Castrol adds value to CAV machining operations

Citation

(2006), "Castrol adds value to CAV machining operations", Industrial Lubrication and Tribology, Vol. 58 No. 4. https://doi.org/10.1108/ilt.2006.01858dad.001

Castrol adds value to CAV machining operations

Castrol adds value to CAV machining operations

Keywords: Lubricants, Component manufacturing

Castrol's Hysol Excel metalworking fluid is estimated to be saving CAV Aerospace, Consett £100,000 a year by reducing coolant usage, system downtime and waste and disposal costs (Plate 1).

The Aerostructures division of CAV Aerospace Limited was formed from the merger of Aerospace Systems & Technologies 2000 Limited, Prematec Corporation Limited and Castillion Aerospace Limited.

Plate 1 Castrol's hysol excel system

The company's plant at Consett, County Durham is dedicated to long bed component manufacture. The workforce of 150 produces high-value airbus wing spars and stringers that are machined form vast billets of aerospace- grade aluminium using sophisticated multi-spindle, multi-axis CNC machines. Two 70,000-litre bulk tanks deliver coolant for the continuous machining operations.

Whilst the company was not experiencing any actual machining problems, the metalworking fluid supplied by CAV's previous coolant manufacturer was deteriorating quickly, and both bulk tanks needed to be emptied and cleaned on a regular basis. The overall cost, including new coolant, disposal costs and machine downtime while the systems were not operational, was becoming prohibitive. There were also some fluid maintenance concerns, including poor dilution control that caused smoking and misting.

At this point Mike Eggleston, Head of Programmes at Consett, contacted Castrol, who had already been awarded a contract to supply its Hysol Excel cutting fluid to CAV's Llantrisant plant, where similar aerospace components were manufactured on similar machines.

Castrol introduced Hysol Excel into both systems during the Christmas shutdown in December 2004, and in the 12 months or so since then, neither of the 70,000-litre bulk tanks has needed its fluid changed.

Commenting on cost savings Mike Eggleston says that simply not having to buy and change 140,000 litres of coolant has provided substantial savings, but when the virtual elimination of waste, related disposal costs and machine downtime are taken into account, the true value of the cost reduction is estimated at £100,000 a year.

CAV Consett now outsources machine maintenance so Castrol works closely with the contractor, visiting the site a couple of times a month to monitor the pH levels, concentration, etc. of the coolant.

Summing up, Mike Eggleston says the change to Hysol Excel has proved that buying coolant on a “pence per litre” basis is a false economy. He adds that for CAV Consett the reduction in cost, downtime, waste and disposal costs represent real value for money and will also prove invaluable as the company works to achieve ISO14001.

For further information visit web site: www.castrol.com/industrial or E-mail: thrussc@castrol.com