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CASTROL INDUSTRIAL CASE STUDIES

Castrol Industrial Case Studies

We Help Make It Happen

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.

Renault Sport F1 Team

The race for the world championship. We help make it happen

Renault Sport Formula One Team

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.

 

The Mission

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. 

 

The Partnership

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.  

 

 

But to do that, It’s important to have the right technical partner onboard. What gave Castrol the edge when we were choosing a partner to work with was the breadth and depth of their industrial experience as they cover a range of fields and specialisms we need.Bob BellChief Technical Officer - Renault Sport Formula One Team

 

The Product

Castrol Hysol and Castrol Tribol
The main products used to improve overall performance and efficiency in the manufacturing of component parts were Castrol Hysol XBB and Castrol Tribol. 
Machine coolants are a hugely important part of the manufacturing process and form a large part of what Castrol supplies in this relationship. We also use Castrol greases, slideway oils and gearbox oils for the machines. The ability to use Castrol products to reduce downtime in the manufacturing process is crucial for us. The products we require must work under extreme conditions, so we not only need products that can perform in demanding environments, but we need to get the right support from our technical partner on an ongoing basis. We work under tight tolerances and are always looking to manufacture the component parts as quickly as possible to get them to the track. Castrol helps us throughout the entire process.Raphael WillieManufacturing Manager - Metallic - Renault Sport Formula One Team

The Performance  

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.

 

 

For us, perfection on track is a result of perfection in the factory. And the machines that produce the parts for our F1 cars are reliant on Castrol products. With Castrol, we’ve got the commitment to apply resources to long terms solutions that others haven’t thought of. Castrol helps us do that in a whole range of areas.Bob BellChief Technical Officer - Renault Sport Formula One Team

 

 

Wind Energy Efficiency

The growth of wind

Wind Energy Efficiency

Renewables are here to stay, and so is Castrol

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.

Designing products for today and tomorrow

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:

Efficient and reliable products
Create efficient and reliable products
Extend equipment life
Extend the life of customer equipment
Extend the life of the gear oils
Extend the life of the gear oils themselves
Reduce need for maintenance
Reduce the need for equipment maintenance

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.

 

 

We often act like a consultant; we help them figure out what is working well and what isn’t, because that’s the starting point for the development of any solution.Daryl LukeGlobal Product Manager at Castrol

Optigear Synthetic X gear oil

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.

 

 

We were able to prove in industry standard laboratory tests that we could get sizeable efficiency gains using Optigear Synthetic X, But, of course, this doesn’t necessarily translate into real-life efficiencies.Phil BookerCastrol Global Account Manager

 

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. 

 

Real-life benefits

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.

 

 

Optigear Synthetic X 320 is a great example of a product that goes above and beyond. The plastic deformation technology can not only extend the asset life while simultaneously reducing wear, but it can also deliver significant energy efficiency savings.Phil Booker

 

Supporting the wider issue 

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.

Find out more about Optigear Synthetic X, and discover how it can help your business operate more efficiently 

Castrol Optigear
Renault Engine Plant

Renault Engine Plant

Driving efficiencies at a massive scale: We help make it happen

Renault Engine Plant

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.

 

The Mission

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.

Anne-Catherine Brieux

The Partnership

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.

 

What are we looking for in our lubricant suppliers?” asks Anne-Catherine Brieux, general manager of the Motores plant. “We’re looking for the most cost-effective product to go with very effective facilities, with digital monitoring.

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.”

Anne-Catherine Brieux

The Product

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.

Engine part

The Performance

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.

 

 

The biggest test, the biggest challenge we face is the increasing demand for consistent quality that Renault sets itself, so that its pieces are always increasing in quality,Gustavo OlmedoPowertrain Liquids Technical Manager at Motores.

 

To succeed in the challenges that we face, we need a supplier that looks beyond the obvious. Not one that simply sees fluid, parameters, quality, but one that also looks at, for example, the systems. And we’ve found this supplier in Castrol.

 

Castrol helps me achieve my objectives through their technology. Their products have great technology, their technical contribution and their support at the factory
Grob-Werk

Maintaining a global machine: Grob and Castrol

Grob can’t afford its systems to go down. Castrol keeps them running

Robot Machinery

An international pedigree

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. 


Quick, responsive service

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.

 

Our main job is to ensure the technical availability of our production systems, so that we can manufacture workpieces for our customers in order to supply the assemblies accordingly,” Boehm says. “Should problems arise, we have to react quickly to restore the technical availability of the system.

This means that Grob needs dependable partners, with global availability.

MARTIN DEMMINGER

A personal, proactive approach

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.

 

For over 20 years we have been providing a high standard of product quality as well as maintaining personal contact with a large number of Grob employeesMartin DemmingerAccount Manager

 

I love visiting customers and implementing projects with them and solving their daily challenges.

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.

Castrol resolutions

Instant resolution

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.

 

Given the multitude of factors that can influence a machining process, it is important for us to be able to rely on stable partners,” says Alexander Boehm. “One of the things that contributes to this is Castrol’s products. Should problems arise, they will be immediately solved.

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.”