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  5. 50% LESSER COST OF RUST-PREVENTING OIL THAN THE PHOSPHATING STAGE

50% LESSER COST OF RUST-PREVENTING OIL THAN THE PHOSPHATING STAGE

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To know more about the cost optimization opportunities that we can offer

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  • Rustilo DWX 30 & Rustilo DW 950
  • Achieved Dry-to-Touch Components
  • Clutch Manufacturer

The challenge

 

A leading clutch manufacturer is adapting the ‘Go Green’ policy worldwide, and their Chennai plant is also required to implement the same here. 

 

1. Currently, their clutch manufacturing process involves the ‘Phosphating’ stage, which is outsourced to their sub-vendors. 

 

2. It also involves rigorous management of vendors such as 

  • Quality audits
  • Rejection Handling
  • Logistics
  • Price Corrections
  • Ensuring stringent quality demand

3. The manufacturer sought to replace the ‘Phosphating’ stage with a simple rust-preventing (RP) oiling stage; thus, adhering to the ‘Go Green’ policy. 


Note: Currently, RP oil is applied after the phosphating stage at vendor sites.


The solution

 

After a thorough client requirement analysis, Rustilo DWX 30 & Rustilo DW 950 was recommended.

 

  1. Rustilo DWX 30 leaves an ultra-thin film mandatory for clutch assembly applications. Any excessive oil results in component rejection.
  2. The said clutch manufacturer invested in an automated oiling stage that included the dipping, draining & drying process. Rustilo DWX 30 suited their overall cycle time requirement. 
  3. Rustilo DW 950 was used for dewatering the components prior to the RP oil stage; thus, helping the bath life extension. 


The business benefit

 

  1. The client achieved ‘dry to touch’ components post-Rustilo DWX 30 application. It further enabled the client to carry out Laser marking & inkjet marking on the components, which was one of the pre-requisites.
  2. As Rustilo DWX 30 delivered the rust protection required for both domestic and export components, the client could eliminate the ‘Phosphating’ process for most of their components. 
  3. In larger diameters clutch covers, the cost of RP oiling was 50% lesser than the phosphating stage.
  4. The 400 litres bath of Rustilo DW 950 & Rustilo DWX 30 has never been entirely changed since it was freshly filled six months ago. This positive change was possible due to Castrol’s technical inputs of top-up ratio based on specific gravity fluctuation. 
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