the Zeta Rod™ for metal working and machining

A variety of cooling and lubricating additives are used in machining operations to remove chips and waste material, prevent overheating of tools and parts, and lubricate cutting surfaces.

Additives are generally mixed in a specified ratio with water in a tank and then distributed to each machine, where the fluid is sprayed onto the work surface during cutting, boring, grinding, extruding, or forming operations.

Spend fluid is often collected, filtered, and returned to the tank and recycled to the machines.

The performance of the fluid system is dependent on the accurate mixing of the additives into the water and the preservation of the desirable properties of the additives.

A major cause of problems in metal working fluids is biological degradation. Microbes such as bacteria and fungi present in the water and air metabolize the additive basestock and various other components of the fluid, excrete undesireable metabolic by-products, and often produce foul odors. Breakdown of the desirable fluid components, proliferation of microbes, and production of waste products compromise the performance of the fluid and lead to clogging of the fluid distribution and filtration systems, poor mcahine tool performance, and shortened tool life. The presence of microbes in the spraying fluid can lead to dermatitis, respiratory problems, and other adverse health effects for workers.

Therefore, biocides are added to the fluid mixture to reduce biological activity. Without the biocides the fluids spoil quickly smell rotten and with the very high bacteria and fungus counts are a health concern. Filtration is not enough and the filter clog quickly with fungus and slime. However, biocides can react with the lubricating and cooling addtives and compromise their performance. Biocides can also present health problems and must be dosed, monitored, and managed carefully. Finally, biocides are exepensive.

Installation of the Zeta Rod stops bad odors and reduces sharply (up to 90%) the amount of biocide needed. The Zeta Rod is compatible with other technologies including pasteurization and Ultraviolet light.

The Zeta Rod system has the ability to clean out the biofilm from fluid storage tanks, filters and distribution system piping. The effect is immediate! Sloughed-off biofilm will usually be seen as sludge rising to the top and floating on the fluid surfaces in the tanks within a few hours. After installation of the Zeta Rod system, severely fouled systems will need frequent filter changes for the first few days as existing deposits are removed.

After the initial clean-up period, filter operation will return to normal with the coolant system stable and odor-free.

Benefits to Zeta Rod users include:

• Reduced worker health and safety concerns
• Control of biological activity with reduced biocide usage
• Reduced fluid consumption and extended fluid life
• Less down time changing filters and replacing spoiled washing water and chemical cleaning solutions
• Less system maintenance on nozzles, valves, pumps, and filters
• No adverse effects on fluid performance or properties.

A Zeta Rod installation extends protection throughout the fluid system, provides stable control of biological activity with reduced biocide usage, and represents an effective, economical method of ensuring the best performance of the fluid system with low monitoring and maintenance.