Chip Disc Filtration: The Unsung Hero of Lights Out Manufacturing Success
April 21, 2023
When you think about lights out manufacturing, the first things you consider are probably how you’re going to keep the spindle fed and how you’ll get parts in and out. A solid consideration! Those aspects certainly are vital.
But one thing people don’t often consider is the concept of chip management. How exactly do you ensure that you get the chips out when you’re not around? Failure to do so means you might have a massive mess on your hands when you come in the next morning.
Well, Hennig helps with that. If lights out manufacturing is your goal, our chip filtration expertise will help you achieve it. In particular, our patented Chip Disc Filtration (CDF) system is instrumental in getting that job done.
Why we created the CDF System
As you likely know, if chips get into the tank, you’re eventually going to have a problem. And there lies the common issue with traditional coolant slots on chip conveyors: inevitably, chips find their way into the coolant tank, ultimately creating plenty of headaches that can drastically impact productivity.
Hennig’s Chip Disc Filtration System was designed to ensure none of the chips get into the tank, and add-ons like bag filtration and cyclonic pumps can bolster filtration even further. Bottom line: you’ll be able to filter a wide range of materials in both water- and oil-based coolants, all the way down to 25 microns nominal—or even further than that. It’s huge peace of mind for the lights out shop.
Don’t forget about the tank
If you’re going lights out and your tank is too small, water quickly starts to evaporate. That means your coolant concentration rises, causing a foaming issue. Not good.
In designing our lights out chip filtration systems for customers, whether it’s CDF or PureFlow, we make sure to provide a coolant tank that’s large enough for those all-night capabilities. The right tank size depends on your specific application, and we work with you to develop a unique solution.
The maintenance issue
Many of our competitors have a drum that’s built into the inside of the conveyor. It’s not terribly easy to access when it’s maintenance time.
But the CDF System has a disc that’s actually on the exterior of the conveyor frame. This easy access means that any required maintenance can be completed in a fraction of the time. We’re talking 15 to 20 minutes from start to finish.
The cost-benefit of the CDF System
The CDF System is a top-of-the-line filtration option, and it’s not a fit for every application. But if you’re running lights out with plenty of volume, it might be a fit for yours.
Something we often tell customers evaluating the CDF is to consider what they want to be doing months and years down the line.
At the low end of the cost spectrum, you have your standard basket tank. It needs to be manually cleaned at least once per day, maybe more. You also will want to clean the coolant from the tank every quarter or so. All that time spent cleaning adds up.
Now, add a Hennig hinge belt chip conveyor to the mix. Suddenly, you only have to perform maintenance every three months because you’re evacuating chips automatically.
Now, add the Hennig PureFlow System. The required tank maintenance jumps up to every six months to one year.
And finally, we have the CDF System, which brings that top-tier lights out capability. You won’t be performing any service relative to the tank in a two to three year time frame.
Imagine all the extra work you could be doing—and money you could be making—if you’re performing tank service every couple years instead of a couple times each day.
Is the CDF System feeling like the right fit for you?
If so, request a quote today. We’ll be in touch right away to wrap our heads around your story and your application.