56 Continued on page 58 a dilution ratio for the lubricant that better improves the process. Proportional mixing machines are a productive and constant means of creating a uniform formula; even the manner used to stir the mix is important, as too much agitation can degrade the die lubricant. Once your lubricant type and ratio are confirmed, consistently test it and the ratio of lube to water. Tests should be performed throughout a shift, a day, a week, a batch, or even from operator to operator, to ensure that improvement will be realized. Testing the lubrication should not only take place from the mixing device or holding tank, but also from the spray nozzle to confirm that the delivery system is working properly. Different testing methods include refractometers, moisture balance analyzer, or a simple and fast hydrometer. The use of evaporators to eliminate waste lubricants is another area of GHG emissions. This process can be minimized or even eliminated by a reclamation system. This allows you to reuse at least a portion of the lubricant, helping to maximize efficiency and minimize waste haul. This will lower overall emissions and improve your ESG score. Again, synthetics work well in reclamation, but there are many to choose from and prior to purchase of any lubricant you need to inform the lubricant manufacturer of your desire to reclaim and reuse. This will allow them to include proper biocide additives that minimize biological growth, which can be harmful both to the product and people touching and breathing it. IMPORTANCE OF DELIVERY SYSTEMS TO REDUCE EMISSIONS The delivery and application of your lubrication will also improve your Scope 1 emissions. A good test for this is to tour your factory and identify misplaced lubricant (e.g., puddles on the floor, machinery, boot soles, spray in the air). Where and how much lubricant being applied can substantially reduce overall consumption and lower your carbon footprint. Spray nozzles are a key component to precise application as they can help regulate the amount of lubricant along with the shape of the spray. Pin-pointing the location of spray is essential in preventing overuse and ensuring proper functionality. However, having a proper delivery system of lube to the nozzle will manage timing and volume automatically, even storing the entire recipe per part number for repeatable process capability. The recipe can then be locked to eliminate any potential of tampering. Up to 24 nozzles can be independently programmed to deliver lube, air, or even skip cycles on these systems to minimize usage. Many times, manual changes are performed in the plant based upon what appears to be lubrication failure. If parts are not forming correctly or releasing, operators adjust as necessary to keep production moving. However, close examination of the process will indicate that, in many instances, an overcompensation of lube is being applied. This is due to either an improper dilution ratio or a bad nozzle that is not spraying correctly. Keep in mind that nozzles typically become obstructed due to lack of maintenance. With a comprehensive delivery system in place, any dormancy would be detected and a purge of the lines and nozzles performed. Flow meters also aid in indicating under or over utilization of lube. If using a water-based lubricant, have your water tested for hardness to prevent a buildup of calcium, which will restrict line size, causing volume issues and potentially blocking lubricant from being dispensed.
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