FAQ's

How does Predator control bacteria and fungus?

The Predator element consists of precision-machined copper-zinc fibers densely wound within a stainless steel cartridge. In the presence of an electrolyte (water), the dissimilar metals undergo a natural oxidation-reduction (redox) reaction. Redox reactions involve the transfer of electrons from one molecule to another. This fluctuation in redox potential inhibits the growth and reproduction of most strains of bacterium and fungus.

How does Predator control odor?

Hydrogen sulfide, a byproduct of bacteria colonies, is responsible for the rotten egg odor frequently emitted by contaminated coolants. Hydrogen sulfide gains an electron in the redox reaction, thus becoming cupric sulfide. This odorless compound is easily flushed from the filter element. By eliminating both hydrogen sulfide and its cause—bacteria—Predator controls odor.

How does Predator reduce heavy metals and inorganic contaminants?

Lead, arsenic and other heavy metals are plated out in a similar fashion to hydrogen sulfide, gaining and losing electrons to the redox reaction.

In what applications can Predator be used?

Predator can be used to control bacteria and fungi in almost any application that uses re-circulating water or a water-based fluid. Predator is most often used in metalworking / cutting tool applications, but can also be applied to boiler systems, cooling towers, chillers, car washes, ornamental fountains and well water distribution systems. It is also effective as a pre-treatment to reverse osmosis (R.O.) or membrane water treatment systems.

How do I monitor microbes (bacteria, yeast, mold and fungi) in my fluid?

At its most basic, monitoring fluid contamination means smelling and visually inspecting a fluid. A foul smell is the most obvious indicator of bacterial presence. Visible discoloration also suggests contamination, whether microbial or otherwise. By the time bacterial contamination is apparent to the human senses, however, it is often too late to control. Replacing tainted fluid will temporarily improve conditions, but without thorough cleaning, bacteria and fungi will remain on the walls and components of a system. These residual microbes will quickly repopulate the system once fresh fluid is replaced. Rather than ridding yourself of microbial contamination, you are simply supplying the microorganisms with a fresh and costly supply of food. The next step up from sensory monitoring is to use a dip-slide. These small, inexpensive kits consist of a plastic slide coated with a sterile culture medium (food source). They can be purchased from Avalon International (www.bugcheck.us). The Bugcheck BF slide kit reveals both bacterial and fungal contamination in industrial fluids. The slide is dipped in the fluid to be tested and set aside. Within 24 hours, microorganisms will have incubated on the culture medium. One side of the slide shows results for bacteria, the other for fungi, molds and yeasts. By comparing your slide with charts provided with the slides, you can estimate your bacterial/fungal count and take any necessary action. The count is expressed in terms of colony forming units (CFU) per milliliter (mL) of fluid. For more details view Metalworking & Fluids Bacteria (PDF)

What is an acceptable bacterial/fungal count?

The chart below shows appropriate measures for a given count (x).

Bacterial/Fungal Count (CFU/mL) Recommended Action
x < 103 GOOD CONTROL
Bacteria/fungi are being maintained at low levels. No further action is required.
103 < x < 106 REASONABLE CONTROL
Review control measures to ensure bacteria/fungi levels remain under control. Risk assessment should specify action to be taken. Biocides and/or cleaning may be indicated. If biocides are used, expert advice should be sought, and the concentration of biocides should be monitored.
x > 106 POOR CONTROL
Immediate action should be taken in line with the risk assessment. Normally, very high levels necessitate draining and cleaning of the system.

Will Predator work with my coolant?

As mentioned, Predator works with almost all water-based fluids. This includes the majority of machine tool coolants. All that is needed is an electrolyte (water) to facilitate the electron transfer. Biocides, on the other hand, are generally compatible with only a narrow range of cutting fluids. You should consult your fluid manufacturer before mixing a coolant with any biocide.

How often / when do I have to replace my Predator element?

This will depend on the specific application. Under typical metalworking conditions, elements must be changed every six to nine months. In a relatively clean system (boilers or groundwater supply systems), the element can last much longer. Dirt buildup can impede the electron transfer which forms the mechanism by which Predator controls microbial contamination. In order to prevent buildup, we usually recommend using a pre-filter. Regular washing (preferably every two weeks) can also prevent dirt buildup, thereby ensuring proper lifespan. The element should also be washed when bacterial/fungal count begins to climb. When washing the element fails to bring down the bacterial/fungal count, it is time to change the element.

How do I wash the element?

A clean water rinse will generally suffice, although a pressure wash is preferred. As mentioned, this procedure should be performed every two weeks, or when bacterial/fungal count begins to climb.

Why bother worrying about bacteria and fungus?

Industry often ignores the potentially hazardous effects of microbial contamination. Aside from generating a foul odor, the bacteria found in metalworking fluids have been linked to a range of health problems. These include skin disorders like dermatitis and lung conditions such as asthma and hypersensitivity pneumonitis (HP). The traditional method of combating bacteria in industrial fluids—antimicrobial chemicals called biocides—poses its own health risks. In fact, it is often difficult to say whether a particular health condition stemming from exposure to machine tool coolants has been caused by bacteria or the biocides used to fight them. Closed water heating and cooling systems are also prone to the development of bacteria and fungi, particularly legionella pneumophila (Legionella), the bacterium responsible for Legionnaire’s Disease. These organisms pose a significant health risk, particularly to those with compromised immune systems. For this reason hospitals are now taking greater measures to prevent Legionella reproduction in their circulating water systems. Bacteria and mold also impede performance. Mold and bacteria form slimy deposits called biofilm. Biofilm buildup on the surface of cooling towers and condenser coils inhibits heat exchange and accelerates scale formation. In the case of metalworking fluids, bacteria and mold reduce finish quality and erode coolants. Additionally, microbes degrade fluid effectiveness, necessitating frequent disposal and replacement of fluids.

Will Predator interfere with system pressure / flow rate?

In systems where flow rate might be adversely affected, Predator can be installed offline.

Does Predator completely eliminate the need for biocides?

In some cases, Predator obviates the need for biocides altogether. However, Predator generally reduces dependence on biocides rather than eliminating it.

Who is using Predator?

Predator has rapidly gained acceptance at a range of manufacturing facilities, from small machine shops to major automotive plants. Honda, Daimler-Chrysler and GM are all solving their bacteria problems with Predator.

What is the advantage of Predator over other non-chemical fluid treatments?

Unlike competing devices, Predator does not require cumbersome and costly maintenance programs. Installing, monitoring and caring for Predator are hassle-free procedures that are easily integrated into any proactive maintenance program.