What is a Chip Management System?
A chip management system is designed to collect, separate and manage metal swarf (also known as metal shavings or machining chips) generated during milling, turning and drilling operations.
Swarf is the waste material produced when metal is cut or machined. Without proper swarf management, chips can:
- Block coolant systems
- Damage pumps
- Reduce coolant pressure and flow to the machine
- Cause machine downtime
- Create handling and recycling challenges
An effective chip management system controls the movement of swarf from the point of production through to collection in swarf bins, while maintaining coolant cleanliness and supporting metal swarf recycling processes.
FSE offer two principle types of Media Free Chip Management
FSE IAD Chip Management System
For chipped and broken free flowing swarf
FSE DCAD Chip Management System
For mixed swarf including stringy, bushy and chips
IAD Chip Management System
The FSE IAD (Integrated Auto Drum) is a media free Chip Management System designed to suit chipped and broken free flowing swarf of multiple material types. The combination of scraper conveyor and stainless steel filter drum provides a robust filtration system suitable for 24/7 operating.
This cost effective filtration solution provides clarification levels between 20 and 50 Micron on a self cleaning fully automatic basis. The result is cleaner coolant, controlled swarf disposal and improved machine reliability.
How the IAD Chip Management System works
The IAD integrates two core technologies into one compact module:
1. Scraper Conveyor System
Designed to transport chipped and broken free-flowing swarf from the machine tool sump efficiently into designated metal swarf bins.
2. Stainless Steel Auto Drum Filtration
A self-cleaning rotating drum provides coolant clarification between 20–50 microns without the need for disposable filter media.
As coolant passes through the drum, fine particles are removed while cleaned coolant is returned to the machine. The automatic cleaning cycle ensures uninterrupted operation — ideal for high-output machining centres.
For higher stock removal applications requiring greater clarification, FSE also offers:
CAD (Conveyor Auto Drum Module) – the FSE CAD system delivers excellent filtration down to 20 microns, designed for high-coolant-flow applications exceeding 350 L/min.
DCAD Chip Management System
The FSE DCAD (Dual Conveyor Auto Drum) is an advanced chip management system engineered to process both stringy/bushy swarf from turning applications and chipped/broken swarf from milling operations all within one integrated unit.
Designed and manufactured by Filtration Service Engineering (FSE), the DCAD combines a heavy-duty primary conveyor with a secondary scraper conveyor and self-cleaning auto drum filtration, delivering reliable swarf management and coolant clarification for complex machining environments.
Ideal for multitasking CNC machines and mixed production facilities, the DCAD provides continuous, media-free filtration for 24/7 operation while maximising machine uptime and protecting coolant systems.
How the DCAD Chip Management System works
The DCAD uses a dual-stage approach to swarf and coolant separation:
1. Primary Heavy-Duty Steel Belt Conveyor
The first stage removes stringy or bushy swarf typically generated in turning operations. The heavy-duty belt design prevents entanglement and ensures reliable chip evacuation into metal swarf bins.
2. Secondary Scraper Conveyor with Auto Drum Filtration
Any smaller chips or fines that pass through the primary stage are removed by the secondary scraper conveyor. Integrated within this stage is a stainless steel self-cleaning auto drum that filters coolant down to 50 microns.
The automatic drum continuously removes contamination without disposable filter media, ensuring uninterrupted coolant clarification and improved machine protection.
This dual conveyor design makes the DCAD ideal for multitasking machines where chip form can vary significantly during production.
Benefits of the IAD & DCAD Chip Management System
Implementing a dedicated swarf management system provides significant operational and financial benefits:
- Improved Coolant Performance
- Cleaner coolant improves tool life, machining accuracy and surface finish.
- Reduced Machine Downtime
- Prevents swarf build-up that can block pumps, pipework and coolant flow.
- Lower Maintenance Costs
- Media-free filtration reduces consumable costs and servicing frequency.
- Efficient Swarf Handling
- Improved collection into swarf bins simplifies disposal and enhances metal swarf recycling opportunities.
- 24/7 Reliability
Engineered for continuous operation in demanding production environments.
Contact us via email at sales@fse.co.uk or call us on 01562 60233
Chip Management Systems supplied, installed and supported by FSE
All Chip Management Systems are designed and manufactured in-house by FSE at our Midlands facility.
FSE provide:
- Full system specification
- Bespoke integration with machine tools
- Swarf bins and material handling solutions
- Coolant filtration integration
- Ongoing service and technical support
Whether you are installing a new milling or multitasking machines or upgrading an existing conveyor system, FSE can engineer a solution tailored to your production environment.
FSE delivers complete UK-wide support including:
- Technical consultation and application review
- Professional installation
- Integration with existing coolant systems
- Service and preventative maintenance
- Long-term technical backup
Our engineers ensure your chip management system is correctly specified to handle your swarf type, production volume and filtration requirements.
Contact us via email at sales@fse.co.uk or call us on 01562 60233
Chip Management & Coolant Filtration solutions from FSE
Whether you are replacing an existing system or upgrading your existing coolant management & filtration solutions FSE can help.
To speak to the FSE team today about chip management & coolant filtration solutions to suit your business, contact us at sales@fse.co.uk or 01562 60233 or by using our online enquiry form.
Frequently asked questions about Chip Management Systems
Poor swarf management can lead to:
- Blocked coolant systems
- Reduced filtration efficiency
- Pump damage
- Increased downtime
- Reduced recycling value
A properly specified chip management system improv
The main difference is what swarf can be handled.
- IAD (Integrated Auto Drum) is ideal for chipped and broken free-flowing swarf.
- DCAD (Dual Conveyor Auto Drum) is designed for mixed applications where both stringy swarf (turning) and broken swarf (milling) are produced.
The DCAD uses a dual conveyor system, making it the preferred solution for multitasking CNC machines.
After large swarf is removed by the primary conveyor, coolant passes through a stainless steel rotating auto drum filter.
The filter drum:
- Filters coolant to 20–50 microns
- Removes fines and smaller metal particles
- Self-cleans automatically
- Operates without disposable filter media
This ensures consistent coolant clarity and reduced maintenance costs.
Multitasking CNC machines generate varying chip forms during a single production cycle. Without proper swarf management:
- Chips can accumulate and block coolant systems
- Pumps may become damaged
- Filtration efficiency may decrease
- Machine downtime increases
A dual conveyor chip management system ensures continuous chip evacuation and stable machining performance.
Media-free systems, such as the IAD, use a stainless steel rotating filter drum rather than disposable filter paper or cartridges. As coolant passes through the drum:
- Fine particles are captured
- Clean coolant returns to the machine
- The drum self-cleans automatically
This reduces consumable costs and allows for fully automatic 24/7 operation.
Aluminium swarf is typically light, free-flowing and produced in high volumes, especially in high-speed machining applications. The best filtration system for aluminium swarf should:
- Handle fine, broken chips efficiently
- Provide reliable coolant clarification
- Prevent pump wear and clogging
- Operate continuously in high-output environments
The FSE IAD (Integrated Auto Drum) system is particularly well suited to aluminium swarf applications. Its scraper conveyor and stainless steel self-cleaning drum provide consistent filtration between 20–50 microns without disposable media, making it ideal for aluminium machining environments. For higher stock removal rates requiring enhanced clarification, the CAD module may also be recommended.
Stringy or bushy swarf is commonly generated during turning operations and can easily wrap around pumps or block standard conveyors.
The best system for stringy swarf must:
- Prevent entanglement
- Handle mixed chip types
- Maintain consistent coolant flow
- Operate reliably in 24/7 production
FSE’s DCAD (Dual Conveyor Auto Drum) system is specifically designed to manage both stringy swarf from turning and broken swarf from milling. This makes it the ideal solution for multitasking machines and facilities running mixed applications.
By separating swarf and fines efficiently, the system will:
- Extend coolant life
- Improve tool life
- Maintain machining accuracy
- Reduce contamination
Cleaner coolant results in more stable machining processes and lower overall operating costs.
Not exactly. Chip management focuses on the collection, separation and handling of swarf and coolant within the production environment.
Swarf recycling refers to processing recovered metal for resale or reuse.
An effective chip management system improves the quality and value of swarf sent for recycling by reducing fluid contamination.
Yes. But it must be correctly specified.
The FSE IAD and DCAD systems are designed to handle multiple material types and varying chip forms, including:
- Aluminium
- Steel
- Cast iron
- Mixed production environments
For facilities running both milling and turning applications, the DCAD configuration offers maximum flexibility.
Yes. The DCAD is designed to manage:
- Stringy/bushy swarf
- Chipped/broken swarf
- Mixed material production
- Multitasking CNC operations
This makes it ideal for modern machining centres that combine turning and milling in one machine.
Yes. By separating coolant efficiently and reducing fluid carryover, the DCAD system produces cleaner swarf. This supports more efficient metal swarf recycling and results in cleaner, drier swarf which is easier to handle and more valuable for recycling.
The DCAD is suitable for a wide range of materials, including:
- Aluminium
- Steel
- Stainless steel
- Cast iron
- Mixed production environments
Correct system specification will depend on chip volume, machine type and coolant flow rates.
Yes. The DCAD is designed for continuous operation in high-output machining environments. Its heavy-duty construction and media-free filtration system minimise maintenance requirements while maximising machine uptime.
Yes. FSE can integrate the DCAD system into new or existing machine tool installations, ensuring compatibility with your current coolant filtration and swarf handling processes.
