At an automotive connecting rod die-casting plant in Cambodia, 12 CNC machines shared a 50m³ centralized coolant system. Since Q3 2023, batch dimension deviations plagued production:
Critical issue: Aluminum rod bore diameter varied by ±0.15mm (±0.05mm required)
Root cause: 40cm foam layer in coolant tank caused unstable jet pressure
Financial impact: 2,800 scrapped parts monthly (USD35000 loss)
Chemi Tech's three-phase intervention:
Foam analysis: Identified 9.7% emulsified oil & aluminum particles
Targeted defoaming: Automated dosing of KM-070 defoamer at 0.25% ratio
Process optimization: Increased jet pressure from 1.2MPa to 1.5MPa
Results after 7 days:
Foam layer reduced to <3cm
Bore tolerance tightened to ±0.03mm
Monthly scrap decreased to 120 pieces
Annual savings: ￥1.82 million
"CPK for key dimensions jumped from 0.82 to 1.68 - our steadiest production in 3 years."
— Production Director Jean, Cambodia customer‘s Manufacturing