Dry Lubrication Plunger Pellets for Die Casting

1. Product Introduction (Key Points)

• Specialized dry lubrication pellets designed for die-casting plungers, reducing metal-to-metal friction in high-temperature environments.

• Compatible with aluminum, zinc, and magnesium alloy die-casting processes, adapting to plunger diameters of 30-120mm.

• Maintains stable lubricity at 300-500℃, eliminating frequent downtime for plunger re-lubrication.

• Reduces mold contamination and post-processing cleaning time compared to liquid lubricants.

• Formulated with eco-friendly, low-volatility ingredients, complying with industrial environmental standards (e.g., RoHS).

• Easy to automate: Works with most die-casting machine’s automatic pellet feeders for unmanned operation.

2. Product Description

Our Dry Lubrication Plunger Pellets were born from a challenge faced by a mid-sized aluminum die-casting factory in 2021. The factory relied on liquid plunger lubricants, which caused two major issues: First, the liquid dripped onto molds, leaving residue that required 60 minutes of manual cleaning per shift—cutting production time by 15%. Second, in high-temperature die-casting (450℃), the liquid evaporated quickly, forcing workers to stop the machine every 2 hours to reapply lubricant, leading to 8+ hours of annual downtime. Our R&D team spent 6 months testing 12 lubricant formulas, focusing on heat resistance, adhesion, and minimal residue, and finally developed these pellets to solve these pain points.

Visually, the pellets are small, uniform cylinders (6mm in diameter, 10mm in length) with a matte gray finish—no clumps or uneven surfaces, unlike cheap pellets that crumble easily. When you hold a handful, they feel smooth and rounded (no sharp edges that scratch plunger sleeves) with a slight 磨砂 texture that helps them adhere to plunger surfaces. Unlike liquid lubricants that emit a 刺鼻 chemical odor, these pellets have only a faint, neutral mineral scent—safe for workers to handle without masks. During use, you’ll notice a clear difference: The plunger moves with a soft, steady glide (instead of the harsh metal-on-metal scraping of unlubricated parts), and there’s no sticky residue on molds—after casting, you can wipe the mold clean with a dry cloth in 5 minutes, not 60. Every detail, from the pellet’s moisture-resistant packaging (prevents clumping in humid workshops) to its consistent weight (±0.1g per pellet for accurate feeding), is designed to make die-casting operations smoother for B2B manufacturers.

3. Product Features and Highlights

• Long-Lasting High-Temperature Lubrication: Formulated with graphite and molybdenum disulfide (high-temperature stable compounds), the pellets maintain lubricity at 300-500℃—the exact range of aluminum/zinc die-casting. This eliminates the need for hourly re-lubrication; one 500g batch lasts 8 hours (vs. 2 hours for liquid lubricants). A die-casting factory producing aluminum auto parts reported reducing downtime by 350 hours annually after switching.

• Minimal Mold Residue: The pellets’ low-volatility formula leaves 90% less residue on molds than liquid lubricants. This cuts mold cleaning time from 60 minutes/shift to 10 minutes/shift—saving a team of 2 maintenance workers 160 hours/year. For a factory running 3 shifts/day, this translates to 480 extra hours of production time.

• Reduced Plunger & Sleeve Wear: The pellets form a thin, uniform lubricating film (5-8μm) on plunger surfaces, reducing friction between plungers and sleeves by 40%. A customer’s wear test showed that plunger sleeve lifespan increased from 3,000 cycles to 5,000 cycles—lowering replacement costs by

  2,400/year(basedon

  600/sleeve).

  
  

• Eco-Friendly & Safe: Contains no toxic solvents (e.g., benzene, formaldehyde) and meets RoHS and REACH standards. Unlike liquid lubricants that produce harmful fumes when heated, these pellets emit zero volatile organic compounds (VOCs)—helping factories pass environmental audits. A European die-casting client avoided a €10,000 fine for non-compliant lubricants after switching to our product.

• Easy Automation Integration: The uniform size and weight of the pellets work seamlessly with automatic feeders (e.g., pneumatic or screw-type). This eliminates manual feeding (which causes inconsistent lubrication) and allows 24/7 unmanned operation. A zinc die-casting factory producing toy parts increased nighttime output by 20% by automating pellet feeding.

4. Technical Parameters (Table)

5. Application Scenarios

This product is tailored to solve lubrication challenges in various die-casting scenarios, with specific benefits for B2B users:

• Aluminum Alloy Die-Casting: Ideal for producing auto parts (e.g., cylinder heads) or consumer electronics components. The pellets’ 300-500℃ resistance matches aluminum’s melting point (660℃), ensuring lubrication during plunger injection. A Chinese auto parts factory reduced aluminum scrap rates by 12% (from 18% to 6%) because consistent lubrication prevented plunger jamming.

• Zinc Alloy Die-Casting: Perfect for small parts like phone casings or hardware. Zinc die-casting runs at lower temperatures (380-420℃), where the pellets’ low residue keeps molds clean—critical for high-volume production (10,000+ parts/day). A Vietnamese zinc die-casting client cut post-processing costs by $800/month by eliminating residue cleaning.

• Magnesium Alloy Die-Casting: Suitable for lightweight parts (e.g., aerospace components) that require strict quality control. The pellets’ eco-friendly formula avoids magnesium oxidation (caused by liquid lubricant residues), improving part strength by 8%. A U.S. aerospace supplier met NASA’s material standards after switching to our pellets.

• Medium-to-Large Plunger Die-Casting (80-120mm): For heavy-duty parts like industrial pump housings, the pellets’ thick lubricating film (5-8μm) prevents plunger wear. A German industrial factory extended plunger lifespan by 67% (from 3,000 to 5,000 cycles) for 100mm plungers.

• Automated Die-Casting Lines: Works with robotic feeders and 24/7 production. A Mexican die-casting plant running 3 shifts/day reduced manual labor costs by $1,200/month by automating pellet feeding (no need for workers to reapply lubricant at night).

6. Core Advantages (Solving B2B Pain Points)

• Cut Downtime: The 8-hour lubrication duration reduces machine stops for re-lubrication by 75%. For a factory with 10 die-casting machines, this adds 2,800 hours of annual production time—enough to make 140,000 extra parts (based on 50 parts/hour).

• Lower Maintenance Costs: Less mold residue and plunger wear reduce maintenance labor and replacement parts expenses. On average, customers save

  4,500/yearpermachine—for5machines,that’s

  22,500/year.

  
  

• Improve Product Quality: Consistent lubrication eliminates defects like cold shuts (from plunger jamming) or surface blemishes (from residue). A European client’s part pass rate increased from 82% to 98%, reducing scrap material costs by $3,000/month.

• Meet Environmental Regulations: Zero VOC emissions and RoHS compliance help factories avoid fines (up to $15,000 in the EU) for non-compliant lubricants. It also reduces waste—unlike liquid lubricants that are often over-applied, pellets are dosed precisely, cutting lubricant consumption by 30%.

• Simplify Inventory Management: The 24-month shelf life and moisture-resistant packaging mean no frequent restocking or waste from expired lubricants. A small die-casting workshop reduced inventory costs by $600/year by switching from liquid (3-month shelf life) to pellets.

7. Usage & Maintenance Guide

Proper use ensures maximum lubrication efficiency and minimal waste—here’s a B2B-focused guide:

• Preparation Before Use:

1. Inspect the pellet batch: Check for clumps (if present, gently break them with a gloved hand—do not use sharp tools that damage pellets).

1. Verify compatibility: Confirm your plunger diameter (30-120mm) and alloy type (aluminum/zinc/magnesium) match the product specs.

1. Clean the plunger sleeve: Remove old lubricant residue with a dry brush (avoid water, which causes rust) to ensure the new pellets adhere properly.

• Usage Steps:

1. Load pellets into the automatic feeder: Fill the feeder to 80% capacity (overfilling causes jamming) and set the dosage to 1-2 pellets per cycle (adjust based on plunger size: 1 pellet for 30-60mm, 2 pellets for 70-120mm).

1. Test run: Run 10 test cycles to check lubrication—look for smooth plunger movement (no scraping) and minimal residue on the mold. If residue is too much, reduce dosage by 0.5 pellets/cycle.

1. Monitor during production: Check the feeder level every 2 hours (set a reminder on the machine’s control panel) and refill when it’s 20% full to avoid interruptions.

• Maintenance & Storage Tips:

1. Daily: Clean the feeder’s discharge port with a small brush to remove pellet dust—buildup causes uneven feeding.

1. Weekly: Inspect the plunger sleeve for wear (use a caliper to check inner diameter—if it’s 0.5mm larger than standard, replace the sleeve to maintain lubrication efficiency).

1. Storage: Keep unopened bags in a cool (15-25℃), dry (relative humidity ≤60%) area—avoid direct sunlight or near heating vents (heat causes pellets to soften).

1. Opened bags: Seal with the included zip tie after use to prevent moisture absorption—opened bags should be used within 3 months.

8. Compatibility Information

A key concern for B2B users is whether the product works with existing equipment—here’s detailed compatibility data:

• Die-Casting Machine Brands: Compatible with most major brands, including:

• LH (e.g., LH-280, LH-500 Die-Casting Machines)

• Yizumi (e.g., DM Series, DP Series)

• Haitian (e.g., ZJ Series, ZS Series)

• Toshiba (e.g., DC Series)

• Ube (e.g., UB Series)

• Plunger Diameters: 30mm (small parts like zinc hardware) to 120mm (large aluminum parts like engine components). For diameters outside this range (e.g., 130mm), contact us for custom-sized pellets (lead time: 7-10 days).

• Lubricant Feeders: Works with all automatic feeder types:

• Pneumatic feeders (e.g., Festo, SMC Models)

• Screw-type feeders (e.g., Bosch Rexroth Models)

• Vibratory feeders (e.g., Eriez Models)

• Alloy Types: Optimized for:

• Aluminum Alloys: ADC12, ADC3, A380 (most common in auto/electronics)

• Zinc Alloys: ZAMAK 3, ZAMAK 5 (used in consumer goods)

• Magnesium Alloys: AZ91D, AM60B (lightweight aerospace/automotive parts)

9. After-Sales Service

We provide reliable support to minimize risks for B2B die-casting manufacturers:

• Warranty: 12-month warranty from the purchase date. If pellets clump, lose lubricity, or fail to meet specs within the warranty period, we offer free replacement or a full refund.

• Technical Support: Our team of 3 lubrication engineers (with 8+ years of die-casting experience) provides 24/7 support via phone, email, or video call. For issues like uneven feeding or residue buildup, we respond within 1 hour and provide step-by-step solutions (e.g., feeder adjustment guides, cleaning checklists).

• Sample Program: For first-time buyers, we offer 500g free samples (you only pay shipping) to test compatibility with your machines. A Brazilian client used the sample to confirm the pellets reduced their downtime by 2 hours/day before placing a 500kg order.

• Bulk Order Benefits: For orders over 1,000kg, we offer:

• 5% discount on total cost

• Free shipping to major industrial hubs (e.g., Shanghai, Detroit, Frankfurt)

• Dedicated account manager for fast reordering (24-hour processing)

• Training: For bulk orders, we provide free on-site training (1 day) for your maintenance team—covering proper feeding, storage, and troubleshooting. A Thai die-casting factory’s team reduced pellet waste by 15% after training.

10. Why Choose Us

• Specialization in Die-Casting Lubrication: We don’t make generic lubricants—we focus exclusively on die-casting plunger lubrication. Our R&D team works with 20+ die-casting factories yearly to test and improve formulas, ensuring our pellets solve real-world problems (not just meet specs).

• Proven B2B Track Record: Over 400 die-casting manufacturers in 35 countries use our pellets, including 2 of the top 5 global auto parts suppliers. A Japanese client reported a 22% increase in production efficiency after switching to our product—and has renewed their annual order for 3 consecutive years.

• Technical Expertise: We hold 3 patents for dry lubrication technology (e.g., high-temperature binder formula, low-residue graphite blend) and meet ISO 9001 quality standards. Our engineers can also provide custom solutions (e.g., larger pellets for 130mm plungers) that generic brands can’t.

• Cost-Effective ROI: Our pellets cost 20% more than liquid lubricants but deliver 3x longer lubrication time and 75% less maintenance cost. Most customers achieve full ROI in 3-4 months—for a factory with 5 machines, that’s $112,500 in savings over 5 years.

• Reliable Supply Chain: We maintain 50-ton stock in 3 regional warehouses (China, Germany, U.S.), ensuring 2-5 day delivery for bulk orders. During peak seasons (e.g., auto parts production surges), we guarantee no stockouts—unlike small brands that often have 4-week lead times.

11. FAQ

• Q1: Can I use these pellets with my existing automatic feeder, or do I need to buy a new one?

A: You can use your existing feeder—our pellets’ uniform size (6mm×10mm) and weight (±0.1g) work with 95% of commercial feeders (pneumatic, screw-type, vibratory). If you’re unsure, send us your feeder brand/model (e.g., Festo DSBG-160) and plunger diameter—our team will confirm compatibility within 2 hours and provide feeder adjustment tips (e.g., optimal vibration speed) if needed.

• Q2: How often do I need to replace the pellets, and how much do I use per shift?

A: For a 50mm plunger (common in aluminum die-casting), 500g of pellets lasts 8 hours (1 shift). For an 8-hour shift, you’ll use 500g per machine—for 3 shifts/day, that’s 1.5kg/day. We recommend ordering 45kg per month per machine (1.5kg/day × 30 days) to avoid stockouts.

• Q3: Do the pellets leave any residue on the final parts, and will it affect post-processing (e.g., painting, CNC machining)?

A: No— the pellets’ residue is only on the mold, not the parts. During injection, the lubricating film adheres to the plunger and mold, not the molten alloy. Our tests show parts have 0.01% residue (undetectable by standard cleaning processes), so they won’t affect painting (no peeling) or CNC machining (no tool wear from residue). A European client confirmed their painted aluminum parts passed 1,000-hour salt spray tests with no issues.

• Q4: What if the pellets don’t work with my magnesium alloy die-casting process?

A: We offer a 100% satisfaction guarantee. If you test the free 500g sample and find it doesn’t meet your magnesium alloy needs (e.g., insufficient lubrication), we’ll refund your shipping cost and work with you to develop a custom formula (adjusting the molybdenum disulfide content) for magnesium-specific use. Custom magnesium pellets take 7-10 days to produce and come with the same warranty as our standard product.