Using a degreasing bath oil separator in a bypass circuit reduces chemical consumption before automotive components are coated.
An automotive-parts supplier and manufacturer operates an electroplating line to apply surface coatings to its components.
In the first process step, every component passes through a degreasing bath to remove residual production oil, grease and particulate contamination. This prepares the surface for the subsequent coating process and helps achieve the best possible coating quality.
The automotive-parts manufacturer noticed that chemical consumption in the degreasing process was rising significantly, requiring frequent replenishment of the bath.
The active ingredients in the degreasing agent were continually consumed as they bound to the removed oil and contamination. The effective chemical concentration therefore declined quickly, driving up operating costs.
At the same time, insufficient or delayed replenishment reduced cleaning performance. Oil gradually accumulated at the liquid surface and formed a visible floating layer, increasing the risk that components would carry oil into the coating stage and compromise the final coating quality.
Both problems—higher chemical consumption and increased product-quality risk—had the same cause: oil was accumulating in the degreasing bath instead of being continuously removed.
As the oil concentration increased, the company had to replenish chemicals more frequently and faced a growing risk of a floating oil layer forming at the surface.
To evaluate the solution, the automotive-parts supplier first rented a FRIESS Skimmtelligent oil separator for a trial.
Although the trial unit was undersized for the bath volume, the effect became apparent quickly:
Following the successful trial, the customer purchased a FRIESS oil-separation system sized for the degreasing bath.
After commissioning, the results were even more pronounced:
The customer reduced chemical consumption and operating costs while significantly improving process stability and product quality.
The oil-separation system has now operated reliably for two years, and the customer is highly satisfied with both its performance and the results achieved.
A compact bypass unit for separating oil that does not readily rise to the surface.
Integrates FRIESS 1U oil-skimming technology to continuously discharge separated floating oil.
