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Summary
Traditional approach
Cleaner production initiatives
Benefits
Where to find additional information
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December 1997
Summary
An innovative computerised closed loop spray booth system designed
by Carramar Lighting has reduced the usage of hazardous chemicals
from 7000 L to 150 L per annum. The spray booth efficiency is
six times higher than the traditional tank pretreatment method.
The unit saves $9000 per annum on chemicals.
Business Profile
Carramar Lighting Pty Ltd, trading as Touch Lights, is
a Mt Gambier lighting manufacturer whose activities include powder
coating and electroplating operations.
Financial assistance provided
An interest free loan of $40,000 for manufacture and installation
of the new technology was provided by the EPA's Cleaner Industries
Demonstration Scheme.
Measures implemented
New pretreatment spray booth for powder coating.
Cleaner production motivators
Increase production efficiency in resource recovery, improve
OHS, reduce operating costs.
Traditional approach
In the pretreatment process aluminium lengths were dipped into
open tanks of process chemicals which, because they were open,
could be spilt. The process chemicals were also eventually exhausted
and disposed of.
Cleaner production initiatives
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| Spray
booth |
Spray booth
The pretreatment booth is a fully enclosed, computerised
loop system, with approx 150 jets in one chamber and capable of
holding and spraying different solutions such as cleaner, rinse,
chromate and final rinse. It uses small sumps which recycle the
process chemicals by directing the alkaline cleaner, rinsewater
and chromate/ phosphate via a three-way valve back to their original
separate holding tanks without any cross contamination. All process
chemicals and rinse waters are held at an elevated temperature
to achieve maximum draining and drying.
Benefits
| Environmental |
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| Waste reduction |
- The self-contained unit does not waste any chemicals
or materials.
- Chemicals are recycled.
- The significant reduction in the amount of chromate
solution discharged reduces disposal requirements.
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| Storage, usage and handling chemicals |
- Hazardous chemical storage reduced from 7000 L to 150
L per annum.
- All unused liquids filtered and reused.
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| Spillage of chemicals |
- The possibility of a spill substantially reduced.
- Minimal or no chances of cross contamination.
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| Water |
- Recycling of water rinse.
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| Economic |
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| Productivity |
- Significantly increased productivity and cost efficiency.
- Up to six times more work processed in the same time.
The spray booth is extremely compact allowing a much quicker
and simpler treatment process.
- Articles pretreated and painted on the same rack, avoiding
double handling.
- Increased processing quality in one load, being racked
only once. Better pretreatment.
- Less room used.
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| Investment |
- $80,000 (includes EPA contribution).
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| Savings, outcomes |
- The rapid turnover time has increased the work capacity.
- Less chromate required: significant cost saving of $9000
per annum on chemicals.
- Savings from reduced wastage and spills.
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| OHS |
- Safer working conditions: all spraying of chemicals
performed within a closed area; no exposure to fumes.
- Reduced hazardous chemical storage minimising the danger
of contamination.
- Less chance of injury and health problems to workers
from chemical exposure and the racking of items.
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Where to find additional information
Mr Steve Karklins
Managing Director
Carramar Lighting Pty Ltd
2 Pyne Close
Mount Gambier SA 5290
Phone: (+61 8) 8724 9299
This page was last modified 21-04-2006
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