Stamping presses might be designed for brute force, but that doesn’t mean they have to operate like blunt instruments. This is especially true when it comes to lubrication. In this article, experts from two Michigan-based companies explain why it’s no longer optional to optimize how lubricant is applied in metal stamping operations.
At Unist Inc., territory manager Will Rungaitis says the practice of applying spotty, inconsistent and, often, excessive oil – or, sometimes, none at all – while hoping for the best is long overdue for retirement; it’s time for precision.
In too many stamping operations, he notes, lubrication is still an afterthought. Instead, manufacturers attempt to prevent galling and reduce tool wear by following the “more is better” strategy. Excessive fluid, however, creates hazards, inflates costs, negatively impacts tool wear and does little to improve the finished part. Unist offers a more deliberate, measured alternative: roller-based lubrication systems that deliver only the fluid needed, exactly where it’s needed.
The right roll
Rather than using nozzles to spray the stock, Unist’s system prefers precision dispenser tubes that sit inside a roller mechanism to apply fluid directly to the coil.
“Obviously, there’s a time for spray, and we support and use that method, but our preferred approach is rolling on lubricant to the top and bottom of the material,” Rungaitis says. “It’s controlled and consistent, keeping fluid where it belongs, which is on the material, not the floor.”
This idea of precision – what Unist calls “the right number” rather than guesswork or tribal knowledge – runs throughout the patented SmartFlow controller platform. Operators can dial in lubricant film thickness down to the micron, selecting from a numeric scale that correlates with the exact amount of fluid needed for the application. Doing so avoids reliance on the old school “finger test” and other visual or tactile cues, providing consistent, quantifiable control that can be programmed per job.
The benefits are obvious. In one example, a large automotive tooling, stamping and assembly producer in Ontario, Canada, cut lubricant consumption by 70 percent after switching to a SmartFlow system. The company also cut die change time by 10 min. per setup because it no longer had to work around nozzle assemblies. This improvement translated directly to increased productivity and less frustration on the shop floor.
There’s also a sustainability angle to consider. Excess spray inevitably ends up in the press pit where it must be vacuumed up and then cleaned or hauled away. This is not only expensive and inefficient but potentially dangerous. By applying only the necessary amount of lubricant, roller-based systems can help reduce environmental impact and eliminate the slip-and-fall hazards that come with oily floors.
A smarter way
Rungaitis is quick to point out that Unist’s patented roller applicators aren’t simply rollers dipped in oil. They use internal dispenser tubes with vertical spray ports that saturate the roller cover from the inside, ensuring even distribution without overspray or mess. This level of control made the company a key player in aluminum can production where lubricant film thickness is critical.
“Our solution is so accurate that 95 percent of all cans in the world now go through one of our systems,” he adds.
The SmartFlow controller integrates easily with shop floor PLCs, allowing job-specific fluid settings to be applied as part numbers change. This speeds up changeovers while eliminating the chance that an operator will forget to adjust the applicator from job to job. The system also allows real-time monitoring of lubricant use. Customers can track consumption, set alarms and even shut down a press if something goes wrong. It’s all part of a broader push toward Industry 4.0 integration, allowing manufacturers to treat lubrication with the same importance they apply to machine tool monitoring and production analytics.
In some cases, shops choose to run dry, counting on the mill oil that remains from steel production. But Rungaitis warns the trade-offs are steep, with galling, splitting and accelerated die wear all likely outcomes. In the end, the goal is to elevate lubrication from nuisance to necessity.
“If you can apply fluids properly, it isn’t just cleaner,” he says. “It’s also safer, more productive and a lot less expensive.”
Changing approach
Troy Turnbull, president of Industrial Innovations, agrees with Rungaitis. Turnbull says there’s no room for guesswork in stamping. Tools wear down, presses run hot and margins are tight. Yet lubrication, which is essential to every stamped part, is often treated as a side note.
“For a long time, shops just flooded everything and hoped for the best,” he says. “We’ve spent the last few decades trying to change that approach.”
That change started with spray-based lubricant systems. Back in the 1990s, Turnbull’s company was awarded a patent for a programmable line that allowed each nozzle to be controlled individually. Spray duration, volume and stroke timing could be tuned to match a specific tool, material or job.
The result was a major shift in how lubricants were applied. Instead of activating every nozzle at once and blanketing the die with fluid, shops could target specific areas, spray at timed intervals and track delivery through flow meters.
“We can even detect if a nozzle is plugged in real time,” Turnbull explains. “If something isn’t working, alarms alert the operator so they can address the issue.”
This level of detail is what defines Industrial Innovations’ Spra-Rite platform. Each press is tied into a central controller that manages up to 200 job recipes. Operators select a part number and the system adjusts accordingly: which nozzles fire, how often and how much fluid to apply. “It’s all automatic,” Turnbull says.
At the heart of the company’s offering is the Pro-Mix line of centralized mixing systems that lock in precise dilution ratios, controlling fluid from the source. Instead of relying on operators to carry buckets across the floor, these systems push mixed lubricant to every press via hard plumbing. This approach not only reduces labor but also eliminates one of the most persistent problems in stamping: variability.
“We’ve all seen what happens when someone decides to hand-mix lubricant on the floor – consistency disappears and costs explode,” Turnbull says.
Flexible fluids
Yet many shops run more than one material type. As such, some parts need a heavier viscosity lubricant while others require something lighter. For these situations, Turnbull’s team offers dual- and triple-feed systems that allow different mixes to be delivered to different presses – or even to different parts of the same press. Here again, the switch happens automatically based on job selection.
“If you have a complex line or are running a variety of materials, the ability to send the right fluid to the right place makes a huge difference,” he says. “We’ve seen shops cut their consumption over 50 percent just by dialing in the spray instead of guessing.”
The benefits go well beyond lubricant cost. Tool life improves. Downtime shrinks. And when spray is used in the die – rather than just at the coil – specific punches or forming stations receive the protection they need, precisely when they need it.
“Most shops still lubricate the coil as it enters the press,” Turnbull says. “But we go further. If you have a punch that runs hot or a section of the tool that’s prone to galling, we can hit that zone directly.”
This level of precision is a strong selling point for high-speed or deep-draw operations, where cooling is just as important as reducing friction. Targeted nozzles deliver lubricant like a scalpel – not a garden hose.
Mixing it up
Over time, the savings compound. In one facility, Industrial Innovations helped reclaim 25 gallons of overspray per shift across five presses, filtering and recycling it back into the system.
“That’s hundreds of gallons a week that don’t get thrown away,” Turnbull says.
The Spra-Rite platform also integrates with the press control itself. Using Modbus or similar protocols, shops can tie their lubricant settings directly to their PLC. The result is full automation – no operator input is required once the press starts running. It also makes the system well-suited for Industry 4.0 environments. In addition to controlling delivery, Spra-Rite monitors fluid usage, identifies performance trends, and helps maintenance teams track nozzle condition and system performance.
Centralized systems aren’t for everyone, though. They require upfront investment and structural modifications that extend beyond the press, and they are typically recommended for operations with at least four machines. But for shops stamping large parts or using expensive lubricant, the ROI can be measured in months. Even smaller facilities are starting to see the benefit.
“If you’re using a $40-per-gallon fluid, you don’t want to waste a drop,” Turnbull says. “Our systems make sure every ounce goes where it’s needed and nowhere else.”
Still, he’s careful not to dismiss competing technologies.
“Some people swear by rollers, which is why we also offer this type of solution,” he adds. “They’re great in the right application. But for die-level control and for tight, area-specific control, spray is the better tool. The bottom line is when you stamp a part, you want the same results every time. We make sure the lubrication side of things supports that standard, but ultimately, your choice should come down to the type of stamping you do, how much flexibility you need and your appetite for automation. Either way, moving toward a precision-based lubrication strategy is a smart investment in productivity, safety and long-term cost savings.”
