Product Highlight: IC 1599-B
Customer: Manufacturer of Deep Drawn, Stainless Steel Componentry (up to 10" deep)
Objective: Replace a Full Synthetic Lubricant with a Higher Performing, Lower Cost Alternative
Description: The customer, exclusively utilizing type 304 stainless steel in all operations, was using a full synthetic forming lubricant at full strength (straight), applied via roll coaters placed between the coils and the presses. Following the draw process, all components are cleaned in a heated, in-line spray washer using alkaline cleaner chemistry. The metal-forming lubricant, applied straight, was also causing cleaning issues: inconsistent results following the wash process, and more consequentially, the lubricant, if left for long periods of time prior to cleaning, would set up and prove extremely difficult to remove. In many cases, multiple passes through the washers were required to remove the dried lubricant, which invariably led to increased chemical usage and the associated costs, in addition to production slowdowns.
ICC representatives surveyed their operations and determined that IC 1599-B was a better and less expensive alternative. Four lubricant samples were sent to an independent laboratory for lubricant ranking evaluations: IC 1599-B at full strength, IC 1599-B at 75% solution concentration, IC 1599-B at 50% solution concentration (1:1) and the competitor’s lubricant, also at full strength (as being utilized at the customer’s manufacturing location).
For the purposes of the lubricant ranking evaluation, the lubricant with the lowest standard deviation is deemed to be superior in draw performance. In addition, the higher average strain value also indicates superior draw performance. The results of this test are located below:
IC 1599-B, at a 50% solution concentration, proved to be the best performing sample sent for evaluation (highest average strain and lowest standard deviation).
Conclusion: The customer switched to IC 1599-B at a 50% solution concentration and realized immediate improvements in all aspects of their operations. Die life was extended, the wash process was made more efficient (eliminated multiple passes to clean the components) and chemical costs were reduced by 60%, year after year.