An invisible problem that was destroying tools: How metal dust was costing a parts manufacturer hundreds of thousands every year
Metal dust in coolant? A hidden problem that damages tools and production quality
An example of a solution in which we used magnetic separation to remove fine metal particles from the coolant emulsion and significantly reduce tool wear.
Production ran without interruption. The CNC machines machined components to tight tolerances, quality control was working properly and orders were dispatched on time.
Despite this, an unusual problem kept recurring – the tools were wearing out significantly faster than usual.
At first, it looked like normal wear. But then a series of complaints arose due to micro-damage on the surfaces of the components, and it became clear that the problem ran deeper.
📊 What did the installation of magnetic separators achieve?
🔍 Where was the problem?
Fine metal dust was produced during machining and gradually accumulated in the coolant. The coolant then carried it back into the process, where it once again came into contact with both the tools and the workpiece.
This created a “grinding paste” effect – metal microparticles accelerated tool wear, impaired surface quality and increased the risk of scrap.
📉 Impact of the problem
⚙️ Our solution
We installed an MMS magnetic separator for liquids directly in the coolant emulsion circuit.
🔧 Device type
Magnetic separator for liquids
📍 Location
Coolant emulsion return circuit before the machine inlet
🧲 Magnetic core
Strong neodymium magnets for capturing microparticles
♻️ Operating mode
Continuous cleaning without operator intervention
👉 The separator captures even very fine metal particles produced during machining that conventional filtration often cannot remove.
💰 Economic benefit
👉 Total savings: CZK 620,000 per year
✅ What does this mean for you?
Not every problem in production is visible.
This one was microscopic — but very expensive.
👉 Do you have coolant circulating in your system?
We will check whether your money is “floating away” in it.
Inquire about our services - you will receive an offer within 48 hours
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