28 Oct Alumol 32 Enhances Efficiency by Over 300% for Indian Wire Manufacturer
Overview - Lubrication in the Enamelled Wire Drawing Process
Metalube India recently partnered with an esteemed Indian wire manufacturer based in Northern India to address their ongoing operational challenges due to inadequate lubricant performance.
The customer’s machinery included fine and Intermediate Wire Drawing (IWD) machines used for single aluminium wire drawing, which had been experiencing issues with their previous industry standard lubricant.
Metalube’s expert technical team conducted a site visit, discussing the manufacturer’s processes and needs to determine the optimal solution to improve production efficiency by extending lubricant life, reducing wire breakages, and ensuring cleaner-drawn wires.
The Problem - Improper Lubrication
The enamelled wire manufacturer was using an industry standard lubricant, that required frequent replacement every 3 to 6 months. This regular maintenance led to extended machine downtime and increased labour costs due to the need for frequent cleaning of tanks and wire breakages caused by inadequate lubrication. Additionally, the wire cleaning process before enamelling was challenging due to excessive lubricant carryover on the wires.
The customer’s wire drawing process involved working with a wide range of wire sizes, and their Chinese-made IWD machine from Jingrun Machinery operated at a speed of 35 meters per minute. The heat exchanger maintained bulk operating temperatures between 35-45°C. However, despite the presence of a high speed centrifugal filtration system, the filtration wasn’t functioning effectively daily, compounding their difficulties with lubricant maintenance.
The Solution - Alumol 32, A Superior Solution
Metalube introduced Alumol 32, our high-performance wire drawing lubricant specifically designed for aluminium wire drawing machines. A trial was conducted to test the effectiveness of Alumol 32 in addressing the customer’s operational challenges, with the primary objective of increasing sump life and facilitating easier removal of lubricant carryover on drawn wires.
During the trial, Alumol 32 was tested in 2 of the manufacturer’s IWD machines. The results were immediately noticeable: Alumol 32 was able to extend lubricant sump life significantly, operating for over 18 months without requiring a tank change or extensive cleaning. This represented a substantial improvement compared to the 3 to 6 months lifespan of the previous lubricant. This led to an efficiency improvement of over 300%, boosting lubricant life by over double the previous maximum lubricant life.
In addition to extending the lifespan, the lubricant also produced cleaner wires post-drawing, which simplified the wire cleaning process before enamelling. The customer was able to draw cleaner wires with minimal lubricant carryover, addressing one of their primary concerns.
The Results - Triple the Efficiency Across the Manufacturing Process
By introducing Alumol 32 into the manufacturer’s process, they saw significant operational improvements including the following:
- Extended Lubricant Life:
Alumol 32 extended sump life from a maximum of 6 months to 18 months. This reduced machine downtime and significantly lowered labour costs associated with frequent tank cleaning and lubricant replacement. - Improved Wire Quality:
The drawn wires were much cleaner, with less lubricant carryover, which simplified the wire cleaning process before enamelling. This also resulted in fewer wire breakages, further enhancing production efficiency. - Cost Savings:
Although exact figures weren’t provided, the longer lifespan of Alumol 32 indirectly reduced costs related to labour, machine downtime, and the purchase of lubricants. By operating continuously for 18 months without requiring a tank change, the customer achieved substantial savings. - Increased Production Output:
For 18 months, the machine processed 1,260 tonnes of aluminium wire, highlighting the robustness and effectiveness of Alumol 32 in supporting continuous, high-volume production.
Conclusion - A Revolution in Lubrication for the Enamelled Wire Industry
By switching to Alumol 32, the Indian wire manufacturer was able to overcome significant operational hurdles, including frequent lubricant thickening and wire breakages.
Speaking on the success of this latest case study, Metalube India’s general manager Amit Gupte said:
“This successful case study proves the efficiency and effectiveness of Alumol 32 for the enamelled wire industry. By offering high quality products and unmatched technical support, Metalube India can maximise efficiency across the enamelled wire manufacturing process.”
Amit Gupte, General Manager - Metalube India
Our aluminium wire drawing solution not only extended the life of the lubricant but also resulted in cleaner wires and reduced downtime. The success of the product trial demonstrates our lubricant’s capability to handle the demanding requirements of aluminium wire drawing machines, making it a cost-effective choice for long-term production needs.
Interested in seeing how our range of aluminium and copper wire drawing lubricants can significantly improve your manufacturing process? Get in touch with our expert team today to learn more about our industry-leading range of products.
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