In the highly competitive world of subcontract machining, where even the smallest process variables can significantly affect profitability, one critical element – cutting fluid – is often overlooked.
Numachine Ltd has addressed this issue directly by partnering with Oemeta UK to achieve measurable improvements in tool life, component cleanliness, and operational sustainability.
Numachine Ltd specialises in CNC machining of complex components for demanding sectors such as automotive, medical, and aerospace, where quality and accuracy are of utmost importance. Its ongoing investment in cutting-edge equipment has cemented its reputation for excellence. According to Managing Director George Hawkins, the company focuses on machining parts from castings, aluminium, stainless steel, mild steels, and plastics.
Six months ago, Numachine faced persistent issues with its existing coolant that were negatively impacting productivity and profitability. These challenges included premature tap failure – which resulted in costly scrap rates – and sticky residues on components, leading to wasted coolant and potential safety hazards. Recognising the need for change, Numachine invited Oemeta UK to review its metalworking fluid requirements.
Through a methodical and data-driven approach, problematic ingredients in the old coolant were identified. The solution was to introduce Oemeta Estramet S95, an advanced ester oil-based metalworking fluid formulated without fossil fuels. This sustainable alternative promised – and delivered – a 20% increase in tooling efficiency, enhanced lubrication, and reduced residue.
A comprehensive six-month trial was undertaken, with key performance indicators (KPIs) closely monitored. From the outset, coolant residue was eliminated, resulting in clean parts and time saved on secondary cleaning processes. Tool life improved considerably, reducing both tool spend and scrap rates.
George Hawkins said: “Since introducing Oemeta’s ESTRAMET S95, we have reduced our consumption and costs for taps and threadmills by almost 40%. Machining castings is a large part of our business, so we have analysed this closely. On a regular batch of cast parts that require 42 holes tapped to 3XD, we were changing taps every 60 parts – it’s now 90 parts before changing taps.”
Beyond enhancements to tool life, Estramet S95 reduced in-machine misting and foaming, contributing to a healthier work environment and more consistent machining performance. Coolant consumption was halved, supporting Numachine’s pursuit of ISO:14001 accreditation and helping to reduce its carbon footprint.
The transition to the new coolant was carefully managed, with a gradual rollout across machines to minimise disruption. Ongoing technical support from Oemeta UK ensures optimal coolant performance through regular monitoring and reporting. Scheduled deep cleans are now faster and less costly, with both labour and downtime reduced by 50%.
The partnership between Numachine Ltd and Oemeta UK has delivered significant technical and financial benefits, as well as establishing a foundation for long-term sustainability and growth.