-90% oil use and improved sawing performance

Situation

An aluminium extrusion producer experienced persistent issues in its billet sawing operation. Saw blades became blunt within 20 days, and teeth would break off, causing frequent downtime and production losses. Additionally, the quality of the cuts was poor, which meant billets failed to feed properly into the press and became jammed.

The root cause was traced to the use of a low-quality conventional lubricant, applied in very large quantities, around 30 litres per day. Despite the excessive application, the lubricant provided insufficient protection and left the work area messy and wet.

Solution

Following expert advice, the company switched to Interflon Lube PN32, a PFAS-free oil with MicPol® technology, applied via an automatic lubrication system. This oil forms a strong, dry film that adheres effectively and stays in place, reducing the amount of product required while providing better protection.

Importantly, Interflon products are often multifunctional, a single lubricant can frequently replace multiple conventional products. This reduces complexity, storage needs and internal logistics, while improving process control.

Results

Performance and savings were monitored over several months and proved stable and repeatable.

Lubricant consumption

• Before: 30 litres/day of conventional oil
• After: 3.5 litres/day of Interflon Lube PN32
• Reduction: approx. 90%

Saw blade life and cut quality

• Saw blades now remain sharp much longer, with no teeth breaking.
• Cuts are clean and precise, allowing billets to feed into the press without jamming.

Energy consumption

• Lower energy usage thanks to smoother operation and reduced resistance during sawing.

Cost savings and operational benefits

Despite the higher price per litre of Interflon Lube PN32, the reduced consumption, combined with lower maintenance and energy costs, resulted in an overall monthly saving of approximately 75% on lubrication-related costs. This was calculated at around $9,030 per month, based on total costs in the sawing department.

Additional benefits included

• Fewer unplanned stoppages
• Cleaner, safer working environment – thanks to less overspray and residue buildup
• Reduced wear and replacement of saw blades
• Improved machine efficiency and lower energy consumption
• Lower inventory levels and reduced product movement within the plant due to less product use

Summary

Switching to Interflon Lube PN32, a PFAS-free oil with MicPol® technology, delivered measurable cost savings, improved process control and greater reliability.

The investment in a high-quality, multifunctional lubricant was quickly recovered through reduced product consumption, fewer interventions, lower maintenance and energy costs, and a cleaner, more efficient workplace.