Across the industrial sector, we work with businesses to overcome challenges and develop solutions to new problems. Here’s how we help make it happen.
Castrol has worked with Renault Sport F1 for 2 years supplying Hysol XBB and Tribol to help translate marginal gains during the manufacturing process into increased performance on the track.
Ultimately, the ambition of the Renault Sport F1 team is to win championships. Together, Castrol and Renault are racing ahead to achieve that goal by translating technological and product innovations on the factory floor into success on the track.
Working with Renault to optmise lubricant efficiency, stability, and performance in the manufacturing process was critical in doing that.
While Renault’s ambition is to win the world championship, Castrol’s ambition is to give Renault a leading edge by improving the way they manufacture vital components for the F1 car.
Unearthing the marginal gains needed in the factory to achieve the marginal gains on the track is the focus of the Renault Sport F1 team and Castrol partnership. For example, in the machine shop where many car components are manufactured, the ability to speed this process up and get those components to the track quicker than ever before enables Renault to have an edge in their performance.
Castrol has been providing gear oils to the wind sector since the early ‘80s, and has played a crucial role in helping it to become the $94.5bn market it is today. And the key to that success has been a stringent focus on research, development, and becoming fully immersed in the wind industry.
The renewables market is only going to grow as companies and countries move away from fossil fuels, and the speed of that growth will owe a lot to wringing efficiencies out of renewable technologies wherever possible.
That’s where Castrol comes in.
Castrol is passionate about harnessing its relationships with customers, distributors, employees, investors and original equipment manufacturers to figure out the wind sector’s key challenges so that we can come up with the most viable and effective solutions.
Castrol’s research into gear oils revolves around the following core aims:
With the industry continually evolving, it is essential that Castrol designs products that are not only capable of delivering optimal performance today, but can increase the effectiveness of wind technologies going forward.
Much of Castrol’s research in this area has been to understand the value of Optigear Synthetic X, and to discover exactly how it benefits wind turbine operators.
Through the use of a highly accelerated life test (HALT), which can accurately predict a product’s lifespan and its long-term performance levels, it was discovered that Optigear Synthetic X could improve turbine performance by as much as 1% when compared to the nearest competitor.
The true value of any product or solution can only be determined when put into a real-life scenario. By working with a large customer, it was quickly established that by using Optigear Synthetic X, wind turbine operators could see savings of as much as $3,700 per year, per turbine.
As part of Castrol’s dedication to taking a more environmentally-conscious approach to all aspects of its operations, all gear oils are now carbon neutral.
The green revolution is going to continue in the years and decades to come, and Castrol is dedicated to being at the centre of the global shift towards greener, more renewable energy production.
Castrol’s Swedish partner reflects its commitment to standing out from the competition
Castrol and ILS Nordic are on a mission to realize production efficiencies.
Castrol and ILS Nordic share the same commitment to excellence.
Like Castrol, ILS Nordic is committed to being best-in-class. Its roadmap to that objective is based on four core pillars: quality, flexibility, involvement and quick response.
These values dovetail perfectly with Castrol’s and ensure the two companies approach each partnership with a common understanding.
One of the partnership’s clearest gains thus far has been achieved by an industrial customer.
The customer had some problems with its tooling life, so Castrol and ILS went in and identified areas for improvement and provided demonstrable evidence that the customer could save on both cost and tooling requirements.
As a result of our partnership’s efforts, the customer has lowered its overall cost and become much more competitive against its rivals.
Now the two parties are looking forward to achieving similarly impressive results with other clients.
How Castrol helped its distributor become an international leader
Telko is among Castrol’s clearest HPL experts
Telko is a lubricants distributor based in Finland, active in 16 countries. Castrol has been working with the company for over 60 years and the two sides have established a particularly close partnership.
Telko strives to work with customers as well as for them.
Telko serves a fleet of leading companies across a portfolio which includes:
As Morten Nedergaard, director of Telko’s Denmark and Norway division explains, “the customers Telko is working together with are really leading industrial customers in our market.”
To serve these customers, Telko strives to go beyond the usual supplier relationship and work with customers as well as for them. Instead of simply supplying products, Telko wants to offer holistic solutions. In Nedergaard’s view, “Telko’s strengths is really deep knowledge about the products. We are really a team of specialists.”
Castrol has helped Telko provide an even better service.
Drawing on its vast experience across a range of fields, Castrol has joined Telko’s mission to over-deliver in its client relationships, working with the distributor to provide an even better service to its customers - considering both industry trends and the wider environmental impact.
Information-sharing is at the core of the Castrol-Telko partnership.
During their six decades of working together, Castrol and Telko have developed a symbiotic relationship. Telko provides information from the field and Castrol uses it to refine its product range, delivering mutual benefit.
Telko sees Castrol as vital to its long-term strategy.
Telko says it is committed to continuously improving its service and going even further beyond what the customer expects.
As Morten Nedergaard explains, “when you succeed and you find the right product, and you see that the customer saves money and they really feel they have the right support from the distributor, that is really what keeps us living. That’s what gives us energy.”
The company sees Castrol as vital in its long-term strategy.
Driving efficiencies at a massive scale: We help make it happen
Castrol has worked with Motores, one of Renault’s biggest mechanical plants, supplying Hysol XBB and the compatible cleaner Techniclean XBC. These hyper-optimized solutions have enabled Motores significantly reduce their water consumption while also working towards evolving environmental standards.
Motores, based in the Spanish city of Valladolid, serves 1.5 million engines a year - 40% of Renault’s entire engine production. This giant plant is constantly looking for marginal gains in its attempt to drive efficiencies, comply with ever-tightening environmental regulations and meet Renault’s relentless demand for self-improvement.
Castrol’s smart lubricants, allied with long-term vision and technical support, have helped meet these challenges.
MOTORES -Valladolid PowertrainPlant Manager, GROUPE RENEAULT - Spain
In its partnership with Castrol at the Motores plant, Renault demands more than just a lubricants supplier. It needs a genuine partner, one that can help anticipate industry changes and keep improving.
In addition to its core lubricant solutions, Castrol has furnished Smart Control machines to remotely monitor the performance of the fluids, backed up by technical support to anticipate problems and find solutions.
Brieux says that the partnership with Castrol “is not a [typical] supplier-customer relationship. Castrol is not expecting the request from Renault, but is very proactive in making new innovation proposals.”
The core products selected for the Motores project are ideally suited to the challenge of minimising waste and environmental footprint.
XBB, free from boron and formaldehyde, complies with the most stringent environmental regulations. XBC, meanwhile, can be recycled back into the coolant system, dramatically reducing water usage and keeping waste to a minimum. The Smart Control system dovetails with these core products by controlling all the key parameters in the coolant and the cleaner 24/7.
Thanks to Castrol’s innovations Renault has saved 1 million litres of water this year alone, and there have even been savings in the core product. More than that, though, they have found a company which shares their desire for continuous improvement, a partner for the long term.
Grob can’t afford its systems to go down. Castrol keeps them running
Grob has earned a global reputation in the industrial systems market
Grobwerke Mindelheim (Grob) has been working in the manufacture of tooling and machine systems for over 90 years. The company’s product line ranges from assembly to electromobility systems and, as the company’s Department Sales Manager Klaus Eberts explains, its reputation is built on “highly innovative production and automation systems.”
The company is active across a range of sectors from medical to automotive, and its consistent excellent is reflected in a list of customers which includes several international brands.
Grob relies on constant technical availability
As Maintenance Manager Alexander Boehm explains, Grob can only serve its global customer roster if it is always on.
This means that Grob needs dependable partners, with global availability.
Grob and Castrol have forged a strong partnership over the past two decades.
Castrol has been working with Grob for the past two decades, supplying a range of products. Today Grob uses the XBB cooling lubricant range, as well as slideway oils and corrosion protection products, applied to machines prior to delivery.
When problems arise, Castrol adopts a proactive approach to their resolution. When Grob recently ran into problems with one of its products, Castrol was able to pour all its resources into finding the right solution.
Grob is extremely impressed with the way Castrol resolves issues
Grob is full of praise for the speed of Castrol’s service, and views Castrol as an integral part of its own operation.
However, perhaps the real key is the two companies’ shared commitment to innovation. As Boehm says, “it is the permanent further development of products that influences the success of the partnership between Castrol and Grobwerke.”
Gehring Group has been in operation for over 100 years, and has developed a world-class reputation for delivering production systems with high productivity and high precision for the automotive and truck industries.
Gehring uses Castrol’s XBB range of cutting fluids to give customers the high performance they demand today, while also future-proofing their operations.
Castrol is the preferred and recommended supplier of cutting fluids for Gehring honing machines. Specifically, Gehring use Castrol’s XBB range, which is free from biocide and Boron, and offers the most sustainable and stable cutting fluids on the market.
As Andreas Osbar, European Industrial Sales Director at Castrol, explains:
“Castrol helps its customers in three ways:
Gehring and Castrol are true partners, working together with the same open attitude to innovation and collaboration to deliver the best results.
And it’s a proven partnership thathas been successful for decades.
Both Gehring and Castrol are committed to continuous improvement in fluid technology, helping to further refine and enhance the honing process for manufacturers.
Castrol is perfectly placed to help Gehring continue to benefit from competitive advantage, by offering:
Castrol delivers major reductions in wear, longer mechanical life spans, and significantly improves oil drain intervals.
In the Australian state of Queensland, the operator of a large open-cut mine recently decided to test Castrol’s Optigear Synthetic PD 680 ES in the wheel motors of its Komatsu 930E haulage trucks, to gauge whether the lubricant could deliver any performance improvement.
Haulage trucks play a crucial role in the performance of a mine, transplanting produce from extraction sites to stockpiles. In surface mines, such as the test site in Queensland, around 40% of all energy consumed on site is related to diesel consumption, and haulage accounts for the vast majority of this usage.
So it is essential that mine operators:
The challenge is enhanced by the sheer size of haulage trucks. The Komatsu 930E weighs over 500,000 kilograms and its tyres weigh a combined 26,000 kilograms. This means that any maintenance or replacement operation is extremely time-consuming and expensive.
With these challenges in mind, the operator of the Australian mine identified Castrol Optigear Synthetic PD 680 ES as an ideal solution.
Manufactured from synthetic lubricants, the Optigear range also includes a special additive package that works to promote plastic deformation, reducing gear friction and equalising surface roughness under heavy loads – thereby alleviating abrasion on the gears’ surface.
The effectiveness of Castrol Optigear Synthetic PD 680 ES has already been proven in a series of tests. For example, the amount of frictional torque (the force which causes an object to wobble on its axis) is reduced by 30% compared to other commercially available industrial gear oils, and the lubricant has been shown to withstand temperatures of 120 degrees.
Before committing to Optigear, the mine operator and Castrol worked together to test it against a conventional synthetic gear oil that had previously been used in the Australian mine’s trucks.
The testers randomly selected four different trucks at the site, although one of them was subsequently withdrawn due to wheel stud failure and product contamination. Each month, an oil sample was drawn from each of the trucks and sent to Castrol’s Oil Laboratory for testing. In total, the tests covered a period of over 4,000 hours.
When analysing the samples, the testing team specifically looked at wear rate, or Fe, measured in parts per million per 100 hours.
Across the three vehicles, the average wear was 1.56 Fe with Castrol Optigear compared with 2.82 Fe with the conventional synthetic gear oil. In fact the total wear across the trial units was reduced by at least 30% over the period of the evaluation. In certain motors, the reductions amounted to 40%.
Based on this improvement, the client believes that by using Castrol as well as making essential maintenance improvements, the target life of the wheel motors can be increased from the current 24,000-hour target life to 30,000 hours.
Furthermore, the reduction in wear suggests that by adopting Optigear, as well as using a kidney loop filtration system (which is renowned for its efficiency in keeping dirt out of fluid), the mine operator may be able to extend its oil drain intervals to 6,000 hours – that is, an annual drain.
In an age when the mining industry is facing unprecedented changes, due to both Covid-19 and the increasingly powerful environmental lobby, mine operators need to find ways of making their facilities as smart and sustainable as possible.
Castrol Optigear has shown, beyond any doubt, that it provides these attributes.
Castrol, the leading global lubricant manufacturer, has signed a strategic Memorandum-of-Understanding (MoU) in Europe with Leadec, a global market leader for industrial services.
Leadec is an expert in engineering, installing, automating, and operating factories and buildings, as well as relocating equipment for manufacturing industries. Leadec’s strong roots in the automotive sector are the perfect complement for Castrol’s expertise in lubricants.
The Castrol and Leadec Group partnership combines Leadec’s expertise in industrial services and Castrol’s expertise in industrial lubricants. This unique partnership means that industrial customers can:
Together, Castrol and Leadec will be able to offer a standardised approach to fluid management across Europe, leveraging local expertise and ensuring a consistent, high-quality service for customers.