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| SUCCESSSTORY:
MIDWEST ENGINE MANUFACTURER |
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OverviewDuring the course of the last half of 2005, a paint defect in the chromate/e-coat Paint line at an engine manufacturer surfaced in which series of pin hole “dots” down to the surface of the substrate material forming. Concerns of corrosion protection for the parts immediately surfaced. During the course of the process to resolve these issues, one of the potential causes was uncovered by beginning to perform daily Total and Free Alkalinity testing on the cleaners being used, among others issues. It was found that the “usable” cleaner (Free Alkalinity) left in the fluid was virtually non-existent even after tank charges but also on an ongoing basis. In order to maintain a sufficient level of this Free Alkalinity level, Total Alkalinity (total concentration) were raised to points such that a white surface residue would be left from the cleaner. |
"Arbortech Corporation's WW1MO Aqueous Cleaner Recycling System" |
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After analyzing this
data, tank dump and recharges were moved to every two weeks,
sometimes more frequent. It became evident that this situation
needed to be better controlled to help remove the contaminants
that are causing the cleaner to be used. INVESTIGATION/TESTING Testing through out this process showed that there were several issues that could be controlled in the cleaner stages of the system that would aide in resolving the issues on the paint defects. The testing showed that the cleaner’s Free Alkalinity level is quickly being used up by strontium leeching out of the parts and tying up the cleaner. As alluded to above, in order to keep the Free Alkalinity levels at a sufficient level, overall concentrations needed to be raised to a point in which the concentration would cause surfactant residue problems. Combined with this, the cleaning of the cleaner tanks themselves was virtually non-existent due to safety concerns. The piping and the tanks were built up with residues that would also tie up the cleaner and also produce floating residues that would help cause the paint defect. Due to the above, two actions were taken. The chemical manager and the paint engineer worked with safety to implement the proper safety equipment and cleaning processes such that the tanks and piping within these systems were properly maintained. The second issue that the chemical manager worked on was to investigate and research ultra filtration units in which the ultra filter would remove the portions of the cleaner that are “used-up”. Research into the different units on the market led to the purchase of two units from Arbortech out of Illinois. One unit was purchased for each cleaner tank on the system and implemented in the February-March timeframe of 2006. Each unit is positioned in front of each of the tanks and dedicated to each tank. Once these units were implemented, the chemical manager continued to perform the daily Total and Free Alkalinity Testing on each of the tanks. The dumping frequency was removed and tank dumps were moved to dumps based off of data from the data collected from the cleaner testing.The chemical manager also took the task of taking daily throughput readings to ensure that the membranes are operating efficient. RESULTS Since the implementation of the ultra filtration unit from Arbortech we’ve been able to move the cleaner tank dump and recharges from a two week frequency to an average of 5.5 weeks over the course of the first year of operation. This frequency increase has provided the manufacturer with cost savings on cleaner as well as on waste treatment costs, not to mention water savings. Cost/Benefit Costs
Ultra-filter Units $19,756
each $39,512
Benefits (Actual) ROI ROI=Costs of Implementation/Benefits
ROI=45,592/45,010.66 |
With implementing the WW1MO, the company's return on investment was one year. “ Savings in the first year was $45,010.” |
Johnsburg, IL 60051-2515 (815)385-0001 Fax (815)385-0089 sales@arbortech.com |
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