In our pursuit of manufacturing high-quality gears and reducers while prioritizing environmental sustainability, Omme Gears has taken an innovative approach by incorporating vegetable oil in CNC machines.
We spoke with Elisa Mancini, our Production Manager, to delve deeper into the reasons for this decision and its tangible benefits.
What were the main factors that led to the decision to switch to using vegetable oil in CNC machines instead of traditional oil?
The main factor that led us to adopt the use of vegetable oil in CNC machines was the need for products with a reduced environmental impact and, above all, formulations that are much safer for the operator’s health, both in terms of direct risk (e.g., inhalation of vapours or skin contact) and indirect risks (e.g., presence of fumes in the workshop).
For example, synthetic products, especially those that are water-emulsified, contain elements such as boron or formaldehyde that are extremely dangerous above certain quantities for the user’s health. Vegetable-based products completely eliminate this risk by no longer containing these elements
What environmental and sustainability benefits have resulted from the adoption of vegetable oil in our production operations?
The main benefits were twofold:
- A significant reduction in processing fumes, thanks to a higher smoke point temperature. This has led to a much healthier environment and significantly improved overall cleanliness in the facility, thereby reducing the need for cleaning interventions
- Greater cleaning capability of these oils in terms of removing residue from machinery, Consequently, there has been a reduction in the need for cleaning and maintenance.
How was the transition from traditional oil to vegetable oil managed in terms of adapting the CNC machines? Were there any particular challenges to overcome?
Relying on a longstanding partner, we managed to transition gradually, which included the possibility of blending synthetic oils with vegetable oils and in some cases before completely replacing the former. This approach allowed for a very smooth management of activities for both operators and machinery, resulting in a rapid and seamless transition without any major disruptions.
In cases where it was necessary to remove synthetic oil to use its vegetable counterpart, we opted for a gradual approach, starting with one machine before moving on to the others. This strategy was necessary particularly because the vegetable oil replaced entirely various types of oil previously used in the machines (hydraulic oil and cutting oil), transitioning from having 2-3 different types of oil for just one product. Thus, it was essential to ensure that operators could assess the performance of the machinery following this change and be certain that it would not lead to any functional anomalies.
What were the effects on the efficiency and performance of the CNC machines following the introduction of vegetable oil?
By using vegetable oil in cnc machines, cleaning and maintenance interventions have decreased because these oils have proven to be highly effective in removing machining residues from said machines. (such as grinding residues in grinding) has exceeded our expectations.
Furthermore, having the same type of oil on the machinery has completely eliminated the risk of mixing different types of oil, for example, due to any breakage resulting in increased fumes during processing, as well as the need to replace the oil with uncontaminated oil.
How is the impact of using vegetable oil in CNC machines monitored and evaluated in terms of costs, energy consumption, and equipment lifespan?
Monitoring primarily revolves around consumption and therefore costs, facilitated by a framework agreement with the supplier, enabling us to meticulously track consumption over time.
Concurrently with the introduction of vegetable oils, we decided to modify the quantities to be sourced by using different packaging than what was typically utilized. This allowed for a reduction in storage space and minimized oil losses resulting from improper storage.
Are you currently considering the introduction of additional sustainable initiatives or improvements in resource utilization in production?
We have already launched a project to reclaim the washing emulsion used during the packaging phase for machining operations. By employing a product compatible with the oils used in production, we can fully recover these waters that would otherwise require disposal.
Additionally, we are considering the possibility of recovering the portion of oil or emulsion lost through machining chips. The use of industrial centrifuges could significantly reduce this type of waste by allowing us to recover these fluids for reintegration into production.
Omme Gears is committed to improving not only in terms of environmental sustainability but also towards social responsibility by embracing the principles of Industry 5.0. Click here to read the article.