U.S. Lubricants has assembled a range of coolant mixing solutions ranging from simple venturi pumps, to coolant proportioners and mixing automation systems, for larger machining operations with multiple sumps.
Venturi Pumps are commonly used as coolant mixers and they are both highly reliable and reasonably precise as well as economical. Proportioning Pumps on the other hand are a better choice in larger operations, are extremely accurate, and once the concentration is set, the pump will deliver accurate mix consistently and at long distances across the machine shop. Coolant Mixing Automation Systems are the best solution in large machine shops with multiple sumps with some systems able to handle up to 10 sumps and up to 2000 gallons, with very heavy oil & solids loading.
Dosatron positive displacement volumetric proportioner pumps allow you to precisely control the coolant volume and automatically compensate for concentrate viscosity, flow, and pressure changes and provide consistent, repeatable results. Proportional coolant mixing systems can help increase tool life, reduce reject rates, control bacterial growth, reduce skin and respiratory issues, and reduce foaming to maximize tramp oil filter efficiency and chip collection.
The mixed coolant discharge line can feed an individual sump, bucket fill station, or can easily be plumbed as a central system. Dosatron pumps are simple to use and easy to adjust allowing for flexible dosage rates with coolant concentrations between 1% and 10%. The proportioner pumps are water powered (use no electricity), highly reliable, easy to maintain, and can be used in numerous applications requiring precise chemical mixing in the metalworking arena. (Machine Tools/Coolants, Rust Inhibitors, Die Lubes in Forming, Casting, Drawing & Stamping, etc) Proportional coolant mixing systems can also be supplied pre-plumbed in a locking cabinet or easy to mount panel.
Caution: Manual coolant mixing can easily result in improper mix concentration. Typical errors involve estimating the machine tank volume inaccurately (causing the wrong volume of coolant concentrate to be added to the water) and improperly ordering the mixing (adding water to the concentrate may cause an inverted emulsion that can affect many performance properties). When adding “soluble oil” concentrate to water, the emulsifiers suspend the oil particles in the water, and will form the stable emulsion desired. On the other hand, if water is added to the concentrate, the emulsifiers “release” part of the concentrate to “grab” for the water. This forms an “inverted emulsion”, causing parts of the fluid such as the lubricant package, biocide package, or rust inhibitor package to be lost. Some or all of the chemical packages within the fluid may be affected. The mix stability, concentration, and the dye may also be affected by inverting the emulsion. The concentration of the fluid will be less than required and the dye (if the metalworking fluid is dyed) will be partially lost to the floating layer, leaving the fluid a lighter color than would be expected with a properly mixed fluid.