Responsible Case Studies

Operators Love It

The Situation

A manufacturer of fasteners and anchors who performs cold heading, screw machining, block threading and Hydromat machining felt they had to eliminate the smoke generated from these operations for the sake of the workers. They hoped one product would solve the problem in all areas. 

The Solution

The manufacturer now uses one oil throughout the plant and it’s NuCut Plus. Smoke was eliminated from all of the operations. As an additional bonus, they were getting four times better tool life in cold heading, the hydraulic blocks ran 40°F cooler and the screw machining block life went from one million to 4 million. The operators loved the performance of NuCut Plus and actually said they would not test any other fluid.

The Results

  • High worker acceptance and satisfaction
  • No smoke.
  • Better output.
  • Increased tool life.

Breathing Easier

The Situation

A fastener manufacturer who worked with aluminum, stainless, steel, brass and copper wanted to improve air quality in the plant for the health and safety of the workers. The current cutting oil wasn’t acceptable and a replacement was needed in both flood and mist applications. 

The Solution

Workers loved the clean air and working conditions after NuCut Light started being used. It was also possible for them to use NuCut Lite for both gear oil and cutting oil. Additionally, tool life increased by approximately 20%. 

The Results

  • One product for two applications
  • No smoke.
  • High operator acceptance and satisfaction.
  • Increased tool life.

One Product Serves Several Needs

The Situation

A tooling shop that focused on tool sharpening was looking for a product that would provide better tool life and not produce smoke, because they did not want to have to install a new ventilation system into the plant.

The Solution

Castrol recommended NuCut Light for its cooler operating temperatures, reduced smoke and minimal mist generation. In production, operators appreciated the lack of smoke and noted that air filters did not need to be changed the way they did with common oils. Additionally, with NuCut Lite the grind stone and wheel life was tripled. 

The Results

  • Greatly improved tool life.
  • No smoke and therefore no need for ventilation system.
  • High operator acceptance.

Increase Tool Life

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The Situation

The owner of a tool and die shop that performed milling, drilling and boring was intrigued by the idea and the technology of renewable, soy-based products. Additionally, he liked the idea of supporting Midwest soybean farmers plus, his state offered credit for testing environmentally friendly products.

The Solution

NuCut Light was brought in to replace the water-based fluid. It was very successful and did not produce smoke while machining in severe operations. The owner believed his tool life had doubled, which can be attributed to NuCut Lite’s highly polar plant-based oils that provide lubricity and cutting surface affinity. 

The Results

  • Satisfied with bio-based product
  • No smoke.
  • Operator acceptance.
  • Increased tool life.

Best For Broaching

The Situation

A hand tool manufacturer was using a chlorinated coolant to broach splines and grips into hand tools. This fluid gave very good broach bar life, but had occasional corrosion issues.

The chlorinated coolant had a high usage rate, due to a large carry-off on the chips. There was also an issue with the tramp oil being emulsified and not able to be skimmed out of solution.

The Solution

Alusol AU 70 was used successfully to vertically broach splines and grips in hand tools. The metals included 1000, 4000 series, and A2 steels. The coolant pressure was 30 psi with a flow rate of 8 gallons per minute. Filtration was a simple chip drag and canister in front of the pump. The coolant tank had a disk type skimmer for removing tramp oil, which was easy to do because of Alusol AU 70’s tight emulsion characteristics.

The cleanliness and high performance of Alusol AU 70 were a true advantage over other coolants used in the operation. 

The Results

  • Low amount of carry-off with the chips.
  • No corrosion issues.
  • Machine operators thought machine stayed cleaner.
  • Biological stability was improved.

Beats The Competiton

The Situation

An agriculture equipment manufacturer’s chlorinated coolant was to be discontinued, so they decided to test new options with Castrol and a competitor. The initial testing was done in a machining operation where 3⁄4” holes were being drilled, finished, and threaded into welded steel plate and tube.

The competitor’s fluid was tested first, but could not produce any quality parts and generated $15,000 in scrap. 

The Solution

Castrol introduced Alusol AU 70, and it performed great right from the start. The plant was impressed that a chlorine-free coolant could perform so well on a wide variety of materials with no changes or adjustments to their process. In addition, coolant usage is projected to drop by at least 30% leading to $56,700 in anticipated annual savings. 

The Results

  • Cleaner work area.
  • Coolant usage to drop at least 30% for $56,700 in annual savings.
  • Tool life equal to that of the chlorinated fluid.
  • Good operator acceptance.

Honing Success

The Situation

After a coolant was discontinued due to a chlorinated paraffin additive, a major diesel engine maker was looking for an environmentally friendly replacement for cylinder bore honing of cast iron diesel engine blocks.

They needed a new fluid that would maintain good honing performance with no change in cylinder bore finish, since surface finish and bore geometry are key to maintaining low emissions and good engine performance. 

The Solution

Castrol recommended the chlorine, boron and secondary amines-free Alusol AU 68 and worked with the hone OEM to test and approve the fluid. Successful OEM approval and a success in the day-to-day operations of the honing department convinced the customer to change their 16,000 gallon central system.

The diesel engine maker is now in a position of having a greener operation with the chlorine component eliminated from their waste stream. 

The Results

  • Fluid clealiness.
  • Foam and bacteria-free system.
  • Satisfactory product finishes and tool life.
  • Good honing performance without chlorine.

Maximum performance for a perfect finish

The Situation

A major automotive manufacturer was seeking a high performance coolant for their valve body machining area. The fluid needed maximum machining performance in order to meet the critical finish on their valve body bores. In addition, the fluid needed to have excellent bio-resistance, good foam control and low total operating costs.

They were using a vegetable-based coolant with excellent lubricity. Coolant usage was 286 gallons per week, water usage was 1,337 gallons per day and scheduled tool changes were at a 67% average. 

The Solution

Castrol engineers had high expectations that Alusol AU 68 would work well in this operation, based on internal machine center testing and external field trials conducted at other plants. During the trial period, the reaming operation was the most critical area monitored. The customer was looking for a mirror-like finish in the valve body bores. The result with Alusol AU 68 was excellent machining performance and part finish, with greatly reduced fluid carry-off, which led to significantly lower coolant and water usage.

With Alusol AU 68, coolant usage was 153 gallons per week, water usage was 837 gallons per day and scheduled tool changes were at a 77% average.

The Results

  • 46% reduction in coolant usage.
  • 37% reduction in water usage.
  • Improvement in scheduled tool changes.
  • $95,975 in annual coolant cost savings.
  • Reduced water consumption by over 120,000 gallons per year.

The Race To Remove Chlorinated Paraffin

The Situation

A racing component manufacturer was using a chlorinated tapping compound to form tap threads into shock tubes. They wanted to get away from the chlorinated paraffin for health and safety reasons. The manufacturer assumed there would be lower performance with the non- chlorinated oil, but was willing to accept lower performance for improved health and safety. 

The Solution

Moly Dee CF is a viscous tapping fluid designed for severe duty thread forming or cutting operations where other Extreme Pressure oils fail, and it had excellent results in this application.
Taps were dipped into the Moly Dee CF before each part was threaded and tap thread were successfully formed into 316 stainless steel. Thread quality was not compromised as the manufacturer thought it might, and the removal of chlorinated paraffin relieved everyone’s’ health and safety concerns. 

The Results

  • Tap life achieved 90% of chlorinated fluid.
  • Moly Dee CF reduced the chance of thread fatigue from chlorine reacting with the surface of the metal.
  • The thread quality was as good as those made with chlorinated oil.
  • Health and safety concerns were resolved.

Putting A Priority On Health And Safety

The Situation

A chlorinated oil was working well for an automotive components manufacturer who was using it for tapping brackets, but for health and safety reasons, they wanted a chlorine-free option without sacrificing performance. 

The Solution

Castrol’s Moly- Dee CF, from the Responsible product line, was just the answer. A tapping fluid that can be used in thread forming or cutting operations, Moly Dee CF is well recognized as a performance leader in the tapping industry.

Moly Dee CF matched the performance of the chlorinated fluid in a cut tapping operation. The thread quality and tap life were the same and Moly Dee CF cleaned easily in the existing alkaline washer. The manufacturer was impressed with the results and glad to be free of chlorinated paraffin.

The Results

  • Chlorine-free Moly Dee CF matched the performance of a previously used chlorinated fluid.
  • Less chance for corrosion of the parts before the cleaning operation.
  • Health and safety concerns were resolved.