Automotive Supplier Reduces Costs by 60%

A multi-national, tier-one automotive supplier was having issues with staining from their fluid that led to their powder coating not adhering to the part. This caused the supplier to wash every part prior to the powder coating process. Our experts performed an analysis of their process and identified two problems: there was excess fluid on the parts and the fluid itself was prone to metal reactivity.

Impact Fluids worked with their staff to reduce the amount of fluid they applied to their parts by installing precision sprays systems. These systems saved 30% in fluid usage. Additionally, we introduced a new fluid that is non-reactive with metals, easier to wash, and much more capable than their existing fluid. With the new fluid, we were able to reduce the water/concentrate ratio from 4 /1 to 7 /1, which is over 40%.

The hard cost savings by applying less fluid and reducing the concentration of a better fluid were nearly 60%. Additional savings were made by the elimination of having to clean each part, part checking and scrap parts. These additional savings can be as much or more than the fluid savings itself.

More Case Studies

Safety Improvements & Waste Reduction Drive Reduction in Fluid Usage by 60%

Armstrong International, headquartered in Three Rivers, MI., is a manufacturer of thermal utility systems components.  They are a 5th generation, family-owned business committed to conserving energy and providing the best possible work environment for their employees.  As part of that commitment, their process engineering department came to Impact Fluids looking for a solution to better…Read the rest of this entry »

Appliance / Automotive Supplier Saves 60%

A stamping company that produces work for both the appliance and the automotive industry was spending over $120,000 on lube annually. Sprayed fluid was dripping off the presses and the costliest issue was that their parts were being rejected regularly by their customer for excess fluid. Their operators were mixing fluids by hand and shutting…Read the rest of this entry »

Automotive Supplier Saves $82K Annually

A Tier One automotive supplier was spending $115,000 annually to provide lubricant to two transfer presses in one area of its shop. The recommendation was to replace the spraying systems on those two presses with roller coaters, to eliminate overspray. Calculating the return on investment, in addition to reducing overall lubricant consumption, we also carefully…Read the rest of this entry »