Product Highlight: IC 848-F2
Customer: Manufacturer of Medical Components for Domestic and International Markets
Objective: Replace a Vanishing Oil Lubricant/Chlorinated Paraffin Blend
Description: The customer, utilizing a combination of a low-viscosity, evaporative metal-forming lubricant and a chlorinated paraffin, which was sourced from two different vendors and blended on-site, needed to find a replacement due to the specific ban on products with chlorinated paraffin content. In addition, the blend proved inconsistent in its performance and the high cost of combining these two products became untenable. The goal was to find a non-chlorinated evaporative solvent-based metal-forming lubricant that provided increased performance and met the international regulations that specifically prohibit chlorinated paraffin usage in any part of the manufacturing process.
Following a survey of the customer’s operations by ICC representatives, it was determined that a version of the International 848 Series of Lubricants would be the solution. However, none of the myriad versions of the base formulation fulfilled all the specific requirements as stated by the customer. Due to the sensitive nature of their products—highly engineered medical components—the ICC Technical Department custom-formulated IC 848-F2 and performed internal testing to ensure its success following implementation.
One of the main concerns of the customer was die life. If the lubricant was not effective, the cost to rebuild each die could be as high as $30,000. If the metal-forming lubricant was unable to match the current die life as provided by their custom blend, if not extend it, the door would close on this opportunity and alternate solutions would be sought. After the customer performed an extensive review of the observed test data as provided by the ICC Technical Department, on-site testing was approved and commenced.
Conclusion: The testing was deemed an overwhelming success. Not only did IC 848-F2 surpass the operational performance of the vanishing oil/chlorinated paraffin blend, it extended die life. But the benefits didn’t stop there. Due to the elimination of the chlorinated paraffin, the components are much more easily cleaned in post-processing (a power spray washer utilizing alkaline chemistry). This is primarily a function of the lower viscosity of IC 848-F2 as compared to the vanishing oil/chlorinated paraffin blend formerly utilized.
The superior wetting characteristics of IC 848-F2 also permitted a diminution of applied lubricant volume, resulting in a further reduction of chemical costs. IC 848-F2 boasted numerous advantages contributing to reduced operational costs, such as the elimination of the chlorinated paraffin, a lower cost evaporative solvent-based metal-forming lubricant, a reduction in the volume of applied lubricant, and an extended die life. Additionally, a lower cost alkaline cleaner would be implemented, and the exposure time necessary to clean the medical components would now be minimized as they are now more readily cleaned.