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It is common for many machine-tool operators to make the mistake of adding coolant concentrate directly into the machine sum to increase concentration or simply adding water when they want to reduce it. Unfortunately, both methods are incorrect and can lead to several coolant-related problems. These issues can impact not only the quality of machine operations but also the lifespan of both the coolant and the tools used.
Some of the most frequent problems that arise from improper mixing include:
- Sticky Coolants: This results in dirty machines and hazy windows, which can obstruct visibility and compromise overall machine hygiene.
- Coolant Instability: Improper mixing causes the oil component of an emulsion to separate, leading to an ineffective, non-homogenized mixture.
- Inconsistent Concentration Readings: When concentration levels are unreliable, it affects tool life, surface finish, bio-resistance, and rust & corrosion control.
The Correct Way to Mix Coolants
For manual coolant mixing, there is only one proper method. First, water should be poured into a container, such as a drum or pail, and then the engine coolant concentrate or cutting fluid concentrate should be slowly added on top. This allows for the concentrate to blend smoothly with the water. Some gentle, low-speed manual stirring is recommended to ensure a thorough and even mix. Once the coolant has emulsified correctly, it can be topped up into the machine’s sump.
This method ensures a homogeneous, consistent mixture of coolant concentrate and water, avoiding the common issues like sticky residue, instability, and unreliable concentration readings that often arise from incorrect mixing techniques.
The Risks of Reverse-Emulsions
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Adding concentrate to water incorrectly—by pouring the concentrate first and then adding water on top—can lead to what’s called a reverse-emulsion. A reverse-emulsion is a thicker, stickier version of a regular emulsion and doesn’t perform as well in dissipating heat. This improper mixture can make the coolant less efficient and lead to increased coolant-related issues, which could affect machine performance and cause the corrosion inhibitor coolant to work improperly.
Adjusting Concentration Levels: Best Practices
If the concentration level in the machine sump is too high and needs to be reduced, simply adding water is not enough. Instead, it’s recommended to prepare a weak mixture—around 1-2% concentration—and use that to top up the sump. This weak solution still contains necessary additives like biocides and emulsifiers, which maintain the biostability and mixture stability of the coolant. Adding only water without these additives can lead to a non-homogenized mixture, causing coolant instability and potential corrosion risks.
In situations where the coolant concentration is too low, adding pure concentrate directly to the sump should also be avoided. Without proper mixing, the concentrate and its additives won’t integrate effectively into the fluid already in the sump. Instead, create a stronger mixture of around 10% concentration following the correct method, and then use this solution to top up the sump. This ensures the concentrate’s additives are properly dispersed, maximizing the coolant’s effectiveness and ensuring consistent performance.
Why Proper Mixing Is Critical
Correct coolant preparation is essential to avoid common coolant problems. Improper mixing techniques can cause inefficiencies that impact tool life, surface finish, machine cleanliness, and overall production quality. Issues like coolant instability and corrosion can compromise the long-term health of both the machine and the workpieces being produced.
A properly mixed coolant ensures smooth operations, better heat dissipation, and improved protection against rust and corrosion. For industries relying on CNC machines or heavy-duty cutting equipment, maintaining the right coolant concentration is crucial for ensuring tool longevity, machine health, and consistent production results.
Additional Tips for Coolant Maintenance
Regular monitoring of coolant concentration levels and machine cleanliness is essential for preventing breakdowns. Using tools like refractometers to measure the coolant’s concentration can ensure that it stays within optimal ranges, and performing periodic sump cleanout can help maintain coolant efficiency. Implementing these best practices will not only extend the life of your coolants but also reduce costs associated with tool wear and machine repairs.
Optimize Your Machinery with Lubricants and Coolants from Fluid Solutions
Looking for a reliable Hydraulic Supplier in the Philippines or a cutting coolant expert? Fluid Solutions offers a wide range of products, including hydraulic oils, gear oils, slideway oils, synthetic lubricants, high-temperature greases, and anti-rust oils. We provide tailored lubrication solutions to meet your business’s specific requirements, ensuring top-notch machine performance and long-lasting results.
Contact Fluid Solutions today at (02) 8370 5928 / (0917) 894 9156 or via email at inquiry@fluidsolutions.com.ph for expert advice on coolant maintenance and lubrication solutions designed to keep your machines running efficiently.
