The PRWIRE Press Releases https:// 2012-09-16T07:50:49Z Fast, precise vice positioning system 2012-09-16T07:50:49Z fast-precise-vice-positioning-system The choice of the right workholding method has a significant influence on the economic viability of cutting processes used for manufacturing, in particular on machining centres. For fast worpiece set-ups and high clamping density Dimac Tooling is now offering the Swiss-made Triag PowerClamp modular workholding system. PowerClamp, a rail-mounted, multi-vice system for clamping lots of parts in a small space, is one of the quickest changeable workholding system available on the market and is ideal for both vertical and horizontal machines. On the PowerClamp, teeth serrations (2 mm spacing) on the base rail allow exact positioning of the vice and end modules. In contrast to many other clamping systems on the market, in which four hold-down screws are necessary for each module, one transverse spindle screw is used. This central spindle screw, which has a right-handed and left-handed thread, pulls two plates with angled faces together. These plates then lock the vice modules onto the base rail with a force of 150kN on either side creating a solid bond between the two components. This feature allows very fast repositioning of the vice modules. Therefore, setting up a PowerClamp is accomplished within seconds, particularly if the magnetic scale is being used. The spindle is accessible from both sides, so that the modules can easily be repositioned, even though adjacent clamping systems are very close. The vice and end modules are available in a variety of standard widths (19 mm – 125 mm). Thus, easy access for machining from three sides on workpieces of various widths is possible. The Triag rail systems allow flexibility in all three axes and offers the highest workpiece density per given machine envelope. High precision component location is based on the vernier effect allowing positioning increments of 2.5mm. If the batch has only a few parts, Triag multiple workholding systems can also be used as a simple machine vice, as the conventional vice is still the favourite choice for many machining tasks. Should the need for a multiple workholding device arise at a later time, as a larger batch has to be machined for example, it is a matter of adding a few extra vice modules to do the job. Dimac offers a Triag starter set, and all the components of the starter set may be used for the multiple layout. Moreover, the PowerClamp system can also be used on a tombstone, on the fourth axis or on a five-axis machine. Five-axis machines are increasingly used by local manufacturers to meet the demands of today's efficient manufacturing in order to remain globally competitive. The Triag five-axis workholding systems’ lower base rails serve both as a mechanical zero-point clamping system, but also as a vice. The Triag system offers fast set-ups, low maintenance and high flexibility: While there might be as many as 50 different clamping modules in use, the interface is always the same, and all parts can be used on horizontal and vertical machines. Contact: Dimac Tooling Pty Ltd 61-65 Geddes Street Mulgrave VIC 3170 Australia www.dimac.com.au Phone: +61 (03) 9561 6155 Fax: +61(03) 9561 6705 Dimac Tooling leads the way in machine tool accessories 2012-05-17T02:02:12Z dimac-tooling-leads-the-way-in-machine-tool-accessories Austech 2012 has been hailed as a huge success by everyone involved in the show, including CNC machine tool accessories specialist Dimac Tooling. Held in Sydney from 8 to 11 May, well over 500 visitors came onto the stand to discuss a range of manufacturing, tooling and production opportunities with Dimac’s sales team. In addition to its wide range of fixtures, vices, chucks and accessories on the stand, including the Kitagawa TJ series trunnion rotary table, which puts 5-axis capabilities well within the reach of the average job shop, the new Cooljet Medium-Pressure Unit proved an extremely popular focus of attention. “For many years we’ve been selling the high-pressure coolant systems, which boost coolant pressure to 70bar (1000psi), and now we have added the medium-pressure system, which features a fixed coolant flow of 30l/min (8gpm) at 20bar (300psi),” Dimac’s Martin Barber explained. “High-pressure coolant is a popular accessory for CNC machine tools, however, many of the earlier machine tools can’t accept high-pressure coolant. The stand-alone medium-pressure unit from Cooljet can be retrofitted to most machines without modifications with many of the benefits of high-pressure coolant.” Visitors to Dimac’s stand were also able to experience how clear visibility of the machining process can increase their productivity, especially during intensive coolant use. Since modern machines prevent the door being opened during operation for safety reasons, a so-called “windscreen wiper”, or “spin window”, which cleans the window by centrifugal forces, can be the solution for a clear view. The spin window is designed to provide visibility into machines with coolant system pressures of up to 80bar, such as those found on through-tool coolant delivery systems. It comes standard with carbon-coated glass for resistance to chip activity and low maintenance cost. A significant number of firm sales leads were taken from Australian manufacturers. Dimac’ Director, Paul Fowler, explained: "Austech provided an excellent platform for us to talk to all existing and potential customers, which justifies the tremendous effort the whole team put organising the exhibition. Also, we're confident that we can carry this momentum over into the next financial year.”www.dimac.com.au Dimac showcases innovative machine tool accessories to drive shops’ productivity 2012-04-10T00:51:20Z dimac-showcases-innovative-machine-tool-accessories-to-drive-shops-productivity Dimac Tooling will take advantage of the captive audience at Australia’s leading trade show for the machine tool and metalworking industry, Austech 2012, and showcase an array of new products and solutions for efficient machining on CNC machining centres, lathes and mills, designed to make for simpler, more economical machining operations. Visitors to Dimac’s Stand (D116) can experience how clear visibility of the machining process can increase their productivity, especially during intensive coolant use. Since modern machines prevent the door being opened during operation for safety reasons, a so-called “windscreen wiper”, or “spin window”, which cleans the window by centrifugal forces, can be the solution for a clear view. The spin window is designed to provide visibility into machines with coolant system pressures of up to 80 bar, such as those found on through-tool coolant delivery systems. It comes standard with carbon-coated glass for resistance to chip activity and low maintenance cost. Machine shops can also reduce costs and at the same time increase productivity through proper coolant maintenance. “Three major forces are making us take better care of our coolants,” Mr Fowler explains. “First, coolants are becoming more expensive. Second, the increasing cost of labour means they are more expensive to take care of. Third and finally, the cost of disposal keeps increasing. In order to keep our coolants working properly for years we have to understand how they work, and why they go bad. Once you understand what is going on, you can expect to use a coolant sump for years before it will need changing or major maintenance.” The Dimac team will explain all aspects of coolant management and maintenance to interested visitors at their stand, and demonstrate the latest additions to their coolant maintenance product portfolio, including the upgraded Zebra Oasis Coalescer System. The Zebra Oasis portable coalescer extends the life of coolant and tooling and prevents shop mist or any health issues. Separating and removing tramp oil is key to the longevity of any coolant. The Oasis is an all-in-one system with a small footprint and not only separates tramp oil, it also includes the added benefits of suspended particle filtration and odour control. Moreover, as an established CNC machine tools accessories supplier in Australia and New Zealand, Dimac Tooling offers more than just a wide portfolio of products and solutions. “We support our customers and markets firstly by providing durable, easy-to-use machine tool accessories specifically tailored to the needs of the Australian manufacturing industry, and secondly with custom-workholding solutions,” says Dimac Director Paul Fowler. He encourages Austech visitors to use the opportunity and talk to the Dimac Team during the show to find out how they can help improve operations. “The correct workholding selection can increase manufacturing process stability, efficiency and safety,” Mr Fowler explains. “An efficient manufacturing process not only requires good machine selection and proper cutting tools, but also the right workholding. The first two areas typically receive substantial consideration, but workholding is often overlooked.” For even more efficiency and flexibility, Dimac introduces the Kitagawa TJ series trunnion rotary table, which puts 5-axis capabilities well within the reach of the average job shop. Available in two configurations with a 380mm plate, the trunnion bolts directly to the table of a 3-axis machining centre and can be easily removed when not needed. For more information please visit www.dimactooling.com.au. Quick and smooth jaw replacement 2011-06-29T07:34:36Z quick-and-smooth-jaw-replacement Melbourne, 29 June 2011 – The proper selection of workholding involves more than simply accepting the chuck that came with the machine as the solution. To incorporate the most efficient processes, workshop managers should invest the time to research the most appropriate solutions. Running high volume parts requires a stable process to ensure consistently produced high quality parts over longer periods of time. This frequently leads to more specialised workholding solutions rather than the flexibility desired in the job shop. Here, with the increasing use of multifunction machines, milling and turning in the same machine, chuck selection needs to focus on flexibility. The standard chuck that comes on the machine may work fine. However, if the lot sizes are very small, requiring frequent change-over, a quick jaw change chuck can be ideal. Dimac Tooling, Mulgrave, VIC, offers the Kitagawa QJR series (Quick Jaw Release), a quick change power chuck. These chucks allow very rapid jaw change to minimise downtime and increase efficiency, delivering more speed, consistent gripping forces and bore size when compared to conventional chucks. The QJR chuck can be easily mounted in place of a standard chuck to keep the installation cost low. QJR are directly interchangeable chuck with the popular BB200 series as they feature the same through bore, plunger stroke and drawtube connection positions. This allows a new QJR08 to effectively replace a BB208 chuck without the need for any special adaption parts. The QJR which uses a quick change base jaw system that can accept standard metric serrated top jaws from existing B200 and BB200 chucks. The QJR series also offers an increase in gripping force when compared to the BB200 series. The chucks are manufactured from high grade alloy steel. This large bore chuck fits Dimac standard metric top jaws, and an optional base jaw allows to fit common cross tenon top jaws. Mounting dimensions are identical to matching B and BB series (B208, BB208, B210, BB210, B212, BB212) so no expensive new connectors or cylinder are required. For more info please visit www.dimac.com.au Dimac Tooling: Caring for your environment at Austech 2011 2011-06-02T03:32:26Z dimac-tooling-caring-for-your-environment-at-austech-2011 02 June 2011 – CNC Machine Tool Accessories specialist, Dimac Tooling, recently returned from Austech 2011 where the company exhibited a series of exciting products, focussing on productivity and the environment. Many enthusiastic visitors experienced Dimac Tooling’s vast range of products firsthand from 24 to 27 April 2011, while the grass-covered environment section of the impressive stand attracted the bulk of visitors. “This year we generated a huge amount of qualified leads over the four days of the show,” comments Dimac Director Paul Fowler. “Enquiries are more than 30% up on the previous Melbourne show and visitors were in a positive frame of mind. The general vibe at Austech was very good!” Under the motto “Caring for your environment”, Dimac presented its environment section, in response to the trends in the advanced manufacturing sector. Apart from concentrating on becoming more efficient and lean, shops increasingly install products and accessories that are not only environmentally friendly, but also help them save some bucks. One of those products is the so called EMC “Water Eater”, a coolant evaporator. It comes at no surprise this product attracted a lot of attention during the show because it saves companies a great amount of money they currently spend on expensive coolant disposal services. “Especially hard hit are SMEs, since they frequently lack the space, the capital or the technical personnel to utilise the exotic recycling or treatment capabilities which larger companies have turned to,” Mr Fowler explains. “Used coolants are normally 97% water. If the water is removed, the amount requiring disposal would be reduced to a mere 3% of the original volume.” The waste fluids are heated through the floor of the unit. At the same time, a power exhaust system continuously draws air across the surface of the heated liquid to speed evaporation and carry the water vapour out of the unit's stack. “The massive reduction in the volume of liquids requiring disposal not only slashes disposal costs, but also economises by reducing storage area requirements, labour and time for handling, and frequency of disposals,” Mr Fowler says. Moreover, to deal with the huge amount of oil used and swarf produced during machining processes, Dimac showcased a range of coolant maintenance products, including the Zebra range of oil separation systems to skim up the surface oil coming from a machine’s lubrication system. The Zebra Oasis portable coalesce, for instance, extends the life of coolants and tooling and prevents shop mist or any health issues, while the very handy and affordable Zebra Oxygenator/Aerator also extends coolant life, but also eliminates foul odours by maintaining high oxygen levels in the tank. “Keeping your coolant in a good condition can prolong the life of your coolant for up to three years,” Mr Fowler says. “As a result, machine shops can save costs while at the same time increasing productivity and part quality.” Naturally, Dimac also had its wide range of fixtures, vises and chucks on display, including the expanded range of the new Kitagawa DH Series collet chucks and the Kitagawa rotary table, which comes in three different sizes and has a great torque capability, making it very rigid and accurate with heavier cuts. Another crowd puller was the live demonstration of the rotary wiper spin window. “Retrofitting a rotary wiper spin window to a CNC lathe or machining centre can deliver great productivity benefits,” Mr Fowler explains. “Spin windows are an essential part of making quick setups as you can see quite clearly what is going on, even in such a harsh environment as that of high-pressure coolant.” For more information please visit www.dimac.com.au. Dimac Tooling: Focus on productivity and the environment 2011-05-10T08:25:15Z dimac-tooling-focus-on-productivity-and-the-environment It’s all about productivity and the environment on Dimac Tooling’s stand (584) at this year’s Austech exhibition in Melbourne from 24 to 27 May 2011. Among the company’s exhibits will be several recent additions to the company’s already impressive line-up of CNC machine tool accessories. Here are some of the new products, all designed to increase shops’ productivity and reduce the environmental impact of machining processes to a minimum: Coolant maintenance In order to deal with the huge amount of oil used and swarf produced during machining processes, Dimac offers a range of coolant maintenance products, which will be demonstrated on the company’s impressive stand over the four days of the show. “Machining coolant (or metalworking fluid) maintenance is still considered an art in many machine shops,” Dimac Director Paul Fowler says. “Smart users know that well maintained cutting fluids can last for years, not weeks or months.” Dimac offers the Zebra range of oil separation systems to skim up the surface oil coming from a machine’s lubrication system. The oil is skimmed on the belt, comes out of the unit into a gravity separator and is then returned at the back of the machine while the coolant is returned to the machine. The Zebra Oasis portable coalescer extends the life of your coolant and tooling and prevents shop mist or any health issues. “Keeping your coolant in a good condition can prolong the life of your coolant for up to three years,” Mr Fowler concludes. “As a result, machine shops can save costs while at the same time increasing productivity and part quality.” Clean air workshops For clean and healthy air in workshops, Dimac showcases the German-made REVEN Recojet oil mist separators and Ultra Cleaners, highly efficient mechanical air filtering units using mechanical separating system X-CYCLONE. Air pollutants and contaminants from oil, emulsions and other fluids are separated from the ambient air as aerosols to a very high extent. This equipment dispenses with auxiliary energy supply as well as any auxiliary material (fabric, etc.). The units are particularly well-suited for the separation of harmful substances from the air including air pollutants in the form of aerosols, mist or vapour (saturated) as well as fine dust. These particles are conducted together with the transporting medium air into the X-CYCLONE separator by forced ventilation (fan). The collected fluids are returned to your equipment and your working environment is mist and particle free. High-pressure coolant Expanding Dimac’s line of versatile CNC machine accessories designed to improve productivity is the Cooljet high-pressure coolant system. “During the metal cutting processes, significant heat is generated at the tool and workpiece interface, primarily from the effects of friction, which can be detrimental to the tool and the workpiece,” Mr Fowler explains. With the on-demand Cooljet coolant system cutting fluids are pumped to pressures of 1000psi (70 bar) or more, and are accurately directed to the cutting zone through an appropriate nozzle. The resultant jet stream of coolant is able to penetrate the high temperature cutting zone, delivering vital lubricants to the cut. “If you are targeting to reduce process cycle times, you will find that your tool life will be significantly extended, and the quality of the cut is considerably increased after applying high-pressure coolant. Its applications are extensive from drilling, grooving, boring, cutting of hard metals which have a high nickel content, to small tooling applications.” Quick Jaw Change Dimac will have a wide range of fixtures, vises and chucks on display, including the expanded range of the new Kitagawa DH Series Collet Chucks, now including the new DHP-42 (42mm diameter capacity) version, which will be available soon and joins the DHP pull back versions currently available. The DH Series is available with quick release gun and specialised collets and is the newest addition to the wide range of quick-release and standard collet chucks already available from Kitagawa. For efficiently changing chucks Dimac will demonstrate the Kitagawa QJR series (Quick Jaw Release), a quick change power chuck. Using a quick change base jaw system it can accept standard metric serrated top jaws from existing B200 and BB200 chucks. These base jaws can be changed quickly and easily using the hand-operated key. For more information please visit www.dimac.com.au. DIMAC releases Coolant Maintenance Manual 2011-03-03T11:58:12Z dimac-releases-coolant-maintenance-manual 02 March 2011 – Dimac Tooling, Mulgrave, VIC, has released the Zebra Coolant Maintenance Manual which offers machine shop operators useful information and advice on all aspects of coolant management and maintenance. “Machining coolant (or metalworking fluid) maintenance is still considered an art in many machine shops,” Dimac Director Paul Fowler says. “Smart users know that well maintained cutting fluids can last for years, not weeks or months. The manual introduces you to the basic elements of getting the most out of your coolant sump system. This will save you money in buying less coolant concentrate, spending less time mixing and measuring it and less money to have someone haul it away.” The Coolant Maintenance Manual contains information for first timers, and detailed information for advanced users. For those who want to dig deeper, this is an essential document for intensive research. “Most machine shop operators think of coolants as a necessary nuisance, something that blows chips off the part,” Mr Fowler says. “In fact, the most important jobs for all metalworking fluids is keeping the tool cool so it lasts longer, and lubricating the tool edge so that it makes a faster and cleaner cut.” Today's coolants are a sophisticated soup of chemicals that all try to do the same thing, blend the best properties of oil into the best properties of water. Along the way the compounders who make these coolants try for other goals as well: rust inhibition, tolerance of a wide range of water hardness, ability to work with many metals, and even environmental safety. “Three major forces are making us take better care of our coolants,” Mr Fowler explains. “First, coolants are becoming more expensive. Second, the increasing cost of labour means they are more expensive to take care of. Third and finally, the cost of disposal keeps increasing. In order to keep our coolants working properly for years we have to understand how they work, and why they go bad. Once you understand what is going on, you can expect to use a coolant sump for years before it will need changing or major maintenance” Chemistry is where it all starts. Coolants are a complex blend of many chemicals, whether organic or fully synthetic. The basic function of these chemicals is to allow oil to emulsify into water, but they also must be able to resist corrosion of steel, not alter the surface of aluminium, to maintain pH stability around 8 to 10, and to resist breakdown from the extreme heat of the tool tip. Biology is where it all ends, because microbes are the real enemy of all coolants. Whether you fight infections with an antibiotic, or enjoy beer with your cheese, you have dealt with a microbe in some form. Given the right conditions and a little bit of time, your pristine sump can go from having only a few hundred microbes in every millilitre (about ten drops) to over a million. Mechanics is what makes the coolants work, and what keeps them working. The pump forces fluids through pipes and onto the workpiece. The fluids then splash down into the collection sump. Oils from the ways, leaking seals, and from other sources ends up in the sump as well, eventually floating on top of the coolants. Chips and dirt from the machine also find their way into the sump, and this collection of fluids and particles presents a very different problem of coolant maintenance for every sump. DIMAC offers several coolant maintenance products, including the Zebra Oasis oil skimmer, and will continue finding the best solutions, methods and products for its customers to help them improve productivity and maximise their return on investment. “Keeping your coolant in a good condition can prolong the life of your coolant for up to three years,” Mr Fowler concludes. “As a result, machine shops can save costs while at the same time increasing productivity and part quality.” Please download the manual here http://www.dimac.com.au/product/turning/coolant/coolant-accessories/coolant-maintenance-manual_colmmor call us on 03 9561 6155. For more info please visit www.dimac.com.au DIMAC Open House highlights productivity gains through high-pressure coolant 2011-03-03T11:54:27Z dimac-open-house-highlights-productivity-gains-through-high-pressure-coolant 03 March 2011 – Checking out the latest machine tool accessories to achieve productivity gains was among the reasons for more than 60 Melbourne-based manufacturers stopping by the DIMAC office in Mulgrave, VIC, for the company’s two day Open House event from 8 to 9 February 2011. The event was a way for local advanced manufacturers to learn what DIMAC has to offer to make their workshop more productive, innovative and environmentally friendly. Naturally, all technologies offered by DIMAC were demonstrated, from collet chucks, soft jaws, a coolant evaporator, fixturing and workholding solutions to the Australian-made Swarf Crusher and DIMAC service products. However, it was the live demonstration of high-pressure coolant that generated the “lion's share” of visitors’ interest. To demonstrate the number of benefits to applying high-pressure coolant using the on-demand coolant system made by Cooljet, DIMAC set up a horizontal machining centre, retrofitted with a range of accessories. Apart from the high-pressure coolant, the machine was fitted with a mist extractor, a spin window for clear visibility into the machine, a Renishaw probe, an oil skimmer and the Zebra Oasis coolant maintenance system. “During the metal cutting processes, significant heat is generated at the tool and workpiece interface, primarily from the effects of friction, which can be detrimental to the tool and the workpiece,” DIMAC Director Paul Fowler explains. “With the on-demand Cooljet coolant system cutting fluids are pumped to pressures of 1000psi (70 bar) or more, and are accurately directed to the cutting zone through an appropriate nozzle. The resultant jet stream of coolant is able to penetrate the high temperature cutting zone, delivering vital lubricants to the cut.” “Temperatures are dramatically decreased due to the reduced friction,” he goes on to explain. “This is very evident by observing the chips produced which are well formed and are generally not heat discoloured. The coolant system also effectively forces chips away from the cutting area especially in deep-hole drilling or pocket machining.” During the Open House show, DIMAC demonstrated these benefits through live drilling operations. Using a Dormer solid carbide drill, the machining centre was drilling 8mm diameter holes, 75mm deep at 3500revs/min with a 0.26 feed/rev. The whole process only took 6sec, which would normally take around 1.15min, Mr Fowler explains. “If you are targeting to reduce process cycle times, you will find that your tool life will be significantly extended, and the quality of the cut is considerably increased after applying high-pressure coolant. Its applications are extensive from drilling, grooving, boring, cutting of hard metals which have a high nickel content, to small tooling applications.” In order to deal with the huge amount of oil used and swarf produced during machining processes, DIMAC offers a range of coolant maintenance products, which were demonstrated on the same machining centre on show over the two days. “We are using an oil skimmer to skim up the surface oil coming from the sideway lubrication system,” Mr Fowler says. “It's skimmed on the belt, comes out of the unit into a gravity separator. The oil comes out of the back of the machine while the coolant is returned to the machine. Moreover, we are also using a coolant maintenance system, the Zebra Oasis system, which is connected to the machine via two hoses. Here, we are skimming off the top of the surface, all the oil is picked up by the diaphragm pump, the dirty coolant comes up through a pre-filter into a settling tank, settling the oil out.” “The resultant clean coolant is picked up from the tank, comes through a 5-micron replaceable filter and returns the clean coolant back to the machine,” Mr Fowler adds. “This process would typically run about 4 hours at the back of the machine and then move on to the next machine. This way, your coolant is kept in a good condition and can prolong the life of your coolant for up to 3 years!” DIMAC will continue finding the best solutions, methods and products for its customers to help them improve productivity and maximise their return on investment. The success of the Open House event shows that DIMAC is offering the right and most of all high-quality products to support Australian advanced manufacturers to stay ahead of the game. For more info please visit www.dimac.com.au Efficient, environmentally friendly coolant disposal 2011-03-03T11:52:30Z efficient-environmentally-friendly-coolant-disposal 04 March 2011 – The disposal of spent coolants has become a significant factor in the operational cost of a plant. Especially hard hit are SMEs, since they frequently lack the space, the capital or the technical personnel to utilise the exotic recycling or treatment capabilities which larger companies have turned to. Yet, their costs and liabilities are proportionately the same or greater. Now, Dimac Tooling, Mulgrave, VIC, presents an entirely different approach to the problem. Used coolants are normally 97% water. If the water is removed, the amount requiring disposal would be reduced to a mere 3% of the original volume. To achieve this goal, Dimac recommends a piece of equipment known as the ‘Water Eater’, made by EMC in Santa Fe Springs, CA, USA. The Water Eater is available in gas and electric heated models. Evaporation rates range from 15 to 208 litres per hour. An optional Auto Fill System automates the process and allows for 24 hour operation. The waste fluids are heated through the floor of the unit. At the same time, a power exhaust system continuously draws air across the surface of the heated liquid to speed evaporation and carry the water vapour out of the unit's stack. Should the unit run dry, an automatic shutoff prevents damage. A unique feature is that it allows almost complete elimination of the liquid waste. The Water Eater waste water evaporator has been engineered to efficiently evaporate the water content from most non-volatile water-based liquids. A power exhaust system releases the moisture safely into the air, leaving only a small residue requiring disposal. The dry residue is simply scraped from the obstruction-free bottom of the unit periodically. Alternatively, the highly concentrated liquid residue, which remains after many reductions, may be taken out before becoming totally dry. To minimise cleanout time, a fully removable cover is provided that allows for complete access to the entire tank. Most Water Eaters have a low top frame height which allows easy accessibility without the need of footstools or stands. The harsh environment inside a wastewater evaporator requires that only heavy gauge materials be used. All tanks (carbon and 316L stainless steel) are of mig welded, 12 gauge steel construction (316L stainless steel units also have covers, lid, and vent stack of stainless steel). To keep the energy costs for evaporation as low as possible, the Water Eater features a large heat transfer area of the burner tube or heat exchanger. The large, 165mm diameter burner tubes on the gas models provide as much as 200% more heat transfer surface than competitive systems, EMC claims, thereby minimising heat-up time and decreasing energy costs. This large surface area has an additional advantage in that fewer hot spots are created and any sludge or scale buildup which can insulate and reduce system efficiency is minimised. The massive reduction in the volume of liquids requiring disposal not only slashes disposal costs, but also economises by reducing storage area requirements, labour and time for handling, and frequency of disposals. All Water Eaters have been designed to operate simply and efficiently, and are constructed of quality materials and equipment to assure trouble-free operation and long-life service. For more info please visit www.dimac.com.au How to crush workshop waste and boost profits 2010-08-10T07:00:48Z how-to-crush-workshop-waste-and-boost-profits-1 09 August 2010 - Inadequate waste control measures in workshops are costly and with labour and material costs on the rise, a solid system for processing scrap is critical. This all-Australian design aims to reduce wasted floor space while earning money for workshops across the country.The latest product from Dimac Australia, the Swarf Crusher, is a unique system designed to reduce the floor area required to store swarf by compacting metal shavings into billets. Meanwhile, the recovery of cutting fluid from this process allows companies to gain a better price from the sale of swarf. The system works by loading the swarf into a hopper where two horizontal augers and one vertical auger feed the swarf into a chamber. From there it is compressed into billets of 53 mm in diameter. Dimac say the length can be varied to suit the material you are processing. Once the metal shavings have been compressed into billets they are then transferred to an elevator and up into a collection drum. During the compressing process, cutting fluids are squeezed out and are recovered in a tray underneath the machine. From here, they can either be pumped directly back into the machine tools tank or into a separate holding container. The robust yet compact design of the system allows it to be installed either underneath the swarf conveyer of a machine tool or as a stand-alone unit to service a number of machines by using individual bins on wheels.“When the swarf is compacted into billets its sale value increases as part of the metal merchants processing has already been taken care of,” said Managing Director, Paul Fowler. “Also, billets are smaller so you can afford to keep them inside and avoid rust issues that can erode profits. It also reduces transport costs by having less pick ups by the metal merchant.“This is not only an economically sound solution is also an environmental one,” added Paul, “with both cutting oils and metals recycled as a result.”Other savings include less burning of material, no more leaking oils down drains and a severe volume reduction of scrap by up to 70 per cent.“Swarf Crusher is such an easy system to implement in any workshop. Without a doubt one of the greatest benefits of the system is that expensive floor space is no longer taken up by large scrap bins,” he said.Suitable for both ferrous and non- ferrous materials, around 95 per cent of coolant from the material is extracted during the compressing process.Dimac say Swarf that used to take up five bins; will now fit into one bin, and all with fewer disruptions to work flow.“A considerable amount of thought has gone into the usability of the system, which has a reliable microprocessor with fault detection, auto power off and totally CE compliant features,” adds Paul.The system comes with a swarf height sensor to turn the machine on and off depending on the amount of swarf in the hopper. Swarf crusher is available in two models – standard and high speed, with an output of 50kg per hour for steel on a standard machine and 90kg per hour on a high speed model.Customers have the option of a bin loading systems, which can make using Swarf Crusher even more cost effective.“By having your specially designed bin under the machine tool conveyor you can easily load up the machine with the push of a bottom, even while its working,” concluded Paul. Contact:Dimac Tooling Pty LtdPaul FowlerPh: 03 9561 6155E-mail: paulf@dimac.com.au