Lubricant Case Study One

Objective: Replace an oil based chlorinated lubricant with a fully synthetic V.O.C. free lubricant
Customer: Manufacturer of cooking appliances.
Recommended Coral product: International Compound 1599
Observed test results:

1. Scrap rate reduced to less than 0.1%

2. Formed parts were cleaned using mild detergent thereby increasing bath life of cleaner by over 50%. Eliminated petroleum oil loading of pretreatment cleaner bath.

3. One lubricant used throughout the entire plant for forming, blanking and piercing.

4. Reduced concentration from 30% to 12%

5. Eliminated lubricant residue associated scrap.

6. Residual lubricant can be welded through without affecting integrity or porosity of weld

7. Eliminated costs associated with disposal of chlorinated oil products

Estimated savings: Approximately $150,000-$200,000 in associated chemical, scrap, disposal and materials costs annually.

Because the customer was using a viscous chlorinated oil, they were experiencing defects in their pre-treatment application. The bath of the cleaner would quickly become loaded with the soluble oil and defects of coated parts would increase. Utilizing the surfactant technology of the International Compound 1599 assisted with the removal of the lubricant and ensured a smooth uniform pre-treatment coating

International Compound 1599 was applied via spray at the same concentration of 30%. However, our technical support team felt that we could significantly reduce the concentration based on the film strength of our product. We gradually lowered the concentration to 12% with success. The residual film on the formed parts was clear allowing for good visual observation of defects and easy removal in the washer.

Lubricant Case Study Two

Objective: Replace straight oil based formulation for forming automotive body components with fully synthetic water-soluble product
Customer: Automotive supplier to Honda, Subaru and Nissan of support frames, bumpers, door mounts and body components
Recommended Coral product: International Compound 2505-C
Observed test results:

1. Improved die life on all presses.

2. 25% reduction overall scrap rates on formed parts.

3. Eliminated difficulty associated with cleaning parts stored for several weeks

4. Eliminated numerous spot welding associated defects because residual lubricant can be welded through without smoking.

5. Plant operations were cleaner and no longer had oil mist and slippery floors.

Estimated savings: approximately $100,000 in associated chemical costs annually.
In cooperation with our customer, ICC integrated a fully synthetic metal forming fluid to form all of the automotive parts, while reducing numerous production and die life issues.

We submitted I.C. 2505-C for comparative field-testing along side four other competitive fluids. The International Compound 2505-C provided the most consistent results at 25% concentration yielding the lowest scrap rate. In addition, the operators approved of the “no-odor” product and found parts were easier to handle than the traditional oil.

The customer was paying $5.75 per gallon for the oil forming lubricant, the I.C. 2505-C yielded a $2.72 use-cost-per-gallon cost generating a 53% savings in lubricant cost to the customer. The customer has since signed a long-term contract with ICC and is integrating the product on other facilities throughout the United States.