Case Studies

Thai Wheel Manufacturer Cuts Cost per Unit by Over 30% with CoolPAK™ COMSOL IIC & XYBEX^® Fluid Recycling

The customer is a well-recognized aluminum alloy wheel manufacturer that is as dedicated to its employees as it is to quality products. Though heavily focused on production for the Southeast Asia region, the customer is increasingly manufacturing aftermarket products for the international market, including the U.S.

THE CHALLENGE

Even with being highly efficient, the customer still struggled with high coolant costs per wheel that were inconsistent. Shop managers were interested in upgrading to a more stable and effective fluid, as well as implementing a comprehensive coolant management program. They partnered with Master Fluid Solutions^® to find a replacement for their existing fluid and develop a comprehensive management strategy that could reduce cost per unit.

THE SOLUTION

The customer switched to CoolPAK™ COMSOL IIC, a soluble oil base especially suited for manufacturing die-cast aluminum wheels and high-value automotive parts. The high-quality fluid provides excellent surface finish and dramatically extends tool life. After production, it easily washes off to reduce cleaning costs and time, maintaining higher throughput. In addition to the new cutting fluid, the customer also purchased a Yellow Bellied Sump Sucker™, a versatile sump cleaner especially adept at filtering chips and other debris out of coolant. With the help of Master Fluid Solutions experts, the customer implemented a XYBEX^® Recycling System that uses centrifuges to separate tramp oil, particulates, and other contaminants as small as 2 microns.

THE RESULTS

The customer replaced their low-quality cutting fluid with CoolPAK COMSOL IIC and began following Master Fluid Solutions' recommended coolant management processes. Over a period of three months, the company observed dramatic improvements to its key performance indicators (KPIs). Prior to switching to COMSOL IIC, they wanted a solution that could reduce cost per wheel to just 2 THB (Thai Baht). With COMSOL IIC and the new coolant maintenance protocols, they succeeded in reducing cost per wheel further than their intended goal, to 1.77 THB. The improved coolant quality also translated to cleaner parts and a more pleasant shop environment for employees, even as productivity increased to more than 40,000 wheels produced per month. The coolant recycling system has also extended fluid life far beyond original targets. Currently, the customer is evaluating how to expand the use of COMSOL IIC and XYBEX fluid recycling systems to their other factories.

THE NUMBERS

Reduced cost per wheel to 1.77 THB, over 30% less than previous solutions
Increased factory productivity to more than 40,000 wheels per month
Dramatically extended fluid life and reduced waste

Thai Wheel Manufacturer Cuts Cost per Unit by Over 30% with CoolPAK™ COMSOL IIC & XYBEX^® Fluid Recycling

THE CHALLENGE

THE SOLUTION

THE RESULTS

THE NUMBERS

Reduced cost per wheel to 1.77 THB, over 30% less than previous solutions
Increased factory productivity to more than 40,000 wheels per month
Dramatically extended fluid life and reduced waste