QCMSSM BEST PRACTICES

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1 QCMSSM BEST PRACTICES OVERVIEW Quaker Chemical Management Services (QCMSSM) utilizes the principal of sharing best practices among sites which saves time, and makes the work easier, and saves the customer money. The subject of best practices can entail a number of different aspects with regard to managing systems and taking care of fluids. Below are some standard best practices that are used in QCMSSM sites. The specific sites are not mentioned because some of the information is proprietary. SALT BUILD-UP WITH METALWORKING FLUIDS Automotive plants can encounter problems with their large central systems if city water continues to be added as make up. As the water is added, systems gradually increase in both hardness and chlorides from their starting values. In order to keep the system at a reasonable hardness level, the plant should utilize a mix of city water and reverse osmosis (RO) or de-ionized water for the make up. This, however, is an expense for the plant (Reference Water Quality). Typical problems the systems experience with high hardness and chlorides are potential splitting of the emulsions and rusting of parts (steel or cast iron). Most metalworking fluids are suitable to add to a system up to 725 ppm with some possible creaming occurring after that point. Rusting of parts is a more difficult issue to assess because rust formation depends on many variables. These variables include hardness and chlorides, total ionic strength, concentration of coolant, incoming part quality, atmospheric conditions (time of year), and the location and amount of time that the parts are sitting at various stages in the process. Currently, high hardness and chlorides have not caused issues with rust or machining of parts. However, certain high water hardness and high chloride conditions can cause rust where there are no other obvious culprits. These extreme conditions can also cause the coolant to break down or split, and in some cases contribute to complete system failure. Evidence from plant sites has shown that many coolant systems can run at high hardness and chloride levels (> 600 and > 150 ppm, respectively) and still perform adequately. If systems are properly monitored and their control plans are followed, partial dumps at upper control limits will allow the system to come into range. If these precautions do not take place, it is necessary for the Chemical Managers to carefully monitor potential negative effects when the systems run above the control plan limits. It is also useful to perform visual inspections of the coolant for 24 hours after sampling, institute part quality metrics, and execute Cast Iron Chip tests to gather predictive data. QCMSSM will continue to monitor fluid characteristics and help identify ways to add de-ionized water to help dilute and further manage central systems.

2 DISSOLVED OXYGEN TESTING Chemical Management sites use different tests to determine the amount of biological activity in their fluids. (Reference Bug Skill Builder) One of the most widely used measurements are Biosticks, however, there can be issues with these test strips making them unreliable. Biosticks require 48 hours for bacterial growth and 72 hours for fungal growth. An alternative and more precise measurement is the Dissolved Oxygen test. When a metalworking fluid mix is exposed to the air or is pumped, it will absorb a certain amount of oxygen. At 68 F/20 C, a circulated fluid mix will dissolve approximately 9-12 ppm of oxygen. When aerobic bacteria grow, they use some of this dissolved oxygen to grow, and at the same time, they excrete certain gases that drive some of the remaining oxygen out of the mixed fluid. As a result, the amount of dissolved oxygen in the metalworking fluid mix is reduced. By using the Dissolved Oxygen test the amount of bacteria present in a metalworking fluid mix can be measured to obtain a relative indication of biological issues. Dissolved Oxygen Test Steps (strips or meter): Take an initial reading of the metalworking fluid mix Allow the metalworking fluid mix to sit for 1 to 2 hours Take a second reading of the fluid If there is a difference of approximately 2 to 3 ppm between the two readings then there is a biological issue The Dissolved Oxygen test is a good method for a quick, on-site determination of any biological problems and is a best practice for QCMS SM. MIST COLLECTOR Mist Collectors at our QCMS SM accounts have been an issue when it comes to high metalworking fluid use. Chemical Management has found a meter can be used to measure the amount of fluid lost due to the collector and fix the issue at the machine or at the mist collector. A major automotive manufacturer was experiencing a high usage rate on a large metalworking fluid system. They installed a meter, and tracked the fluid loss over a period of 48 hours to see if the Mist Collector was causing the issue. The results of the meter tracking are below. Potential savings if flow rate continues at current rate: 400 gal at 10%/day 200 gal/week of a Quaker fluid concentrate $16.00 x 200 = $3,200/week or $153,600 annually In conclusion, Mist Collectors can cause higher use and should be monitored for fluid loss and be tracked like other chemicals at the facility.

3 COOLANT CONVERSIONS There are a number of ways to conserve coolants, washer fluids, and other liquids in the plant. The number one method is proper concentration control. When the concentration changes like a see-saw, the operation is not in control. The proper control makes sure that the product is in the right range. It also impacts product tool life where lubrication is an issue. Skimming tramp oil improves in two areas. The first is to save the coolant by removing a food source for bacteria. The second is to recycle so that it can be used for other operations or for general reclaim. Both of these approaches save time and money. Watching volumes helps to maintain a proper system. Making sure that the correct amount of fluid is being used also helps the site maintain a more conservative approach. This can also help keep help to identify leaks in the system or other mechanisms that permit the loss of fluids from the system. Recycling coolant is another way of making sure that the fluid is in control. This can imply removing tramp oil, adding biocide to control bacteria, adjusting the concentration to the proper level and making sure that the ph is at the correct level. Adjusting the coolant permits the fluid to be reused over and over to make the best use of its potential. Some customers have chip wringers that let them remove more coolant from the chips. The reclaimed coolant lets them return it to the system without discarding it. This also creates an improvement for the chips since they don t contain any fluids. Sometimes there are applications for a particular fluid no longer being used in a plant. This fluid can be moved to another plant for use instead of disposal. This helps both plants. Another area that helps the customer is the use of empty totes. The coolant in a smaller, individual machine tools can be pumped into a tote while the machine tool is cleaned out or has equipment updated. The use of the tote lets the coolant be sidelined until it can be returned into the machine tool. Changing coolants has a large impact especially if the new coolant provides the same performance as a lower price. Coolant testing must take place to insure that the new coolant satisfies the criteria for the system. It must machine the same as the previous coolant and provide the same corrosion protection and biological stability. Other criteria may be added to the coolant selection. FILTER PAPER Filter paper is the tool used to remove oils, debris and fines from the fluid in the system. Using filter paper provides the opportunity to optimize cycle times, will permit longer cycle times that permit a better use of the filter paper.

4 Some suppliers have alternative paper that will provide the same level of filtration at a higher level of cycle time. In some situations it is more opportune to change to a permabelt that lasts longer than the paper. This change requires input from the supplier to make sure that the permabelt will satisfy the requirements for the operation. Filter bags are another area that can improve filtration. There are different types of bags that can be used to slowly increase the level of liquid filtration without doing a major change to the filtration system. This can improve the filtration of the liquid without a major change in the filtration. RECYCLED OIL There are many customers that have oil leak programs that focus on the leaks, examining where the leaks are and fixing them. The oil collected from the leaks can be recycled for reuse or can be used as a waste product. Other customers recycle cutting oils and other sources of oil. The recycling permits the customer to reuse the oil for multiple purposes. As long as the recycling is effective in removing moisture, dirt, and other debris, the program can save money and time. There are rules and regulations in place for the recycling of oils if the intent of the program is to resell or re-use the fluids outside of the current application. The Federal Government plays a part in these regulations in terms of what you can call the recycled oil. Again, the rules are strict on what you can do with the oil. Many customers have considered changing to recycled oil from Safety-Kleen. Safety- Kleen offers a handful of recycled products for different levels of lubrication. The Safety-Kleen products tend to be lower cost because of the recycling. BIOCIDE OPTIMIZATION The Federal Insecticide, Fungicide and Rodenticide Act (FIFRA) governs the use of all biocides in the United States. Many customers have specific personnel who are authorized to handle the biocides in the plant. Biocides are very dangerous if not handled properly. Many customers like to keep a bare minimum of biocides in their plant. They should be locked up in order to control them. Some customers have reduction programs to minimize the use of biocides. Other customers prefer to dispose of the biocides. The focus should be on the optimization of the biocides to make sure that the correct biocides are being used to handle the correct situation. Again, this requires a level of training to make sure that the users know what they are doing. Southwest Engineers has provided lower costs for some of its biocides to replace fluids from other suppliers. The change in suppliers appears to be somewhat simple when the same chemistry is being applied at a better price.

5 THIRD PARTY TESTING There are many third party companies that can conduct testing for a company because it is their expertise. In some applications, the company can conduct the testing themselves and save money by keeping the testing internal. The training of the appropriate personnel is important to make sure that the correct procedures are being used and are repeatable. VENDOR CHANGE There are some applications where a change in vendor provides an opportunity for the new vendor to meet certain expectations at a lower cost. The new vendor must provide all of the information required to become a new vendor and meet the cost requirements. If there is a change in the requirements for the customer, the staffing requirements can change. The opportunity is to make sure that the number of Associates can provide the necessary level of service to the customer. CONCLUSION The Quaker site personnel can share information easily and help multiple customers save money. The best QCMS SM Practices makes the job easier for each site to help their customers. The practices also can be used going forward to continue to optimize savings for the customers. STAFFING OPPORTUNITY Each site has a prescribed number of Associates to conduct the work and get the job done for the customer. During shut downs and holidays the staffing requirements can change. With fewer Associates, the fees are reduced. A LOCAL PARTNER YOU CAN DEPEND ON. ANYWHERE IN THE WORLD. Our Associates are on the ground in every region of the globe. That means our entire infrastructure (from sales to service, R&D to manufacturing) is designed to support our customers at a local level, whether in one facility or spread across multiple plants worldwide. Put the right partner to work for you during every step of success. Contact Quaker today to transform your business from the inside V002