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Pre-treatment for the final coating of parts is a Catch-22 for automotive manufacturers. While pre-treating provides necessary adhesion qualities and protection against corrosion, it bears environmental consequences in terms of waste treatment and energy conservation. Today, new chemical technologies and practices allow manufacturers to continue producing quality parts while increasing profits and reducing environmental harm.
JTEKT Automotive Tennessee-Vonore, Inc. (Vonore, Tenn.), a manufacturer of rack-and-pinion steering systems and hydraulic hose assemblies for domestic and international original equipment auto manufacturers, has integrated an eco-friendly technology into its powder coating process, saving the company more than $180,000 in its first year of use.
At JTEKT, pre-treatment for the final powder coating of parts has had a long history. From the time the 370,000 sq ft plant opened in 1989, operators used an iron phosphate chemical for pre-treatment. In 2007, the company increased the number of parts entering its powder coating operation by 250 percent to produce 6,200 steering systems and more than 12,400 hose assemblies daily. However, this wound up increasing chemical costs, as well as the facility's waste burden.
There were three options to improve the pre-treatment process: continue using iron phosphate, but implement a sub-supplier process upgrade; use a new supplier while trying to reduce water use; or stay with the current supplier but switch to zirconium phosphate, a biodegradable coating.
Based on a deep awareness that environmental conservation is one of its most important duties as a company, JTEKT sought an alternative process to reduce waste from the pre-treatment operation. Led by project manager Elizabeth Kahler and process engineer Frank English, JTEKT's Powder Coat team launched an investigation into the waste burden, which revealed three main contributors:
- • The pre-treatment process relied on a high level of energy due to the large temperature-controlled baths.
- • The process required a constant water-overflow and frequent change-out of both the iron phosphate chemical and rinse baths due to sludge and soil build-up.
- • The wastewater treatment process was time-consuming and costly.
With a goal of reducing its spend on waste treatment by at least 30 percent, JTEKT turned to Houghton International, Inc. (Valley Forge, PA), its longtime chemical supplier, for assistance in finding a pre-treatment alternative that would slash costs and improve the plant's environmental performance.
SEEKING ALTERNATIVES
The Powder Coat team generated three possible alternatives to improve its pre-treatment process. In making its choice, the team needed to select the best option that would maximize the efficiency of the powder coat process in order to support increased production.
Its first option was to stay with its current supplier, continuing to use iron phosphate but implementing a sub-supplier process upgrade. The second choice was to use a new supplier to provide pre-treatment chemicals while trying to reduce water use. The third option was to stay with the current supplier but switch to zirconium phosphate, a biodegradable coating, for its pre-treatment operation.