Carbide Reclamation Provides Significant ROI On New Filtration System

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Denic began Quality Carbide Tool in 1986 with 5 people and some manual cutter/tool grinders. The focus was making blueprint specials, in either carbide or HSS, for a variety of industries. By 1988, QCT purchased CNC machines and were able to expand their operation to include a line of standard tools such as drills, end mills, reamers, and burs.

Growth has steadily continued, so that in 2001 QCT became a wholly owned subsidiary of OSG Tap & Die. In 2006, QCT moved into a brand new 65,000 square foot facility. “The new facility”, explained Denic, “was the result of not merely growth, but fulfilling our vision to be a world leader in cutting tools through efficient, state-of-the-art manufacturing.” Today, it houses over 80 four, five and six axis machines, a unique, automated carousel system for the inventory of finished goods, in-house coating systems for the tools and a centralized filtration and cooling system that is expandable to meet any future growth.

A Centralized Filtration System Is Pivotal In Making The Vision Reality
Prior to moving into the new facility, QCT used a centralized, centrifuge system. “It really wasn’t living up to our expectations”, commented Denic. “Our oil just wasn’t as clean as we needed to consistently manufacture the quality of tools we knew we could produce given our other investments in machine technology.” Denic went on to say that the system required a lot of maintenance, as well as, the dirty oil caused significant wear and tear on the machines and disposal of the sludge and debris was a problem. “At $7 a pound”, said Denic, “we knew our 72 machines were producing a lot (of carbide) to recycle, but separating it from the debris with our existing filtration system was virtually impossible”.

It was then that Denic got in touch with Transor Filter (Elk Grove Village, IL). After hearing about the many benefits that Transor’s One Micron Filtration (OMF) had brought to other cutting tool manufacturers, Denic knew that this technology was what he needed in the new facility. As plans progressed for the new building, QCT, working in conjunction with Transor’s Sune Backman, developed a modular, centralized system that incorporated Transor’s OMF technology while enabling QCT to utilize the existing chillers from the old facility.

“The Transor was just what we had hoped for”, said Denic. “The benefits of the one micron filtered oil were immediately noticeable.” While the system is new and results are being tracked, Denic was quick to comment, “seconds and minutes are being chopped off existing cycle times, down-time for wheel dressing is dramatically reduced, while overall wheel life is greatly improved”. Denic also pointed to improvements in finished product quality as well. “We see much less stress scratches and burns”, he said, “because with clean oil our wheels are free from the sludge and filth that typically results in extra finishing or re-works.”

One Micron Filtration Is Critical In Producing Micro Tools
Like many tool manufacturers, the Nunez brothers understood the need for filtration when producing larger cutting tools. With larger tools and heavier stock removal, the need for keeping particles away from the wheel to maximize speed was obvious. Nunez used an example. When manufacturing a tool 1” diameter by 6” length from a solid piece of carbide, typically, the inside of the machine would be covered with dirt and debris. By eliminating this, the role the Transor plays in filtration is visually noticeable, he commented. But with micros, the stock removal is so minimal, one would tend to ignore the need for the one-micron capability, based on what the eye can see.

But in recent years Best Carbide has had an ever-growing business in micro tools. “We specialize in micros,” said Mark Nunez, “and the Transor has made a big difference in that part of our operation. Not everybody can make micros under 0.002”, but because we can hold our corners, they’ve really become one of our specialties.”

He went on to discuss that any small amount of debris that embeds itself on the wheel can make a difference when producing a tool the size of a human hair. He emphasized how critical the edge is to obtaining size control, finish, accuracy and that the Transors’ One Micron Filtration was key to this aspect of their business. He also noted that the Transor has enabled Best Carbide to virtually eliminate any scrap, a common problem in manufacturing micros.

The Filter System Exceeds QCT Expectations
Reduced maintenance, longer wheel life and faster cycle times were all benefits that Denic knew QCT would experience after talking to other Transor customers. “Those are a few of the reasons we use to justify OMF”, said Transor president Irv Kaage. “But it’s funny. Virtually every new Transor user will discover unique benefits to their operation once the system is installed.” QCT was no exception.

One major benefit that Denic did not factor into his ROI equation for the Transor was the cleanliness of the finished tools. “With the Transor System”, he said, “there is absolutely no time spent on washing or cleaning the tools!” Today, QCT tools come right off the machines, through inspection and put directly into inventory. “Talk about tremendous savings”, he continued, “this is a huge benefit being able to eliminate the time and labor of cleaning ALL our tools. When you consider we’re running 3 shifts a day, six days a week, on over 80 machines, well, it adds up fast!” Previously QCT had one person each shift to clean and wash the tools. Denic also pointed to all the extra handling, and with carbide being very fragile, the possibilities of scrap due to chipping and damaging are now virtually eliminated.

“Now let’s refocus on the carbide reclamation issue”, emphasized Denic. Inherent with Transor’s One Micron Filtration, capability is the separation of the carbide residue from the machining process. In QCT’s installation, like all Transor Systems, the centralized system includes “sludge boxes” with disposal bag liners. The sludge boxes pullout and are easily accessible via convenient doors on the side of the unit. “So, if you start to do the math”, stated Denic, “eighty machines operating 24/7, and $7.00 a pound for reclaimed carbide… it really adds up. Needless to say, it has had a real impact on the ROI of our Transor purchase.”

Achieving The Vision Of Being Global Supplier
Denic concluded by stating that during the recent IMTS, Quality Carbide Tool celebrated their 20th anniversary. Opening the new plant for visitors, several noted how clean and quiet the facility was. In addition, the clean oil was void of odor typical to many coolants.

With over 10,000 products in their standard catalog, QCT also sees continuing growth with their blueprint specials. As part of the OSG group of companies, QCT is truly global in their scope. “With globalization today, combined with the OSG exposure worldwide, QCT sells on every continent”, said Denic. “One of the reasons we purchased this building and invested in technology like the Transor is that our vision is to become one of the best companies in this business Not only selling to the American market, but wherever quality tools are demanded.”