Molygraph’s SmoothKut SS 5200 is a breakthrough in metalworking fluids

By Staff Report March 7, 2025 6:46 pm IST

A leading auto component manufacturer faced coolant-related issues, causing rust, high costs, and inefficiencies. Switching to Molygraph Smoothkut SS 5200 Premium improved sump life, stability, and machining quality while reducing costs by 20-22%. This case highlights the impact of superior lubrication solutions.

Automotive manufacturing requires optimised production efficiency and cost-effectiveness. A leading auto component manufacturer specialising in grey iron disc brakes for OEMs faced a significant challenge with their machining process. Frequent coolant-related issues were causing increased costs, rust formation, and production inefficiencies. This case study explores how a switch to Molygraph Smoothkut SS 5200 Premium transformed their operations, leading to substantial cost savings and improved performance. 

The challenge: Rising costs and operational setbacks 

• Rust formation –  Rust was observed on machined parts despite applying coolant, leading to quality concerns.

• Frequent coolant concentration & pH drops – The coolant required constant monitoring and frequent adjustments to maintain efficiency.  

• Short sump life – The coolant had a lifespan of only about a month, necessitating frequent replacements.  

• Bacterial contamination – The formation of bacteria inside the coolant tank led to hygiene and odour issues.  

• Tramp oil accumulation – Excessive tramp oil accumulation caused a foul smell and further compromised coolant performance.  

• Rising costs – Direct and indirect costs increased due to high coolant consumption and maintenance efforts.  

Expectations: The need for a reliable solution

The manufacturer required a coolant that could –

• Extend sump life  
• Maintain stable concentration and pH levels  
• Prevent rust formation  
• Eliminate bacterial contamination  
• Effectively reject tramp oil and reduce sludge formation.  

The solution: Molygraph Smoothkut SS 5200 Premium 

After careful evaluation, Molygraph Smoothkut SS 5200 Premium was introduced into the machining process. This high-performance coolant provided multiple benefits – 

• Excellent emulsion & bio-stability – Ensured optimal performance even in hard water conditions.  
• Superior tramp oil rejection – Prevented oil accumulation and foul odours. 
• Rust & bacteria prevention – Enhanced metal protection, eliminating rust formation and bacterial growth.  
• No sludge or scum formation – Maintained a clean coolant system, reducing maintenance efforts.  
• Improved surface finish – Enhanced machining quality and efficiency. 

The outcome: Measurable performance gains 

Following the implementation of Molygraph Smoothkut SS 5200 Premium,  the manufacturer experienced significant improvements – Extended sump life, stable concentration & pH levels, elimination of rust & bacteria, reduced coolant consumption, operator satisfaction, and cost savings (20-22% bi-monthly cost reduction) were achieved. 

This case study underscores the importance of choosing the right lubrication and coolant solutions to optimise industrial operations. 

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Molygraph’s expertise in speciality lubricants continues to drive efficiency and innovation across industries. For more details on our products and offerings, contact us at +91 8104409925 or email at sales@molygraph.com