Client Overview

A 50-year-old export-oriented surgical knife manufacturing company based in Delhi was facing scale-up challenges in late 2015. Known for their high-precision tools supplied exclusively to Switzerland, the client operated in a tightly regulated industry where coolant clarity and consistent machining quality were critical. They approached Lex Technoaid seeking a smarter, scalable solution to enhance their Coolant Filtration for Grinding Machines and expand operations without increasing shop floor space.

Challenges

• The client operated 15 grinding machines and aimed to increase capacity by 30%, but lacked the physical floor space to install more machines.
  
• Their existing imported filtration system failed to deliver the coolant clarity required for surgical-grade tools.
  
• Maintenance was time-consuming and costly, with each machine needing its own coolant filtration system, pump and spares.
  
• High energy consumption and scattered maintenance efforts led to inefficiencies across the shop floor.
  

Solution

Lex Technoaid designed and installed a Centralized Coolant Filtration System that eliminated the need for individual units on each machine. This innovative coolant filtration system was placed on a mezzanine floor, freeing up valuable shop floor space.

The centralized setup enabled the company to:

• Double their grinding machine capacity from 15 to 30
  
• Consolidate filtration system components into a single, VFD-driven unit
  
• Use IoT-based alerts for centralized coolant management to monitor performance and failures
  

This solution stood out as a strong example of industrial coolant filtration solutions tailored for high-precision manufacturing environments.

Outcome

• 50% increase in machine capacity without expanding floor area
  
• 40–60% power savings via shared filtration and energy-efficient VFDs
  
• 65% reduction in daily maintenance and spares
  
• Improved coolant quality led to better product output and reduced downtime.
  
• The Lex Technoaid filtration system delivered a full Return On Investment within just 18 months.
  

By moving to a centralized coolant filtration system, the client now benefits from optimal space utilization, efficient operations and a scalable setup for long-term growth.

Conclusion

This case demonstrates how a thoughtfully engineered centralized coolant filtration system can transform a capacity-constrained manufacturing unit into a high-efficiency operation. By centralizing processes, leveraging advanced coolant filtration system design and integrating VFD technology with IoT feedback, Lex Technoaid delivered not just a product — but a complete industrial coolant filtration solution. The result: enhanced productivity, minimized energy costs, reduced maintenance and a future-ready shop floor.