Zinc Phosphate Pretreatment Coatings and Wastewater
Opportunity
The customer has two facilities; each has a zinc phosphate immersion line for pretreating fasteners with unique corrosion resistance requirements. In addition corrosion resistance, the zinc phosphate crystals provide a surface structure that allows specialty coatings to adhere during the Dip and Spin paint process.
The customer was struggling to produce zinc phosphate coating weights meeting their customers’ requirements. In addition, the zinc tanks generated excessive sludge, consumed unnecessary chemistry and required frequent dump/ recharge. The customer was also having difficulty treating their wastewater and had excessive zinc in their discharge water that was not meeting daily limitations. Their current chemical supplier did not have the technical expertise to solve their problems.
The DuBois Solution
DuBois partnered with the customer to improve quality and restore environmental compliance. Our local technical team and application specialists audited one of their facility’s zinc line and continuous wastewater treatment system. DuBois team identified several chemical, equipment and process improvement opportunities that they agreed to pursue. We then coordinated the zinc pretreatment line start-up with a sampling program that allowed us to evaluate coating weights and optimize wastewater treatment effectiveness. The results met customer quality expectations and environmental compliance. After proving our capabilities in Iowa, the customer converted to the DuBois program at their second location.
Results and Benefits
Industry News / 07.14.19
Matt Roeser, DuBois Sales Representative – Wisconsin, was awarded the Supplier of the Year by the Wisconsin Chapter of CCAI. This was primary due to Matt’s efforts and leadership within the association. CCAI works to raise the standards of finishing operations through educational meetings and seminars, training manuals, certification programs, and outreach programs with colleges and universities.
Training / 02.12.19
This conference will bring stampers and die shops up to date on new lubricants for stamping and tool and die machining, and help them evaluate new formulations and select the right lubricant for the job. Rick Bulter, DuBois R&D Manager, will be part of the training team at this event sponsored by the MetalForming magazine with support by the Society of Tribologists and Lubrication Engineers.
Recent Events / 06.18.18
The acquisition of U.S. Industrial Lubricants adds high temperature and food grade lubricants to DuBois product offering. Our high temperature synthetic oven chain lubricants are widely used in the fiberglass insulation, textile finishing, food processing, plywood, corrugated paper, automotive and many other manufacturing industries.
