OEM Manufacturing

Metalworking fluids (MWF): Liquids used in machining (turning, milling, grinding) for cooling/lubrication. Types: (1) Straight oils: Mineral/vegetable oil, no water. (2) Soluble oils: Oil-in-water emulsion (3-10% oil). (3) Synthetics: Water-based, no petroleum oil. (4) Semisynthetics: Blend of soluble + synthetic. Mist formation: High-speed machining (spindle RPM 5,000-30,000+), cutting action atomizes coolant creating aerosol mist (droplet size 0.5-10 micron) suspended in air. Also evaporation from hot workpiece/tooling. Mist concentration: CNC machine without collection: 0.5-5 mg/m³ oil mist in immediate vicinity (exceeds 0.5 mg/m³ ACGIH TLV). Accumulates in building reaching 0.1-1 mg/m³. Hazards: (1) Respiratory: Inhalation causes occupational asthma, bronchitis, hypersensitivity pneumonitis. Carcinogenic potential (straight oils contain PAHs). (2) Skin: Dermatitis, folliculitis, oil acne from skin contact. (3) Safety: Mist settles on floors creating slip hazard. Accumulation on electrical creating short-circuits, fires. (4) Housekeeping: Mist coats windows (vision loss), machines (gummy buildup), product (contamination). Collection: Mist collector on individual machine: Extract air from machining enclosure, pass through coalescing filter (droplets coalesce on media, drain by gravity), discharge clean air. Efficiency 95-99%. Airflow 500-3,000 CFM per machine. Centralized system: Duct network collecting from multiple machines to central filter house. Benefits of collection: Healthier workplace, regulatory compliance, cleaner facility, machine reliability (no oil buildup in controls/electronics), recovered oil returned to sump reducing consumption 10-30%.