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Used Oil vs. Waste Oil

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The life of your oil-based lubricant does not end when it is time for a change. In fact, after draining a used lubricant, the oil will begin a new lifecycle thanks to advancements in recycling and recovery technology. 800 million of the 1.3 billion gallons of waste oil produced in the United States is recycled every year. To increase the amount of recyclable oil, manufacturers must collect and disposed of used and waste oil in safe, sustainable, and environmentally way. To achieve this, it is essential to follow best practices for used and waste oil management. However, there are key differences between “used oil” and “waste oil.”

Used Oil Defined

“Used oil” and “waste oil” are often used interchangeably, but the EPA defines them differently. The EPA defines used oil as:

“Used oil is any oil that has been refined from crude oil or any synthetic oil that has been used and as a result of such use is contaminated by physical or chemical impurities.”

This does not include any vegetable or animal-based oils. Simply, this is any petroleum or synthetic oil that has been used in operations and have reached the end of its service life.

Waste Oil Defined

Waste oil is much broader in its definition. Waste oil is “oil that has been contaminated with substances that may or may not be hazardous.” A lot of waste oil has not been used and was contaminated before use. A common example is a loose drum cap leaked and the oil mixed with water, rendering it unsuitable for use in lubrication.

Waste oil is considered a hazardous waste. In terms of regulations and compliance, that makes it a completely different product than “used oil.” That brings more liabilities and procedures needed to ensure it is handled properly. Additionally, used oil with certain additive mixtures and water can be classified as waste oil. Off-spec oils with exceeding amounts of arsenic (5 ppm), cadmium (2 ppm), chromium (10 ppm), lead (100 ppm) and halogens (> 4000 ppm) and a flash point above 100 F will also qualify as waste oil.

Best Practices for Storage and Removal

Even though the contents of waste oil may be similar to used oil, it is still classified as waste oil due to the method in which contamination occurred. Used oil is a by-product of doing business, thus allowable to be stored onsite. One mandatory practice for used oil is labelling the storage tanks correctly. Used oil tanks, drums, totes, containers, etc. must be labelled “Used Oil” in order to be in compliance with environment regulations.

By ensuring not cross-contamination, clearly label containers for waste oil and used oil. This prevents potentially spoiling non-hazardous used oil. Waste oil and used oil may be contain similar content mixes, but whether it is used makes all the difference. If an open or leaking drum is contaminated, it is considered waste oil as the contaminant is not known and not incurred during the course of operations.

One way to avoid accumulation of waste oil is ensuring storage best practices are maintained and the integrity of your drums and totes is maintained. If you store your oil near chemicals and solvents, potentially hazardous contamination can occur and proper waste oil procedures must take place. To save on handling costs of waste oil, consider a lubricant storage program and dedicate space for lubricants away from already-hazardous materials.

Learning from your Used Oil

Before dumping your used oil, it is advised to take a sample of the used oil and used oil filters. You can test the used oil and learn a lot about contamination and oil life. This can be a key part of your oil analysis program and help extend your service life and improve lubrication-related decision making and handling.

Key Takeaways

Proper planning and storage of unused lubricant will reduce the accumulation and likelihood of waste oil. Clearly labelling “Used Oil” and “Waste Oil” tanks will keep your facility in compliance and ensure used oil is not contaminated with hazardous materials. By using certified haulers, like Gemini Disposal Services, and recyclers more oil can be recycled and reduce harmful environmental activity like drilling and pipelines. For example, 1 gallon of used motor oil can provide the same 2.5 quarts of lubricating oil as 42 gallons of crude oil.

How to Monitor Alkaline Cleaning Tanks

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After machining parts, manufacturers have to clean them. Once clean, the parts may be painted, assembled, or stored with a rust inhibitor coating. That makes cleaning crucial. Poor cleaning could lead to rust, uneven painting or failure in assembly. Many manufacturers do not have the time or budget to rapidly change out (1-day to 1-week intervals) cleaning tanks; if you are fortunate to have short intervals, little maintenance is required as there is limited time for problems to arise. However, you should still perform basic tests to ensure your cleaner is working properly.

For manufacturers with longer tank life, there are 2 main properties to monitor to ensure the performance of your alkaline cleaner: pH and concentration. When the pH and concentration change, the efficacy of the cleaners can decline and lead to more frequent change-outs and greater cleaner consumption. Basic monitoring can prove to be highly cost effective and extend tank life. 

pH Testing

The ability to remove soils declines as the cleaner’s pH drops. The recommended pH for cleaning non-aluminum parts is > 9.0 and > 9.5 for aluminum parts. Additionally, many corrosion inhibitors have a pH-dependent solubility curve. As the pH drops, less inhibitor is incorporated into the solution and the more likely corrosion on cleaned parts can occur. These inhibitors start to drop around 10.2 pH, but do not cause significant issues until the pH drops below 9.5.

Maintenance programs typically attempt to adjust the pH back into range after falling out rather than monitoring the pH for remaining in range. We recommend the latter method as this ensures the pH does not drop dangerously low and potentially renders the solution unusable. Trying to keep the pH between 9.5 (or higher) and 10.5 is ideal. Adding a caustic to boost pH could cause problems as you will get a false concentration reading. If you plan to adjust the pH, have a qualified on-site analytical chemist perform the adjustments.

To measure the pH, pull a sample of agitated solution and wait for it to cool to room temperature. Once cooled, use a narrow range pH strip to test the pH. Higher temperatures can render pH tests unreliable and measuring in the tank could capture the pH of contaminants on the strip.

Concentration Testing

The other key test involves testing the concentration using titration. Titration is used to find the tank strength (concentration). Titration involves adding an acidic reagent to a know volume of tank solution until a defined pH is reached. This can be done simply by adding drops of a reagent to the tank solution. This process involves a dye that changes colors at the defined pH endpoint. This is useful for finding the concentration with a +/- 2% tolerance.

This method is rather crude, but can be highly refined by having a trained chemist use lab equipment to run the test. Lab equipment is required for tests that require tighter tolerances than +/- 2%. Look for a constant concentration over time. If the concentration drops, some likely suspects are: cleaner carry-out, leaks, overly aggressive oil skimming, pH degradation by contaminants, and excessive raw material stripping. If the concentration increases, some likely suspects are: excessive add-back of cleaner or the presence of metalworking fluids. Sometimes soil could affect the strength reading and could indicate rising concentration or stable concentration when the strength is actually dropping.

Takeaways

The pH and concentration tests should be conducted each shift in the manner described above. Investing in lab equipment may prove worthwhile if you have stringent tolerances. If the concentration is too low, add some cleaner to put the solution in the proper range. If too high, add water to bring solution within the proper range. pH adjustment is not recommended unless you have a trained chemist on-site. For more information on cleaner management, contact Twin Specialties and ask about our “Coolant Management Guide” that includes tips and information for aqueous cleaners.

7 Steps for a Successful CNC Restart

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After an extended production shutdown, it is imperative to get restarted quickly and efficiently. Maintaining your coolant can be the difference between success and failure. It is key to clean, refill (if necessary), and run according to the manufacturer’s recommendation.

These steps will depend on whether you emptied the sump before the shutdown. If you have emptied the coolant, ensure that the machine is cleaned out; Astro-Clean A can be used to clean the machine and remove and residual coolant and contamination in tough to reach places.

If your coolant remains in the sump after the shutdown, follow these steps for a successful restart:

  1. Inspect the coolant sump/tank for any problems.
    • Remove any tramp oil by using skimmers.
    • Remove any swarf or solids with filters or skimming nets.
    • If there are significant solids, the tank and machine should be cleaned out before proceeding.
  2. Do not add any coolant unless there is not enough to circulate through the machine. If you need to add coolant, add coolant at or above the target concentration.
  3. Circulate coolant through ALL pumps for 60 minutes to ensure all nozzles are flushed out.
  4. Check the concentration from the nozzle using a refractometer (either manual or digital).
  5. Top off the sump to 95% capacity to the target concentration + 2%.
  6. Check the pH and odor. Test the pH from the nozzle.
    • If it is too low (8-9 pH), add 3% volume of coolant and circulate for 30 minutes. Repeat until pH is acceptable.
    • If pH is below 8, the coolant is spent and must be replaced. Use Astro-Clean A to clean out machine.
  7. Add fresh coolant to bring tank/sump volume to 100%.

Bonus Tip: To keep coolant fresher during shutdowns, run skimmers and fish-tank fans to prevent tramp oil contamination and coolant breakdown. Circulating the sump coolant may reduce odor.

Following these steps will ensure a successful restart. Equally important is continuous monitoring of the sump/tank. One individual should check concentration daily and pH weekly. If something is off, act accordingly and quickly. Keep records in a coolant log for each machine to ensure continued success.

Contact Twin Specialties about our coolant guide for information about success coolant management. Twin Specialties has over 65 years of experience with metalworking fluids and is your go-to source for metalworking fluids, cleaners, and rust preventatives/inhibitors.

5 Factors for Drawing Fluid Selection

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In drawing processes, there two main types of lubrication. Firstly, there is fluid or hydrodynamic lubrication, which is the separation of metal surfaces with a continuous film of lubricant that prevents contact of those metal surfaces. Secondly, there is boundary lubrication, which is separating metal surfaces by a film only a few molecules thick.

The drawing process generates extreme pressures and the lubricant needs to perform to ensure proper separation of metal surfaces.

Factors for Drawing Fluid Selection

There are many factors that will affect lubricant selection. We will examine these factors and how they may affect lubricant selection and use. Considering these factors will ensure proper separation and excellent performance.

Type of Metal

Not all metals are alike. The first classification for metals is whether it is ferrous, non-ferrous, or an alloy. The hardness of metal will also be a key factor. Harder metals will require higher pressures, thus higher operating temperatures. A harder metal will need a lubricant that provides excellent cooling to prevent poor finishes or melting. Resistance to rust and corrosion varies metal to metal. Porous metals, such as cast iron, are porous and can rust quickly during annealing. Applications with those kinds of metals may require a lubricant that has rust/corrosion preventative additives.

Severity of Operations

The severity of the operation will be key to determining what kind of lubricant you need. Operations with extreme pressures may require lubricants with extreme-pressure and anti-wear additives to maintain proper lubrication. Operating speeds play a key role in determining the viscosity needed. Higher speeds will require lower viscosities so that the lubricant will adequately circulate. As temperatures rise, viscosity can degrade quickly. When the lubricant becomes too “thin” or “runny”, proper separation may be lost. Some lubricants will include viscosity index (VI) improvers to help maintain proper fluid thickness as temperatures rise.

Tooling

The tooling used in drawing may affect the lubricant selection. Some of the tools used in drawing include:

  1. Dies for cold drawing
  2. Rolls for forming strips and shapes
  3. Cutting tools
  4. Extrusion dies
  5. Heading dies
  6. Plugs
  7. Mandrels

The material of the tools also matters. In high temperatures, tool life may diminish and a lubricant that extends tool life improves performance and reduce costs. Tooling can be made of the following materials:

  1. Steel
  2. Carbide
  3. Diamond (synthetic or natural)

Subsequent Processes and Applications

Once a workpiece has completed the metal working process, most likely it still has to go through more manufacturing processes. Some of these include: annealing, cleaning, painting, and assembly into the final product. Cleaning the workpiece is import for final assembly as you want to avoid rust and corrosion. Drawing fluids that are emulsifiable are easier to clean and are preferred by some manufacturers. The cleaning process used also matters. Whether you use a dip tank, spray washer, or vapor degreaser, selecting a fluid that can wash away while also reducing rust and corrosion will be dependent on the cleaning process. Many fluid manufacturers, such as Twin Specialties, supply cleaners that are developed with their drawing fluids in mind.

Economic Considerations

With limited budgets, manufacturers must be pragmatic in selecting a fluid. Opting for a less expensive product may have hidden costs that are not realized at time of purchase. Lower quality fluids may reduce tool life and the fluid itself may need to be changed more frequently. These costs can add up and may not be realized until the job is completed. If your budget allows for it, opting for a synthetic fluid may prove to be a smart choice. Even though lubricants do not make up most of the budget, selecting the right lubricant can create tremendous cost savings on other parts of the income statement.

Takeaways

Each manufacturer has unique conditions and budgets; thus, no lubricant can be a one-size-fits-all product. Analyzing your metal workpieces, operations, tooling, cleaning and assembly processes, and budget will provide clarity. That clarity can aid lubricant selection and allow you to focus more on your manufacturing.

Working with manufacturers and distributors to determine the proper lubricant is the best strategy to maximize efficiency and boost the bottom line. Twin Specialties can analyze your processes and budget considerations to find the optimal lubricant.

What is DEF?

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DEF Defined & EPA Requirements

DEF, also known as Diesel Exhaust Fluid, is an aftertreatment fuel system liquid that is used in diesel engine vehicles to reduce air pollution. Specifically, DEF is designed to reduce the concentration and emission of nitrogen oxides (NOx), by converting nitrogen monoxide (NO) and nitrogen dioxide (NO2) molecules into:

  • Harmless nitrogen molecules, which are the most abundant in our atmosphere
  • Water
  • Carbon dioxide, which is harmless to humans, but still plays a role in climate change

By transforming harmful emissions into harmless gases, DEF plays a key role in reducing emissions over the past few decades. The 2010 EPA Emission Requirements for diesel engines are:

  • 0.2g/HP-hr of NOx
  • 0.1g/HP-hr Particylate Matter

Looking at the chart to the right, DEF has helped reduce emissions by 98% since the late 1980s. This has led to a cleaner environment with less “black” fuel exhaust. These results have made DEF and essential fluid for all diesel engine vehicles.

Ingredients & DEF Standards (ISO 22241)

Sometimes to solve complex problems, all you need is a simple solution. DEF is a simple product consisting of only 2 ingredients: urea and deionized water. With such a short ingredient list, why would it be tough to manufacture DEF? In order for DEF to work effectively and protect your engine and fuel system, DEF must be made with extremely pure urea and water. These purity requirements are clearly defined in ISO 22241, Diesel Engines – NOx Reduction Agent, Aqueous Urea Solution (AUS 32). Additionally, DEF products that meet ISO 22241 may be licensed to display the API DEF Certification.

What requirements are needed to meet the ISO 22241 standard? Each ingredient has the following requirements:

  • Technically Pure Urea with traces of biuret, ammonia, and water only. Urea that is free of aldehydes or other substances such as anticaking agents. The urea is to be free of contaminants such as sulfur, chloride, nitrate, or other compounds.
  • Water with very low inorganic, organic, or colloidal contaminants. This is achieved by single distillation, deionization, ultra-filtration, or reverse osmosis.

Using these purified ingredients, DEF must have a urea concentration of 32.5%. This ensures that enough urea is present to convert the NOx and ensures reliable operation of the selective catalytic reduction (SCR) systems. It is also the concentration that produces the lowest freezing temperature of 12 F. If the fluid does not meet these ISO 22241 standards, it cannot be classified or called a diesel exhaust fluid.

How does it Work?

Now that we have found the fluids needed to convert the NOx, we need the technology and equipment to catalyze those chemical reactions. The most common systems used are Selective Catalytic Reduction systems (SCR). The SCR allows the following chemical reaction to occur:

  1. Water evaporates and urea decomposes into ammonia and isocyanic acid
  2. Isocyanic acid reacts with the water vapor and hydrolyzes into carbon dioxide and more ammonia
  3. In the presence of oxygen and a catalyst, ammonia reduces NOx into nitrogen and water

SCRs have proven to be the most effective solution in reducing NOx emissions. SCRs are the only solution that curbs emissions without compromising fuel efficiency and engine performance. As an aftertreatment system, a system that does not work within the engine, SCRs allow engineers to tune engines that can help performance and efficiency. All diesel vehicles produced today have some sort of SCR built in.

SCRs also have safeguards in place to ensure a diesel engine is not operating without a proper amount of DEF. Many vehicles have warning systems to warn operators to refill their DEF tanks. If those fail, engines will shut down and will not engage until there is a sufficient amount of DEF in the tank to reduce any NOx produced by the engine. It is important for operators to monitor the DEF tank just like they would their fuel tank.

Benefits and Costs of DEF

With increased fuel efficiency, many fleets are noticing around a 5% fuel savings compared to older models. Off-road vehicles and equipment that use SCRs and DEF can see fuel savings well beyond 5%. With large fleets, that 5% can add up significantly over many vehicles and miles.

The DEF needed to properly reduce NOx is generally 2-6% of a vehicles fuel consumption (e.g. 2-6 gallons of DEF needed for every 100 gallons of diesel fuel consumed). To figure out your DEF needs, simply determine: miles driven by your vehicle, miles per gallon (MPG), and DEF dosing rate (2-6%). By dividing miles driven by the MPG, you find your fuel consumption. Multiply your fuel consumption by the dosing rate to get your required DEF volume.

The cost of the DEF is the only extra cost to SCR systems, but those costs can easily be offset (and then some) with the 5% fuel savings. The weight of a full DEF tank is only 5-9 lbs., which is negligible in large commercial vehicles. In passenger cars with diesel engines, typically you need to fill your DEF tank at each oil change. Fortunately, a 2.5-gallon container of DEF can be found for under $20 at most retailers.

Storing and Handling DEF

DEF has a freezing/crystallization point of 12 F. As DEF freezes into a crystalline slush, its volume can expand as much as 7%. Many vehicles have heating elements that ensure in-tank DEF does not freeze or threaten vehicle failure. Freezing does not affect the efficacy of the product, but it is important to store it in tanks at appropriate temperatures.

The shelf life of DEF is about 1-2 years, but could be reduced if the fluid is exposed to direct sunlight or stored at temperatures above 86 F. The water can evaporate in tanks, so it is important to keep the tanks sealed and at an ambient temperature around 75 F. If the fluid evaporates, do not add your own mixture as that can upset the precise chemical balance of manufactured DEF.

Where to get DEF

For commercial fleets and clients, speak with a distributor about solutions and certified products. Twin Specialties offers DEF in drums, totes, and bulk. Additionally, we can work with certain businesses interested in buying larger amounts of retail/consumer-packaged DEF products. Individuals who drive a diesel-engine vehicle can purchase bottles or DEF at gas stations, hardware stores, or auto shops. As diesel-engine vehicles become more popular, especially in Europe, many gas stations are adding AdBlue pumps where drivers can pump DEF directly in their car from the pump for cost savings.

Lubricants for Cold Weather

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During the winter months and in cold weather regions, operators will face cold starts regularly and must select lubricants that ensure proper performance and protect your machine or engine. We will focus on key features that will differentiate lubricants that excel in cold weather and lubricants that will lead to machine or engine failure.

Viscosity

Not all cold starts are equal. There are varying temperatures and the lubricant you need will depend on the ambient temperature. If temperatures are below -20 C/- 4 F, it is recommended to use base oils that can flow in low temperatures. For engine oils, using an SAE 0W or SAW 5W grade lubricant is recommended. When the temperature drops below -30 C/- 22 F, operators should use a SAE 0W or SAE 5W lubricant, but whose base oil is a synthetic base stock and/or a base oil that is considered “multi-grade” or “multi-viscosity.”

Many of these multi-viscosity and multi-grade lubricants are designed for extreme weather conditions including cold start conditions. These lubricants maintain their viscosity better than conventional lubricants. Generally, multi-viscosity lubricants exhibit viscosity characteristics found in 2 different ISO viscosity grades (i.e. ISO 32-46) and multi-grade lubricants exhibit viscosity characteristics found in 3 different ISO viscosity grades (i.e. ISO 32-46-68).

Viscosity Index

When the temperature drops, the lubricant becomes more viscous, thus making it more difficult to circulate and flow through the engine or machine. Having a lubricant with a high viscosity index, defined as a viscosity index greater than 130, ensures that your lubricant better maintains its viscosity in extreme temperatures. Lubricants with high viscosity indices have either a highly refined or synthetic base stock or include viscosity index improver additives.

Monograde lubricants will have viscosity indices in the 95-105 range and will not perform as well as in cold start conditions. Many operators will use different monograde lubricants depending on the ambient temperature. This may cause issues with change outs and cold temperature properties.

Pour Point

As mentioned earlier, not all cold starts are created equal. In colder temperatures, a lubricant’s pour point could be the difference between success and failure. Pour point is defined as when a lubricant no longer flows and congeals. When operating in temperatures below -30 C/-22 F, it is imperative to use a lubricant with a pour point lower than -50 C/-58 F. Similar to viscosity index, lubricants with highly refined or synthetic base stocks have lower pour points. Some lubricants are manufactured with pour point depressants that prevent wax formation and the congealing of the lubricant.

Oil Integrity and Storage

While you can meticulously select the perfect lubricant based on your OEM requirements, ambient climate, and budget, it could be costly if you do not maintain it properly. Just like any oil, it is important to regularly check the oil for cleanliness and contamination. Taking regular samples is key to ensure your lubricant and machine is in good health. When storing lubricants. It is helpful to store the lubricant indoors or in a warmer environment so that it flows easily during start-up. Proper storage will also protect against contamination. If contaminated, the additives such as VI improvers or pour point depressants may not be as effective and could hurt lubricant performance.

A Guide to Base Oil Groups

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In any oil-based lubricant the base oil will compose 80-99% of the product you use. What are differences in the main ingredient of your lubricant? The American Petroleum Institute classifies base oils into 5 groups. These classifications are based on the chemical composition of the base oil and the treatment of the base oil.

If a base oil is classified as Group I-III, that base oil will be composed of crude oil that has been treated. The differences depend on the treatment processes applied to the oil.

Petroleum Base Oils

Group I

Group I base oils are the least refined base oil. Two main characteristics of Group I base oils are that they are composed of less than 90% saturates and/or greater than 0.03% sulfur. If either of these conditions are satisfied, then the base oil will be classified as Group I. The only process that is used is solvent refining, which allows Group I base oil products to be cheaper than their more refined equivalents. These are generally used for less-demanding applications and could be ideal for applications where lubricant consumption is high.

Group II

Group II base oils are more refined than Group I. In addition to solvent refining, these oils are also hydrocracked purify the oil. Unlike Group I base oils, these base oils must contain over 90% saturates and less than 0.03%. The greater percentage of saturates gives these lubricants better antioxidation properties than Group I base oils.

Failure to meet either of these requirements will result in a Group I classification. These products also have a viscosity index of 80-120. These oils have good performance in volatility, oxidation stability, wear prevention, and flash point. They only have fair performance in cold temperature environments. Given costs of treatment today, Group II lubricants are most commonly used today and many users have switched from Group I oils to Group II oils.

Unofficially, there is a Group II+ that are composed of high-end Group II base oils. These base oils must have a viscosity index of 110-120 to be considered Group II+.

Group III

Group II base oils must meet the same conditions (saturates and sulfur) as Group II, but also must have a viscosity index greater than 120. These base oils are severely hydrocracked, hydroisomerized, and hydrotreated to crate the best grade of petroleum base oil. These products offer superior stability and molecular uniformity, which makes them ideal for some semi-synthetic lubricants.

Some people consider Group III base oils to be synthetic. The API classifies them as mineral oil since they are derived from crude oil. They do mimic characteristics of synthetic oils including high viscosity indices. A lawsuit between Mobil and Castrol occurred due to Castrol marketing their Syntec lubricant as a synthetic even though it was composed of Group III base oils. In a 1999 ruling, the product was allowed to marketed as a synthetic.

Many people reject the decision and only consider Group IV and Group V base stocks as “synthetic.” Some Group III lubricants outperform Group IV lubricants if they contain excellent anti-wear, anti-oxidant, and other additives. Similar to Group II, Group III base oils have an unofficial Group III+, which consist of Group III oils that have a “Very High Viscosity Index (VHVI).” The VHVI minimum is anywhere between 130-140.

Synthetic Base Oils

Group IV

Group IV base oils are synthetic base oils that composed of polyalphaolefins (PAOs). These products have a viscosity index of 125-200. These base oils are not extracted from crude oil, but made from small uniform molecules. The uniformity and manufacturing of these oils allows for predictable properties that assure performance in tough conditions. These properties include extreme temperature stability, which makes these products ideal for cold and hot weather climates.

Lubricants composed of polyinternalolefins (PIOs) are considered to be in the unofficial Group VI. Similar to PAOs, PIOs use different chemicals in its synthesis process to obtain an even higher viscosity index. Their official API classification would be Group V. Certain food grade lubricants are composed of Group IV PAOs.

Group V

Group V base oils are any base oil that is not classified as a Group I-IV base oil. Common Group V base oils are polyalkylene glycols (PAGs) and various esters. One exception is white oil, which is a very pure lubricant commonly used in cosmetics and food processing. Also used in food grade lubricants, Group V base oils such as PAGs or esters can be used in certain biodegradable base stocks rather than vegetable or seed oils. It is important to note that most PAGs are only compatible with other PAGs.

Key Takeaways

When selecting a lubricant, it is important to understand what base oil is used. Given that the base oil is 80-99% of a lubricant, you should know what base oil you are using. Upgrading the Group III or Group IV could improve performance and reduce consumption. Twin Specialties offers a variety of industrial and specialty lubricants made from a variety of base stocks to meet your operating and budgetary requirements.

A Guide to Chemical Grades

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Chemicals are key for many products in commercial, industrial, and consumer industries. Creating proper formulations is merely the beginning of the process, but manufacturers need a product to use and one that meets whatever specifications necessary to ensure performance, purity, integrity, and safety. These specifications and requirements are outlined by organizations such as the United States Pharmacopeia (USP), American Chemical Society (ACS), and many others.

Why do Chemical Grades Matter?

These grades indicate the purity and quality of a chemical. Certain applications such as consumer or medical products, require stringent quality standards compared to industrial or educational applications. It is important to know what grade you need so you do not make costly mistakes or non-compliant products.

For example, all drug and drug products in the United States must be in compliance with USP-NF current standards as outlined in the USP-NF Compendium of monographs. Each chemical has a monograph that serves as a standard. These monographs provide information about a chemical’s appearance, solubility, weight, safety, and purity. Purity standards will include testing information and acceptable results. These purity standards help control quality and maintain the integrity of chemicals and end-products. The FDA approves all products and is responsible for compliance and regulation of food, drug, and other consumer products.

What are Some of the Chemical Grades?

There are a variety of chemical grades including industry-wide standards and some specialized for specific scientific applications. We will highlight some common grades used in commercial, industrial, and consumer applications. Some key grades are:

  • ACS Grade: Chemicals that are ACS grade meet or exceed standards set forth by the American Chemical Society. This is the most stringent grade and requires high purity. Products with ACS grade are acceptable for use in food, drug, or medicinal uses.
  • FCC Grade: Chemicals that are FCC grade meet standards outlined in the Food Chemicals Codex. The FCC was acquired by the USP, but still uses the Codex for food chemical standards. This applies specifically for food ingredients and includes special tests for toxicity and ensure suitability for human consumption. The FCC is not officially recognized in the United States, but FCC standards are incorporated into hundreds of FDA food regulations.
  • Lab Grade: Chemicals labelled as Lab Grade have unknown levels of impurities. These are popular for educational or demonstration purposes. However, they fail to meet purity standards for food, drug, or medicinal uses.
  • Reagent Grade: Chemicals with a Reagent Grade generally equal ACS grade standards. These are acceptable for food, drug, and medicinal use and are suitable for use in many laboratory and analytical applications.
  • Pharmaceutical Grade (USP): Chemicals with a Pharmaceutical Grade meet or exceed requirements of a national pharmacopeia. The most common pharmacopeia is USP, but these can meet the standards of the British, Japanese, European, and other pharmacopeias. Many countries incorporate USP standards into their own national pharmacopeia.
  • Technical Grade: Chemicals meeting a Technical grade are used for commercial and industrial purposes. It is not pure enough to be used in any food, drug, or medicinal applications. Like Lab Grade chemicals, these are suitable for demonstration purposes.

Considerations for Selecting a Grade

It is critical to know these grades and which one is required for you process as these grades ascertain: identity, potency, purity, and performance. Having chemicals that are certified ensure your commercial, industrial, or consumer products are in compliance of all standard and regulations. If you need to substitute for cost or availability reasons, it is important to understand these grades as well as the following considers:

  • What is the minimum grade required? Can I use a lower quality grade?
  • What are the differences and similarities of the grades considered?
  • What are the regulatory and economic consequences of the higher or lower grade?

When making a decision on chemical grades, keep these considerations in mind as well as understanding regulatory considerations. Understanding these grades will reduce headaches and confusion and ensure you are making the best product possible. Twin Specialties has a large catalog of chemicals and chemical substitutes that meet your manufacturing need.

5 Ways to Improve Safety and Accountability

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Workplace Safety – It’s everyone’s responsibility.

According to the U.S. Bureau of Labor Statistics, 2.8 million nonfatal workplace injuries and illnesses occurred in 2019.  While the number of these occurrences remained flat of 2018, workplace injuries can be devastating to an employer and employees.  Aside from the obvious emotional pain of having one of your team members injured, the costs and lost time of such injuries can also significantly impact production – particularly when many companies have had to cut personnel because of various pandemic-driven and economic-driven factors.

Manufacturing accounted for 15% of all private industry nonfatal injuries and illnesses and in fact, saw a slight decrease over 2018.  Also, the median number of days away from work was 8 days.

It is up to the leaders of any organization to initiate and introduce new strategies and safety protocols to their team members.  That said, it is up to everyone to incorporate those protocols into their everyday work behaviors – especially on the manufacturing floor.  Here’s how to lay the foundation for change in making your workplace more safe.

  1. Lay the foundation for change.  Maker sure your employees know the statistics and the impact that workplace injuries have on your operation.
  2. It’s up to the leaders to communicate, starting at the “bottom of the food chain” and inform personnel of specific high risk behaviors and experiences.
  3. A company-wide culture needs to be adopted. Everyone needs to be talking about safety and put words into action.
  4. Track your measurables and celebrate your milestones. Learning to frequently and purposefully share stories and deliver words of recognition are some important, immediate steps you can to take to begin shifting your company culture toward improved health and safety outcomes.
  5. Encourage employees to hold each other accountable. If an employees sees something that doesn’t seem safe, that employee has an obligation and a responsibility to say something – if the culture of safety is a sound one.  Employees take ownership of the situation.

When leaders make employee safety a top priority and integrate it into their Key Results — while creating an environment of respect and openness in the workplace — employees feel valued. This bodes well for productivity.

 

How to Get Rid of Microbes in Your Sump

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Bacteria or Fungus in the Machine Sump

At some point, your metalworking fluid will go bad. Hopefully, in most cases it has ran through its effective life and can safely be removed or recharged with a fresh batch. However, sometimes a fluid’s life will be cut short due to unforeseen circumstances. This may involve machine leaks, breakdowns, or outside contamination. In some instances, your fluid and machine may be filled with bacteria or fungus. When this happens, it is imperative to stop operations and remove all fluid from the sump to prevent any further issues.

If there is any remaining contaminated fluid still in the machine, it will decrease the life and effectiveness of the new charge as the fungus and bacteria will continue to thrive in the existing fluid. It is best to also run a cleaner through the machine to help clean hard-to-reach areas such as pumps and hoses. In addition to cleaning out the contaminated fluid, the cleaner removes process oils, gummy deposits or oil, grease, swarf and other outside contaminants. Monroe Fluid Technology’s Astro-Clean A contains special additives designed to render the machine neutral of bacteria and fungus.

Bacteria and fungi grow in the presence of increased surface area in a fluid. As more bacteria and fungus are in the machine, the faster the growth. This exponential growth problem can wreak havoc on your machine and lead to serious problems. That is why it is important to be proactive in managing your fluid. This will lead to reduced down time and increased performance. The main component of fluid maintenance is following the manufacturers recommended concentration and regularly checking the fluid and adding any additives necessary to maintain the highest performance.

Biocides and Metalworking Fluid Additives

One key additive is biocide. Biocides are designed to kill bacteria, fungus, and other living microbes that will damage the fluid. These additives can simply be added to any sump or central system. Grotan is designed specifically for metalworking fluids to extend fluid life. Grotan is meant to be added at 0.15% (1500 ppm) and will fight bacteria and fungus. Many products are formulated with a biocide, like Grotan, to help protect machinery, tools, and work pieces.

Metalworking fluids with biocides are constructed with recommended concentrations in mind. This matters when a machine may be running “lean” on a fluid. If the manufacturer calls for 4%, but the machine is running at 2%, the machine only has half as much additives as needed. There must be a minimum level of biocide present in a solution in order for it to be effective. If there is not enough biocide, the bacteria will not disappear and slowly but surely repopulate. Therefore, it is imperative to follow manufacturer guidelines to enough there is enough biocide and other additives in your solution.

To ensure proper performance, it is important to regularly check the concentration of the solution to ensure the product performs as expected. Using refractometers to measure the Brix/concentration is crucial in maintaining an aqueous solution. This allows users to see the exact concentration and make adjustments as necessary. It is recommended to record the concentration level daily. Due to water evaporation, it is important to add concentrate to your sump to maintain recommended concentration. Never add just water or concentrate, it is recommended to add both to maintain the sump for longer tool life. Mixers are recommended to ensure consistent refills and measurements.

Cleaning Best Practices

It is also important to hand-wash/hand-wipe reachable areas of the machine to remove any solids from the sump. If these solids are not removed, it can result in continued growth of fungus or bacteria. Fungus typically grows by attaching itself to a solid in the sump or system. Theses solids may be outside contamination or smaller clusters of fungus. Therefore, it is crucial to remove solids and deposits before AND after running a cleaning solution through your machine.

If you are unable to dedicate a time to clean and service the machine, the cleaner can be added to the metalworking fluid solution at a concentration of 1-3%. This allows for cleaning while machining parts. Build-up will release from the machine as production continues. It is important to remove these residues and solids after the system is drained. As new fluid flows through the machine after recharging, some deposits may dislodge and appear in the sump. This is normal and should occur during the first week of a new charge.

Contamination that Grows Bacteria and Fungus

In addition to using a cleaner after draining the sump, it is important to follow fluid maintenance best practices. For example, it is recommended to have some method of skimming tramp oil. This can be done by hand or by having an oil skimmer installed in your tank or sump. When tramp oil gets into the mixture, contaminants from the oil can become “food” for bacteria. The tramp oil will also sit on the top of the sump and provide a “seal” which will allow anaerobic bacteria to thrive and multiply. This results in rancidity, which can create less than ideal work environments.

Sometimes outside contaminants can get into the sump and can create surface areas for bacteria and fungus to attach themselves and grow. This build-up can lead to dead zones in the machine where fluid flow is limited or halted completely. It is important to have mechanisms in place to regularly remove solids from the sump. Some examples of tools include: magnetic wheels, conveyors, and indexable filters. In the case of fungi, the fungal mass will remain in the system since it will not disintegrate in the fluid. Therefore, it is important to remove any fungal mass to prevent future growth. Having these items in the machine allow for solid removal and higher performing fluids.

Twin Specialties Can Help

If your sump is filled with harmful microbes, we are here to help. Twin Specialties has a variety of products and resources available to help get rid of microbes. We offer cleaners and biocides that can be incorporated into your sump and metalworking fluids. Contact us for a coolant management guide, a site visit, or fluid testing. We can discuss how to fix your sump and establish practices to uphold the integrity of your metalworking fluids.