The global chemical manufacturing industry generates about $5 trillion in annual revenues. Several of the world’s largest chemical producers are located in the United States. Recent reductions in energy cost, mostly relating multidirectional drilling and shale gas fracking, have caused a resurgence in the U.S. chemical industry. Many companies such as Quaker Chemical Corporation are taking full advantage. Quaker is a leading provider of process chemicals, chemical specialties, services and technical expertise to a wide range of industries, including steel, automotive, mining, aerospace, tube and pipe, coatings and construction materials.
With their 2011 acquisition of G.W. Smith & Sons Inc., Quaker has become a leading provider of die casting lubricants. A 70-year established business reputation and $14 million in net annual sales, along with a wide line of complementary products, made this company an ideal fit for Quaker.
Operating out of Dayton, Ohio, G.W. Smith produces a variety of high-quality die cast lubricants and metal working fluids to its customers. The process includes high levels of precise chemical mixing. Chemicals are mixed with various temperature additives to accommodate a specific client’s recipe.
The Problem: During an expansion in 2006, the operations systems engineering for G.W. Smith consulted with IKA Works Inc. in Wilmington, N.C., and several other mycologist consultants to build a lubricants mixing system. The mixing system is fed by a large storage tank or a reactor. The storage tank is set on load cells to ensure proper feed levels. The oil based liquid must be circulated and kept at a constant temperature of 150-165° F to prevent solidification.