DMG MORI Introduces Adaptive Coolant Flow to Cut Energy Use and Boost Machining Efficiency!

DMG MORI has unveiled its latest innovation in sustainable machining technology with the launch of Adaptive Coolant Flow, a system designed to automatically regulate coolant usage during machining processes. The solution focuses on reducing unnecessary energy consumption and CO₂ emissions while maintaining high levels of machining performance, tool life, and surface quality.

In conventional machining environments, high-pressure coolant systems typically operate at maximum output regardless of actual requirements. This often leads to excessive coolant usage, wasted energy, and increased operational costs. Adaptive Coolant Flow addresses this inefficiency by dynamically adjusting coolant flow based on the specific cutting tool and machining conditions. By delivering only the required amount of coolant at the right pressure, the system optimises resource usage without compromising productivity.

At the core of the solution are two integrated components: intelligent software that calculates and regulates the optimal coolant flow rate, and a dedicated control unit mounted directly on the coolant tank. This combination allows real-time adjustments during machining, ensuring that coolant delivery is always aligned with process demands. As a result, the system significantly reduces unnecessary load on high-pressure pumps.

According to DMG MORI, Adaptive Coolant Flow can cut energy consumption of coolant pumps by more than 80% compared to traditional systems. This reduction translates not only into lower energy costs but also into a meaningful decrease in carbon emissions, supporting manufacturers in achieving their sustainability goals.

The system also incorporates advanced engineering enabled by additive manufacturing. Key high-pressure piping components—difficult or impossible to produce using conventional machining—are manufactured using metal additive processes on DMG MORI’s Lasertec 30 SLM platform. This allows for a compact and highly efficient design that integrates seamlessly into the coolant tank, improving pressure control and system responsiveness.

In addition to energy savings, Adaptive Coolant Flow enhances overall shopfloor conditions. Built-in sensors continuously monitor critical parameters such as flow rate, pressure, coolant concentration, and temperature. This data is displayed in real time via DMG MORI’s Ergoline X interface with Celos X, providing operators with full visibility and control over the machining environment.

Another important benefit is the reduction of coolant mist and evaporation in the machining area. By optimising flow and minimising excess usage, the system decreases total coolant consumption, leading to fewer refills and lower maintenance requirements. This contributes to improved workplace conditions and more stable operations, particularly in automated or lights-out manufacturing scenarios such as overnight or weekend production.

With Adaptive Coolant Flow, DMG MORI is addressing a critical intersection of productivity and sustainability. The solution not only enhances machining efficiency but also supports manufacturers in reducing their environmental footprint—an increasingly important factor in today’s competitive and regulation-driven industrial landscape.