Fluid Recycling Equipment w

8/10/2019 Fluid Recycling Equipment w

1/12

MAXIMIZE PRODUCTIVITY

AND MINIMIZE WASTE

WITH XYBEX

FLUID RECYCLING EQUIPMENT


2/12

MAXIMIZE PRODUCTIVITY

AND MINIMIZE WASTE

WITH XYBEX


Customers who recycle their fluidsrealize a 40%80% reduction in coolantand fluid purchases.

A UNIQUE PERSPECTIVE.

Master Chemical Corporation, thecompanythat invented coolantrecycling, is unique in the metalwork-ing fluid industry. ItsXYBEX FluidRecycling Equipmentoffers expertmachining fluid management solutions.But we dont just sell equipment, butrather, equip our customers with thetools and training they need to optimize

the products we sell.The key to using less fluid is to institutea fluid recycling program.

An effective fluid recycling programrequires:

> Stable, bio-resistant fluids which canwithstand repeated recycling

> Management control and activesupervision of the recycling program

> Properly designed and sized recyclingequipment and systems capable of

maintaining the fluid in consistentlygood condition

> Control of the mechanisms whichcause coolants and cleaners to fail

You may have the mistaken impressionthat fluid recycling is complicatedor costly. Instead, its an easy way tooperate more efficiently and moreaffordably, so it virtually pays for itself.

2

PUT XYBEX TO WORK FOR YOU: PAGE

Recycling Fluids with XYBEX 3-4

Filtering and Removing Solids 5-7

Removing Tramp Oil 8-9

Controlling Concentration 10

Measuring Fluid Properties 11

Using Pure Water 11

About Us/Contact Info Back cove


3/12

Master Chemical Corporation has put

all the aspects of good coolant andfluid management to work in a singlemachine, theXYBEXFluid RecyclingSystem.

A XYBEXSystem maximizes the recyclingof water-miscible fluids and minimizesor eliminates disposal, reduces fluidconcentrate use, and improves plantprofitability and productivity. Thesystems range in size from small tolarge and feature low maintenance,unattended operation, and fast return

on investment. Increase profits year afteryear with a XYBEX system.

The smallerXYBEXSystem 600 is a

feature-packed, modular, yet low-costcoolant recycling system. The standardunit is designed for use with water-miscible coolant and cleaner productswhich reject tramp oils. XYBEX System600 supplies the basics for fluid recycling,yet offers the flexibility to meet thecustomers future needs. With a conve-nient side-by-side tank design, it canexpand as your business grows by simplyreplacing the standard coalescer modulewith a centrifuge module.

XYBEX

System 750packs in evenmore features. Its stacked tank designis ideal for the shop trying to conservefloor space. With its standard high-speed centrifuge, this system allowsfor complete recycling of any premiummetalworking coolant. Because XYBEXSystem 750 uses a true high-speedcentrifuge, only one pass through the

system is necessary to remove tramp

oils, particulate matter, and evensome bacteria. Cleaning the fluid tothis degree eliminates the need forexpensive, energy-intensive coolantpasteurization.

XYBEXSystem 1000delivers an evenlarger centrifuge for higher processingrates. Its standard high-speed centrifugeis capable of processing up to 90 gallonsof fluid per hour. Higher flow rate centri-fuges are available. The feature-packedsystem also allows greater flexibility for

adding optional equipment. The XYBEXSystem 1000 is ideal for companies want-ing to include pure water delivery as anoption with their single-skid system.

This system can also easily be outfittedwith a reverse osmosis system, ordeionizer system.

(continued, next page)

RECYCLING FLUIDS

WITH XYBEX SYSTEMS

XYBEX System 750 with standardhigh-speed disc bowl centrifuge and anover and under tank design is idealwith limited floor space.

The smaller XYBEX System 600is a feature-packed, modular,low-cost coolant recycling system.

3


4/12

FLUID RECYCLING EQUIPMENTRECYCLING FLUIDS

WITH XYBEX SYSTEMS

4

The System 1000 series also offersan optional dual product design, the

XYBEXSystem 1200, which featurestwo clean and two dirty tanks for thosecompanies running two products (suchas one for cutting and one for grinding).

For the ultimate in fluid recycling, thelargest standard order XYBEX System thatMaster Chemical makes is theXYBEXSystem 2001. It is a complete, full capa-

bility, single-product recycling system forthe medium-to-large sized metalworkingplant operating with machine tools fittedwith their own coolant sumps. The XYBEXSystem 2001 is equipped with a high-speed centrifuge, includes a larger, morefully instrumented control panel, and

an ergonomically-friendly centrifugepre-filter package. The XYBEX System2001 will provide makeup coolant andwill recycle a sufficient quantity of fluiddaily to support a total of 6,000 or moregallons of coolant in the machines.

Do you have a situation where greaterflow rates or higher processing capaci-ties are required? Custom configurationsare also available. Just name your

requirements and we can customengineer a system especially for you.

XYBEX System 2001 is a complete,full capability, single product coolantrecycling system for the medium-to-large-sized metalworking plant

operating with machine tools fittedwith their own coolant sumps.

All XYBEX Systems include anappropriately-sized dirty tank and cleantank; UNIMIXTMautomatic coolantproportioning pump for coolantmakeup and concentration control,and a SCROUNGER Oil Skimmerforremoving free-floating, nonemulsifiedtramp oil from the dirty tank. Optionsinclude coalescers and other trampoil removal devices. The larger XYBEX

Systems include a high-speed, liquid-from-liquid disc-bowl centrifuge to purifythe fluid, removing tramp oil to less than0.5% and solids to the 2- to 5-micron level


5/12

5

MAXIMIZE YOUR COOLANT DOLLARS!

You can recycle coolant virtuallyindefinitely in a well-managed fluidmanagement program fashioned arounda Master Chemical Corporation XYBEXFluid Recycling System. Let our years ofexperience work for you. After all, MasterChemical is the company that inventedcoolant recycling.

Solids collect in the bottom of individual

machine sumps and the bottom of largecentral systems. Having this reactivemetal in contact with the coolant cancause many problems. Its important toget the chips and fines out of a systemin order to achieve optimal systemperformance. The machines that do thisrange from simple to sophisticated.

FILTERING AND

REMOVING SOLIDS

The Drum Top Sump Cleaner convertsan existing open top drum into apowerful machine tool cleaning system.

Two inexpensive solutions for useon individual machines are theDrum Top Sump Cleaner and theMCC Reversible LIQUI-VAC.

The Drum Top Sump Cleaner is avacuum unit that converts an exist-ing open-top drum into a powerfulmachine tool sump cleaner. The DrumTop Sump Cleaner also removes chipsand fines and is an economical alterna-

tive to a dedicated sump cleaner.

The Reversible LIQUI-VACis big enough for tough jobs, yetsmall enough to fit in your hand.

The MCC Reversible LIQUI-VAC isanother inexpensive solution to yoursump cleaning problems. It readilyconnects to a closed-head drum, yet issmall enough to fit in your hand.

Both these small units suck up trampoils, used oil, and waste coolants quicklyand efficiently.


6/12


6

Every metalworking plant faces the

problem of how to clean machinesthoroughly and effectively yet minimizethe downtime for machine tools. If youwant the job done right, then nothingworks better than the Yellow BelliedSump SuckerTM(YBSS). With solid hold-ing capacities to 5.3 cubic feet, and liquidcapacities to 1,000 gallons, the YBSS willclean virtually any machine tool sumpquickly and thoroughly.

During the machine cleaning process,the YBSS removes coolant, sludge, and

chips from the sump, filters the sludgeand chips from the coolant in the integralfilter liner, then returns the filtered cool-ant back to the sump. The polypropylenesleeve filters to a nominal 50 microns.Where finer filtration is needed, such

as for grinding, a single-use paper filter

sleeve can be inserted into the chipbasket to filter 20 micron particulate.

Once the machine cleaning processis complete, and the filtered fluid isreturned to the machine, then the chipbasket can be removed from the chiptower so that the chips and the sludgecan be dumped. The perforated metaltower and solid steel bottom design arerugged. The basket can hold up to 800pounds of chips. When ready to be emp-tied, it should be lifted with an overhead

hoist or another suitable lifting deviceand the solids safely disposed of in a chiphopper. The bottom of the chip basket isequipped with a trap door design, whichcan be activated at a safe distance withthe remote cable latch release.

With YBSS, machines are cleaned in a

fraction of the time required by othermethods. Better still, machine toolsarent sitting idle for extended periodsof time. Get your machines back up andrunning parts quickly with a YBSS!

A VARIETY OF UNITS/CONFIGURATIONS

> Single compartment from50 to 1,000 gallons

> Twin compartment from40/40 to 500/500 gallons

> Tow units up to 1,000 gallon single or

500/500 gallon twin units> Truck-mounted units up to 400 gallon

single or 200/200 gallon twin units

> Push-around models up to 275 gallonsingle to 100/100 twin units

For large plants, the tow, truck-mounted, orpush units would be needed, as the sumpsucker size is determined by the size andnumber of machine tool sumps in the plant

FILTERING AND REMOVING

SOLIDS WITH THE

YELLOW BELLIED SUMP SUCKER

Yellow Bellied Sump Suckers continue to be the workhorses of the coolant industry. Once the machine cleaning process is complete, the chip tower (shown below in cut away) can be hoisted from the YBSS so that chips and sludge can be dumped fromthe remote-activated trap door.


7/12

7

Yellow Bellied Sump Sucker is ideal forexpansive plants with lots of squarefootage to cover.

The LIL Sucker is a 50-gallon, 120 voltelectric sump sucker fits almost anywherethat floor space is a premium.

All the features of our standard YBSSare available in easy-to-use, virtuallymaintenance-free, air-venturi units.

The smallest unit is the LIL SuckerTM

50-gallon, single compartment tank, whichis an excellent addition to a smaller shopwith limited floor space. The small push-around units include many of the samefeatures of the larger units.

Consult your Master Chemical Corpora-tion distributor for help selecting a sumpsucker for your operations.

Power options include air venturi,120 VAC single-phase, 220/440 VAC3-phase electrical, and even an LP unitwith self-contained Kohler engine.

THE YBSS IS FAST!

In a typical example, a cylindrical grindersump with 120 U.S. gallons (454 liters) ofcoolant and 700 pounds (318 kilograms)of sludge was completely cleaned, thecoolant filtered, and returned to thesump in just ten minutes.

FILTERING AND REMOVING

SOLIDS WITH THE

YELLOW BELLIED SUMP SUCKER


8/12


8

Tramp Oil Terminator the portablecentrifuge that removes even thepeskiest tramp oil and is easily movedon its mobile platform.

Self-cleaning, high-speed, disc-bowlcentrifuges keep central systemsrunning clean and tramp oil free.

Getting rid of tramp oil should be high on

the priority list of all metalworking shops.Excess tramp oil causes smoke, mist, andbacterial infestation of the metalworkingfluid. Additionally,excess tramp oil is acontributor to dermatitis. It can adverselyaffect surface finish as well as dimensionaltolerance control. Fortunately, removingtramp oil is easy.

XYBEX larger-scale tramp oil separatorsystems use a rugged, reliable, high-speed disc bowl centrifuge system.These systems are normally set up in

a stationary position and coolant orcleaner brought to them for recycling. Insuch cases, they are part of ourXYBEXRecycling Systems(pages 2-3). Portableunits are also available.

The portable, compact Tramp Oil

TerminatorTMis used in smaller shopsrequiring more than just free-oil removalSome of the peskiest tramp oils are thosewhich emulsify in the carrier fluid eitherthrough light chemical bonding ormechanical shearing. The high-speed,Tramp Oil Terminator centrifuge removestramp oil from both water-miscible cool-ants and aqueous cleaners to provideclean, reusable coolants and cleaners. Itsmobile platform means fluid recyclingcan be taken sump side for more

efficient use of machine up-time. Simplydrop two hoses into the machine sumpand start the centrifuge to effortlesslyremove tramp oil while the machine toolcontinues to run.

REMOVING TRAMP OIL

Large-scale centrifuge systems purify

fluids and remove tramp oil from largecentral systems. The centrifuge pulls fluidfrom the central system in a side loop,purifies the fluid, removes tramp oil, andreturns cleaned fluid to the system.

High-speed, disc bowl centrifuges areavailable with either a solid-wall bowldesign (which is manually cleaned) or atwo-part bowl design (self-desludging,automatically cleaned). The self-desludging design is preferable forhigher solid situations and on central

system equipment.High-speed centrifuges purify the fluid,removing tramp oil to less than 0.5% andsolids to the 2to 5-micron range.


9/12

9

The Sump Side CoalescerTMis a

small, inexpensive coalescing unit forsump-side use. Flow rate is 1.5 U.S.GPM (5.6 LPM). This device is used insituations where it is impossible ordifficult to provide idle time for themachine sump to allow tramp oils torise naturally. Coalescing in the SumpSide Coalescer takes place outside themachine tool sump, allowing tramp oilto rise naturally.

TheSCROUNGEROil Skimmerfeatures an oleophilic belt and a uniquemethod of stripping the separated oilfrom the belt. The SCROUNGERJr.uses the same oil loving belt, but usesa more compact scraper blade to stripthe separated oil from the belt.Theselow-maintenance items also can beequipped with a timer, so the unitruns only when the machine is idleand tramp oil has risen to the surfaceof the sump.

The Master Coalescer IITMmeets the

needs of any multiple-machine metal-working plant for a simple, effective,low-cost tramp oil separator which canbe moved from machine to machine.Master Coalescer II processes machinetool coolants to remove tramp oil andfines and provide clean, reusable coolant.

The oleophilic coalescing plate packswhich remove oils effortlessly andefficiently, come standard with an air-feedpump or heavy-duty, electric-feedpump. The unit also can be used on high

temperature fluids, such as cleaners. Asingle portable machine can supporttramp oil removal for an entire shop!

The portable Master Coalescer JrTMis ahigh-performance coalescer in a smallpackage. Perfect for modern CNC machinetool sumps, it comes with an air feedpump, high-efficiency coalescing platepack, and a small floating skimmer pick upthat fits in small spaces and shallow sumps.

Master Coalescer II the ultimatecoalescing unit for use with large sumpsand/or a large number of machine tools.

SCROUNGERand SCROUNGERJr. oilbelt skimmers can be used in verytight quarters.

Sump Side Coalescer a quiet, economical option.

Master Coalescer Jr. low-maintenancecoalescer removes tramp oil whilemachine is running.

REMOVING TRAMP OIL


10/12

UNIMIX dispenses coolant on demandat the desired concentration.


10

When mixing cleaners, there is often

more than one product to mix. Whatbetter way to mix them than with a two-product mixer? Skrambler2is a ruggedindustrial grade, dual-ratio mixer withdual 3.5 GPM air gap eductor proportion-ers made for dispensing Master STAGESCLEAN products. You can dispense thesame product at two different ratios ortwo differing products at the same ordiffering ratios.

Tackling tough cleaning applicationsand want economical mixing? Choose

The Whammer.The Whammer isa simple, durable, low-cost foamingdispenser for Master STAGESTM CLEANmaintenance cleaners. It is especiallyuseful when cleaning machine tools. Youcan easily see where machine cleanerhas been sprayed both inside andoutside the machine.

Maintaining tight control of the fluid

concentration ensures the fluid neverbecomes too lean or too rich. When theconcentration is too lean, the result oftenis rust, bacterial infestation, and poor toollife. When the fluid concentration is toorich, the mixture often causes eye, nose,and skin irritation, and is simply a wasteof product. Mechanical mixers ensureconsistent concentration under all typesof conditions.

XYBEX offers a complete line ofmechanical concentrate mixers to meet

the needs of all metalworking shops.

When more accurate and automatic

mixing is required, consider UNIMIX.UNIMIX is a water-driven, positive-displacement proportioner, whichdispenses coolant on demand at thedesired concentration. Average flow ratethrough all units is 5 GPM. Mixing rangesare available from 1%15%. Special unitsare available for high alkalinity partswashing fluids. UNIMIX has the benefit ofkeeping the concentration the same atall times, despite varying water pressuresor fluid levels in supply containers.

Master Mixis a compact, easy-to-useventuri mixer for combining water withcoolant concentrates. Water jettingthrough the unit creates a vacuumthat siphons concentrate from thedrum. A needle valve allows for infiniteadjustments across the mixture range.Available in 3 and 10 GPM versions,with mixing ranges adjustable from2%25%.

CONTROLLING CONCENTRATION

Master Mix is an economical,easy-to-use venturi mixer.


11/12

No fluid maintenance concentration

control program is complete withouta method to check the concentrationon a periodic basis. After all, you cannotcontrol what you dont measure!

Charting daily refractometer readingsand tracking actual-versus-desiredconcentration is the easiest way toprevent deviation from the desiredconcentration. This allows the operatorto make daily adjustments to keepconcentration on target.

Sometimes it is difficult to measure

concentration by refractive index dueto physical factors. In those cases,Master Chemical Titration Kits CL-1and CGF-1 are used to check theconcentration of Master STAGEScleanersand TRIMcutting and grinding fluids.While checking concentration, alwayscheck the pH. Using Master ChemicalCorporationpH Test Stripsis a simpleway of determining the degree of acidity/alkalinity of aqueous solutions.

Keeping the concentration controlled,

and the pH within the recommendedrange will help fluids perform muchbetter and last much longer.

The Misco Palm Abbe Digital

Refractometer

is fast, convenient, andeasy to use. With a drop or two of fluidin the titanium well, it delivers a readoutin degrees Brix. Nonlinear temperaturecompensation is automatic and ensuresfluids read between 32F122F(0C50C) are measured accurately.

The large LCD display is easily read, evenin dim light. The user interface has twobuttons one for readings, the other formenu options.

No special calibration solutions or toolsare needed, as Palm Abbe automaticallycalibrates itself to water and is ready touse in seconds. No screws to turn andnothing to adjust.

Difficult-to-check fluids areeasily checked with (below left)Titration Kits CL-1 and CGF-1.

The Palm Abbe Digital Refractometergives fast, accurate measurementof coolant concentration.

MEASURING FLUID PROPERTIE

AND USING PURE WATER

Using pure water is key toexcellent coolant performanceand longevity.

Pure water key to excellent coolant

performance and longevity comes inmany forms such as distilled, deionized,and reverse osmosis water. Typically,deionizer systems are rented from localvendors and distillation units fromcompanies who specialize in this process.

An economical way to provide purewater is with a reverse osmosis (RO)system. Reverse osmosis is a process thatremoves up to 98% 99% of dissolvedminerals and virtually 100% of colloidaland suspended matter. Compared with

other processes, it provides excellentquality water at a relatively low cost

Theres a XYBEX Reverse OsmosisSystemto fit your needs. RO systems aresized based on your raw water qualityand the quantity of RO water your plantneeds. Your Reverse Osmosis system canbe skidded for ease of movement in yourplant, and comes ready for utilities hookup. RO systems are expandable and canbe custom configured for up to 10,800gallons per day capacity.


12/12

Master STAGES: Products toClean, Coat, and Protect

Master STAGES surface treatmentsinclude cleaners and corrosion inhibitorsto keep you environmentally compliant,up and running at peak performance,and more profitable.

Have health and safety issues? Highdisposal costs? Need to prevent rust orclean lubricant from parts? Whateveryour production problems and concernswe have a performance-proven productsure to make the difference. The MasterSTAGES differencethe right solution forthe job at the right price.

Specifications may change without notice in the interest of product improvement

2013 Master Chemical Corporation. TRIM, XYBEX, and SCROUNGER are

i t d t d k f M t Ch i l C ti M t STAGESTM i

For prices or additional information on special units or special applications,contact your Master Chemical Corporation Distributor:

Committed Todayfor a Greener Tomorrow

Our corporation is committed to sustain-ing our natural resources, protectingour environment, and leaving a smallerfootprint on the places we all call home.

As a manufacturer of fluids and fluidrecycling equipment, we are committedto promoting conservation in manufac-turing and helping customers maximizeproductivity while minimizing waste.

Just visit masterchemical.com and clickon Green Policy to learn more aboutour commitment to environmentalstewardship.

Cutting and Grinding Fluidsthat Lead the Industry

Master Chemical has been recognizedfor more than 60 years for its TRIM familyof metalworking fluids for all types ofcutting and grinding operations. Knownworldwide for superior performance,TRIM meets the demands of specializedindustries such as automotive, aerospace,and medical parts manufacturers.

For the full range of cutting and grindingapplications for synthetics, semisynthetics,and soluble oils, TRIM products deliverlonger tool and sump life, better finishedparts, and a better bottom line.

Master Chemical Corporation501 West BoundaryPerrysburg, OH 43551-1200 USA

Tel: 419-874-7902

www.xybex.comTECH SERVICE HOT LINE: 1-800-537-3365

Documents

Fluid Recycling Equipment w