Most finishers regard parts cleaning as a process that can be dirty,
time-consuming and fraught with headaches (such as dealing with
EPA regulations) that ultimately eat up a lot of the time they would
rather spend finishing parts.
A new venture called MPW
Recovery Technologies is hoping that those headaches are enough
to drive finishers through the doors of its facility in Fairborn,
Ohio. Recovery Technologies is actually an offshoot of MPW Industrial
Services, based out of Hebron, Ohio. Some finishers may already
be familiar with the parent company, as it provides a variety of
cleaning and plant management services for industries ranging from
automotive, power, chemical, petroleum and pulp and paper. It has
made a name for itself in the metal finishing industry by offering
paint booth cleaning services.
Recovery Technologies is the brainchild of Tom Brooks, the Director
of Facility Management and Support Services of MPW Industrial Services.
In talking with finishers at the Coating 2001 show in Orlando, Mr.
Brooks found that many of them were frustrated by the fact that
they were spending too much time and money on cleaning, depriving
themselves of the ability to focus on their core competencies.
Mr. Brooks surmised that finishers would welcome the opportunity
to do away with the problems associated with parts cleaning. And
while the outsourcing of parts for cleaning is not a unique concept,
he theorized that by introducing fast turnaround of parts into the
mix, MPW could carve a niche for itself in the industry.
Mr. Brooks approached MPW Management about his concept, and the
idea was eventually approved. Now, less than two years after the
idea was conceived, MPW Recovery Technologies is up-and-running,
offering parts cleaning services to finishers in Ohio, Indiana,
Michigan and surrounding areas.
Starting Up
In order to meet the expectations of its
customers, MPW explored a variety of cleaning and stripping technologies.
Factors considered included:
- Cleaning time
- Ability to clean a diverse array ofsubstrates
- Environmental and waste disposal regulations
- Quality of cleaning
- Diversification of service offerings
Turning to Kolene
Corporation (Detroit, MI) for assistance, MPW elected to base
its operations around two core cleaning technologies. The first
is a molten salt bath, used primarily for cleaning racks, fixtures,
tooling and other components of paint and powder coatings. The second
involves the use of Kolene’s RecoverTM Technology, ideal for
use on a wide variety of temperature-sensitive substrates.
Once MPW and Kolene began working together, the relationship between
the two companies evolved well beyond the traditional customer/vendor
relationship into a strategic partnership. Mark Neiswander, a Sales
Representative for Kolene who was instrumental in developing the
new association, actively participates in helping the company maximize
its use of the Kolene cleaning technologies. Both companies understand
that the market is moving towards outsourcing philosophies, and
that there is a need for high-end service to an ever-demanding customer
base. By cleaning parts more quickly, MPW is able to offer overnight,
same shift, or "while you wait" services, depending on
customer need and schedule.
Great Balls of Fire!
Many of the parts that come to MPW for cleaning
are racks, crossbars, hooks and other accessories. Typically, these
parts have little aesthetic value and have been coated hundreds—if
not thousands—of times over. MPW decided that the best way
to manage the cleaning of these types of parts was with the use
of a molten salt bath using Kolene's No. 5 process, which enhances
cleanliness and reduces maintenance of parts.
Molten salts are a class of inorganic chemical compounds, heated
to a temperature above their melting points to form a working fluid.
By combining the building blocks of inorganic salt compounds, a
variety of melting points, chemical reactives and degrees of stability
can be achieved for a working bath. While molten salt baths are
commonly used in organic stripping applications, they also can be
used for casting cleaning, engine remanufacturing and descaling.
As parts come into MPW, the are unloaded from a truck, loaded into
baskets and weighed. After being weighed, the parts are immersed
in the molten salt, where a “cocoon” of solidified salt
forms on the cold workload. As the load heats up in the 900F bath,
the solid salt remelts and the reaction between the soils and salts
begins. Low boiling point/high vapor pressure organics will vaporize
and react with the salt; depending on the amount present, some of
the vapor will escape from the bath and ignite above its surface
(due to the introduction of oxygen). Unignited vapors condense upon
cooling and are removed in an air exhaust wet scrubber.
Upon exiting the molten salt bath, parts are immersed in cold water
quench and then a hot water rinse. MPW is currently planning to
introduce to the line a citric acid bath, which will be used to
brighten up select parts. (See our sidebar article, “The Sludge
Factor,” for more information about the molten salt bath.)
Recovering Parts… and Profits
The most recent addition to MPW's facility
is a cleaning system designed for use on temperature-sensitive substrates
that would not be able to withstand the heat and other factors associated
with the molten salt bath. These materials include ferrous alloys
(including galvanized steels), pot metals, aluminum, magnesium and
other substrates. The system’s primary component is Kolene’s
Recover™, technology.
RecoverTM is a low temperature cleaning process designed for compatibility
with a variety of substrates. Used full-strength in specially designed
process equipment, it is heated to between 250F – 350F, depending
on the substrate. Once at operating temperature, components are
simply immersed into the liquid for stripping and/or cleaning. Cleaning
time ranges from several minutes to an hour of more, depending on
the substrates and coatings involved. After removal from the Recover™
bath, parts are submitted to a simple water rinse to complete the
cleaning process.
Because Recover™ is a gentle
cleaning process, MPW considers it an ideal process for reclaiming
parts and components, which may have paint blemishes or coating
defects.
MPW Plant Manager Ron Klenk also sees the introduction of the Recover™
technology as a move that is consistent with MPW’s focus on
quality cleaning with speedy turnaround time. “The one step
cleaning process completely removes organic coatings from a variety
of substrates, so there’s no need to follow-up the initial
cleaning with additional processes to assure proper cleaning. This
leads to quicker turnaround and better quality.”
Moving Forward
Assuming that MPW Recovery Technologies proves
to be a hit with finishers, the company hopes to expand its depot-style
cleaning facilities across the United States. According to Mr. Brooks,
the prospects for growth are very good. “By combining quick
turnaround with a sense of professionalism and our logistical abilities,”
he says, “We think we can fill a hole in the market in a lot
of places.”
