Chip-Tote® hinge belt chip conveyors are recognized for reliable and efficient handling of chips from machine tools. Tank cleanout frequency can be extended from as often as daily with chip trays to weekly to quarterly with chip conveyors, giving significant reductions in labor costs and machine downtime.
Using a hinged steel belt conveyor, Chip-Tote chip conveyors easily handle hot chips, wet or dry chips, borings, turnings and other scrap material.
- A range of belt pitches to fit most machine tool applications
- Proven roller block design for longer chain life
- Robust overload protection for drive to extend motor life
- Hardened component option available for applications involving abrasive materials
The ConSep® conveyor-separator provides outstanding chip removal and coolant cleaning for your machine tool. With the capability to handle nearly any chip type and material, while providing coolant cleanliness to 50 microns, ConSep systems are well suited for general purpose machining. Tank cleanout periods can be extended from monthly for standard chip conveyors to annually for ConSep systems, reducing downtime and maintenance costs.
The ConSep MKII system, with a lower profile design, allows for an easier integration into certain machining centers and lathes, while providing for floor space savings. A special indexing drum option is available to provide further improvements in coolant cleanliness.
- Integrated media-free backwash system eliminates filter replacements, clogged screens and pumps
- Space-saving single platform design
- Plug and run packages available for many machine tools to ease installation
- Hardened components option available for applications involving abrasive materials
High-Pressure Coolant Systems
High pressure coolant systems integrated with chip conveyor or ConSep® and MagSep® systems help increase speed in cutting, milling, and drilling operations while enhancing product quality by keeping tools and workpieces cool and removing chips quickly. Integrating the high pressure coolant system with the chip conveyor incline or coolant tank saves on floor space and eases installation.
Designs are available in constant or variable speed or pressure to suit a wide range of applications. Various filtration solutions, including the AT-Cleaner Coolant Filtration system, provide for filtration to 10-15 microns, increasing coolant, pump and tool life while improving machining accuracy and part finish.
AT-Cleaner for Coolant
The AT-Cleaner coolant filtration system offers advanced cleaning for water-soluble coolants using a proprietary hydraulic centrifugal separator that is media and maintenance-free. The media-free design offers for significant savings on consumables and downtime versus typical bag filters. The cleaner coolant, to 10-15 microns, increases coolant, pump, and tool life while improving part accuracy and finish.
A coolant cleaning and high pressure coolant system integrated with the chip conveyor and coolant tank can reduce floor space and piping requirements, saving costs and adding additional convenience.
Chip Shredders / Crushers
Chip shredders and crushers are often the first step in a chip handling and processing system to reduce the chip size to enable proper processing or transport, especially via overhead systems. Chip shredders also provide value as a potential stand-alone solution to reduce the volume and transportation costs associated with your scrap.
With over 13 models available, covering a range of throughputs and sizes from machine-tool level to central systems, Mayfran can provide a system that fits your specific needs. All models are auto-reversing to clear jams and can include tramp part rejection. The products offered include:
- MA (Mono Shaft) shredder for at-the-tool applications (video)
- TA (Twin Shaft) shredder for greater throughput in a compact package
- Rip Shear shredders for feeding TD-Series pneumatic discharge wringers (video)
- VC (Vertical Shaft) crushers for high-capacity central processing systems (video)
Chip Wringers / Swarf Centrifuges
Chip wringers (or chip centrifuges) dry chips from machining or grinding sludge to recover valuable coolant, and increasing their scrap value. These chip processing solutions can generate a rapid payback on investment while simultaneously meeting ever more stringent environment regulations regarding chip disposal. Depending on the material and cutting fluid, dryness to less than 2% residual coolant can be achieved in your chip recovery operation.
Our wringers are designed for heavy-duty continuous operation and include hardened components to reduce wear and prolong life. To serve a range of throughput rates, material types, Mayfran offers three different wringer types:
- TD-Series Pneumatic Discharge wringers, an ideal solution for lighter materials like aluminum, and capable of processing steel, brass, and stainless steel (video)
- VBU-Series (Vertical Bowl Up) wringers, for compact applications including at the machine tool (video)
- ArmorLift® LBC (Lift Bottom Centrifuge) wringers for high throughput applications (video)
Chip and Coolant Handling
Central chip handling systems based on pneumatic, push-bar, steel belt, drag, or screw conveyor designs, can reduce costs and forklift traffic by automating the collection and transport of chips from machine tools to central binning or processing systems. These systems complement the machine tool conveyor solutions we provide to create a clean and effective manner for managing your flow of scrap from metalcutting operations.
machine tool conveyor solutions we provide to create a clean and effective manner for managing your flow of scrap from metalcutting operations.
Mayfran’s pneumatic chip / swarf conveyor systems provide for efficient and cost-effective collection of scrap from machining operations and transport to a central binning or processing operation. With designs based on blowing or suction technology, flexible layouts provide for further expansion while freeing up floor space from conveyors and forklift traffic.
The versatile Power-Trof® trough-type conveyor effectively conveys loose or bundled metal chips, fines, curls, turnings and strings, as well as coolant, over short or long distances. It can economically handle large or small quantities of swarf. An efficient series of one-piece, cast iron plows, mounted on a round steel shaft and pushed by a hydraulic cylinder, transports material through the trough by means of reciprocating action.
Mayfran offers a range of solutions for central chip handling systems based on steel belt, drag, and screw conveyor technology. These provide the ability to handle nearly any chip and coolant situation, transporting chips and coolant to local or central load-out, processing, or filtration systems.
Central Filtration Systems
Mayfran designs and builds complete tailor-made filtration plants for coolant and chip handling, supporting flow rates of up to 40,000 l/min (10,500 gpm). With a range of coolant filtration technologies to choose from, including gravity, pressure, or vacuum filters, we can select the coolant filtration solution most suited to your needs. Designs incorporating paper media or permanent belts are available.
With years of experience designing and implementing central coolant filtration systems in demanding applications, and deep project management and engineering resources, Mayfran is the safe choice for developing your coolant filtration solution. Additionally, our ability to incorporate the unique Viavent overhead pump system and chip handling and chip processing solutions allows us to deliver an optimized chip and coolant management system, helping you reduce operating costs.
Viavent Overhead Pump Systems
The Viavent® overhead pump system is a closed loop system for the automatic recirculation of chips and coolants from machine tools through central filtration systems. The modular overhead design provides maximum flexibility in initial installation and future expansion, as machine setup does not need to be dependent on floor channels. Combined with Mayfran’s proven pumpback station design, Viavent systems have been successfully installed in some of the most advanced manufacturing facilities in the world.
This animation shows the operating principles of the Viavent system.
- Operating costs are reduced through automation and the self-cleaning properties of the system
- The closed cycle reduces coolant use and losses and extends its life, and reduces the size of filters required.
- Environmentally friendly design providing for cleaner factory air (no misting) and coolant is kept out of the ground water.
View a video of the Viavent system in operation.
Local Filtration Systems
With a broad range of solutions suitable for oils or emulsions and all types of materials and processes, we can meet the demand for even greater levels of coolant cleanliness through local filtration systems. Supporting machine-tool or cellular-level operation, these designed meet increasing customer demands for outstanding workpiece quality through coolant performance.
The MMF Filter range is a modular platform solution for coolant cleaning directly at the machine tool. A range of coolant tanks and filter modules are available to meet the various customer requirements. Both paper media and permanent media (endless belt) designs are available.
The VacuFilter® filtration system uses a disposable paper media to effectively filter find chips and particles from metalworking fluids. Cleanliness to 15 microns can be achieved at a throughput of up to 600 gpm, and the system can also effectively eliminate tramp oils, split emulsions, and other undesirables from the fluid.
MagSep Magnetic Separator Conveyor
Magnetic separator conveyors provide cleaner coolant compared to drag conveyors in ferrous applications involving fine chips, particularly cast iron. Tank cleanouts can also be extended from weekly to quarterly, significantly reducing maintenance costs and downtime.
The MagSep® magnetic separator conveyor is ideal for dedicated cast iron and carbon steel applications generating chips smaller than 50 microns. This system utilizes a drag conveyor design with a charged magnetic bed to separate ferrous chips from coolant.
For gear cutting, broaching, and hobbing applications involving oil, the magnetic roller separator conveyor provides outstanding coolant cleanliness down to 99.9% of ferrous particles by weight.
Mayfran leads the industry in magnetic separator conveyor offerings and has additional designs available for specialized applications; please contact us and we can work with you to solve your specific challenges.