How to diagnose and solve odor problems has become a huge challenge faced by the workshop, because its source may be difficult to locate, this article takes you to the source analysis, identify the cause and solution of odor generation. Usually, odors are classified as biological (from bacterial/fungal growth in metal processing fluids) or chemical. Biological The most common cause of odor complaints is rancidity or bacterial growth in the liquid For example, rotten eggs and sulfur smell. Metal processing fluids contain organic compounds and other components, which bacteria use as a source of nutrition. Less commonly, the presence of fungi or molds may cause odors, typically manifested as moldy changing room odors. In addition to producing unpleasant odor, bacteria and fungi will also cause various problems, including pH reduction, corrosion protection and lotion stability reduction, formation of mucus and residues, and deterioration of tool life and surface finish.
Due to the almost ubiquitous presence of bacteria in typical machine workshops, the chances of bacterial growth in liquids are very high. Once bacteria are inoculated into metal working fluids, their growth rate is fast. Bacterial deterioration is one of the most common causes of shortened lifespan and frequent replacement of metal working fluids, and may have a significant impact on profits. Another method, besides replacing the liquid, is to use the sterilization agent treatment system on the tank side. Fungicides approved for use in metal working fluids are usually very expensive and may expose operators and factory personnel to potential harmful chemicals. Although this method may extend the service life of the liquid, it is usually a short-term solution. Lubricants that do not contain FRAs, boron, and biocides can be used, which helps to extend the lifespan of lubricants and improve working conditions. Basic measures to prevent bacterial or fungal growth: The first step is to choose a specially designed and tested Metal Working Fluid to resist biological growth; Step 2: Correct liquid maintenance. The use of high-quality metalworking fluids and good maintenance measures will minimize odor problems caused by bacteria and fungi. If there is an odor, how to troubleshoot and resolve it? However, when there are odor complaints, the first step in troubleshooting is to understand the nature of the odor and whether it is caused by anaerobic or aerobic bacteria. For example, anaerobic bacteria proliferate in a hypoxic environment, such as in an idle oil pool where a layer of floating oil floats on the surface. This situation usually occurs during weekend shutdowns. When the liquid covered by oil is idle in the oil pan, oxygen will be depleted, causing these anaerobic bacteria to proliferate in large numbers. Many workshops install compressed air bubblers or other equipment to maintain liquid circulation and oxygen. This may be an expensive temporary method. Maintaining liquid circulation only limits the growth of anaerobic bacteria; Aerobic bacteria are still proliferating, leading to odor and other issues.
Whether it is sour or moldy, or caused by bacteria or fungi, the following steps can eliminate the odor and prevent its recurrence.
Step 1: Firstly, confirm that the odor is caused by bacteria, fungi, or both. As an immediate corrective measure, it may be necessary to treat with fungicides to eliminate existing bacteria and fungi.
Subsequently, the key to eliminating future bacterial and fungal outbreaks is to diagnose how and why they occur. The first step in maintaining a metal working fluid free of bacteria and fungi is to continuously maintain an appropriate concentration level, usually between 5 and 10. When the concentration level is low. The components in the fluid that provide biological resistance are not sufficient to prevent biological growth. For most metal working fluids, low concentrations are usually below 4. Regular addition of concentrate is crucial for ensuring optimal fluid performance.
If the concentration level is fully controlled, please check the system for excessive contamination. Contaminants may come from machine tools or processing processes, such as miscellaneous oil, debris, and metal chips, or from external sources.
Impurity oil is an ideal food source for bacteria and fungi, so it is important to take measures to remove it from the liquid. Due to the inability of the coolant and its biological resistance components to fully penetrate the accumulated metal debris, the accumulation of metal debris and debris in the coolant container also creates potential breeding grounds for bacteria. As a good internal management and fluid maintenance, it is necessary to actively prevent external pollutants from contaminating the metal working fluid.
Step 4: If neither the concentration nor the pollutants seem to be the root cause of the biological odor, please check the system for any stagnant areas. These are ideal breeding grounds for bacteria and fungi. If stagnant areas or machine tools are found to be idle for a long time, take necessary steps to ensure sufficient circulation of the liquid.
Chemical properties
Although odors related to metal working fluids are usually considered biological, chemical odors occasionally occur. Chemical odors can usually be divided into odors caused by liquids and odors caused by pollutants.
Each liquid has its unique odor. Some liquids have a strong odor when initially charged, but it dissipates over time. The chemical odor caused by liquid is different from the normal liquid odor. The most common is that chemical odors related to liquids are the result of high concentrations, generally greater than 15. If the concentration is too high, please dilute the system with sufficient water.
It is relatively rare that chemical odors are caused by reactions in liquids. For example, some liquids have added formaldehyde releasing fungicides as preservatives. Under appropriate conditions, a reaction may occur, releasing ammonia gas from the liquid. Using liquids that do not contain formaldehyde releasing fungicides is a preventive method.
The chemical odors caused by pollution can vary greatly, depending on the pollutant. Firstly, review the chemicals in the mechanical workshop to determine which chemicals (if any) may have been unintentionally added to the metalworking fluid. Secondly, perform a visual inspection to determine if the liquid is contaminated. A sudden and noticeable change in the appearance of a fluid, such as a change in color, is usually a sign of contamination. Other changes, such as foaming or pH changes, are also potential signs of pollution.
