Behind the innovations: HRE Automation

ESTHER VELASCO JUANES – Gerente de HRE AUTOMATION
ESTHER VELASCO JUANES - Manager of HRE AUTOMATION

Advanced Manufacturing – What was the motivation for developing this product?

Esther Velasco: At HRE Automation, we have been developing solutions in the field of fluid automation for over 40 years. Historically, we are an innovative company and have undertaken more than 20 R&D&i projects in collaboration with technology centers and universities since 2006. The great success of this project is that we have brought it to market.

The motivation to develop BeCold arose from our vision of a future where machining is intrinsically ecological and sustainable—a standard that new generations will adopt without question. We identified three key challenges in current machining processes: high production costs, negative environmental impact, and health risks for workers due to the use of cutting fluids and oils.

BeCold was created in response to these needs, aligning with our trajectory of sustainable solutions and circular economy principles based on the three R’s: Recover, Recycle, and Reuse. This approach has led us to design a system that drastically reduces the carbon footprint by eliminating traditional cooling systems and replacing them with a cleaner, more efficient, and environmentally friendly solution. We firmly believe that initiatives like this are essential for transforming the industry toward more sustainable and responsible models.

HRE Automation

AMM – Can you tell us about the process of developing the product? Any anecdotes or obstacles you encountered along the way?

E. Velasco: The development of BeCold began in 2014 with an initial research phase, but it wasn’t until 2019 that its industrialization was solidified. This project, a result of close collaboration with TECNALIA and UPV/EHU, combines Minimum Quantity Lubrication (MQL) systems with biodegradable oils and cryogenic cooling using recycled CO₂, offering a sustainable solution for machining.

One of the biggest challenges was designing a system compatible with both new machinery and existing equipment, which required developing specialized tool holders to prevent dry ice from forming in the conduits. This tested our capabilities across all company areas, from R&D Engineering to Manufacturing, and showcased the effectiveness of collaboration between private and public entities in achieving innovative and efficient outcomes.

At HRE Hydraulic, we hold the exploitation license, have industrialized the prototype, and launched it to the market. We’ve successfully sold units in countries like Poland and Japan.

AMM – What technology underpins this innovation?

E. Velasco: BeCold combines two key technologies:

  1. Minimum Quantity Lubrication (MQL): A system that uses minimal amounts of biodegradable lubricant in aerosol form, significantly reducing oil consumption.
  2. Cryogenic cooling with CO₂: This employs recycled carbon dioxide to efficiently and cleanly cool cutting tools and machined parts. When the gas expands, it reaches temperatures as low as -78°C, improving tool lifespan and machining quality.

The system is also modular and adaptable (plug & play), allowing for easy installation on existing machines with minimal modifications.

AMM – What are the main advantages of this innovative product? What needs does it address, and how can it improve companies’ operations?

E. Velasco: BeCold provides benefits in four key areas:

  • Economic: Reduces operational costs by minimizing cutting oil consumption, shortening machining times, and extending tool life.
  • Environmental: Virtually eliminates oily waste and minimizes the carbon footprint by using recycled CO₂.
  • Occupational health: Enhances workplace safety by eliminating harmful substances such as biocides and toxic mists associated with traditional cutting fluids.
  • Productive efficiency: Increases cutting speed and reduces tool wear, boosting productivity.

These advantages make BeCold an ideal solution for companies aiming to be more competitive and sustainable.

AMM – Which industries is this innovation primarily targeted at?

E. Velasco: BeCold is aimed at sectors that use machining processes, particularly for materials that are difficult to machine, such as titanium or advanced alloys. Target industries include:

  • Aerospace
  • Medical (prosthetics and devices)
  • Automotive
  • Naval
  • Rail
    We are also exploring applications in machining plastics, polymers, and wood, where cryogenic cooling has demonstrated significant benefits.

AMM – What are the main challenges faced by a company developing an innovative product?

E. Velasco: Developing an innovative product like BeCold involves overcoming several obstacles, especially for an SME like HRE, which has a team of just 25 people.

  • Economic: Initial investment for research, prototyping, and validation is substantial. Allocating financial and human resources to innovation is a risky investment that may or may not pay off in the future.
  • Technical: Ensuring technologies work efficiently in different environments and are compatible with existing machinery.
  • Cultural: Convincing companies to adopt new technologies, especially in traditional industries.
  • Regulatory: Ensuring the product complies with safety and quality regulations.
  • Market access: Identifying the right distribution channels and building trust with early customers.

The key to overcoming these challenges has been strategic collaboration with technology centers like TECNALIA and universities such as UPV/EHU, along with the flexibility to adapt to the specific needs of each client.

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