Sustainable Solution Transforms Tooling Performance
Margins are measured in microns and seconds in subcontract machining, and every process variable has a cost implication that demands scrutiny. Yet one of the most critical elements, cutting fluid, can be overlooked. At Numachine Ltd, that oversight has been addressed through a partnership with Oemeta UK, which has delivered measurable improvements in tool life, component cleanliness, and operational sustainability.
Established in 2019, Numachine specialises in CNC machining of complex components where cost reduction, repeatability, and accuracy are paramount. The company has invested in the latest machining and metrology equipment to build an enviable reputation in the automotive, medical, and aerospace sectors, where quality standards are uncompromising.
George Hawkins, Managing Director, explains the company's focus: "Numachine specialises in machining parts from castings, aluminium, stainless and mild steels and plastics."
Identifying the Challenges
Roughly six months ago, Numachine invited Oemeta's Ryan Aviles to assess their metalworking fluid requirements. The company had been experiencing persistent issues with their existing coolant that were impacting both productivity and profitability. "We had been using a standard coolant for a number of years, and we knew that if we changed fluids, we could potentially witness benefits on the shop floor. Predominantly, we had issues with our tapping and threading on the machines, especially in our castings," George reveals. "We found that the taps weren't lasting as long as they should."
The implications of premature tap failure in machining casting are severe. "When tapping castings, if the tap breaks or wears, it scraps the component, which is a significant time and cost loss to us," George explains. This wasn't the only challenge facing the Herefordshire manufacturer. "When we removed parts from the machine, there was a residue of coolant on them which would fall onto the floor or the bench," George continues. "We would obviously lose money due to physically losing coolant, but it was also a trip hazard."
A Systematic Approach to Solutions
Ryan Aviles from Oemeta UK recognised the challenges required a methodical, data-driven approach. "The relationship with Numachine started six months ago. They invited us in for a meeting where they shared a couple of the challenges they were facing with their current coolant," Ryan explains. "They were spending too much on their tooling and were facing a lot of sticky residues on components and on the machine, but also they wanted to move to something more sustainable."
After analysing the situation, Oemeta's technical team identified the root cause of the residue formation. "We identified two ingredients which could be the cause of the residue formation. We removed these from the process," Ryan notes. The solution was Oemeta's Estramet S95, a cutting-edge metalworking fluid that addresses all three of Numachine's concerns simultaneously.
The Technical Advantages of ESTRAMET S95
"We recommended ESTRAMET S95 as it's free from fossil fuels. It's made up of ester oil, which is essentially a vegetable-based oil," Ryan explains. "This provided Numachine with a sustainable solution. Additionally, we looked at the data and realised that we could deliver a 20% increase in tooling efficiency as well."
The formulation of ESTRAMET S95 represents a significant advancement in technology. Based on renewable ester oils rather than mineral oils, the fluid delivers superior lubrication characteristics at the cutting edge, reducing friction and heat generation during demanding operations such as tapping in cast materials. This enhanced lubricity translates directly to extended and consistent tool life, critical for machining expensive castings that undergo a significant level of machining.
The ester base solution has a formulation that also exhibits low residue characteristics. This means that components emerge from the machine clean and ready for subsequent operations, eliminating the secondary cleaning steps that were previously required.
Beyond performance, ESTRAMET S95's environmental credentials align perfectly with Numachine’s sustainability targets. The elimination of fossil fuels reduces the carbon footprint of the machining process, whilst the renewable ester base offers improved biodegradability compared to traditional mineral oil-based coolants.
Rigorous Testing and Measured Results
Before committing to a complete changeover, Numachine and Oemeta agreed to a comprehensive six-month trial period with clearly defined key performance indicators (KPIs). "Ryan visited Numachine to outline the KPIs that they would monitor; he performed testing on all of these KPIs," George confirms. "This has been for six months, and we're still seeing improvements on the tool life, misting, residue on components, and foaming KPIs that are being monitored."
Ryan reports: "Numachine agreed to trial our products, and from day one, they noticed that coolant residue was eliminated and parts were coming off machines clean, saving secondary part cleaning. The tool life also improved, reducing their tool spend to a level that covers the additional cost of the coolant and more."
The improvement in tool life is particularly significant. The 20% increase in tooling efficiency translates directly to bottom-line savings, with reduced tool purchases, fewer machine stoppages for tool changes, and decreased scrap rates from tool breakage. Detailing the benefits, George adds: “Since introducing Oemeta’s ESTRAMET S95, we have reduced our consumption and costs for taps and threadmills by almost 40%. Machining castings is a large part of our business, so we have analysed this closely. On a regular batch of cast parts that require 42 holes tapped to 3XD, we were changing taps every 60 parts – its now 90 parts before changing taps.”
Operational Benefits
The benefits of ESTRAMET S95 extend well beyond tool life and component cleanliness. The reduction of in-machine misting creates a healthier working environment and reduces part changeover times. Lower foaming characteristics ensure consistent coolant delivery to the cutting zone, eliminating the performance variability that foam can cause in high-speed machining operations.
Alluding to this, George adds: “The misting of machines and coolant evaporation has completely disappeared, and the noticeable smell of coolant in the workshop has gone. The coolant makes the working environment a much nicer place to be, and as we have a target of achieving ISO: 14001 accreditation soon, we know that changing coolant will be a major benefit in our drive to achieve accreditation.”
Strategic Implementation Across the Facility
"We encouraged Numachine to take a six-month trial, giving them the chance to evaluate ESTRAMET S95 and the level of our service that we provide," Ryan notes. The implementation strategy was carefully planned to minimise disruption whilst maximising evaluation opportunities. "
Commenting on the successful rollout, Ryan adds: “We extended the trial to two additional machines, topping up over their existing coolant to demonstrate compatibility and to avoid complete tank dumps. This approach proves that ESTRAMET S95 can be introduced gradually without the expense and downtime of complete system flushes. Six months into the partnership, Numachine has started rolling out our coolant across all machines. With our support, we aim to make the transition as smooth as possible, sampling all machines, initially to assess their condition."
Highlighting both the environmental and cost benefits of ESTRAMET S95, George continues: “We used to go through a barrel of coolant every two to three weeks, but since we have been using Oemeta, we have only used two full barrels, which equates to a barrel every 6 weeks – a 100% reduction in cutting oil consumption.”
Comprehensive Technical Support
For Ryan Aviles, supplying the product is only the beginning of the relationship. "Our aftercare is critical to everything we do. We need to make sure we're offering the support and keeping the coolant in top condition. Our technician, John, regularly visits Numachine to complete their coolant testing, and he gives detailed feedback through reporting."
This ongoing technical support ensures that the coolant continues to perform optimally throughout its service life. Regular monitoring identifies any developing issues before they impact production, whilst the detailed reporting provides Numachine with quantifiable data on coolant performance and condition. The proactive coolant management extends fluid life, ensuring the operational and economic benefits continue long-term. Discussing this, George says: “Every machine is scheduled for a ‘deep clean’ every 12 weeks, and the labour, machine downtime time and waste fluid removal cost to us would be £250 per machine. With Oemeta, the machines are much cleaner at our scheduled clean-out dates, making our turnaround times much shorter and reducing our costs and labour input by 50%.”
A Partnership Built on Results
George Hawkins is unequivocal about the value Oemeta has brought to Numachine. "We chose Oemeta because of their technical support. Ryan monitored everything and included us every step of the way. If anybody is looking for a new coolant supplier, I would certainly recommend Oemeta."
Concluding, Ryan says: "We're committed to delivering innovative, sustainable solutions that truly make a difference for our customers. The successful partnership with Numachine demonstrates our dedication to quality, performance and exceptional service. We look forward to building a long-term relationship based on trust and shared success with Numachine."