Cutting fluids are used as coolants, lubricants and corrosion inhibitors in many metal-working processes. Cutting fluids however represent health dangers. Machine manufacturer Glück installed a siphon which filters aerosols and prevents them from being released into the surrounding air

The task

Glück is a metal-processing company in Upper Austria. Its main activities are production, grinding and case hardening of metal parts. During the processes of cultivating and grinding, it is important that the tool is cooled and lubricated with the aid of a coolant. This cutting fluid is pumped into the tool. As the tool rotates, the coolant is vaporised and builds aerosols. The task has to be performed daily for each employee during 8 hours per day. The employee's working clothes are usually soaked with the chemical substance.

The risks

The employee is exposed to aerosols, which may harm the respiratory system and damage the lungs. Polluted cutting fluids may produce fungi that can cause skin and eye irritation. Depending on the quality of the water used for diluting, nitrous gas may be produced. If cutting fluids are not given regular maintenance, mould may appear.

The solution and methodology

The company performed a risk assessment prior to the solution to determine on the one hand the risks of the chemical product (Streulichtanalyse), and on the other the general working conditions with regard to the machines, the workplace etc.

In order to reduce the exposure, a technical solution has been implemented by means of the installation of an "aerosol trap". Aerosols are siphoned directly above the metal pieces in order to prevent the aerosols being released into the ambient air. Initially, the drops are separated by a metal filter and then passed onto a 4-level plastic filter, which separates the drops into 10 µm, 2 µm and 0,2 µm. 99.92% are separated in the filter (99.8% separation in total). The provider of the technical solution is the company Kappa Arbeitsschutz und Umwelttechnik GmbH, Steyr.

The effectiveness of results

The solution is transferable to other environments where metal is processed. The good practice example eliminated or at least reduced the risk considerably: 99.9% seperation production; 80-85 % are siphoned by the machine.

The employee participation

All employees working on these machines have been involved in the development and implementation of the good practice example. They have also received training on how to work safely with the siphons.

The costs and benefits

A clear cost-benefit relationship could not be established. However, there was a perciptible reduction in the tiredness and irritability of employees, as well as an increase in their ability to concentrate.

Work organisation has been improved. Employees are less irritable. The quality of products has been improved by 9%. This example shows that occupational health and safety in SMEs leads to increased productivity and therefore better economic performance.

Entrepreneur’s Testimony "In the future, the manufacturing of a good product will only be possible if the working environment is good and well-trained workers are available "