From Tool Life to Holistic Process Optimization

Maschinen- & Anlagenbau Prinzing (MAP) relies on Zeller Gmelin for machining—and benefits from process stability, longer tool life, and greater efficiency.

Gingen an der Fils / Eislingen – Precision, process reliability, and customized solutions are part of everyday business at Emil Prinzing & Söhne GmbH & Co. KG. The family-owned company, headquartered in Gingen an der Fils, has more than 60 years of experience in mechanical engineering and is better known in the market as Maschinen- & Anlagenbau Prinzing (MAP). As a system supplier, MAP develops and manufactures sophisticated components and assemblies—from design through production.

A distinctive feature is the mineral cast material offered under the DUROPOL brand, which MAP manufactures in its own foundry. This material is used to produce custom machine beds and clamping plates. The portfolio also includes machine enclosures, control panels, custom control cabinets, welded structures weighing up to 60 metric tons, and components manufactured using modern sheet metal technology.

The high level of vertical integration places special demands on the processes. In milling operations, MAP achieves tolerances of up to 0.005 mm per meter. This makes reliable lubrication systems all the more important—systems that not only support the machining process but can also be integrated into subsequent process steps.

With stainless steel, the requirements increase

For a long time, MAP primarily milled components using dry machining. As the company became increasingly involved in stainless steel machining, the topic of coolant came more into focus.

“In recent years, we have become increasingly involved in stainless steel machining. To extend tool life, we have tested a wide variety of approaches, and the coolant itself was also put to the test,” reports Hans Prinzing, managing director of Emil Prinzing & Söhne GmbH & Co. KG.

In MAP, lubricants affect tool life, surface quality, and machining reliability. At the same time, they must take subsequent processes into account: Many components are subsequently painted or chemically coated externally. Residues of cooling lubricants must therefore be reliably removable. In addition, reliable corrosion protection is required between manufacturing steps.

“Lubricants are an important part of a stable manufacturing process for us,” explains Lars Prinzing, Junior Manager at MAP. “In machining, they ensure long tool life, high surface quality, and reliable machining—whether milling, drilling, or threading.”

Zeller Gmelin analyzes the process

In its search for ways to optimize operations, MAP had not received the desired support from its previous cooling lubricant supplier. During his very first visit, Thomas Schmid—the Zeller Gmelin sales representative responsible for MAP at the time—conducted a detailed analysis of the production process and asked numerous questions about the existing processes.

“From the very beginning, we had the impression that this wasn’t just about selling a product, but about truly understanding our processes,” said Lars Prinzing, managing director of Emil Prinzing & Söhne GmbH & Co. KG.

This approach convinced MAP. Today, Zubora 60 H Ultra is used in machining. In addition, the company uses Divinol T 6 EP ISO 68 and Divinol GWA ISO 32 as hydraulic, transmission, and ways oils. Mergal is used as a bactericide and Zubora RF as a system cleaner. Other applications, including cleaners for the wet paint shop and products for the mineral casting sector, are currently being evaluated.

A Seamless Transition with Measurable Added Value

Zeller Gmelin provided comprehensive support throughout the coolant change. In addition to collecting the relevant process data, water samples were analyzed in the laboratory, and MAP was consulted on the cleaning of tanks and machinery.

“The MWF changeover went completely smoothly,” reports Lars Prinzing. “As a result, major production interruptions were virtually avoided during the fluid change.”

The results were also impressive. The initial focus had been on improving tool life. Additional benefits became apparent during operation.

“Looking back, the switch was definitely the right decision for us,” says Lars Prinzing. “Originally, we just wanted to improve tool life. But we actually found that bath life has also increased and the overall maintenance effort has decreased.”

Regular laboratory tests and service visits help MAP monitor the condition of the coolant and maintain stable processes. Training sessions led by Zeller Gmelin field service representative Julian Butz round out the support.

“The regular lab tests and training sessions led by our designated ADM, Julian Butz, provide us with added value that we didn’t have before,” emphasizes Lars Prinzing.

A Partnership with an Eye Toward the Future

For MAP, one thing is clear: What matters is not just the quality of a lubricant, but the combination of the product and technical support.

“What we value most about this partnership is the expert and solution-oriented support. Our contacts are easy to reach, have a wealth of technical expertise, and regularly provide us with on-site support,” says Lars Prinzing.

This support will continue to grow in importance as we look to the future. In the face of international competition, MAP must combine technologically advanced products with high manufacturing quality and efficient processes. At the same time, the demands on materials, machining processes, resource efficiency, and tool life are increasing.

For Hans Prinzing, collaborative partnership is a key factor in success: “Just as we advise our customers and support them in further developing their products, Zeller Gmelin also works with us as a partner. The technical support and our shared perspective on our processes provide us with real added value. It’s important to us that we can develop solutions together and continuously improve our manufacturing,” he explains.

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