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Contents
About Us
About the Founder
YoY Revenue Growth
YoY Volume Growth
Expected Qualities of Cutting Oils
Products & Applications
Case Studies
Comparison Chart
ELPL Proposal for M&M
Out-of-the-Box (Case Studies)
Our Clients
Future Plans
4
5
6
7
8
9
12
30
32
33
41
43
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• Founded 1974
• Located at W-45 & T-120 in MIDC, Bhosari, Pune
• Plant and office spread over 30,000 sq.ft.
• Equipped with Modern machinery Storage tanks Blending vessels Esterification & sulphurization unit Thermic fluid boiler
• Well equipped in-house R&D and testing facility
• Experienced technical and administrative team of over 40 people
• Strong dealer network
About Us
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• Mr. R. Y. Bhosale, MD, Emulsichem Lubricants
• M.Sc (Organic Chemistry)
• Served as Chief Chemist in reputed MNCs
• More than 40 unique formulations to his credit
• Developed major import substitute products
About The Founder
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1998-99
1999-00
2000-01
2001-02
2002-03
2003-04
2004-05
2005-06
2006-07
2007-08
0
1
2
3
4
5
6
1.07 1.129999999999991.21 1.26 1.31
1.54
2.35
2.98
3.46
5.44
SALES in INR (Crores )
SALE (Rs. Cr )
YoY Revenue Growth
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YoY Volume Growth
1998-99
1999-00
2000-01
2001-02
2002-03
2003-04
2004-05
2005-06
2006-07
2007-08
0
1
2
3
4
5
6
2.7 2.8 2.93.2 3.4
3.6 3.84.1 4.2
5.1
Quantity in Kilo Litres
QTY (KL)
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• Primary importance: Cooling properties
• Secondary importance: Lubricating properties
• Excellent wetting and detergency
• Easy flushing of chips
• Good anti-rust film for job and protection of machine parts
• Provide adequate lubrication to avoid wear and tear of tools
• Impart good surface finish
• Environment and operator friendly
• Longer bath life for better economics
• Consistent performance over assured bath life
Expected Qualities of Cutting Oils
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CuttingOils
Neat Type
Sulfurized
Moderate Heavy Duty
Sulfur & Chlorine
Free
Moderate Heavy Duty
Water Soluble
Emulsion Type Synthetic Semi
Synthetic
Classification of Cutting Oils
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Neat Cutting Oil (Product List & Operations)
Tapemol - 56M All kind of Tapping operations
Tapemol - 100H Especially for Nut Tapping
Honikut - 60/70 All Honing operations
Honikut - 100 Heavy duty Honing operation (Cast Iron)
Honikut - 100NS Valve seat Grinding operation
Metalfin - 40 Gear Grinding, Gear Drilling, Turning, Cutting
Metalfin - 62 Gear Grinding, Gear Drilling, Turning, Cutting
Metalfin - 70 Gear Hobbing, Broaching, Thread Rolling
Metalfin - LV Super finished, Deep Hole Drilling
Rustproof - 274 Oil base Rust prevention
Rustproof - DW 917 Dry film type Rust prevention
Metalform - RN 100 Forming & Drawing
Product Application
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Water Soluble (Product List & Operations)
Greenlake - 55 Grinding & Leak Testing Synthetic
Lavisa Super - 90 Multipurpose Semi Synthetic
Lavisa - 9000 Broaching, Hobbing Semi Synthetic
Emulkut - 1101 Multipurpose Semi Synthetic
Emulkut - 1240 Deoiling & Degreasing Synthetic
Emulkut - 1872 Aluminum Machining Semi Synthetic
Stoll Super - 90 Multipurpose Semi Synthetic
Stoll - 16 General Machining Emulsion Type
Metalform - RN200 Forming & Drawing Semi Synthetic
Product Application Classification
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TATA Motors / Emulkut 1872
Emulkut - 1872 : Key Features
Type of operation
Material removal
Type of material
Type & make of tools used
Dilution (water : oil)
Existing product
Rear & Front Boring
0.4 - 0.5 mm
Aluminum
Carbide
1:20
Cottola
1/A
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Case Studies
Out-of-the-boxcase studies
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• Bath Life : Assured 6 months with filtration of coolant after every2 months.
• Total oil consumption for 3 months : 105 L (50 L for initial bath charging + 55 L for Topping up)
• Surface Finish / Antirust & Oxidation Properties : Satisfactory
• Ra Value : within specified range.
• No black spots or pit marks observed on components.
• Mechanical maintenance problem - Nil
• Flushing Properties : M/c area remains clean.
• Excellent Operator Comfort : Absence of foul smell even if M/c remains non operational for 4-5 days.
• Tool Life : Same as Cottola.
• For f72 (F) & f57(R) 260 to 280 no. of components per resharp tool.
Emulkut - 1872 : Observations & Comments
1/BCase Studies TATA Motors / Emulkut 1872
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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Lavisa Super 90 : Key Features
Type of operation
Material removal
Name of component
Type of material
Type & make of tools used
Dilution (water : oil)
Existing product
Drilling, Milling, Boring,
Reaming & Tapping
4 to 6 mm
2.2 Cylindrical Block & Head
Cast Iron / Aluminum
MAPAL TOOLING-Carbide
1:20
Blasocut 4000 strong
2/ACase Studies TATA Motors / Lavisa Super 90
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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Lavisa Super 90 : Observations & Comments
• Boring Bar of MAPAL for Ø45 Operation Tool life - 1000 Component.
• Boring Bar of MAPAL for Ø38 Operation. Tool life - 1000 Component.
• PCD Reamer of MAPAL Ø 9 = 400 Component, Ø 10=400 Component
• Oil exhibited best cleaning & flushing properties.
• Absence of foul smell even if M/c remains non operational for 4-5 days.
• Highly acceptable by the operating staff.
• Tool life same as Blasocut.
2/BCase Studies TATA Motors / Lavisa Super 90
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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Emulkut - 1240 : Key Features
Type of operation
Type of material
Dilution (water : oil)
Existing product
Washing of Cylindrical Block / Head
Cast Iron / Aluminum
1:20
Castrol DG Cleaner /
Technoclean SF
3/ACase Studies TATA Motors / Emulkut-1240
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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• The product exhibited excellent cleaning & anti rusting(48 hrs) properties.
• Cylinder Head Oil Passage ≥ 30
• Cylinder Head Water Passage ≥ 50
• Temperature maintained : 50-60°C
• The product is regularized with consistent result within specified range.
Emulkut - 1240 : Observations & Comments
3/BCase Studies TATA Motors / Emulkut-1240
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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4/ACase Studies Bharat Forge / LavisaSuper 90
Lavisa Super 90 : Key Features
Type of operation
Type of material
Type & make of tools used
Dilution (water : oil)
Existing product
Turning, Boring, Threading,
Drilling & Milling
Forged Steel
Inserts
1:20
NA
Note : Trial conducted on newly installed transfer (K) line.
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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4/B
• Knuckle's Turning & Threading operation on Motch Machines.
• Oil sustains tremendous heat generated during heavy operation.
• Best cooling performance with low evaporation rate.
• Absence of foul smell even if M/c remains non operational for 4-5 days.
• Good anti rusting properties for 48 hrs.
• Bath Life : Individual machine - 6 months and Centralisedbath - 2 years
Lavisa Super 90 : Observations & Comments
Case Studies Bharat Forge / LavisaSuper 90
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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5/A
Honikut - 70 : Key Features
Type of operation
Material removal
Type of material
Type & make of tools used
Existing product
Gear Teeth Honing
50 to 70 Micron
Steel 16mn CUGN
Harden to 60 HRC
Fasselar honing wheel
HONEX-7 (Shell)
Case Studies Bajaj Auto / Honikut - 70
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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5/B
• Excellent surface finish within specified Ra value.
• No dust was settled on honing wheel.
• Machine area remains clean.
• Oil has no stickiness.
• No foaming was observed.
• 2000 gears per shift per day.
Honikut - 70 : Observations & Comments
Case Studies Bajaj Auto / Honikut - 70
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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6/A
Gear Grinding
0.5 mm
Steel
Winterthur / Norten
Grinding wheel
Servocut-353
Metalfin 40 : Key Features
Type of operation
Material removal
Type of material
Type & make of tools used
Existing product
Case Studies Bajaj Auto / Metalfin 40
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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6/B
• Reduction of wear on grinding wheel.
• Reduced dressing frequency.
• Good surface finish, within Ra = 0.35µ
• Machine area remained cleaned due to good flushing properties and there was clear visibility during the entire operation.
• 2000 gears per day per shift.
Metalfin 40 : Observations & Comments
Case Studies Bajaj Auto / Metalfin 40
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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7/ACase Studies Bajaj Auto / Metalfin 62
Metalfin 62 : Key Features
Type of operation
Material removal
Type of material
Type & make of tools used
Existing product
Gear Grinding
0.5 mm
Steel
Winterthur / Norten grinding
wheel
NA
Note : Trial conducted on new machine
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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7/B
• Tested on LIEBHERR LCS-150, a high-speed gear-grinding machine with an oil tank capacity of 3500 L
• Good flushing properties imparts excellent surface finish.
• Metalfin 62 free of chlorine & sulfur additives.
• Highly acceptable by the operating staff.
Metalfin 62 : Observations & Comments
Case Studies Bajaj Auto / Metalfin 62
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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8/A
Metalfin 40 : Key Features
Type of operation
Type of material
Type & make of tools used
Gun Drilling of oil hole
Forged steel
Wedia
Case Studies Cummins India / Metalfin 40
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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8/B
• 10 inches deep hole.
• Wedia tool of 6.35 mm
• Material hardness : 28-32 RC.
• The efficient extreme pressure and surface tension reducing additiveshelp the oil penetrate deep along with the drill.
Metalfin 40 : Observations & Comments
Case Studies Cummins India / Metalfin 40
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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9/ACase Studies Cummins India / Tapemol 56M
Tapemol 56M : Key Features
Type of operation
Type of material
Type & make of tools used
Existing product
Tapping of connecting rod
Forged Steel
UNF 5/8 inches
NA
Note : Trial conducted on new machine
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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9/B
• 100 holes per tap.
• Material hardness : 28-32 RC.
• The efficient extreme pressure additives help the oil withstand the heat and friction developed during the operation providing smooth tapping without any breakages of tap.
Tapemol 56M : Observations & Comments
Case Studies Cummins India / Tapemol 56M
Tata Motors Ltd.
E-1872
LS 90
1240
Bharat Forge
LS 90
Bajaj Auto Ltd.
Honikut 70
Metalfin 40
Metalfin 62
Cummins India Ltd.
Metalfin 40
Tapemol 56M
Out-of-the-boxcase studies
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Cost for 1000 L tank capacity of coolant with 1.5% topping up per day for 1 year
Sr. No Description Blasocut -
4000Emulkut -1101 Emulkut -1872 Lavisa Super - 90
1 Basic Rate (Rs.) 250/- 160/- 125/- 120/-
2 Dilution Ratio for fresh tank 14:1 20:1 20:1 20:1
3 Cutting oil requirement to prepare bath 74.4 ltr 50 ltr 50 ltr 50 ltr
4 Per day addition 1.5 ltr X 310 days 465 ltr 465 ltr 465 ltr 465 ltr
5 TOTAL 536.4 ltr 515 ltr 515 ltr 515 ltr
6Total basic cost for 1000 ltr bath
For one year
536.4 x 250
134100.00
515 x 160
82400.00
515 x 125
69725.00
515 x 120
61800.00
7 Net saving in Rs. -- 51700.00 64375.00 72300.00
8 Net saving in % 38.55% 48% 54%
Comparison Chart with Blasocut - 4000
Cost Comparison
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0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
BLASCUT-4000 EMULKUT-1101 EMULKUT-1872 LAVISA SUPER-90
Quantity ComparisonQty
140000
120000
100000
80000
60000
40000
20000
0
Comparison Chart with Blasocut - 4000
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• Identifying the requirements and recommending the product/s
• Conducting trials on individual machine/s for a period of 30 days
• Monitoring trial results and submitting report to the SME
• If required, provide M&M the customized formulation/s
• Monitoring and analyzing the daily performance of products by our Application Specialist (AS)
• Monthly submission of reports to the designated SME by our AS
• Prompt technical support for better productivity for observed escalations/problems
• Commercial Cost – Comprehensive
ELPL Proposal for M&M
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Gandhi Special Tubes / Metalform RN 100
Metalform RN 100 : Key Features
Type of operation
Type of material
Type & make of tools used
Existing product
Nut Forming
AISI 1010 / 1015.
Forming dies & punches
Castrol ILOFORM-168
11/A
Gandhi Special Tubes Ltd.
Metalform RN 100
Tapemol 100H
Simmonds Marshall Ltd.Tapemol 100H
Kalyani Lemerz
Metalform RN 200
Case Study
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• Fast cooling due to low viscosity.
• Gives better punch & die life.
• Good ID finish.
• Less carry over loss due to low viscosity.
• No cracks & burning marks on nuts.
• Low fumes.
• Chlorine free additives.
• Environment and operator friendly.
Metalform RN 100 : Observations & Comments
11/BGandhi Special Tubes / Metalform RN 100Case Study
Gandhi Special Tubes Ltd.
Metalform RN 100
Tapemol 100H
Simmonds Marshall Ltd.Tapemol 100H
Kalyani Lemerz
Metalform RN 200
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Tapemol 100H : Key Features
Type of operation
Type of material
Type & make of tools used
Existing product
Nut Threading
AISI 1010 / 1015.
Emkay & Sakai Taps M-14 &
M-12
Castrol NEATCUT-611
12/AGandhi Special Tubes / Tapemol 100HCase Study
Gandhi Special Tubes Ltd.
Metalform RN 100
Tapemol 100H
Simmonds Marshall Ltd.Tapemol 100H
Kalyani Lemerz
Metalform RN 200
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Tapemol 100H : Observations & Comments
• Emkay & Sakai Tap M-14 x 1.5, Drill 13.60.
• Jobs T-04 & T-03.
• Increased tap life (upto 25,000 per tap).
• Good cooling due to low viscosity.
• Good lubrication for better thread finish & tap life.
• Low carry over loss.
• Better flushing properties.
12/BGandhi Special Tubes / Tapemol 100HCase Study
Gandhi Special Tubes Ltd.
Metalform RN 100
Tapemol 100H
Simmonds Marshall Ltd.Tapemol 100H
Kalyani Lemerz
Metalform RN 200
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Tapemol 100H : Key Features
Type of operation
Type of material
Type & make of tools used
Nut Threading
AISI – 1010
Enkay Tap M-18
13/ASimmonds Marshall Ltd / Tapemol 100HCase Study
Gandhi Special Tubes Ltd.
Metalform RN 100
Tapemol 100H
Simmonds Marshall Ltd.Tapemol 100H
Kalyani Lemerz
Metalform RN 200
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• Nut Threading length 9 to 10 mm.
• The product gave excellent tool life against existing coolant.(12000-15000 nuts per tap against existing tap life2000-3000)
• Good threading finish.
• Low carry over losses.
• Low heating of nuts & tap.
• Good flushing properties ensured smooth surface finish.
• Environment & operator friendly.
Tapemol 100H : Observations & Comments
13/BSimmonds Marshall Ltd / Tapemol 100HCase Study
Gandhi Special Tubes Ltd.
Metalform RN 100
Tapemol 100H
Simmonds Marshall Ltd.Tapemol 100H
Kalyani Lemerz
Metalform RN 200
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Metalform RN 200 : Key Features
Type of operation
Thickness of sheet
Type of material
Type & make of tools used
Dilution (water : oil)
Existing product
Wheel Forming
12 mm
MS
Dies
1:1
Henkel Multan
14/AKalyani Lemerz Ltd. / Metalform RN 200Case Study
Gandhi Special Tubes Ltd.
Metalform RN 100
Tapemol 100H
Simmonds Marshall Ltd.Tapemol 100H
Kalyani Lemerz
Metalform RN 200
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Metalform RN 200 : Observations & Comments
• 20% increase in die life.
• Good cleaning and better lubrication properties.
• No crack and burning marks on formed wheel.
• Smooth operation even after hot welded job was put for forming.
• Environment & operator friendly.
14/BKalyani Lemerz Ltd. / Metalform RN 200Case Study
Gandhi Special Tubes Ltd.
Metalform RN 100
Tapemol 100H
Simmonds Marshall Ltd.Tapemol 100H
Kalyani Lemerz
Metalform RN 200
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Our Clients
• Alfa Laval India Ltd., Pune
• Amtech Siccardi Ltd., Gurgaon
• Amul Industries Ltd., Rajkot
• Ashok Iron WorksBelgaum (All Plants)
• Aurangabad Electricals Ltd., Aurangabad
• Autofield Engineers Pvt. Ltd., Sahajpur, Pune
• Bajaj Auto Ltd., Aurangabad
• Baker Gauges India Ltd., Pune
• Bharat Forge Ltd., Mundhwa & Chakan, Pune
• Bulk Containers Pvt. Ltd., Pune
• Carraro India Ltd., Ranjangaon
• Concentric Engg. Pvt. Ltd., Pune
• Cooper Foundary Pvt. Ltd., Satara
• Cooper Metals Pvt. Ltd., Satara
• Crompton Greaves Ltd., Ahmednagar
• Cummins India Ltd., Pune
• Duro Valves Ltd., Aurangabad
• Forbes Marshall Ltd., Pune
• Gandhi Special Tubes Ltd., Baroda
• Godrej & Boyce Ltd., Mohali
• Himson Textile (Engg. Div), Surat
• Indo-Nikko Bearings Ltd., Chakan, Pune
• Indo-Schotle Auto Parts Pvt. Ltd., Pune
• Involute Technologies Pvt. Ltd., Markhal, Pune
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• Jayhind Engineering, Belgaum
• Kalpana Tools Ltd., Saswad
• Kalyani Forge Ltd., Sanaswadi
• Kinetic Engg. Ltd., Pune & Ahmadnagar
• Kirloskar Oil Engines Ltd., Nasik
• Klause Union Engg. Ltd., Pune
• Larson & Turbo Ltd., Mumbai
• Lunar Enterprise Pvt. Ltd., Pune
• Manugraph India Ltd., Kolhapur
• Mather & Platt Ltd., Chinchwad
• Mazagaon Dock Ltd., Mumbai
• Medical Equpt. Co. Ltd., Nasik
• NRB Bearings Ltd., Jalana
• Perfect Engineering, Lonavala
• PTC Industries Ltd., Ahmedabad
• Raja Agro Services, Shimoga
• Rane Engine Valve Ltd., Chennai
• Shanu CNC Machines Ltd., Ahmedabad
• Shrinivas Enginering, Pune
• Simmonds Marshall Ltd., Pune
• Sona Okegawa Precision & Forging Ltd., Pune
• Sonai Engineering, Kolhapur
• Standard Engineering Works, Belgaum
• Tata Motors, Pimpri, Pune
• Vickers International System Ltd., Pune
Our Clients
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• Setting up a new in-house R&D facility complimenting the existing one
• Efforts are underway to formulate economical automotive lubricants and coolants
• Offering more advanced solutions in industrial lubricants and coolants with improved features
• Pan India expansion of dealer network to support the ever growing clientele
Future Plans
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Emulsichem Lubricants Pvt. Ltd.
T-120, MIDC, Bhosari, Pune 411026
Maharashtra, India
Tel: +91 20 2712 1925
Email : [email protected] | [email protected]