Metalworking Fluid Condition Monitoring

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1 Metalworking Fluid Condition Monitoring Microbial Contamination Monitoring The QGO-M Value Proposition F. J. Passman, PhD, STLE Fellow BCA, Inc., Princeton NJ USA

2 QGO-M Value Proposition The Economics of Speed ATP v. Culture data Case study

3 The Economics of Speed Assumptions: MWF cost/l 1.00 ( $5.00/gal) Normal dragout/turnover = 5%/d Waste hauling cost/l 0.5 ( $2.50/gal) System size 38 m 3 (10,000 gal) Cost/part = 1.00 ( $1.30) Price/part = 2.00 ( $2.60) Normal parts/h = 100 Cost/tool 500 ( $650) Normal #parts/tool = 500 Normal production = 12h/d x 5d/wk x 48wk/a = 2,880h/a

50/gal) System size 38 m 3 (10,000 gal) Cost/part = 1.00 ( $1.30) Price/part = 2.

4 The Economics of Speed Normal Operations Item Cost ( ) MWF D&R 114,000 Normal drag 399,000 Fluid total 513,000 Production Parts/y 576,000 Tools/y 576,000 Production total 1,152,000 Total Costs 1,665,000 Gross Revenues 2,880,000 Net Revenues 1,215,000 Biodeterioration Impact Item Cost ( ) MWF D&R 228,000 Normal drag 638,400 Fluid total 866,400 Production Parts/y 518,400 Tools/y 691,200 Production total 1,209,600 Total 2,076,000 Gross Revenues 2,592,000 Net Revenues 516,000

Net Revenues 1,215,000 Biodeterioration Impact Item Cost ( ) MWF D&R 228,000 Normal drag 638,400 Fluid total 866,400

/a The Economics of Speed 3 000 000 2 500 000 2 000 000 1 500 000 1 000 000 500 000 -

5 /a The Economics of Speed Basis: 10% productivity 20% tool life Δ=58% = 700,000 /a Normal Inadequate Microbial Control

/a The Economics of Speed 70000 60000 50000

6 /a The Economics of Speed Culture Δ CM cost = 340% (45,000 /a) Assume 1% risk of D&R QGO-M 1% risk of D&R QGO-M Culture Cost/site visit

[ATP] cell -1 constant; no growth or metabolism needed after sample collected @ 1fg

+28 more generations visible colony 10 9 cells generation time 1h 1.

7 [ATP] cell -1 constant; no growth or metabolism needed after sample 1fg active cell -1 1,000 cells pg -1 1CFU ml -1 Every active cell measured! +28 more generations visible colony 10 9 cells generation time 1h 1.5d to visible colony X X no reproduction no colony generation time 4h 5d to visible colony Slow growing & injured active cells missed!

Obligate aerobes (require oxygen) Obligate anaerobes

8 1. Not all microbes like the same food 2. Different types of microbes have different oxygen needs Obligate aerobes (require oxygen) Obligate anaerobes (can t tolerate oxygen) Facultative anaerobes (grow with or without oxygen)

9 3. Microbes with doubling times >4h won t be seen until after 5 days incubation; most tests stop at 3 days T G = 0.5h T G = 4h Day 1 Day 5 Day 1 Day 5 a Day 5 b Under any one set of growth conditions cell per 1,000 Will be detected as a colony

5h T G = 4h Day 1 Day 5 Day 1 Day 5 a Day 5 b Under any one

10 Cased Study ATP MWF Field Evaluation 11 Sumps Range of MWF ATP B/F CATALASE ALKALINITY ph RI [MWF] [TRIAZINE]

11 Case Study ATP MWF Field Evaluation Fluid Type Machine Type Sump Capacity (L) Emusifiable Oil Shaver 210 Vertical Broach 760 Semi-synthetic Hobbing 190 Grinding 870 Blanchard 570 Synthetic Lathe 660 Broach 950 Radial Drill a 20 Radial Drill a 40 Radial Drill b 950 Radial Drill b 950

Semi-synthetic Hobbing 190 Grinding 870 Blanchard 570 Synthetic Lathe

12 Case Study ATP MWF Field Evaluation Parameter [ATP] Catalase Activity Log CFU B/mL Brix [Triazine] Alkalinity ph [ATP] (0.08) (0.33) (0.27) (0.38) Catalase Activity (0.05) ) Log CFU B/mL 1.00 (0.05) (0.40) (0.20) (0.37) Brix (0.12) [Triazine] Alkalinity ph 1.00 The critical value for the correlation coefficient, r = at P=0.05 and at P=0.01

15 0.10) Log CFU B/mL 1.00 (0.05) (0.40) (0.20) (0.37) Brix 1.00 0.57 0.54 (0.12) [Triazine] 1.00 0.41 0.

13 QGO-M Value Proposition The Economics of Speed Reduce end-user annual fluid management costs Increase plant productivity Cut site visits in half Reduce risk of untimely corrective action Reduce service provider fluid management costs Increase productivity & profitability

visits in half Reduce risk of untimely corrective action Reduce

14 QGO-M Value Proposition The Economics of Speed ATP v. Culture data ATP data in <5 min v. 2 to 10 days ATP captures all active microbes; culture is selective

15 QGO-M Value Proposition The Economics of Speed ATP v. Culture data Case study ATP covaried with Culture [Biocide] [MWF], ph & alkalinity Fast reliable data better system control

16 aqua-tools BCA, Inc M1cRoe1AL CONTAMINATION CONTROL SERIVCES - LUMINULTRA -suthtught AQUA-TOOLS 26, rue Charles Edouard Jeanneret Poissy - France Tel : + 33 (0) Fax : + 33 (0) contact@aqua-tools.com Technical question Scientîfic support Marc RAYMOND Camille l!llavot Time to reorder Order information Alex.indra OUFRENNE contact@aqua-tools.com info@aqua-tools.com

Edouard Jeanneret 78300 Poissy - France Tel : + 33 (0)1 39 75 02 20 Fax : + 33 (0)1 39 75 08 28

17 LuminUltra Technologies Resources Visit for product information. Visit academy.luminultra.com for application training. View our blog at lumicast.luminultra.com. Visit for application note, video, publication

com for application training. View our blog at lumicast.

18 Thank you for your attention! Biodeterioration Control Associates, Inc. Resources Microbiological Audit MWF, Lubricant & MWF System Articles & Papers

Resources Microbiological Audit http://www.

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