Simple Solutions That Work! Issue 16

AUTOMATE LUBRICATION FOR PRECISE SPRAYING Application automation is another excellent choice for improvement so that lubrication is very consistent. Many facilities choose to have operators hand spray their dies using a long wand. Although the person does their best to coat the surfaces the same every time, spending long hours press side only equates to over or under coverage and a very tired arm (yes, worker safety and well-being is an ESG initiative not covered in these Scopes). A reciprocator machine is ideal for many applications as it extends the lubricating nozzle into the die area and accurately layers the target zone with lube and can even blow air separately to remove debris. Another option is to outfit a robot or a cobot with a nozzle or a manifold loaded with a host of spray tips that will lubricate precisely. The cobot or robot can manipulate the spray nozzle or spray manifold like a human to mimic the same application process consistently. Both machines utilize the same technology of delivery as discussed so that each part can be programmed and stored for future use. Overall, Scope 1 improvements can be directly linked to overall lubrication reduction without compromising production performance. Improving your ESG Scope 2 levels deal with a reduction in your general power consumption. The very nature of using lubricants is the reduction of friction that can cause unnecessary force or delays in your process with parts sticking to dies. The proper lubricant and application enhance both issues and can help lower your power use. A much-neglected source of power utilization is your need for a pressured air supply via a compressor. The demand for air in plants is always at a premium and the easiest fix is to add another compressor, but this comes at a high cost of power and investment. Again, using the correct lube and dilution ratio, applied correctly, will minimize the amount of air required to lubricate. If you are supplying parts to a company that is measuring their ESG performance, then you are their biggest target of improvement in Scope 3. Everything covered in Scope 1 and 2 will benefit you greatly if true progress is made. Scope 3 has two areas of focus upstream and downstream sources. In both of these category’s freight can be a large spend and once again proper dilution and lubricant application can lower these costs. Maximizing your dilution ratio using less lube means lower incoming shipments, and less waste hauling. RECLAMATION OF LUBRICANTS FOR ADDITIONAL SAVINGS Reclaiming lubricants instead of disposing just makes environmental and economic sense. Purification systems suited for hydrocarbon oils are known for reducing lubrication requirements up to 70% while reducing machine downtime. The ideal system doesn’t use absorbents but the buoyancy of oil droplets instead and can eliminate disposal issues, a definite ESG improvement. To begin the journey, set the baseline and capture important KPI’s such as: required dilution ratio, current dilution ratios throughout the facility, present lubricant usage via flow meter totalizer, cost of mixed lubricant at each machine, total water usage, energy consumption (kW), freight charges for lubricants and waste haul expenses. No one likes EPA mandates. However, this new sustainability reporting mechanism in regards to lubricants, presents opportunities to generate new costs savings— all while gaining a competitive advantage. The key is to—start now! Shows improper mixing and evaporating 12 Contact: TROY TURNBULL tturnbull@industrialinnovations.com