Metals industry equipment

Unlocking $2.6m in savings for Egyptian Iron and Steel Company

Shell Lubricant Solutions collaborates with Egyptian Iron and Steel Company to deliver millions of dollars of savings

Challenge

The Egyptian Iron & Steel Company manufactures steel products including steel sections, flat steel sheets and rebar. The company was experiencing high operational costs because of the poor performance and low efficiency of its existing lubricants. Operators needed to grease the casting machine every 75 hours, which generated a significant loss in production and increased operating costs.

Solution

The Shell technical team recommended a high base oil viscosity grease, Shell Gadus S3 V460, made with a lithium complex soap thickener, which is particularly suitable for the heavy-duty operations of a factory. This product was recommended because its formula resists water washout, copes well in high temperatures and withstands continuous vibrations and shocks, which makes it particularly suitable for the heavy-duty factory operations.

Results

  • As a result of switching to Shell Gadus S3 V460, the Egyptian Iron & Steel Company extended the greasing intervals for the casting machine from 75 to 250 hours, an increase of 333%.
  • This resulted in decreased maintenance costs and lubricant consumption and increased production time through trouble-free operation.
  • The company has reported total annual savings of US$2,688,000 through the elimination of production downtime.

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