SOlUTIORubriknS
A switch that pays off for everyone: Mettler, Schmitt and Kozok are as enthusiastic about iron phosphating as the
assembly employees on the enamelling line. No more nasty smells, no more sludge full of heavy metals
of environmentally certified suppliers. Of some 350 series suppliers, 20 per- the facility’s upper storey is used to dry the parts after pre-treatment. “We want
cent are already certified. “That may not sound like a lot at first, but we are to lower the enamelling temperature significantly from its current level of 200
adding to this number all the time, and all of the top suppliers comply with the degrees Celsius and are working closely with powder manufacturers to do just
ISO 14001 standard.” Furthermore, the certification plays an important role in that,” Kozok relates. Even today, the cooling effort has been decreased greatly,
evaluating new suppliers. “We want to increase suppliers’ awareness of our which also benefits the assembly employees at the plant. There, tropical temper-
green technology strategy. Even if it does not make financial sense for every- atures once prevailed, but today the area no longer even needs air conditioning.
body yet, it has enormous potential for the future. Certification is also a good
reference for suppliers.” A clean coup was accomplished in Mulfingen, both in powder coating and
Markus Mettler also wants to raise awareness of green issues. The Techni- cataphoresis coating: the switch from zinc to iron phosphating in surface treat-
cal Operations Manager gives presentations and serves on the board of Modell ment. This saves money, hazardous substances and nerves, as Supervisor Ste-
Hohenlohe e.V., a regional business association (see page 26). “Energy efficiency fan Schmitt knows from experience. “The zinc sludge was nasty stuff indeed,
is my hobby,” he says with a grin. Though Mettler gives up some free time to take chock full of heavy metals. We used to have to clean the entire zone, including
part in Modell Hohenlohe’s work groups and the “Energie Effizienz Tisch (EET),” the pipes, with acid every four weeks!” The advantages are particularly dramatic
an energy efficiency roundtable, his participation benefits the company. From for cataphoresis coating, in which conversion coating using Oxsilan, an organic
the energy efficiency roundtables, he has taken away many ideas that were then silicon-hydrogen compound, takes place. Unlike zinc phosphating, this works
implemented at ebm-papst, such as optimising heat distribution systems, com- at room temperature, and thus does not require a heated bath, which keeps
pressor systems, lighting systems and production equipment. The projects that the 5,000 litres at a constant temperature of 50-70 degrees Celsius. This not
are now in place save approximately 500,000 euro in energy costs each year. only allows the heating energy to be saved, but also makes it unnecessary to
use 30 hazardous substances. The wastewater volume could be reduced by
The engine of savings lies in production, as Mettler and his colleagues in the two-thirds in the process. “The zinc sludge, which as hazardous waste required
environmental team have discovered. The prime example: the new ultra-thin special disposal, could be omitted entirely,” Schmitt is pleased to report.
layer (UTl) powder coating facility, which has been in operation since January Staff at the St. Georgen are likewise busy finding new ways to lower con-
2008. This is currently one of the most state-of-the-art methods on the market, sumption of process media. The screw compressors at Plant 1 had long been a
as Production Manager Thomas Kozok emphasises. The two-storey enamel- source of irritation to Martin Hug. The Manager of Plant and Building Maintenance
ling line is in a separate hall and works with almost zero emissions: “We have a had to quite literally purchase the compressed air production at a high price. For
100 percent powder recovery system in place.” The powder that does not adhere technical reasons, the compressors need a lot of time and energy before they
to the workpiece — which is some 60 percent — is completely extracted, recy- reach the necessary operating state for supplying adequate compressed air
cled and fed back to the process. The heat given off by the enamelling oven in to the workstations. He then discovered a control system for the compressors,
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