{"id":10078,"date":"2026-07-28T14:46:35","date_gmt":"2026-07-28T05:46:35","guid":{"rendered":"https:\/\/www.dry-fog.com\/en\/?post_type=cases&#038;p=10078"},"modified":"2026-07-28T14:46:35","modified_gmt":"2026-07-28T05:46:35","slug":"nozzle-ind-cool-010","status":"publish","type":"cases","link":"https:\/\/www.dry-fog.com\/en\/projects-technology\/cases\/nozzle-ind-cool-010\/","title":{"rendered":"Automatic Mist Cooling Cuts Cycle Time in Cast-Iron Parts Production"},"content":{"rendered":"<section style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"text-align: center;margin: 50px 0\">\n        <a href=\"https:\/\/www.dry-fog.com\/en\/contact\/\" style=\"background-color: #e67f00;color: #ffffff;font-size: 15px;font-weight: bold;text-decoration: none;padding: 15px 30px;border-radius: 5px\">Contact Us<\/a>\n    <\/div>\n<div style=\"margin-top:5rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<section>\n<h3 style=\"font-size: clamp(20px, 2vw, 30px);padding-left: 14px;margin: 0 auto 2rem;border-left: 5px solid #0c9b6f\">Key Reasons for Implementation<\/h3>\n<ul style=\"list-style-type: disc;margin-left:2.8rem;font-size: 1.125rem;line-height:2rem\">\n<li style=\"margin:0 auto 0.5rem\">Reduction in workpiece cooling time from 20\u201330 minutes to approximately 9 minutes<\/li>\n<li style=\"margin:0 auto 0.5rem\">Portable design allowing the unit to be moved and set up wherever spraying is required<\/li>\n<li style=\"margin:0 auto 0.5rem\">Integrated control box enabling easy switching between automatic and manual operation and simple setting of spray and pause durations<\/li>\n<li style=\"margin:0 auto 0.5rem\">Efficient automatic spray operation with minimal capital investment<\/li>\n<\/ul>\n<\/section>\n<div style=\"margin-top:5rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<section>\n<h3 style=\"font-size: clamp(20px, 2vw, 30px);padding-left: 14px;margin: 0 auto 2rem;border-left: 5px solid #0c9b6f\">Challenges Faced by the Customer<\/h3>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">At a plant manufacturing undercarriage components for transportation equipment, reducing production cycle time had become a key challenge.<\/p>\n<div style=\"text-align: center;margin-top:2rem;margin-bottom: 10px\">\n        <img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/07\/nozzle-ind-cool-010-image_11.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><figcaption style=\"margin: 1rem auto 3rem;text-align: center;font-size: 0.85rem;color: #666\">From left: Transportation equipment; undercarriage assembly; undercarriage component<\/figcaption><\/div>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">After casting, each workpiece underwent shot blasting for initial surface preparation, followed by CNC machining operations such as cutting and drilling. A further surface-finishing process was then performed to achieve the required finish.<br \/>\n    The cooling time required after this process was a major obstacle to reducing cycle time.<\/p>\n<div style=\"text-align: center;margin-top:2rem;margin-bottom: 10px\">\n        <img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/07\/nozzle-ind-cool-010-image_2.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><figcaption style=\"margin: 1rem auto 3rem;text-align: center;font-size: 0.85rem;color: #666\">Machining Line for Undercarriage Components<\/figcaption><\/div>\n<div style=\"text-align: center;margin-top:2rem;margin-bottom: 10px\">\n        <img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/07\/nozzle-ind-cool-010-image_31.jpg\" alt=\"Side View of the Mist Spray Layout\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/>\n    <\/div>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">The workpieces were made of cast iron and weighed approximately 30 kg each. During surface treatment, friction raised each workpiece\u2019s surface temperature to <span style=\"font-weight:bold\">150\u00b0C (302\u00b0F)<\/span>, so it had to be cooled to <span style=\"font-weight:bold\">60\u00b0C (140\u00b0F)<\/span> before operators could handle it manually in the next process.<\/p>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">Previously, the workpieces were left to cool naturally on the line, <span style=\"font-weight:bold\">taking 20 to 30 minutes<\/span> to reach 60\u00b0C. This <span style=\"font-weight:bold\">cooling time significantly reduced overall production efficiency<\/span>, and the plant repeatedly failed to meet its daily production targets.<\/p>\n<div style=\"text-align: center;margin-top:2rem;margin-bottom: 10px\">\n        <img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/07\/nozzle-ind-cool-010-image_4.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><figcaption style=\"margin: 1rem auto 3rem;text-align: center;font-size: 0.85rem;color: #666\">Natural cooling from 150\u00b0C to 60\u00b0C took 20\u201330 minutes, causing daily output to fall short of plan<\/figcaption><\/div>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">Conventional water-spray or immersion cooling would have required drainage systems, water temperature control, and drying equipment, resulting in substantial capital investment. <\/p>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">The customer therefore sought a method that could cool the workpieces gradually, minimize the risk of damage from rapid cooling, and <span style=\"font-weight:bold\">require only minimal additional equipment<\/span>. Given IKEUCHI\u2019s proven track record in industrial mist cooling systems, the customer approached IKEUCHI for a solution.\n<\/p>\n<div style=\"text-align: center;margin-top:2rem;margin-bottom: 10px\">\n        <img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/07\/nozzle-ind-cool-010-image_52.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><figcaption style=\"margin: 1rem auto 3rem;text-align: center;font-size: 0.85rem;color: #666\">From left: Mist cooling of die-cast aluminum products; mist cooling of aluminum wheels<\/figcaption><\/div>\n<div style=\"text-align: center;margin: 50px 0\">\n        <a href=\"https:\/\/www.dry-fog.com\/en\/contact\/\" target=\"_blank\" rel=\"noopener noreferrer\" style=\"background-color: #e67f00;color: #ffffff;font-size: 15px;font-weight: bold;text-decoration: none;padding: 15px 30px;border-radius: 5px\">Contact Us<\/a>\n    <\/div>\n<\/section>\n<div style=\"margin-top:5rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<section>\n<h3 style=\"font-size: clamp(20px, 2vw, 30px);padding-left: 14px;margin: 0 auto 2rem;border-left: 5px solid #0c9b6f\">Solutions Proposed by IKEUCHI<\/h3>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">After reviewing the application, IKEUCHI selected a <a href=\"https:\/\/www.dry-fog.com\/en\/products\/noz-pne-bimv\/\" style=\"color: #00a273\" target=\"_blank\" rel=\"noopener\">BIMV<\/a> Series pneumatic spray nozzle, which atomizes water with compressed air to produce a fine mist. As the mist evaporates, it absorbs heat from the workpiece, providing effective cooling.<br \/>\nIKEUCHI then proposed a spray cooling system combining the BIMV nozzle with a <a href=\"https:\/\/www.dry-fog.com\/en\/products\/uni-con-funmusya\/\" style=\"color: #00a273\" target=\"_blank\" rel=\"noopener\">portable automatic spray unit<\/a>. <\/p>\n<div style=\"text-align: center;margin-top:2rem;margin-bottom: 10px\">\n        <img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/07\/nozzle-ind-cool-010-image_61.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><figcaption style=\"margin: 1rem auto 3rem;text-align: center;font-size: 0.85rem;color: #666\">From left: BIMV pneumatic spray nozzle; portable automatic spray unit<\/figcaption><\/div>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">The portable automatic spray unit consists of a pressurized water tank and a spray control box mounted on a wheeled frame. Measuring approximately 970 mm high, 370 mm wide, and 370 mm deep, the compact unit can be moved and positioned <span style=\"font-weight:bold\">wherever needed on the production floor<\/span>.<\/p>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">Three features make the unit especially practical:<\/p>\n<div style=\"text-align: center;margin-top:2rem;margin-bottom: 10px\">\n        <img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/07\/nozzle-ind-cool-010-image_7.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><figcaption style=\"margin: 1rem auto 3rem;text-align: center;font-size: 0.85rem;color: #666\">From left: Portable design; control box; optional mounting accessories<\/figcaption><\/div>\n<ul style=\"list-style-type: disc;margin-left:2.8rem;font-size: 1.125rem;line-height:2rem\">\n<li style=\"margin:0 auto 0.5rem\">The <span style=\"font-weight:bold\">portable unit<\/span> can be moved and set up wherever spraying is required. It is ready for use once connected to a compressed-air supply and power source.<\/li>\n<li style=\"margin:0 auto 0.5rem\">The control box includes a start button, an automatic\/manual selector switch, and separate timers for <span style=\"font-weight:bold\">setting the spray and pause durations<\/span>, allowing operators to adjust the operating cycle easily.<\/li>\n<li style=\"margin:0 auto 0.5rem\">A wide range of optional nozzle-mounting accessories supports layouts tailored to each production site.<\/li>\n<\/ul>\n<\/section>\n<div style=\"margin-top:5rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<section>\n<h3 style=\"font-size: clamp(20px, 2vw, 30px);padding-left: 14px;margin: 0 auto 2rem;border-left: 5px solid #0c9b6f\">Benefits Achieved<\/h3>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">Following the proposal, IKEUCHI conducted a spray test under conditions reflecting the actual production environment. The test used air pressure higher than the standard setting, liquid pressure kept to a minimum, and a spray distance of 150 mm from the workpiece. The results confirmed sufficient cooling performance, leading the customer to adopt the system.<\/p>\n<div style=\"text-align: center;margin-top:2rem;margin-bottom: 10px\">\n        <img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/07\/nozzle-ind-cool-010-image_8.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><figcaption style=\"margin: 1rem auto 3rem;text-align: center;font-size: 0.85rem;color: #666\">Spray test confirms cooling performance<\/figcaption><\/div>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">With natural cooling, lowering the workpiece surface temperature from 150\u00b0C to 60\u00b0C took <span style=\"font-weight:bold\">20 to 30 minutes<\/span>. Mist cooling reduced this time to approximately <span style=\"font-weight:bold\">9 minutes<\/span>.<br \/>\nThis significantly shortened overall cycle time and <span style=\"font-weight:bold\">improved productivity without requiring major capital investment<\/span>.<\/p>\n<div style=\"text-align: center;margin-top:2rem;margin-bottom: 10px\">\n        <img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/07\/nozzle-ind-cool-010-image_9.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><figcaption style=\"margin: 1rem auto 3rem;text-align: center;font-size: 0.85rem;color: #666\">Mist cooling reduced cooling time from 20\u201330 minutes to approximately 9 minutes<\/figcaption><\/div>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">Today, IKEUCHI\u2019s spray nozzle products continue to support stable, efficient production of undercarriage components for transportation equipment.<\/p>\n<div style=\"text-align: center;margin: 50px 0\">\n        <a href=\"https:\/\/www.dry-fog.com\/en\/contact\/\" target=\"_blank\" rel=\"noopener noreferrer\" style=\"background-color: #e67f00;color: #ffffff;font-size: 15px;font-weight: bold;text-decoration: none;padding: 15px 30px;border-radius: 5px\">Contact Us<\/a>\n    <\/div>\n<\/section>\n<div style=\"margin-top:5rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<section>\n<h3 style=\"font-size: clamp(20px, 2vw, 30px);padding-left: 14px;margin-top: 0;margin-bottom: 0.8rem;border-left: 5px solid #0c9b6f;line-height: 1.4\">SDG Contributions<\/h3>\n<p style=\"margin: 0 auto;padding: 0 10px 20px 10px;text-align: left;max-width: 100%;font-size: 1.125rem;line-height: 2.1rem\">Relevant SDG goals for this case.<\/p>\n<div style=\"--col:3;width:100%;max-width:800px;margin:20px auto;overflow:hidden\">\n<div style=\"float:left;width:calc(100% \/ var(--col) - 2%);margin:1%;height:55px;min-width:100px;background-color:#A21942;color:#fff;text-align:center;font-size:13px;line-height:1.3;padding-top:12px\">8. Decent Work <br \/>&amp; Economic Growth<\/div>\n<div style=\"float:left;width:calc(100% \/ var(--col) - 2%);margin:1%;height:55px;min-width:100px;background-color:#FD6925;color:#fff;text-align:center;font-size:13px;line-height:1.3;padding-top:12px\">9. Industry, Innovation <br \/>&amp; Infrastructure<\/div>\n<div style=\"float:left;width:calc(100% \/ var(--col) - 2%);margin:1%;height:55px;min-width:100px;background-color:#BF8B2E;color:#fff;text-align:center;font-size:13px;line-height:1.3;padding-top:12px\">12. Responsible Consumption <br \/>&amp; Production<\/div>\n<\/div>\n<\/section>\n<\/section>\n","protected":false},"featured_media":0,"template":"","cat_cases":[541],"tag_cases":[566,533,543,534],"acf":[],"_links":{"self":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cases\/10078"}],"collection":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cases"}],"about":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/types\/cases"}],"wp:attachment":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/media?parent=10078"}],"wp:term":[{"taxonomy":"cat_cases","embeddable":true,"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cat_cases?post=10078"},{"taxonomy":"tag_cases","embeddable":true,"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/tag_cases?post=10078"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}