Case Studies

Asian Automotive Manufacturer Enhances Operations with MicroSol^® 690XT

A large automotive parts and components manufacturer, the customer specializes in die-cast aluminum engine heads and powdered metal valve seats. Their high-volume operation produces superior precision parts with top-quality finishes. As the company looks to the future, they are interested in implementing environmentally friendly production methods.

THE CHALLENGE

After looking into chlorine-free metalworking fluid options for all machining operations, the customer tested ten chlorine-free products to replace their previous solution. Tool life, cost per unit, and part finish were the main key performance indicators (KPIs) they used to measure performance among the various cutting fluids. They also examined each fluid's characteristics, including cost per gallon, foam profile, coolant usage, biostability, emulsion stability, operator acceptance, residue, and mist.

THE SOLUTION

After testing ten cutting fluids from numerous companies over some months, the company decided to convert their operation to Master Fluid Solutions' TRIM^® MicroSol^® 690XT. The coolant is a chlorine-free, premium semisynthetic microemulsion prized for its foam control and extended sump life. MicroSol 690XT also performs exceptionally well in mixed metal environments and is compatible with aluminum and ferrous engine materials.

THE RESULTS

The majority of testing was conducted on a 2,500-gallon central coolant system that supplies fluid for the chamfering operation. MicroSol 690XT outperformed all other competing cutting fluids throughout testing in almost every measurable area. MicroSol even had greater aluminum protection and lower conductivity, providing better corrosion resistance than the company's previous solution.

After seven months of use in the sump, MicroSol reduced coolant consumption by 13 percent. During that same period, there were no issues with foam, residue, or mist.

Since then, Master Fluid Solutions representatives have implemented a continuous fluid improvement program, setting up protocols for coolant management and offering additional support to aid the overall quality of MicroSol and its use in the plant. These improvements are expected to further reduce cost per unit and improve productivity.

THE NUMBERS

MicroSol outperformed 9 competitor fluids during the trial phase
No reported issues with residue, foam and misting after 7 months of usage
13% reduction in overall fluid consumption

Master Fluid Solutions. Master Fluid Solutions^®, TRIM^® and MicroSol^® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions.