Analysis of a case study on Castrol Rustilo DW806: exceptional results and cost reduction

At Enriel, as a Castrol Ambassador, we believe that case studies are the most practical way to understand real-world lubrication challenges and results. Castrol Rustilo DW 806 is our solvent-deposited, dewatering rust preventive that forms a thin protective film on metal surfaces. In a recent benchmark trial, it demonstrated significant improvements in efficiency, safety, and cost control. In this article, we share the main findings of that study so that plant, quality, and purchasing teams can make confident, data-driven decisions.

Background to the Rustilo DW 806 case study

• Industry and components. The evaluation was carried out on spring components; the batch included 100 parts, each weighing approximately 2.72 kg.
• Existing challenges. The incumbent rust preventive showed higher evaporation, a thicker film layer, lower coverage per litre, and shorter protection windows. These factors increased consumption, handling risk, and the total applied cost. Objectives. We set clear objectives: to reduce consumption without compromising protection, improve safety conditions with a higher flash point, and deliver predictable corrosion performance that supports product quality and throughput.

Key features of Rustilo DW 806

• Dewatering and thin-film technology. Removes residual moisture and leaves a highly uniform film of approximately 0.9 μm, helping to prevent stickiness and fluid build-up.
• Quantifiable corrosion protection. Offers up to six months of protection in indoor storage conditions and one to two months of outdoor protection.
• High flash point and lower evaporation. Flash point around 80 °C, compared to 40 °C for the competitor’s product, with approximately half the evaporation loss in a like-for-like comparison.
• Excellent coverage and fluidity. A viscosity of approximately 2.3 cSt at 40 °C aids wetting and drainage, allowing for coverage of up to 200 m² per litre in the test pool.
• Easy to process. The thin film facilitates faster handling and cleaner downstream operations, such as packaging and shipping.

Lessons learnt from implementation

1) Operational efficiency

• The thin, uniform film reduced drag-out losses and, ultimately, consumption.
• Coverage was approximately double that of the competitor, at 200 m² per litre, simplifying planning and inventory management.
• Lower evaporation reduced top-ups during extended production periods.

2) Cost control without compromising quality

• Total oil consumption to produce a similar quantity of components was reduced by 65%.
• Despite a higher initial price per litre, the net cost of the rust preventive oil used dropped by 2.5 times.
• The net effect was a significant reduction in the applied cost, whilst meeting the anti-corrosion performance target.

3) Health, safety, and environment (HSE) confidence

• The higher flash point improved handling safety and reduced volatilisation losses.
• Lower evaporation contributed to a cleaner working environment and more consistent film integrity.
• The dewatering action helped minimise the risks of moisture retention prior to storage.

4) Quality and reliability

• Both products remained rust-free even after 55 days in outdoor storage conditions and open packaging, confirming that Castrol Rustilo DW 806 provides the desired protection.
• The superior film thickness provides better product quality.

Real-world applications

Rustilo DW 806 is designed for operations requiring reliable rust prevention without excessive residue, helping teams to handle parts during storage, transport, and subsequent processes with confidence. Its dewatering action, thin and uniform film, and high coverage make it particularly useful when cleanliness, predictable protection periods, and cost control are sought.

Castrol Rustilo DW 806 can be used to protect:

• Tubes / Pipes
• Gears
• Springs
• Steel rods
• Steel bars
• Simple hand tools
• Other machinery components

Best practices for using Rustilo DW 806

• Preparation and dewatering. Allow adequate drainage time after dipping or spraying so that the displaced water is completely removed.
• Process discipline. Keep tanks covered wherever possible, check viscosity regularly, and top up with fresh product to maintain performance.
• Handling and storage. Ensure good ventilation, avoid ignition sources, and store packaged parts in accordance with recommended conditions to maximise the protection period.
• Verification. Carry out simple checks, such as mass increase per part, coverage logs, and periodic sampling in salt spray or humidity cabinets, to confirm consistency.

Conclusion

The Rustilo DW 806 case study demonstrates how a thin-film rust preventive with dewatering properties can improve performance and safety, whilst reducing the total application cost. We achieved double the coverage, lower evaporation losses, and a clear reduction in consumption, with corrosion resistance that met the target. For teams evaluating rust preventive oil manufacturers in India, the lesson is clear: focus must be placed on the total applied cost, film behaviour, and coverage.

If you wish to review your current process, we can help you compare consumption, validate film weight, and optimise protection intervals with Rustilo DW 806.

Contact our technical team: castrol.es@enrielcastrolindustrial.com