Extraction systems deal with oil mists and smoke

Renishaw has installed Kitagawa extraction systems to eliminate problems caused by oil mists and smoke emitted form machine tools.

When Renishaw moved into 100,000 sq ft premises in Stonehouse, Gloucestershire, in January 2006, the company realised immediate benefits from a state-of-the-art extraction system from Kitagawa Europe – a specialist provider of tailored custom workholding and manufacturing systems. Renishaw is using Kitagawa's ODF2000HPS and ODF1000S systems that are claimed to outperform industry-standard centrifugal and ionised element units to achieve at least 99.97 per cent oil separation.

In addition to the £5million purchase cost of the factory, Renishaw invested a further £2.5million to transform it into one of the UK's most efficient precision engineering operations. The 70,000 sq ft machine hall in the new facility for the company's machining and piece part manufacturing operation houses an impressive line-up of equipment, including high-performance Citizen M32 sliding head and Mori Seiki mill turn lathes, and Mazak vertical machining centres.

Renishaw manufactures its precision parts in one process at high speeds to give a very fine surface finish. As the neat oil used as lubrication for cutting and cooling heats up, it gives off smoke – causing a health and safety hazard, both from reduced visibility and potential respiratory problems.

Smoke stops work

David Pilborough, senior development engineer, explains: "When we first installed the Citizens we found we could employ more aggressive machining strategies. The new-generation machines allow much faster processes, but also generate lots of smoke. The only solution when the atmosphere gets that bad is to switch off the machines – and that is obviously detrimental to productivity."

Renishaw approached this problem in the way it has always done when purchasing equipment. Appropriate filtration systems were investigated thoroughly in terms of operation, cost and servicing. Various technologies were considered: 'box' type, centrifugal (Renishaw already had some on other machines – but they had always been problematic) and electrostatic.

Centrifugal units that were being used for mist control purposes caused vibration that was transmitted through the mountings, resulting in a poor surface finish on components. Smoke was escaping from every crevice of the machines. This problem was the main driver behind the purchase of filtration equipment from Kitagawa.

Free trials

Pilborough says: "We accepted that we would have to adopt a filtration solution throughout the machine hall, especially in view of current HSE requirements. We also have our own internal standards to provide employees with a pleasant atmosphere to work in, so it was essential that we tackled this issue in the best way and as soon as possible."

Renishaw took advantage of free trial offers, talked to companies involved in similar manufacturing processes and asked searching questions of suppliers – carefully reviewing all available data.

Even so, with machinery standing idle or operating at reduced performance, there had to be a limit on the amount of time that could be spent on trials. While there were less expensive options available, technical data was a much more important consideration than the price. Nothing would be gained long-term from installing filtration equipment that did not do the job properly or required constant maintenance.

Available in both oil and dust filtration versions featuring an advanced design that is said to provide a far greater filter area than competitive products, Kitagawa's systems achieve at least 99.97 per cent oil separation. They also eliminate sub-viral sized particles and carcinogenic contaminants down to 0.1 microns diameter.

Risk management

Renishaw had previous experience in using Kitagawa's system since testing the ODF2000HPS for a 10-week period commencing September 2002. The first installation was a single unit servicing two Citizen M32 machines, but the company now has one ODF-1000S on each because of aesthetics and risk management issues.

Pilborough states: "We monitored the quality of the air output from the units – filtered down to micrograms – and measured the particle contaminants. We found the units extremely effective, having only this year changed the filters on the first Kitagawa units we installed back in 2002. The filters on other 'box' systems we have in the factory need to be changed with much greater frequency.

"By default we are specifying and using the Kitagawa systems with our Citizen M32 machines. Without question, they have proved to be the best solution where neat oil/smoke is affecting the atmosphere."

Filtration units from Kitagawa also solved the problem caused by Renishaw's six Mori Seiki lathes. These use water-soluble oil that generates a mist that is emitted when a ceiling shutter is opened to position the gantry robots into the machines. There are three ODF-2000 units on the line, each shared between two lathes.

All the units are linked to beacons via an electronic pressure sensor to indicate when they fail to do their job – but, as yet, they have remained at 'green'.

Pilborough adds: "For the most part, the efficiency of the filter systems depends on the quality of the installation. The fitters must understand how they work to ensure that the ducting, flanges, positioning, etc are correct and possible leakage points identified. It is worth paying that bit extra for peace of mind and the confidence that we can 'fit and forget'.

"The equipment from Kitagawa is very reliable – it gives us no problems whatsoever. To meet best practice as set out by the HSE, we are considering fitting the filtration units to all of our other machines - even those not causing any mist or smoke – because they vastly improve the air quality for our employees working in the factory."

Kitagawa Europe Ltd

Unit 1, The Headlands
Downton
Salisbury
SP5 3JJ
UNITED KINGDOM

+44 (0)1725 514000

enquiries@kitagawaeurope.com

https://www.kitagawa.global/

More applications
20 minutes ago
Lenze opens door to digitalisation at ITMA
Lenze is using ITMA as a platform to showcase how textile machine providers can exploit the opportunities of digitalisation and be ready for future challenges with today’s solutions.
1 hour ago
New Norgren website offers extended self-serve functionality
Norgren has launched its enhanced global website, offering customers improved functionality that includes the ability to select, order and track products on a ‘self-serve’ basis.
1 day ago
Spelsberg UK announces nationwide roadshow and open day
Spelsberg UK is excited to announce its “Spelsberg on the Road” roadshow. A state-of-the-art tour bus, equipped with a working showroom, will visit numerous locations across the country beginning late May.
2 days ago
Single controller for robot and machine axes optimises productivity
Installing a robotic pick-and-place and integrated conveyor solution has increased productivity for a pharmaceutical manufacturer while maintaining regulatory compliance. Combining a vision system optimised for accuracy that assures end-to-end traceability, a single controller from Trio manages both the robot and conveyor axes, increasing reliability for the end user.
2 days ago
Schaeffler rewards suppliers for outstanding performance
Schaeffler presented 19 of its suppliers with the Schaeffler Supplier Award at the Supplier Day in Herzogenaurach, Germany, in honour of their exceptional performance.
2 days ago
Educational programme announced for Manufacturing and Engineering Week
With just under two weeks until Manufacturing and Engineering Week 2023 and its centrepiece exhibitions open their doors on 7th and 8th of June at Birmingham’s NEC, the full educational programme has been announced.
2 days ago
Streamlining banding machines for sustainable packaging
When sustainable bundling and banding solutions company Bandall faced the challenge of using different sensors for detecting various product formats, it turned to Omron for a solution.
3 days ago
Acorn partners with Bosch Rexroth
Acorn has announced its appointment as an LT Solution Partner for Bosch Rexroth Linear Motion Technology. Rexroth offers a very wide range of linear motion solutions, from a single component to multi-axis complete systems.
1 week ago
See the latest and greatest in Machine Vision Technology at MVC 2023
Now in its seventh year, the Machine Vision Conference and Exhibition is recognised as the leading machine vision trade show worldwide. This year’s show will feature an exciting range of new machine vision technology including the latest products from leading companies.
1 week ago
Unlocking success for UK manufacturers amid industry challenges
Omron’s highly anticipated Discover Omron Roadshow will bring together industry experts, thought leaders and manufacturers to exchange invaluable insights and empower participants with strategies to overcome hurdles, reduce costs, optimise efficiency, and drive overall cost-effectiveness in their operations.

Login / Sign up