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K &L
K&L is a small electroplating job-shop located in Lancaster, Pennsylvania. Since 1955, the company has provided plating and metal finishing services including nickel, chrome, zinc, electroless nickel, phosphating, passivation and irridite (a chemical process on aluminum). Since taking over ownership in 1996, James Struck has overseen a shift in the way K&L does business. “There was a lot of room for improvement when we started,” Mr. Struck said. An important part of the new company philosophy was joining the SGP. Mr. Struck is excited about the competitive edge the SGP has provided by reducing overall costs associated with the finishing process, and feels that being more efficient has allowed K&L to maintain competitive pricing. K&L’s efforts have been rewarded; in 2000, K&L reduced wastewater discharges by more than 44%, while increasing production some 180%.K&L has made excellent progress in reducing its impact on the environment. Water volume savings are two million gallons annually, accomplished through the use of flow restrictors, spray header rinsing and improved operator practices. This saves the company $6,000 each year. Water treatment savings conserved 3,000 pounds of sodium hydroxide and 2,300 pounds sulfuric acid annually by using spent cleaners and acids instead of raw materials to neutralize pH. This change and the elimination of cyanide processes resulted in savings of $20,000 annually for wastewater treatment. The installation of a filter press to dewater sludge resulted in a reduction of 40% in the water content of sludge. The cost to remove the sludge is now $175 per ton instead of forty cents per gallon.
K&L also made changes to several systems. The company converted and/or eliminated all cyanide-bearing plating solutions in 1999. This change eliminated the use of approximately 2,000 pounds of both zinc and sodium cyanide and 18,500 pounds of sodium hypochlorite solution used to treat wastewater annually. Mr. Struck comments that, “It is dangerous to work with cyanide, plus we eliminate cost of treatment, and the dangers of being out of compliance.” K&L is now using alkaline solutions instead of cyanide.
K&L also closed the loop on its hexavalent chromium process through atmospheric evaporation, resulting in zero chemicals or water to waste treatment. Chromium is returned to the tank, effectively eliminating the need for 1,000 pounds of chromic acid annually. No chrome is going to waste treatment. The company is also recycling 30% to 40% of treated wastewater back to nonessential rinsing processes.
Mr. Struck is enthusiastic about the benefits of the SGP. “The Pennsylvania SGP created a first time opportunity for plating companies to openly communicate with industry and regulators as a whole. Bravo!” For more information on K&L’s SGP progress, contact James Struck at (717) 397-9819.