Eisenhauer, Chemetall Groups technical marketing manager for metalworking, based that assessment on the results of an in-depth customer survey the company conducted. She offered details about the survey in a presentation to the Society of Tribologists & Lubrication Engineers annual meeting in St. Louis last May. And the full range of results will be covered in an in-depth article in LUBES N GREASES October issue.
Among the surveys findings was that odors, not biocides or disposal issues, are the number one metalworking fluid concern for many end users. Also, the metallurgy mix is shifting, with users now seeing a higher percentage of nonferrous and even exotic metals. Finally, although many metal removal shops have installed modern equipment, older machines are still in place at about 40 percent of the companies surveyed.
The survey began, Eisenhauer explained, as basic research for her job, to figure out what my customer base is about, where the holes are and what they need, and what environmental concerns they have. In the course of the survey, Chemetall, which is based in New Providence, N.J., held discussions with end users over an 18-month period.
We ended up with 150 well-qualified respondents, Eisenhauer said. They represented metal removal companies from the United States, Mexico and Canada, and included job shops, large OEM operations and specialty shops.
A number of common themes emerged from our analysis, Eisenhauer told the STLE meeting. For instance, all accounts reported that business had improved significantly over 2010.
Also, the metallurgy mix is moving to a higher percentage of nonferrous and exotic metals. That is, more aluminum alloys, Inconels and Monels are being used, accounting for 67 percent of parts produced by the surveyed companies.
About 16 percent of respondents reported increased use of high-speed, high-pressure and through-the-tool technology. About 25 percent are using robotics and computerized machining centers, and 20 percent are using recycled fluids in an effort to reduce cost and waste.
To Eisenhauers surprise, biocides and VOCs were not a top issue for most companies surveyed. The top concern of fluid users is an improved work environment with low odors, low residue and no misting.
Second is a desire for fluids that are easily disposed and easy to change or replenish. Third, companies are looking at recycling as a way to minimize their environmental footprint and reduce costs.
Although most respondents noted that biodegradable fluids do not work well in older machines, Eisenhauer said, they stated that market forces will likely drive them to convert to green technology. This is mainly due to the fact that government regulations and incentives have created a favorable climate to change.
In addition, the inherent safety of the fluids makes them attractive, as do the increased lubricity of newer products and their ease of disposal.
In the final analysis, fluids users are showing an increased interest in going green, Eisenhauer said. To fill this demand, newer technologies will be needed that improve sump life and biostability. The fluids also need improved compatibility with existing fluids and lubricant chemistries, she concluded.