The right lubricant saved over SEK 795,000 a year

A large manufacturer of plumbing and bathroom products needed to review its work processes to increase efficiency and reduce costs. They initially used an effective basic drawing oil when drawing bathtubs. However, the oil meant that all the bathtubs had to be washed before going on to welding, steeping and enamelling – a time-consuming process. The company also needed to replace the very old washer with a new one, which would be a huge investment. For this reason the company contacted us to see whether we could help to simplify the production process.

Problem:

• Time-consuming washing process.
• A very old washer that would need replacing very soon.
• The company needed to cut costs.

Solution:

• Full-scale testing with our water-soluble emulsion ECOCOOL BOOSTER L1 (previously named COOLWAY BOOSTER L1) when drawing bathtubs.
• Since ECOCOOL BOOSTER L1 can be mixed with water, the tubs did not have to be washed but could go directly on to welding, steeping and enamelling.

Results:

• A total saving of SEK 795,330 a year!

Energy saving in the washer:
Boiler 300 kW/h
Five spray pumps + driveline = 15 kW x 6 = 90 kWh
Total = 390 kWh
390 kW x SEK 0.70 = SEK 273/h
SEK 273/h x 1206 h = saving of SEK 329,238

Costing calculation:
Run time 0.0351 x SEK 280 = SEK 9.82 each
SEK 9.82 x annual forecast 35,000 bathtubs = saving of SEK 343,980

Washing detergent:
Estimated annual consumption (3200 L x SEK 29.90) = SEK 95,680
90% of annual consumption = saving of SEK 86,112

Waste management in washer:
Estimated annual cost (3 x empties x 12000 L x SEK 1.50) = SEK 54,000
One empty a year remains = saving of SEK 36,000