Designing sanding processes economically RUF briquetting systems bring back valuable cooling lubricants

Briquetting systems are a good investment for many metalworking production companies. They pay for themselves particularly quickly in the area of grinding processes - here the purchase often pays for itself within just a few months. To this end, RUF Maschinenbau is constantly developing its briquetting systems. The latest innovation: a so-called cooling lubricant flange increases the productivity of the machines.

Grinding machines are often used when metal components with the highest precision and surface quality are required. This is particularly true for manufacturing companies that serve highly demanding industries such as aerospace, medical technology or the automotive industry. However, in order to survive in this industrial environment, it is not enough to “only” guarantee the highest quality. Suppliers must also be convincing when it comes to cost-effectiveness.

In addition to qualified employees and efficient sanding machines, it is important to keep an eye on the entire sanding process. This also includes the professional and economical handling of the large quantities of grinding sludge produced. This mixture of very fine metal chips, corundum abrasion and the cooling lubricant used causes high disposal costs, as it is classified as hazardous waste according to the German and European Waste Catalogue. But this does not have to be the case. The use of high-quality briquetting systems - such as those produced by RUF Maschinenbau GmbH & Co. KG in Zaisertshofen - can provide a remedy.

Grinding sludge - a mixture of very fine metal chips, corundum abrasion and cooling lubricant causes high disposal costs, as it is classified as hazardous waste according to the German and European Waste Catalogue. Pictures: RUF Maschinenbau GmbH & Co. KG

Amortization of RUF briquetting systems in a short time

RUF Brikett Schleifschlamm — RUF presses transform grinding sludge into compact briquettes. These are easy to handle and inexpensive to dispose of. In some cases, they can even be sold at a profit.

The trick: RUF briquetting systems press up to 90 percent of the coolant contained in the grinding sludge out of the grinding sludge and collect it. This is a large amount, as grinding sludge often consists of about half liquid such as oil or emulsion. The other half is solids - a mixture of microscopic metal chips and grinding wheel abrasion. This solid content is ultimately ejected in the form of compact briquettes, which are easy to handle and much cheaper to dispose of than grinding sludge. RUF Sales Manager Bernd Ellenrieder adds: "Unlike grinding sludge, briquettes are not classified as hazardous waste. In some cases, they can even be sold at a profit."

More importantly, the collected coolant can be reused in many cases. Not directly, but after passing through single or multi-stage filter systems, which RUF also offers in different versions.

"Our experience shows that even when using one or two medium-sized grinding machines that produce between 10 and 30 tons of grinding sludge per year, the payback period for our systems is less than a year. The more grinding sludge is produced, the better the ROI," - Bernd Ellenrieder, RUF-Sales Director

In this way, users save a lot of money, meaning that the investment in an RUF system pays for itself in a short time. "Our experience shows that even when using one or two medium-sized grinding machines that produce between 10 and 30 tons of grinding sludge per year, the payback period for our systems is less than a year. The more grinding sludge is produced, the better the ROI," confirms Ellenrieder.

The grinding sludge presses from RUF are perfectly designed for the special requirements. This means that particularly wear-resistant components are used to withstand the increased abrasion as well as possible. In addition, the pressing process sequences are adapted and special hydraulic systems are used.

Despite the best possible basic design, the experts around Bernd Ellenrieder customize their systems for each customer and recommend having test presses carried out with the material to be briquetted in advance: "We offer this free of charge in our technical center. This allows us to adapt the system to the individual requirements of our customers and guarantee maximum efficiency."

Latest innovation: KSS flange

At the Zaisertshofen-based machine manufacturer, such comprehensive services go hand in hand with constant further developments. The aim: to productivity, reliability and durability of the briquetting systems. The latest innovation is a so-called cooling lubricant flange. It ensures that particularly wet grinding sludge is pre-dried.

More precisely: with the help of the new additional module, the moisture content of the grinding sludge is reduced from over 50 percent in some cases to as little as 20 percent even before it enters the press unit. "This is an enormous relief for the briquetting system, which reduces wear and is reflected in higher throughput rates. This means that a smaller, more compact and cheaper briquetting system is sometimes sufficient for the needs of some grinding specialists."

RUF Maschinenbau offers a large selection of grinding sludge presses. Equipped with motors that deliver between 4 and 22 kW, they achieve a throughput of 40 to 350 kg per hour. As the smallest machine, the 1.6 meter high RAP only takes up 1.3 square meters of space. But even the largest machine, known as the RUF 22, has a compact design - with a footprint of six square meters and a height of two meters.