Client Overview

A manufacturer operating with high-volume carbide tool grinding machines required a filtration system capable of supporting continuous 24/7 production. The challenge was to maintain oil quality, extend filter life and minimize downtime even under heavy machining loads.To remain competitive, the manufacturer needed a solution that would deliver long-term reliability without frequent oil changes and reduce dependency on consumables and spare parts. Consistent coolant quality was critical, as even minor variations could directly impact tool accuracy, surface finish and production efficiency.

Challenges Faced

• Maintaining coolant oil clarity during uninterrupted production.
• Shorter filter life with conventional systems.
• Frequent maintenance and spare replacement add to operating costs.
• Ensuring reliability under heavy-duty grinding conditions.

Solution by Lex Technoaid

Lex Technoaid installed a One Micron Candle Filtration System connected to two tool grinding machines. Engineered for ultra-fine particle removal, the system ensures continuous filtration even during backwash, allowing uninterrupted grinding operations. Its design retained coolant oil quality over extended production cycles, keeping the oil golden in color without the need for replacement. With automatic backwashing, reduced consumables and minimal maintenance needs, the system proved highly efficient for 24/7 heavy-load operations.

Outcome

• Proven Filter Life: The system has already run for 16,336 hours with back pressure stable at 2 bar, showing potential to operate smoothly for another 3–4 years.
  
• Oil Quality Retention: Even after such extended use, the oil remained gold in color and had not changed, proving its long-term stability.
  
• Continuous Operation: The system supported 24/7 heavy-load production without interruptions.
  
• Low Maintenance: Consumables and spare requirements were significantly reduced, lowering overall operating costs.
  
• Scalability: This successful installation demonstrated that candle filtration systems can reliably support centralized grinding setups.