How does DUPUY help optimize the removal of oil and metal chips?
Metal Cap Manufacturing: Managing Oil and Metal Chips in Machine Tools
In the metalworking industry, the production of metal components requires precision machining that involves the use of oils and coolant fluids. During these operations, metal chips and debris are also generated; when mixed with the process fluids, they tend to accumulate inside the tanks of machine tools.
This situation also characterized the production process at an Italian company specializing in the manufacture of metal caps. The specific shape and size of the waste generated during processing required a powerful extraction system capable of effectively handling both liquid and solid components.
Cleaning the tanks was essential to prevent material buildup, keep the machines running efficiently, and facilitate maintenance work.
The customer was therefore looking for a mobile and versatile solution that could be easily moved between different production sites and used even in the most confined spaces.
Key Project Data
2-IN-1
Suction and Separation
A single solution for collecting oils and metal chips, separating solids from recoverable liquids.
1,000 liters
In approximately 5.3 minutes
Theoretical time required to transfer 1,000 liters of liquid at the pump’s maximum rated flow rate.
Simultaneously vacuum up oil and metal chips without slowing down production
During the manufacture of metal caps, machining residues accumulated in the tanks of the machine tools, forming a mixture of oil, coolant, and metal particles.
The main challenge was the need to remove materials with different physical properties in a single cleaning operation.
The shape and size of the metal residues also required high suction capacity, while the presence of liquids made it necessary to properly manage the collection, separation, and discharge processes.
Another challenge concerned the layout of the machine tools. Operators needed to be able to reach even the least accessible areas of the tanks, moving easily between the various workstations.
The customer therefore needed to speed up cleaning operations, minimize material buildup, and facilitate the maintenance of production facilities.
Reduce cleaning time and recover process fluids
In metalworking operations, the presence of oil and metal shavings inside the tanks requires periodic cleaning to ensure the proper operation of machine tools.
For the customer, the requirement was not only to remove the accumulated residue, but also to effectively manage the separation of the solid and liquid components.
Having a system capable of performing both operations meant simplifying maintenance and making it possible to recover process fluids for reintroduction into the production process.
Mobility was another key requirement. An easily transportable solution would have made it possible to use the same vacuum cleaner on multiple machines, eliminating the need to dedicate a different system to each workstation.
The goal, therefore, was to find an industrial vacuum cleaner capable of combining high performance, material separation, and ease of use, thereby helping to reduce the time required to clean the tanks.
DUPUY OILVAC 200 T: Suction and Separation of Oils and Metal Chips
For this application, DUPUY supplied the OILVAC 200 T, a mobile solution specifically designed for extracting oils, coolants, and metal chips from machine tools.
The system is equipped with a 4-kW side-channel blower capable of delivering an airflow rate of 450 m³/h and a vacuum of 3,200 mmH₂O. This performance allows for the effective extraction of both metal residues and liquids from the tanks.
The use of suction hoses with diameters of Ø50 and Ø70 mm allows the system to be adapted to different operational needs, facilitating access even to the hardest-to-reach parts of the machines.
One of the distinctive features of the OILVAC 200 T is its built-in separation screen, which traps metal chips and allows the extracted liquid to be recovered. This enables the machining fluid to be handled separately from the solid residues and reused in the production process.
The independent drain pump, with a maximum flow rate of 180 l/min, also allows for the rapid transfer of the recovered liquid, speeding up the draining and cleaning processes.
Thanks to its compact and mobile design, the dust collector can be moved between different machine tools, offering a flexible solution even in tight workspaces.
Before the order was confirmed, the solution was tested directly under the customer’s operating conditions. The successful outcome of the test demonstrated the system’s effectiveness in that specific application and led to the confirmation of the purchase.
Faster tank cleaning and efficient waste management
The introduction of the OILVAC 200 T has enabled the customer to improve the cleaning of machine tool tanks, thanks to its ability to simultaneously extract oil, coolant, and metal chips.
The built-in separation screen traps solid residues, separating them from the liquid component. This facilitates subsequent collection, discharge, and handling of the materials, while also enabling the recovery of process fluids.
The mobile configuration also allows a single vacuum cleaner to be used on multiple machines along the production line, ensuring greater flexibility and simplifying operations in tight spaces.
The combination of liquid suction and drainage helps speed up the cleaning of the tanks, thereby helping to minimize machine downtime for maintenance.
The main benefits achieved:
- Simultaneous extraction of oils, coolants, and metal chips.
- Effective separation of solid residues from the liquid component.
- Ability to recover and reuse machining fluids.
- Rapid drainage of liquids thanks to the independent pump.
- Greater operational flexibility thanks to the mobile design.
- More efficient tank cleaning and simplified maintenance.
The test conducted directly at the customer’s site confirmed the solution’s effectiveness under real-world operating conditions, leading to the order being confirmed.