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About AUMA Riester
With 2,300 employees worldwide, AUMA Riester manufactures electric actuators for valves. Actuators are critical components for any material flow, ensuring the safety and operational efficiency of entire industrial plants. Products from this family-owned company can be found worldwide in power plants, water supply systems, offshore facilities, and refineries, as well as in virtually all areas of industrial production. The housings for the rotary unit and control system are made of gray cast iron or cast aluminum and are manufactured in foundries worldwide.
In Müllheim, various actuator, bevel gear, and spur gear housings, as well as output flanges and control housings made of aluminum, are machined to size using high-performance machining centers. Machining steps include drilling, milling, turning, thread milling, and thread forming. The machining centers for heavy-duty and light-duty machining generate plenty of chips in the process.
The Challenge
When AUMA Riester decided in 2010 to switch to modern metalworking fluids in its manufacturing process, the reasons behind this decision included not only production considerations but also health concerns and a sense of responsibility toward employees and the environment. This stems from values that have long been deeply rooted in the family-owned company.
The company therefore wants to move away from metalworking fluids that contain questionable ingredients. Although there have been no incidents or complaints from employees to date, nothing is yet known about the long-term effects of frequent contact with the preservatives.
Furthermore, AUMA Riester wants to act responsibly before any potential risks become known. The company also aims to stay one step ahead of legal regulations. “We are all aware that legal regulations are becoming increasingly stringent in the context of growing health awareness,” assures Andreas Völker, Group Leader of Resource Planning at AUMA Riester in Müllheim.
In-depth analysis and recommendations for NOVAMET 910.
In Oemeta Chemische Werke GmbH, AUMA Riester has found a competent partner that is not only a supplier but also a proven manufacturer of metalworking fluids. During the analysis of the situation, residues of the MWF were found in the internal cooling system of the spindles, among other things. Furthermore, it became apparent that the control system for the boron-containing predecessor product was not optimally adjusted, which contributed to mold growth. A decision was quickly made to use Oemeta’s NOVAMET 910 universal cooling lubricant.
The solution:
“NOVAMET 910 is a versatile product for machining applications such as turning, drilling, and milling, and is particularly notable for its high performance across a wide range of applications and materials, as well as its low consumption,” says Thomas Matter, Oemeta’s regional sales manager, who has been working with AUMA Riester for many years.
High cleaning and rinsing power, as well as reliable corrosion protection.
NOVAMET 910 is free of boric acid and formaldehyde, making it ideal for machining steel, gray cast iron, aluminum alloys, and yellow metals, while offering exceptional stability and long service life. Recommended for use on individual machines
and in centralized circulation systems, it ensures clean machines and workpieces thanks to its high washing and rinsing power as well as reliable corrosion protection. It is also exceptionally skin-friendly. All of these are requirements that AUMA Riester sought.
Improved tool life and cleaning performance.
After a six-month trial period on two machines using a single supply of 1,500 liters of MWF, the manufacturing properties and advantages of NOVAMET 910 promised by Oemeta were quickly confirmed. “Above all, tool life and cleaning performance were significantly better,” recalls Andreas Völker. Drilling performance—especially for small diameters—has also increased significantly due to improved chip breaking. And so the switch is being made on all machines.
“When we switched to boron- and formaldehyde-free metalworking fluids for machining, our costs initially spiraled out of control, contrary to our expectations,” recalls Andreas Völker. “Once we entrusted Oemeta with our fluid management, things improved dramatically, and today we save around 40,000 euros annually, ” reported the head of resource planning at AUMA Riester.
As usual, the metalworking fluid is replaced after about six months based on visual inspection and if an odor develops. However, since the boron- and formaldehyde-free NOVAMET 910 has a higher purchase price than its predecessor, this places a greater financial burden on the production department than anticipated. Especially after production downtime in the summer and at Christmas, the metalworking fluid is completely replaced due to the odor development of the
. “In addition to the product costs, there is also the machine downtime caused by the filling time of approximately 240 minutes—which doesn’t exactly boost productivity,” recalls Völker.
Fluid management extends the service life of the metalworking fluid.
AUMA managers learn from Thomas Matter that a loss of productivity is avoidable as he explains a fluid management system—known as Oemeta Coolant Management—to them. The key takeaway: The service life of the metalworking fluid is extended by about four times to two years, costs are reduced, and the cost of switching metalworking fluids comes closer to the original estimate.
For AUMA, Oemeta has compiled effective measures from a modular system into a coolant management package. In addition to the procurement of metalworking fluids, the service covers monitoring, maintenance, laboratory services, documentation management, control measures, and disposal.
In this specific case, Oemeta provides the following services for AUMA:
- Weekly measurement of single-use systems in accordance with TRGS 611 and DGUV Rule 109-003, including electronic recording via a barcode system
- Complete documentation
- Preparation of a progress report with notes on immediate actions
- Creation of a weekly to-do list
- Provision of measuring equipment
- Creation of a maintenance plan (following an on-site assessment)
- Implementation of necessary immediate measures, such as adding concentrate, preservation in case of bacterial contamination, and adding various stabilizers
“What really won us over was their professional approach,” emphasizes Völker. “Oemeta’s service staff even have a route map that optimizes the paths between the machines.” Through regular measurements and immediate corrective actions, the metalworking fluid can be used significantly longer on each machine without losing performance. Lubrication performance remains optimal at all times and is “far superior to before.” When all factors are considered, these improvements result:
The following improvements have been made:
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Reduced MWF consumption and increased machine uptime due to fewer re-machining operations
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Cost reduction in terms of re-coating, labor hours, and disposal
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Increased process reliability and assurance of continuous improvement
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Prevention of machine downtime caused by fungal growth and extreme concentration fluctuations
What impressed Andreas Völker the most was “that Oemeta offers this service and accepted the order even though it meant a drop in revenue, since we have to order new metalworking fluids less frequently.” This is not a contradiction to Oemeta’s core values, as Regional Sales Manager Gerrit Walker notes: “For us, people, the environment, and long-term customer relationships come first—not the quick buck.” And so Walker also hopes for customers who are willing to be patient. “Because things improve quickly. But they only reach their optimal state when you can compare them to previous months.”
Coolant management is intended to become part of the continuous improvement process (CIP) and contribute sustainably to increased productivity. All parties involved confirm that this has been impressively achieved at AUMA Riester, partly because AUMA Riester and Oemeta, as family-owned businesses, share similar values. And so, beyond the considerable annual cost savings of 40,000 euros, there remains the satisfying feeling of having also done something for the health of the employees and the environment.
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