The research and advancement of neat oils in high speed metal cutting application is aimed at achieving higher productivity and improved surface quality. Unlike water miscible cutting fluids which are typically designed to dissipate heat, neat oils are formulated to reduce frictional heat making it convenient for applications from light machining to heavy-duty operations.

While the use of conventional neat oils often poses challenges of retaining lubricity and certain safety hazards, synthetic based neat oils deliver twin advantage of better lubricity and higher flash points. Keeping these parameters in focus, Bechem’s advanced range of neat oils have been developed to cover complete spectrum of materials and metal cutting applications.

Below case studies demonstrate how advanced synthetic neat oils can positively affect tool life and process reliability

Trial of component 1

Component: Automotive components

Material: Mild steel

Machining process: Parting, grooving, drilling and turning

Issues faced:

• High foam generation during normal operating conditions
• High consumption: High carry over of the existing oil with the machined chips and swarfs resulted in higher oil consumption
• Unhealthy work environment: Oil misting resulting in high smoke generation

BECHEM’s application team reviewed the operations and recommended a trial with Bechem’s synthetic based neat oil, “Berucut XC 1010”.

Trial observations with Berucut XC 1010:

• Reduction in foam generation during the trial period
• No fume formation: Oil mist was not observed during the entire span of operations
• Low consumption: Oil carry over reduced notably with less consumption of oil thereby extending relubrication intervals
• Improvement noted in surface finish of the component as well as in cleanliness of the machines.

Trial of Component 2:

Component: Nuts for medical industry machineries.

Material: Stainless steel (SS 303)

Machining process: Parting, grooving, drilling, milling, tapping, boring.

Issues faced:

• Low tool life leading to higher production cost
• Extended operation cycle with low spindle speed.

Based on machining parameters, BECHEM’s engineering team proposed to conduct a trial with “Berucut XC 1010” a non-water miscible coolant developed for high speed machining processes.

Trial Observations with Berucut XC 1010:

• Operation time for each cycle reduced from 90 seconds to 43 seconds
• Spindle speed increased from 2000 to 4000 rpm
• Tool life extended remarkably across the production range. (data as per below)

Berucut XC 1010, a non-water miscible oil fully based on synthetic fluids for superior performance and high-speed machining processes.

• Single product to meet entire machining needs with zero foaming issues
• Longer tool life: Fortified with excellent extreme pressure and anti-wear additives, ensures longer tool life
• Safer work place: Developed with synthetic base oil and free from unsaturated hydrocarbons and other aromatic agents, ensures an oil mist-free environment
• Low consumption: Low carry over characteristics and low evaporation tendency ensures minimal consumption and hence cost effective
• Better surface finish and cleaner machines : Berucut XC 1010 with optimal viscosity (13 cst at 185 ˚C) and low stickiness ensures cleaner machines. Also, high surface-finish and dimensional accuracy of the finished product can be achieved.

Having evidenced the results of Berucut XC 1010 to optimize production process and with the clear possibility of achieving substantial reduction in production cost the satisfied customer shifted over to “Berucut XC 1010”.

For more details on Bechem’s neat oil range, write to us at [email protected]

Case study demonstrates the impact of lubricating oil in the process efficiency of sheet metal drawing and blanking operations.

Deep drawing is one of the most convenient sheet metal forming process, widely used to produce cup, box, hollow shaped and other complex -curved metal objects of high precision in large volumes. However, during cold forming processes, the act of forcing metal into a given shape can cause a host of possible problems due to the amount of pressure and stress generated. Die wear, wrinkling, tearing of sheet metal, poor surface finish, scratches and cracks on the drawn product or on the edges of punched-out pieces are some operational challenges that manufacturers encounter regularly.

The effectiveness of a deep drawing oil generally depends on its ability to form a lubricating film of sufficient strength.  This resilient film forms a ‘boundary,’ preventing direct metal-to-metal contact under the conditions of extreme surface pressure during deep drawing and blanking operations.

Regular oils with poor lubricating properties can cause heating and breakdown of the lubricating film. This further leads to abrasive wear of the tool and workpiece, resulting in higher rejection rates and production downtime. Beruform MF 155 C is a specially developed forming oil with excellent lubrication properties recommended for cold extrusion, sheet forming, piercing, punching, blanking and drawing operations.

Below example illustrates how Beruform MF 155 C replaced multiple forming oils used for drawing and blanking operations of varying sheet thicknesses.

Customer: A leading Indian manufacturer of precision bearing cages and stamped components in terms of capacity and operations. The technology driven company has an extensive production infrastructure comprising of manual, semi-automatic and fully automatic machineries. The company supplies to diverse industries including automotive and engineering across the globe and has its processes certified to ISO and IATF standards.

The Production team used different drawing oils for different sheet thicknesses.

Brand “X” with a viscosity of 171mm²/s for 2 – 4 mm and brand “Y” for 4 to 12.5 mm sheet thickness.

• No drawn line marks observed, excellent surface finish
• Single product utilization for a range of sheet thickness from 2 mm to 12.5 mm
• During prolonged exposure to normal temperature, drawn products remained rust-free
• Manual application process can be replaced through spraying

Having observed performance of the product in optimizing production process efficiency and minimizing rejection rates during the trial period, the satisfied customer switched over to ‘Beruform MF 155 C’.

Beruform MF 155 C helped increase process efficiency as well as better surface finish of formed components.

Advantages with Beruform MF 155 C,

Beruform MF 155 C is a non-water miscible forming oil for the processes of cold extrusion, sheet forming, piercing, punching, blanking, drawing etc.

1. Formulated on ultra-refined base oils and superior quality additives, Beruform MF 155C provides optimum lubricity for a longer span of operations
2. Developed with extreme pressure and anti-wear additive package, Beruform MF 155 C forms consistent lubricating film and prevents metal-to-metal contact under high load conditions. The forming oil provides intermediate rust protection to dies and workpieces
3. Beruform MF 155 C has low-fume characteristics even at a very high-speed drawing speeds
4. Due to the excellent lubrication performance and maintenance of dies and equipment, Beruform MF 155 C improves safety quotient of the work environment significantly with minimum man and machine interference
5. Beruform MF 155 C is compatible with both ferrous and nonferrous metals like steel, stainless steel, aluminium, copper, brass etc.

Performance report of Berusynth 46 and 68 H1 as food grade hydraulic oil for manufacturing of molded pulp products

Molded pulp products are an eco-friendly, affordable and sustainable alternative to plastic and styrofoam packaging products. Typical molded pulp products are made from recycled raw materials such as paper, cardboard or other natural fibers (sugarcane, bamboo, wheat straw etc.) and are usually recycled again after active use. In case products are discarded after their service life, molded pulp products are biodegradable unlike plastic and styrofoam material, hence eco friendly.

Over the years, with significant improvement in the manufacturing technology, the final molded products have smoother surface and sophisticated look and feel. Molded pulp products now find use in variety industries like food, healthcare, pharma, cosmetics, electronics etc. Also, the growing importance of sustainability has helped make pulp packaging an attractive option that demonstrates commitment to the environmental cause.

Type: Pulp thermoforming press

Hot pressure – 80 tons

Daily output – 2.5 tons

No. of press – 10

• Food grade oil with power transmission capacity
• Viscosity of the food grade oil should be 46/68 cst as recommended by the OEM
• The food grade oil should be NSF H1 certified

BECHEM’s high performance, synthetic food grade oils are available in varying viscosities. Due to their special formulation, the Bechem synthetic oils are meant for use in multiple applications, including in hydraulic systems.  They are designed to provide power transmission with lowest energy losses and corrosion protection of sensitive parts in the hydraulic system.

• Fully synthetic PAO (Polyalphaolefins) base oils with proprietary additives available in varied viscosity range
• High viscosity index (VI) (140 for Berusynth 46 H1 and 145 for Beruynth 68 H1) provides superior lubrication over a wider temperature range
• NSF H1 and ISO 21469* certified for lubrication of machinery and components in food processing industries
• High oxidation and thermal stability, inhibits formation of sludge/varnish, thereby ensures longer component life and minimizes operational costs
• Fortified with anti-wear additives, Berusynth 46/68 H1 helps to reduce wear, enhances equipment reliability
• Very good oxidation stability extends oil change interval
• Superior corrosion protection properties of Berusynth H1 range inhibit rust and corrosive wear and ensures longer equipment life

Berusynth 46 and 68 H1 range of food grade oils performed consistently as per the OEM’s expectation for over two years. The customer’s Maintenance team too vouches for the long-life performance of Berusynth 46 and 68 H1 as well as machine reliability achieved with the food grade oil.

Berusynth H1 range of food grade oils are also recommended for lubrication of gears, drive chains and as circulatory oils in compressors in food processing and allied industries. For more details of the case study, write to us as [email protected]

*ISO 21469 is global standard for food grade lubricants that verify compliance and specifies hygiene requirements for product formulation, manufacturing and packaging requirements. Additionally, ISO 21469 specifies hygiene requirements for use and handling of lubricants during manufacture and processing, that can come into incidental contact (e.g. through heat transfer, load transmission, lubrication or the corrosion protection of machinery) with products and packaging used in the food, food-processing, cosmetics, pharmaceutical, tobacco or animal-feeding-stuffs industries.

Customer: A mid-sized manufacturer of knit fabrics located in Ludhiana in the state of Punjab, India with supplies to export market. With focus on product quality and timely supplies, the company over the years, has been consistently rated excellent by its Global customers.

Application: Circular knitting
Machine OE: Popular brand from China with proven performance in the market
Material to be knit: 100% cotton fabric
RPM (revolutions per minute): 18.3 (Avg.)
Existing knitting oil: Brand K oil – M series
Knitting oil consumption with existing product: 72 drops per minute
Avg. life of needles and sinkers: 92,000 kg. of knitted fabric

Two identical knitting machines, A & B with similar processes were identified for the trial. Circular ‘machine A’ was run with the existing knitting oil, ‘Brand K oil – M series’ while ‘machine B’ was run with BECHEM Staroil KNT 22.

Performance of both the products on the respective machines was observed for a period 1 week with temperature observed at key points (needle cam, needle cylinder and sinker cam) of the knitting bed. The oil consumption for ‘Brand K oil – M series’ was maintained at 72 drops per minute as per the existing practice. The BECHEM team however after studying the process parameters recommended an optimised oil flow at 55 drops per minute with BECHEM Staroil KNT 22.

• An average reduction in temperature of about 5.5°C was observed with BECHEM Staroil KNT 22 across the points
• 24% average reduction in oil consumption
• 100% washable: Indicating the washable property of the oil, all materials processed during the trial period was approved by the QC

Having evidenced the results, the Customer switched over to BECHEM Staroil KNT 22 and has been experiencing better needle and sinker life. The Customer is impressed with the washable property of the knitting oil and now vouches for the performance and quality of BECHEM Staroil KNT 22.

BECHEM Staroil KNT range of knitting oils are developed on ultra-refined base oils and performance additives which ensure high lubricity and low frictional coefficients between the frictional partners of sinker and needle.

The special anti-wear additive package within Staroil KNT 22 and 32 helps in reducing severe friction and wear during the emergency run conditions of the knitting machine such as start-up and shutdown phase. The best-in-class lubrication performance of BECHEM Staroil KNT reduces friction, wear and unnecessary temperature rise, thereby increasing the productive life of needle and sinkers. Additionally, the Staroil KNT range of knitting oils have lower volatile losses thereby ensuring lower oil consumption per machine per day.

The knitting oil range of BECHEM Staroil KNT 32 and 22 are GOTS approved (Global Organic Textile Standard) as knitting oil inputs for application in the processing of GOTS certified textile products.

Customer: Manufacturer of knit fabric and garments located in Tirupur, in the state of Tamil Nadu, India with complete supplies to export market.

Application: Circular knitting machine
Machine OE: Reputed German brand with history of developing advanced knitting machines
Material to be knit: Cotton grey
RPM (revolutions per minute): 25.4 (Avg.)
Existing knitting oil: Brand K oil – M plus
Knitting oil consumption with existing product: 700 ml/da

Two identical knitting machines numbered, 8 and 9 with similar processes were selected for the trial. Machine no.8 was run with the existing knitting oil, ‘Brand K oil M Plus’ while ‘machine no. 9’ was run with BECHEM Staroil KNT 32.

Performance of both the products on the respective machines was observed for a period of 3 months with temperature monitored at key points (needle cam, needle cylinder and sinker cam) of the knitting bed.

Average oil consumption in machine no. 8 with ‘Brand K oil M plus’: 700 ml/day
Average oil consumption in machine no. 9 with BECHEM Staroil KNT 32: 550 ml/day

● Reduction in temperature: Average reduction in temperature of about 2.6 °C in needle cam and cylinder section was observed with BECHEM Staroil KNT 32 over ‘Brand K oil M plus’. The average reduction was higher at about 3.6 °C in the sinker cam section with BECHEM Staroil KNT 32.
● 21% reduction in oil consumption was observed with BECHEM Staroil KNT 32 (550 ml per day) against ‘Brand K Oil M Plus’ (700 ml per day).
● At a reduction of 150 ml per day, the Customer was able to reduce about 54 liters in a single machine in the 3-month trial period with BECHEM Staroil KNT 32.
● 100% QC Approved : Demonstrating the washable property of Staroil KNT 32, the material processed during the trial stage was approved by Quality Control Department.

Based on the trial result, the customer shifted over to BECHEM Staroil KNT 32 for all the circular knitting machines in his plant.