Cost optimization through oil separation in degreasingOil separator Skimmtelligent
Reduction of chemical consumption in the degreasing of automotive components prior to coating by using an oil separator in a kidney loop.
Situation
A supplier and manufacturer of automotive components operates an electroplating line to coat the components it produces. In a first step, the components are always treated in a degreasing bath to remove oils, greases, and particulate contaminants originating from the manufacturing process, in order to achieve the best possible coating result.
Problem
For some time, the personnel responsible for the plating line had been struggling with increased chemical consumption due to the constant need to replenish the chemicals of the degreasing bath. This was necessary because the active cleaning substances were rapidly consumed as they bound to the washed-off contaminants.
As a result, treatment costs increased. At the same time, quality suffered if the chemicals were not replenished quickly enough. In such cases, an oil/grease layer could form on the surface of the immersion degreasing bath, increasing the risk of contaminated components entering the coating process
Solution: Skimmtelligent Oil Separator
The common root cause of both problems (increased chemical consumption and quality risks) was the uncontrolled accumulation of oils and greases in the degreasing bath. Since these were not removed, constant replenishment was required, and there was a risk of phase separation.
To address this issue, the supplier’s staff initially deployed a Friess Skimmtelligent oil separator on a trial basis during a rental period. Although the test unit was undersized for the bath volume, the first results were quickly evident: no oil layer formed, and the demand for chemicals decreased.
As a result, a properly sized oil separator was ordered. With this system, the improvements became even more pronounced. The need for chemical replenishment was drastically reduced, significant quantities of oil and grease were removed from the degreasing bath, and production quality is now consistently at the desired level.
The oil separator has now been in operation for two years to the customer’s full satisfaction.