Metalworking Fluid Condition Monitoring

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

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

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

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

/a The Economics of Speed 3 000 000 2 500 000 2 000 000 1 500 000 1 000 000 500 000 - Basis: 10% productivity 20% tool life Δ=58% = 700,000 /a Normal Inadequate Microbial Control

/a The Economics of Speed 70000 60000 50000 40000 30000 20000 10000 0 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 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!

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)

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

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

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

Case Study ATP MWF Field Evaluation Parameter [ATP] Catalase Activity Log CFU B/mL Brix [Triazine] Alkalinity ph [ATP] 1.00 0.11 0.85 (0.08) (0.33) (0.27) (0.38) Catalase Activity 1.00 0.15 0.10 (0.05) 0.15 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 0.14 Alkalinity 1.00 0.27 ph 1.00 The critical value for the correlation coefficient, r = 0.204 at P=0.05 and 0.268 at P=0.01

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

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

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

aqua-tools BCA, Inc.-------- M1cRoe1AL CONTAMINATION CONTROL SERIVCES - LUMINULTRA -suthtught AQUA-TOOLS 26, rue Charles Edouard Jeanneret 78300 Poissy - France Tel : + 33 (0)1 39 75 02 20 Fax : + 33 (0)1 39 75 08 28 contact@aqua-tools.com www.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

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

Thank you for your attention! Biodeterioration Control Associates, Inc. Resources Microbiological Audit http://www.biodeterioration-control.com/audit.htm MWF, Lubricant & MWF System Articles & Papers http://www.biodeterioration-control.com/articles.htm