sometimes to solve your problems, it just takes a whole new solution

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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

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http://www.emulsichem.com/

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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


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Lavisa Super 90 : Key Features

Type of operation

Material removal

Name of component

Type of material



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


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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


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Emulkut - 1240 : Key Features

Type of operation

Type of material


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


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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


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4/ACase Studies Bharat Forge / LavisaSuper 90

Lavisa Super 90 : Key Features

Type of operation

Type of material



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


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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


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5/A

Honikut - 70 : Key Features

Type of operation

Material removal

Type of material


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


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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


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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


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


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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


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


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7/ACase Studies Bajaj Auto / Metalfin 62


Type of operation

Material removal

Type of material


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


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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.



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


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8/A


Type of operation

Type of material


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


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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.


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


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9/ACase Studies Cummins India / Tapemol 56M

Tapemol 56M : Key Features

Type of operation

Type of material


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


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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


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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


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


Metalform RN 100

Tapemol 100H


Kalyani Lemerz

Metalform RN 200


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Tapemol 100H : Key Features

Type of operation

Type of material


Existing product

Nut Threading

AISI 1010 / 1015.

Emkay & Sakai Taps M-14 &

M-12

Castrol NEATCUT-611

12/AGandhi Special Tubes / Tapemol 100HCase Study


Metalform RN 100

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


Metalform RN 100

Tapemol 100H


Kalyani Lemerz

Metalform RN 200


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Tapemol 100H : Key Features

Type of operation

Type of material


Nut Threading

AISI – 1010

Enkay Tap M-18

13/ASimmonds Marshall Ltd / Tapemol 100HCase Study


Metalform RN 100

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


Metalform RN 100

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



Existing product

Wheel Forming

12 mm

MS

Dies

1:1

Henkel Multan

14/AKalyani Lemerz Ltd. / Metalform RN 200Case Study


Metalform RN 100

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


Metalform RN 100

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]

mailto:[email protected]

mailto:[email protected]


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