Unique advantages thanks to innovative HERA™ release agent with micro-spray application

Case Study Die Cast:
The next level is achieved.

WHAT WE ACHIEVED.

An industry-leading European die caster has focused on developing an increased competitive edge while facing ever-increasing competition and cost pressures. They were looking for an efficient method of optimizing their production processes for a significant number of die casting machines.

Chem-Trend was able to provide immediate and wideranging impact through water-based HERA™ (High Efficiency Release Agent) products in micro spray application. The impact of the move resulted in efficiencies and savings throughout the process, including:

• Need for freshwater was reduced by 99%.
• Wastewater volume was reduced by 100% due to no excess release material flowing off the mold.
• Blisters were omitted, creating a 20% reduction in rejection rate.
• Remarkable extension of mold life thanks to elimination of thermal shock.
• Reduction in spray and air blow time reduced cycle by 20%.
• Significant reduction of energy costs.
• HERA™ contains no organic solvents, therefore reduced VOC exposure.
• Elimination of fire risk and reduced smoke emissions often associated with oil-base materials.

Due to the highly positive results, the die caster has set a goal of converting all of its international facilities to the solution provided by Chem-Trend within the next three years.

HOW WE GOT THERE.

Through assessment and testing, we identified opportunities:

• Relatively long cycle times for application of release agent.
• High consumption of freshwater for release agent application.
• High wastewater volume for reprocessing or disposal due to excessive release agent application for die thermal management.
• Unnecessary energy usage through thermal cycling of the mold due to reheat after excessive cooling by release agent.

OUR SOLUTION.

We implemented advanced HERA™ materials capable of solving the majority of issues. The materials do not lower mold temperatures, due to their ultralight application of a fine spray producing a thin layer of release agent. This dramatically reduces process thermal shock for improved die life while also leading to significant cycle time improvements.

We then installed a thermal process monitoring system, recording thermal data in real time using infrared cameras permanently installed on the machine. This allowed for continuous process monitoring and optimization with HERA™ release agents.

The results exceeded all expectations of the customer. This led them to switch all machines in the facility to use the new products and associated technologies.

100%

Wastewater volume reduction.

20%

Cycle time.

20%

Scrap rate reduction.