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 ---
Click on the Movies and see some video from folks who have used this product. Hear what they have to say...
The Benefits of Bio-Based Lubricants
If your company is interested in increasing factory throughput, reducing tool costs, and improving product quality in a safer environment, you may want to consider switching to bio-based metalworking fluids.
They have excellent lubricity and superior viscosity vs. temperature characteristics. The use of vegetable, orbio-based, oils can contribute to the goals of energy independence and a cleaner environment. In the past, the problems of oxidative stability and poor cold flow performance limited the use of these products. Targeted research has successfully addressed these problems. Bio-based metal cutting oils and coolants are being used effectively by many companies for gear cutting, grinding, and general machining. Aside from the environmental advantages, which we will discuss here, bio-based metalworking fluids have many advantages over petroleum-based products:
• Naturally better lubrication; • Superior viscosity/pressure performance; • Better thin film strength; • Lower volatility; • Higher flash point, less smoke and risk of fire.
This breakthrough technology has been in development for many years. In 1991 a research project at University of Northern Iowa utilized genetic engineering to increase oxidative stability of oil made from seed crops. This was expanded in 1995 into the Ag-Based Industrial Lubricants (ABIL) Research Program. ELM (Environmental Lubricants Manufacturing) was incorporated in 2000 to bring these technical advances to market as commercial products. Performance Biolubes was formed in 2008 to market bio-based lubricants to the metalworking industry.
Petroleum-based lubricants get most of their lubricity from additives, such as chlorine and sulfur. Bio-based lubricants have superior lubricity without the need for these chemical additives. This added lubricity reduces friction. With less friction created, cutting forces are reduced and less heat is produced in the metal cutting process, allowing tools to be fed faster. Less friction also reduces wear on cutting tools and grinding wheels, usually extending tool life.
Bio-based oils have a much higher flash point than petroleum. Flash points go down as viscosity of oils is reduced. Comparing oils at a viscosity of 40 cSt, bio-based oil has a flash point of 310 degrees C (590 degrees F) and petroleum has a flash point of about 148 degrees C (300 degrees F). This increased flash point reduces smoke while cutting metal, allowing higher feed rates and providing a less smoky working environment. Complimentary bio-based way oils and hydraulic oils can be introduced to help maintain a pure bio-based system with the highest possible flash point to reduce smoke.
Another characteristic of bio-based lubricants is their polar attraction to metal (see fig. 1). Petroleumbased fluids have no polarity and therefore no affinity to metal. Therefore, they tend to run off of tools and workpieces, leaving surfaces without protective lubrication. The polarity of bio-based lubricants provides metal affinity and more effective thin film protection at the cutting tool/workpiece interface.
The processes of hobbing, shaping, shaving, grinding, and broaching can all benefit from the characteristics found in bio-based cutting oil. The typical performance improvement is increased tool life when petroleumbased cutting oil is replaced by properly formulated biobased oil. When cutting tools are run at normal feeds and speeds, tool life increases by up to 100 percent. Since cutting forces and heat from friction are reduced, feeds and speeds can usually be increased. Fewer tool changes and faster machining processes can lead to productivity increases of 20 percent or more. Part quality will improve due to better tool condition and improved surface finishes. Bio-based oils provide significant improvements for gear grinding. Reductions in friction and the heat produced allows for faster grinding with less chance of burning the part. Surface finish is improved, and grinding wheels retain their size and form longer to improve quality and extend wheel life. Reduced friction improves dressing efficiency and improves dresser life. When gear cutting tools are reground using bio-based oils, the surface finish on the cutting edges is improved to prevent premature cratering that causes reductions in tool life.
Water Soluble Coolants
When machining with water miscible coolants, the latest bio-based products offer features that can lead to cost savings, quality improvements, and increased productivity. They provide improved lubricity for better tool life and surface finish. Increased feeds are often possible, as these coolants reduce friction and heat. Excellent sump stability and reduced toxicity make bio-based coolants easy to maintain. Operators are very unlikely to experience dermatitis or any sensitivity to these coolants.
There are bio-based coolants for use on all metals, including the most sensitive aluminum, yellow metals, stainless steels, aerospace alloys, and the usual range of carbon, alloy, and tool steels. The added lubricity is especially helpful when machining difficult stainless steels. Heat is reduced, extending tool life and allowing higher feeds and speeds. Aluminum machining is dramatically improved because bio-based coolants provide improved finishes, reduced tool wear, and reduced builtup edge—the most common reason for tool failure.
In the past, bio-based coolants were not effective in machining cast iron. Cast iron fines were retained in the coolant, causing the creation of a gray paste that coated machine surfaces, creating serious maintenance issues. This problem has been solved with the latest highly refined bio-based coolants made from special bio-esters. These newly formulated coolants are clean running, providing improved tool life, long sump life, and low maintenance. Grinding operations can benefit greatly from the new bio-based coolants. When grinding these coolants reduce friction, causing abrasive grains to stay sharp longer, allowing much longer time between wheel dresses. This is especially important when form grinding. Wheel life and accuracy is improved. If heat checking is a problem, bio-based coolants reduce the heat generated in most grinding operations. This allows feed rates to be increased without introduction of excessive heat into the part. Since the increased lubricity also provides better surface finish, feed rates can be increased without sacrificing finish.
Some users take full advantage of bio-based coolants and adjust wheel specifications to compliment the new coolants. They change to a coarser abrasive and a more-open wheel structure. These changes let the wheels grind faster and cooler while maintaining surface finish and accuracy due to the extreme lubricity of the bio-based coolant. Overall, grinding productivity and part quality can be dramatically improved with bio-based coolant technology.
Bio-based oils and coolants are easily cleaned from parts and machines with soap and water. Mineral spirits and other petroleum based degreasers are not effective. When bio-based residue is left on steel parts it acts as an effective in-process rust preventative. These products are non-staining on most metals, including brass and most aluminum alloys.
Bio-based lubricants are non-hazmat (not ecologically hazardous) prior to being used. Mist from these products forms large droplets that tend to fall close to the source. OSHA limits for bio-based vapors are much higher than for petroleum-based vapors. Dermatitis is not a problem with bio-based fluids, as the operator’s skin doesn’t dry out and crack after contact with these fluids.
Case studies reveal very real improvements in tool life, surface finish, and productivity from the use of bio-based cutting oil and water soluble coolants. A Detroit gear manufacturer was running production two shifts per day. Tool costs were reducing profitability on this part. They changed from petroleum-based cutting oil to Performance Biolubes NuCut Plus cutting oil, and tool life was increased by 300 percent. Another company was using a shaper and achieving 11 parts per tool sharpening. After converting to NuCut Plus tools lasted twice as long, and they were able to increase feed rates by 10 percent to further increase throughput. Fig. 1: Bio-based lubricants possess a polar attraction to metal, while petroleum-based fluids have no polarity and therefore no affinity to metal.
High Performance “Green” Lubricants formulated to achieve maximum productivity at the lowest cost. Performance Biolube’s vegetable based fluids have greater lubricity than petroleum oils resulting in faster cutting speeds, greater feed rates and higher part quality. The oils’ natural polarity causes them to be attracted to metal, resulting in improved surface finishes.
• Excellent lubricity to reduce friction
• High Flashpoint — (590º F)
• Safer Smoke Free workplace
• High viscosity index for wide temperature range
• Exceptional oxidative stability
• Eliminate or reduce smoke and improve tool life in:
MAY 2010 A supplier of aerospace components uses CBN plated form wheels to grind hardened carbon steel parts for proprietary power transmission products. The problem was heat buildup in the part, which could cause part failure and potential loss of life. Expensive quality control processes were in place to reduce risk. Wheel life was approximately 2,500 parts before wheels had to be stripped and re-plated. These CBN wheels were recognized as the highest cost perishable tool in the plant. Some of the grinders were using water-soluble coolant and some were using neat oil. Neither product worked well on this difficult application. After testing, the company converted all grinders to NuCut Plus bio-based cutting oil. The heat checking (grinding burn) was eliminated, allowing increases in production rates and reduction of QC efforts. The grinding wheel life increased to over 10,000 parts per wheel, dramatically reducing tool costs.
This Tier Two supplier to a large bearing manufacturer had a contract to cutoff 85,000 pieces per week from a carbon steel tube. The operation was running 24 hours per day, seven days a week. They selected a Modern cutoff machine and tooled it with blade style indexable carbide cutoff tools. Tool life was approximately 700 parts per tool. To improve the profitability of the job the manufacturer wanted to further improve tool life and reduce cycle time. They replaced the petroleum-based coolant with XXL Plus biobased coolant from Performance Biolubes. It was determined that tool life doubled and feed rates were increased by about 10 percent. Annual cost savings were approximately $39,000 per year.
Environmental and health concerns are important to most shop owners and corporate managers. Performance Biolubes’ metal cutting fluids are truly “green” products, made from North American renewable seed crops. There are no known cases of dermatitis from this product, and most users say that they have eliminated dry skin and cracking that occurred when working with petroleum-based coolants. The vapors from NuCut Plus are not hazardous. Petroleum-based oils get lubricity from additives such as chlorine and sulfur. Bio-based products don’t need these additives due to the much higher natural lubricity. When both the performance and sustainability of bio-based metal cutting fluids are considered, a compelling case can be made for their use. Savvy shop owners and managers will use these products to cut cost, improve profits, and reduce the shop’s carbon footprint. In addition, health benefits will accrue, resulting in a cleaner, healthier, and more-productive workplace.
about The authors:
Bob Frazier is the CEO of Performance Biolubes, and Dwight Smith is president of Cole Mfg. Systems, Inc.
Visit online at [www.performancebiolubes.
web: performancebiolubes.com 8011 Parkside Ave. | Morton Grove, IL, 60053 | Toll Free 866-947-8991
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!
Another reason to Go Green
Product: NuCut Plus Bio-Based Cutting Oil
Process: Gear Shaper / Tool Sharpening
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.
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.
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.
Bio-Based Metal Cutting Fluid
XXL Plus Water Soluble Coolant
Machining the face of a
carbon steel automotive part with a .7 (metric) micro-finish requirement.
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.
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.
Customer added five
gallons of Performance Biolubes’ Bio-Cool XXL Plus coolant concentrate to the
current semi-synthetic coolant in their 100 gallon sump.
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.
company can see these same cost reductions by using this Bio-Based
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.
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.
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
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.
company can see these same cost reductions by using this Bio-Based
Technology. Give us
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.
Miller Products Company, a manufacturer of screwmachineproductsand turnedparts 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.
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