A large automobile casting and forging parts manufacturer, focusing on the production of complex aluminium cast parts such as engine blocks, shock towers, and transmission cases. The company operates multiple large die-casting machines, ranging from 1650T to 4500T.
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The Challenge


The facility was experiencing significant sticking and sludge formation on die surfaces during production of engine block. These issues negatively affected the surface quality of the castings and led to increased downtime. Manual cleaning of the dies was consuming valuable time during each shift, further affecting productivity.
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MotulTech's Solution

MotulTech’s team conducted a comprehensive field analysis of the customer's existing processes and identified high wax content as a major contributing factor. Based on this, we recommended CASTING 116K, a superior die release agent designed to reduce sludge buildup, meanwhile maintain good demolding effect. The solution was introduced with the same dilution ratio as the previous product, ensuring a smooth transition. A trial was conducted over multiple continuous production days.

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The Outcome

• Cleaner dies: Significantly reduced sludge buildup

• Improved parts quality: Achieved a whiter, brighter surface on the workpieces

• Increased productivity: Together with the workshop engineering team, we successfully reduced the time required to remove the sticking aluminium part from the mold by 1.3 minutes. This improvement increased productivity in the overall die casting process, allowing the customer to produce two additional parts per working day, resulting in an additional annual output value of USD 340,000.