Nigerian manufacturers losing billions — Tobechukwu Abor

In an era where Nigerian manufacturers are seeking cost-effective and environmentally friendly solutions to remain competitive, one emerging technology promises to revolutionize metal cutting operations across the country. Tobechukwu Abor, a Nigerian graduate student at the Mechanical and Aerospace Engineering Department, Missouri University of Science and Technology, USA, shares insights on Minimum Quantity Lubrication (MQL) […]

In an era where Nigerian manufacturers are seeking cost-effective and environmentally friendly solutions to remain competitive, one emerging technology promises to revolutionize metal cutting operations across the country. Tobechukwu Abor, a Nigerian graduate student at the Mechanical and Aerospace Engineering Department, Missouri University of Science and Technology, USA, shares insights on Minimum Quantity Lubrication (MQL) and why Nigerian companies must embrace this innovation.

Thank you for speaking with us today. Can you explain what Minimum Quantity Lubrication is and why it matters?

Thank you for having me. Minimum Quantity Lubrication, or MQL, is an advanced machining technique that uses very small amounts of cutting fluid—typically between 10 to 100 milliliters per hour—delivered as a fine mist directly to the cutting zone. Compare this to conventional flood cooling, which can use 10 to 60 liters per minute. We’re talking about reducing lubricant consumption by up to 99 percent while maintaining, and often improving, machining performance.

That sounds remarkable. How does it work exactly?

Tobechukwu Abor: The system atomizes a mixture of compressed air and cutting fluid through specially designed nozzles. This creates a fine aerosol that’s precisely directed to where the cutting tool meets the workpiece. The compressed air helps cool the cutting zone while the minimal lubricant reduces friction and prevents tool wear. The beauty of MQL is that it combines the cooling effect of dry machining with the lubrication benefits of wet machining, giving you the best of both worlds.

What are the main advantages for manufacturers?

Tobechukwu Abor: The benefits are substantial and multifaceted. First, there’s significant cost savings. Companies spend enormous amounts on cutting fluids, their storage, maintenance, and disposal. MQL drastically reduces these costs. Second, it’s environmentally friendly—less fluid means less waste, fewer harmful emissions, and reduced environmental contamination. Third, worker health improves because there’s minimal exposure to coolant mists and skin irritants that are common with flood cooling. Fourth, you get better product quality with cleaner workpieces that require less post-processing. Finally, tool life often improves because of better chip evacuation and reduced thermal stress.

You mentioned worker health. Can you explain this more comprehensively?

Tobechukwu Abor: This is critically important and often overlooked. Traditional flood cooling systems expose workers to numerous health hazards. Workers breathe in aerosols containing bacteria, fungi, and chemical additives that can cause respiratory problems, dermatitis, and allergic reactions. Some develop occupational asthma or chronic skin conditions from prolonged exposure. The work environment becomes slippery and hazardous, increasing the risk of workplace accidents.

MQL dramatically improves workplace conditions. The minimal amount of lubricant means workers are exposed to far fewer harmful substances. The workspace remains cleaner and safer, with reduced slip hazards. Workers report fewer skin irritations, respiratory complaints, and overall better health outcomes. This translates to reduced absenteeism, lower healthcare costs for companies, improved worker morale, and increased productivity. For Nigerian manufacturers, where worker welfare should be a priority, MQL represents a moral imperative as much as an economic one.

You mentioned environmental benefits earlier. Can you elaborate on this more strongly?

Tobechukwu Abor: Absolutely. This cannot be overstated. Traditional metalworking fluids contain various additives—emulsifiers, biocides, corrosion inhibitors, extreme pressure additives—many of which are toxic and carcinogenic. When disposed of improperly, these fluids contaminate soil, groundwater, rivers, and ultimately affect entire ecosystems and communities that depend on these water sources.

In Nigeria, where environmental regulations are still developing and enforcement remains challenging, this is a catastrophic concern. We’ve seen industrial waste devastate communities, poison water supplies, and cause long-term health problems. MQL offers a transformative solution. By reducing cutting fluid consumption by up to 99 percent, we’re talking about preventing thousands of liters of toxic waste from entering our environment annually—per factory.

Furthermore, the reduced fluid usage means less energy consumption in fluid production, transportation, and disposal. It reduces carbon footprint significantly. For a country like Nigeria that’s increasingly aware of climate change and environmental sustainability, and as we work to meet international environmental standards, MQL represents not just a pathway to greener manufacturing, but a necessity for sustainable industrial development.

What types of industries or operations would benefit most from MQL?

Tobechukwu Abor: MQL is particularly effective in operations like turning, milling, drilling, and grinding. Industries that would benefit include automotive parts manufacturing, aerospace components, oil and gas equipment fabrication, general metal fabrication shops, and even small-scale machine shops. Essentially, any operation involving metal cutting can potentially benefit. In Nigeria’s context, I’m thinking about companies manufacturing parts for the automotive sector, equipment for the oil and gas industry, and the numerous fabrication shops across the country.

What about the initial investment? Is it affordable for Nigerian manufacturers?

Tobechukwu Abor: This is an important question. Yes, there’s an initial investment in MQL equipment—nozzles, air compressors, control systems—but the return on investment is typically rapid. When you factor in the dramatic reduction in fluid costs, disposal costs, cleaning costs, improved worker health reducing medical expenses and absenteeism, and improved productivity, many companies recover their investment within a year or two.

Moreover, MQL systems are scalable. Small shops can start with basic systems costing a few thousand dollars, while larger manufacturers can invest in more sophisticated setups. The key is that the long-term operational savings far outweigh the initial capital expenditure. Companies also avoid future costs associated with environmental penalties, workplace safety violations, and potential litigation from worker health issues.

Are there any challenges or limitations companies should be aware of?

Tobechukwu Abor: Like any technology, MQL isn’t a universal solution for every situation. It works best with certain materials and operations. Some difficult-to-machine materials or heavy-duty operations might still require conventional cooling. There’s also a learning curve—operators need training to optimize MQL parameters for different applications. Additionally, proper nozzle positioning and air-fluid mixture ratios are critical for success. However, these challenges are manageable with proper training and technical support. The benefits far outweigh these initial hurdles.

Based on your research and knowledge, what would you say to Nigerian manufacturing companies?

Tobechukwu Abor: My message is clear, urgent, and unequivocal: Nigerian manufacturers cannot afford to ignore MQL technology. We’re operating in a global economy where efficiency, sustainability, and cost-effectiveness determine survival, not just competitiveness. Companies in Asia, Europe, and America have been adopting MQL for years, gaining massive competitive advantages. Nigerian manufacturers must do the same immediately to remain viable, especially as we seek to grow our manufacturing sector, create jobs, and reduce import dependence.

The benefits—dramatic cost savings, environmental protection, worker health and safety, improved product quality—align perfectly with Nigeria’s economic and developmental goals. This isn’t just about profits; it’s about building a sustainable industrial future, protecting our workers, preserving our environment for future generations, and positioning Nigeria as a responsible manufacturing hub in Africa and globally.

We have the technical capacity in Nigeria to implement this technology. What we need is awareness, political will, and commitment to invest in modern manufacturing practices. The technology exists. The benefits are proven. The only question is whether Nigerian manufacturers will seize this opportunity or be left behind.

What would be your specific recommendations for implementation?

Tobechukwu Abor: I have concrete, actionable recommendations. First, companies must immediately conduct comprehensive assessments of their current machining operations to identify where MQL would be most beneficial and calculate potential savings. Second, invest heavily in training—send technicians and engineers for specialized training on MQL systems, partner with universities and technical institutions to build local expertise.

Third, start with pilot projects rather than complete overhauls. Test MQL on specific operations, measure the results meticulously—document cost savings, health improvements, quality enhancements—then scale up aggressively. Fourth, partner with reputable equipment suppliers who can provide ongoing technical support during the transition. Fifth, document and publicize the benefits to build industry-wide momentum.

Finally, I call on the Nigerian government, manufacturing associations, and industry leaders to create awareness campaigns, offer incentives for MQL adoption, and potentially mandate environmental standards that make MQL adoption economically compelling. We need a coordinated national effort to modernize our manufacturing sector.

Any final thoughts?

As a Nigerian studying advanced manufacturing technologies abroad, I’m passionate about seeing our country’s industrial sector not just survive but thrive and lead. MQL represents the kind of practical, proven, transformative technology that can make a real difference in our industrial development trajectory.

This is not experimental or risky—it’s established technology that works, backed by decades of research and successful implementation worldwide. Nigerian companies must embrace it not just to reduce costs, but to save workers’ lives and health, protect our environment from industrial pollution, position themselves as modern and responsible manufacturers capable of competing globally, and contribute to building the Nigeria we all envision.

The question isn’t whether to adopt MQL, but how quickly we can implement it across our entire manufacturing sector. Every day we delay is a day of wasted resources, environmental damage, and worker exposure to harmful substances. The time for debate has passed. The time for action is now.

Thank you for your time and these powerful insights.

Thank you. I sincerely hope this conversation sparks a manufacturing revolution in Nigeria. Our future depends on it.