FERROCOTE ® 150

CASE STUDY − ROLL FORMING

 

CHALLENGES


 

A manufacturer of welded pipes in Brazil needed to:

  • Eliminate the use of mineral oils in its forming and final preservation processes (for health and safety reasons)
  • Maintain high corrosion protection of hot and cold rolled steel as well as galvanized material
  • Reduce total applied costs
  • Improve quality, especially with regards to reduced white rust on galvanized materials

To help improve their operations, Quaker recommended FERROCOTE ® 150, a water-soluble synthetic fluid. By making this switch, Quaker wanted to show the manufacturer it could:

  • Eliminate use of mineral oils
  • Achieve excellent lubrication and corrosion protection
  • Maintain compatibility with galvanized steel
  • Realize a significant savings in applied cost for each ton of pipes produced

 

THE SOLUTION


 

Quaker introduced FERROCOTE ® 150 into the manufacturer′s 15,000 liter system, which fed one of six forming lines (producing 6 tons/month of cold rolled, hot rolled and galvanized welded pipes). During a 2.5-month evaluation period:

  • Fluid consumption was reduced by over 71%
  • Total applied cost was reduced by over 65% equating to an annualized cost savings of over R$ 99.000 (USD $57,000)

In addition, during the trial period Quaker was able to further customize the product formulation in order to ensure that the fluid was capable of performing all of the functions in the process including:

  • Lubrication
  • Corrosion protection
  • Compatibility with galvanized pipes