EcoShot™ Spray System

For simulation-optimized die lubricant spray patterns

  • Up to 95% reduction in die lubricant usage compared to other models on the market

  • Up to 90% reduction in Air Blow Time 

  • Eliminate need for exhaust hoods and air curtains

  • Simulation program optimizes spray patterns, enabling optimal coating thickness and reducing the occurrence of defects

  • Achieve ROI in as little as 6 months

  • Rapid pulse spray 50x faster spray response than conventional nozzles

Typical Savings

The savings you can realize when switching to RYOEI's EcoShot™ spray system are dependent on your die lubricant type (water-based, hybrid, or oil-based).

Water-based Lubricant

EcoShot™ + Current Water-based Lubricant:

  • Up to 50% cut in Air Blow Time

  • Up to 50% decrease in Lube Volume

  • Up to 5% cut in Total Spray Cycle

Hybrid Lubricant

EcoShot™ + Switch to hybrid lubricant:

  • Up to 80% cut in Air Blow Time

  • Up to 95% decrease in Lube Volume

Oil-based Lubricant

EcoShot™ + Switch to Oil-based Lubricant:

  • Up to 90% cut in Air Blow Time

  • Up to 95% decrease in Lube Volume

  • Die modifications may be required

Case: ROI with EcoShot™

Actual Customer Experience (engine block / 3500T)

Our customer's optimized cycle time with EcoShot™ application meant fewer machines were required for the same production volume. This customer went from using 6 die casting machines (DCM) to 4 DCMs, with 2 DCMs being repurposed for other work. Fewer DCMs permitted less manpower to be used to produce the same production volume (reduced labor costs of 3 people).

 

ROI was achieved just 6 months after installation

Improved Adhesion

When a water-based lubricant is applied with a continuous spray pattern, the lubricant evaporates upon contact with the high-temperature die and water droplets bounce off the surface, causing poor adhesion. This phenomenon is known as the Leidenfrost effect. Due to the Leidenfrost effect, an excess of lubricant might be observed in some areas, which can cause porosity when the lubricant evaporates once the alloy is injected. In areas where lubricant does not properly adhere, the casting can stick to the die, causing defects and damage to the mold. The large application amount with continuous spray causes a significant amount of waste liquid.

 

Pulsed spray patterns will mitigate the Leidenfrost effect observed with water-based lubricants, thereby enabling these lubricants to adhere to the die. The initial spray of water-based lubricant is applied to the die, cooling its surface and evaporating. Immediately after evaporation, a second layer of lubricant is applied. Since the die has been cooled and water vapor has dissipated, the second layer adheres more effectively. This process is repeated until the desired result is achieved. Rapid spray nozzle response time is required to achieve such results (such as Ryoei’s nozzle response time of 10 milliseconds).

Minimized Cycle Time

By integrating RYOEI's EcoShot™ into your die casting process, cycle time can be significantly reduced. Shorter nozzle response time means lower cycle time. Pulse spraying with a nozzle response rate of 10 milliseconds permits faster robot movement without sacrificing lubricant coverage (image below). With a robot speed of 20” per second, lubricant thickness can be accurately controlled, as nozzles can achieve up to 6000 pulses per minute.


Conventional spraying with nozzle response times of 500 milliseconds causes undesirable spacing when the robot arm moves at a speed of 20” per second (Image below). In order to achieve lubricant coverage comparable to that of the pulse method, the robot would need to move much more slowly at just 0.4” per second. 

Complete 3D Spray Process Simulation

  • Simulates Nozzle Number/Placement, Spray Pattern Volume, Angles, Spray Film Thickness

  • RYOEI’s 3D Simulation can check the processes and confirm the cycle time of an entire cell

  • Water-based lubricants adhere best at die temperature of 200-300°C (390-570°F), so RYOEI’s simulation is based on an extreme condition of 350°C (660°F)

  • Oil-based lubricants adhere best at die temperature of 300+°C (570+°F), so RYOEI’s simulation is based on an extreme condition of 250°C (480°F)

Improved Workspace Environment

Holding Plant
Industry, Technology, Borough Of Industr
Construction Worker

Minimized Waste

  • Reduce or eliminate excess spray volume with Fluid Waste Management

  • Reduce or Eliminate lubricant waste with Fluid Recycling

Lower Cleanup Costs

  • Reduce in-house labor costs for cleanup

  • Reduce waste fluid collection costs

Less Airborne Lubricant

  • No need for expensive air ventilation systems

  • Create a cleaner, safer workplace for employees

More Benefits...

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Fewer Nozzles, Fewer Cables

  • Fewer spray and air nozzles reduce the weight of the spray head and decrease the load on the robot without compromising film application

  • Fewer cables means less interference with robot motion

  • Compatible with Fanuc, Motoman, ABB

Pulse and High Volume Spray

  • RYOEI's EcoShot™ Nozzle enables immediate spray response

  • 50x faster than conventional spray nozzles

  • Rapid Pulse Spray / High Volume Spray / Combination Spray

  • Dual air and lube flows prevent residue buildup

Industrial worker working on machine in
Rain

Streamlined Nozzle Maintenance

  • Nozzles are easy to Remove, Inspect, Clean, and Reassemble

  • Nozzle tips can be exchanged to adjust spray angle and spray cone

  • Never need to manually adjust nozzles

One System, Hybrid Capabilities

  • Compatible with water-based lubricants when external cooling is required

  • Compatible with oil-based lubricants when internal cooling is sufficient

  • Combined oil/water based lubricant system for the most flexible spray application

  • Compatible with all types of water/oil based lubricants

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RYOEI USA

8545 Challenger Dr, Indianapolis, IN 46241, USA

info@ryoei-usa.com

RYOEI Japan

RYOEI Thailand

©2020 by RYOEI

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