PRESCRIPTION FOR SUCCESS: METALWORKING FLUIDSPROTEINS:A CUTTING EDGE CLEAN TECHNOLOGYADDITIVE FOR METALWORKING FLUIDSHOW CAN A SHOP REDUCETHEIR OPERATING COSTS WHEN
THEY FACE THE CHALLENGES OF
MACHINING DIFFICULT-TO-CUTMETALS AND TEMPERATURERESISTANT SUPER ALLOYS,IMPROVING EMPLOYEESAFETY, AND BEING MORE
ENVIRONMENTALLY FRIENDLY?
ONE SOLUTION LIES IN
PROTEINS… YES, THAT’SRIGHT, PROTEINS.
By Dr. Matthias ReihmannTotal global consumption of metalworking fluids(MWFs) is expected to reach around 2.8 milliontons by 2020, with increased use of special alloys
H eidelb e rge r D ruc k uses H akuform A805 metalworking fluid inturning and milling of st e el, stainless st e el, aluminum, non - fe rrous
and demand for more high performance fluids. For
metals and composit es for inc re ase d t o ol life, broad suitabilit yexample, the automotive industry is using aluminumfor diffe rent mat e rials, less fluid consumption, fewe r e quipment
Dr. M at t hias
and titanium as lightweight alloys for fuel efficiency,
maint enance issues, e asie r cle aning of machines and e quipment
Reihmannparts,andimprovedskintole
ranceofoperators.
while aerospace and other industries introduce moreG elita AG
difficult-to-cut metals and temperature-resistant superalloys.1 With certain industry mandates to eliminate
hazardous performance additives (chlorinated paraffin and boronic
protein production to metalworking applications, functional proteins
acids) and biocides (formaldehyde releasers) from MWFs, metal fabcan combine efficiency advantages with health and environmental
ricators and machine shops are seeking more natural alternatives
friendliness in MWFs to help shops improve their productivity andthat do not compromise performance and efficiency. As competitive
efficiencies and reduce costs, all while being friendly to the environinnovations shift them toward a broader and more diverse range ofment and operators alike.
metals, these shops demand MWFs to keep pace.
NOVOTEC® is a new class of functional proteins that changes
That’s not all: The paramount importance of user safety and wellsurface technology from hydrophobic (water repelling) to hydrophilic
being demands improved environmental friendliness and user safety,(water attracting). Scientists have discovered proteins that attach firmly
whether in the form of air quality, reduced oil-contaminated waste orto surfaces such as metal or glass. The molecules combine with eachskin protection. And shops must still find ways to reduce processing
other to form a stable, resistant layer. As water hits the surface, thecosts – including those of MWF disposal, because with traditional
protein layer attracts water and creates a smooth, hydrophilic surface
MWFs the re-processing of metal flakes is hindered as the oils of thecoating. From this, NOVOTEC CL800 has been developed as anMWFs adhere to the flakes. What can possibly help shops address
additive for water-based MWFs where the proteins form lubricating
all of these issues? Proteins… yes, that’s right, proteins.
layers of hydrated protein chains that facilitate cooling and protect
surfaces from wear and offer reduced consumption and increased
skin tolerance.
THE NOVOTEC EFFECT
Traditional MWFs use a combination of oil or synthetics for lubriProteins are a key performance factor in complex biological systems
cation and water for cooling. With oil, cooling performance is limlike the human body, where proteins help lubricate joints, stabilizebones and protect the skin. By transferring the technical knowledge of
ited as the emulsified oil hinders the water to effectively dissipate

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PRESCRIPTION FOR SUCCESS: METALWORKING FLUIDSADVANTAGEDISADVANTAGE

heat from surfaces. As a result,Low price, good lubrication
Limited cooling, limited
Crude oil (paraffinic
WATER-BASEDresidues from cracked mineral oil
performancebiodegradability, nonor napthenic
MWFS
renewable raw material, poor
destillates)and oxidized metal alloy are creskin tolerance, hazardous oilated at the surface of machined
aerosol, high cost for disposal
tools. Additionally, skin contact
Vegetable oils (palmGood lubrication performance
Limited cooling, poor skin
EMULSION
often results in irritation or a moreoil, rapseed)tolerance, high cost forsevere allergic reaction due to thedisposal, often reduced
lifetime, efforts for cleaning
surfactants needed to stabilize theoil in the emulsion. Several fully synLow price, good lubrication
Limited cooling, limited bioSynthetic oil
performancedegradability, non-renewable(polyester,thetic MWFs have been developed
raw material, poor skinpolyalphaolefines,
based on water soluble lubricating
tolerance, hazardous oildiesters)
polymers like polyglycols. However,aerosol, high cost for disposal
the lubrication performance ofNOVOTEC® CL800
Limited compatibility with oil
Improved cooling, facilitatedthese polymers is limited because
as additive
cleaning, potential benefits forthe water soluble polymers are notskin tolerance
absorbed effectively to the surface.
Glycerols
Cooling, facilitated cleaning,
Limited lubrication
WATER-BASEDIn contrast, NOVOTEC CL800 isless consumption, low priceperformance
MWFSa protein-based liquid concentrate
Polyglycoles
Cooling, facilitated cleaning,
Limited lubrication
SOLUTION
that can be used as base stock orless consumption, low priceperformance
performance additive in water-misModified Celluloses
Renewable raw material
Bad re-solubility, tackiness at
cible MWFs. It is comprised of natulow concentrations
ral polyfunctional protein molecules® CL800Tackiness at highNOVOTEC
Renewable
rawmaterial,and provides strong intermolecular
as base stock
improved cooling, better surface concentrations
interactions with water and numerquality, potential benefits forous application surfaces (steel,skin tolerance, less consumption,
reduced efforts for cleaning
glass, aluminum, etc.). Use of thisprotein-based liquid concentrate
allows an efficient combination ofcooling capacity and lubrication
performance by providing a highly water soluble biopolymer thata fluorescence microscope. Figure 1 shows the microscopic imageof Fluorescein-marked NOVOTEC protein molecules (green) boundalso has a strong affinity for numerous surface types. The end result ison a steel surface.
more efficient heat transfer during metalworking and a better surface
quality of machined parts. Processed parts can often be used for
Various experiments were conducted, including wear resistancefurther production without the need for subsequent intensive cleantests with a Cross-Cylinder-Tester (XTC) apparatus according toing, provided that they do not need conservation against corrosion.
Reichert setup. The main axes of the ellipse shaped scars (worn areas)
Because NOVOTEC CL800 is produced from pure collagen, it has
were measured. NOVOTEC CL800 was compared with various mineral oil-based products and synthetic fluids. Even a pure dilution ofan excellent toxicological profile and can help to improve the skin tol5 percent NOVOTEC CL800 in water without any further additive
erance of MWF formulations (see nearby chart). It is inactivating formaldehyde releasers, which ensures that these biocides are not used forthe stabilization of the new MWFs. This means formulators are either
using more modern biocides, such as Benzisothiazolinone (BIT) and/or Methylisothiazolinone (MIT), in order to stabilize MWF concentrates or they switch to biostable formulations without additional preservatives. Like all synthetic water soluble MWFs, NOVOTEC CL800based MWF needs an effective water soluble corrosion inhibitor. The
better surface quality and improved cleanliness of the machined parts
makes it even more important that the MWF containing NOVOTEC
CL800 has an effective corrosion inhibitor for protection.
NOVOTEC CL800 is prepared from collagen material, including hydrolyzation and extraction processes followed by subsequent
enzymatic treatment to achieve proper functionality and molecularsize. The protein molecules of this protein-based liquid concentrate
are high in hydroxyproline content. This amino acid is not found inother protein species, such as plant protein or milk protein, and it
gives NOVOTEC CL800 a unique and much more polar structurethat allows a fast absorption to metal surfaces, especially steel. To
prove this mode of action, NOVOTEC CL800 was combined with aFigure 1. M ic roscopy of fluorescein - lab ele d N OVOTEC solution (gre en)bound on a st e el surface demonst rat es high p e ptide - surface affinit y.
UV-marker so that the protein film on a surface was directly visible via
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COMPARISON OF SURFACES AFTERPROCESSING WITH COOLING LUBRICANTS
Piston surface diameter 100 mm

Figure 2. Test cylinde rs af t e r Reiche rt we ar t est. Fluid use d from lef t t o right.
Wat e r, 5 p e rcent standard MWF 5 p e rcent N OVOTEC CL80 0.

resulted in the same low Reichert value as 5 percent of a standard
synthetic fluid tested and left no residue (see Figure 2).
In cooperation with Theodor-Frey-Schule technical college(Eberbach, Germany), researchers studied pressure resistance. A piston (AlSi12) with a diameter of 105 mm was placed in a metalworking
lathe. A hole was drilled in the middle of the piston and then machinedfrom the inside to the outside at constant rotation speed (1,000 U/min,feed 0.19 mm). The surface of the piston machined with the mineraloil-based product was completely blocked by welded material, while
the NOVOTEC CL800 prevented the material from welding under thesame conditions due to the nature of the protecting protein films andthe better cooling performance (see Figure 3).
Because NOVOTEC CL800 is not a standalone solution for MWFs,
we worked together with other additive producers such as LANXESS
Rhein Chemie Additives (Cologne, Germany), an expert in the areaof high-performance additives for lubricants, to develop a guideline
formulation for a MWF with NOVOTEC CL800. Among the first MWF
producers using NOVOTEC CL800 in a commercially available MWF
was Chemische Werke Kluthe GmbH (Heidelberg, Germany), whichdeveloped and now actively markets their own NOVOTEC CL800based product, Hakuform A805.
G+F Sondermaschinenbau GmbH (Beerfelden, Germany), a manufacturer of special machinery and equipment for the food, beverage and printing industry, was the first to test Hakuform A805. Theiremployees and machine tools deal with a variety of materials (brass,aluminum, steel and stainless steel) and machining steps (sawing,milling, drilling and turning). After extensive and diverse testing withHakuform A805, G+F reported performance efficiencies that included improved surfaces, especially when machining non-ferrous metals,
longer life of saw blades, little foaming – even at high pressure (20bar), and an elimination of residues – even without an ion exchangesystem. Operator benefits were equally positive. Those with known
allergies to conventional MWFs could use Hakuform A805 withoutreaction. Even operators without known reactions to traditional fluids
expressed a higher skin tolerance to the NOVOTEC formulation. The
G+F Beerfelden shop changed all of their machines to Hakuform
A805 MWF in January 2015.
In another field test at Heidelberger Druckmaschinen AG((Heidelberg, Germany), the shop used Hakuform A805 in turningand milling of steel, stainless steel, aluminum, non-ferrous metals andcomposites. Besides increased tool life and a broad suitability for
different materials, they reported less consumption of metalworking
fluids, fewer equipment maintenance issues, and easier cleaningof machines and equipment parts. Users also reported a notable
improved skin tolerance, even compared with full synthetic MWFs.
Heidelberger Druck is now installing a central supply system forHakuform A805 to run this MWF on several machines in their technical training center.

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Piston surface diameter 60 mm
Conventional coolant with
5% oil leaves residues

Clean surface after
use of coolant with 2%NOVOTEC® CL800

Figure 3.

A CUTTING EDGE
SOLUTION

By using NOVOTEC CL800,
manufacturers of MWFs cangenerate products that address
the challenges of modern metalworking and offer improved
cooling and lubrication that
decreases wear on equipment, lowers maintenance costs, improves
skin tolerance, and reduces chemical vapors and odor. Efforts for dailycleaning of machine tools can be reduced significantly because they canbe cleaned with the cooling lubricant itself. MWFs like Hakuform A805
have provided immediate and significant benefits for those shops that
seek all-around performance improvements, as opposed to optimizing a
singular component of their processes. Manufacturing environments thatexperience irregular downtime or do not have machine tools with proper
exhaust ventilation are also ideal candidates for these MWFs. And any
shop where operators cannot avoid direct skin contact with MWFs and/or are working to avoid or reduce oil pollution in their factories or surrounding environments can realize improvements.
NOVOTEC CL800 is still not fully competitive in pricing compared
to existing water-soluble lubricants such as polyglycols, but it offers
better cooling and lubrication performance, allows decrease of AW
additives and gives rise to less aggressive formulations. Field tests
show a decrease in consumption of up to 40 percent compared tomineral oil based products, due to better cooling and less discharge
via flakes. In case of subsequent processing steps, such as coating,phosphating, painting, gluing or welding of the processed parts,
NOVOTEC CL800-based MWFs can significantly reduce overall production cost and process time because the cleaning of the processedparts from oil residues is no longer necessary.
References
1. Source: https://www.nynas.com/de/media/newslist/growth-opportunities-in-the-mwf-market)
Matthias Reihmann, PhD, is the head of global product management atGelita AG, Uferstraße 7, 69412 Eberbach, Germany, +49 6271 8401,
www.gelita.com. For additional information in the U.S., please contact
melissa.simon@gelita.com.

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