No Sizing Without Data
We checked PH, mold, yeast, cutting fluid concentration, bacteria levels…
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AUTOMOTIVE SECTOR CASE STUDY
OPEX REDUCTION
ANNUAL CO₂ SAVED
QUALITY GAIN
WEEKLY SAVINGS
THE SITUATION
A major automotive powertrain facility was facing a critical operational bottleneck. Their metalworking fluid was being replaced every four to six weeks. Bacterial contamination was degrading fluid chemistry faster than traditional treatment could stabilize it.
Production quality was suffering, and disposal costs were climbing rapidly. The operation had tried conventional approaches—and those approaches had simply not delivered.
A small amount of contaminated fluid can have a major impact on a metalworking fluid system.
Preventive monitoring and treatment are the key to stability and cost-efficient operation.
If 1 litres of contaminated process fluid containing 10⁷ CFU/mL is mixed into 1,000 litres of metalworking fluid, the resulting microbial level can be around 10⁴ CFU/mL, i.e. above the limit value.
Even so, metalworking fluids are often monitored and treated less rigorously. That is when instability, quality problems and hidden costs can arise.
THE PROBLEM
The facility had initially installed UV treatment to manage bacterial elimination. However, the UV system was actually counterproductive: it degraded the specific cooling curve leaving the underlying contamination problem unresolved.
THE COST OF REACTIVE MANAGEMENT:
THE BRAIRTECH SOLUTION
Brairtech does not size systems from brochures. Before any configuration was proposed, the facility’s fluid was sampled and submitted to rigorous bench testing.
We checked PH, mold, yeast, cutting fluid concentration, bacteria levels…
Calibrated pilot phase under real production conditions confirmed treatment performance and regrowth behavior.
The IPC platform integrated directly into the circulation loop with zero major equipment replacement.
SuMmary of success
OPEX SAVED
LIFESPAN
EXTENSION
CO₂ REDUCED
QUALITY GROWTH
WEEKLY PROD
RECOVERED