At a Glance

The aim of this project was to reduce

usage of materials and emissions at
two sister electroplating sites.
This involved achieving reduced zinc
and cyanide concentrations in the
electroplating baths without impacting
the quality of the product produced at
the Galway site of Irish Finishing
Technologies Ltd. and its sister site
Waterford Plating Ltd.
Concenctrations were successfully
almost halved. Zinc and cyanide
concentrations were reduced from
27g/l and 70g/l to 14g/l and 38g/l
respectively.
The key benefits were a reduction in
metal hydroxide sludge generation and
a reduction in water use. The
generation of the hydroxide sludge,
which is a hazardous waste, has been
reduced by 40% at the Galway site.
Water use has been reduced by 40%,
saving over 200 litres per round
produced or approx. 2,200 m3 per
annum for IFT (comparing the first
quarter of 2005 and 2006).
The improvement also resulted in
reduced usage of zinc since:
1) the required overall customer
specification for distribution level can
be achieved using a lower amount of
zinc since the lower concentration
provides a more uniform distribution of
metal on the surface, and

CGPP2004/7
The optimisation of
electroplating activities
Irish Finishing Technologies Ltd
Waterford Plating Ltd

Irish Finishing Technologies,

35 39 Ballybane Industrial Estate,
Galway

Zinc plating line

Waterford Plating Ltd.,

605-606, Northern Industrial Estate,
Waterford.

The two sites gradually depleted the

concentrations in the process baths with time.
Cyanide depletes relatively quickly, whereas zinc
reduction took place over a longer period
(approx 9 months). Zinc depletion was achieved
through the replacement of some zinc anodes
with steel anodes.

Irish Finishing Technologies Ltd. is a subcontract electroplating facility located in the

west of Ireland. Founded in 1998, services
provided include anodizing, rack and barrel
zinc plating aluminium conversion coating
and stainless steel passivation. Formed in
1991, Waterford Plating provides subcontract metal treatment services including
zinc plating, aluminium conversion coating,
stainless steel passivation and wet and
powder painting.

Aim of this Project

The aim of the first part of this project was to
reduce zinc and cyanide concentrations in the
electroplating baths of the Galway and
Waterford sites without impacting on the quality
of the product produced.

2) drag out of zinc from the process

solution is reduced due to the lower
concentrations.
A second element to the project was
the introduction of trivalent chromium
passivation
at
Irish
Finishing
Technologies Ltd. to replace the
existing hexavalent chromium process.
This is a less hazardous chemistry and
has been taken up by a number of
major customers.
Example of typical product processed

The second part of this project was to introduce

a trivalent passivation process at the Galway site
to replace the existing hexavalent passivation
finish.

Project Description

At all times during the reduction process, the

quality of product achieved was examined in
relation to the aesthetics of the finish, the
thickness of coating, the level of roughness in
the finish. At the same time these results were
compared to the operating parameters of the
process, namely bath concentrations, current
density, voltage required, temperature and
plating time.
For part 2 of the project involving the trivalent
chromium passivate equipment and chemistry
were sourced. Product trials with the trivalent
chemistry were then carried out. Samples of the
products were supplied to customers and
feedback obtained. Testing of corrosion
protection performance was also carried out.
While performance matched the same
requirements as the hexavalent process, the the
aesthetic finish resulted in a slower than
anticipated uptake of the trivalent finish.
An alternative process was trialled using a
trivalent clear passivate followed by the
application of a colouring dye and a final seal.
This produced the same aesthetic finish as a
hexavalent passivate. However while successful,
this process worked out to be too expensive to
implement.

Achievements
The successful implementation of the project has
resulted in the environmental savings
documented in Table 1. There has been a small
increase in energy use per round produced
(13%), as a result of operating at the lower
concentrations but this additional cost has been
off-set by the other savings.

Water
usage
(m3)
Quarter 1 2005
Quarter 1 2006
Water savings

colour passivate finish. A different approach

has since been taken with the marketing of the
new chemistry as an innovative and high
quality product to meet various specifications.

Water
usage
(m3/round)

1399

0.540

%reduction

859

0.320

per round

540

0.213

40%

Table 1 Total Water savings

More uniform distribution of metal on the

surface of the product was attained due to the
lower zinc in the process and this more uniform
finish was attained in similar process times. This
uniform distribution provides an overall lower
thickness of coating on the finished product
while still maintaining the same performance.
This means less zinc is used while product still
meets customer specification.
Reduced water use and reduced zinc losses in
drag out has resulted in the reduction of water
treatment plant sludge generated by 60%.
More controlled operating conditions have
been implemented with close monitoring of
the process solution which has resulted in a
lower rework count.
In the 12 months since the trivalent process
was operational, there was a 30% reduction in
the level of product going through the
hexavalent process.

More Information
For more information on this project please
contact:
Brendan Marlborough,
Irish Finishing Technologies Ltd.,
35 Ballybane Ind Est, Tuam Rd., Galway,
Ireland.
tel.
fax.

00 353 (0) 91 773 353

00 353 (0) 91 773 363

Cleaner Greener Production Programme

The Cleaner Greener Production Programme
(CGPP) of the EPA was funded under the
National Development Plan 2000 2006. The
CGPP was launched in 2001 as a grant
scheme to Irish organisations to implement
cleaner greener practices while achieving
significant cost savings.
Cleaner Greener Production is the application
of integrated preventive environmental
strategies to processes, products and services
to increase overall efficiency and reduce risks
to humans and the environment.
Production processes: conserving raw
materials and energy, eliminating toxic raw
materials, and reducing the quantity and
toxicity of all emissions and wastes
Products: reducing negative impacts along
the life cycle of a product, from raw
materials extraction to its ultimate disposal.
Services: incorporating environmental
concerns into designing and delivering
services.
The programme aims are focussed on avoiding
and preventing adverse environmental impact
rather than treating or cleaning up afterwards.
This approach brings better economic and
environmental efficiency.
Under Phase 2 of CGPP, 22 organisations were
funded from a variety of sectors (e.g.
chemicals, food, metals, electronics, service).
The total achievements from the projects for
the participating organisations included
annual reductions of 250,000 tonnes in
input/output streams (water/waste water),
660 MWh energy reduction and 1.6m cost
savings.
The programme will continue to be funded by
the EPA in the NDP 2007-2013.

Product samples with hexavalent (left)

and trivalent chromium passivate

Observations
One of the greatest benefits was in the training
and education of staff in the use of cleaner and
more efficient techniques.
The project has resulted in improved operator
awareness the line operators have gained a
more rounded knowledge of the operation
including water, energy and chemical
conservation techniques. The reduction in
usage of water was an area where the line
operators were responsible and therefore a
large emphasis was placed on their training.

Lessons
The implementation of reduced process bath
concentrations at two different sites with very
different operating equipment with no
variation in the quality of product attained
confirms that this project could be duplicated
at other electroplating sites around the country.
In part two of the project the main problem
encountered involved the marketing of the
new trivalent chemistry to customers. The
approach taken was to offer this alternative
chemistry as a replacement for the hexavalent

This case study report is one of the reports

available from the companies that
participated in the second phase of the
Cleaner Greener Production Programme.
A summary of all the projects and CD
containing all the reports are also
available.
More information on the programme is
available from the EPA:
Ms. Lisa Sheils or Dr Brian Donlon,
Environmental Protection Agency,
Richview, Clonskeagh Rd., Dublin 14, Ireland.
www.epa.ie/researchandeducation/research/

Programme Managers...
The Clean Technology Centre (CTC) at Cork
Institute of Technology was appointed to
manage the programme. Established in 1991,
the CTC is now nationally and internationally
regarded as a centre of excellence in cleaner
production, environmental management and
eco-innovation across a range of industrial
sectors.