Master Fluid Solutions - Cutting Edge Metalworking Solutions

Racing Manufacturer Cuts Costs by 10%

Leading Indian Auto part Manufacturer Reduces Cost Per Unit by 16% with TRIM™ OM 222 Leading Indian Auto part Manufacturer Reduces Cost Per Unit by 16% With TRIMª OM 222

Accurate Product Corporation has emerged as the leading manufacturer in India for components ranging from grease fittings and cups and relief valves to air breathers and precision turned parts, among other critical automotive parts.
Their products are available in over 72 countries, serving almost every major original equipment manufacturer (OEM) for automotive producers in India, in addition to others worldwide.

THE CHALLENGE

THE SOLUTION

Accurate conducts various drilling, thread forming, and grooving operations on multi-spindle automatic machines and other equipment to create high-quality automotive components. As the company grows, management remains diligent about improving productivity without sacrificing part quality.
To fight rising operating costs, Accurate used the same economically priced neat oil for 40 years. However, after reaching the limit of the fluidÕs capabilities, the only option remaining for the company was to explore an oil upgrade.

Accurate switched to TRIMª OM 222, a high-performance straight cutting oil specifically designed for hard-to-machine materials. With superior lubricity, OM 222 excels at preventing the formation of built-up edge thatÕs common with tough ferrous metals and stainless steel alloys. The versatile product is also compatible with nonferrous metals.
This fluid is ideally suited for AccurateÕs manufacturing operation, which includes the use of a wide array of materials on a daily basis. Because OM 222 is low odor and light in color, it offers better operator acceptance than similar fluids.

THE RESULTS

With shop layout, ergonomics, and workflow already optimized, the only way to improve productivity was to transition to a higher performance cutting fluid. OM 222Õs enhanced lubricity and cooling ability allowed Accurate machine operators to significantly speed up production without reducing part quality.
In the first phase of testing OM 222Õs capabilities, operators reduced cycle time from 8 seconds down to 7.5 seconds per part. After proving machines could consistently produce high-quality results, operators shaved even more from cycle times. In the second phase of trials, operators reduced time per unit to 7 seconds, and finally to 6.8 seconds in phase three.
By cutting 1.2 seconds from cycle time, Accurate increased daily output by 1,500 components. Even though OM 222 costs three times more than their previous cutting fluid, the drastic increase in productivity lowered the cost per unit by 16 percent, paving the way for significant growth in revenue.

THE NUMBERS

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Increased output by 1,500 components per day

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Reduced cycle time from 8 to 6.8 seconds per component

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Lowered cost per unit by 16%

©2021 Master Fluid Solutions. Master Fluid Solutions¨, TRIM¨ and MicroSol¨ are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-08-02

16% Cost Reduction with TRIM

Automotive Parts Manufacturer in Thailand Reduces Coolant Consumption by 42% With WEDOLiT™ FW 7652 Automotive Parts Manufacturer in Thailand Reduces Coolant Consumption by 42% With WEDOLiTª FW 7652

Based in Thailand, the customer is a well-respected and growing auto and motorcycle parts manufacturer. They specialize in producing stainless steel parts for exhaust systems, especially pipes and inlet tubes. The company has been instrumental in the expansion of the automotive industry in Thailand and South Asia.

THE CHALLENGE

THE SOLUTION

One of the biggest problems the customer encountered during manufacturing was their previous coolant left a sticky residue on the tubes. The fluid also created substantial foam during operation, contributing to low-quality surface finishes for their parts. The additional cleaning and reworking significantly reduced throughput and labor efficiency.
Additionally, the sticky residue and foam caused the machines, dies, and rollers to get dirty and accumulate contaminants, requiring special cleaning that further reduced production output. The foam, along with a short sump life, led to frequent fluid changes, driving up fluid costs.

The customer transitioned to WEDOLiT FW 7652, a specialty fluid best suited for wire drawing and forming welded stainless steel tubes. In addition to providing superior lubrication and forming ability, FW 7652 offers significant corrosion protection, even at a concentration of four to six percent. The productÕs excellent thermal stability allows it to be used throughout the production process, including initial forming, high-heat welding, calibrating, and sawing.

THE RESULTS

THE NUMBERS

WEDOLiT FW 7652 produces no foam and keeps workpieces and machines clean throughout the manufacturing process. After switching to the new product, surface finish for completed parts immediately improved. Machine operators also reported a better shop environment due to less odor, and significantly improved tramp oil rejection over their previous product.
Another advantage is WEDOLiT FW 7652 features a robust formulation and excellent sump life, even without additional tank side additives. Combined with a lower carry-off rate, the new WEDOLiT formula has allowed the customer to lower their fluid usage from 35 liters per month down to 20, a 42 percent decrease.

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Customer drastically reduced foam, residue and extended sump life

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Reduced fluid consumption 42%, from 35 to 20 liters per month

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Decreased residue on tubes, leading to lower production costs

©2021 Master Fluid Solutions. Master Fluid Solutions¨, TRIM¨ and MicroSol¨ are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-07-21

Coolant Consumption Reduced by 42%

Leading Indian Auto and Aerospace Parts Manufacturer Lowers Coolant Consumption by 22% With TRIM™ E860 Leading Indian Auto and Aerospace Parts Manufacturer Lowers Coolant Consumption by 22% With TRIM™ E860

The customer established their operation in India in 1991 to manufacture aftermarket brake parts for the North American market. In 1995, the company expanded to include master cylinder castings, turbocharger components, and numerous other specialty automotive and aerospace products. Dedicated to fostering talent, a majority of their team has been with the company for more than a decade, helping them grow into a global leader with over $100 million in annual revenue.

THE CHALLENGE

THE SOLUTION

The customer’s large manufacturing facility houses hundreds of CNC machines, which carry out complex milling, drilling, tapping, and multi-step forming operations primarily with cast aluminum. However, their polycrystalline diamond (PCD) tooling left behind bore marks on a number of finished parts, leading to a high and unacceptable scrap rate.
Their previous coolant, with it’s high carry-off, increased the makeup rate as well as overall coolant consumption and fluid costs despite the fluid’s low price. Frequent coolant change-outs also decreased productivity and raised labor expenses.

The company upgraded their cutting fluid to TRIM™ E860, a leading-edge, general-purpose emulsion formulated for compatibility with a wide range of ferrous and nonferrous metals. The fluid’s benefits — which include excellent tramp oil rejection, overall cleanliness, higher lubricity at lower concentrations, and easy maintenance — make it especially suitable for their complex operations with cast aluminum.

THE RESULTS

THE NUMBERS

After only two months in their machine sumps, E860 completely eliminated bore marks in the parts. TRIM E860 has also eliminated the staining and white corrosion on the aluminum. All products achieved a noticeably superior finish with less rework. Machine cleanliness has improved as well.
Most importantly, E860 achieved superior results with only a seven percent concentration in the sump — significantly less than their previous cutting fluid. Makeup averaged only 1.5% vs the previous product’s 2.5%. Though E860 costs more than the customer’s previous cutting fluid, the company reduced coolant consumption to a level where they reduced coolant spend.

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Drastically reduced coolant consumption by 22%

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Previous product usage was 7 drums per month, now 5.5 with TRIM E860

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Significantly improved part quality and reduced scrap

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Achieved superior results with only 7% cutting fluid concentration in sumps with 1.5% makeup concentration

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30 machines in master cylinder cells converted to TRIM E860

©2021 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-06-21

Coolant Consumption Lowered by 22%

Precision Forged Parts Manufacturer Improves Tool Life Over 10% With TRIM™ E860
Precision Forged Parts Manufacturer Improves Tool Life Over 10% With TRIM™ E860

Since 1995, Sivaramakrishna Forgings PVT LTD (SRKF) has manufactured precision parts for global leaders in the automotive, rail, power, valve, and trucking industries. They have emerged as the leading supplier to Indian manufacturers, such as M/S Super Auto Forge Ltd, M/S Brakes India Ltd, and M/S Aztec Auto Ltd. Globally, SRKF produces hot forged and critical safety parts like brakes and meets the export requirements of their customers.

THE CHALLENGE

THE SOLUTION

At their manufacturing facility in India, SRKF’s operations include drilling, turning, tapping, and boring on materials such as carbon steels, steel alloys, and stainless steel. With their previous coolant, which was chosen for its low price, the customer faced short tool and sump life, significantly driving up operating costs. They also faced rust and corrosion problems on their cutting tools and finished parts, forcing them to scrap numerous parts further affecting overall profits.

In a trial of five machines, SRKF switched their cutting fluid to TRIM™ E860, a high-quality, general purpose emulsion used in various grinding, cutting, and drilling operations. The solution is compatible with a full range of ferrous and nonferrous metals, but its consistent performance makes it the perfect choice for precision parts manufacturing with forged steel.

THE RESULTS

THE NUMBERS

In the two months after switching to E860, SRKF drastically extended tool life up to 15% in certain applications. The new cutting fluid keeps machine tools cleaner, preventing rust formation and other corrosion. Plus, the formula is resistant to tramp oil, making it easier to maintain and live longer in the sump without change-outs. Combined with reduced carry-off, E860 helped the customer to reduce their total coolant consumption by reducing makeup rates by 40%. Previous makeup rate was 2.5%, and now they are at 1.5% with TRIM E860. SRKF is now converting the rest of their machines to TRIM E860.

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Drastically improved tool and coolant life in machines.

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Eliminated rust and corrosion from cutting tools and finished parts.

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Reduced makeup rates by 40%

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Increased tool life by 10-15%

©2021 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-06-21

Improved Tool Life Over 10%

20% Cost Reduction with TRIM^®

Global Tool Manufacturer Reduces Cleaner Costs by 15% with Master Fluid Solutio™ Global Tool Manufacturer Reduces Cleaner Costs by 15% With Master Fluid Solutionsª

Since the mid 1800s, our customer has built their tool manufacturing empire into a catalog of globally recognized brands and services. Their growing product portfolio encompasses consumer and industrial tools, vehicle and electronic fasteners, and even cutting-edge security services.

THE CHALLENGE

THE SOLUTION

At their flagship manufacturing facility, our customer sought to reduce operating costs by $2 million by consolidating vendors and utilizing superior fluid solutions, including cleaning products.
Previously, the facility used various cleaning solutions to handle different tasks, such as mopping floors, wiping surfaces, washing parts, and removing oil spills. In total, they used approximately 30,000 gallons of cleaning products per year.

Master Fluid Solutions helped the manufacturer consolidate their cleaning needs and solutions into one product: Master STAGESª CLEAN F2ª, an all-purpose concentrate designed for multiple cleaning applications. The versatile formula can also be used to manually mop floors, clean spills, wipe down numerous surfaces, and wash parts. It includes the capability to remove heavy soils from floors without harming concrete, tile, and linoleum coating, or paint, and it doesnÕt leave sticky or slippery residues in the process.
Formulated without silicates and high pH additives, Master STAGESª CLEAN F2 offers an excellent environmental footprint and doesnÕt negatively interact with or degrade TRIM¨ fluids. In addition, it can be put into spray bottles, providing exceptional cleaning at diluted concentrations that are safe for operators, and reducing consumption and costs.

THE RESULTS

THE NUMBERS

Master STAGES CLEAN F2 replaced an entire line of competitorsÕ cleaning solutions and equipment. Due to its superior performance, the customerÕs custodial staff achieved better results with a lower concentration of the solution.
By tapping the power of Master Fluid Solutions and Master STAGES, our customer simplified and minimized their chemical inventory with a multi-use formula. The company also reduced its overall cleaning solution consumption rate, translating to a 15 percent reduction in cleaner costs.

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Consolidated numerous cleaning products into one solution

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Reduced cleaner consumption by upgrading to higher-performing solution

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Reduced cleaning supply costs by 15%

©2021 Master Fluid Solutions. Master Fluid Solutions¨, TRIM¨ and MicroSol¨ are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-06-14

Cleaner Costs Reduced by 15%

$Injection Mold Manufacturer Improves Productivity and Tool Life With TRIM® E923 Injection Mold Manufacturer Improves Productivity and Tool Life With TRIM¨ E923 One of North AmericaÕs leading mold builders creates high-quality, precision plastic injection molds for automotive original equipment manufacturers (OEMs). Globally recognized for their high-tech tool production capabilities, the company has maintained a strong reputation of quality and precision for more than 30 years. THE CHALLENGE THE SOLUTION The injection mold manufacturer machines various steels, including AISI 4140, P20, and H13 tool steel. They use 11 machines to gundrill workpieces, each averaging a hole depth of 45 inches. Their previous cutting fluid had poor lubricity and created tacky residues, causing chips to become stuck and drag on the workpieces. This resulted in poor-quality finishes that frequently required reworking. The existing fluid also accumulated dirt and contaminants, making parts difficult to clean and resulting in frequent coolant replacement and high coolant consumption. Clogged filters, proxy switches, and lasers also caused machine downtime, forcing workers to clean and address the issues, leading to lost productivity. The company switched to TRIM¨ E923, a proprietary blend of extreme pressure additives and new vegetable-based technology that requires minimal management for optimal performance and trouble-free machining. The high-quality emulsion extends tool life and optimizes lubricity Ñ even in the most difficult cutting operations. Formulated for extreme pressure and difficult materials, E923 can even replace traditional heavy-duty neat cutting oils in some applications. THE RESULTS THE NUMBERS Over a three month trial, the customer significantly improved drill life and surface finishes on completed molds without additional rework. TRIM E923 eliminated clogged filters, sticking proxy switches, and fouled lasers, greatly decreasing production time. Since filters lasted longer, their usage and associated costs were also reduced. E923 also evaporates less than the previous coolant, lowering makeup rates and overall coolant usage while improving air quality. There has also been a significant increase in tool life, providing additional cost savings and productivity improvements. Additional savings have come from no longer needing to use special competitor test strips to monitor coolant concentration, as E923 is more compatible with refractometers. The vegetable ester enhanced formulation improved the sustainability profile of the customerÕs operation. Plus, the customer reported that service and support has been noticeably better with Master Fluid Solutions than their previous supplier. ¥ 11 machines run with increased production efficiency and reduced machine maintenance and cleaning. ¥ Operating costs reduced by lower fluid consumption, longer tool life, less filter use, and replacing special testing strips with refractometer usage. ©2021 Master Fluid Solutions. Master Fluid Solutions¨, TRIM¨ and MicroSol¨ are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-04-27$

Improved Productivity with TRIM E923

Coolant Speeds Up Production

Precision Stamping Manufacturer Cuts Tooling Costs by 67% with HyperSol™ 888NXT Precision Stamping Manufacturer Cuts Tooling Costs by 67% with HyperSol™ 888NXT

A precision stamping manufacturer for the automotive, aerospace, and defense industries designs and builds progressive dies in their facility in California. They use these dies to produce high-quality, customized stampings for clients.

THE CHALLENGE

THE SOLUTION

A longtime Master Fluid Solutions™ customer, this manufacturer works with Inconel® 718, a nickel-based alloy used to produce parts and components for jet engines and high-speed airframe components. These parts, such as buckets, wheels, and spacers were previously machined using TRIM® E906, a premium, high-lubricity low-foaming cutting fluid known for extending tool life on challenging materials.
While using E906 at high concentrations and three-edged grooving inserts, the company achieved a tool life of 50 parts per edge. At this rate, tool costs equated to $0.33 per part. However, the customer sought a way to increase throughput, reduce fluid consumption, and further minimize the cost per part.

Master Fluid Solutions provided the manufacturer with a trial of TRIM HyperSol 888NXT, a patented, environmentally friendly, low-foam, low-odor, neo-synthetic coolant, which provides exceptional performance on Inconel® and other difficult materials. It excels with its superior lubricity, which is necessary for the most challenging applications and customers looking to maximize productivity.

THE RESULTS

THE NUMBERS

The advanced performance of HyperSol 888NXT allowed the customer to cut their coolant concentration by more than half, from approximately 35% to 15%. In a three-day period, the company tripled tool life from 50 parts per edge to 150 parts per edge — simply by upgrading the cutting fluid. This translated to a reduced tool cost to $0.11 per part, a 67% decrease.
Previously, the customer spent $6,666 on inserts to produce 20,000 parts. Using tool life-extending HyperSol 888NXT, the customer reduced costs associated with the edge inserts down to $2,222, saving the end-user more than $4,000.
Now, the precision stamping manufacturer has ordered HyperSol 888NXT to use on other machines in their shop.

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Reduced coolant concentration from 35% to 15%

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Tripled tool life from 50 parts per tool edge to 150

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Reduced tool cost per part by one third from $0.33 to $0.11, a 67% decrease

©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

Tooling Costs Cut by 67%

Precision Machining Operation Doubled Productivity with TRIM<sup>®</sup> HyperSol™ 888NXT Precision Machining Operation Doubled Productivity With TRIM¨ HyperSolª 888NXT

For over two decades, a Silicon Valley-based manufacturer has provided precision machining services in the aerospace, defence and medical industries, as well as for global original equipment manufacturers (OEM). The manufacturer excels at short- and long-run production, making high-quality prototypes for various engineering projects.

THE CHALLENGE

THE SOLUTION

The manufacturer has 12 machines on-site for milling, turning, and five-axis machining operations. Workpieces include 17-4 stainless steel Ñ a challenging grade that contains 15 to 17 percent chromium, three to five percent copper, and three to five percent nickel Ñ and Inconel¨, a durable nickel and chromium alloy used for aerospace applications.
The high-lubricity, machine-friendly characteristics of TRIM¨ MicroSol¨ 585XT allowed the manufacturer to maintain a long sump and tool life with an impressive throughput of 16 to 18 parts per hour.
They were also seeking a simple method to further improve productivity while reducing fluid consumption. Therefore, Master Fluid Solutionsª identified a coolant upgrade as the best plan of action.

The customer transitioned to the advanced TRIM¨ HyperSolª 888NXT, Master Fluid SolutionsÕ first patented neo-synthetic coolant. Previous metalworking fluid categories include straight oils, emulsions, semi synthetics, and synthetics. Each category is recognized for their unique strengths and weaknesses in regards to cooling and lubricity. HyperSol 888NXT stands out with its unparalleled cooling and high lubricity Ñ a combination thatÕs never been achieved in a single cutting fluid. HyperSol 888NXT provides exceptional performance on hard aerospace metals, such as titanium and high-nickel alloys, stainless steels, and Inconel¨, which are all used daily in the customerÕs operations. Certified as a USDA Biopreferred cutting fluid, HyperSol 888NXT also improved the customerÕs environmental footprint.

THE RESULTS

THE NUMBERS

After 45 days of use, and changing nothing except the coolant used in their operation, the aerospace, defense, and medical equipment manufacturer more than doubled the throughput of stainless steel from 16 to 18 parts per hour to between 36 and 40 parts per hour. Coolant consumption also decreased drastically because TRIM HyperSol 888NXT requires lower concentrations and makeup rates.
The Silicon Valley manufacturer has ordered additional drums of the new HyperSol 888NXT for use in its Inconel¨ machining operations.

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Increased productivity by over 100%

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Fluid consumption and makeup rates reduced

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Doubled production throughput from 18 parts per hour to 36

©2021 Master Fluid Solutions. Master Fluid Solutions¨, TRIM¨ and MicroSol¨ are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-04-02

Double Productivity with HyperSol 888NXT

Automotive Components Manufacturer Cuts Cleaning Chemical Cost By 34% With Master STAGES™ Task2™ GF Automotive Components Manufacturer Cuts Cleaning Chemical Cost By 34% With Master STAGES™ Task2™ GF

A manufacturer with facilities across North America, Europe, and Asia, has been an automotive industry leader in the design, engineering, and manufacturing of fixed pedal modules, sensors, and throttle controls. In the last 70 years, they’ve grown into a global company.

THE CHALLENGE

THE SOLUTION

In their Canadian headquarters, which focuses on R&D and engineering, the manufacturer uses a substantial amount of stamping oils and other industrial lubricants in their daily operations. Oil mist, leaks, and spills are difficult to clean, and must be done regularly to protect the health and safety of employees and maintain the environment of the facility.
The manufacturer’s previous citrus-based cleaner performed adequately but was only effective at high concentrations, contributing to higher cleaner costs.

The manufacturer agreed to trial Master STAGES™ Task2™ GF, a powerful, non-butyl, water-based cleaner designed to fight tough grime in industrial, commercial, and office environments. Though the formula has a low VOC content, it has proven to be high-performing enough to achieve the stringent Pratt & Whitney Aerospace Approval PMC 1247-1. Additionally, it’s environmentally friendly and certified as “Readily Biodegradable” by the Organization for Economic Co-operation and Development (OECD). It’s specially formulated to work in conjunction with TRIM® metalworking fluids.

THE RESULTS

THE NUMBERS

Task2 GF costs $550 less per drum than the manufacturer’s previous cleaner, reducing spend by 34 percent. In spite of the lower price, the Master Fluid Solutions™ cleaner performed more effectively than the manufacturer’s previous citrus solution, greatly decreasing the amount of solution needed on a daily basis, translating to additional savings. The manufacturer is currently assessing how to implement Master Fluid Solutions’ cleaning products at their other facilities worldwide.

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Savings of over $550 on cleaning supplies

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A 34% reduction in spend per drum

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Significantly reduced consumption of cleaning solution

©2021 Master Fluid Solutions. Master Fluid Solutions®, TRIM® and MicroSol® are registered trademarks of Master Chemical Corporation d/b/a Master Fluid Solutions. 2021-04-02

Cleaning Costs Cut by 34%

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

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50% reduction in coolant application rates

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8.48% reduction in cost per part

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25% extended tool life

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$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 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.

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10% reduction in overall consumption and future order quantities

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Significantly reduced production time through the automation of the application process

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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

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90% reduction in filter bags used

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50+ machines in operation

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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

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Lowered customer complaint rate to under 10%

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100% reduction in the necessity of VCI packaging

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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

50% Coolant Reduction

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%

Flawless Parts

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® MicroSol® 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
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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

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