Cutting Rust Prevention Costs by 38% Without Compromising Performance

About the company

A leading manufacturer of hydraulic cylinders, producing over 1,00,000 precision metal components every month for heavy machinery and industrial equipment.

The Challenge

The company incurred high operational costs in their rust-prevention process. Using a solvent-based solution applied through a dip method, the company faced a monthly expense of ₹76k to protect approximately 1,00,000 components. While the technique ensured effective corrosion protection, it presented a clear opportunity for cost optimisation without compromising on quality, process efficiency, or component performance.

The Solution

Lubeco Green Fluids proposed Lubeco Rustseal 55 SX 2, a solvent-based rust preventive designed to deliver reliable corrosion protection with lower consumption and better economics. The product was introduced using the same dipping application method to ensure a smooth transition without disrupting existing workflows.

Results

Lubeco Rustseal 55 SX 2 required only 230 ML per use, a 35% reduction compared to the 353 ML consumed by the existing product.
Reduced total rust prevention cost from ₹76k to ₹47k
Resulting in a projected annual saving of ₹3.5L.
The clear fluid finish gave components a more polished and shiny appearance.
The thin protective layer minimised carryover, resulting in reduced waste.
The product was odourless, creating a healthier and more pleasant work environment.

Testimonial

Lubeco cut our chemical usage by 35% from day one. We are saving ₹3.5 Lakhs a year, the terrible smell on the shop floor is completely gone, and our parts actually look better. It fixed our high-cost problem instantly.

Plant Manager, Hydraulic Cylinder Manufacturing Unit