CASE STUDY 2

Unlocking Efficiency in Automotive Manufacturing:

Reducing Mold Release Agent Consumption by 20% and Saving $40,000 USD Annually

Challenge

IAC Toluca faced excessive mold release agent consumption in the production of headliners. The existing product’s inefficiency led to higher costs and reduced productivity.

Results

  • Reduced mold release agent consumption by 20%.
  • Increased production output by 16 additional headliner pieces per shift.
  • Achieved annual savings of $40,000 USD.

Solution

Intermol 505, a semi-permanent water-based release agent, was introduced. Combined with a new atomized application system, it improved efficiency and minimized waste.

Impact

Improved cost-efficiency and production capacity.

Volkswagen (Mexico)

Achieved a 20% noise reduction and enhanced compliance with OEM standards through InterMotive OPF 526.

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KIPP Car Comfort Systems (Brazil)

Cut lubricant consumption by 15% and logistics costs by 50% with InterMotive GPX 201.

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Acumuladores Moura (Brazil)

Streamlined lead casting processes with Intercad TF Spray, eliminating mold lock-ups, reducing spray consumption by 288 cans annually, and boosting productivity by 20%.

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GDBR (Brazil)

Improved microwave conveyor bearing efficiency with Interplex 1500 2, reducing lubricant consumption by 50 kg annually and extending relubrication intervals from 120 to 720 hours.

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VW MAN (Brazil)

Optimized truck engine assembly with InterMotive DE 205, reducing lubricant consumption by 119 liters annually and achieving annual savings of R$30,004.70.

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Sogefi Engine Systems (Mexico)

Enhanced production reliability with InterMotive GHC 501, passing critical sealing tests, resisting extreme conditions, and supporting annual output of over 40,000 units.

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