GOODBYE CATCH-22

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.

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:

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.

Evaluators knew the selected solution would need to handle the 250-percent production increase, as well as meet quality standards established by customers. Additionally, it had to meet safety standards required by ISO 14001. JTEKT also wanted the solution to:

After extensive testing and review, JTEKT chose to stay with its current supplier and switch to the zirconium phosphate product called Houghto-Prep ZP. Unlike a typical iron or zinc phosphate system that operates at about 120 deg F or higher, the zirconium phosphate chemical would operate at a near ambient temperature. Because of that, the Powder Coat team anticipated a substantial reduction in energy costs.

The previous process also averaged water use of about 1.1 million gallons annually, whereas the new process would use a nearly closed-loop system to save on water-consumption costs. JTEKT believed that the new system would alleviate its wastewater stream and reduce its chemical needs.

ENVIRONMENTAL AND OPERATIONAL SAVINGS

When the changeover began, some JTEKT employees were skeptical that the new process would make a large positive impact on the powder coat pre-treatment process. But after one year, with each set goal met, employees are highly satisfied with the results. "The new chemistry provides a worry-free process," said Greg Jump, Powder Coat Team Leader.

At the start, the Powder Coat team estimated that the paint pre-treatment switch would reduce operational costs by 30 percent. It had been costing about $165,000 annually for all chemicals, both paint pre-treatment and waste treatment, to maintain the five-stage washer system. They hoped to decrease the company's spend to $115,000. After the changeover, annual chemical costs dropped to $31,000, or an 81 percent savings. This remaining cost represents the total for all of the paint pre-treatment chemicals used — all that is now needed for the washer. This chemical-cost reduction is attributed to the elimination of most of the waste treatment chemicals previously needed.

Waste treatment chemical usage declined 90 percent. In addition, landfill dumps were eliminated because the zirconium phosphate chemical contains no heavy metals and produces zero sludge. Finally, annual BTU consumption decreased by more than 25 percent because the pre-treatment process now operates at an ambient temperature. JTEKT also reduced its total water consumption (specific to the pre-treatment process) to an average of 112,600 gal annually by decreasing water usage from about 24,000 gal/week to an average 2,500 gal/week through the closed-loop process. This was a 95-percent reduction in water use after the chemical switch.

Once the new pre-treatment process was stabilized and running for a full year, JTEKT reduced the total cost of its powder coat pre-treatment operation by $180,933. "The new process has exceeded our expectations, and we have received several awards of recognition for the process change," said Elizabeth Kahler. Most recently, Honda Automotive selected JTEKT for two awards, one for quality improvement and the other for project management. Both were directly related to the new pre-treatment process.

As for the engineering group, Frank English said, "The ZP is providing a superior coating on an increased production load. This was the goal and we accomplished it. In addition, we increased operator safety and eliminated many common headaches associated with the pre-treatment process."

JTEKT Automotive Tennessee-Vonore, Inc., 55 Excellence Way, Vonore, TN 37885, 423-884-9200, Fax: 423-884-9295, www.jtekt-na.com.

Houghton International, Inc., Madison & Van Buren Avenues, PO Box 930, Valley Forge, PA 19482-0930, 610-666-4000, Fax: 610-666-5689, www.houghtonintl.com.