Are you ready for a HSE

inspection?

Safety with Metalworking Fluids (MWF)

The Health & Safety Executive (HSE) has identified that there is

a potential health risk for operators exposed to oil mist leading

to respiratory diseases. Mist can be generated from both neat &

soluble metalworking fluids during use and employers have a duty

of care to ensure that adequate measures are taken to reduce the

level of operator exposure.

As with any fluid there is always the potential for the formation of

mist. But this can vary significantly depending on both the type

and condition of the fluid and the surrounding environment. Mist

may be generated when oil is sprayed at high pressure or when oil

connects with a high temperature surface and vaporises.

In addition it is also equally important to consider that a

metalworking fluid is usually used in an open system susceptible

to contamination over a long period of time. This can be both

chemical such as tramp oil and biological such as bacteria and

the subsequent endotoxins from live and deceased bacterial cells.

This therefore raises the question if you can’t 100% control what

is in the fluid how can you control what goes into the mist?

Working safely with metalworking fluids

Risk to health

Misting & Metalworking Fluids

The HSE has identified a risk of lung disease for operators

exposed to MWF mist as chemicals and micro-organisms can

irritate the lungs resulting in breathing difficulties. This can

be exasperated by those who already suffer from asthma.

Conditions can vary from mild to extreme and affect both the

quality of life and ability to work.

Employers are responsible for controlling exposure to

hazardous substances & suppliers are responsible to report

these substances, however the hazards associated with mists

can be less obvious and not immediate. It is possible to select

a less hazardous fluid in its supplied state, however the logic

is that the inhalation of any liquid or solid particulate is not

beneficial to health i.e. there is no such thing as a healthy mist!

2

What the law requires When an inspector calls

The control of substances hazardous to health (COSHH) 2002

requirements are enforced by law & can be summarised

as follows;

• Requires employers to carry out a suffi cient risk assessment for

those who come into contact with MWF’s and identify measures

to control & reduce exposure.

• COSHH requires that records of any checks made

(e.g. MWF quality, concentration, pH) are retained for 5 years.

• COSHH requires that a suitable health surveillance programme

is provided. Records of exposure to hazardous substances and

employee health records must be retained for 40 years.

HSE inspections are already taking place.

It is understandable that an inspection from the HSE can cause

alarm but it is important to bear in mind that the objective of the

program is to assess, highlight and offer improvements in working

practices. Your lubricant supplier can also help and as such Q8Oils

can provide training and advice to improve working practices to

meet the HSE guidelines.

HSE Inspection

• Are control systems in place?

• Are there reasonable measures to reduce the exposure to MWF?

• Is there a fl uid management process in place?

• Are there records that show the MWF is under control?

The HSE is aware of the need to involve industry experts and is

heavily involved in working together with lubricant industry bodies

such as the UKLA as well as lubricant suppliers such as Q8Oils.

It is strongly recommended by most lubricant suppliers that full fl uid

condition monitoring program is carried out in accordance to HSE

guidelines & that records are kept for a minimum of 5 years.

Q8Oils QCare service includes training and advice to improve working

practices to meet the HSE guidelines. A proactive approach such as

implementing a fl uid condition monitoring program is highly recommended

as this demonstrates a record of your fl uid condition and whether it is within

acceptable limits.

Choosing the right product

It’s a smart solutions!

Read on for more details on QCare

Advice & MWF technical service

Whilst it is vitally important to install and maintain a fl uid management

program, it is also important to select the best product that combines

health & safety with performance and economy. Q8Oils offer a full range

of neat & soluble metalworking fl uids designed to provide the optimum

balance of safety and productivity through out the full life of the fl uid.

When choosing the best supplier, its all about the performance

of the product and the people. QCare delivers both.

3

Welcome to QCare Technical services and support for metalworking fluids & industrial lubricants

4

Training & technicalsupport

Q8Oils is well known for our industry-leading range of high-quality metalworking

fluids. But we are far more than just a manufacturer and pride ourselves on the high

level of support we offer our customers. Through our QCare service, we offer a wide

range of technical services to help you get the most from your Q8Oils products.

The risks involved in working with metalworking fluids is under the spotlight of the

Health & Safety Executive and we can guide you on the latest legislation and provide

support in how to use our products safely.

Our Technical Services team will work with you to optimise performance and resolve

any technical issues. We also offer training seminars and a range of high-quality

equipment solutions.

The Q8Oils brand of technical service is designed to help our customers get the most out of Q8 products, optimising your processes and ensuring a safe and operator-friendly working environment.

A dedicated on-site service where

an Industrial Application Specialist

manages your MWF’s in

the machine

Equipment to facilitate the

optimal use of MWFs and other

industrial lubricants

Knowledgeable expert advice

to guide and assist with any

problems and a dedicated suite of

on-site training packages

An experienced and knowledgeable

team that can advise and help you

meet national and international

health & safety requirements

Page 6

Page 16Page 14

Page 9 Page 12

Page 17

Performance testing to identify

wear, contamination and additive

levels of your MWF or lubricant

Working in collaboration with

our team of experts to deliver

product and equipment solutions

for process improvements

Fluid management

Equipment solutions

Health & Safetysupport

Q8 analyticalservices

What our customers say

QCare

5

As a leading manufacturer of metalworking fl uids, Q8Oils is

committed to supporting our customers in working safely with these

fl uids and ensuring you are aware of the latest legislation.

Health & Safety support

QCare

You must keep records in accordance with COSHH requirements:

Did you know?

Fluid monitoring checks and LEV maintenance

Records of exposure to hazardous substances and employee health records

5years

40years

6

You can achieve adequate control to exposure by:

• carrying out a risk assessment and identifyingmeasures to minimise exposure

• using the most appropriate product • providing adequate local exhaust ventilation (LEV) • conducting and recording a fl uid monitoring programme

Your duty of care

The Health & Safety Executive (HSE) has identifi ed that

exposure to metalworking fl uids can be hazardous to the skin,

eyes and more critically to the airways and lungs, potentially

resulting in serious respiratory diseases.

As an employer, you have a duty of care to take adequate

measures to protect your operators from this exposure. This is

enforced by law under The Control of Substances Hazardous

to Health Regulations (COSHH) 2002.

Helping you work safely with metalworking fl uids

In 2017 the HSE announced plans for a proactive inspection

programme for workers who are exposed to asthmagens and/or

carcinogens generated during production. A main area of focus is

metalworking fl uids.

The inspection checks ensure that control systems are in place,

that reasonable measures are being taken to reduce exposure

and the required records are kept.

HSE Inspection programme

How Q8Oils can help

Q8Oils works closely with the HSE. We are a key member of the

UKLA MWF Guidance Advisory Panel, which includes experts

from the HSE, health and safety laboratories and industry.

We can help you choose the most appropriate metalworking

fl uid for your application, balancing effi ciency, safety and offer

advice to help you comply fully with HSE regulations. We can

provide assistance with fl uid condition monitoring and give

general advice on applications, as well as help with responding

to any issues. We have produced a pocket guide to help you

understand the risks involved and the measures that should be

taken to manage them in accordance with HSE guidelines.

QCare

7

Not all the points are specific legal requirements, but each point can help employers

comply with the COSHH Regulations. If in doubt, contact your MWF supplier.

Following simple guidelines will help minimise the risks associated with exposure to MWFs. These steps will also help maintain fluid quality, which

will extend fluid life in protecting both the machine and finished parts, leading to a reduction in overall costs.

Guidance on the safe use of MWFs

General • refer to the Safety Data Sheet• conduct a risk assessment• maintain records of local exhaust ventilation,

fluid monitoring and employee health• regularly check for dermatitis and respiratory

problems and report symptoms promptly• store packages and drums correctly• provide training and instructions for employees in the safe use

of MWFs and correct use of Personal Protective Equipment (PPE)• use PPE when handling MWFs and when cleaning out machines

Machine operation • provide and maintain local exhaust ventilation • follow correct working procedures• allow a time delay before opening machine enclosures• ensure correct MWF flow and delivery• use machine guards and spray covers properly• observe good personal hygiene• avoid using compressed air

Fluid maintenance • ensure personnel responsible for MWF maintenance are trained• conduct regular monitoring of MWFs• record and act on the MWF condition monitoring results• use a refractometer to check the MWF is at the correct dilution• mix MWFs and top-up sumps correctly• keep the machine and surrounding area clean• keep the MWF tank covered• use filters to remove swarf and fines• remove tramp oil regularly using appropriate equipment

Cleaning • use a system cleaner compatible with the MWF• thoroughly clean sump, pipework, machine and

guards before re-filling with fresh MWF• use a clean reliable source of water

QCare

8

As a global supplier of soluble and neat MWFs, Q8Oils can advise

and assist you regarding the best way to install an efficient and

adequate fluid monitoring programme.

Various measurements are recommended to ensure the long-

term stability of a MWF. The table below highlights the most

important factors when considering the associated health risks.

Choosing the correct product with the right balance of safety and

performance is an important step in improving productivity and ensuring

the protection of employees.

It is important to understand that when in use the composition of a MWF

will change. This can include both chemical deterioration and contamination

(such as tramp oil) and also microbiological contamination.

It is therefore critical to monitor MWFs to maximise product performance

and ensure health & safety requirements are met. A full fluid condition

monitoring programme is the best way to achieve this.

Fluid management

QCare

Measurement How Frequency Comments

Fluid appearanceand general condition

Visual and odour Daily • does anything look or smell different?

Concentration Refractometer Minimum weekly • it is advisable to conduct a quick daily and record at least weekly

• check the concentration is within the recommended product parameters

• remember to always use the refractometer conversation factor when calculating the concentration

pH pH meterpH strips

Minimum weekly • check the pH value is within the recommended product use range

Microbiologicalcontamination

Dipslide Weekly unlessconsistently <104CFU/ml

• frequency can be reduced if previous results and other parameters (pH & concentration) demonstrate the fluid is under control

• there must be a record to demonstrate control

Tramp oil Measuring cylinder orvisual check

Minimum weekly • tramp oil should be kept to a minimum• when checking visually, a full layer of oil

would usually indicate >2%• use a tramp oil skimmer or absorbent mats

Conduct and record a fluid monitoring programme

9

On site analysis

Fluid M8QCare

Cancel

Refractometer pH pS Tramp Clear Dip N/A

Last Clean 19 July 2016

Save

Our fi eld based Industrial Application Specialists are on hand to help you minimise unscheduled

maintenance, increase coolant life and optimise performance, resulting in improved

productivity and reduced machine downtime.

QCare

10

Fluid M8 enables Q8Oils Industrial Application Specialists to monitor

fl uids, complete audits and deliver the results whilst still on your site.

Our specialists can assist you to identifying any problems and help

to correct them.

Once all checks are completed, a report will be displayed

demonstrating the current condition of the fl uid in each machine.

Traffi c-light system

streamline your metalworking

operation

signifi cantly reduce operating

costs

increase tool life

improve production rates

reduce coolant usage

improve operator acceptability

Our easy to follow reporting system helps you identify fl uid

condition and when to take action. All the results are displayed

using a simple traffi c-light system.

Fluid within recommended parameters

Caution: fl uid should be monitored further

and action may be necessary

Action required

The combination of highly-trained Q8Oils Industrial Application Specialists and Fluid M8 will enable you to:

You can log on to the Fluid M8 system using your own smart

phone, tablet or desktop computer and view a full historical report

at any time and share it with colleagues.

Fluid M8 is a user-friendly, fully-automated system using graphical

charts and reports showing the full history of each metalworking

fl uid system.

Fluid M8QCare

11

Analyticalsolutions

QCare

Oil analysis is the best tool for early detection of wear in

your machinery. Frequent analysis can help prevent serious

damage or breakdowns by showing what action you need to

take. Detecting problems early helps to avoid repair costs or

downtime, saving you money.

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Q8Oils Used Oil Test Analysis

Where further investigation is needed, or as

part of routine monitoring, samples can be

sent to a fully accredited laboratory which

uses advanced testing facilities to evaluate the

performance of your lubricant or MWF. Testing

suites include the latest organic and inorganic

spectroscopic techniques plus physical and

chemical properties which are critical in

providing a lubricant or fluid health check .

In addition to condition monitoring

and routine analytical testing,

Q8Oils’ global network of research

and testing facilities is designed for

more in depth investigative analysis

of all our lubricant product ranges.

This includes;

• analytical testing

• performance and tribology

• viscosity and rheology properties

• physicochemical properties

(TAN, TBN, flashpoint, water)

• organic spectroscopic (GC, HPLC, FTIR)

• inorganic analysis (ICP, AAS, XRF)

• thermogravimetric analysis (TGA)

• oxidation / ageing

• lubricant tribology testing

• microbiological analysis

• lubricity

• tapping Torque, Reichert, 4ball, Cameron plinth

• foam testing

• emulsion / hard water stability

• stain testing

• corrosion

• tramp oil splitting

• microbiological challenge testing

QUOTA

Other analysis Analytical testing Performance & tribology

You will receive a report with a detailed

analysis of your oil and any wear to your

machine. A traffic-light system – green

for normal, amber for caution and red for

serious – shows at a glance the condition

of your oil and we can recommend what

action you need to take.

Frequent oil analysis helps prevent

serious damage or breakdowns by

indicating what action should be taken

and how urgent the action is. QUOTA

provides preventative maintenance by

analysing problems statistically and

indicating their causes. This reduces

repair costs and avoids downtime.

monitors oil condition to predict

fluid lifecycle

helps to detect problems early

enables effective maintenance

planning

reduces operating costs

reduces machine downtime

Benefits

QCare

Established 50 years ago,

Q8Research is a world leader in

petrochemical and lubricant research.

Its activities encompass new product

development, specifications for products

and legislation compliance. Q8Research

also provides product testing, certification

and quality control services.

50years

ISO40+ TESTED

of petroleum research and development

ISO 9001, OHSAS 18001, ISO 14001 &

RC 14001 certified

scientists and support staff

Testing 50,000 samples and 350,000 analyses

every year

Research

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We appreciate that when you need technical

support, it must be fast and easy to access.

Whatever your query or problem, we offer a

range of options to give you expert advice.

Our highly-experienced fi eld based industrial technicians will help

you get the most out of our lubricants and MWFs. They can offer

guidance on the best product for your application and how to

work safely and in compliance with HSE regulations.

They work with you to increase the life of your tooling and

machinery, to reduce maintenance costs and ultimately

increase profi tability.

Whatever your problem or query, our expert team is there to

provide support to you.

Our technical experts can recommend the best product for

your application, verify OEM approval of our products, provide

product information, give guidance on health and safety – and

much more.

Q8Oils Industrial Application Specialists

Technical Help Desk

T: 0113 236 5223E: techdesk@Q8Oils.com

Open Monday to Friday: 08:30 to 17:00

Training & Technical support

QCare

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Q8Oils Hub is a blog platform that keeps you

in touch with the latest developments in the

industry. Our blog is regularly updated with articles

related to the metal manufacturing, automotive,

general industry and energy sectors. Our technical

experts share their knowledge with you and offer

advice. We will also tell you about new Q8Oils

products that could benefi t you.

It is a great way to keep up to date and fi nd

out more about important topics.

HUB

Customer training

We offer a range of training seminars, each run by an experienced Q8Oils technical

specialist, to help you work safely and effi ciently with metalworking fl uids.

Training can be catered to your individual needs and delivered on site.

Introduction to MWFs

• what are metalworking fl uids?

• metalworking fl uid types

• functions of a metalworking fl uid

• summary of MWF composition

• application of MWFs

• MWF selection criteria

• impact of legislation on MWFs

Guide to working safely with MWFs

• the risks associated with exposure to MWFs

• HSE legislation

• MWF condition monitoring and guidance

• MWF maintenance and machine

cleanout guidance

Q8Oils equipment solutions

• advice and guidance on equipment solutions

• accurate mixing systems

• tramp oil removal

• low cost MWF reclaim

• swarf removal / fl uid cleaning

• oil fi ltering

• swarf processing

• water treatment

Seminars include:

QCare

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At Q8Oils we are much more than just an industrial lubricant supplier.

With a comprehensive inventory of equipment solutions and dedicated technical

personnel, we can further support your operations in optimising process effi ciency.

Equipment requirements are often overlooked, which can be counter productive to

the safe use of MWFs.

Another important factor is the signifi cant benefi t that correctly selected

equipment can bring to your process, by reducing costs and waste generation.

Smart equipment solutions go hand in hand with manufacturers working to

implement effective environmental management systems such as ISO14001 and

OHSAS 18001. Q8Oils can recommend, assist and supply equipment suitable for

monitoring and maintaining MWFs. From mixing units to fl uid recycling systems

we have a solution for every scenario.

Fluid management control kit

Measures pH level, indicating

the chemical acidity or

alkalinity on a scale of 1-14

The most frequently used method of

measuring microbial activityDetermines the

concentration of the

metalworking fl uid

Incubates dipslides at

controlled temperatures for

accurate results

Manufacturing equipment from Q8Oils

Below, we recommend equipment suitable for meeting the minimum

fl uid monitoring requirements advised by the HSE.

Refractometer DipslidespH indicator strips Incubator

QCare

Equipmentsolutions

Mixer unit

Easily and accurately dispenses MWFs

with built in WRAS-approved backfl ow

prevention

Soluble MWF mixer unit

Machine cleaning and waste management

Vacuum Equipment

Rapidly removes and regenerates MWFs

from machine tool sump systems

Fluid maintenance

Tramp oil removal (Skimmer)

Combats the problems associated

with tramp in machine tool coolant

systems

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Many of our customers benefi t from the wide-ranging support

that Q8Oils provides.

What our customers say

QCare

“The product selection is key as it has to suit the application and with the Q8Oils technical team this is always assured. Additionally we are able to give our customers peace of mind because the QCare service offers condition monitoring, health & safety advice and on-site technical support. Basically it’s a full support service, with highly-trained Q8Oils engineers. Not only do we get the correct product for the application, we make sure it stays that way with QCare.”

Paul Fairbrother, Sales DirectorFair Hydraulics & Pneumatics

“We receive regular technical support from our Q8Oils Industrial Application Specialist who works with our operators to ensure they are using products correctly and that we are optimising usage to extend product life.”

Charles Smith, Machine Shop ManagerTechnoturn Limited

“We have been supplied by Q8Oils for a number of years. We have always received excellent technical service from our Q8 Industrial Application Specialist – this service covers condition monitoring, health & safety, onsite technical support and advice. Q8Oils has recommended products, provided our management and operators with training programmes, consultation in regards to HSE matters and helped when we were in need of equipment. We believe in the value of QCare which helps to increase the life of our machinery, reduce maintenance costs and ultimately increase profi tability.”

George Corbett, General ManagerBelmar Engineering Service

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Q8 Brunel metalworking fluids deliver the very best in performance with superior

wetting, anti-wear and extreme pressure characteristics. They maximise cooling, resist

foaming, improve tool life and component surface finish, whilst protecting sensitive

material grades such as aerospace aluminium alloys.

Q8 Brunel is fully compliant with European environmental and chemical legislation and

is free from:

• boron

• chlorinated paraffin

• formaldehyde releasing biocides

• boric acid

• secondary amines

• nitrites

To help our customers achieve their technical and environmental targets, the Q8 Brunel

range is extensive, ensuring a solution for every application.

Q8 BrunelProduct Type

Oil Content

High oil

Medium oil

Low oil

Non Oil

Ester based

PAG based

Fully synthetic

Applications

Grinding

Milling

Turning

Deep hole drilling

Skiving & Roller burnishing

Broaching

Forming

Materials

Carbon steel

Cast iron

Stainless steel & Nickel alloy

Aerospace aluminium

Aluminium

Copper / Copper alloys

Titanium

Tungsten carbide

Hard / Super alloys

Composites

Emulsion appearance

Refractomer factor

pH @5% in D.I. water 9.1 9.4

2.10 1.50

9.0

1.20

9.2

1.30

9.0

0.80

9.6

0.90

9.2

1.60

9.2

2.40

9.6

1.50

9.4

1.50

9.3

2.00

Translucent Translucent Semi-translucent Semi-translucent Milky white Tight milky white Semi-translucent Yellow solution Colourless solution Colourless solution Colourless solution

Lubricity

Q8 Brunel XF 111

Q8 Brunel XF 132

Q8 Brunel XF 263

Q8 BrunelXF 343

Q8 Brunel XF 277

Q8 Brunel XF 280

Q8 Brunel XF 450

Q8 Brunel XF 442

Q8 Brunel XF 527

Q8 Brunel XF 530

Q8 Brunel XF 575

Our metalworking fluids are the result of more than 100 years of product development and

application experience. Our chemists and product engineers take a unique, innovative and

progressive approach to developing different grades for different applications. We develop

smart products that extend tool life and significantly reduce operating costs, while staying

a step ahead of the new demands arising from higher fluid pressures, faster cutting speeds,

new materials and tool technologies.

Q8 Brunel

Soluble MWF product range

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Q8 BerliozProduct Type

Oil Content

High oil

Medium oil

Low oil

Non Oil

Ester based

PAG based

Fully synthetic

Applications

Grinding

Milling

Turning

Deep hole drilling

Free from

Chlorine

Formaldehyde

Secondary amine

Skiving & Roller burnishing

Broaching

Forming

Materials

Carbon steel

Cast iron

Stainless steel & Nickel alloy

Aerospace aluminium

Aluminium

Copper / Copper alloys

Titanium

Tungsten carbide

Hard / Super alloys

Composites

Emulsion appearance

Refractomer factor

pH @5% in D.I. water 9.8

0.90

9.4

1.50

9.5

2.30

9.3

1.60

9.1

1.00

9.3

1.30

9.4

1.00

9.3

2.00

9.6

2.30

Milky white Semi-translucent Translucent Translucent Tight milky white Semi-translucent Tight milky white Yellow solution Colourless solution

Lubricity

Q8 Berlioz XMR

Q8 Berlioz XAD

Q8 Berlioz XRC

Q8 Berlioz XVP

Q8 Berlioz XVH

Q8 Berlioz XMA

Q8 Berlioz EPS

Q8 Berlioz XHS

Q8 Berlioz XRS

Q8 Berlioz is a full range of soluble metalworking grades designed to balance

the latest European legislation requirements with performance. Q8 Berlioz is a full

compliment of products which encompasses the latest in additive technology and

designed to cover every application.

• Free from formaldehyde, secondary amines & chlorinated additives*.

(except Q8 Berlioz EPS)

• Fully compliant to TRGS 611 legislation.

• Covers a full range of applications & materials from economical to high

performance.

• Demonstrates low foaming and stability in all water hardness.

• Superior bio-stability and corrosion protection.

Q8 Berlioz

Marian House, Colton MillBullerthorpe Lane, Colton, Leeds LS15 9JNTel: +44 (0) 113 235 0555Email: Marketing@Q8Oils.comwww.Q8Oilshub.co.ukwww.Q8Oils.co.uk

Customer Service:Tel: +44 (0) 113 236 5204Email: customerservices@Q8Oils.com

Technical Help Desk:Tel: +44 (0) 113 236 5223Email: techdesk@Q8Oils.com

Apr

il 20

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