Understanding proportioning pump mix ratios is crucial, especially when it involves the delicate balance of industrial coolant and water. It’s not just numbers; it’s a carefully calibrated dance that ensures efficiency and performance.
For instance, one of our flagship products, MIXPP518 Proportioning Pump, demonstrates a flexible range of mix ratios. From a gentle 1 part coolant to 70 parts water (a ratio of 1:70 or 1.4%) to a more robust 1 part coolant to 7 parts water (expressed as 1:7 or 12.3%), the variability caters to various needs.
But, these percentages are not to be confused with BRIX concentration readings. Here’s where it gets fascinating…
A Real-World Example:
I recently had a call with a client using Fuchs ECOCOOL 711. This coolant has a refractometer correction factor of 1.4. The recommended usage concentrations for this coolant, expressed as a water-to-coolant ratio, lie between 20:1 (equivalent to ~5%) and 10:1 (corresponding to ~9%), which fall within the mixture range of the MIXPP518.
Now, how do we find the precise refractometer reading for the customer's target of 10% BRIX?
Take the aimed concentration and divide it by the correction factor. In the case of ECOCOOL 711 with its 1.4 correction factor, the refractometer reading would be ~ 7.2 (10/1.4). Simple yet precise.
Step Up Your Game
Integrating a Digital BRIX Refractometer to monitor the coolant is a game-changing innovation that adds a new dimension of accuracy and control to this process. Unlike traditional optical methods, a digital BRIX refractometer provides real-time, precise measurements of the coolant's concentration, ensuring that the ratios are consistently maintained at optimal levels. This not only enhances efficiency but also minimizes the risk of errors that can lead to costly downtime or quality issues.
The ability to continuously monitor the coolant with a digital BRIX refractometer represents a significant step forward in predictive maintenance and process optimization, aligning with the industry's move towards more accurate decision-making. It's an investment that pays off in improved performance, reduced waste, and the assurance that your systems are operating at peak efficiency at all times.
This method is an integral part of our Dazzle 2 full automation solution. By maintaining a consistent BRIX reading along with sump level monitoring, your machines are automatically set to operate at their peak performance.
10 Reasons Why Proportioning Pumps are Important
Proportioning pumps offer several unique benefits in various industrial applications, particularly where precise control of fluid mixing is required.
Precision Control: Proportioning pumps enable highly accurate control over the mixing ratios of different fluids, such as coolant and water. This precision ensures that the final mixture meets the exact specifications required for a particular process or application.
Cost-Effective: By automating the mixing process and delivering precise amounts of fluids, proportioning pumps reduce coolant waste and enhance efficiency. This not only minimizes material costs but also saves valuable time.
Enhanced Safety: Automated mixing reduces the need for manual handling of potentially hazardous materials. This helps in maintaining safety standards and minimizing the risk of accidents or spills.
Versatility: These pumps can handle a wide variety of liquids with different viscosities and chemical compositions. This makes them suitable for diverse applications across industries.
Consistent Quality: Proportioning pumps ensure that the mixed product is consistent in quality. The consistency in mixing contributes to the overall quality of the finished product.
Energy Efficiency: These pumps are designed to use energy efficiently, especially when compared to some traditional mixing methods. This not only contributes to cost savings but also aligns with sustainable practices.
Integration with Automation Systems: Modern proportioning pumps can be integrated into broader automation systems like the Dazzle 1 Coolant Automation system. This flexibility further streamlines operations and enhances productivity.
Adaptability to Different Ratios: As demonstrated in the MIXPP518 example above, proportioning pumps can easily adapt to different mixing ratios. This adaptability allows for quick adjustments to the process parameters as needed, without significant downtime.
Maintenance and Reliability: Proportioning pumps are known for their reliability and ease of maintenance. Regular maintenance schedules and timely interventions can keep them running smoothly for extended periods, reducing the risk of unplanned downtime.
Compliance with Regulations: By ensuring precise control over the chemical composition of mixtures, these pumps help industries comply with stringent regulations related to environmental protection, safety standards, and quality control.
This technical detail is just a glimpse of what we here at Zebra Skimmers offer. Providing world-class customer service and technical support has been the hallmark of our reputation since our founding. We are passionate about our work, and we are always here to help, ensuring you get the best out of our products.
Need assistance or want to learn more? Reach us at 440-349-0141. Your success is our success!
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About Zebra Skimmers:
Our mission has always been simple. It is to provide the metal working industry with the oil skimmers and metalworking fluid management systems they need to complete jobs quickly and efficiently. Innovative and affordable solutions have gained us many accolades. Our continued growth is due in no small part to our excellent customer service… Not to mention our satisfaction guarantees and the performance of our tools.
Among our diverse options of oil skimmers and metal working fluid management systems, you can expect to find:
- Coolant management equipment, which includes coolant mixers, proportioning pumps, and also coolant automation systems to mix and deliver fluid solutions at the desired concentrations.
- Industrial oil skimmers, including tramp oil belt skimmers, disk skimmers, tube oil skimmers, and individual sump coalescers as well for the removal of surface and tramp oils from fluids.
- Aeration or circulation equipment and sump odor control tablets to control fluid odor and overall machine shop smell
- Industrial fluid monitoring equipment, including brix refractometers to verify fluid solution concentrations, pH test strips and also water hardness testing sticks.