{"id":10400,"date":"2026-09-29T13:38:26","date_gmt":"2026-09-29T04:38:26","guid":{"rendered":"https:\/\/www.dry-fog.com\/en\/?post_type=cases&#038;p=10400"},"modified":"2026-09-29T13:40:31","modified_gmt":"2026-09-29T04:40:31","slug":"nozzle-metal-006","status":"publish","type":"cases","link":"https:\/\/www.dry-fog.com\/en\/projects-technology\/cases\/nozzle-metal-006\/","title":{"rendered":"Low-Flow Spray Nozzles Cut Rolling-Oil Use by 50% in Metal Foil Production"},"content":{"rendered":"<section style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<!-- \u30b7\u30e7\u30fc\u30c8\u52d5\u753b\u30ea\u30f3\u30af --><\/p>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<p style=\"font-size: 1.2rem;line-height:1.6rem\"><a href=\"https:\/\/www.youtube.com\/shorts\/BzN970M0xeo\" style=\"color: #E60023\" target=\"_blank\" rel=\"noopener\">\u25b6 Watch this case in a short video<\/a>\n<\/p>\n<\/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<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\">50% reduction in rolling oil consumption using compact, ultra-low-flow pneumatic spray nozzles.<\/li>\n<li style=\"margin:0 auto 0.5rem\">Spray headers sized to match the rolling-line width, allowing each header to be installed and serviced as a unit.<\/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 metal foil manufacturing plant, the issue arose in the rolling process, where metal slabs are pressed between rollers and progressively reduced in thickness until they become foil.<\/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\/09\/nozzle-metal-006-image_1.webp\" alt=\"\" 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 process depended on a steady supply of rolling oil to the rollers. The oil lubricated the interface between the rollers and the workpiece, cooled the workpiece, flushed away wear debris, and stabilized the surface finish. Rolling oil was essential to the process, but the <span style=\"font-weight:bold\">high level of consumption<\/span> was a major concern.<\/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\/09\/nozzle-metal-006-image_2.webp\" 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\">Rolling oil being supplied to the rollers<\/figcaption><\/div>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">Oil consumption reached 124 L per hour\u2014nearly <span style=\"font-weight:bold\">3 metric tons per day<\/span> under 24-hour operation. Beyond the substantial cost burden, oil splashing from the line soiled nearby equipment and floors, creating safety and hygiene risks and significantly <span style=\"font-weight:bold\">increasing the cleanup workload<\/span>.<\/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: 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\">To reduce oil use without compromising application quality, IKEUCHI proposed the compact <span style=\"font-weight:bold\"><a href=\"https:\/\/www.dry-fog.com\/en\/products\/noz-pne-cbimv\/\" style=\"color: #00a273\" target=\"_blank\" rel=\"noopener\">CBIMV<\/a> pneumatic spray nozzle series<\/span>. The nozzle atomizes rolling oil with compressed air to <span style=\"font-weight:bold\">produce a thin, fan-shaped spray pattern for uniform application<\/span> to the mill rolls.<\/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\/09\/nozzle-metal-006-image_3.webp\" 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\">Compact CBIMV pneumatic spray nozzle and its spray pattern<\/figcaption><\/div>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">The lowest-flow model was chosen, and the CBIMV nozzles were mounted on spray headers of different lengths to match the rolling-line width. This allowed <span style=\"font-weight:bold\">each header to be installed and serviced as a unit<\/span>.<\/p>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">Because each nozzle is compact and lightweight, even a multi-nozzle setup places little mechanical load on the header, eliminating the need for a heavy-duty header structure.<\/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\/09\/nozzle-metal-006-image_4.webp\" 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\">CBIMV multi-nozzle header<\/figcaption><\/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\">Benefits Achieved<\/h3>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">The plant replaced its conventional rolling-oil supply method with three spray headers carrying a total of 62 CBIMV nozzles. Under the new setup, each nozzle applied 1 L of oil per hour. With all 62 nozzles operating 24 hours a day, <span style=\"font-weight:bold\">total consumption was 1,488 L per day\u201450% below the previous method<\/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\/09\/nozzle-metal-006-image_5.webp\" 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\">CBIMV-equipped header | Rolling oil consumption reduced by 50%<\/figcaption><\/div>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">Along with cutting material costs by 50%, the system eliminated oil-related soiling on equipment and floors. Minimizing cleanup work also helped reduce operating costs. The cleaner work environment contributed to greater employee satisfaction as well.<\/p>\n<p style=\"margin: 2rem auto 1.5rem;font-size: 1.125rem;line-height:1.6\">IKEUCHI spray nozzles continue to support efficient and stable operations at this metal foil manufacturing plant.<\/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<div style=\"max-width:824px;margin-left:auto;margin-right:auto;text-align:center;margin-top:3rem\">\n        <iframe loading=\"lazy\" width=\"100%\" height=\"422\" src=\"https:\/\/www.youtube.com\/embed\/xlNCDPwtFj0\" title=\"YouTube video player\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\"><\/iframe><figcaption style=\"margin: 1rem auto 3rem;text-align: center;font-size: 0.85rem;color: #666\">Please turn on English subtitles.<\/figcaption><\/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":[87],"tag_cases":[566,383,543],"acf":[],"_links":{"self":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cases\/10400"}],"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=10400"}],"wp:term":[{"taxonomy":"cat_cases","embeddable":true,"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cat_cases?post=10400"},{"taxonomy":"tag_cases","embeddable":true,"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/tag_cases?post=10400"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}