Effect of Waste Micro-Particles on Metalworking Fluid Efficiency and Biodegradation During the Cutting Process

This study investigates contaminants in metalworking fluids (MWFs) from an industrial band saw, focusing on microparticle classification and microbial quantification linked to fluid degradation. Most particles were under 50 µm, primarily aluminum and iron oxides from tool wear; oxygen- and sulfur-containing particles suggested corrosion. Microbiological analysis showed high contamination, with culturable microorganisms exceeding 1000 CFU/mL. A pathogenic strain associated with biodeterioration was identified, underscoring the need for microbial control. Filtration and ozonation have been used as decontamination methods to improve the purity and biological stability of the process fluid. Filtration enabled selective removal of metallic microparticles. Among six nanofiber filters, the Berry filter achieved the highest efficiency (70.8%) for particles ≥ 7.3 µm, while other filters were faster but less efficient. Ozonation proved highly effective for microbiological decontamination, reducing viable microorganisms by over 95%, improving visual clarity, and lowering pH from 9 to 8 while remaining within operational limits. Unlike filtration, ozonation significantly reduced microbial load. The combination of both methods is proposed as a sustainable strategy for maintaining process fluid quality under industrial conditions. These findings support integrated decontamination approaches to extend fluid life, reduce fresh MWF consumption and waste, and enhance workplace hygiene and safety in machining operations.