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When discussing automation with various plating shops, the most common response is, "Well, we’ve always done it this way," often followed by, "It’s too expensive." Such phrases can be quite damaging. Consider the following process-related questions: Can we operate within a tighter process window? Is our final finish more consistent? Can we perform real-time data collection? Do we receive real-time alarm notifications? How do time and cost improvements affect us? Can real-time analysis help minimize overhead? How reliable is our manual testing? Can we decrease chemical feed for better inventory management and reduced waste? Are we neglecting other value-added tasks due to a lack of resources?
If you find the answers unsatisfactory, it may be time to consider the strategic use of automation.
Where Might We Find Operational Efficiencies?
Five areas to consider include:
- Pretreatment
- The process itself and the final finish/product
- Incoming and reused water
- Utilities
- Wastewater treatment
Pretreatment
Pretreatment is crucial in the industrial manufacturing process. All parts must be cleaned, degreased, and thoroughly dried to ensure proper adhesion of intermediate or final finishes. This process applies to plating, anodizing, powder coating, and painting. Pretreatment systems typically incorporate alkaline or acid cleaners and may include multiple cleaning stages. They might also feature a conversion coating stage with materials like iron or zinc phosphate or non-phosphate alternatives such as zirconium. Maintaining rinse bath cleanliness is vital to inhibit unwanted chemical reactions and minimize carryover between stages.
Monitoring and controlling pretreatment is achievable through several methods. Manual controls measure total and free acid or alkali for cleaners. Conversion coatings and sealers are monitored for total and free acid, along with specific activators and accelerators, particularly in zinc phosphates. Chrome-containing pretreatments are similarly monitored for total and free acid levels and other relevant metrics. Automation can enhance these controls, making it possible to manage cleaner concentrations and flow rates effectively.
Figure 1 illustrates a multi-I/O microprocessor controller used to monitor and control a multi-stage washer.
Figure 1: 5-stage pretreatment system.
Photo Credit: All images courtesy Walchem
Process
Automation of the plating process can lead to numerous improvements. These include more robust and stable plating baths, which allow for tighter process control and greater consistency in the final finish. Real-time alarm systems enable operators to rectify issues before they escalate. Moreover, automation can minimize chemical feed, leading to better inventory management and waste reduction. Automated real-time analysis further cuts the costs associated with manual testing while freeing resources for other critical tasks.
Figure 2 highlights an electroless nickel (EN) bath before and after automation.
Both nickel concentration and pH metrics showed over a three-fold improvement post-automation. Testing time was cut by 75%, resulting in annual savings of nearly $4,000 per bath. This efficiency allows operators to focus on essential aspects of the process, thereby enhancing plating quality and consistency. The use of LNS decreased by 6-8%, maintaining the same coverage. Reductions in manual testing materials led to savings of $1,700 per bath, while chemistry-related issues were nearly eliminated.
Incoming & Reuse Water
The quality of incoming water and that which is reused from rinse baths and wastewater treatment greatly affects process outcomes. Incoming water can vary in hardness and mineral content, potentially shortening bath lifetimes and leading to defects like spots and flaky deposits.
Methods for water treatment include ion exchange, ultrafiltration, and reverse osmosis (RO), used individually or in combination to achieve the desired quality.
Figure 3 illustrates a typical RO system, which can be automated utilizing a microprocessor controller.
Figure 3: A typical RO system and its automation.
Source water typically undergoes chlorination before passing through a multimedia filter. It is then dechlorinated to prolong membrane lifespan, with an anti-scalant added. After passing through the RO membrane, two streams are produced: concentrate and permeate. The concentrate aids in recovery rinse tanks, returning useful chemicals to the plating baths, while the permeate is recycled back into the process, achieving recovery rates of 95% for standard finishing operations.
Utilities
This encompasses cooling water, boiler water, and pollution controls, especially fume scrubbers.
If you're interested in learning more, visit our website PIONEER.
Temperature control in cooling water is essential for optimal reactions in electrolytic solutions. Temperature requirements can range from 28°F in hard coat anodizing to 130°F for chromium plating. Various factors can influence these temperatures, including tank size and room conditions.
Appropriate control equipment can reduce water consumption, allowing for recycled water use in processes and HVAC systems, subsequently lowering chemical usage. This approach enhances corrosion and scale resistance, thereby extending equipment lifespan. Some municipalities may even provide sewer credits for evaporative loses. Moreover, effective cooling tower monitoring can reduce the risk of Legionella growth.
Wastewater Treatment
Treatment processes often involve pH neutralization, metal recovery, water reclamation, and filtration. Waste streams may contain hazardous heavy metals, oils, and solids, necessitating careful management before disposal.
Hydroxide precipitation and additional post-treatments can be toxic. Typically, streams undergo polymer flocculation before clarifying. Sludge collected is processed further before disposal, while water collected can be treated for reuse or disposal in compliance with regulatory permits.
Conclusions:
Microprocessor-based controllers offer flexibility and functionality across various areas within metal finishing shops. These units can collect and store data locally and connect to cloud-based management tools for remote monitoring and control. They can easily integrate with existing plant systems.
Evaluate your facility's automation potential and identify areas with the best return on investment. Begin implementing automation gradually and witness cost savings throughout your operations.
About the Author
Photo Credit: LinkedIn
Robert Rumelfanger
Robert Rumelfanger serves as the Northeast Regional Sales Manager and Surface Treatment Champion for Walchem - IWAKI America, Inc. Visit walchem.com/metal-finishing-surface-treatment for more details.
In today's fast-paced world, businesses continually seek ways to enhance efficiency and cut costs. An excellent method to achieve this is by investing in an automatic plating line. This automated production system conducts the plating process without requiring manual intervention. Here, we will discuss the reasons and benefits of implementing an automatic plating line.
Increased Productivity
The primary advantage of an automatic plating line is the noticeable increase in productivity. Automated systems facilitate a faster plating process, resulting in higher production outputs. They can operate continuously, 24/7, without breaks. As a result, businesses can produce more items in less time, significantly boosting overall productivity.
Consistency in Plating Quality
Another benefit of an automatic plating line is the guarantee of consistent plating quality. Parameters for the plating process, such as time, temperature, and current density, can be predefined and maintained throughout. This consistency is critical in industries like aerospace, automotive, and medical, where product quality is paramount.
Reduction in Labor Costs
An automatic plating line leads to reduced labor costs. With automation, fewer operators are required to manage the plating line, allowing for leaner staffing that focuses on system oversight and maintenance tasks, resulting in significant long-term savings.
Improved Health and Safety
Health and safety in the workplace also improve with automated plating lines. Automation minimizes the manual handling of hazardous materials, lowering exposure risks. Furthermore, automated systems are capable of recognizing and addressing potential safety hazards, such as leaks or malfunctions, proactively.
Greater Flexibility
Flexibility in production is another significant advantage of automated systems. It allows for quick transitions between different plating processes and products. This adaptability meets evolving market demands and helps businesses maintain a competitive edge.
Improved Environmental Impact
Lastly, an automatic plating line can enhance environmental performance. By accurately controlling plating parameters, waste and chemical usage can be reduced. Automated systems help identify and resolve environmental risks, such as leaks or spills, before they escalate.
In conclusion, an automatic plating line brings numerous benefits, including increased productivity, consistent quality, lower labor costs, improved health and safety, enhanced flexibility, and positive environmental impacts. If you aim to optimize your plating processes, consider investing in an automatic plating line. As a leading supplier of automatic plating lines, feel free to contact us now for more information!
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