Client Overview

A leading Indian carbide tool manufacturer using CNC Carbide Grinding Machines and Tungsten Carbide Tool Grinding Machines approached Lex Technoaid to solve productivity and space-related issues in their plant. The client relied on high-quality grinding for cutting tools but was constrained by shop floor layout and spiraling coolant and tooling costs.

Challenges Faced

The client’s core issues were:

• Limited floor space—unable to install a third CNC Carbide Tool Grinding Machine.
  
• High cost of coolant (~₹700/litre) with short lifespan due to poor filtration.
  
• Murky coolant from the Centralized Carbide Filtration System  affected cutting performance.
  
• Diamond wheel wear increased due to abrasive-laden coolant.
  
• Loss of valuable tungsten carbide scrap, which mixed with the contaminated oil and became difficult to resell.
  

Solution by Lex Technoaid

Lex Technoaid proposed a Centralized Carbide Filtration System and chilling solution:

• Removed individual tanks and introduced a One-micron Candle Filtration System for Carbide Grinding Machines.
  
• Designed the layout to fit all three machines—including a new CNC Tungsten Carbide Grinding Machine—within the same floor space.
  
• Installed a Centralized Chiller to ensure consistent coolant temperature and improve tool performance.
  
• Enabled recovery of tungsten carbide powder by separating it cleanly from the oil, enhancing resale value.
  
• Supplied Mist Extraction Systems with nanotechnology to reduce oil mist in the atmosphere and return oil back to the system.
  

Outcome for the Client

• Cost per component reduced by 52%, giving the client a competitive pricing edge.
  
• Diamond wheel consumption dropped by 48%, saving substantially on tooling.
  
• The same batch of coolant has been used for over 5 years—only topped up for evaporation- oil top up cost reduced by 75%.
  
• The shop floor now houses three Grinding Machines without additional construction.
  
• Recovered carbide scrap now fetches higher resale rates, unlike the unusable slurry from earlier.
  
• Cleaner air and operator-friendly environment due to high-efficiency mist extraction.
  

Original filters rated for 1 year are still running strong after 60,000 hours of use—proving Lex Technoaid’s system durability. Consumable cost for at least  5 years – ZERO!