TOTAL USE – Maximum utilization, minimum waste
In traditional handling of drawing lubricants, the change usually occurs after a fixed time interval or when a visible deterioration of a quality characteristic is observed. This approach often leads to unnecessary material consumption, production interruptions and avoidable costs.
Our TOTAL USE approach takes a different path: The goal is to maintain the stable functional state of the drawing lubricant over a longer period in the process. As long as the drawing lubricant in the drawing box does not show clumping, black residues, or dusty behavior, it can continue to be used. Instead of complete changes, only targeted refilling takes place during ongoing operations.
The key is to keep the stability of the grain size and the lubricating effect constantly at an optimal level. The wire should only absorb as much drawing lubricant as is necessary for efficient lubrication – no more and no less. This avoids overdosing, reduces clumping, and preserves the grain structure.
The effect is measurable: In numerous customer projects, the consumption of drawing lubricants could be reduced by an average of around 20% – with consistent or even improved process stability.
The advantages at a glance:
- Cost reduction: Less drawing lubricant requirement means lower production and storage costs.
- Sustainability: Reduced material consumption decreases waste and lowers CO₂ emissions along the supply chain.
- Process stability: Targeted refilling avoids unplanned downtimes and increases efficiency.
- Individual optimization: Existing drawing lubricants can be further adapted through small modifications – without compromising on quality.
Energy Efficiency – More performance with less energy
A second approach to increasing efficiency lies in the targeted reduction of energy consumption through the selection of the optimal drawing lubricant and the adjustment of process parameters.
Together with the production team of a US wire manufacturer, we analyzed the customer-specific drawing process. Based on this data, a customized product was recommended – with the goal of saving energy while simultaneously increasing productivity.
In practice, the drawing lubricant used could not only reduce the energy requirement in the drawing process by around 3%, but also increased the production speed –with hourly output increasing by up to 40% on some machines.
These results show how much the right lubricant can influence the entire process: Optimized lubrication reduces friction, lowers wear, and enables higher drawing speeds while maintaining consistent product quality.
The advantages at a glance:
- Energy savings: Optimized lubrication reduces the energy requirement per ton of wire.
- Productivity increase: Higher drawing speeds lead to higher overall output.
- Reduced tool wear: Less friction also means a longer service life for drawing dies and tools.
- Sustainable production: Energy efficiency makes a direct contribution to reducing the CO₂ footprint.
Conclusion: Small adjustments, big impact
Whether through extending the service life of drawing lubricants in line with the TOTAL USE approach or through targeted optimization of energy consumption – both strategies show that significant savings and environmental benefits can be achieved with well-thought-out solutions without having to invest in new machines or equipment.
We look forward to discussing these approaches with you at the AWPA Operations Managers Meeting 2025 – and working together to explore the potential in your production.