soybean oil has a higher molecular weight and flash point
when compared to petroleum oil. These properties help soy
oil bond well with metals serving as an effective
friction reducer (lubricant). They also decrease heating,
minimizing smoke and mist problems by not burning off at
high temperature points such as the tool-to-part contact point.
Soy oil also include reduction or elimination of dermatitis
due to its compatibility with natural skin oils and the lack
of harsh chemical additives.
The reduced wear on tools and machinery
is an environmental benefit by enhancing
the longevity of these durable goods.
One of the most obvious environmental benefits of soy is
that it’s a biodegradable product that comes from a
renewable resource. Regulatory Using straight oils
for machining in this shop eliminated spent metalworking
fluids as a waste stream since all of the product
(whether soy or petroleum) is consumed in the process.
During the conversion from petroleum-based MWFs to
the ELM soy product, used oil was generated. The used
metalworking fluid was recycled by a local used oil
marketer under the Used Oil Management Standards
(40CFR279). Disposal is not usually an issue with the
neat oil in this shop. The central reservoir system is
equipped with a centrifuge that removes the metal
fines and continually recycles the oil. The soy oil is
being used in the same recovery system without any
modification. The metal fines are recycled.
Outcomes Pollutant Reduction Outcomes
Every industrial process has inputs and outputs.
Material that is not incorporated into the finished
product eventually becomes a waste. Implementing
pollution prevention can increase industrial efficiency
and potentially decrease costs.
Hazardous material reduced in pounds per year:
5,000 pounds per year The shop’s increase in
productivity by an average of 25% equates to a reduction
in material usage of 5,000 pounds per year.
Environmental & Health Outcomes The health and
safety benefits of soy MWFs include reduced dermatitis
issues and reduced smoke that causes inhalation problems.
Soy oil’s superior adhesion properties also reduce safety
concerns by not creating slippery work surfaces.
Substitution of a petroleum product with a biodegradable
product manufactured from a renewable resource that
benefitsagribusiness has many known environmental benefits.
“Businesses can improve the work environment for their
employees by using biochemicals and thus reduce health
and safety risks. Plant matter-derived chemicals are typically
lower in toxicity, flammability and corrosivity than their
petrochemical counterparts.”5 Economic Outcomes Increased
productivity and reduced retooling costs are the most
significant economic benefit of this pollution prevention
application. The cost benefit analysis provided here is
an extrapolation for an entire production year based on
the data collected during the test period. The shop rate
was based on an average rate for the industry. This shop
preferred not to publish an exact shop rate as their rates vary.
The cost calculator developed to estimate the benefits
of switching to soy oil is available at
http://www.iwrc.org/netsb/.
Cost of Petroleum Product................. $6.49 per gallon
Cost of Soy Product.... .. $11.53 per gallon
Average shop hourly .......... $75.00
System capacity.................. 1500 gallons
Annual make up................ 1000 gallons
Cost of Petroleum MWF annually at $6.49 per gallon........ $16,225.00
In-house sharpening of high-speed circular form tools
was conducted twice per day for about 15 minutes for
each spindle (40) on 252 production days per year.
0.25 hours X $75 shop rate X 40 spindles X 252 days = $132,300
Retooling cost annually with petroleum..................... $132,300.00
Annual cost of using petroleum at baseline production rate....... $148,525.00
Cost of Soy MWF annually at $11.53 per gallon...... $28,825.00
Retooling cost annually with Soy
(doubled the life of the tools).... $66,150.00
Annual cost of using soy............................... $94,975.00
Annual savings of using soy MWF................... $53,550.00
Estimated increased productivity by 25%................ $1,058,400.00
Projected total cost savings & estimated increase in productivity........ $1,111,950.00
GO GREEN!!!
