Efficient manufacturing of high-precision parts. Blaser Swisslube metalworking fluids enabled Daiichi Sokuhan to reduce cycle times by 25%.

Immediate results with Synergy 735

Seeking a reliable solution, Daiichi Sokuhan evaluated products from Blaser Swisslube. In June 2019, a trial with the water-miscible, full-synthetic metalworking fluid Synergy 735 delivered immediate results. Dimensional accuracy and surface quality were excellent from the first parts, without the need for extended process adjustments. Most importantly, machining cycle times were reduced by 25 percent, directly increasing output. Because Synergy 735 is oil-free, concentration control became far simpler, reducing the daily workload for operators. Following the successful test, the fluid was introduced across six CNC lathes and machining centers, ensuring stable and efficient turning operations.

Daiichi Sokuhan achieved a major performance leap by focusing on an often-overlooked factor: metalworking fluids.

“Based on the in-depth analysis and after consultation with our laboratory specialists, we recommended the use of the water-miscible coolant B-Cool 755,” explains Hans-Peter. B-Cool 755, originally developed for machining aluminum and aluminum alloys, delivers outstanding performance even with a demanding mix of materials. Hans-Peter: “Whether soft or hard aluminum alloys, titanium, nickel-based alloys, heat-resistant steels or INOX – you can rely on B-Cool 755. The chlorine-free, mineral oil-based product is characterized by its low foaming, good stability and good ferro-corrosion protection properties.” The high stability of the emulsion ensures a long sump life, while the outstanding rinsing behavior leads to extremely low consumption. B-Cool 755 is ideal for high cutting speeds and high-pressure applications.

The collaboration between Tribur Invent GmbH and the productivity partner Blaser Swisslube is multifaceted. The coolant specialists from Blaser not only regularly monitor and analyze the metalworking fluid, but also provide customer service and Remote Care, logistics, empty container return and disposal, as well as free specialized seminars. In monitoring the coolant, the sensor from Blaser’s sister company Liquidtool Systems is in use, which delivers real-time data on fill level, temperature, and concentration. Regarding automation, Matthias Salzmann still sees optimization potential: “With the Liquidtool AutoPilot, a service from Blaser Swisslube, an innovative solution is ready that will definitely be interesting for us. The AutoPilot can independently replenish the coolant, thereby achieving the highest stability and process security. Manual refilling will then be eliminated, which will relieve our employees.”
Tribur Invent GmbH and Blaser Swisslube are planning to continue and deepen their already successful collaboration. Together, they aim to further exploit the potential and maximize economic efficiency and quality in Tribur’s production.

Since starting production in October 2023, F&P CNC Technik GmbH has placed its trust in high-performance metalworking fluids from Blaser Swisslube. This newly established, state-of-the-art contract manufacturing company benefits not only from the quality of the metalworking fluids used – B-Cool MC 600 and Blasomill 10 – but especially from comprehensive automation, which also involves the refilling system from Liquidtool Systems, a sister company of Blaser Swisslube. The partnership is an example of modern manufacturing at the highest level.

The F&P manufacturing process uses high-alloy stainless steel, Hastelloy duplex steel, and other materials that are difficult to machine. Drawing on 15 years of experience in a management position at a milling and turning company, F&P Managing Director Florian Fassbender was very familiar with complex manufacturing processes and the associated specific demands placed on metalworking fluids. “Many people fail to understand the importance of the metalworking fluid for process security,” he stresses. For this reason, the specialists from Blaser Swisslube were on board from the very beginning in the quest to find the ideal metalworking fluid solution for the complex processes.

Working together, the companies identified which Blaser products perfectly matched F&P’s requirements: While Blasomill 10, a high-performance mineral oil-based cutting oil with excellent wear protection, is used for turning and milling operations, the universal metalworking fluid B-Cool MC 600 covers a wide range of machining applications. B-Cool MC 600 is a water-miscible, chlorine- and boron-free mineral oil-based metalworking fluid that guarantees the best surface quality for both large and small production runs.

… with sensor technology and data for efficient and reliable machining

For many years, Blaser Swisslube has been developing metalworking fluids that are used worldwide in a wide variety of machining processes. The combination of basic research, its own technology center, and application-oriented development enables the company to tailor products specifically to real manufacturing conditions.

The focus is on understanding the entire machining process – i.e., the interaction between the machine, tool, material, machining parameters, and metalworking fluid. To precisely record and understand these complex interactions, Blaser Swisslube relies on sensor technology, digital data acquisition, and evaluation.

On the machine side, spindle loads, axis positions, and macro variables are recorded. In addition, vibration sensors at several positions measure vibrations in the range from 10 Hz to 10 kHz – ideal for detecting phenomena such as the runout of the bars in the magazine, chattering during machining, and changing cutting forces. Pressure, flow, and temperature sensors monitor the cooling lubricant supply, while air quality sensors quantify the oil mist concentration in the machine environment.

Vibration sensor in the LNS bar feeder magazine

Intelligent data management

The large amount of sensor data is collected via the Microsoft Azure IoT Stack and analyzed in real time, so that experiments can be safely stopped if any definable limits are exceeded. In addition, Power BI helps to create dashboards that visualize the current process status and highlight trends, anomalies, and potential for improvement.

Measurable added value

Using modern sensor technology, Blaser Swisslube is able to objectively prove the effectiveness and added value of its high-performance cutting oils. The combination of process knowledge, data-based analysis, and practical testing methods creates the basis for optimized machining processes – with maximum productivity, high process reliability, and measurable customer benefits.

In cooperation with Blaser Swisslube, Sumec AG, a Swiss machine and production system manufacturer based in Niederbipp in the canton of Bern, has carried out a test phase with the Blasocut 201 metalworking fluid and the Liquidtool AutoPilot. The ambitious requirements: universal application, skin compatibility, no foaming, a pleasant odor and, finally, a reduction in coolant and tool costs. All these objectives were achieved. Thanks to the longer service life of the metalworking fluid and a 66% reduction in tool wear, process reliability was maximized and total savings of almost 17.000 Swiss francs was achieved. Sumec and Blaser will continue to intensify their successful cooperation.

Sumec AG is a second-generation, family-run company specializing in mechanical and plant engineering. Based in Niederbipp, the company has been offering the highest quality and pursuing permanent technical progress in the service of its customers for 40 years. Sumec designs and develops systems, maintains, repairs and adapts machines and production systems and develops them with new pipelines. CNC manufacturing is primarily carried out as part of contract manufacturing for external customers from the railroad technology, food and beverage industries as well as general mechanical engineering. In addition, parts developed in-house for the designed systems are manufactured internally.

In their search for the optimum metalworking fluid solution, the decision-makers at Sumec turned to the experts at Blaser Swisslube. The defined requirements: universal application, skin compatibility, no foaming, a pleasant odor, and a reduction in coolant and tool costs.

The test phase was a complete success: Blasocut 201 proved its universal applicability. A pleasant odor and good skin compatibility were ensured, and foaming was avoided at the same time. “The longer service life of the coolant enabled us to reduce costs. The tool life was also optimized with a wear reduction of 66%. This led to greater process reliability and a total savings of almost 17,000 Swiss francs,” reports a satisfied Dominik Schneeberger, CEO of Sumec AG. The laboratory analysis of the used emulsion at the end of the test showed that all measured values were within the specified limits.

To further maximize these successes, Sumec and Blaser are aiming for a holistic conversion and expansion of coolant automation. Thomas Flückiger, Business Development Manager at Blaser Swisslube, explains: “The metalworking fluid test with Blasocut 201 has led to significant improvements, cost savings and increased process reliability. To further increase the results, the complete changeover and coolant automation are the next logical steps. Blaser offers comprehensive services including a monitoring concept, laboratory analyses, on-site measurements, meetings and measures to extend tool life – all from a single source. With this expertise, the metalworking fluid becomes a Liquid Tool.”

Fully automated management enables additional savings on coolant consumption. In addition, time is saved when measuring, documenting and tracking, process stability is improved, and metalworking fluid performance is optimized. The fully automatic coolant system can also reduce the number of employee days lost. According to Flückiger, faster cycle times will have the greatest leverage effect on overall costs.

Dominik Schneeberger and Thomas Flückiger emphasize that the goals they have set themselves are a significant increase in machine availability and a sustainable improvement in process reliability.

In the 1970s, during his apprenticeship as a toolmaker, Heinz Leuthold developed and manufactured special parts for the machine industry in his father’s basement after work. Since 2012, Leuthold Mechanik AG (HLM), which has around 175 employees, has been manufacturing for customers from all over the world at its Einsiedeln site in the heart of Central Switzerland. The company has established itself as a global leader in the manufacture of machines for the production of thin-walled aluminum packaging and delivers top precision in the fields of mechanical, equipment and tool engineering. Production is carried out for companies in the automotive and aircraft industries as well as the medical sector and the food and packaging industries

Successful cooperation: Blaser application engineer Marco Frey and Benjamin Schroth, Head of Hard Machining at Leuthold Mechanik AG

The partners worked together on an in-depth analysis in order to identify specific weaknesses. Clear goals were defined that went beyond mere technical solutions: an environment that smells pleasant, allowing employees to work comfortably, efficient foaming behavior, good human compatibility, and universal application of the new coolant.

The experts at Blaser Swisslube not only had these specific challenges on their to-do list, but also wanted to implement further optimizations besides. Concrete goals were set, including reducing coolant consumption, extending coolant service life, and thereby increasing the efficiency and sustainability of production processes.

View into production

The next project – a collaboration between Leuthold Mechanik AG, GF Machining Solutions and Blaser Swisslube

After this first successful cooperation, a second, highly interesting project was also started in 2021 – a collaboration between Leuthold Mechanik AG, GF Machining Solutions, and Blaser Swisslube. In the course of acquiring a new GF Machining Solutions machine, the experts from Blaser were brought on board as a coolant partner. The aim here was to implement an ideal coolant solution for a demanding mixed production process involving grinding and milling. Following detailed analysis of the process, the versatile grinding oil Blasogrind GTM 10 was trialed in a four-month test phase.

“A true all-rounder,” says Blaser Application Engineer, Marco Frey. “In addition to its ability to precisely machine a wide range of common tool materials, Blasogrind GTM 10 delivers remarkable performance by successfully combining two different operations without compromising on the desired results.” The results were indeed impressive: increased productivity, a significant reduction in cycle times and costs, more efficient processes, and maximized product quality.

Blaser Swisslube, in collaboration with its industry partners, embarked on a unique and ambitious project: CNC machining a model of the Lamborghini Huracan Evo 2 Super Trofeo race car . This endeavor was carried out alongside Nigel Bailly, a Blaser-sponsored racecar driver in the international Lamborghini Super Trofeo Series.

“From the beginning I thought this was a superb idea! The challenge to match the car and machine it at 1/8 scale shows the amazing abilities of the team at the Blaser technology center. I’m so excited to see this piece of art in person!” said Bailly.

The partnership brought together machine tool OEMs, fixture and tooling suppliers, and software and programming experts. Each company contributed technology and expertise to over 40 projects in the past year. The collaboration culminated in this exciting Lamborghini video project, shared across social media platforms, reaching a wide audience of machining and metalworking enthusiasts.

Blaser’s in-house machinists began by analyzing photos and videos of the racecar. Using hyperMILL software from Open Mind Technologies, the team meticulously modeled the car and developed the program required to machine it from a solid block of 6082 aluminum.

Tool path clearance was a particular challenge. The 2024 release of hyperMILL saved enormous amounts of time by seamlessly linking CAD functionality to CAM programming. The intricate process involved one month of designing and programming, ensuring every detail of the race car was accurately captured.

The 5-axis GF Mikron Mill has a tilting, rotating table for complex contours.

The combined efforts from each of the partners came together to ensure every element of the Lamborghini Huracan Evo 2 Super Trofeo was faithfully recreated. To add realism, the machining experts at Blaser Swisslube used various surface finishing techniques to replicate the car’s distinct textures like carbon fiber and aluminum trim. Note the reflective surface finish of the model car’s windows and mirrors, which required a specialized diamond-bit finishing tool from Dixi Polytool.

Blaser’s B-Cool MC 660 metalworking fluid also played a pivotal role in the final result. Selecting the right coolant for the application allows higher feed rates, reduces tool wear, and delivers exceptional surface finish. The Rotoclear S3 self-cleaning spinning window allowed a perfect view of the work envelope, and the C2 camera system captured every move in high definition.

“The Lamborghini project is a testament to the power of collaboration and the importance of focused partnerships among industry specialists,” said Marc Blaser, CEO of Blaser Swisslube. “When experts in an industry come together with a shared vision and commitment, the potential for innovation and excellence is unparalleled. These collaborations not only push the boundaries of what is possible but also set new standards.”

As manufacturing challenges become increasingly complex, the value of these synergistic partnerships becomes evident, highlighting the need for ongoing cooperation and mutual support to drive progress and success.

International company ITT Bornemann tailors its high-tech pump systems to satisfy individual customer requirements. The pumps produced by the innovative company are primarily used in the oil and gas industry, as well as in the food, chemical and pharmaceutical sectors. The broad diversity in production means that the demands placed on coolants are also very high. The company managed to increase coolant sump life eightfold in co-operation with Blaser Swisslube by using B-Cool 9665. Machine cleanliness, human compatibility and consumption have all been optimized. 

The Bornemann Locksmith’s store company was founded no less than 170 years ago, in 1853. Headquartered in Obernkirchen near Hanover, ITT Bornemann is now an internationally active manufacturer of high-tech pump systems. The company employs 250 people and has been part of the ITT Group since 2012, with its parent company located in the US.

Bornemann has been delivering continuous innovation to market in the pump segment for a whole century. The twin-spindle screw pump with external bearing was patented in 1934. Three-spindle screw pumps and progressive cavity pumps followed in the 1960s. In the 1980s, Bornemann’s multiphase pumps tapped into previously unknown economic opportunities. Multiphase technology avoids the so-called “flaring” of gas during oil production, allowing the gas to be recovered and utilized. In the food sector, Bornemann has developed self-cleaning pumps that have no dead legs. The stainless-steel pumps transport food with care and meet the highest quality standards.

High coolant demands

ITT Bornemann’s pumps are used in the oil and gas industry, as well as in the food, chemical and pharmaceutical sectors. Each year, around 2,500 pumps are produced and individually adapted to customer requirements. In particular, the gradient and conveying capacity are tailored to customer specifications in line with the particular application. Due to this very high level of variance, the production processes at ITT Bornemann are also very diverse. “We use a wide range of machine types. These include numerous turning machines for producing screw profiles, but also grinding and milling machines,” ITT Bornemann explains. “This means that the demands placed on the coolant are particularly stringent: We need a highly versatile product that works reliably and guarantees a high level of machine cleanliness.”

Executives from ITT Bornemann sought a meeting with the coolant experts from Blaser Swisslube in 2015. The coolant supplied by a competitor was a cause for concern: “The coolant was constantly spilling, forcing us to change it four times a year. As a result, the process stability was unsatisfactory and coolant consumption was too high,” recalled the experts from ITT Bornemann.

Following thorough on-site analysis, the Blaser specialists recommended B-Cool 9665. Carsten Liesegang, Application Engineer at Blaser Swisslube, explains: “B-Cool 9665 is a water-miscible, chlorine-free and semi-synthetic coolant with a low mineral oil content. The product is suitable for various machining processes and grinding tasks and is characterized by high cutting performance, low foaming, excellent corrosion protection, as well as very good rinsing and drainage properties. Finally, we expected B-Cool 9665 to provide a very high level of emulsion stability.”

Application Engineer Carsten Liesegang, Blaser Swisslube, is responsible for on-site service at ITT Bornemann and carries out regular measurements in accordance with TRGS 611.

“We offer more than just a coolant. Through our advice and all-around service, as well as the precise adaptation of the coolant to the respective challenges faced, we offer a Liquid Tool that increases overall productivity,” emphasizes Joe Hollmann, Technical Sales Advisor at Blaser Swisslube. “Technical dialog with customers and regular monitoring of the metalworking fulid are key.”

The ITT Bornemann team sums up in conclusion: “In terms of biostability, productivity, human compatibility and versatility, Blaser B-Cool 9665 is the best coolant we have ever had. We are looking forward to further boosting productivity when we switch over our entire production to Blaser.”

BOOM – strong collaboration.
Left to right in the photo: Joe Hollmann, Technical Sales Advisor at Blaser Swisslube; Oliver Sievert, CNC/CAM Programmer at ITT Bornemann; Philip David, Engineer at ITT Bornemann and Carsten Liesegang, Application Engineer at Blaser Swisslube.

Micro-Cut, based in Kirishima City, Kagoshima Prefecture, specializes in high-precision machining of difficult-to-machine materials and complex shapes. With its strengths in advanced professional technology and thorough quality control, the company aims to become a world-class, cutting-edge manufacturing group. Micro-Cut’s management policy is to establish the world’s most advanced standardized machining technology and manufacture products that contribute to the development of its customers.

In cooperation with the team of Blaser Swisslube Japan, Mr. Nishibeppu conducted a one-month test of these two products. After seeing the overall positive test results, he decided to use Synergy 735 on two NC lathes that process parts for medical-related equipment and Blasomill GT15 on five NC automatic lathes that process parts for semiconductor manufacturing equipment.

Hizima Seiki, whose main factory is located in Nanto City, Toyama Prefecture, is engaged in the design, manufacture, and maintenance of plastic injection molds. Since its establishment more than 70 years ago, the company has been manufacturing molds mainly for round products and has accumulated a unique technological know-how. Hizima Seiki specializes in multiple-cavity cap molds for products in the pharmaceutical industry, medical devices, and food. The company is constantly striving to improve the three levels of its operations: high-specification machines, operators who are proficient in using the machines, and the technical skills of the mold finishing craftsmen. The innovative company’s strength lies in the thorough dimensional control and fast delivery speed achieved through integrated production at its own factory.

When Mr. Kawai shared the issues with Mr. Naohiro Shimaura, a Blaser Swisslube sales representative, he was recommended Synergy 735, which has a very low odor and minimal skin impact, and Vascomill 10, which has excellent lubricity and is gentler on the skin than mineral oil. Since the switch was made three years ago, the coolant has not caused hand irritation and odor. Synergy 735 was also beneficial in that it is clear and unobtrusive, making it easier to clean the machines.