Category: Cost management and purchasing advice | Author: Kimiya Sanat Savalan Research and Development (R&D) Unit
In Iran’s industrial lubricants market, the first question that purchase managers or workshop supervisors ask when choosing metalworking fluid (MWF) is: “How much is the price per liter?”
But focusing solely on the “initial purchase price” is a big miscalculation. The real cost of a water-miscible metalworking fluid includes the purchase price, the useful life of the fluid in the tank (replacement cycle), the rate of wear of the diamonds and cutting tools, the sleep time of the machine for cleaning and the waste disposal costs. In this article, we compare the three main machining fluid technologies from a technical and economic point of view to determine which option will reduce your “final cost of production”.
1. Knowing the three main technologies at a glance
A) mineral emulsifying fluids (Soluble Oils / Conventional
These products contain a high percentage of mineral base oil (more than 60%) along with emulsifiers. After mixing with water, they create a milky and cloudy emulsion.
- Equivalent SVL Grade: Grades
SVL-CL050andSVL-E100. - The main advantage: Excellent physical lubrication, very cheap initial purchase price, suitable for general and light work.
- The main flaw: Low stability against bacteria, short life in the tank (requires frequent replacement), high evaporation and unpleasant odor in summer.
b) Semi-Synthetic Fluids
These products are a combination of mineral base oil (about 5% to 30%), water and chemical additives and advanced emulsifiers. After mixing with water, they create a semi-transparent or milky emulsion.
- Equivalent SVL Grade: grade
SVL-SS400. - The main advantage: Very high biological stability, better cooling than mineral oil, good resistance to hard water and useful life 2 to 3 times that of mineral oil.
- The main flaw: Higher average price, need for more precise concentration control.
c) Full Synthetic Fluids
These fluids are completely free of mineral base oil and are composed of polymer compounds, glycols and chemical additives completely soluble in water. After mixing with water, they create a completely clear solution (like water).
- Equivalent SVL Grade: grade
SVL-FS500. - The main advantage: Excellent cooling, no free oil (no fat accumulation on the part), very long tank life (sometimes up to a year without needing to be drained), excellent chip washing and absolute resistance to decay.
- The main flaw: Less physical lubrication at ultra-heavy pressures (not suitable for soft metals such as aluminum in certain processes), high initial purchase price.
2. Functional technical comparison (ranking table)
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| Technical Parameter | Conventional Mineral-Oil Fluid (SVL-CL050) | Engineered Emulsion (SVL-E200-HW) | semi-synthetic (SVL-SS400) | Fully synthetic (SVL-FS500) |
|---|---|---|---|---|
| Cooling Performance | weak | average | good | Excellent (max) |
| Lubricity | Excellent | Excellent | good | average |
| Fluid Service Life and Microbial Resistance | Very short (1 to 3 months) | Medium (3 to 6 months) | Long (6 to 9 months) | Very long (up to 1 year) |
| In-Process Visibility | Opaque, milky (limited visibility) | Opaque, milky emulsion | Translucent (medium visibility) | Clear, with Excellent Tool Visibility |
| Foaming Tendency | very little | low | average | High (requires a suitable defoamer) |
3. Economic analysis: why the cheapest oil ends up being the most expensive?
Let’s compare an average CNC workshop with a 200 liter tank. This workshop examines two scenarios throughout the year:
Scenario A: Using cheap mineral water-miscible metalworking fluid
- purchase price: About 40% cheaper than semi-synthetic grade.
- Sump Change Interval: Due to bacterial growth and odor, every 1.5 months The entire tank must be drained, washed and recharged (8 changes per year).
- Hidden costs: Eight working days a year lost to cleaning; higher water and coolant consumption; faster cutting-insert wear at elevated temperatures; and the cost of wastewater disposal.
Scenario B: migration to semi-synthetic water-miscible metalworking fluid (SVL-SS400)
- purchase price: 40% higher.
- Sump Change Interval: Due to the advanced formulation, each 6 months Needs replacement (only 2 times a year).
- Cost Savings: Reducing the total oil consumption per year by 50%, reducing machine sleep by 75%, increasing the life of the chipping tool between 15 and 25% due to high temperature stability, and greatly reducing the bad smell in the workshop.
4. Final selection guide based on application
- If you have modern high speed CNC machines and you machine steel and cast iron parts:
- Optimal choice:
SVL-SS400(semi-synthetic) gives you long life, no bad smell and excellent surface quality.
- Optimal choice:
- If you have a high speed grinding operation:
- Optimal choice:
SVL-FS500(synthetic) due to excellent cooling, non-adhesion of particles to sandpaper and clarity of solution.
- Optimal choice:
- If you have heavy machining operations on hard metals with traditional machines:
- Optimal choice:
SVL-E300-HL(Emulsion with vegetable/mineral enhanced lubrication) to provide a strong oil film.
- Optimal choice:
conclusion
A low-cost mineral-oil coolant may save money on the initial purchase yet cost more over a year once maintenance and production downtime are included. Reviewing fluid selection and management can be a practical way to improve a workshop’s operating costs.
Technical experts Kimiya Sanat Savalan They are ready to perform ROI calculations for upgrading your workshop lubrication system for free by reviewing the type of your machines and parts.
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