Case Studies

Boiler Manufacturer Eliminates Rust, Odor, and Fluid Waste with TRIM^® MicroSol^® 585XT

The customer is a multinational company based in India that specializes in all aspects of manufacturing supercritical boilers and pulverisers. Formed in 2007, the firm's expertise encompasses design, engineering, selling, maintenance and servicing of their products. They have built one of the most state-of-the-art plants in India, with an optimized layout, machinery, and systems for maximum efficiency.

THE CHALLENGE

After a long partnership with Master Fluid Solutions^®, the customer began to experiment with cutting fluids from other suppliers, trying to find products that matched the premium high quality of TRIM^®, but at a lower cost. Within two months of switching from TRIM, the new cheaper coolant had a major negative impact on nearly every aspect of their operation.

Immediately, tool life significantly dropped, driving up tooling and material costs, reducing throughput. Fluid life also significantly deteriorated. The customer had a difficult time maintaining proper coolant concentrations, further increasing maintenance and material costs despite the lower price per drum. The competitor fluid also had poor bacteria and tramp oil resistance, causing severe odors to emanate from all machines. As a result, rust was a common issue on their machines.

THE SOLUTION

The customer switched to TRIM MicroSol^® 585XT, a premium semisynthetic microemulsion designed for long sump life. Using some of the most cutting-edge advancements in semisynthetic formulation, MicroSol 585XT offers superior foam control while providing maximum lubricity. It also drastically extends useful life by resisting bacteria without the use of biocide additives. The fluid is compatible with a wide array of materials, including cast irons and copper, as well as advanced steels, titanium, aluminum alloys, and many plastics and composites.

THE RESULTS

After recharging one machine sump with MicroSol 585XT, the customer noticed an immediate elimination of previous issues. Odor disappeared from the facility, surface finish quality improved, and the fluid stopped rust on the machines. Fluid concentration remained stable with less frequent top ups, and tool life increased, significantly reducing material and overall costs, despite the premium price of the TRIM cutting fluid.

Over the coming year, the customer will phase out the competitor's oil and replace with MicroSol 585XT.

THE NUMBERS

Sharp decrease in fluid consumption
Drastic increase in tool life
Significant cost reductions from eliminating material waste

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