Food Grade Lubricants
Automotive Robotic Gearboxes
QUAKERTEK® AXFG 2202-EPW
A food processing plant was looking to add a grease to their operations that resisted water washout, good shear stability, and a broad operating temperature range. They were also looking for a supplier to provide training for their operators and maintenance associates on how to determine the correct grease to use, the importance of using a grease and the application. Quaker scheduled a training session with the plant to train employees on role lubricants play in the design, performance and operating life of engineered devices. By conducting a full study on the grease the plant was currently using, and the QUAKERTEK® AXFG 2202-EPW, they were able to find a product the met or exceeded all of their product requirements.
Steel Mill Bearings
QUAKERTEK® AXIAL 00-32
A large North American automotive plant desired to improve robot lubrication through lower operating costs to increase their competitive advantage, improve production quality, increase output, improve supplier services, and overall reduced costs. Switching to QUAKERTEK® provided overall improvements in grease performance across major bench mark ASTM tests, resulting in over $12k/yr savings and significantly improved vendor service.
High Temperature, High Load Bearings
QUAKERTEK® CS 4602-EP
Steelscape, national supplier of metallic-coated and painted steel, was experiencing corrosion on the bearings in their Galvanize and Cold Mill lines. The corrosion was shortening bearing life, causing them to be replaced up to 9 times a year, at a cost of $6,200 per bearing for a total of cost $55,800per year. By switching to the QUAKERTEK® CS 4602-EP calcium sulfonate grease, bearing replacements have been decreased by greater than 4x providing a total savings (including materials) of $34k/year.
High Pressure Aluminum Die Casting
QUAKERTEK® UX 4615-EP
A large steel mill was accumulating plates at extreme temperatures on their output tables, causing the bearings to work under high loads and extreme temperatures and resulting in melted grease and lubrication loss. Thus, output table rolls were failing regularly with 4 roll breaks/month on average causing lowered production rates and delays. Additionally, there was increased risk to worker safety. The mill was looking for a grease that could handle the demand of the environment and solve the stated issues. By switching to QUAKERTEK® UX 4615-EP, the mill found a prouct that could handle the extrem environments of the mill and provided a nearly 15x decrease monthly materials, repairs and labor costs. While improving worker safety.
DIE SLICK® 3550
One of the world’s largest manufacturers of small gasoline engines was looking to improve productivity within their die casting operations by optimizing their process by eliminating solder and quality issues, and improving biological resistance to minimize maintenance. Quaker Chemical initiated a thermal imaging study at the manufacturer leading to recommending implementation of DIE SLICK® 3550 with Smart Polymer Technology in their process. As a result, the customer experienced brighter and cleaner castings, less thermal shock over the life of the die, 40% lower die release consumption, 25% reduction in spray times, and improved biological resistance.
Finish Case Washers
QUAKERCLEAN® 680 VDA
A diesel engine block manufacturer was having difficulty with 6 cylinder engine blocks remaining wet after the washing operation, causing in-storage rusting issues between machining operations and assembly. The customer specifically wanted to: eliminate rusting by utilizing a faster drying cleaner. QUAKERCLEAN® 680 VDA was introduced at 3.5% concentration into their 1,250 gallon wash tank, and lead to a nearly 50% reduction in drying times with no rusted parts experienced over 30 days of storage.
QUAKERCLEAN® 624 MPC
A major automotive producer was using a cleaner/corrosion preventive on the finish case washers. They were experiencing inadequate rust prevention, sticky residues, limited biostability, and decreased sump life. This producer was looking for a product that would improve upon all the previously stated product issues. By introducing QUAKERCLEAN® 624 MPC in the producer’s process, they experienced a total chemical cost savings of $11,651 for one finish case washer per year, and the scrap/rework rate dropped by 40%.
Cold Rolled Steel
QUAKERCLEAN® 624 CP
A major automotive manufacturer needed a cleaner for use in their new final connecting rod washer at its engine production plant. The plant was washing HS170 powdered metal connecting rods with bronze brushings and required 30-60 days of indoor rust protection. By employing QUAKERCLEAN® 624 CP, Quaker Chemical delivered clean parts with 90 days of rust protection at 4% solution concentration, for a total annual cost of only $3,808 after ramp up. As a result, Quaker Chemical was awarded the entire cleaning business at the plant.
A major cold rolled sheet producer who supplied the automotive market was being plagued by rejects due to stain. While some defects were detected when “in-process,” many were not discovered until delivery was made to the customer, resulting in costly claims and rework. By switiching to FERROCOTE® EGL-1 the producer was able to achieve annual cost savings of over $3 Million through product cost savings, decreased rejects, and decreased rework.
Tapping Steel Auto Components
FERROCOTE® 5856 BF T1
A major producer of bearings wanted to improve operational efficiencies at one of its manufacturing sites by Improve long-term corrosion protection on parts, eliminating an aqueous process cleaning step, and reducing overall manufacturing costs. By switching to FERROCOTE® 5856 BF T1 the producer was able to eliminate the process cleaning step resulting in a savings of $75,000/yr, reduced labor costs of 15%, 20% cost reduction in corroded parts, 1.5% improvement in part failures.
Heavy Equipment Components
A major global automotive components manufacturer in the United States was experiencing issues with their competitive coolant including low tool life, poor surface finish, and high consumption leading to high cost. The customer was specifically looking for Quaker to improve tool life, reduce dermatitis, and decrease foaming. QUAKERCOOL® 7450, a semi-synthetic, low foaming micro-emulsion designed to provide the lubrication needed for demanding machining such as tapping, deep hole drilling and reaming provided a 17% Increase in tool life on rack tap, cost savings by reducing the concentration from 17% (competitive fluid) to 10% (QUAKERCOOL® 7450), eliminated dermatitis issues, extended sump life, and reduced carryout rates.
Machining & Grinding
A major manufacturer of precision pins, planet shafts and sleeves for trucks and heavy equipment was experiencing microbiological mold and fungi issues, including some machine rusting. The customer turned to Quakercool 750 which resolved the initial issues in addition to providing an improvement in tool wear and overall cost savings.
Stainless Steel Machining
A global automotive manufacturer performing machining and grinding on cast iron cams and cranks was looking to replace their current coolant in order to reduce coolant costs, lower usage rates. By switching all three of their coolant systems to QUAKERCOOL® 740, the customer realized a total annual cost savings of $50,033, lowered usage rates due to reduced carry off on the part, and reduced make-up rates by 2.5%.
Titanium & Alloy Steel
A large machining workshop specializing in bar turning and precision machining of small to medium series parts on various materials such as steel, stainless steel, aluminum, and yellow metals was looking to Increase tool life, lower consumption, and improve productivity. After a three month trial of QUAKERCOOL® 7350, the customer realized the a nearly 100% increase in tool life for stainless steel turning inserts, improved machine cleanliness and detergency, and lowered consumption due to 1% decreased make up rate.
Hot Mill Rolling
A large manufacturer of cycling equipment in the United States was producing machined components including cranks, hubs, and free wheels from a number of different materials. The customer was looking to replace a chlorinated coolant, eliminate occasional foaming, remove tacky residues and reduce costs without diminishing machining performance. QUAKERCOOL® 7350 met all of these objectives while reducing cost per gallon and showing an average tool wear reduction of 11-13% on operations as difficult as titanium hobbing.
A UK Steel producer was implementing a modification to their passive transfer system based on a high-water content HF to help improve operational efficiencies, but were experiencing delays and lost coils. By switching to QUINTOLUBRIC 888® 46 the reliability significantly improved to 65% decrease in delays and no lost coils.
One automotive supplier acted to prevent fire hazards, loss of production and personnel injuries by evaluating solutions to their press hardening lines. Through careful consideration amongst cross functional teams, the supplier identified switching from a mineral oil hydraulic fluid to QUINTOLUBRIC® 888-46 as the best solution to bridge cost-effectiveness, downtime, and overall safety.
Continuous Steel Casting
One automotive supplier making die cast parts was experiencing significant costs due to pump wear and short lifetimes. The outcome of switching to QUINTOLUBRIC® 888 was a 91% reduction in pump wear, 5x longer pump life, up to 3x longer seal life, and 5% reduction in power consumption.
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A major stainless steel producer was experiencing severe reliability issues with their hydraulically actuated slab tongs on their continuous slab caster line. The hydraulic system ran on a premium water-glycol fluid. By switching to QUINTOLUBRIC® 888-46 the steel producer experienced significant cost reduction on hydraulic pumps, components, and fluid maintenance and costs.
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