Unified Emulsion Selection and Recycling System
Waste Type:
Main Circular Economy Strategy:
Company:
KEYWORDS
Summary
Matro Ltd. In Hungary decreased the amount of machining emulsions and solutions free of halogens (EWC Code 12 01 09* ) by testing different emulsions, selecting appropriate products and recycling the emulsion by removing metal chips.
Description:
Matro Ltd. is a medium-sized Hungarian company and a leading automotive supplier based in South Transdanubia. Operating for over 30 years with a workforce exceeding 300 employees, Matro produces components for gasoline and diesel engines, brake systems, hook parts, CNC machine tool holders, and precision-turned parts for automotive and general industrial applications. The company identified significant environmental impacts related to machining emulsions, particularly cooling-lubricating emulsions used in CNC milling processes, generating approximately 50 tons of hazardous waste annually To tackle the environmental and operational challenges posed by emulsion waste, Matro implemented a structured approach involving optimized lubricant selection and enhanced recycling practices: Unified Cooling-Lubricant Selection Previously employing two different lubricants, Matro transitioned to a single cooling-lubricating emulsion compatible across their diverse machinery portfolio. Undertook rigorous product testing to select emulsions with superior refill properties and biostability, ensuring longer operational life, reduced contamination risk, and enhanced compatibility for recycling. Integrated Emulsion Recycling System Leveraged existing separation equipment to systematically filter used emulsions, removing metal chips and contaminants effectively. Collaborated with fluid management consultancy Lub Service to design and implement a precise fluid management protocol, mitigating risks of contamination by fungi and bacteria and enabling reliable reuse of emulsions. Process and Administrative Optimization Introduced structured administrative controls and monitoring processes to enhance emulsion management, ensuring optimal emulsion recycling and usage efficiency across the expanding machinery park. These targeted measures significantly reduced hazardous emulsion waste and improved overall operational efficiency at Matro.
Environmental Perspective
Matro’s optimized emulsion use and recycling initiative delivers notable environmental benefits: Significant Reduction in Hazardous Waste: Between August 2017 and the present, successfully recycled and reused approximately 13,219 liters (66 barrels) of concentrated cooling-lubricating emulsion, corresponding to approximately 13.5 tons reduction in hazardous waste generation. Decreased Emulsion Consumption per Production Unit; Achieved consistent reduction in emulsion waste generation relative to processed material, from 67.41 kg/ton in 2021 to 50.83 kg/ton in 2023, demonstrating continuous improvement in emulsion efficiency and waste reduction. Resource Efficiency and Circularity: Enhanced material efficiency by reusing emulsions multiple times after filtration and contamination removal, aligning clearly with circular economy principles. Reduced Risk of Environmental Contamination: Improved fluid management and biostability significantly minimized the risks associated with bacterial and fungal contamination, thus safeguarding environmental and workplace health. Through these integrated efforts, Matro exemplifies meaningful progress towards reducing environmental impacts associated with machining operations.
Economic Perspective
Matro’s approach has generated substantial economic benefits through direct cost savings and increased operational efficiency: Cost Savings from Emulsion Recycling: Achieved cumulative savings exceeding 17 million HUF (~42,500 EUR) since 2017 through reduced consumption of cutting oil due to effective recirculation and recycling practices. Reduced Waste Management Expenses: Realized additional savings of approximately 25,000 EUR by decreasing hazardous waste transportation and disposal requirements through systematic emulsion reuse. Operational Cost Efficiency: Transitioning to a single lubricant product streamlined procurement, reduced complexity in storage, and improved operational efficiency across Matro’s diverse machinery park. Minimal Upfront Investment: Leveraged existing separator equipment, avoiding substantial capital expenditure; the primary investment was associated with implementing robust fluid management processes and administrative controls. Enhanced Long-term Profitability and Competitiveness: Improved environmental and resource efficiency strengthened Matro’s competitive market positioning, enabling the company to meet evolving customer expectations and regulatory requirements effectively. Matro’s targeted interventions demonstrate clearly that circular economy practices can deliver significant cost reductions and operational improvements alongside environmental benefits.
