The abridged version of this application success story appeared in the November, 1999 issue of Automatic Machining.
The Right Thing to Do
— Automatic Chip Processing

Higher value scrap. Cutting fluid reclamation. Labor savings. Enhanced housekeeping. These are just a few of the reasons to make the investment in an automatic chip processing system. But, for Larry Drew, founder of Drew's Manufacturing Company, there was really only one reason. Drew, who's steadily grown the company to over two dozen employees and 21,000 square feet, sums it up quite simply. "Automatic chip processing is the right thing to do."

When Drew entered the precision machining industry in the 70's, pollution legislation impacting the industry was still in its infancy; employee health and quality of work life issues ranked second to production. But, the young owner marked success by environmental responsibility, and satisfied employees—in addition to customers. Thus, he sought ways to assure his company looked out for the environment and its employees. An automatic chip processing system was integral to both. But, not just any chip processing system...

Goal:

In the 70's, when Drew's first began spinning scrap to remove fluids, a garage sale washing machine—stripped to just the spin cycle—was used. Although messy and labor-intensive, it did help the small company reclaim some oil.

The company grew, and this Wyoming, Michigan manufacturer graduated from washing machine to batch wringer. It too was messy and labor-intensive, and left the chips less than dry. Drew set his sights on an automatic chip processing system to reduce labor and more thoroughly dry the chips.

To minimize capital outlay, the company's first automatic chip processing system was a used Mayfran system that proved to be problematic. As production increased, Drew's traded up to a used Reclamet system. It achieved the goal of reclaiming more oil, but it too was noisy, and not without headaches. In time, Drew learned why.

"Bill Nemedi of Inter-Source helped me understand that scrap varies greatly from facility to facility. Only a system designed for our scrap could optimize our return-on-investment," explained Drew. Nemedi, President of Kalamazoo, Michigan's Inter-Source, notes that no two chip processing applications are alike. That's why Inter-Source developed its unique 'systems approach to chip processing'. "This 'systems approach' provides a company with the optimal performance of a system developed just for them, without the cost for customization," Nemedi remarked.

Drew says the more chip processing systems they investigated, the more convinced he was that Inter-Source was the vendor of choice. In 1999, his company achieved their long-term goal of installing an Inter-Source automatic chip processing system, integrated as part of their building expansion program.

System Overview

The 8,000 pounds of oil-laden scrap Drew's produces daily are fed into the system by an automatic cart dumper, which Inter-Source designed to utilize existing carts and thus protect that investment. The carts empty into a screw conveyor, which meters scrap as well as provides initial separation of solids from chips. The scrap then flows through a parts separator, which pneumatically completes the solids/chips separation. Drew's has found this a highly effective method for separation of the higher-valued solid scrap, compared to the separation approaches provided by the previous systems.

Many automatic chip processing systems include a shredder -- to sheer apart bales and stringies, and dislodge nested solids. While the composition of Drew's current scrap doesn't require a shredder, future scrap composition may differ. Thus, Inter-Source built-in a "place holder" for a shredder.

"This flexibility for future needs is another advantage of our 'systems approach'," explained Nemedi. "If and when Drew's scrap changes, a shredder can be incorporated without substantial rework."

Essential to every chip processing system is the wringer, which removes fluids via centrifugal force. Drew's Inter-Source system features a 30" continuous chip wringer. A sample analyzed by an independent lab testifies as to the patented wringer's effectiveness: 1.17% oil content after processing. Inter-Source guarantees less than 2%.

Mike Haviland, Plant Manager, needed no such proof. "You can see how much drier the chips are by looking in the collection bin. You can no longer see an oil silhouette where the chips sat against the side."

The dry chips are pneumatically discharged out of the building into a bin; the wringer's swarf discharge is filtered through a two step process. First, it collects in a settling tank, which provides gross separation. The oil is then pumped to a magnetic filter, which removes residual swarf. Both the magnetic filter and settling tank are self-cleaning.

Happy Owner, Unhappy Hauler

The Inter-Source chip processing system dramatically and positively impacted manufacturing. "Within a week," said Drew, "you could see a huge difference. The reclaimed oil was much cleaner and part finish improved." Drew is confident in time he'll save wear on coolant pumps and increase tool life.

Another benefit of the automatic chip processing system is greatly reduced housekeeping. Haviland noted that prior to Inter-Source, the screw machines required cleaning out at least weekly because of the swarf returned with the oil. The filtration process results in oil that "looks like new," and now the machines rarely require cleaning. Haviland admits he laughed at the filtration process at first, disbelieving it could be effective. Now he's amazed at the results, as well as appreciative of its self-cleaning. For this application, probably the greatest tangible benefit of the Inter-Source system is oil savings. Because of the amount reclaimed, oil use has been cut in half. That savings alone results in an eighteen month return on investment. "Our customers range in size from small shops, like Drew's, to automotive and aerospace giants," offered Nemedi. "With our equipment, even a small shop can quickly gain their return on investment in automatic chip processing."

Oil savings, increased tool life, lower machine maintenance, better housekeeping...what the Inter-Source system does for Drew's Manufacturing Company is all positive—with one exception. Haviland described the scrap hauler's reaction. "He complained because he couldn't drive as fast any more. When he pulled out of here the first time the chips were so dry they were flying all over."

Environmental Responsibility

Owner Larry Drew, who has always made environmental protection a primary concern, was surprised by a regulatory visit to investigate a complaint about oil leaking from a chip container.

" I knew it wasn't our oil," explained Drew. The container had come from another manufacturer; the oil was left over in it. Nonetheless, Drew's bore the expense of clean-up. Drew found it "particularly painful to have to clean up after someone else's ignorance." It reinforced his determination to protect the environment, as well as his interests. Drew now insists that the scrap hauler return the same bins. "I know our bins don't have oil in the bottom. I want a clean site. I knew Inter-Source could deliver."

Employee Appreciation

A machining shop is by nature noisy, oily, and difficult to keep clean. But, skilled employees are hard to find, and Drew is continually working to improve their environment. The shop's typical oily mist is minimized via massive air-handling equipment. High ceilings allow heat, mist, and noise to move out of the immediate production environment.

It was important to Drew that the automatic chip processing system not add to in-plant noise or oil on the floor, as previous systems had. Based on site visits and his own experience with other vendors, Drew knew Inter-Source would provide the quietest, cleanest system. "The employees appreciate what the Inter-Source system does, and I appreciate how it improves our working environment," says Drew.