Finishing Talk Newsletter - March 2008

MARCH 2008

VOLUME 1, ISSUE 2

Protective Coatings NDT

CONTENTS PROTECTIVE COATINGS NDT

1

INDUSTRY EVENTS

2

NEWS & NOTES

3

FINISHING SPOTLIGHT

4

FROM THE FORUM

6

THE LAST WORD

15

ENERGY SAVING PAINT

specialized coating system.

Abstract A leading problem with the use of protective coatings occurs when structure life exceeds coating life and creates a need for additional recoating operations to maintain effective corrosion control.. Protective Coatings NDT is a lifetime maintenance program that has been developed to provide consistent corrosion protection for steel structures based on the application and maintenance of one highly

PC/NDT uses a principal of non-destructive testing (NDT) where fluorescence and black light illumination are used to locate surface defects. By integrating a defect detection indicator (fluorescence) into the original coating formulation, black light inspections allows workers to inspect large or complex surfaces in relatively short period of time and determine exactly where and when maintenance is required.

Note: The average worker with 20 x 20 vision can locate a coating defect 50 microns in size and given enough time for a thorough visual inspection. The same worker inspecting fluorescent coating by black light can easily locate a defect 10 microns in size or smaller even in low light or during production painting operations.

Inside This Issue: From the Forum: Finishing Spotlight: Interview with Cleaning expert Dr. John B. Durkee

(page 4)

Placement of Anode Baskets

(page 6)

Protective Coatings NDT (page 8)

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INDUSTRY EVENTS 2008 March 16-20: Corrosion 2008 New Orleans, Louisiana 800.797.NACE [email protected] http://www.nace.org March 18-20: 3-Day Spray Finishing Technology Workshop Mt. Wachusett Gardner, MA Ken Hanson at 978-630-9179 [email protected] March 18-20: Process Technology Expo Charlotte Convention Center Charlotte, NC www.ptxsouth.com

March 26-28: Nanotechnology in Coatings Orlando, FL www.coatingstech.com

April 9-10 Powder Coating School Denver, CO surfacefinishingacademy.com

March 31-April 1: Electroplating Know How Basics Greenville, SC [email protected] www.platingschool.com

April 21-23: Coatings for Plastic Symposium Chicago, Illinois (888) 530-6714 www.coatingsforplastics.com

April 1-3: Metal Form Birmingham Jefferson Convention Complex Birmingham, AL www.metalform.com April 3-4: Electroplating Know How Basics Cincinnati, OH [email protected] www.platingschool.com

April 21-24: NA 2008 I-X Center Cleveland, OH www.nashow.com

Have an upcoming event? Tell us about it at: www.finishingtalk.com!

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VOLUME 1, ISSUE 1

NEWS & NOTES West Haven, CT Enthone Inc. celebrated the grand opening of its advanced plating applications laboratory with an open house attended by more than 150 customers, state and local government officials and company employees. The laboratory houses multiple plating lines that enable processing of functional, decorative and electronic coatings on parts used in automotive, plumbing, printed wiring board (PWB) and other applications. It features dedicated lines for plating-on-plastics, copper/ nickel/chrome, passivation processes, surface preparation chemistry, zinc and zinc alloys, hard chrome and electroless nickel. Washington, DC

The National Association for Surface Finishing (NASF) has named Fred Barnes, political commentator and cofounder and executive editor of The Weekly Standard, the keynote speaker for the Washington Forum, April 22–24. Barnes is set to deliver his speech on Wednesday, April 23, during a special luncheon at the L’Enfant Plaza Hotel. Currently, Barnes co-hosts (along with Mort Kondracke) the "Beltway Boys" on FOX News. He also hosts the weekly radio show, "Issues in the News" on Voice of America. Barnes appears regularly on FOX’s "Special Report with Brit Hume." For more information about the Washington Forum, and an extensive biography on Mr. Barnes, please visit www.nasf.org.

Charleston, SC

Southern Metal Finishing, an annual metal finishing conference held each year in historic Charleston, S.C., has announced that registration is now open for its Sept. 14–16, 2008, conference and tradeshow. This year’s conference will be held at

the majestic Francis Marion Hotel. The event will feature the Powder Coating School, taught by the experts at Tiger Drylac, and 21st Century Cleaning Technologies, taught by Dr. John B. Durkee, world-renowned cleaning expert and Metal Finishing columnist. In addition, participants are invited to take part in a variety of events over the duration of the show. For more information about the upcoming conference or to register, please visit www.surfacefinishingacademy.com and click on "Conference."

Nationwide

As part of the alliance between NASF and the U.S. Occupational Safety and Health Administration, OSHA provides NASF with information on its compliance assistance resources. The latest update is a link to a list of OSHA’s new compliance assistance products that may be helpful for surface finishing industry operations, including publications,

eTools, Safety and Health Topics pages, and success stories with the appropriate links. A list of available health and safety compliance assistance tools is available on the NASF website at

www.nasf.org Nationwide

The National Paint & Coatings Association (NPCA) and the Federation of Societies for Coatings Technology (FSCT) recently signed a Memorandum of Agreement, which outlines the details of a prospective merger of the two organizations. The agreement describes a "governance merger" that will consolidate the governance, management and administrative functions of both groups under NPCA, while preserving each organization’s separate identities, operations, functions, and member services. In short, NPCA and FSCT will remain as separate organizations managed through a common governing structure.

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FINISHING TALK FINISHING SPOTLIGHT:

T

his month, Finishing Talk interviewed professional consultant, author, and educator in cleaning sciences, Dr. John B. Durkee, PhD., P.E. Having served as an experienced chemical and engineering professional for more than 25 years, in addition to innumerable accomplishments, awards, and publications, Dr. Durkee has become an industry leader in his field. In this interview we discuss how he got to where he is today, current and future issues that effect the industrial cleaning sector, Dr. Durkee’s most recent publication and his upcoming workshop. FTalk: How long have you been

working in the critical, precision, and industrial cleaning sector, and what got you interested in this industry?

JD: In 1989, I was assigned by Du Pont and Conoco to develop equipment and chemistry for cleaning technology to replace CFC-113 ("Freon") as a core business. My work involved extensive contact with end-use customers to learn of their needs and preferences, as well as partner firms who produced equipment for use with Du Pont's proprietary cleaning chemicals. A significant portion of my time was spent in understanding competitive patent art, as well as that owned by Du Pont, so that a proprietary basis for commercialization could be found. This work involved cleaning operations from critical cleaning in a

clean room to metal cleaning in a working machine shop. In 1993, Du Pont sold this business. At this point, I retired from Du Pont to pursue independent opportunities as a professional consultant in industrial cleaning. In 1993, along with several associates, I formed Creative EnterpriZes with the mission of providing consulting service to both end-use and supplier firms with technology to replace CFC-113 and other ozone-depleting chemicals. Nearly all work on the ozone-depletion initiative was confidential for a variety of reasons. However, it included: cleanliness evaluation and monitoring, product and process selection, market research about industry needs, parts drying, and drying equipment, management of hazardous chemicals, ultrasonic and megasonic cleaning and rinsing, control of particles via hydrodynamic and other means, solvent substitution and selection, and many other affairs. I have taught cleaning science by invitation to firms and chaired and/or presented technical papers at conferences and seminars such as Clean-Tech, NEPCON West, APEX, the Phoenix Solvent Substitution Workshops, the NASA Aerospace Conferences on Environmental Affairs, the International Conferences on Elimination of CFCs, International Symposia on Particles on Surfaces: Detection, Adhesion and Removal, International Symposia on Contact Angle, Wettability and Adhesion, and oth-

DR. JOHN B. DURKEE

ers. Clients which can be identified include the Los Angeles South Coast Air Quality Management District (SCAQMD), the U.S. Air Force, the U.S. Army, the U.S. Department of Justice, and the U.S. Environmental Protection Agency. I am frequently asked to, or do, comment on pending environmental regulations. In 1999, I ceased being part of and managing an organization providing consulting services. I accepted an assignment which lasted through 2002 to a single client, Flo-Matic, located in Rockford, Illinois. At Flo-Matic, we developed technology for cleaning machinery parts without use of cleaning solvents or detergents. This technology is protected by U.S. Patent No. 6,368,414. Ultrasonic force was applied and controlled for this purpose. We designed, constructed, and sold several machines to local machine shop customers. The machines provided dry parts through management and application of compressed air, and efficient waste disposal through a unique evaporator. My assignment with Flo-Matic was terminated in 2002 due to lack of funding. In 2002, I initiated work to complete a self–generated challenge. The industrial cleaning industry has little unbiased science-based literature about the foundations of its technology. Moreover, the industry had little or no literature about management of that technology. Since 2003, I have endeavored to develop and provide

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VOLUME 1, ISSUE 1 that literature through lasting resources: books, magazine columns, training courses, and occasional papers. In 2004, I started a self-funded and managed project to invent and develop replacement cleaning technology for users doing, or wanting to do, solvent cleaning. The approach, long laying fallow, is to use binary azeotropes to replace single solvents. I have developed, with the University of Massachusetts (Lowell) Toxic Use Reduction Institute, basic data teaching and showing how this technology works. I have recently filed an application for comprehensive U.S. patent covering a broadbased new approach to solvent cleaning which involves new process technology and new cleaning formulations. This work is ongoing with more tests being conducted. FTalk: What is the most com-

mon question, concern, or problem that arises from the companies and individuals who request your consulting services? JD: Question: “Tell me in twenty five words or less how this works, and don’t cost me any money in doing so!” Concern: “I’m whipsawed between increased demand for quality and consistency by my customers, and increased need to make quantum-sized (major) reductions in cost by management’s need to preserve jobs in the U.S. I want something better, but I can’t spend any money to get it; if I knew what it was.” Summary = frustration. Problem: “Finishing work is be-

ing driven by environmental regulations which are out of my control, whose details are so complex I need a specialist, and whose cost appears unjustified. I’m a good citizen. I don’t pollute. I don’t violate laws. I want to protect the environment. But how do I deal with environmental regulators who can see only one side of my situation?” FTalk: What is the biggest trend, from your perspective, that is going on right now in the industrial cleaning sector? JD: TODAY: Getting toxic metals (Chromium, Lead, Cadmium, etc.) out of wastes. TOMORROW: EPA has regulated since 1970 on the basis of mass amount of emissions of specific chemicals. Their decisions were fairly easy to understand. Now that pollution has generally been reduced by ~80% or so, EPA is starting to regulate based on risk

to human life. Future decisions will be harder to understand and accept because the basis for risk determination is not consistent, well-proven, or well-known. FTalk: In addition to consulting,

you are also known for your various publications – most recently being Management of Industrial Cleaning Technology and Processes, published by Elsevier, 2006, (ISBN 0-0804-48887). In your opinion, who would benefit the most from the information and insight you present in this book, and what are some of the major themes you touch upon? JD: Firms and persons trying to manage cleaning better using existing technology and not spending substantial new investment for quality, safety, and environmental improvements. Persons seeking to understand the fundamentals of technology, Continued on page 12….

Your Total Finishing Resource. T: (800) 438-6880 T: (828) 464-1376 F: (828) 464-7094 www.jacksonlea.com

1715 E. Conover Blvd. Conover, NC 28613

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FROM THE FORUM: PLACEMENT OF ANODE BASKETS IN TANK Posted on February 16, 2008 In this month’s column, Finishing Talk forum members Toyota111, DustinGebhardt, and Skelton discuss issues relating to the proper placement of anode baskets in an anodizing tank. Feel free to add your thoughts to their ongoing discussion by visiting the forums at www.FinishingTalk.com/ general-discussion and then clicking on the thread entitled “Placement of Anode Baskets in Tank”. For more ‘From the Forum’ discussions, check out our monthly internet television show, Finishing Talk Live, where hosts Paul Fisher and Paul Skelton bring the boards to life!

www.finishingtalklive.com Toyota111: Hi, I'm new to this and could use some help. I am plating zinc onto pot metal holley carburetors and wondering if anyone could tell me about the formula for calculating the amount of zinc anode to be used, and placement of the anodes in the tank. Also, any clearances between the anode and the piece to be plated. I have a 22" x 21" x 19" deep tank with a penguin agitation pump. Any help would be greatly appreciated. Thanks. Skelton: Welcome to the wonderful world of metal finishing.....welcome to finishingtalk.com too! Why, may I ask, are you zinc plating a carburetor? I am no 'Cooter' from Hazzard county, but I believe your carb may be zinc alloy - if not an aluminum alloy and not pot metal. Correct me if I am wrong, maybe you are just using the slang term "pot metal"??? Regardless, all three base metals have similar characteristics in that you just do not plate any of these without the proper pre-cleaning and pre-plate process; i.e. a copper strike…but that's another topic (focus Skelton). As for you question regarding anode baskets, I am going to assume you may have 2" diameter SHG zinc ball anodes in titanium baskets, which of course will not require much anode surface area

due to the size of your tank and the assumed maximum current of your rectifier - again, relative to the size of your tank, I am guessing maybe 100 amps or less? Which relates to approx. 5 sq.ft. of anode surface area at 20 asf or approx. 60 - 2" dia. zinc balls in 2 - 6 anode baskets (depending on style of basket) As for placement, 2 - anode bars on each side of the tank (parallel) with 1 - 3 anode baskets on each anode bar, with plenty of distance from anode to cathode...and you will be ready to plate your holley carburetor. Woo hoo! I hope this helps, good luck. Toyota111: Thanks for getting back to me, I have a 200 amp lamda rectifier. I’m using zinc slabs about 8" x 2.5" x 1" thick. The carbs. are zinc alloy. From your message, I have to run the anode baskets which are 12" x 12" x 3" along the two sides of the tank, not on all four sides. If so, that’s good because I have anode bars running parallel on two sides built into the tank. I am assuming the pump will keep the bath agitated enough that anodes are not required on all 4 sides of the tank. Like I said, this is just a hobby I'm getting into and any help or advice you can give me would be GREATLY appreciated. If you ever want to learn how to run a track excavator let me know, that’s what I can do. And I'm told I'm not to shabby at it. Thanks. DustinGebhardt: Why are you trying to plate zinc on to a zinc alloy? Regarding the anode placement: The anode placement helps determine the "line of sight" for the deposition of the zinc metal onto your carb. If you use two anodes, you will build up more zinc on the sides facing the anodes. Now, you can help offset that by increasing the spacing between the anodes and your part. This will make the deposit more uniform, but it will never be as uniform as using anodes on all sides of your part. Increasing the solution flow will also help prevent burns in the high-current-density areas of the part. It won't help with deposit uniformity. As long as you have a good amount of flow across the entire part (coupled with enough wetter) you shouldn't have to worry about burning the part unless you

VOLUME 1, ISSUE 1 really crank up the current. Ideally, you'll have anodes on all sides of your part if you want maximum uniformity. As for the amount of anode surface area that you need, I'll make some assumptions. First, I'll assume that you are using an acid electrolyte. You will want the same amount of anode surface area as your part surface area AT THE MINIMUM. Most people have 1.5-2x the anode surface area than the part surface area. You will have to calculate the surface area of your carb and use that number to determine how much anode surface area you need. Does this help, or am I on the wrong track? Toyota111: Ok, yes you are very helpful; you’re the pro. I’ll try it!! Thanks for your help.

Join in on this conversation and other finishing discussions at www.finishingtalk.com. Maybe your advice, views, or opinions will end up in a future installment of ‘From the Forum’.

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PROTECTIVE COATINGS NDT - SUBMITTED BY JAMES DEARDORFF When fossil fuels are converted into energy they produce carbon dioxide a green house gas. Each year, 6.1 billion metric tons of greenhouse gases are added to the atmosphere. Greenhouse gases causes global warming, severe climate changes, rising sea levels, and diminished land usage patterns. Experts generally agree that no combination of alternative technologies will replace the worlds’ dependence on fossil fuels in the near future. Corrosion is a terrible waste of energy and costs the United States economy over $500 billion per year. This represents 6 percent of the Gross Domestic Product (GDP) valued at $8.79 trillion. Using a simple comparison, the annual cost of corrosion equals the cost of 5 billion barrels of oil. Advanced Maintenance Technologies (Background) In the early 1960’s, the crash rate for jet aircraft was alarming high. In an attempt to reduce crash numbers American Airline’s senior management with the approval of the Federal Aviation Agency (FFA) began intensive engineering studies on in-service aircraft. The studies proved that the major assumption that every component in first generation jet aircraft had a specific “lifetime” of reliable service after which had to be repaired or replaced in order to prevent catastrophic failures proved to be wrong in virtually every specific case. Many of the discoveries made by the airline revolutionized the maintenance discipline for industrial assets. This has been the basis for a new generation of highly effi-

cient maintenance programs known as: Reliability Centered Maintenance (RCM). Currently, industry recognizes four major maintenance classifications. -Reactive -Preventive -Predictive -Reliability Centered Maintenance (RCM)

Reactive Maintenance is where

an asset is allowed to operate to failure before repairs or replacements are performed. It is estimated that 55% of all industrial repairs are based on reactive maintenance.

Preventive Maintenance is where

repairs or replacements are scheduled at predetermined time intervals. Work is based on performance estimates and operational histories. It is estimated that 31 % of all industrial repairs are based on preventive maintenance.

Predictive Maintenance is where maintenance is scheduled based on current asset condition. Predictive maintenance relies on the precise evaluation to detect minor changes in operational performance. Repairs or replacements are planned before a major performance changes occur. It is estimated that 12 percent of all industrial repairs are based on predictive maintenance. Reliability Centered Maintenance

(RCM). This maintenance concept utilizes preventive and predictive maintenance techniques with root cause analysis. RCM

is based on a program of scheduled inspections to determine when a component has reached a predetermined unacceptable condition. At this point, repairs or replacements are performed to prevent a more costly failure from occurring. The identification of wear stressors, by root cause analysis, can aid facility owners in improving the effectiveness of future maintenance operations through design changes or modifications. Saving Comparison - 0% Reactive - 25% to 35% Preventive - 45% to 55% Predictive - 60% to 80% RCM with root cause analysis, Protective Coatings NDT Protective Coatings NDT removes the cost, production, and technical barriers that prevent the coating industry from using Predictive or Reliability Centered Maintenance programs. PC/NDT is based on the formulation of coatings to fluoresce at a specific wavelength (365nm) in the electro-magnetic energy spectrum. When fluorescent coatings applied in alternating layers with non-reactive (NR) surfaces or standard NR coatings, black light produces an Enhanced Visual Signature (EVS) that dramatically increases a workers ability to locate, define, and repair coating. PC/NDT is the only quality control process that has an inspection speed comparable to the application rate of modern spray equipment. Line of sight inspec-

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VOLUME 1, ISSUE 1 tions can be performance as fast as the hand can more a black light and as fast as the human eye can follow. The following explains the procedure for black light inspections:

Fluorescent Primer EVS: Film coverage defects are located by the dark shade of bare metal showing through voids in the fluorescent primer.

Finish Coat NR Applied Over Fluorescent Primer EVS: Defects are located by the glow of the fluorescent primer shinning through voids in the NR finish coat. Note, this combination is the most visible of the NDT / EVS inspection process.

Complete System making maximum use of NDT / EVS technology: -Fluorescent Stripe Coat EVS -Primer Coat NR -Fluorescent Intermediate Coat EVS -Finish Coat NR

ergy, in the form of photons, causes one or more electrons to be “kicked up” into a higher energy state. These electrons are extremely unstable and will eventually lose this excess energy and return to their original state. This release of excess energy is what we see as fluorescence. Black Light Black Light also known as Wood’s Light, Blue Light, or Long Wave ultraviolet, is a form of Electromagnetic energy that occurs just below the visible end of the visible light spectrum. This low energy wavelength covers the range between 320 and 400 nanometers (NM). Unlike ordinary light bulbs that create light by moving electricity through a filament wire, black light is produced by sending electricity through a tube filled with an inert gas (such as argon)) and a small amount of mercury. An electric spark passed across an electrode makes the mercury atoms move a high velocity. As they slow down they release excess energy in the form of Black Light UV-A. Solid State Black Light

PC / NDT Maintenance Operation When coatings are inspected for damage to plan for maintenance repairs, defects are located by the fluorescence of the based coats showing through faults in the non-fluorescent finish coat. Fluorescence More than 3,000 natural and man -made substances can transform invisible energy into longer visible wavelengths that produce fluorescence. These substances react because they composed of easily excitable molecules. When exposed to black light this en-

In the past, a major problem with black light inspections is the inability to produce a noticeable fluorescent response in normal light. This problem has been virtually eliminated with the introduction of new, solid state, black light inspection lamps. These new lights make use of transistorized power supplies and state-of-the-art bulb design for increased power and intensity. Advantages -Produces 10 times the power and intensity found in conventional lights -Produces a minimum of 40,000 uW/ cm at one meter -Light Weight -Cool to the touch Solid State Black Lights provide a tremendous advantage over traditional models due to their increased power and inspection range. Coverage defects 4 to 8 feet from the black light focus point will begin to fluoresce when scanned by solid state lamps. This saves time and inspection costs for large surface areas.

Continued on next page...

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PROTECTIVE COATINGS NDT - CONTINUED -Return On Investment (ROI) 10 fold (based on rising energy costs).

Black Light Laser Sight The solid state black lights have a range of 50 to 100 feet. At this distance it is difficult for workers to determine exactly where the black light energy is focused. (black light is invisible until it comes into contact with a fluorescent material). The laser sight attachment is fitted directly to the light and allows workers to perform accurate, long range inspections of surfaces. Primary Corrosion Sites Virtually all man made structures contain areas that are commonly known as primary corrosion sites. These points include welds, joints, corners, edges, nuts, bolts, rivets, fasteners, cracks, cervices, or anywhere there is a sharp change in surface contour. The use of a fluorescent “stripe” coat can perform a dual function for reducing premature failure for primary corrosion sites. For welds, cracks, and crevices black light insures complete wetting of voids. For joints corners, or edges black light shows where coatings have cured away from a sharp edge and require additional film thickness. Two-Component Mixing Many applications specify twocomponent coatings due to increased chemical resistance and durability. To insure that performance standards are achieved it is important that the part A (base) is completely blended with the part B (activator). By adding fluorescence to part B and mixing with part A until a solid EVS is achieved complete blending is

-Increased equipment and structure life -Reduced corrosion related repairs, downtime and early replacement costs -Improved performance and operational readiness

Maxima 3500 Black Light (Spectroline)

insured. Note incomplete blending produces a candy cane effect under black light. Training PC/NDT provides a valuable training tool for new workers learning basic application techniques. In addition, EVS allows experienced applicators to make “real time” adjustments for specification changes, varied structural designs, or new coating formulations. One of the most effective training programs would involve applying fluorescent coatings in a total black light working environment. Under true black light illumination there are only two major shade variations, black for metal surfaces or standard coating and the particular shade for fluorescent coatings. Advantages The two major advantages for Protective Coatings NDT are the virtual elimination of catastrophic coating failure and crisis condition recoating. Additional advantages include:

-Improved worker safety and moral -Reduced wastes and disposal costs -Reduced VOC’s and negative environmental impact -Improved remanufacturing and recycling potential -Lean Engineering, A reduced need to over-design products to resist corrosion. -Reduced energy demands for corrosion prevention maintenance programs. Maintenance Personal The savings produced by PC/ NDT would allow facility owners to hire full time coating engineers to monitor and schedule maintenance operations based on black light evaluations. Safety As with any high energy illumination source, safety precautions should be followed. Black light (UV-A) requires no protective clothing but, it is recommended that uv blocking eye ware be worn during black light quality control inspections. These spectacles make coating defects easier to see by increasing fluorescent contrast. They also, protect

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VOLUME 1, ISSUE 1 eyes from repeated uv exposure. Note, in 2007 no major airline accidents were reported in the United States. References:

“Corrosion Costs and Preventive Strategies in the United States” 2002, US Federal Highway Administration Highway research Center. “The Coating Consumer: Understanding Initial and Long-Term Painting Costs”. Dec 1993, Gordon “Brevoot, The Journal of Protective Coatings and Linings”. “Performance of Coating Systems Using Numerical Life Predictions” July 1998, Neil P. Adamson, Journal of Protective Coatings and Linings”.

August 1994, Materials and Performance an Offical NACE Publication. “Black Light Measurement for NDT Copyright @ 1983 The American Society for Nondestructive Testing “Shedding Light On UV Test Equipment” Sept 1992, Quality By: Les Davis

Progress,

External Links, “http://en.wikipedia.org/wiki/ Reliability Centered Maintenance (RCM).

Dec 1992, Journal of Protective Coatings & Linings, Volume 9, Number 12 Innovative Practice, “Industrial Coating System Simplifies Inspection”. August 1994 Materials and Performance an official NACE publication Focus on Industry, “Black Light Reactive Coating Eases Flaw Detection”. March 1994, Pipeline Digest “Quality Control, Savings in New Coating System”.

Published Articles Nov 1992, Industrial Finishing

“Economics of a Total Maintenance Coating Program”.

Detection”

Technology Update:, “Black-Light Early-Warning Coating-Defect

Nov / Dec 1995, PWC, Painting and Wall Covering Contractor, Industrial Products,“Black Light

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F I N I S H I N G S P O T L I G H T , CONT FROM PAGE 5... medical and environmental hazards, and organizational management applied to cleaning work. The chapter themes are: (1) how the unit operations of cleaning, rinsing, and drying work, (2) environmental regulations and trends from a global point of view, (3) hazard management and recognition, (4) process control using simple and powerful techniques well-known in other industries, (5) evaluation of cleanliness quality, (6) specific equipment guidance, and (7) special topics such as particle removal and how to purchase new equipment. There are two appendices, one of which provides specific instruction on use of spreadsheets to manage cleanliness based on statistical principles. FTalk: What kind of impact do you think current

environmental and global issues will have on parts cleaning? JD: They are everything! Globalization is driving prices that customers are willing to pay down by large increments. Differentiation between developed and developing countries in international environmental regulation generates contempt for the

former and a cost advantage for the latter. FTalk: You will be teaching a workshop on clean-

ing technology later this year at the annual Southern Metal Finishing Conference in Charleston, SC. Who will benefit from taking this course, and what should they expect to learn during the class? JD: The course includes most of the materials mentioned above in Management of Industrial Cleaning Technology and Processes. But the course material is tailored for those doing aqueous cleaning in the finishing industries. If you read, or should read, Metal Finishing Magazine, you should attend this course. Ftalk: Will you be giving presentations or speak-

ing at any other locations this year?

JD: Yes. I will be speaking at both the Sixth International Symposium on Contact Angle, Wettability and Adhesion; and the Eleventh International Symposium on Particles on Surfaces: Detection, Adhesion and Removal. Both will be held July 16 18 (2008) at the University of Maine, Orono, Maine. My workshop, 21st Century Cleaning Technology, may also be presented in locations other than Charleston; these locations are still being determined, and will be announced at a later date. FTalk: Do you have plans for another publication

in the near future?

JD: I am completing preparation of forthcoming book Solvent Cleaning for the 21st Century, also to be published by Elsevier, in 2009. I write monthly columns in Metal Finishing Magazine, Controlled Environments Magazine, and Galvanotechnik Magazine; and contribute occasionally to Process Cleaning Magazine. ~FT~

For more information about Dr. Durkee, he can be reached directly phone at (830)-238-7610 or by e -mail at [email protected]. Visit his website at www.precisioncleaning.com. For information about his upcoming workshop hosted by the International Surface Finishing Academy, visit www.surfacefinishingacademy.com.

VOLUME 1, ISSUE 1

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THE LAST WORD GREENING YOUR SUPPLY CHAIN

A

cross the U.S. and around the globe, large companies are taking it upon themselves to shrink their environmental footprint – a dramatic and important step towards a cleaner, and more environmentally sound future. Realizing that it’s not just regulations that are forcing the change – but an equally worrisome rise in energy costs and quality issues – manufacturers are taking matters into their own hands. And they are starting with their suppliers. According to a recent survey of supply chain professionals carried out for eyefortransport’s ‘Green Transportation and Logistics Report’, green issues are rated by 94% of executives as a business priority. This is occurring in response to the high demand by large manufacturers – corporate giants such as Wal-Mart who are leading the way by revaluating and reorganizing their current supply chain (which is responsible for 92% of the retailer’s environmental impact) - to be more environmentally friendly. Ship Smart The number one energy culprit in industry is transportation and logistics – making up a whopping 75% of a company’s carbon impact. By making efficient shipping decisions, such as planning a shipping route that will transport the most products with the least wasted energy and money, companies can reduce their carbon footprint and save money. Look at the Big Picture The concept of Green Supply Chain Management – taking into account the entire life cycle of a product and the culmination of its environmental impact – is something that is taking hold in industry right now. Due to demands from consumers, government, and advocacy groups,

BY: ANNA LEVITSKY, EDITOR

many companies are now evaluating the environmental impact of a product, from ‘birth’ to ‘death’. This cycle encompasses the product’s design, the sourcing and selection of material, the way in which it is manufactured, purchase by the consumer, maintenance of the product, and finally its disposal, is taken into account. Get to Know Your Suppliers According to the EPA’s “Lean and Green Supply Chain” Guide (Jan. 2000), “direct interaction with supply chain partners can enable a company to reduce total inventory levels, decrease product obsolescence, lower transaction costs, react more quickly to changes in the market, and respond more promptly to customer requests”. Many companies have begun to reduce their supplier base down to only a few key suppliers, and “implementing lean manufacturing methods”. Get Started The Lean and Green Supply Chain guide suggests a four step program to making your supply chain more efficient: 1. Identify Costs: Review materials management practices to identify areas and activities that incur significant environmental costs. For example, the electroplating industry tends to spend resources on large storage and waste treatment areas within a facility. Therefore, storage costs would be an ideal place to start. Two common approaches to identifying sources of environmental costs are materials tracking and EH&S performance reviews. 2. Determine Opportunities: Which identified areas provide the greatest opportunity for improvement? This can be accomplished by implementing Pareto diagrams and other bar charts to display environmental costs by supply chain activ-

ity and to rank opportunity areas by value. It can also be accomplished by identifying the root causes of wastes by constructing cause-andeffect diagrams or by continually asking why certain problems or procedures exist. 3. Calculate Benefits: Next is the calculation of costs and benefits of various options. You can conduct quantitative evaluations, which rely on empirical Data (for example, the Internal Rate of Return (IRR) and Economic Order Quantity calculations are two methods). Another approach is through qualitative evaluation, based on observation and judgment. 4. Decide, Implement, and Monitor: After completing the first three steps, the last step to take into consideration involves making a decision, implementing the changes, and monitoring progress. Without these things, your management plan will either fall through or never even begin. It will be, essentially, ‘unsustainable’ – which is exactly what you are trying to move away from. It will take time and patience to get your supply chain where you want it to be. There are steps that can be taken to make the transformation to a greener management system, and as long as you are willing to do the research, communicate your goals, and keep track of your progress, you will be on your way to sustainability. It won’t hurt that you will probably increase product quality, boost consumer confidence and respect for your company, maybe even get some government or private organization recognition for your effort, and of course, save money. Not to mention the planet will thank you.

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Rutherfordton, NC 28139 March 2008 Anna Levitsky, Editor Phone: 704-995-2263 [email protected]

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