The cost of cleaning glass processing machinery combined with waste water disposal charges can run into the tens of thousands. Lisa Tooth, Bohle Machinery Coordinator, explains how to avoid them.
Margins remain tight but they can also always be better. Cooling glass and machinery tools during manufacture and disposal of waste water remains a significant overhead for glass processors.
Clean cooling water increases the performance of machinery by up to 20 per cent and the service life of tools by up to 30 per cent - but it can all too easily become contaminated with particles from drilling, polishing and grinding.
The cost of replacing contaminated water or coolant quickly adds up. Using just 400 litres of water as part of your weekly cleaning cycle equates to a yearly water consumption of approx. 20,000 litres as well as high cost for its disposal.
This is governed by a raft of EU regulations and in the UK, the Water Resources Act. The addition of coolant makes the disposal process even more complicated.
This makes replacing water and coolants used in glass processing a high but sometimes unseen cost. Irregular cleaning of water and machinery properly also carrying a potentially far higher price tag in lost man hours, falling product quality, and reduced service life of equipment.
Although the industry has traditionally relied on centrifugal water cleaning systems these can’t filter glass particles < 5 µm. This is something which, can overtime, contribute to lower product quality and a build up of concretion in the machine and its tanks. Sedimentors not only filter glass particles of < 5 µm or less but do so using far less energy.
Bohle’s range of Sedimentors are suitable for a wide assortment of grinding, drilling and sawing glass equipment, using a sophisticated multi-stage process to remove contaminants from coolants and water.
First, water is pumped into a specially contoured settling tank allowing coarse, higher density glass particles to be separated from the coolant and settle to the bottom. Simple, low energy but highly effective, the filling process removes more than 70 per cent of contaminants.
Then fine particles are separated out in the flocculant dosing process. Aided by optimised dispensing of granulated flocculant and a controlled current flow, the system then captures and binds even the finest glass particles. The particles then sink to the bottom of the Sedimentor in an automated cycle producing virtually clear process water. Importantly, any coolant products used with the water are retained.
At the end of the cleaning process, a timed valve at the floor of the tank opens and the accumulated sludge of glass finings and flocculant is flushed into a filter bag by the water pressure. This leaves the cleaned cooling water ready to be returned back into the cooling circuit.
A key feature of Bohle’s range is that it uses a ‘bypass system’ for batch cleansing. This isolates water, coolant and flocculant, from the line during the cleaning process, completely eliminating the potential risk from flocculant contamination and tool damage.
Bohle manufactures and supplies three different sedimentors, the 2.4, which has a filling quantity of 2100 litres, the 1.0, (1,000 litres) and the 0.3, which has a filling capacity of 320 litres. Its technical team, working closely with its customers to identify and model their requirement, while also offering training and through-life support.
Paying for itself in as little as a year, the benefits are immediately tangible in the form of better quality finishing, improved tool life and lower maintenance costs.
The impact that this can have on your profitability as a glass processor, plus savings in water disposal and downtime, can make an incredible contribution to your bottom line.
Watch the video here
To find out more email firstname.lastname@example.org or call the customer services team free on 0800 616151 for more information.