When not managed correctly, metal chips and cutting fluids generated in machining processes create significant storage, logistics, and cost burdens.
As Pergel Conveyor, we analyze each facility's scrap-management processes from the ground up according to plant scale, chip type, and recovery targets, and provide end-to-end, high-efficiency engineering solutions.
Our objective is to minimize chip volume, recover valuable coolant/cutting oils at the highest possible rate, and create sustainable economic added value for your business.
Our Integrated System Analysis and Engineering Methodology
To design the most appropriate integrated chip and oil-separation system for your facility, our team carefully identifies the following technical parameters through on-site analysis.
Current-State and Separation Analysis
- The presence of an existing chip-transfer or oil-separation infrastructure at your facility is evaluated.
- The current coolant/oil ratio in the chips (moisture content) is measured according to laboratory/site criteria.
Feeding and Automation Method
- The feeding mechanism suitable for the facility's internal logistics flow is determined.
- Manual labor / Manual feeding
- Dumping Lifters
- Feed Conveyors
- Forklift dumping systems
- For lifter-fed configurations, the dimensions and geometry of the chip carts used and their mechanical compatibility with the lifting mechanism are verified.
Chip Characteristics and Metal Metallurgy
- The types and proportions of materials being machined are detailed (Steel, Stainless Steel, Brass/Brass Alloys, Aluminum, Cast Iron, etc.).
- The physical form of the chips is analyzed.
- Stringy, long, and bundled chips
- Broken and short chips
- Fine dust or casting sludge
- For mixed-chip lines, the percentage distribution of material types and the need for crushing/centrifuging are determined.
Cutting-Fluid and Oil Management
- The type and viscosity of the coolant used are examined (water-soluble emulsion / soluble oil, neat cutting oil, etc.).
- The risk of different types of oil mixing throughout the facility and their effect on separation quality are evaluated.
- The process target is clarified according to the customer's priority.
- Maximum Oil Recovery (focused on environmental performance and raw-material cost)
- Maximum Chip Dryness (focused on logistics/scrap sale value)
- Combined Improvement (optimization of both criteria)
Capacity and Discharge Logistics
- The system's hourly and daily processing capacity (kg/h or m³/h) is calculated.
- The discharge method for processed and dried chips is designed.
- Discharge conveyors with a custom dumping height
- Automatic tower/silo storage systems
- Big-bag or container filling stations
- Additional fine-filtration requirements (settling, paper filter, separator) are determined so that recovered cutting oil can be fed back into the process.
Our Chip and Scrap Management Solution Stages
- Site Survey and Data Collection: Identification of detailed technical parameters for the correct equipment configuration.
- Engineering and 3D CAD Design: Engineering drawings fully compatible with your facility and layout plan.
- Manufacturing and Equipment Integration: Manufacture of Chip Crushers, Centrifuges / Chip Dryers, Conveyor Lines, and Lifting Systems.
- Commissioning and Training: System installation with high efficiency, low maintenance cost, and continuous operation.
