MAINTENANCE MATTERS

New base substance for oil-free cooling lubricants

Three test rollers used in lubrication tests for abrasive wear
(Reichert): Left, lubricated with water; centre, using a standard
cooling lubricant; right, with Novotec CL 800 (five per cent ineach). Source: Gelita AG

With its latest invention, Gelita AG ispaving the way for the production ofhigh-performance, oil-free coolinglubricants, which are completely freefrom allergens and toxic substances.
Instead of conventional oil,functional proteins ensure thatmetal-processing can be carried out
smoothly. A further advantage is thatunwanted oily residues are avoided.
In the metal-processing industry,cooling lubricants are indispensablefor protecting work pieces and tools
against wear and overheating duringlathing, drilling, milling or grinding.
Conventional cooling lubricants
therefore consist of an oil-in-water
emulsion – the oil is used forlubrication and the water for cooling.
The disadvantage is that the oil does
not dissipate any heat, thus preventing
the produced heat from being
effectively transported away from thework piece. In addition, during metalprocessing, an oil mist that is harmful
to health can be produced.
Disposing of the cooling lubricant isexpensive and, not least, oil resources
are finite so that, due to the increasing
scarcity of raw materials, they are
subject to constant price increases.
In Europe alone, approximately 320,000
tons of metal-processing lubricating
concentrates are consumed eachyear. Gelita experts have already been
researching alternatives for four years.

Looks like water, performs better than oil and enables the manufactureof environmentally friendly cooling lubricants: Novotec CL 800
Source: Gelita AG

Together with a well-known
automotive part supplier and a local
industrial college in Eberbach, Gelita
scientists have developed an innovative
raw material for a new generation ofoil-free cooling lubricants: the liquid
protein concentrate Novotec CL 800.
“Metal-processing fluids basedon this functional protein look likewater, perform better than oil andshow significantly better cooling thanmineral-oil based products as they aremuch more stable than an oil emulsion,”
explains Dr Matthias Reihmann,
Product Manager for photographic
and technical gelatines. This wasdemonstrated in a comparative testwith a reference recipe using devices
to measure the pressure stability of thelubricating film (Reichert Wear Test). An
additional 15-month field test confirmed
routine performance and aging stability.
While developing the reference recipe,
Gelita worked together with two
experienced German companies in thearea of high-performance additives andpreserving agents for cooling lubricants.
Advantage compared with oil-freepolymer-based cooling lubricants:
Metal-processing fluids basedon Novotec CL 800 also have an
advantage compared with oil-freepolymer-based cooling lubricants:
they leave no unwanted residues
on work pieces, tools or shavings.
Processed parts can thus be used forfurther production, such as bonding,welding, painting or coating, without
the need for intensive cleaning. Theshavings that are produced can also
be directly processed. This reduces
costs and increases the efficiency ofproduction. Moreover, Novotec CL 800
is ecologically degradable and free ofallergens and pollutants. The Gelita
protein concentrate is suitable for theproduction of environmentally friendly
cooling lubricants for all modernproduction procedures.

In practice
Gelita initially tested the developmentof the protein-based substance forpracticability in its own workshops in
Eberbach, Minden and Memmingen.
Numerous cooling lubricant producers
are currently testing how the protein
solution works for use in their own
products. In close collaboration with
Gelita developers, the components arebeing integrated into specific recipes.
Volker Sigmund, Head of Maintenancein Eberbach, is optimistic: “The key
advantages are obvious – Novotec CL
800 is biologically degradable and does
not form an annoying oil film on theprocessed surface, and all that with
better cooling lubricant performance.
A truly clean solution.”•

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