24 x 7 = 168. We believe that the most competitive manufacturers learn how to produce around the clock with minimized labor input. This company class will own the future.
A refractometer, either digital or traditional handheld. Values are submitted to our Coolant Health App to give you clear trendlines. The submitted brix readings are combined with the top-off ratio in a graphical format, allowing an operator to visualize a clear relationship between the top-off being used versus the sump concentration.
Experience has taught us that a CNC sump is a challenging environment for a refractometer to live in. Sensors are easily fouled and require constant cleaning. We believe this is impractical and undesirable for our customers. The other hurdle from a commercial perspective is the cost of ruggedized inline refractometers — they simply are not affordable for this application. FullShop™ uses individual dosing and our easy-to-use app does a great job stabilizing sump concentrations.
Yes. Each sump can have unique target concentrations. The top-off ratios used to accomplish this are individualized by sump and controlled by the user.
No. Multiple redundancies are built into FullShop™ to avoid overfilling. Also, the FullShop™ email feature will alert you in real time of any overfilled conditions. More than ten years of real-world experience in our machine shop has proven to be very valuable when commercializing this product for others.
We believe that our customer is typically best-positioned to handle plumbing and general installation. This may appear daunting, but simple PEX plumbing and basic sensor wiring require about the same effort as adding an air line to a CNC. Our guides and pre-planning documents make sure that installation is simplified. Local FullShop™ distributors are also available to assist you. If you feel you need additional support, let us know.
Mainly two things: submit refract readings to the mobile app and trim/offset dosing ratios based on the trendline. This is a minimal effort for a plant when compared to manual sump management. Users find that FullShop™ frees up many hours that can be used elsewhere, including the production of more parts.
1. Opportunity/Labor cost: People are your most valuable resource, and they should always be focused on production. Manual top-offs add to indirect costs. Given the challenges of finding skilled labor, our industry needs to eliminate dull, dirty and dangerous tasks an embrace automation. If 10 to 15 minutes were freed up on each of your machines per shift, could you produce more? This adds up over time and we encourage you to document these costs.
2. Unplanned downtime: We run a shop and have visited countless others. Many of us have war stories about how coolant mishaps interrupted production. Low coolant levels, concentrations that are way off, spills, earlier-than-required sump changes — these issues are a reality in shops that continue to choose manual coolant management. Unplanned downtime events interrupt production. If you had sumps filled to the right ratios all the time, would you see more production?
3. Consumables: Data gathered on coolant consumption shows us it is highly likely that a typical user with a FullShop™ system in place spends 25 to 35% less on coolant. This is the result of individualized dosing optimized by the CNC to use the minimal amount of coolant. Another long-term cost that is harder to quantify is perishable tooling — it has been proven that sumps with low concentrations burn up tools. Your savings would be based on how out of control your system is today versus predictable sump concentrations with FullShop™.
4. Opportunity: Can your equipment run lights-out and unattended over weekends with your current manual coolant management? Manpower planning for nightly or weekend coolant management is an expensive proposition. FullShop™ can be part of your strategy for more predictable unattended production hours and lowered operations costs.
Yes. We have hundreds of CNCs set up with these scenarios. When coolant goes low somewhere, we can monitor and refill the tank where the volume is decrementing.
No. The FullShop™ sensor will fit in the smallest machines and our 4 gpm fill rate is sufficient for the largest sumps. Our standard sensor is capable of measuring depths up to 1 meter and we have solutions for bigger sumps.
Consider a machine accessory like the LNS Venturi. It draws coolant out of your chip hoppers back into the CNC sump, and can be thought of as a simple coolant recycler. When combined with a FullShop™ system, the LNS Venturi lowers your coolant consumption, waste stream and processing cost for wet chips. Learn more here.
FullShop™ is compatible with DI, RO, municipal and well water. FullShop™ uses a water quality sensor to continuously monitor your water and alert you if there are unexpected changes in quality or temperature. Consult with your coolant vendor to select an optimal water solution for your plant and metalworking fluid. Remember, the emulsion is over 90% water so it's important to have good controls in place.