Resource-saving manufacturing, reduced emissions and the circular economy are currently some of the key topics in industrial production. One company that has consistently implemented and embraced these values over many years is Geiger GmbH based in Pretzfeld, Germany – a medium-sized supplier of high-precision components.
For almost 15 years, the SWISSCUT ORTHO NF-X 15 cutting oil from MOTOREX has been in continuous use and continues to play a key role in ensuring premium surface quality.
The automotive industry is undergoing a major transformation. Numerous components and assemblies are now no longer required or are being relocated to lower-cost countries. This presents enormous challenges for suppliers and their partners. Exceptional performance is required to compete in this environment. Geiger GmbH from Pretzfeld, a traditional medium-sized supplier with 120 employees, specialises in highly complex parts made of high-alloyed steels, which are manufactured with the highest precision and the best surface quality. One example of its products are components for common rail systems with system pressures of up to 2,700 bar. Special steels without sulphur and phosphorus are processed to manufacture these components, and this processing calls for special know-how.
This development meant Geiger had to make significant investments of time and money before the process was stable. The company is increasingly acting as a system partner for its customers, which helps it to stand out from the competition. Together with their customers, the project team develop the best machining strategy for the workpiece in question. In this work, the company demonstrates a high level of agility and flexibility across all departments. The team has around 70 state-of-the-art CNC machines at its disposal for implementation, covering the entire spectrum of metal working. Currently, almost one hundred different parts are manufactured each year in batch sizes ranging from 10 to 500,000. As a rule, this can be achieved with accuracies of up to 5 μm for moulded and turned parts, with position tolerances of up to 10 μm and IT 6 for diameters. Geiger can dispense with the grinding process for many workpieces, as the required surface quality is already achieved during turning. In addition to the automotive industry, more and more companies in the mechanical engineering, medical technology and electronics sectors have recently come to appreciate Geiger’s precision.
For Dieter Neller and his team, the technological advantage is only one side of the coin. Having close, reliable partnerships with customers and suppliers as well as a responsible attitude to the environment is equally important to them. This is reflected in the fact that most of their customers and suppliers have been part of trusted working relationships with the company for more than ten years. They appreciate Geiger’s adherenceto delivery deadlines and consistent reliability. Over the years, the company has had hardly any complaints or returns. Geiger is a reliable link in the supply chain, as it not only maintains good relationships with its customers, but also with its suppliers. Its partnership with MOTOREX has now lasted almost 15 years and began in 2011. The company’s site is surrounded by nature at the gateway to idyllic Franconian Switzerland, and it is fully committed to environmentally friendly production. Initially, Geiger was looking for alternatives in order to reduce the emissions from the cutting oil it was using at the time. One of Geiger’s major customers recommended MOTOREX SWISSCUT ORTHO NF-X 15, as they had very positive experiences using it. As MOTOREX and Geiger share the same values, this immediately created a common ground between them and Geiger decided to switch completely to this premium Swiss product. Just a few weeks later, three tankers arrived from Switzerland and filled the two central systems with 15 m³ and later 70 m³ of cutting oil. This is a decision that Geiger has never once regretted, as this oil has not yet been replaced, is still in the circuit and remains as effective as on the first day.
SWISSCUT ORTHO NF-X 15 is a high-performance cutting oil that can be used to achieve optimal results when machining both high-alloyed steels and aluminium. It has very good air release and foaming behaviour. As a result of this switch to the new oil, emissions reduced to almost zero and there were no more unpleasant odours. At the same time, the high-quality performance additives resulted in a higher level of performance and better surface qualities. The oil was thinner, yet much more effective than the one previously used. This switch also brought benefits for the employees, as the oil does not cause any skin problems and is odourless. But how is it possible for a cutting oil to maintain its performance for more than ten years? As a system provider, MOTOREX supports its customers with coolant monitoring and care.
In collaboration with the responsible sales partner Erhard-Bürk Kauffmann and the MOTOREX laboratory, comprehensive lab-based analytical support is provided on an ongoing basis. As a result of the introduction of other oils and particles, the cutting oil becomes thicker over time. Fluid Manager Tobias Gemsjäger at Geiger and the experts from Erhard-Bürk Kauffmann therefore assess the quality at regular intervals and readjust the additives and create lower viscosity oil if necessary. As Geiger works at high pressures up to 70 bar, larger particles would have a negative effect on the surface quality. For this reason, the company has installed a precoated filter that also traps very fine particles. In order to reduce the oil discharge through chips, Geiger has also installed a unit that breaks and spins the chips until their residual moisture content is 0.1 %. The oil collected in this way is fed back into the circuit. This is another important element in creating more resource-efficient and sustainable production. As a result of these positive experiences, the company now also purchases the majority of its water-miscible coolants from MOTOREX, as these boast good production results, long service lives and excellent employee acceptance. As partners, Geiger and MOTOREX are then taking a joint step closer to achieving their objectives of eliminating or limiting environmental pollution.
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