 |
| One
of the plating lines at Seaboard Metal Finishing, which features
an automated chemical addition system. The addition system
maintains the correct amount of chemicals in the plating bath,
ensuring that neither too much nor too little chemical is
added.
|
Faced with shrinking
profits and increased costs, many small and mid-sized plating companies
are looking for new ways to lower costs, increase production and
remain profitable. Fierce competition, increased labor costs and
the current economic slump threaten to drive some out of business;
however, there are other strategies.
Seaboard Metal Finishing
in West Haven, Connecticut has built a solid strategy to help it
remain profitable. Recognizing the need to stay competitive, the
company partnered with local chemical and equipment distributor,
Gilbert and Jones, (New Britain, CT) to keep updated on new developments
in chemicals as well as state-of-the-art equipment. "Distributors
are an often overlooked resource when companies are determining
their purchasing strategies," Mentioned Steve Tarantino, president
of Seaboard Metal Finishing. "They are the first to know about
new products and, in many cases, how these new products can cut
costs."
Seaboard plates parts
for the automotive, marine, military, electronics, hardware, eyelet,
stamping and turning, and telecommunications industries. The plating
ranges from nickel to tin to a black chrome finish used mainly for
the medical and military. Other specialized finishes include an
antique finish for the hardware industry and the Seachrome finish,
which is a tin-cobalt alloy for parts that require a decorative
chrome look without the chrome.
Seaboard partnered with
Gilbert and Jones without changing any of its bath chemistries.
It simply wanted more control over the tin-plating baths, which
are particularly expensive to run chemically. The company also wanted
greater control of the brighteners in the nickel baths.
One example of cost savings
suggested included the purchase of brightener feeders. Manual chemical
additions were a significant cost to Seaboard. In labor alone, Seaboard
figures cost savings of almost $14,000 annually by managing the
chemicals automatically. The company installed seven Systematics
Bathminders on both tin- and nickel-plating baths. According to
Mr. Tarantino, "A couple of them have been in there for 10
years. We never had an issue with them."
|
| Samples
of part plated at Seaboard Metal Finishing. Parts range in
size, shape and diameter.
|
By using the chemical
feeders, Seaboard has not only saved money, but it has also been
able to provide consistently high quality products. Staying ahead
of the competition in a highly concentrated area of plating shops
is difficult. High quality and consistency are crucial to keeping
customers satisfied. Brightener feeders make small, regular additions
of chemicals to plating baths in order to maintain a consistent
plating environment and avoid rework and stripping costs associated
with adding too much or too little chemical. Seaboard uses the chemical
feeders on both alkaline tin and nickel baths.
Prior to using the chemical
feeders, Mr. Tarantino explained, "We used to buy 400-500 lb
a week of potassium stannate. Now we buy 100 lb a month. That's
only because we have control of the metal through these chemical
feeders. We've saved a tremendous amount of costs associated with
that." In fact, the cost savings is between $250-300/week,
according to Mr. Tarantino. "The nickel plating baths are controlled
with chemical feeders, which does the proper amount of nickel brightener,
thereby reducing the potential for too much chemical addition that
can result in ductility issues as well as wasteful use of chemicals.
The consistency of the final product is what we all strive for in
order to maintain our competitive edge. Maintaining the proper brightener
adds with a brightener feeder has reduced not only our chemical
costs but also the amount of rework."
An equally important
factor in Seaboard's success has been its ability to differentiate
itself from its competition by providing uncommon finishes. "We
offer a couple of finishes that are not that prevalent out there
- black chrome and Seachrome, which is a tin-cobalt alloy finish
with a chrome look. It is more environmentally friendly than traditional
hexavalent chrome," stated Mr. Tarantino.
Brian Chenette, sales
manager for Gilbert and Jones added, "It has many of the qualities
of chrome that people look for in terms of looks and good corrosion
properties without the toxicity associated with the hexavalent chrome
finishing process."
Even in these difficult
economic times, Seaboard maintains 24-hour operations with three
shifts. Cost savings through automation, high-quality products and
business savvy are the things that Mr. Tarantino is relying on to
maintain that success. As far as choosing which distributor to work
with, Mr. Tarantino advises companies to determine the level of
support that the distributor has to offer. "When something
is not working, you want someone physically there. Certainly you
want to be able to reach them quickly."
