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TRIM Metalworking Fluids For more than 60 years TRIM® metalworking fluids has lead the industry for all types of cutting and grinding operations. Known worldwide for superior performance, TRIM meets the demands of specialized industries such as automotive, aerospace, and medical parts manufacturers. For the full range of cutting and grinding applications for synthetics, semisynthetics, and soluble oils, TRIM delivers longer tool and sump life, better finished parts, and a better bottom line.
neo-synthetic neo-synthetic Our neo-synthetics, a revolutionary new category of fluid formulated with leading edge technology, is changing the way the industry looks at coolants. Neo-synthetics keep machines running clean using the most environmentally-safe ingredients satisfying strict environmental advocates, safety professionals and demanding production managers alike.
neo-synthetic
MicroSol MicroSol® Products For ultimate performance: TRIM® MicroSol® semisynthetic microemulsion coolants deliver high-performance lubricity and ultimately lowers costs. Achieve precision parts, exceptional tool life, extended sump life, assured regulatory compliance, and greater profitability with the MicroSol product just right for your production. Designed to meet the rigorous demands of the aerospace, medical, automotive, or high production, precision parts manufacturing industries, there's a MicroSol to answer your concerns, ramp up your production, and boost your bottom line.
MicroSol
Emulsions Emulsion Cutting & Grinding Fluids Geared up for production: With superior lubricity and a higher oil content, TRIM® emulsions provide a greater boundary layer between the tool and the material. TRIM Emulsions are ideal for lower, less than 600 SFPM, applications such as broaching, reaming, deep hole drilling, drilling, tapping, and centerless grinding. Emulsions work well for machining copper, yellow metals, steel alloys, cast aluminums, wrought aluminums, and tough-to-machine titanium and nickel-based alloys.
Emulsions
Semisynthetics Semisynthetic Cutting & Grinding Fluids Cutting edge solutions: TRIM® semisynthetics offer the cooling and lubricity of a synthetic without the higher oil content of an emulsion. Designed to operate at higher SFPM, semisynthetics perform well on many operations including face milling, cut-off turning, grinding, tapping, and drilling — depending on the specific product. Semisynthetics are compatible with alloy steels, tool steels, cast irons, copper alloys, as well as plastics and composites. With less carryoff, semisynthetics use less material — it all adds up to lower costs.
Semisynthetics
Synthetics Synthetics Cutting & Grinding Fluids Peak your performance: TRIM® clean-running synthetics contain little-to-no oil. They are hard-water tolerant with good corrosion protection. Plus, synthetics leave very low residue for easy cleaning. Paired with extremely low carryoff, synthetics translate to less maintenance and lower operational costs, saving you time and money. Run clean and long with TRIM synthetics.
Synthetics
VHP VHP® Product (Very High Pressure) Stand up to pressure: TRIM® VHP® (Very High Pressure) fluids perform in high-volume, high-pressure applications with little to no foam. These specialized heavy-duty emulsions (or soluble oils) are used in very high-pressure operations where extreme lubrication is required. VHP soluble oils provide the boundary lubrication necessary in operations such as creepfeed grinding, drilling, milling, turning, tapping, or roll-form threading of multiple metals. VHP soluble oils leave a soft, fluid film for easy cleaning, and lower maintenance costs.
VHP
Straight Oils Straight Oil Cutting & Grinding Fluids Straight to the point-of-cut: TRIM® straight oils, used "straight up", without dilution of water, provide maximum lubricity. Typically used for operations such as Swiss-style screw machines, honing, grinding very difficult-to-machine materials, and gun drilling. Depending on the specific product, some TRIM straight oils are a high-end blend of various base oils; while others contain extreme-pressure additives to control built-up edge and for added tool life. Get straight to the cut with TRIM straight oils.
Straight Oils
High Performance Straight Oils High Performance, Highest Purity Straight Oils Tough water white grinding oils: Use TRIM® high purity, high performance straight oils for tough carbide and HSS tool grinding. Utilizing either highly refined hydrocracked base oils, fully saturated esters or a combination of the two ensures very low levels of mist, foam and consumption rates while delivering safe, high flash points. TRIM high performance straight oils provide excellent wheel flushing properties, good friction reduction qualities and workpiece cooling. High purity delivers tough grinding performance.
High Performance Straight Oils
Tapping Tapping Compounds Added machinability: With strong friction-reducing properties, TRIM® TAP synthetic and synthetic blend straight oils are made for metals of low machinability. For added lubricity on extremely tough jobs, TAP oils ensure longer tool life, excellent surface finish, and parts size control. All TAP products are compatible with all TRIM coolants. Don't get tapped out — put TRIM TAP fluids to work for you.
Tapping
Honing Honing Oils For production honing and superfinishing operations. TRIM® Honing Oils can be used with a variety of work materials and stones.
Honing
Specialty Specialty Fluids Specially suited to your operation: TRIM® specialty fluids are specifically tailored to unique needs, such as very high-pressure or high-volume applications, or to address specific code or approval requirements. Whatever your problem or unique requirement, there is always a TRIM solution for you.
Specialty
Master STAGES Cleaning & RP Fluids As effective cleaning and metal protection is essential to attaining precision parts and exceptional surface finish, Master STAGES' products include a full line of parts cleaners, corrosion inhibitors, and maintenance cleaners. Designed for aerospace, medical, automotive, energy exploration, heavy equipment, and general manufacturing production, these products meet stringent requirements to keep customers environmentally compliant, running at peak performance, and more profitable. Have health and safety issues? Problems with foam? Rust? Coolant or oily residue on parts? High disposal costs? Whether you are a mega-manufacturer or job shop, whatever your production problems and concerns, we have a performance-proven product specifically designed to meet your needs and make the real difference. It's the Master STAGES difference — the right solution for the job at the right price.
Cleaners Master STAGES™ Cleaners & Washing Compounds For single to multi-stage spray, high-pressure, immersion, and ultrasonics washers, Master STAGES™ highly-concentrated cleaners and aqueous-based washing compounds offer long sump life and tramp oil rejection, low foam, low mist, low carryoff, and biostability — many with no EP additives or SARA 313 reportable ingredients. Looking for onestep corrosion protection? Have problems with hard water? Or foam? Looking for cleaner parts at lower cost? Cleaning residues from coolant and light oil? Or removing more stubborn grease, heavy oil, drawing compounds, lubricants, waxy soil, oxidation, or rust? For metals ranging aluminum, steels, cast iron, stainless steels, alloys, brass, bronze, copper, to magnesium, there is a Master STAGES cleaner targeted to do the job. Master STAGES line of synthetic and semisynthetic in-process sump and central system cleaners dramatically extend coolant life and remarkably reduce downtime. And our hard-working maintenance cleaners get the grit and grime from machines, work surfaces, ceramics, plastics, glass, and floors — without harmful, corrosive, chemical compounds. Get it really clean with Master STAGES!
Cleaners
Spray Spray Alkaline In-process Cleaners By flooding parts with the chemical cleaner, spray cleaning offers a fast, effective way to remove soil, coolant, and oil residue from a variety of metals, and Master STAGES spray cleaners are specially tailored to do the job quickly, effectively, with less makeup, and no staining of parts. Master STAGES in-process spray cleaners are tough and fast-acting with very low V.O.C. and no SARA 313 reportable ingredients. There's a Master STAGES spray cleaner specifically designed for cleaning residues ranging from coolant, light to heavy oil, grease, drawing compounds, lubricants, waxy soil, oxidation, or rust from metals ranging from aluminum, steels, cast iron, stainless steels, alloys, brass, bronze, copper, to magnesium. Offering increased life, good tramp oil rejection, low odor, low foam, and low mist, and additional corrosion protection, highly-concentrated Master STAGES spray cleaners produce clean parts while reducing overall costs.
Spray
Immersion Immersion Alkaline In-process Cleaners Immersion washers effectively remove residue from light to heavy soils, light rust, coolant, oil, drawing compounds, lubricants, waxy soil, and corrosion inhibitors. Designed for cleaning aluminum, steels, cast iron, stainless steels, alloys, brass, bronze, copper, and magnesium and for multiple-metal situations, Master STAGES highly-concentrated cleaners allow immersion washers to run at lower concentrations and lower temperatures with increased bath life, less foam, and added corrosion protection. Environmentally friendly, and free of SARA 313 reportable ingredients, cost-effective Master STAGES immersion cleaners ensure exceptional parts cleaning while using less product and less energy — for a better bottom line.
Immersion
Ultrasonics Ultrasonic Alkaline In-process Cleaners Ultrasonic parts washers — widely used in the medical, aerospace, automotive, mining, energy, and precision parts industries — offer results often far beyond that of traditional cleaning methods. Master STAGES specifically developed ultrasonic in-process cleaners are highly effective in removing dirt, oils, rust, bacteria, grease, drawing compounds, waxy soil, and other contaminants from a wide variety of metals. Whether cleaning aluminum, steels, cast iron, stainless steels, alloys, brass, bronze, copper, or magnesium, Master STAGES has the ultrasonic in-process alkaline product to get it really clean. Offering exceptional wetting ability, reduced cycle times, longer bath life, and faster, safer precision parts cleaning, yet are environmentally friendly and free of SARA 313 reportable ingredients, Master STAGES ultrasonic cleaners are the cost-effective solution to achieving a matchless surface finish.
Ultrasonics
Maintenance Maintenance Cleaners Whether cleaning true grit or light soil from machines, work surfaces, glass, or floors, there's a highly-concentrated, cost-effective Master STAGES cleaner to get the job done and save hours of maintenance. So, don't just get it clean — get it Master STAGES clean! Master STAGES highly concentrated Whamex™ sump and central system cleaners for interim and full cleanouts extend sump life, are very cost effective, and greatly reduce downtime. All Master STAGES environmentally-friendly products are safe for human contact and free of harmful, corrosive chemicals and troublesome SARA 313 ingredients.
Maintenance
Corrosion Inhibitors Master STAGES™ Corrosion Inhibitors Nothing is more counterproductive to superior surface finish than corrosion. Highly-effective Master STAGES corrosion inhibitors provide excellent protection on metals ranging from cast iron, steels, and other ferrous metals, aluminum and copper alloys, brass, and bronze with protection ranging from several days to a full 12 months and longer. Whether needing indoor corrosion protection during interim steps of the machining process, long-term outdoor protection, or for shipping parts overseas, there is a Master STAGES product to give you the assurance you need. Master STAGES rust preventatives (RPs) can be applied by dip, flood coating, ambient-temperature or heated spraying, roller, or brush, are easily removed — and most are barium-free with low V.O.C. content. Get cost-effective protection you can rely on with Master STAGES RPs.
Corrosion Inhibitors
Synthetics Synthetic Corrosion Inhibitors Highly-concentrated and economical, Master STAGES™ synthetic corrosion inhibitors leave a thin, water soluble film to provide one-to-two months of rust and oxidation protection. Clean and very low foaming, Master STAGES synthetic corrosion inhibitors are barium-free with very low V.O.C. content.
Synthetics
Emulsions Emulsion Corrosion Inhibitors Protect metal parts from rust and oxidation for up to six months with super-concentrated, very economical Master STAGES™ emulsion corrosion inhibitors. Barium-free with very low V.O.C. content, environmentally friendly Master STAGES emulsion corrosion inhibitors are built for low-pressure spray, immersion, and dip applications.
Emulsions
Cleaners+RP Cleaners+RP Corrosion Inhibitors Master STAGES™ CLEAN family of advanced-technology products offer highly effective cleaning and with the same in-process "one-step" method, leave behind an effective, short-term, anticorrosive film. Designed for specific metals, desired length of corrosion inhibition, and applications ranging from spray, immersion, ultrasonic parts, and dip tank cleaning, Master STAGES cleaners+RP inhibitors are all highly concentrated and economical, most with low foam and very low V.O.C. content.
Cleaners+RP
Oil/Solvent Oil/Solvent Corrosion Inhibitors Master STAGES™ oil- or solvent-based corrosion inhibitors, or rust preventatives, are nonstaining, water displacing, and can be used on a wide variety of metals. Whether dipping or spraying, short or long term, there's a very highly concentrated, rugged Master STAGES corrosion inhibitor to give you the protection you need.
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TRIM<sup>®</sup> Coolant Speeds Up Production of Valuable Compressors Needed to Fight COVID-19 Pandemic TRIM® Coolant Speeds Up Production of Valuable Compressors Needed to Fight COVID-19 Pandemic Due to the COVID-19 pandemic, medical centers and pharmacies have had an unprecedented need for refrigeration units to help store lab specimens, medications, and vaccines. Therefore, refrigerator manufacturers have required a high volume of compressors on extremely short notice. The demand has become so high that several companies — including plants based in Asia producing bearings and rollers for rotary compressors — have seen their lead time increase from two to eight weeks, significantly slowing down the production of these life-saving components. THE CHALLENGE THE SOLUTION The customer grinds large amounts of cast iron and steel to produce compressor components. Despite replacing their synthetic coolant every three months, the customer struggled with the effects of dirty coolant, foam, and inadequate rust protection. This led to inconsistent finishes and the need to rework parts. The downtime for cleaning machines and changing coolant, grinding wheel replacement, and scrap parts lowered throughput and overall productivity. This was very costly from a production standpoint as well as delaying the delivery on life-saving components. The customer switched from their existing synthetic coolants to the TRIM® cutting fluids from Master Fluid Solutions™. The signature coolants provide improved sump life, foam control, filtration capability, tramp oil rejection, and reduced carry off compared to competitors. Many also have the multi-metal compatibility demanded by the HVAC manufacturing industry. Several of our TRIM fluids meet the requirements of the ASHRAE 97 standard sealed tube tests, and we will run additional individualized manufacturer tests as needed. TRIM C380 and TRIM C270 offer a wide range of ferrous compatibility and corrosion protection; and semisynthetic solutions such as TRIM MicroSol® 585XT and the new HyperSol™ 888NXT are chlorine-free, offering a lower environmental impact. HyperSol 888NXT is also a USDA Certified Biobased Product due to its sustainability profile. THE RESULTS THE NUMBERS After switching to TRIM, the customer experienced an immediate improvement in their productivity. TRIM coolants stay cleaner for longer, reducing the amount of machine downtime, disposal odors, and mist in the environment. Foam was also significantly reduced, leading to improved filterability and increased productivity. TRIM is so successful at rejecting tramp oil, the customer has not had to replace their coolant in over eight months, eliminating machine downtime for system cleanouts. Both plants have cut their coolant consumption by 50 percent and reduced fluid costs by 30 to 40 percent. The higher quality of TRIM cutting fluids has led to more consistent finishes and eliminated the need for costly rework. The increased productivity and reduction of waste have caused profits and productivity to soar for both facilities. • Reduced coolant consumption by 50% • Reduced cutting fluid costs by 30-40% • Reduced machine downtime and additives for foam • Extended coolant life to 8 months and counting • Eliminated machine downtime needed for system cleanouts ©2021 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-04-14
Coolant Speeds Up Production
Global HVAC Industry Leader Cuts Production Costs With TRIM<sup>®</sup> MicroSol<sup>®</sup> 692XT Global HVAC Industry Leader Cuts Production Costs With TRIM® MicroSol® 692XT Our customer is a manufacturer recognized as a global leader in the field of high-precision metal components, especially those with single-digit micron tolerances. The company has over a dozen facilities worldwide and provides components for several industries, including automotive, HVAC, consumer goods, and fluid power. THE CHALLENGE THE SOLUTION The customer has three drill machines dedicated to manufacturing metal shafts for compressors. The machines required 10 gallons of makeup coolant per day to maintain proper concentrations, leading to a high consumption rate and coolant costs. From past experience, the shop floor manager was aware the cutting tools were not lasting as long as they should. So, the company approached Master Fluid Solutions to find a cost-effective way to mitigate coolant makeup rates and extend tool life. After an on-site consultation and review with a Master Fluid Solutions district sales manager, the customer took advantage of our FIRST CHARGE NO CHARGE® Program and began a one month trial of TRIM® MicroSol® 692XT. The high-lubricity, semisynthetic, microemulsion coolant was perfectly suited to materials they were machining. This next-generation formulation provides greater biostability and foam control while extending sump life compared to the semisynthetic microemulsions of the past. Immediately, the customer discovered that MicroSol® 692XT maintained proper coolant concentrations with half the amount required by their previous cutting fluid. THE RESULTS After upgrading from their previous cutting fluid to TRIM® MicroSol® 692XT, the coolant makeup rate was cut by 50%, and the customer went from using 10 gallons of coolant to only 5. With MicroSol® 692XT as their coolant, tool life was increased substantially. The company only had to change tools 813 times per year, down from 1,083, a 25% decrease. By extending tool life, each drill processed 800 metal shafts before needing replacement, compared to 600 with their previous coolant solution. These factors contributed to a massive increase in productivity with substantial cost savings. Total cost per part was reduced to $0.2114, down from $0.2310. This brought annual costs of production down to $142,688 from $156,807. Though TRIM® MicroSol® 692XT costs more than the company’s previous coolant solution, the increased productivity and lower production costs translated to $14,119 in savings annually. THE NUMBERS • 50% reduction in coolant application rates • 8.48% reduction in cost per part • 25% extended tool life • $14,119 in annual savings ©2021 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-2-23
MicroSol® 692XT Cuts Cost
WEDOLiT™ FW 9200 Replaces Lubricants, Coolants & Corrosion Protectants in 18-Step Ammunition Manufacturing Process WEDOLiT™ FW 9200 Replaces Lubricants, Coolants & Corrosion Protectants in 18-Step Ammunition Manufacturing Process The customer has produced ammunition from their site in Germany for over 60 years. Recognized as a leader in the European defense industry, the company currently offers three primary product lines designed to meet the needs of police departments and military personnel. THE CHALLENGE THE SOLUTION To manufacture ammunition, the customer follows an 18-step process that draws brass cartridges using a variety of Fritz Werner machines. The equipment ranges in age, from brand-new models to others that are approximately 30 years old. Therefore, the number of steps in the production process and the differing needs of the machinery require numerous fluids that are specific for forming, lubrication, and cooling operations. Utilizing multiple fluids across the production line increases material costs and the amount of time for each phase of production. Although specialty fluids were used when manufacturing, the brass workpieces often could not withstand the drawing process or caused stains to appear on the metal after tempering. The customer switched to WEDOLiT FW 9200, a versatile, ester-based, water-miscible forming lubricant that can be universally applied throughout forming and drawing processes of brass and non-ferrous metals. FW 9200 can be applied at higher or lower concentrations, adapting to the severity of the forming process at hand. THE RESULTS THE NUMBERS FW 9200 features advanced wetting ability and stable load carrying capacity, allowing the customer to use one fluid across the entire 18-step production process. The superior forming lubricant better protected the brass workpieces during production and also eliminated staining after tempering. Cutting the number of fluids needed for manufacturing to only one, significantly reduced both material costs and production times, as workers no longer needed to remove and apply multiple products. The success of FW 9200 inspired the customer to try WEDOLiT CS 8376 on their other operations, with more trials to come. • The versatility of WEDOLiT FW 9200 allowed the customer to replace a full-range of specialized fluids from multiple manufacturers with one single solution • FW 9200 outperformed every specialty fluid previously used and eliminated workpiece staining ©2021 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-2-19
WEDOLiT™ FW 9200 Replaces All
Global Automotive Parts Manufacturer Eliminates Corrosion With WEDOLiT™ AN 7210 Global Automotive Parts Manufacturer Eliminates Corrosion With WEDOLiT™ AN 7210 As a global automotive parts manufacturer, the customer’s production line processes metals and alloys — including numerous steel grades — for automakers and their suppliers around the world. THE CHALLENGE THE SOLUTION The customer’s products need to be treated with anti-corrosion solutions to prevent degradation during shipping, especially when sent overseas with long transit times. Due to the various metal and alloy types that the customer works with, solutions are limited to those designed to be compatible with a wide array of workpieces. Also, as the customer ships worldwide, products require protection to sustain extreme temperature ranges. The customer’s previous anti-corrosion product frequently failed, resulting in a high damage rate. Corrosion was found to occur during international transport and interim storage at recipients’ facilities, especially within unheated hallways. The customer’s previous corrosion preventative also contained a high concentration of Volatile Organic Compounds (VOCs) hindering their sustainability and eco-friendly efforts as a business. The customer began a trial of WEDOLiT™ AN 7210, a high technology corrosion inhibitor that works well with steel and other metals and alloys. AN 7210 offers long-term protection for indoor storage and the low viscosity makes it suitable for use in sprayers or as an immersion bath (for hollow parts). It’s specially formulated to prevent corrosion during overseas transport and is free of VOCs, allowing customers to minimize their environmental footprint. THE RESULTS THE NUMBERS The customer experienced immediate cost savings when switching to WEDOLiT AN 7210. The high-quality product required less solution than the customer’s previous anti-corrosion product, translating into a 10 percent reduction in overall consumption. Productivity was also increased because the corrosion preventative no longer had to be applied manually. The lower viscosity formulation allowed the product to be sprayed, making for a more efficient application. What’s more, the elimination of VOCs allowed the company to better align with its environmental protection commitment. Finally, customer complaints were noticeably reduced to less than 2 percent as shipments no longer arrived damaged and the low-odor formula became less of a nuisance. • 10% reduction in overall consumption and future order quantities • Significantly reduced production time through the automation of the application process • Customer complaint volume was reduced to less than 2% ©2021 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-02-01
WEDOLiT AN 7210 Eliminates Corrosion
Driveshaft Manufacturer Drastically Reduces Costs and Filter Bag Use with Master Fluid Solutions Driveshaft Manufacturer Drastically Reduces Costs and Filter Bag Use with Master Fluid Solutions A quality automotive part, particularly something like a driveshaft, helps ensure that drivers return home safely. In auto repair, both original equipment manufacturer (OEM) and aftermarket parts are used, and these parts need to meet certain specifications regardless of the price paid by the consumer. A driveshaft manufacturer, who manufactures both OEM and aftermarket driveline components, needs their parts to perform well in commercial and off-road vehicles, as well as in industrial applications. From their manufacturing headquarters in the Midwest, they conduct turning and milling operations on steel, aluminum, and carbon fiber. The company operates over 50 metalworking machines to manufacture driveshafts, driveline components, and universal joints for OEM automotive, agriculture, and off-road vehicles. THE CHALLENGE THE SOLUTION The driveshaft manufacturer was currently using a coolant which had poor sump life and was causing rusting and residue issues. The rusting, in particular, was a big concern for the company, as was the heavy, green residue buildup on tool holders, doors, and walls. They decided to search for a new coolant, hoping to resolve these issues. TRIM® MicroSol® 585XT was chosen to replace two different coolants that they were using. This is a high-lubricity, semisynthetic, microemulsion coolant that is ideal for a variety of materials, including all the materials commonly used in the manufacturing of driveline components that the manufacturer works with on a daily basis. Additionally, MicroSol 585XT helps inhibit corrosion and keeps the machines clean, leaving only a soft film that can be easily removed during routine cleaning and maintenance. THE RESULTS After switching to MicroSol 585XT in February 2020, the manufacturer immediately noticed a significant reduction in the filter bags they used – down to two per month, from 19 with the previous coolants. Additionally, there was no more heavy, green residue on the machinery or rusting issues. Due to the success of switching to MicroSol 585XT, the driveshaft manufacturer is planning to test additional products from Master Fluid Solutions. Additionally, the success is proving to be a driving force for many other improvement projects across their metalworking shop floor. THE NUMBERS • 90% reduction in filter bags used • 50+ machines in operation • 5,000-gallon central system ©2021 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-01-29
90% Filter Bag Reduction
WEDOLiT™ AN 7321 Eliminated Need for VCI Packaging WEDOLiT™ AN 7321 Eliminated Need for VCI Packaging The customer is an international parts manufacturer serving automakers and their suppliers worldwide. The company operates multiple production lines that process an extensive array of materials, ranging from unalloyed and low-alloyed to high-alloyed steels. THE CHALLENGE THE SOLUTION The customer’s products are shipped overseas to environments that include extreme high and low temperatures — and these conditions make them vulnerable to corrosion. Despite using high-quality protective volatile corrosion inhibitor (VCI) packaging, products still suffered from high damage rates due to corrosion. The items that arrived undamaged would frequently corrode during interim storage, especially in facilities with unheated hallways. The previous anti-corrosion solution left materials prone to under-rusting, creating smoke when applied on parts still warm from the production line. Additionally, due to the variety of metals and alloys the customer worked with, it was a challenge to find a corrosion protection formula that could be universally applied. The customer began a trial of WEDOLiT™ AN 7321 anti-corrosion oil. It works by forming a non-hazardous and non-toxic oil film on the metal surface to provide protection against weather, moisture, and extreme temperatures. Additionally, the flashpoint of AN 7321 is higher than 195°C, making it adept at preventing corrosion in the most extreme temperatures and offers several months of protection for indoor storage. THE RESULTS After converting to WEDOLiT AN 7321, complaints from overseas customers dropped to less than 10 percent, a significant decrease from the high damage rate and dissatisfaction from the previous competitor product used. Plus, AN 7321 created significantly less smoke than the customer’s previous product when applied to warm workpieces, allowing employees to maintain productivity without affecting air quality inside the workshop. WEDOLiT AN 7321 offers strong enough protection that VCI components are no longer needed. The non-hazardous formula is more beneficial for workers as well. Since the trial, nearly every production line has switched to WEDOLiT. THE NUMBERS • Lowered customer complaint rate to under 10% • 100% reduction in the necessity of VCI packaging • Significantly reduced smoke produced in workshop ©2021 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-1-29
VCI Packaging Not Needed
Mechanical Parts & Tool Manufacturer Reduces Coolant Spend by 55% with TRIM<sup>®</sup> Mechanical Parts & Tool Manufacturer Reduces Coolant Spend by 55% with TRIM® For over 100 years, the customer has produced high-quality motors, industrial tools, and solenoids for a variety of industries. The manufacturer prides itself on using the latest technology to deliver orders to specifications and meet OEM requirements, and all components are manufactured in its 100,000 square foot facility in the Midwest. It primarily works with aluminums, stainless steels, and steels on various machining centers. THE CHALLENGE THE SOLUTION The customer had to use high concentrations of its existing coolant to achieve acceptable tool life and surface finishes. However, this meant using more coolant than necessary, driving up costs and leaving sticky residues on machines that required regular cleaning. Additionally, the coolant supplier didn’t provide support for mitigating these issues. They considered purchasing expensive coolant recycling equipment, hoping the investment would pay for itself. Unfortunately, projections indicated there would be little ROI, and the maintenance of the equipment could outweigh the savings. After meeting with Master Fluid Solutions representatives, the customer recharged its sumps with TRIM® MicroSol® 585XT, a high-lubricity, semi-synthetic, microemulsion coolant, which is more suited to their multi-metal machining operations. TRIM® MicroSol® 585XT also requires lower recommended concentrations and lower makeup rates than their existing coolant which could help lower costs. THE RESULTS THE NUMBERS After the switch to higher-quality TRIM® MicroSol® 585XT, coolant use decreased sharply (by 360 gallons annually) because it requires less frequent charging and disposal. Though TRIM® MicroSol® 585XT is 15 percent more expensive than their current product, the customer is expected to save over $7,800, or 55%, per year in coolant spending, and has improved tool life and finishes when machining aluminum. By choosing Master Fluid Solutions’ coolant, they avoided capital and maintenance expenses related to purchasing new equipment. After receiving free product for testing, and assistance from Master Fluid Solutions in cleaning and recharging two of their machines, the customer grew interested in learning more about other Master Fluid Solutions’ products. A free one-gallon trial of Master Stages Skramex immediately proved to have more cleaning power at lower concentrations than their current floor cleaning solution, resulting in the company converting to this product as well. • 360 gallon decrease in annual coolant use • 55% decrease in coolant spending • $7,816 in annual savings • Increased tool life ©2021 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-1-27
Reduced Coolant Spend by 55%
Steel Plant Celebrates 20 Years Without Product Corrosion Due to WEDOLiT AS 2603 Steel Plant Celebrates 20 Years Without Product Corrosion Due to WEDOLiT AS 2603 The customer is a globally recognized mechanical engineering plant specializing in the manufacturing of large steel parts for industrial concrete products. The company serves markets in all climates across the world, including the United States, Canada, Vietnam, Australia, and the United Arab Emirates. THE CHALLENGE THE SOLUTION The plant ships and stores large steel workpieces (ranging in size from 10-15m.) overseas through incredibly diverse climates and environments, with temperatures ranging from as low as -30°C to as high as 40°C and above. Workpieces must be treated with an anti-corrosion solution to prevent degradation while transported and stored in extreme temperatures. The customer’s previous solution was unsuccessful, resulting in high damage rates during shipping and issues with pitting corrosion from long-term storage. In 1999, the customer switched to using WEDOLiT AS 2603, a solvent-containing, high-protection wax-dispersion fluid ideal for providing corrosion protection for steel parts during overseas transport. After forming a protective film on the metal surface, the anti-corrosion agent protects against atmospheric contaminants such as dissolved gases. AS 2603 was formulated with an innovative thixotropic solution designed to provide protection for extended periods without risking corrosion from high or low temperatures. As a universal solution, it was also compatible with the customer’s existing spraying units. THE RESULTS Since switching to WEDOLiT AS 2603 more than two decades ago, the customer has been able to transport large workpieces to every continent and type of climate in the world without corrosion issues. The solution also prevented corrosion on parts stored in suboptimal conditions for extended periods. In the two decades since converting to WEDOLiT AS 2603, the customer has tested 42 competitor products but still hasn’t found anything better than or even comparable to this Master Fluid Solutions’ product. Preventing corrosion has allowed the customer to drastically increase profits by mitigating costly workpiece damage, replacement, and reshipping. As the customer launches new production lines, estimates indicate that current revenues will increase by 100 percent. THE NUMBERS • 20+ years of overseas shipping and storage in extreme temperatures with no corrosion • AS 2603 proved to perform better than 42 competitor products • Estimated 100% increase in revenues due to cost-savings from well-protected parts ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-11-16
20 Years, No Corrosion
Lakshmi Machine Works Slashes Coolant Spend by 32% with Master Fluid Solutions Lakshmi Machine Works Slashes Coolant Spend by 32% with Master Fluid Solutions The textiles and apparel industry is the second-largest employer in India, with 45 million workers. It comprises 13% of the country’s export earnings, with anticipated 28% annual growth through 2021. As a critical component of the Indian economy, textile manufacturers need to know their machines are reliable. Lakshmi Machine Works Limited (LMW) produces the machines that power this economic sector. It’s the largest manufacturer of textile machines, and it works primarily with steels and grey irons. The company provides the latest spinning technology to Indian textile mills, and it also produces CNC machine tools. THE CHALLENGE THE SOLUTION Grey iron poses challenges to metalworking shops due to its propensity to rust. It also causes some coolant emulsions to fail quickly, change colors, leave heavy residue on machines, and develop rancid odors. In particular, if LMW let a machine sit idle for a few days, the odor from its incumbent coolant would be overpowering upon startup. The coolant formed residue buildup on sensors, which caused the machine to malfunction and necessitated unplanned maintenance. The poor coolant performance not only required cleaning out sumps every six months, but would also create rust issues on parts, requiring downtime and extra steps to create usable parts. LMW chose Master Fluid Solutions’ TRIM™ SC9030SGM, a high-oil semisynthetic coolant designed to inhibit corrosion on ferrous and nonferrous metals. This fluid can resist the “smutting” that results from machining cast irons and reduce residue formation. Additionally, TRIM SC9030SGM helps keep machines clean and eliminates rancid odors. THE RESULTS THE NUMBERS After the switch to TRIM SC9030SGM, sump life increased by 50%, from six months to 9 months. The new coolant eliminated rust issues and drastically reduced smutting, resulting in cleaner machines. LMW was able to reduce the amount of concentration used, resulting in a 32.2% cost savings for coolant. And because it didn’t need to clean machines and change over the coolant as often, LMW decreased its downtime by 30%. In addition, LMW created better working conditions for the operators by eradicating rancid odors. Fewer parts need to be rejected due to rust, and sensor failures due to residue buildup are no longer an issue. • 50% increase in sump life • 32.2% decrease in coolant spend • 30% reduction in downtime ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-11-5
Reduced Coolant Spend by 32%
Steel Tube Manufacturer Halves Dewatering Process Time with WEDOLiT AS 1012 Steel Tube Manufacturer Halves Dewatering Process Time with WEDOLiT AS 1012 A global steel tube manufacturer that has seven plants across Europe and America, has been operating for over a century producing tailor-made tube products for the energy and automotive sectors. The seamless and welded tubes they manufacture need short-term corrosion protection to ensure that no corrosion occurs during the entire process chain. THE CHALLENGE THE SOLUTION THE RESULTS THE NUMBERS In the past, the tube manufacturer has changed the dewatering fluid it used multiple times due to problems with the performance. It also required a premium quality fluid that could cope with the high-volume throughput in its 706-cubic foot immersion bath. The manufacturer wasn’t fully convinced — even after their laboratory tests showed outstanding product performance from the WEDOLiT range — as they didn’t believe that any technology could be better than the one they were currently using. As a result, the manufacturer trialed WEDOLiT AS 1012, a leading-edge dewatering fluid which uses surfaceactive substances to displace both water and emulsions from the metal surface extremely quickly and has corrosion protection properties. After evaporation of the solvent, a thin non-adhesive protective film remains on the surface, which offers corrosion protection for short-term to intermediate storage. Any water or emulsions that enter the bath settle on the bottom of the tank after a short period of time, and can then be drained off. Using WEDOLiT AS 1012, the dewatering time significantly reduced from less than 10 seconds to less than 5 seconds. As a bonus, the length of the short-term indoor storage corrosion protection also drastically improved from a few days to more than three weeks. The manufacturer was so impressed with the results that it has started running trials of other products from the WEDOLiT range throughout the plant. For this steel tube manufacturer, opening the door to Master Fluid Solutions and their technologically advanced WEDOLiT products has proved beneficial. • Reduced dewatering time by 50% • Increased corrosion protection from a few days to more than 3 weeks • Doubled possible throughput of immersion bath ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-07-28
Reduced dewatering time by 50%
Drivetrain Components Manufacturer Reduces Coolant Spending by $186K with Master Fluid Solutions ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-06-18 A drivetrain components manufacturer, specializing in automotive torque converters, primarily engages in turning applications with steel alloy. It operates three large central coolant systems: one at 30,000 gallons, one at 20,000 gallons, and one at 10,000 gallons. There are 100, 50, and 30 machines on each system, respectively. Its primary customers are large automotive manufacturers across the United States. THE CHALLENGE THE SOLUTION THE RESULTS THE NUMBERS In addition to the age-old cost reduction challenges, the components manufacturer was also faced with sump life and service life issues on its machines. Its incumbent fluid resulted in too much foam, smoke in the air, and residue all over the machines. The company decided it was time to reevaluate its entire fluid program to tackle these issues and reduce the amount of metalworking fluid it used. Any fluid it chose would need to be operator-friendly, as well as have a long life in the sump. Changing out the central systems can shut down the entire plant because of the size and number of machines connected to them. The components manufacturer brought in three different metalworking fluid providers to run 60-day tests on its systems. Master Fluid Solutions’ TRIM® SC620 performed well in the test but also offered significant cost savings in the long run. TRIM® SC620 is a low-foam, semisynthetic coolant that is ideal for high-speed milling and turning applications. It provides a long service life, long sump life, and is low-maintenance, which is critical for central systems like the one running at the components manufacturer’s facility. Master Fluid Solutions also provided tramp oil removal systems, and continuously conducts weekly coolant sampling and laboratory evaluations. Based on the results of these reports, Master Fluid Solutions adjusts the coolant. Master Fluid Solutions includes this maintenance as a value-add to help its customers better manage their coolant usage and spending. After switching over to TRIM® SC620, the components manufacturer saw a massive decrease in coolant spending, going from $386,000 to $200,000 annually, a 48% savings. Additionally, the company saw a 22% increase in tool life, an improved surface finish on the final product, and clean machines, without foaming or smoke in the air. Thanks to Master Fluid Solutions, the components manufacturer has achieved its goal of cost savings and improved both the work environment and the finished product. • $186,000 saved annually • 48% reduction in coolant spending • 22% increase in tool life Drivetrain Components Manufacturer Reduces Coolant Spending by $186K with Master Fluid Solutions
$186,000 saved annually
RBC de Mexico Vastly Improves Processes, Cuts Costs with Master Fluid Solutions RBC de Mexico Vastly Improves Processes, Cuts Costs with Master Fluid Solutions ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-06-05 RBC de Mexico, RBC Bearings’ Reynosa plant, primarily machines steel and stainless steel for aerospace, automotive, and industrial customers. The location also handles some aluminum and harder to machine metals, and works on thousands of different parts and models. RBC de Mexico is a major turning facility owned by RBC Bearings and operates 24 hours a day, seven days a week, for 340 days out of the year, requiring long-lasting, durable coolant. THE CHALLENGE THE SOLUTION THE RESULTS As is the case with a lot of metalworking shops, RBC de Mexico wanted to extend sump life, cut coolant costs, and properly maintain its coolant. Several years ago, the company struggled with dirty sumps, rust issues, and rancid coolant odors. The sump was full of bacteria and a health risk to workers. RBC de Mexico wanted a better-quality coolant at a reasonable price, as its incumbent provider was overpriced and not effective. However, the engineering team met with some resistance internally when wanting to bring in new vendors to test different fluids. Some were skeptical that a new coolant could make a difference, and the engineering team had their work cut out, not only to prove that there would be ROI from switching to a new coolant, but also that a new vendor could help improve RBC de Mexico’s processes. RBC de Mexico began an active search for a new coolant. Ultimately, the plant brought in Master Fluid Solutions. TRIM® MicroSol® 585XT was chosen for its machining operations, and Master Fluid Solutions also provided actionable recommendations on how to improve conditions on the floor, like installing skimmers on each machine to remove tramp oil and using water filters and smog hogs. Master Fluid Solutions impressed the team at RBC de Mexico with its deep knowledge of metalworking, and was one of the few vendors willing to travel to Reynosa to tour the plant, demonstrating the company’s commitment to supporting RBC de Mexico during and after the transition. After almost two years of using TRIM® MicroSol® 585XT, RBC de Mexico has achieved approximately $150,000 in overall savings, including what it has saved in coolant costs due to the fluid lasting longer in the sump. However, the real value has come in the form of process improvements that have led to a much cleaner facility. The sumps are cleaner than ever before, meaning less bacteria and less health risks for the workers. Installing the skimmers has reduced the amount of tramp oil in the sumps, drastically reducing the smoke that would accumulate over the machines and increasing the life of the sumps — and smog hogs take care of the rest. RBC de Mexico has had such good results partnering with Master Fluid Solutions that it now plans to implement a coolant recycling program to save even more money. For the Reynosa plant, not only were they able to reduce costs and improve their operations, but they also found a trusted partner in Master Fluid Solutions to guide them through the process. “The service and product knowledge from Master Fluid Solutions is far superior than anything we had received from any of the other companies we had talked to. Their patience and determination helped everything fall into place.” -John Taylor, Engineering Supervisor
$150,000 Saved!
Wilson Tool Finds the Formula for Worker Health & Safety with Master Fluid Solutions Wilson Tool Finds the Formula for Worker Health & Safety with Master Fluid Solutions Global custom tooling company Wilson Tool International provides a complete line of tooling products for the additive, tableting, stamping, bending, and punching industries. From the louvers on the back of a microwave to the back panel of a computer server, if a company needs something to stamp out different forms, Wilson Tool likely makes it. THE CHALLENGE THE SOLUTION THE RESULTS Wilson Tool provides parts to a wide variety of industries, from automotive to information technology. Parts have to be delivered to specifications, with very low tolerance for error. Nothing can be delivered with scratches or dents, and fluids play a large role in ensuring that Wilson Tool’s products meet its customers’ exacting standards. To meet its different metalworking application needs, Wilson Tool purchases three different fluids from Master Fluid Solutions that can be adapted to different applications. TRIM® OGR 263 is the straight oil solution that Wilson Tool uses, along with TRIM® C270 for grinding and TRIM® MicroSol® 690XT. Additionally, worker health and safety can’t be overstated. Employees spend a lot of time in contact with the different fluids for milling, cutting, and other metalworking applications. Regardless of whether the fluid is oil-based, water-based, or pure oil, it needs to minimize dermatitis cases. Wilson Tool has dramatically reduced coolant waste and dermatitis cases on its production floor. The company uses 8,000-gallon tanks to run coolant through its three systems and the coolant lasts at least seven years before it needs to be cleaned out and recharged. The most recent system Wilson Tool cleaned out had been running smoothly for 17 years. Going so long between system cleanouts means less waste is created which equates to a savings of roughly $35,000 every time it can be skipped. With 400 people at its St. Paul, Minnesota facility, it’s very rare that even a single case of dermatitis is reported. While coolant cost and longevity is important, healthy employees have a major effect on the bottom line, too. ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-05-07 “Master Fluid Solutions built a coolant that we can recycle and send back through our machines, and all improvements were made by them. We’ve built a good relationship, and they’re an important partner of ours.” – Duane Berg, Maintenance and Facilities Manager
Coolant Waste Dramatically Reduced
Aerospace Components Supplier Resolves Contamination using Master Fluid Solutions Aerospace Components Supplier Resolves Contamination using Master Fluid Solutions As a leading supplier of aerospace components, contamination is a serious problem. One UK-based supplier that performs milling, turning, drilling, and tapping operations at its facility had to face such an issue. This supplier machines aerospace-grade aluminum, with 19 machines in total consisting of mills, machining centers, and lathes. The aerospace industry requires a precision operation, while also minimizing downtime for the machines. THE CHALLENGE THE SOLUTION THE RESULTS The aerospace components supplier encountered a problem controlling bacterial contamination in its metalworking fluid. This meant it had to conduct regular machine cleans of approximately two to three machines per month. It took half a day to clean and refill the machines and the lost machine time cost $76 per hour. The existing metalworking fluid also periodically caused machining issues. The machines would tap oversize holes, which meant those component parts would have to be completely scrapped. Each scrapped component resulted in a $2,330 loss. Weary of losing more money and productivity, the aerospace components supplier agreed to a six-week trial of TRIM® E715, run at 6% to 10% concentration. TRIM E715 is a universal soluble oil that requires minimal maintenance and is suitable for machining aluminum, steel and nickel alloys, as well as cast iron and yellow metals. The trial of TRIM E715 resolved the bacterial contamination issue completely, eliminating the need for costly cleanouts, a saving of nearly $9,325 per year. Resolving bacterial contamination also removed the bad odors that operators frequently complained about. All machines have since been switched over to TRIM E715. TRIM E715 also fixed the issue with oversized holes that resulted in scrapped parts. The aerospace components supplier has had no reports of issues since the conversion. And, as a bonus, several operators who suffered from dermatitis with the former metalworking fluid have had their skin clear up since the switch to TRIM E715. ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-04-16 “During the six-week test run, we resolved the bacterial contamination issue, leading to no need for costly cleanouts since April 2019.” -Machine Shop Manager
Saved Nearly $9,325
Aerospace Components Manufacturer Reduces Consumption with Master Fluid Solutions Aerospace Components Manufacturer Reduces Consumption with Master Fluid Solutions Even a company with decades in the industry will occasionally struggle with its cutting fluid consumption. A large UK-based aerospace components manufacturer that performs milling, turning, and grinding operations experienced this firsthand. Their location houses over 100 machines that work with a range of materials, including aluminum, steel, titanium, and Inconel. Along with achieving performance objectives, they also needed to meet local and internal health, safety, and environmental standards. THE CHALLENGE THE SOLUTION THE RESULTS Poor coolant stability resulted in a costly and time-consuming regime of biocide additions to the majority of the machine sumps at their manufacturing site. Without the biocide additions, the coolant would not meet regulatory health, safety, and environmental requirements or internal health and safety standards. The components manufacturer set a coolant life expectation of 18 months as part of the planned maintenance clean-out process, but the biocide was necessary to reach that target. Additionally, machine operators did not like the existing coolant; it emitted a bad odor. To deal with this challenge, the components manufacturer actively sought out a product to test in its machines to eliminate the need for additives and improve operator acceptance. That product was TRIM® MicroSol® 590XT, an environmentallyfriendly, semisynthetic, microemulsion metalworking fluid. A six-month test run of TRIM MicroSol 590XT proved that no biocide additions were needed to meet the company’s coolant life expectancy standards. Additionally, using TRIM MicroSol 590XT reduced consumption. The top-up strength for its former coolant was 2%, and with TRIM MicroSol 590XT, it was lowered to 1%. Machine operators also accepted the new coolant enthusiastically. They began asking for TRIM MicroSol 590XT to be put in all of their machines. The company is currently in a planned conversion process with the possibility of the remaining machines moving to TRIM MicroSol 590XT. They’re also looking at opportunities to supply TRIM products to the remaining companies under their company umbrella. ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-04-16 • Top-up strength halved from 2% to 1% • Biocide additions no longer needed • Machine operators requested TRIM MicroSol 590XT in all their machines
Reduced Consumption!
High-Precision, Tier 1 Aerospace Parts Manufacturer Increases Tool Life 234% with Master Fluid Solutions High-Precision, Tier 1 Aerospace Parts Manufacturer Increases Tool Life 234% with Master Fluid Solutions ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-04-16 A European manufacturer specializing in high-precision parts for the aerospace industry is a top-ranking supplier to major companies, including Airbus. It operates eight different sites across the continent and is dedicated to providing reliable, on-schedule production and innovative parts, as well as meeting the comprehensive requirements of its customers. THE CHALLENGE THE SOLUTION THE RESULTS Like all metalworking shops, aerospace part manufacturers are constantly striving to produce quality parts in an increasingly competitive environment. Lowering production costs through reduced usage of consumable items, such as cutting tools or increasing productivity through reduced part production cycle time, are well known methods. Master Fluid Solutions recommended that the aerospace parts manufacturer run a trial of HyperSol 888NXT in parallel with their incumbent metalworking fluid product. HyperSol 888NXT is an innovative, water-soluble metalworking fluid that Master Fluid Solutions specifically designed for the aerospace industry, particularly for working with harder alloys such as titanium, Inconel, and steel alloys. HyperSol 888XT was installed into two CNC lathes machining 35NCD16 steel alloy. For four months, the aerospace parts manufacturer used HyperSol 888NXT for its steel alloy machining and turning applications in two machines. It proved to be a huge success; tool life increased 234%, while running at a higher speed and much lower top up concentration. HyperSol 888NXT also produced no foam or odor, an added bonus for employees. Based on the company using HyperSol 888NXT in just these two machines for a one year period, it would be able to decrease spending on metalworking fluid by 7.6%. Due to increased tool life and productivity gains, it would save an additional 20.2% or $69,900 in costs. For the highprecision aerospace parts manufacturer, using HyperSol 888NXT proved to be the solution it needed to increase tool life. THE NUMBERS • 234% increase in tool life • 7.6% reduction in fluid spending over one year • 20.2% or $69,900 yearly savings in overall costs for just two machines
Tool Life up 234%
Nuclear Components Manufacturer Reduces Consumption by 30% with Master Fluid Solutions Nuclear Components Manufacturer Reduces Consumption by 30% with Master Fluid Solutions A nuclear components manufacturer produces a wide range of products, including microelectronic hardware, radiation monitoring systems, and integrated instrumentation diagnostic systems. The production facilities include everything needed for the full production cycle, from machine processing and printed circuit board production to surface mounting, assembling, welding, and testing. Its primary metalworking applications are milling, drilling, and turning of aluminum alloys and heat-resistant steel alloys, across approximately 100 CNC machines. THE CHALLENGE THE SOLUTION THE RESULTS THE NUMBERS The advanced nature of the nuclear components from the manufacturer’s metalworking applications means tight tolerance specifications. However, its existing coolant exhibited poor washing properties, which led to flaws in the finished product. The product also experienced short sump life and high fluid consumption, which slowed down production. The nuclear components manufacturer agreed to a trial of TRIM® MicroSol® 515 for its metalworking applications. This coolant is a medium to high lubrication, semisynthetic microemulsion coolant. TRIM MicroSol 515 is ideal for working with mixed metals and aluminum alloys and its translucent emulsion characteristics reduce carryoff to lower costs. The trial period of TRIM MicroSol 515 has been running for two years. In that time, the nuclear components manufacturer has doubled its sump life. Additionally, metalworking fluid consumption has been reduced by approximately 30% and the cost savings overall total 15%. Buoyed by the success of this trial, the nuclear components manufacturer plans to convert all its machines to TRIM MicroSol 515. The high quality of TRIM MicroSol 515, combined with Master Fluid Solutions’ reputation and commitment to its customers, has encouraged the company to expand its product usage. Tests of a neat grinding oil and ultrasonic cleaning fluid are underway. ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-04-16 • Doubled sump life • 30% reduction in fluid consumption • 15% overall cost savings
15% Cost Reduction
Automotive and Aerospace Components Manufacturer Increases Tool Life by 22% with Master Fluid Solutions Automotive and Aerospace Components Manufacturer Increases Tool Life by 22% with Master Fluid Solutions The UK arm of a global manufacturing company specializes in the manufacture of impellers for automotive turbochargers and aerospace turbojet engines. Fully automated 5-axis machining of the titanium, Inconel, and forged aluminum impellers requires high precision and very predictable tool wear. The manufacturer runs 32 machines on site, both roughing and finishing the impellers. ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-04-16 THE CHALLENGE THE SOLUTION THE RESULTS Tool costs are a significant contributor to the overall component cost, especially for titanium and Inconel impellers. Tool life savings are vitally important to improve the competitiveness of the manufacturer versus its rivals. The manufacturer wanted to test a new coolant with the aim of increasing tool life without decreasing machine productivity. After meeting with representatives from Master Fluid Solutions, the components manufacturer agreed to a trial of HyperSol 888NXT. This new class of synthetic watersoluble metalworking fluid was specifically designed for machining the harder metal alloys typically used in aerospace applications. As such, it was the obvious choice for this manufacturer’s challenging requirements. The trial of HyperSol 888NXT lasted four months in the titanium impeller end milling application and one month in the slot cutting application of forged aluminum PS3955. By all accounts, the trial was a resounding success for the components manufacturer. HyperSol 888NXT increased tool life by 22% on the titanium milling application versus a well-known, very high performance aerospace emulsion product. Feedback from machine operators indicated that it was also a much better product to work with due to its superior cleanliness, lack of odor, and significantly lower consumption. Additionally, the components manufacturer achieved $5,683 annual savings per machine. The projected annual tool life savings will be $93,808, and annual coolant concentrate consumption savings are expected to be $17,450. For the components manufacturer, using HyperSol 888NXT not only greatly extends tool life, but also further reduces overall costs by keeping machines and components cleaner, and by reducing coolant concentrate consumption by 50%. THE NUMBERS • 22% increase in tool life • $5,683 annual savings per machine • Annual tool life savings will be $93,808 • Annual coolant concentrate consumption savings of $17,450
Tool Life Up 22%
Aircraft Components Manufacturer Reduces Coolant Usage by 50% with Master Fluid Solutions Aircraft Components Manufacturer Reduces Coolant Usage by 50% with Master Fluid Solutions A U.S.-based aircraft components manufacturer that produces fuselages, pylons, nacelles, and wing elements for commercial and defense aircraft needed to find ways to improve productivity in their plants and decrease costs. They operate multiple facilities globally and provide critical parts to several well-known aircraft manufacturers. THE CHALLENGE THE SOLUTION THE RESULTS THE NUMBERS The manufacturer’s existing coolant was going rancid in a very short period of time. Every two to three months, the coolant had to be completely dumped and replaced. As a result, each CNC machine required a twohour shutdown for cleaning and recharging to prevent clogged filters, foul odors, mist and steam, and tool life failure. With their existing coolant lifespan averaging three months, even a minimal improvement of coolant life could provide significant productivity gains and costs savings. The manufacturer decided it was time to investigate new suppliers. It brought in several companies, including Master Fluid Solutions, to run a seven-month trial of different products, including TRIM® MicroSol® 590XT. This semisynthetic microemulsion coolant is formulated specifically for aerospace applications and uses the latest technology to provide long life and protect sensitive alloys. Because of these unique properties, MicroSol 590XT was able to improve sump life and last longer in the manufacturer’s machines. In addition, MicroSol 590XT’s existing approvals from Airbus, Boeing, and other aerospace manufacturers made it stand out even more among the competition. Due to the strong positive results from the trials, Master Fluid Solutions was chosen as the manufacturer’s supplier. During the initial seven-month trial period, the manufacturer did not have to swap out MicroSol 590XT from any of the test CNC machines. In fact, once all 340 machines were charged with MicroSol 590XT, they were able to use the coolant for 12 to 13 months without having to clean out the sump, saving an impressive $500,000 in coolant costs annually. On top of the financial savings from not having to purchase and replace coolant as often, the manufacturer also achieved additional savings through increased productivity. Before, each machine had to be taken offline to dump, clean, and recharge with coolant every quarter, taking two hours per machine and causing a loss of 2,720 production hours each year. Using an industry standard burden rate of $100 per hour, with MicroSol 590XT, the manufacturer is now saving an additional $272,000 per year. Each machine cleanout also required at least one maintenance employee for two hours at a labor rate of $40 per hour. By reducing the need for frequent coolant changes, they yielded an additional $108,000 in savings from labor costs. For the aircraft components manufacturer, not only did they cut their coolant usage in half, they improved productivity by increasing machine utilization, resulting in substantial cost savings. ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-04-16 • 50% reduction in coolant usage • $500,000 saved in coolant costs annually • Coolant life of 12 to 13 months • $272,000 annual cost savings from increased machine utilization • $108,000 in reduced labor costs annually • $880,000 total annual savings
50% Coolant Reduction
Industrial Fluid Solutions Expands Customer Offerings with TRIM<sup>®</sup> MicroSol<sup>®</sup> Products Industrial Fluid Solutions Expands Customer Offerings with TRIM® MicroSol® Products Wisconsin-based Industrial Fluid Solutions is a metalworking fluid distributor and fluid maintenance service provider that sells to CNC machine shops, die casting companies, mold makers, and heavy equipment manufacturers. Their customers range from small metalworking shops to large equipment and component suppliers in the midwest. THE CHALLENGE THE SOLUTION THE RESULTS When metalworking companies and manufacturers look for industrial fluid, they generally take one of two positions: either they want the best price, or they want the fluid that offers the best performance. Most believe these qualities are mutually exclusive. Because many of IFS’s customers work in industries like automotive and heavy equipment parts, their fluid requirements are stringent. The products they use must prevent corrosion, odors, foam, and dermatitis. Industrial manufacturing companies throughout Wisconsin and Illinois turn to IFS for fluid maintenance programs and services. To meet the needs of their customers, IFS must provide them with cutting fluids that not only work great, but also eliminate specific complications like odor and tool life issues — while still being cost-effective. IFS began offering several products in the Master Fluid Solutions’ TRIM® MicroSol® product line. These products were formulated specifically to meet the needs of modern manufacturing and have shown great results in all industries. It allowed customers the ability to machine both ferrous and non-ferrous metals at a price point that worked for the customers. TRIM MicroSol’s new technology increases sump and tool life, a definite advantage for manufacturing facilities. Additionally, the biostability and extreme pressure components allowed it to be used in a variety of machining applications, essentially replacing two products with a single solution. For IFS, working with Master Fluid Solutions has provided the support they need to offer customers both fluids and services above and beyond their competition. Master Fluid Solutions’ deep understanding of both customer and distributor needs helps IFS consistently provide highquality products for their customers’ unique applications. In turn, IFS is able to build strong, long-lasting customer relationships. By switching from two products to one, along with increased tool and sump life, IFS’s customers have seen savings of up to 30% annually on coolant after switching to the TRIM MicroSol product family. Additionally, IFS has consistently seen Master Fluid Solutions’ products win after testing in production, increasing customer loyalty and driving additional revenue. ©2019 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-01-23 “Working with MFS has been a really positive experience. We were able to offer another product line, expand it with different options, and grow our customer base with their support.” – Courtney Green, Service Manager
30% Annual Savings
Signicast Improves Employee Morale with Master Fluid Solutions Signicast Improves Employee Morale with Master Fluid Solutions Signicast manufactures precision investment castings for a variety of industries, including firearms, mining and oilfield, recreational vehicles, and aerospace. With three plants located in the United States and three in Europe, Signicast can meet the needs of small to large runs of components for a wide range of applications. THE CHALLENGE THE SOLUTION THE RESULTS Biostability and customer service are the two main factors that drive Signicast’s metalworking fluid purchases. The fluid needs to avoid changing colors or developing a bad smell, which can indicate the presence of harmful bacteria or tramp oil and make for an unpleasant work environment for employees. Signicast also wants to know that its metalworking fluid provider will provide assistance if needed. Nonexistent customer service from a previous supplier led Signicast to find a new provider. Its Milwaukee, Wisconsin-area facility uses a 10,000 gallon system, and the company needed to know that it would get technical support when it had questions about managing its fluid. After evaluating several metalworking fluid suppliers, Signicast chose Master Fluid Solutions and its TRIM® MicroSol® 585XT for its operations. TRIM MicroSol 585XT does not require extra biocides or fungicides to remain biostable. The District Sales Manager from Master Fluid Solutions helped steer Signicast to the correct fluid for its machines, was knowledgeable about the product line and metalworking, and was confident that the product would work. TRIM® MicroSol® 585XT became part of Signicast’s overall efforts to achieve longer tool life, and it certainly has contributed to the initiative. The machines are cleaner and do not have a brown sludge buildup, saving approximately $16,000 per year in its main coolant system. However, it’s Master Fluid Solutions’s customer service that has really stood out to the company. When Signicast has a question about how to improve its shop floor, Master Fluid Solutions is there to provide information. Master Fluid Solutions also sent in its own service engineers to assist with discharge, clean, and recharge (DCR) to ensure a proper, thorough and quick process. Additionally, the biostability of TRIM MicroSol 585XT has contributed to happier employees, who no longer continually have to report problems with the fluid. This takes the pressure off the Plant Engineer, who can focus on proactively managing and maintaining equipment on the shop floor and continue to reap the benefits of the cost savings, turning that toward strategic initiatives. “Master Fluid Solutions isn’t afraid to jump in and get dirty. With them, it’s all about customer service.” – Matthew Speier, Plant Engineer ©2019 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-01-22
$16,000 Per Year Savings!
Aerospace Manufacturer’s Holes Per Drill Soar with Master Fluid Solutions Aerospace Manufacturer’s Holes Per Drill Soar with Master Fluid Solutions At 30,000 feet, there’s no room for error. Aerospace companies have to meet that high standard when they design, manufacture, and support products that keep airline passengers safe in flight. One aerospace components manufacturer based in the Northeast focuses on aerospace propulsion components, flight control components, and aero engine components — all of which require high quality and precision to meet safety standards and specifications. The company machines a variety of alloys, including low carbon, hardened steel, aluminum, titanium, and nickel, as well as stainless steel, using drilling, reaming, tapping, milling, turning, and grinding operations. THE CHALLENGE THE SOLUTION THE RESULTS The aerospace components manufacturer could only get six holes per drill on a small drill with its incumbent coolant. This was not enough and led the company to start searching for a new coolant that could yield more holes per drill, as well as increase the life of its tools and reject tramp oil. Coolants used in the aerospace industry must meet the demands of high-pressure, high-volume applications. The aerospace components manufacturer began testing TRIM® E925AE for these rigorous applications, as it uses a proprietary lubricity package for a better surface finish and longer tool life when machining aerospace materials. TRIM® E925AE protects sensitive aluminum and nonferrous alloys, and its soft fluid film protects chucks, ways, and tool holders. The test run of TRIM® E925AE was a resounding success for the components manufacturer. TRIM® E925AE yielded 96 holes per drill, a 1500% increase. Additionally, part finishes were excellent, and drilling and reaming sizes, along with turning, milling, drilling, and reaming results overall were very good. Tool life was extended, and TRIM® E925AE rejected tramp oil well. The fluid ran clean in the machine, leaving no residue. For this aerospace company, using TRIM® E925AE has allowed them to improve production and extend tool life. THE NUMBERS • 1500% increase in holes per drill • 96 holes per drill with TRIM® E925AE vs. 6 holes per drill with the previous coolant • Total tooling spend decreased by 90% ©2020 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-01-22
Holes Per Drill Up 1500%
Seeing flawless parts and dramatic results with TRIM<sup>®</sup> MicroSol<sup>®</sup> 690XT premium microemulsion. www.masterfluidsolutions.com/na/en-us/ ©2015-2019 Master Fluid Solutions. TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-01-06 TRIM® MicroSol® 690XT Cuts to the Chase HY-SPEED MACHINING GRANTS PASS, OREGON INNOVATIONS FOR LONGER SUMP A N D T O O L L I F E General Manager Mike Mills, Sr. Check out Mike Mills, Sr.’s video testimonial at https://2trim.us/v/?v=420. For more video interviews from our customers about MicroSol 690XT performance, visit our web site at: www.microsol-690xt.com Seeing flawless parts and dramatic results with TRIM® MicroSol® 690XT premium microemulsion. Experiencing huge savings in time and costs. For more than 30 years Hy-Speed Machining has been producing quality, precision-machined parts primarily for the commercial and military aerospace industry. They had tapping issues on their CNC and lathes– having to program stops in order to manually add tapping fluid. And to go from water soluble synthetic for aluminum to a straight cutting oil for Inconel®, they had to stop production and clean the machines to make the switch. They ran a trial on MicroSol 690XT and found dramatic results. They no longer needed to waste time switching from straight oil to coolant to run different metals because the MicroSol 690XT did it all– whether milling, turning, or tapping 6061 or 7075 aluminum, steel, 316 stainless, 17-4, 440C heat-treated stainless, or Inconel. “We ran some tapping tests,” General Manager Mike Mills, Sr. notes. “We went from 2-56, 4-40, 6-32, to 8-32 form taps to tap 30 holes each in a block of 6061 aluminum– without any issues or need for tapping fluid at all– same tap no changes in speeds and feeds. Then “we tapped 17-4 stainless on the lathes with it without any extra tapping fluid. MicroSol 690XT has increased the life of our taps dramatically, decreased our machine downtime, and improved our production rates.” MicroSol 690XT provided impressive results from the start. First, they ran a small, 100-piece Inconel job. Rather than having to switch their cutoff tool every 5 pieces, they ran the whole job without changing it. With the flat-bottom, carbide drill going 800 thousandths deep, they ran all the parts on one drill – rather than changing the drill for every 10 pieces as in the past. Mills says MicroSol 609XT proved to be “a dramatic improvement, cutting is just incredible, and on that small job alone we saved about $3,000 on tooling costs.“ And that’s just one job! Additionally, with the switch to MicroSol 690XT, Mills mentions that the floors and machines are free of sticky residue and the operators have had no problems with dermatitis. The switch “saves us a lot over a year,” says Mills. Hy-Speed Machine continues to run strong with MicroSol 690XT and could not be more impressed with the difference to their bottom line. Peak your performance and profits with MicroSol 690XT.
Flawless Parts
TRIM<sup®</sup> MicroSol<sup®</sup> 690XT has produced astonishing results for Hy-Speed Machining www.masterfluidsolutions.com/na/en-us/ ©2015-2019 Master Fluid Solutions. TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2020-01-06 TRIM® MicroSol® 690XT Saves on Tooling and Run Times HY-SPEED MACHINING GRANTS PASS, OREGON INNOVATIONS FOR LONGER SUMP A N D T O O L L I F E CNC Programmer Mike Mills, Jr. Check out the video testimonial featuring Mike Mills Jr. and others from Hy-Speed Machining at https://2trim.us/v/?v=420 For more video interviews from our customers about MicroSol 690XT performance, visit our web site at www.microsol-690xt.com TRIM® MicroSol® 690XT has produced astonishing results for Hy-Speed Machining Making a big difference to the bottom line. Hy-Speed Machining, an Oregon job shop whose majority of work is for the aerospace industry, runs aluminum along with lots of tough-to-machine Inconel® and other aerospace alloys. Having to stop their CNC machines to add tapping fluid to cut challenging metals was costing them a lot of money— both in production time and tapping fluid. With a successful trial, they changed the whole shop over to MicroSol 690XT with impressive results. CNC programmer Mike Mills, Jr. has been amazed at the difference in production and huge cost savings since their switch to premium semisynthetic MicroSol 690XT. Mills sites the new coolant’s performance with a recent job cutting Inconel, “Since we switched to the MicroSol 690XT, we were able to increase our surface footage, our speed rates, our chip loads, and our tool life. We literally get up to six times the tool life that we were getting with the former coolant. On this one job, we went from 12 minutes per part down to four and one-half minutes—with a tenth of the coolant cost. “With this Inconel job,” he continues, “we use a $450 drill. Before, we were going through four to five of them on the run of 150 parts. With the MicroSol 690XT, we use ONE drill for the entire run and it’s still good to run more parts! We definitely have cut our tool and coolant costs down, sped the run time up... we are looking at saving thousands of dollars on this job.” That is just one example of the dramatic results they see with MicroSol 690XT day in and day out. “It has really changed our world here at Hy-Speed Machining, it has been a great success for us,” adds Mike. “MicroSol 690XT has helped our bottom line tremendously; with the savings on coolant, tooling costs, the time it took to switch out tools, and the faster run times, we’ll see savings of hundreds of thousands per year. It’s incredible.” See your profits soar with MicroSol 690XT.
Astonishing Results
Revved-up Performance: Global Automotive Crankshaft Manufacturer Saves Coolant Costs www.masterfluidsolutions.com/na/en-us/ Rev-up your performance. Have our team of Camshaft/ Crankshaft Grinding Experts baseline your operation. Call 800-874-0105 today to improve your productivity PROVEN COST SAVINGS Downtime due to foaming and bacteria was eliminated and production is up. Application Specifications Grinder: Landis Multi-Wheel Wheel: Norton SG Material: powdered metal Operation: journal grind Filter: vacuum paper bed INNOVATIONS F O R L O N G E R S U M P A N D T O O L L I F E ©2019 Master Fluid Solutions. Master Fluid Solutions® and TRIM® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2019-12-05 ReOvvveedr -tUhep LPoenrfgo rHmaaunl ce Additional significant savings were realized by eliminating the need for costly additives to reduce bacteria and foam levels. C270 reduced oil mist, kept the work environment cleaner, improved part cleanliness for process gauging, and increased operator acceptance. Now crankshaft and camshaft production is running smooth with C270. When a world leader in automotive manufacturing had a problem, TRIM® experts provided the solution. Problem: A global automotive manufacturer’s crankshaft production at one facility fell short of its 1500 crankshafts per day objective. Analysis proved further production time was being lost due to foaming and heavy bacterial contamination of a heavy-duty ester-based coolant. Solution: TRIM® C270 proved the perfect solution. Independent testing confirms C270 dissipates foam 13.9 times faster than the competition, and operates at a very low bacteria level. The automotive manufacturer changed to C270 with dramatic savings in coolant costs, water, filter media use, and downtime. Coolant costs dropped by $36,000 per year. Water consumption decreased 40%. Filter media use down over 30%. BBEEFFOORREE WITH TRIM C270 BBEEFFOORREE WITH TRIM C270 $ $ $ $ BBEEFFOORREE WITH TRIM C270 DOWNTIME COOLANT COST WATER USE FILTER MEDIA 72,000 36,000
Costs Dropped By $36,000
Zooming Production: Global Camshaft Producer Reduces Filter Media by over 98%
Filter Media Reduced 98%
Excel Manufacturing Boosted their bottom line with TRIM<sup>®</sup> MicroSol<sup>®</sup> 690XT www.masterfluidsolutions.com/na/en-us/ ©2015-2019 Master Fluid Solutions. TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2019-12-03 Here’s how TRIM® MicroSol® 690XT semisynthetic outperformed expectations for Excel Manufacturing MicroSol 690XT saves time and money Brad Watts, Makino a81 operator, is thrilled with their change to premium semisynthetic MicroSol 690XT. They had been using two different coolants in their shop, one of which was targeted specifically at their foaming issues. Now they were looking for one high-performance solution that could do it all. After a threemonth trial, Excel Manufacturing changed over their whole shop to MicroSol 690XT. They find MicroSol 690XT has provided much better lubricity with low foam and much less coolant consumption. They had been running their coolant with a high refractometer reading in an effort to address their problem with excessive foam. Now they run MicroSol 690XT at half the refractometer reading with no foaming issues at all. Brad Watts attests, “Even with the previous, reliable low-foam coolant, foam would build up in the reserve wait area so high that it coated the drum and caused the machine to go into a low-coolant false alarm. With the MicroSol 690XT, foam barely builds up, then breaks down quickly without a problem. MicroSol 690XT is going to save us a lot of money... and I’m really excited we got it shop-wide.” Longer tool life and less foam with MicroSol 690XT Maintenance supervisor Curt Metcalf tells us about their successful three-month testing of MicroSol 690XT. “We tested it on aluminum, cast iron, and ductal iron. It solved a reaming problem we were having on aluminum, and we saw improved tool life. Operators like the low chemical smell and the parts are much cleaner.” To resolve their foaming issues Curt says they had tried other quality coolants, even those specially designed to be low-foam. One premium microemulsion did solve the foam problems, but resulted in shorter tool life. With excellent low-foam properties and exceptional tool life, Curt says, “MicroSol 690XT does it all!” Boost your profits and production with MicroSol 690XT! View testimonial for Bradford Watts, “MicroSol® 690XT Runs at About Half the Concentration...” at https://2trim.us/v/?v=419 Check out video testimonial “Curt Metcalf Solves Reaming Problem with MicroSol® 690XT” at https://2trim.us/v/?v=415 For more video interviews from our customers about MicroSol 690XT performance, visit our web site at: www.microsol-690xt.com TRIM® MicroSol® 690XT Boosted their Bottom Line EXCEL MANUFACTURING OF SEYMOUR, INDIANA INNOVATIONS FOR LONGER SUMP A N D T O O L L I F E Maintenance Supervisor Curt Metcalf Makino a81 Operator Brad Watts
Boosted the Bottom Line
Arkansas Automotive Products Facility Cuts Costs by 30% with Master Fluid Solutions Arkansas Automotive Products Facility Cuts Costs by 30% with Master Fluid Solutions A Heber Springs, Arkansas facility, as part of a global company, focuses on suspension products for the automotive industry using COBAPRESS™, gravity die casting, low-pressure casting, machining, and assembly. The facility works with aluminum alloy. THE CHALLENGE THE SOLUTION THE RESULTS Machine operators handle parts all day that are saturated in metalworking fluid, and environmental health and safety for these employees is a big concern for the facility. Dermatitis not only affects employee morale but also productivity. Additionally, at a plant like this one, a lot of fluids are used on a day-to-day basis. A significant driver for choosing fluid is how to lower the cost per piece, which in this case is how much metalworking fluid is used to manufacture one part, measured in gallons of concentrate. The facility chose a TRIM® MicroSol® product that has moderate to heavy lubricity, as well as low carry off on the parts. It meets the health and safety standards set by the company, as well as a cleanliness specification to protect the state-of-the-art machines in the plant. In addition to providing guidance for choosing fluid, Master Fluid Solutions also came on-site to implement service aspects to better control fluid management. This included weekly fluid sampling and concentration checks, as well as training for facility employees. This ongoing on-site maintenance and education helps them improve the life of their fluid. The cost savings alone have proven that the TRIM® MicroSol® fluid is ideal for the facility. The company was able to slash its cost per piece by 30%, a savings of approximately $180,000 per year or $540,000 over the three-year contract signed with Master Fluid Solutions. The facility is also seeing a cleaner working environment. And as a result of the improved metalworking fluid management techniques implemented alongside Master Fluid Solutions, the company has also reduced the need for service labor and floor maintenance due to equipment failures. Anticipated three-year savings: $540,000 with TRIM® MicroSol® 2019-12-02
Cost Per Piece Slashed by 30%
Over the Long Haul: Commercial Truck and Van Engine Manufacturer Eliminated Rust Problem: This manufacturer’s engines are found in virtually every type of commercial truck and van on the road today, yet they were using an inexpensive local coolant and were plague with rusting parts and excessive foam. With poor sump life, their 6,500- gallon central system needed to be dumped every three months. Besides reducing overall coolant costs and related downtime, improvements include: no more rusty parts to rework, reduced oil mist, cleaner parts and work area, and better operator acceptance. Solution: They needed a coolant that offered low foaming, long sump life, and rust protection – TRIM® C270 was the solution. They made the switch and the system has been up and running over eight months without needing to be dumped. Though the local coolant was one-tenth the cost of C270, the switch to C270 has paid for itself already. www.masterfluidsolutions.com/na/en-us/ Is your coolant good for the long haul? Have our team of Camshaft/Crankshaft Grinding Experts baseline your operation. Call 800-874-0105 today to improve your productivity PROVEN COST SAVINGS & PROCESS IMPROVEMENTS Annualized coolant costs dramatically reduced – payback in eight months. Downtime for cleanouts down by 400 percent – from quarterly to ZERO. Application Specifications Grinder: Landis Wheels: Norton vitrified CBN Material: cast iron and steel Operation: journal grind Filter: vacuum paper bed C270 did away with rusted parts and costly parts reworks. INNOVATIONS F O R L O N G E R S U M P A N D T O O L L I F E ©2019 Master Fluid Solutions. Master Fluid Solutions® and TRIM® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2019-11-29 OvOerv ethre t hLeo nLgo nHga Hulaul BBEEFFOORREE 12 months 8 months WITH TRIM C270 None CLEANOUTS PER YEAR Every 3 months ANNUALIIZED COOLANT COSTS IIN MONTHS WITH TRIM C270 BBEEFFOORREE When a worldwide manufacturer of engines had a problem, TRIM® experts had the solution. RUST LIKE THIS? NEVER AGAIN! COSTS: DOWN CLEANOUTS: DOWN RUST: GONE
Downtime for Cleanouts Down by 400%
Going the distance: Chinese Diesel Engine Manufacturer Improved Sump Life www.masterfluidsolutions.com/na/en-us/ ©2019 Master Fluid Solutions. Master Fluid Solutions® and TRIM® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2019-11-26 INNOVATIONS F O R L O N G E R S U M P A N D T O O L L I F E Application Specifications Grinder: Landis, Schleifring Wheels: vitrified CBN Material: steel Operation: journal, lobe grind Filter: paper media Does your coolant go the distance? Have our team of Camshaft/Crankshaft Grinding Experts baseline your operation. Call 800-874-0105 today to improve your productivity PROVEN COST SAVINGS Eliminated need for costly additives to control foam and bacteria No foaming problems meant no sump pumpout downtime FOAM DOWNTIME Solution: Starting in 2003, TRIM® C270 was used in a group of existing Landis grinders. Impressive results led to C270 replacing other coolants throughout the plant. When new Schleifring grinders were installed, C270 was their fluid of choice. Problem: This Chinese diesel engine manufacturer needed to improve their overall camshaft/crankshaft grinding process and reduce costs. They’d used both an expensive, high-tech, semisynthetic coolant and a less expensive local blend; both had problems with foam and short sump life. Having eliminated foaming, the need for additives, and having improved sump life, the manufacturer now uses C270 exclusively in their entire grinding process — over 100 machines of various sizes. Going the Distance When a global engine and parts manufacturer had a problem, TRIM® experts had the solution.
Improved Grinding & Reduced Costs
Don’t get it SIMPLY clean, get it Master STAGES™ REALLY clean! A customer using Simple Green asked for a cleanabilty analysis of Simple Green versus Master STAGES. Using the LAB/TECH SERVICE Test Methods Section 906, Master Fluid Solutions professional chemists conducted blind head-to-head tests of Master STAGES CLEAN F2 and Task2 Grime Fighter against Simple Green Industrial Cleaner and Degreaser. The results speak for themselves. Both Master STAGES CLEAN F2 and Task2 Grime Fighter remarkably outperformed Simple Green in cleaning various machine shop soils. and have cleaner machines, parts, and workplace with Master STAGES. Save money and maintenance time NOTHING BUT THE FACTS. Chlorinated Oil Hydraulic Oil Sulferized Oil Used Motor Oil Metalworking Fluid Residue Master STAGES CLEAN F2 TEST RESULTS at 5% product dilution with water Master STAGES Simple Green Task2 Grime Fighter Make it easy to boost your bottom line – with Master STAGES. Test procedures: Steel test strips were submerged in mixtures of chlorinated, hydraulic, sulfurized, and tramp oils to replicate standard machine shop soils, cured for 24 hours, then cleaned with the respective cleaners. Products were tested with 5%,10%, and 20% dilutions of deionized water and tested at 50°C for five minutes. Product performance was similar at all dilutions per the above chart (10% and 20% dilution results not shown for lack of space) and IN NO TEST DID THE SIMPLE GREEN OUTPERFORM the CLEAN F2 or Task2 Grime Fighter. www.masterfluidsolutions.com/na/en-us/ ©2019 Master Fluid Solutions. Master Fluid Solutions® is a registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. Master STAGES™ and Task2™ are trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2019-10-16 = Completely Cleaned = Mostly Cleaned = Partially Cleaned It’s that SIMPLE. Master STAGES™ Task 2™ and CLEAN F2™ out clean Simple Green. The proof is in the CLEAN! Don’t get it SIMPLY clean, get it Master STAGES™ REALLY clean! Completely Cleaned Mostly Cleaned Partially Cleaned INNOVATIONS F O R L O N G E R S U M P A N D T O O L L I F E ™
REALLY Clean!
Ace Manufacturing of Cincinnati, Ohio | TRIM<sup>®</sup> MicroSol<sup>®</sup> 690XT Raised the Bar on Productivity www.masterfluidsolutions.com/na/en-us/ ©2015-2019 Master Fluid Solutions. TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2019-09-24 TRIM® MicroSol® 690XT produced dramatic results for Ace Manufacturing Ace Manufacturing of Cincinnati, Ohio had been running another coolant with far less than desired results. They were experiencing multiple problems: ”tap break and a real terrible tool life”, along with problems with foam, shop uncleanliness, rust on machines, and foul odor. Within weeks of beginning their trial of MicroSol 690XT on three CNC machines, they reported tool life was dramatically improved. Highly lubricious MicroSol 690XT was keeping the machines lightly oiled, rust-free, and definitely cleaner without any residue build up. Tapping into fluid savings - and bonuses - with MicroSol 690XT Ace supervisor Chuck Adams says, ”We’re losing a lot of coolant because it was foaming out of the side of the tanks, especially the two Morey’s with the high-pressure units. We were losing 15 to 20 gallons a week just from overflow. Since we have changed to MicroSol 690XT, we have no foam at all! Our operators like the pleasant odor and the shop environment is cleaner. We’re changing the entire shop over to MicroSol 690XT.” ”We were having a lot of tap wear and tap breaks trying to tap titanium,” Chuck testifies. ”After putting in MicroSol 690XT, tapping is much better, lubricity much higher, we’re having less failure, and our taps are lasting a lot longer. We are not shutting down to change tools as often, so we exceeded our production target and got our bonus this past quarter!” MicroSol 690XT, the problem solver Ace Manufacturing’s CNC operator Phil Smith couldn’t be more impressed with MicroSol 690XT’s performance. Phil reports “Since we have switched to using MicroSol 690XT, it has eliminated all my rust issues, all of my tapping and tooling breakage problems, all the odor issues, and all of the foaming issues! It has been a great coolant!” Let MicroSol 690XT put you at the top of the pack! Check out our MicroSol 690XT customer video testimonials at: https://2trim.us/v/?v=416 Chuck Adams, Machining Titanium with MicroSol® 690XT https://2trim.us/v/?v=417 Chuck Adams, Tapping into Fluid Savings with MicroSol® 690XT https://2trim.us/v/?v=418 Chuck Adams, Wants to Convert Whole Shop to MicroSol® 690XT https://2trim.us/v/?v=414 Phil Smith, Eliminates Tool Breaking Issues with MicroSol® 690XT TRIM® MicroSol® 690XT Raised the Bar on Productivity ACE MANUFACTURING OF CINCINNATI, OHIO INNOVATIONS FOR LONGER SUMP A N D T O O L L I F E CNC Operator Phil Smith Supervisor Chuck Adams
Tool Breakage Problems Eliminated
TRIM<sup>®</sup> MicroSol<sup>®</sup> 690XT Raised the Bar on Cleanliness www.masterfluidsolutions.com/na/en-us/ ©2015-2019 Master Fluid Solutions. TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2019-09-24 Ace Manufacturing enjoys keeping it clean with the switch to TRIM® MicroSol® 690XT. When Ace Manufacturing of Cincinnati, OH switched to MicroSol 690XT shopwide, here is what Shop Supervisor Chuck Adams reported...“after just the first couple weeks, the inside of the machines, way covers, and jigs are rust free and the machines are definitely a lot cleaner. It keeps the inside of the machines lightly oiled with a light film, but there is no discoloration or residue buildup.” Chuck continues, “With the MicroSol 690XT, we have virtually no residue in our machines. The operators like the coolant a lot better because it keeps their machines clean and they don’t have to work hard cleaning the parts after machining. Not only are the parts themselves cleaner, but the smell’s better and the workplace is cleaner.” Choose MicroSol 690XT: > highest lubricity MicroSol product for markedly longer tool life and superior finish > exceptional foam control, low carryoff > dramatically extended sump life for substantial savings on time and material > soft aqueous film protects parts, keeps machines clean > multimetal, multi-operation versatility > superior corrosion inhibition on ferrous and nonferrous metals > nonchlorinated; no nitrates, triazine, phenol, or sulphurized EP additives > no need for tank-side biocides or fungicides > boron- and halogen-free Use MicroSol 690XT especially for: > steel, stainless steel, copper, titanium and aluminum alloys, and most composites > high-pressure, low-foaming operations Keep it really clean with MicroSol 690XT! INNOVATIONS FOR LONGER SUMP A N D T O O L L I F E TRIM® MicroSol® 690XT Raised the Bar on Cleanliness ACE MANUFACTURING OF CINCINNATI, OHIO Typical semisynthetic leaves sticky residue. TRIM MicroSol 690 XT keeps machines clean! Check out our MicroSol 690XT customer video testimonials at: https://2trim.us/v/?v=416 Chuck Adams, Machining Titanium with MicroSol® 690XT https://2trim.us/v/?v=417 Chuck Adams, Tapping into Fluid Savings with MicroSol® 690XT https://2trim.us/v/?v=418 Chuck Adams, Wants to Convert Whole Shop to MicroSol® 690XT https://2trim.us/v/?v=414 Phil Smith, Eliminates Tool Breaking Issues with MicroSol® 690XT
Very Clean Machines
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Videos

WEDOLiT VCI Packaging byMaster Fluid Solutions (English)
2021-01-04, US-English

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WEDOLiT Brand Introduction Video

WEDOLiT Brand Introduction Video

2020-11-02, US-English

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10 Reasons to test TRIM® MicroSol® 455

2019-01-04, US-English

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Total Cost of Coolant

2018-10-30, US-English

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Three Steps to Extend Your Coolant Life

2017-03-08, US-English

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