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TRIM®
Emulsje
Jakościowe środki chłodzące zwiększające produkcję
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Master STAGES™
Płyny czyszczące i zapobiegające rdzewieniu
Zyskaj WIĘCEJ niż tylko czyszczenie z Master STAGES
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TRIM®
Materiały syntetyczne
Precyzja, powtarzalne części – dzień za dniem
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TRIM®
MicroSol®
Nowa definicja wydajności w obróbce metali
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TRIM®
MicroSol®
Nowa definicja wydajności w obróbce metali
Dowiedz się więcej >
TRIM. Płyny do obróbki metali. Od ponad 60 lat płyny do obróbki metali TRIM® są czołowymi w branży produktami dla wszystkich typów skrawania i szlifowania. Znane na całym świecie z doskonałej skuteczności środki TRIM spełniają wymagania specjalistycznych branż takich jak motoryzacyjna, lotnicza czy producentów części medycznych. W pełnym zakresie zastosowań skrawania i szlifowania w przypadku olejów syntetycznych, półsyntetycznych i rozpuszczalnych TRIM zapewnia dłuższy okres eksploatacji narzędzi i żywotności roztworu w zbiorniku, lepsze wykończenie części oraz lepsze efekty.
MicroSol. Produkty MicroSol®. Dla najlepszej wydajności: Półsyntetyczne mikroemulsyjne środki chłodzące TRIM® MicroSol® zapewniają doskonałe właściwości smarne i najniższe koszty. Uzyskiwanie precyzyjnych części, wyjątkowo długi okres eksploatacji, dłuższa żywotność roztworu w zbiorniku, zapewniona zgodność z regulacjami oraz większa rentowność produktów MicroSol to idealne właściwości dla produkcji. Marka MicroSol przystosowana do spełnienia rygorystycznych wymagań branży produkcji części lotniczych, medycznych, motoryzacyjnych lub produkcji wysokiej jakości i części precyzyjnych stanowi odpowiedź na problemy, poprawia produkcję oraz przyspiesza efekty.
MicroSol
Emulsje. Płyny emulsyjne do skrawania oraz szlifowania. Przygotowanie do produkcji: Dzięki doskonałym właściwościom smarnym i większej zawartości oleju emulsje TRIM® tworzą grubszą warstwę graniczną między narzędziem a materiałem. Emulsje są idealne do niższych zastosowań (poniżej 600 SFPM), takich jak wytaczanie, rozwiercanie, wiercenie dogłębne, wiercenie, gwintowanie i szlifowanie bezkłowe. Emulsje działają dobrze w przypadku obróbki miedzi, żółtych metali, stopów stali, odlewów aluminium, aluminium topionego i tytanu solidnego dla maszyny oraz stopów na bazie niklu. Przygotuj się do pracy z emulsjami TRIM przystosowanymi do Twoich potrzeb produkcyjnych.
Emulsje
Półsyntetyki. Półsyntetyczne płyny do skrawania oraz szlifowania. Nowoczesne rozwiązania: Środki półsyntetyczne TRIM® zapewniają chłodzenie i właściwości smarne środków syntetycznych bez większej zawartości oleju w emulsji. Przystosowane do działania przy większym poziomie SFPM środki półsyntetyczne są skuteczne w wielu zastosowaniach takich jak frezowanie czołowe, toczenie odcinające, szlifowanie, gwintowanie i wiercenie (w zależności od konkretnego produktu). Środki półsyntetyczne są odpowiednie do stali stopowych, stali narzędziowych, żeliw, stopów miedzi oraz plastików i kompozytów. Dzięki mniejszym stratom przez „wynoszenie” w przypadku środków półsyntetycznych zużywa się mniej materiału, co skutkuje redukcją kosztów.
Półsyntetyki
Środki syntetyczne. Płyny syntetyczne do skrawania oraz szlifowania. Poprawa wydajności: Środki syntetyczne TRIM® do czyszczenia na bieżąco zawierają niewielkie ilości oleju lub nie zawierają go wcale. Są tolerancyjne w przypadku twardej wody i zapewniają dobrą ochronę antykorozyjną. Ponadto środki syntetyczne zapewniają łatwe czyszczenie dzięki temu, że pozostawiają niewielkie ilości osadów. W połączeniu z bardzo niskimi stratami przez „wynoszenie” środki syntetyczne charakteryzują się niewielką koniecznością konserwacji i niskimi kosztami roboczymi, co oszczędza czas i pieniądze. Czyste i długie funkcjonowanie ze środkami syntetycznymi TRIM.
Środki syntetyczne
Gwintowanie. Środki do gwintowania. Większe możliwości obróbki: Dzięki silnym właściwościom redukującym tarcie oleje syntetyczne TRIM® TAP i syntetyczne mieszane oleje czyste są przystosowane do metali o niskich właściwościach obróbki. Dzięki większym właściwościom smarnym w skrajnie trudnych zadaniach oleje TAP zapewniają dłuższy okres eksploatacji, doskonałe wykończenie powierzchni oraz kontrolę rozmiaru części. Wszystkie produkty TAP są zgodne ze wszystkimi środkami chłodzącymi TRIM. Nie pozwól, by praca Cię wyczerpała – niech płyny TRIM TAP pracują za Ciebie.
Gwintowanie
Master STAGES. Płyny czyszczące i zapobiegające rdzewieniu. Ponieważ skuteczne czyszczenie i ochrona metalu mają kluczowe znaczenie dla uzyskania precyzyjnych części i doskonałego wykończenia powierzchni, produkty Master STAGES obejmują pełny asortyment środków do czyszczenia części, środków antykorozyjnych oraz serwisowych środków czyszczących. Przystosowane do branży lotniczej, medycznej, motoryzacyjnej, eksploatacji energii, sprzętu ciężkiego i produkcji ogólnej – te produkty spełniają najbardziej rygorystyczne wymagania, zapewniając zachowanie przez klientów zgodności z wymogami środowiskowymi przy najwyższej wydajności i większej rentowności. <br> <br> Problemy z BHP? Problemy z pienieniem? Rdza? Pozostałości środka chłodzącego lub oleju na częściach? Wysokie koszty utylizacji? <br> <br> Dla wielkich producentów lub zakładów produkcji jednostkowej, bez względu na problemy i kwestie związane z produkcją, mamy sprawdzony w praktyce produkt przeznaczony specjalnie do potrzeb i stwarzający prawdziwą różnicę. To różnica Master STAGES – właściwe rozwiązanie do pracy za odpowiednią cenę.
Środki czyszczące. Środki czyszczące i myjące Master STAGES™. Do myjek natryskowych pojedynczych lub wielokrotnych, wysokociśnieniowych, zanurzeniowych i ultradźwiękowych – środki czyszczące o wysokim stężeniu oraz środki myjące na bazie wody Master STAGES™ charakteryzują się długą żywotnością roztworu w zbiorniku i wydzielaniem obcych olejów, niewielkim pienieniem, niewielką mgiełką, niskimi stratami przez „wynoszenie” i biostabilnością: wiele z nich nie ma dodatków EP ani składników zgłoszonych w SARA 313. Szukasz jednoetapowej ochrony przed korozją? Masz problem z twardą wodą? Lub pianą? Poszukujesz sposobu na czystsze części mniejszym kosztem? <br> <br> Chcesz się pozbyć pozostałości z czyszczenia środków chłodzących i lekkiego oleju? Usunąć uporczywy smar, ciężki olej, środki do ciągnienia, smarów, zanieczyszczenia z wosku, utlenianie lub rdzę? W przypadku metali takich jak aluminium, stale, żeliwo, stale nierdzewne, stopy, mosiądz, brąz, miedź, magnez właściwym środkiem czyszczącym jest Master STAGES. <br> <br> Seria syntetycznych i półsyntetycznych procesowych środków czyszczących do szlamu i systemów centralnych Master STAGES znacznie wydłuża okres użytkowania środka chłodzącego i zauważalnie skraca przestoje. <br> <br> Nasze skuteczne konserwacyjne środki czyszczące usuwają żwir i brud z maszyn, powierzchni roboczych, ceramiki, plastików, szkła i podłóg – bez stosowania szkodliwych związków chemicznych powodujących korozję. Prawdziwa czystość z Master STAGES!
Środki czyszczące
Spray. Alkaliczne procesowe środki czyszczące w aerozolu. Dzięki całkowitemu pokrywaniu części chemicznym środkiem czyszczącym czyszczenie aerozolem stanowi szybki i skuteczny sposób usuwania zabrudzeń, pozostałości środka chłodzącego i oleju z różnych metali, a środki czyszczące w aerozolu Master STAGES są specjalnie dostosowane do wykonania pracy szybko, skutecznie, przy użyciu mniejszej ilości preparatu i bez plamienia części. Procesowe środki czyszczące Master STAGES w aerozolu są solidne i działają szybko. Zawierają niewielką ilość lotnych związków organicznych i nie zostały w nich użyte składniki podlegające zgłoszeniu SARA 313. <br> <br> Środek czyszczący w aerozolu Master STAGES jest specjalnie przystosowany do czyszczenia pozostałości środka chłodzącego, lekkiego i ciężkiego oleju, smaru, środków do ciągnienia, środków smarnych, zabrudzeń woskowatych, utleniania i rdzy z metali takich jak aluminium, stale, żeliwo, stale nierdzewne, stopy, mosiądz, brąz, miedź i magnez. <br> <br> Środki czyszczące w aerozolu Master STAGES o wysokim stężeniu charakteryzują się dłuższym okresem eksploatacji, dobrym wydzielaniem obcych olejów, słabym zapachem, słabym pienieniem, małą mgiełką oraz zapewniają dodatkową ochronę antykorozyjną, dzięki czemu po ich użyciu części są czyste, a ogólne koszty niższe.
Spray
Zanurzanie. Zanurzeniowe alkaliczne procesowe środki czyszczące. Myjki zanurzeniowe skutecznie usuwają pozostałości lekkich i ciężkich zabrudzeń, lekką rdzę, środek czyszczący, olej, środki do ciągnienia, smary, zanieczyszczenia z wosku i środki antykorozyjne. Środki czyszczące o wysokim stężeniu Master STAGES przeznaczone do czyszczenia aluminium, stali, żeliwa, stali nierdzewnych, stopów, mosiądzu, brązu, miedzi i magnezu oraz różnych metali umożliwiają myjkom zanurzeniowym pracę w niższych stężeniach i mniejszych temperaturach i zapewniają wydłużenie okresu wytrzymałości w kąpieli, zmniejszenie ilości piany i dodatkową ochronę antykorozyjną. <br> <br> Ekologiczne, niezawierające składników podlegających zgłoszeniu SARA 313, przystępne cenowo zanurzeniowe środki czyszczące Master STAGES zapewniają doskonałe czyszczenie części przy użyciu mniejszej ilości produktu oraz energii, co zapewnia lepszy efekt.
Zanurzanie
Konserwacja. Środki czyszczące do konserwacji. Do czyszczenia ciężkich zabrudzeń lub lekkich zanieczyszczeń na maszynach, powierzchniach roboczych, szkle lub podłogach służy wysoko skoncentrowany, przystępny cenowo środek czyszczący Master STAGES, który pozwala wykonać pracę i oszczędzić trwających godzinami prac konserwacyjnych. To nie jest zwykłe czyszczenie, to czyszczenie przy użyciu Master STAGES! Wysoce skoncentrowane środki czyszczące do systemów roztworów i systemów centralnych Whamex™ służą do tymczasowego i całkowitego czyszczenia oraz wydłużają żywotność roztworu, są przystępne cenowo i doskonale skracają czas przestoju. <br> <br> Wszystkie ekologiczne produkty Master STAGES są bezpieczne dla człowieka i nie zawierają szkodliwych środków chemicznych powodujących korozję.
Konserwacja
Środki antykorozyjne. Środki antykorozyjne Master STAGES™. Nic nie wpływa gorzej na właściwe wykończenie powierzchni niż korozja. Bardzo skuteczne środki antykorozyjne Master STAGES zapewniają doskonałą ochronę metali takich jak żeliwo, stale oraz inne metale żelazne, stopy aluminium i miedzi, mosiądz i brąz, która trwa od kilku dni do pełnych 12 miesięcy, a nawet dłużej. Produkt Master STAGES daje potrzebną pewność w zakresie ochrony antykorozyjnej we wnętrzach podczas etapów pośrednich procesu obróbki, ochrony długoterminowej na zewnątrz lub transportu części drogą morską. <br> <br> Środki zapobiegające rdzewieniu (RP) Master STAGES można stosować przez zagłębianie, powlekanie całopowierzchniowe, natryskiwanie w temperaturze otoczenia lub podgrzewane, rolki lub szczotki, łatwo je usuwać i najczęściej nie zawierają baru oraz tylko niewielką ilość lotnych związków organicznych. Uzyskaj przystępną cenowo ochronę, na której można polegać dzięki środkom zapobiegającym rdzewieniu Master STAGES.
Środki antykorozyjne
Środki czyszczące i zapobiegające rdzewieniu. Antykorozyjne środki czyszczące i zapobiegające rdzewieniu. Rodzina zaawansowanych technologicznie produktów Master STAGES™ CLEAN zapewnia bardzo skuteczne czyszczenie tą samą metodą procesową „jednego kroku”, pozostawiając skuteczną, krótkotrwałą warstwę antykorozyjną. <br> <br> Zaprojektowane z myślą o określonych metalach, żądanej długości ochrony antykorozyjnej oraz zastosowaniach takich jak czyszczenie części przez natryskiwanie, zanurzanie, ultradźwiękowe oraz czyszczenie wanien ochronne środki czyszczące i zapobiegające rdzewieniu Master STAGES mają bardzo wysokie stężenie i są ekonomiczne, większość z nich pieni się w niewielkim stopniu i zawiera małą ilość lotnych związków organicznych.
Środki czyszczące i zapobiegające rdzewieniu
Case Studies
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!
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
TRIM<sup>®</sup> MicroSol<sup>®</sup> 590XT Eliminated Production Problems and Increased Profits! TRIM® MicroSol® 590XT eliminated production problems and increased profits! www.masterfluidsolutions.com ©2019 Master Fluid Solutions. TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions; Master Fluid Solutions™ is a trademark of Master Chemical Corporation d/b/a Master Fluid Solutions. 2019-02-12 A UK manufacturer of aerospace components had seemingly insurmountable problems using Houghton Aquacare AL– then TRIM MicroSol 590XT saved the day! The Houghton Aquacare AL coolant caused sticky residue buildup in machines and produced parts so sticky it added process time to get them clean. Extremely high levels of bacteria and fungus caused a horrid foul odour, employee breathing problems, and health and safety issues. Measuring probes distorted by coolant fungal growth caused inaccurate tooling measurements, and off-spec parts. They needed a change! Master Fluid Solutions recommended TRIM MicroSol 590XT. The new charge of high-performance MicroSol 590XT eliminated all problems with foul odour, fungus, and unreliable laser probe readings and subsequent defective parts. Annual coolant consumption was reduced by 32,000lts! Long-lasting MicroSol 590XT dropped coolant spend by £10,000 annually and massively reduced machine and component cleaning costs. Using MicroSol 590XT, they were able to implement a fluid recycling program to reuse an average of 5,000lts per week. Previously paying £150 per 5,000lts to dispose of waste coolant, the customer saved £7,800 annually. Better for their green credentials and the planet. Additional savings overall due to > increased component surface quality > cleaner components > longer sump and tool life > considerably lower machine maintenance > less machine downtime has this customer realising huge savings with MicroSol 590XT. HOUGHTON AQUACARE AL TRIM MICROSOL 590XT £7,800 ANNUAL SAVINGS £150 weekly savings by recycling HOUGHTON AQUACARE AL TRIM MICROSOL 590XT 36% LOWER CONSUMPTION 117,000lts 85,000lts HOUGHTON AQUACARE AL TRIM MICROSOL 590XT £270,000 annual spend £260,000 annual spend £10,000 COOLANT SAVINGS £150 weekly disposal costs
Production Problems Eliminated
TRIM<sup>®</sup> MicroSol<sup>®</sup> 590XT beseitigte Produktionsprobleme und steigerte den Gewinn! TRIM® MicroSol® 590XT beseitigte Produktionsprobleme und steigerte den Gewinn! www.masterfluidsolutions.com ©2019 Master Fluid Solutions. TRIM® und MicroSol® sind eingetragene Marken der Master Chemical Corporation, firmiert unter dem Namen Master Fluid Solutions; Master Fluid Solutions™ ist eine Marke der Master Chemical Corporation, firmiert unter dem Namen Master Fluid Solutions. 2019-02-12 Ein britischer Komponentenhersteller für die Luft- und Raumfahrtindustrie hatte mit seinem Kühlschmierstoff Houghton Aquacare AL scheinbar unüberwindliche Probleme – bis TRIM MicroSol 590XT die Lage rettete! Mit Houghton Aquacare AL lagerten sich Rückständen in den Maschinen ab; die erzeugten Teile waren so verklebt, dass für ihre Reinigung eine zusätzliche Bearbeitungszeit erforderlich war. Ein extrem hoher Bakteriengehalt und Pilzbefall verursachten einen höchst unangenehmen Geruch, Atemprobleme unter den Mitarbeitern und diverse Gesundheits- und Sicherheitsprobleme. Von Pilzwachstum im Kühlschmierstoff beeinträchtigte Messsonden zeigten unzuverlässige Werkzeugmessungen und nicht spezifikationsgemäße Teile an. Etwas musste sich ändern! Master Fluid Solutions empfahl TRIM MicroSol 590XT. Gleich mit der ersten Charge des Hochleistungskühlschmierstoffs MicroSol 590XT konnten alle Probleme in Verbindung mit unangenehmen Gerüchen, Pilzen und unzuverlässigen Lasersonden, deren fehlerhafte Messungen vermeintlich defekte Teile auswiesen, gelöst werden. Der jährliche Kühlschmierstoffverbrauch wurde um 32.000 l reduziert! Das lange vorhaltende Produkt MicroSol 590XT senkte die jährlichen Ausgaben für Kühlschmierstoffe um 10.000 £; zudem sorgte es für eine massive Reduzierung der Kosten für die Maschinen- und Komponentenreinigung. Mit MicroSol 590XT konnte der Kunde ein Flüssigkeits-Recyclingprogramm implementieren, das die wöchentliche Wiederverwendung von durchschnittlich 5.000 l ermöglichte. Der Kunde, der für die Entsorgung seines Kühlschmierstoffabfalls zuvor 150 £ pro 5.000 l bezahlt hatte, verzeichnete jetzt jährliche Einsparungen von 7.800 £. Eine Lösung, die für das „grüne“ Selbstverständnis des Unternehmens – und auch für den Planeten – besser ist. MicroSol 590XT ermöglicht diesem Kunden enorme zusätzliche Einsparungen durch > erhöhte Qualität der Komponentenoberflächen > sauberere Komponenten > längere Standzeit des Kühlschmierstoffs und Werkzeugs > deutlich geringeren Aufwand für die Maschinenwartung > weniger Maschinen-Stillstandszeiten. HOUGHTON AQUACARE AL TRIM MICROSOL 590XT JÄHRLICHE EINSPARUNG VON 7.800 £ Wöchentliche Einsparung von 150 £ durch Recycling HOUGHTON AQUACARE AL TRIM MICROSOL 590XT 36 % WENIGER VERBRAUCH 117.000 l 85.000 l HOUGHTON AQUACARE AL TRIM MICROSOL 590XT Jährliche Ausgaben von 270.000 £ Jährliche Ausgaben von 260.000 £ KÜHLSCHMIERSTOFFEINSPARUNG VON 10.000 £ Wöchentliche Entsorgungskosten von 150 £
Beseitigte Produktionsprobleme
Coolant Costs Reduced 40% While Profits Soar with TRIM<sup>®</sup> E950! With TRIM® E950 High Performance Machining Emulsion, a large manufacturer of aerospace, offshore, and energy industry precision parts is saving more than 40% a year on coolant costs! Operating more than 40 CNC machines turning, machining, drilling, surface and cylindrical grinding tough-to-machine aluminium, titanium, Inconel, steels, and stainless, their high-volume operation produces precision parts day-in, day-out. They were using Blaser Vasco 7000 with good results, but were looking to reduce coolant costs without sacrificing quality. After detailed analysis of their production, Master Fluid Solutions recommended testing high-performance TRIM® E950 against the Blaser Vasco 7000. They ran head-to-head tests of both products in several types of machines, varying operations and metals, and using the same feeds and speeds to compare identical conditions. The results proved in all applications that the TRIM E950 outperformed or equaled the Blaser Vasco 7000 with: > longer tool life > pristine surface finish > an astonishing 40% reduction in coolant cost! Results far exceeded the minimum 10% cost reduction Master Fluid Solutions had assured the manufacturer. Impressed with the clean-running, excellent performance of E950, the facility converted all their machines to TRIM E950. After 12 months, the properly monitored and maintained E950 is still going strong. Saving more than 40% on coolant costs to produce the same high-quality precision parts, E950 has exceeded all expectations! www.masterfluidsolutions.com Coolant Costs Reduced 40% While Profits Soar with TRIM® E950! ©2018 Master Fluid Solutions. TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions; Master Fluid Solutions™ and Cutting Edge Metalworking Solutions™ are trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2018-09-05
Coolant Costs Reduced 40%
Reduzierung der Kühlschmierstoffkosten um 40 % bei gleichzeitiger massiver Gewinnsteigerung – mit TRIM<sup>®</sup> E950! Mit der Hochleistungs-Zerspanungsemulsion TRIM® E950 reduziert ein großer Hersteller von Präzisionsteilen für die Luft- und Raumfahrt-, Offshore- und Energieindustrie seine Kühlschmierstoffkosten um über 40 %! Das Unternehmen betreibt über 40 CNC-Maschinen, die schwer zu bearbeitende Aluminium-, Titan-, Inconel-, Stahl- und Edelstahlkomponenten drehen, bearbeiten, bohren sowie flach- und rundschleifen. Auf diese Weise werden täglich Präzisionsteile in hohen Stückzahlen produziert. Der Hersteller hatten immer Blaser Visco 700 verwendet und damit auch gute Resultate erzielt; er wollte allerdings seine Kühlschmierstoffkosten senken, ohne Qualitätseinbußen hinzunehmen. Nach einer Detailanalyse des Produktionsbetriebs empfahl Master Fluid Solutions einen Vergleichstest seines Hochleistungsprodukts TRIM® E950 mit dem Vasco 7000 der Firma Blaser. Daraufhin wurde ein Direktvergleich beider Produkte in mehreren Arten von Maschinen vorgenommen, bei verschiedenen Abläufen und mit verschiedenen Metallen. Um vergleichbare Bedingungen zu schaffen, wurde mit den gleichen Beschickungsmengen und Geschwindigkeiten gearbeitet. Die Ergebnisse zeigten bei allen Anwendungen, dass TRIM E950 dieselbe oder eine höhere Leistung als Blaser Vasco 7000 erzielte, was sich niederschlug in: > einer längeren Werkzeugstandzeit > einer makellosen Oberflächengüte > und einer Reduzierung der Kühlschmierstoffkosten um erstaunliche 40 %! Die Ergebnisse übertrafen die von Master Fluid Solutions zugesagte Mindestreduzierung der Kosten um 10 %. Die Werksleitung war von dem sauber arbeitenden TRIM E950 und seiner hervorragenden Leistung derart beeindruckt, dass sie alle ihre Maschinen auf dieses Produkt umstellte. Heute, zwölf Monate später, erbringt das ordnungsgemäß überwachte und gewartete E950 immer noch seine volle Leistung. Mit einer Senkung der Kühlschmierstoffkosten um über 40 % ohne jegliche Qualitätseinbußen an den produzierten Präzisionsteilen hat das E950 sämtliche Erwartungen übertroffen. www.masterfluidsolutions.com Reduzierung der Kühlschmierstoffkosten um 40 % bei gleichzeitiger massiver Gewinnsteigerung – mit TRIM® E950! ©2018 Master Fluid Solutions. TRIM® und MicroSol® sind eingetragene Marken der Master Chemical Corporation, firmiert unter dem Namen Master Fluid Solutions; Master Fluid Solutions™ und Cutting Edge Metalworking Solutions™ sind Marken der Master Chemical Corporation, firmiert unter dem Namen Master Fluid Solutions. 2018-09-05
Reduzierung um 40 %
Process Improvement Results in $2400 a Day Savings PDF Case Study Colmar Industrial Supplies, LLC Based in Northbrook Illinois, Colmar Industrial Supplies (www.colmarindustrial.com) is an industrial distributor of metalworking tool and abrasives including: Read More Illini Coolant Management Corporation Illini Coolant Management Corporation (www.illinicoolant.com) is the Chicago Metro area’s complete coolant management resource. “Our goal is to provide our customers with much more than industrial cutting fluids,” said President of Illini Coolant Management, Max Bailey. Read More For more information: Master Chemical Corporation 501 West Boundary Perrysburg, OH 43551-1200 Phone: 419-724-7729 mscherer@masterchemical.com Suruga USA CORP. Process Improvement Results in $2400 a Day Savings Using exactly the right coolant for the turning centers meant not having to stop to change tools and brush on tapping compound so frequently; helping Suruga pick up more than 2.5 hours per machine per shift—for a savings of about $2400 per day. Addison, Illinois-based Suruga USA Corp.manufactures metal forming machinery and accessories, and special mechanical parts for factory automation. As sister company and sole distributor to Misumi USA, a subsidiary of the Misumi Corporation of Japan, Suruga’s mission is to provide highly original products with high quality, competitive prices and short delivery times. “Our customers want and need the finest quality parts possible when they are doing factory automation and we have both first class people and the tools here to provide just that,” said Wally Campbell, plant manager of Suruga USA. Suruga manufactures precision plant automation components in lot sizes from one to more than 100 parts with very short lead time. The twin goals of very high quality and very short turn-around time leads Suruga to do much of its machining in the “hard”. Typical materials are 52100 at 58RC, 440C, A2, 304, and 316. “I have been making parts of one kind or another out of a wide variety of materials for more than thirty years,” said Mr. Campbell. “Each of the plants I have worked with in the past has had one or more tough jobs. Here we have very few easy jobs and we regard tapping the end of a 52100 shaft at 58RC as standard fare,” he said. Combining tight tolerances and surface quality requirements with small lot sizes causes constant searches for better ways to produce parts. “One of the key goals of every modern manufacturer is to make a better part at lower cost,” said Wally Campbell. “I started looking at my costs and production choke points and realized I needed to focus on tapping the ends of the shafts because we make a lot of shafts and I was only getting a few parts per tap.” Supply Chain Collaboration Mr. Campbell brought in tooling professional, Jeff Whyle, of Colmar Industrial Supplies, for assistance. Colmar is a supplier to Suruga and prides itself on providing not only tools but creative solutions to process problems. “Suruga was spending more than 2 ½ hours every day shutting down machinery in order to apply and re-apply tapping compound,” said Mr. Whyle. “They were applying tapping compound manually and were not getting the expected tap life,” he said. The tapping fluid was causing other problems,” added Mr. Whyle. The tapping fluid was polluting the cutting fluid in the machine, degrading the coolant and causing rancidity. Lubrication is critical to the machining process—coating sliding surfaces, eliminating wear by carrying away the heat generated by friction, and helping to remove chips from the cutting zone. Jeff Whyle suggested involving an expert in coolant management and recommended Max Bailey, of Illini Coolant Management. “You can minimize coolant problems and increase throughput by partnering with an expert,” said Mr. Whyle. Coolant management is the monitoring and control of all coolant-related variables to optimize tool life, increase productivity, improve the overall shop environment, and reduce coolant waste disposal problems. Control of these factors can yield significant bottom-line gains. Coolant contaminated with tramp oil in the coolant sump can develop bacteria, becoming rancid and foul smelling. Bacteria can be a major contributor to coolant failure. It chemically alters coolants and destroys the lubricants and corrosion inhibitors in the process. It can also pass off corrosive acids and salts into the coolant, which can lead to low pH and corrosion problems. Parts and tools can be contaminated causing damage or excessive wear. “Being a believer in optimizing the process as much as possible when I am tinkering, it only made sense to ask Max for help,” said Mr. Campbell. According to Mr. Campbell, partnering with a coolant distributor to identify the product best suited for the operation improves machining processes and lowers costs. Illini Coolant Management is a Premier Distributor of Master Chemical Corporation’s TRIM® product line and prides itself on providing its customers with complete solutions. In addition to providing coolant, and the services needed to maintain coolant, Illini’s expertise extends to an understanding of machining processes. According to President, Max Bailey, “Illini has spent many years developing a network of relationships with other vendors including tooling companies like Colmar, grinding wheel specialists, and waste haulers. We have a good working relationship with Colmar,” said Mr. Bailey. “We are able to assist Colmar’s customers when they have coolant management issues and we call on Colmar when our customers have tooling issues,” he continued. As a Master Chemical Corporation Metalworking Fluids Specialist, Max Bailey has undergone years of training in cutting and grinding issues, coolant management and recycling, and methods to diagnose and fix coolant-related function problems. “Master Chemical teaches its distributors to identify and solve cutting fluid problems in the field. We are trained to understand not only cutting and grinding and coolant-related problems but machinery issues as well,” said Max Bailey. “We don’t provide cookie cutter solutions,” he continued. “We are prepared to analyze a customer problem, review the range of possible solutions, and make our recommendation. According to Mr. Bailey, Illini offers a no-cost risk proposition. “We’ll come in and do all the work. We’ll guarantee the product and if the product doesn’t work, we’ll remove it, so the customer risks nothing,” he stated. Cost Savings Realized Max Bailey ran tests and assessed the situation. At this point—while using a tapping compound that had to be applied manually—the tapping operation was averaging four parts per tap at a cost of approximately $23 each. Stopping to change taps and apply tapping compound was costing Suruga an average of two and a half hours per machine, on ten machines, running two shifts. “Solving cutting fluid problems can seem pretty straight forward,” said Max Bailey. “But the process is complex. Machining coolants come in a range of chemical compositions and you need to match the properties of the fluid with the demands of the job,” he concluded. After reviewing test results Mr. Bailey proposed a different solution. “We elected to proceed with a high-lubricity, low-foam synthetic, because it had the potential to be used across the board—eliminating the need to manage three different fluids,” said Mr. Campbell. “We chose a TRIM synthetic coolant that approaches the machining performance of premium soluble oils. Even with its very high performance, the coolant meets or exceeds the most stringent environmental standards,” he stated. As soon as the product had been chosen, Illini Coolant Management technicians cleaned a machine to conduct a trial and recharged with the new TRIM fluid. More than a year later, Wally Campbell is still pleased with the solution. Eliminating the noncompatible tapping compound has saved time and increased productivity as well as extending the sump life and reducing fluid contamination. Suruga has standardized using the TRIM product. “The TRIM coolant is about 15% more expensive on average than the products it replaced,” observed Mr. Campbell. “However, we use about 40% fewer gallons and the machines are running cleaner with less odor,” he concluded. Additional Benefits: Savings in Cost AND Time Savings Illini Coolant Management continues to identify changes to further improve processes for future cost savings. Suruga has added eight small, inexpensive coalescing units designed for sump-side use with a flow rate of 1.5 U.S. gpm (5.6 lm). The Sump Side Coalescer™ was developed by Master Chemical Corporation (the originators of coolant recycling) to meet the needs of any metalworking plant for a simple, effective, low-cost tramp oil separator. The Sump Side Coalescer will process machine tool coolants to remove tramp oils and fines and provide clean, reusable coolant. Wally Campbell can list the benefits of the fluid change. They include longer tool life, improved part quality, reduced rejects and scrap, less machine downtime, and improved work environment. Suruga’s average tap life is up from four parts to more than 30. The cost per tapped hole has gone from $5.75 to $.77 per hole. As a result of not stopping so frequently to change tools and brush on tapping compound, the company has picked up more than 2.5 hours per machine, per shift, for a savings of about $2400 per day. “Using this TRIM product has resulted in finding the equivalent of three new machining centers worth of capacity without spending a dollar in capital,” stated Wally Campbell. TRIM® and XYBEX® are registered trademark of Master Chemical Corporation The Sump Side Coalescer™ is a trademark of Master Chemical Corporation ©2008 Master Chemical Corporation | www.masterchemical.com | PDF/Download Help | 2008-05-21 Back to Case Study Colmar Industrial Supplies, LLC Based in Northbrook Illinois, Colmar Industrial Supplies (www.colmarindustrial.com) is an industrial distributor of metalworking tool and abrasives including: * Cutting Tools-HSS and Carbides * Indexable Carbide Tooling * Abrasives * Workholding and Toolholding * Measuring Tools * Shop Supplies * Machinery As a child, Colmar President Aaron Shapiro’s basement had toys on one half and tools on the other. His father had started a company that sold tools out of the back of his station wagon, and used the basement for overstock. By age 12, he was grinding points on used taper shank drills to makeup sets. Mr. Shapiro’s father always said that customers were loyal to distributors that save them money. Today Aaron Shapiro understands that if a distributor provides the tools and services that deliver value and cost reductions to the customer, the distributor’s business will grow. “In the 25 years I have been in the Industrial Distribution industry, I have learned to empathize with the customer,” said Mr. Shapiro. “I know if I can't bring more value to my customer than the competitors, the competitors will get the orders,” he stated. The Colmar philosophy is that the people who actually run a company are its customers. Colmar works to earn the customer’s trust by providing the highest quality tools and by being creative problem solvers. “Part of the value we provide is our knowledgeable, experienced staff and our understanding of industrial processes,” said Mr. Shapiro. Colmar has built a strong business network and partners with colleagues to provide customers with expert solutions to machining problems. ©2008 Master Chemical Corporation | www.masterchemical.com | PDF/Download Help | 2008-05-21 Back to Case Study Illini Coolant Management Corporation Illini Coolant Management Corporation (www.illinicoolant.com) is the Chicago Metro area’s complete coolant management resource. “Our goal is to provide our customers with much more than industrial cutting fluids,” said President of Illini Coolant Management, Max Bailey. Illini Coolant Management Corporation’s expertise extends well beyond coolant management and recycling and methods of diagnosing and fixing coolant-related function problems to include cutting and grinding issues and a solid understanding of machining processes. Illini has built a network of vendor relationships including tooling, grinding, and waste, which enables it to provide complete solutions for its customers. “Our customers know that when you buy a drum of coolant from Illini you’re getting much more than the coolant,” he stated. Managing coolants effectively and proactively can improve processes and lower cost. According to R. Eric Bevevino, CLS, U.S. companies lose an estimated $4 billion annually by not adhering to a proactive coolant maintenance approach and responding to ensuing lubrication-related failures. “Among the benefits of single-source coolant management are single-source responsibility and environmental compliance,” said Mr. Bailey. “Not to mention the savings in process efficiencies,” he added. Illini Coolant Management has both the technology and expertise needed to maintain the daily requirements of industrial metalworking equipment. As a Premier Distributor of TRIM brand fluids and XYBEX recycling equipment from Master Chemical Corporation, Illini personnel has undergone extensive training. Master Chemical’s training programs are based on 50 years of research and studies in the metalworking industry. Illini Coolant Management’s experienced technicians use Master Chemical’s portable recycling equipment for in-plant coolant recycling services. The company maintains a state-of-the-art laboratory, constructed in cooperation with Master Chemical Corporation, for the purpose of conducting coolant testing, which helps maintain optimum coolant performance. Illini’s onsite coolant recycling allows the customer to benefit from the cost savings of recycling fluid without a capital investment. Cost savings are realized in the reduction of waste disposal and eliminating the cost of replacing reusable coolant. The company offers economical programs to meet customers’ specific needs. Illini Coolant can help control metalworking fluids and meet water minimization goals, whether a facility includes one, or hundreds of machine tools. Illini Coolant Management’s services include tank-to-tank centrifugation of fluids, centrifugation of fluids from machine tool reservoirs, cleaning of machine tool reservoirs, and the full cleaning of machine tools. Illini Coolant Management is so confident in the quality of its products and services that it offers a no-risk guarantee. “We will come in and do all the work,” said Max Bailey. We guarantee the product and if the product doesn’t work we’ll remove it so you risk nothing.” According to Mr. Bailey, this customer-focused approach combined with the high quality Master Chemical TRIM fluids and XYBEX recycling equipment has been spectacularly successful. ©2008 Master Chemical Corporation | www.masterchemical.com | PDF/Download Help | 2008-05-21
$2400 per Day Savings
A Light Construction Manufacturer Builds Their Bottom Line. A Light Construction Manufacturer Builds Their Bottom Line. Case History A manufacturer of light construction/excavation vehicles with two large Midwestern facilities was looking for cost savings and measurable performance improvements. Critical steps of preparation, cleanout, and conversion were carefully planned to minimize customer downtime and ensure a problem-free conversion. The Master Chemical Partnership Process With meticulous preparation, MCC works with potential, new, and existing customers through cost analysis, projected tooling savings, product comparisons, and planning prior to the process of cleanout and the conversion to the MCC fluid. Cost Analysis MCC collected customer data of their current system; including coolant usage, cleanouts, and time required. Based on these values, calculations show that by converting to TRIM® MicroSol® 585, along with an improved fluid management program, the customer could save at least $267,000 per year in fluid costs. Additionally, pilot testing was conducted on the customer’s machines using MicroSol 585 and projected tooling savings between 20 and 30 percent. Master Chemical Corporation partners with existing and prospective clients, investing our time and experience to help customers improve their bottom line. CALCULATIONS Existing MCC Status Proposal Total sumpage 6000 6000 Average per gallon cost of coolant per total sumpage $0.91 $1.22 Gallons of coolant concentrate used for makeup per year 23,040 15,360 Gallons of coolant concentrate used for charging sumps per year 1,260 960 Cost of makeup concentrate per year $264,960 $215,040 Cost of charging concentrate per year $14,490 $13,440 Coolant disposal costs per year $1,800 $1,200 Total coolant cost per year $281,250 $229,680 Overhead cost due to major cleanout downtime $288,000 $144,000 Overhead costs due to recycling pumpout downtime per year $216,000 $144,000 Total metalworking fluid cost per year $785,250 $517,680 The Maste r Chemical DIFFERENCE – annual sa vin gs $267,570 www.trimfluids.com © 2007, Master Chemical Corporation. TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation. 5/15/07 ANNUAL PROJECTED SAVINGS BETWEEN 20 AND 30 PERCENT USING TRIM MICROSOL 585 30% Reduction 20% Reduction 0 $200,000 $400,000 $600,000 $800,000 $1,000,000 $1,200,000 $1,400,000 ANNUAL COST SAVINGS Reductions Reductions in Changeover Costs in Tooling Costs $856,000 Combined Savings $1,284,000 Combined Savings $460,000 Tool Savings $690,000 Tool Savings $396,000 Savings in Changeovers $594,000 Savings in Changeovers Estimated cost savings were projected based on testing on customer’s machines. Savings are calculated on a one changeover/ day/machine/plant baseline, assuming 90% plant utilization. Annual baseline annual cost of $2.3 million ANNUAL FLUID SAVINGS USING TRIM MICROSOL 585 Original Fluid Company Master Chemical Corporation 0 $100,000 $200,000 $300,000 $400,000 $500,000 $600,000 $700,000 $800,000 ANNUAL COSTS Total Coolant Cost Overhead Cost Due to Major Cleanout Downtime Overhead Cost Due to Recycling Pumpout Downtime The Master Chemical Difference $267,570 The Master Chemical Difference $229,680 $144,000 $144,000 ® $281,250 $288,000 $216,000 Proven Results The plant manger reported that for the first time in 22 years he received a letter from a union leader complimenting them on a job that was in progress. The union leader wrote to say he was extremely pleased with the job MCC and the manufacturer were doing for the workers – including the pre-planning and training; and that employees continued to comment about the great job that MCC did conducting 12 safety training sessions of more than 230 employees. Their labor relations supervisor commented, “I just wanted to pass on a conversation I had regarding the coolant change process which got underway today.” He expressed gratitude to MCC in the communication process that kept him and the union informed and the effort made to utilize their own people as much as possible. Furthermore, he stated that he “appreciated this whole process and looked forward to doing it in the future when there are changes in order to avoid potential issues or grievances.” Another Satisfied Customer TRIM MicroSol 585 is performing above expectations. The manufacturer is achieving better machinability at all levels – expecting improved overall performance in most noncutting functions and realizing tool cost savings between 20 and 30 percent. Value-added Service Leads To Customer Satisfaction TRIM® MicroSol® 585. The clean performance of a synthetic AND the protection of a soluble oil. n Clean running – keeps machines and parts clean, reduces post-machining operations, and cleaning costs n Excellent lubricity – multi-metal compatibility, superior machining performance, and corrosion resistance n Machine protection – protects machine tools and parts like a soluble oil without the oily residue n Biostable – for lower risk, longer sump life, minimized disposal requirements n Minimized residue on machines and parts for a cleaner work environment MicroSol 585. Innovation that pays off on your bottom line.
$267,000 Saved Annually
Reduction in Use & Disposal of Cleaner Chemistry: $590.635 Saved Annually Reduction in Use & Disposal of Cleaner Chemistry
$590.635 Saved Annually
United Technologies Corporation: $2.65 Million Saved Annually Maximizing Productivity – Minimizing Waste.sm TRIM® is a registered trademark of Master Chemical Corporation Maximizing Productivity – Minimizing WasteSM is a service mark of Master Chemical Corporation © 2006 Master Chemical Corporation • Revised 5-11-06 501 West Boundary Perrysburg, OH 43551-1263 Phone: 419-874-7902 Fax: 419-874-0684 Visit us on the web: www.masterchemical.com Before: $2.8 Million TOOLING COST/YEAR After: $700,000 Before: 600 Machine Tools MACHINE TOOLS EFFICIENCY IMPROVED After: 350 Machine Tools Before: 600 Drums After: 42 Drums COOLANT PURCHASED/YEAR Before: Six Workers Required After: Three Workers Required COOLANT MANAGEMENT CREW Before: 1 Million Pounds After: 30,000 Pounds DISPOSAL OF LIQUID WASTE Case Study: UNITED TE CHNOLOGIES CORPORAT ION Ongoing $2.65 Million Saved at a Single Plant With Master Chemical’s assistance Hamilton-Sundstrand, a division of United Technologies Corporation, established a coolant committee with representatives from plant management, health and safety, manufacturing, engineering, purchasing, maintenance, and machine operators. The program included: • MCC-provided training sessions • Implementation of ongoing recycling systems • Monitoring of coolant and machine sump conditions The following results where obtained: $2.1 Million Saved Productivity Savings of 42% $301,320 Saved A Savings of $46,746 $210,000 Saved
$2.65M Saved Annually
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