Case Studies
Dura Automotive Systems are a major first tier supplier to the Automotive Industry with seventy facilities in fourteen countries worldwide. Clearwater Industrial has enjoyed a strong working partnership with Dura's UK e-coating facilities in Nottingham and Stourport (formerly Rearsby) for over fifteen years.
In August 2001, Clearwater Technologies -- the plant installation division of the Clearwater Group -- contacted the Nottingham site regarding new Directives that were affecting their market sector. In this case it was the Chemical Agents Directive and specifically lead in paint that was the focus of the attention. The corrosive nature of unleaded paint meant extensive changes to the mild steel paint circulation infrastructure. Aware and as always keen to stay ahead of impending legislation, the management team invited Clearwater to table a proposal to make the necessary plant alterations to facilitate this move. Always mindful of enhancement, Clearwater outlined a solution that not only facilitated the basic needs of the project, but several alterations that made the proposal a far more rewarding investment.
With several similar projects already completed that year and with strong working relationship already in place within the group, Clearwater's proposal was accepted.
Being a first tier supplier to the automotive sector, it was imperative that any plant alterations did not affect production. Clearwater's engineers also had to be mindful at all stages of strict Health and Safety policies on site. In keeping with the above the entire project was completed and commissioned within the summer shut down period.
Undertaken enhancements:
- Relocation of key equipment -- easing operation and maintenance saving both time and frustration
- Improved clarity of process -- the location of simple monitoring equipment, allowing greater control and peace of mind.
- Improved Ultrafiltration -- the addition of further membranes, creating greater volumes of Ultrafiltrate. This improvement to counter flow saves paint, ensures re-working is kept to a minimum and aids the continuum of high quality finishes.
- Improved paint bath turnovers -- closer specification of pumps in the system significantly reduces the potential for settlement and problems with finish.
- Upon completion operation and maintenance manuals were submitted to ensure that once Clearwater let site, the new system could be operated and maintained correctly.
- Keith Walters, Production Director said: "Clearwater dealt with the installation effectively and efficiently in the time stipulated."
Since installation, Clearwater Technologies and Dura Automotive continue to benefit from a close working relationship.
Burnsall Ltd is a leading electro-painting, powder coating, chemical blacking and phosphating business with clients throughout the UK and Europe.
As a second tier supplier to the automotive industry, Burnsall have operated at the forefront of manufacturing for over 30 years.
Due to their inclusion in this critical loop, Burnsall found themselves falling within ever-tightening Directives from both commercial vehicle manufacturers and the European Union. Compliance in this particular project meant the removal of lead in their painting process.
Burnsall in line with the majority of plants used mild steel pipe work and components in their paint plant. Unleaded paint by nature has a corrosive effect on this type of steel and therefore all mild steel had to be replaced before the new paint could be fed on.
Clearwater Industrial was invited to table a proposal for a full system conversion and an evaluation of the current process to site any improvements that could be made. At all stages our engineers had to be mindful of process disruption, system life expectancy, process control and monitoring.
The Solution
Clearwater's proposal not only satisfied the primary remit of this project, but also cited several enhancements that eased both operation and maintenance. This in-depth knowledge of process and attention to detail ensured Clearwater were named as the supplier of choice.
Implementation was scheduled for Burnsall's October shut-down with a detailed timing plan. The upgrade was completed within a week and fully commissioned in time for the delivery of the new unleaded paint.
Since installation, the new system has worked without fault. Clearwater has since installed a new cleaning system for Burnsall's Ultrafiltration unit, which we continue to regularly service.
Managing Director Ron Chew commented: "From as early as the design phase we knew Clearwater were the company we felt most comfortable with. The implementation was as smooth as we could have hoped for and our customers saw a seamless transfer."