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Avoid fungal prevention better than cure
Microbes are present in almost every environment, and fungi are among the most common. Fungal growth tends to be more severe under favorable conditions like rainy weather or during planting and harvesting seasons. Fungi reproduce through spores—like mushrooms, yeasts, and molds—which are highly resilient, capable of surviving extreme temperatures, and easily spread through air and water. They typically thrive in warm, moist, and dark areas, making machine coolant tanks an ideal breeding ground. As a result, fungal contamination is frequently seen in machining systems.
Fungi consist of a network of fine filaments called hyphae, which can originate from dead or living organisms. Once established, they can cause significant damage to the host organism. Removing fungi after they have formed hyphal structures is extremely difficult, as chemical treatments struggle to penetrate these complex networks.
In the metalworking industry, fungal issues often arise due to the warm, humid, and dark environments found in machinery. When fungi multiply inside machine tools, it not only causes unpleasant odors but also poses health risks and disrupts the entire production process. Fungi can consume various components in metalworking fluids, leading to several problems:
1. Fungi lower the pH of the coolant, creating a more favorable environment for other microorganisms.
2. They increase the size of emulsion particles, potentially causing poor fluid discharge or reduced processing performance.
3. When fungi consume key ingredients in the fluid, more frequent top-ups become necessary.
4. Fungal hyphae can clog nozzles or filters, interrupting coolant supply and leading to inadequate cooling and lubrication, or even halting operations.
5. Fungi may cause black rust and etch pits on cast iron surfaces.
Detecting fungi can be challenging. A common method involves using a microscopic test strip, such as "Biostick," where one side of the agar medium is specifically designed to support fungal growth. If fungi are present, they will appear after a few days of incubation. Since fungi grow slowly, results are usually observed after three days. Unlike bacteria, fungi form hyphal structures that make them less mobile, so they can multiply in coolants without being detected by standard bacterial tests. It’s important to act quickly if any signs of fungi are observed, whether on the test strip or on the machine itself.
Prevention is always better than cure. To avoid fungal issues in coolant systems, it's essential to understand the factors that promote fungal growth:
1. Coolant fluids often contain bactericides, amines, and maintain a specific pH level to inhibit fungal growth. If these levels drop, fungi can proliferate.
2. Poor circulation allows fungi to develop in stagnant areas. Long periods of inactivity or incomplete system drainage can increase the risk of contamination.
3. Residual liquid left after cleaning provides a perfect environment for microorganisms, including fungi, to grow. Killing fungi is time-consuming and requires strong disinfectants.
4. External pollutants like hydraulic oil can introduce nutrients that encourage fungal growth.
To prevent these issues, it's best to implement good maintenance practices. Using biostable products that don’t rely solely on fungicides can help reduce microbial buildup. Designing systems with proper flow and avoiding dead zones is crucial. During downtime, circulating the coolant or using a small amount of air can prevent stagnation. Thorough cleaning of machines, including biocidal agents, is also recommended. Reducing external contamination by managing oil leaks and maintaining cleanliness can further minimize fungal growth.
In summary, preventing fungal growth in metalworking fluids is vital to avoid increased costs and operational disruptions. A well-planned prevention strategy ensures smooth machine operation, extends coolant life, and supports safety and profitability.
Quaker has introduced advanced fungal-free technology solutions. For more information on their innovative products and services, contact Quaker Chemical. As a globally integrated company, Quaker delivers high-quality products and services worldwide, providing value at every stage and becoming an essential partner for all users.