Sustainability in Metal Surface Treatment

Technical performance and sustainability go hand in hand

Sustainability in metal surface treatment extends beyond energy and water consumption. The substances used, VOC emissions, employee exposure, process bath maintenance, waste streams, process reliability and the service life of treated components are equally relevant.

AD Chemicals develops and supports chemical treatment concepts that can address several of these factors. Depending on the application, selected technologies may contribute to lower process temperatures, fewer process stages, reduced water or chemical consumption, less sludge formation and a lower demand for cleaning and maintenance.

Alternatives without VOC emissions or substances such as Chromium(VI) are also available for selected applications. These technologies can help reduce emissions and employee exposure to specific substances or vapours.

The achievable results always depend on the substrate, existing production line, application method, bath management, corrosion protection requirements and coating system.

Where chemistry and process optimisation can make a difference

Lower energy and water consumption

Process bath temperatures, the number of treatment stages and the configuration of rinsing zones directly influence the energy and water consumption of a pretreatment line.

Selected cleaning and pretreatment systems can operate at lower temperatures. More compact processes and an effectively configured cascade rinsing system may also contribute to lower water consumption.

The actual saving depends on factors such as bath volume, initial process temperature, operating time, line configuration and the required surface quality.

Efficient use of chemistry and materials

A stable process starts with appropriate product selection, effective bath management and controlled dosing. This allows process chemistry to be used efficiently and helps prevent unnecessary consumption.

Depending on the process, multifunctional treatments can combine cleaning, degreasing, corrosion protection and improved coating adhesion. This may allow treatment stages to be combined and the overall process demand to be reduced.

Lower VOC emissions and employee exposure

Traditional solvent based cleaning and paint stripping processes can result in VOC emissions and employee exposure to solvent vapours. AD Chemicals develops alternatives that can reduce or avoid the use of these solvents in selected applications.

Depending on the product and process, aqueous or VOC free systems may contribute to:

1. Lower VOC emissions during application.
2. Reduced exposure to solvent vapours.
3. Replacement of substances facing increasing regulatory pressure.
4. Improved working conditions around the treatment process.

Product selection must always be based on the specific application, the applicable safety data sheet, the risk assessment and the relevant operating instructions.

Reduced maintenance and more stable process baths

The maintenance demand of a pretreatment line is influenced by bath contamination, sludge formation, chemical stability, carryover and process control.

Lower sludge formation, effective filtration, stable bath parameters and fewer process stages may contribute to longer bath life, less frequent cleaning and fewer production interruptions.

The actual result depends on the installation, production volume, contamination load, process conditions and bath management.

Corrosion protection and service life

Effective pretreatment supports the adhesion of powder coatings and wet paint systems and contributes to the required corrosion protection of the finished product.

A longer service life for metal components can reduce the need for maintenance, repair or replacement. Effective corrosion protection can therefore also contribute to more efficient material use during the service phase.

The required performance is determined by the substrate, application, corrosive environment, coating system and relevant quality standards.

Technical validation comes first

Not every technology produces the same result in every production line. AD Chemicals therefore evaluates the complete treatment process, including:

1. Substrate and surface condition.
2. Type and level of contamination.
3. Process stages and application method.
4. Bath temperature and contact time.
5. Rinsing process and water quality.
6. Required coating adhesion and corrosion protection.
7. Production volume and line speed.
8. Safety and environmental requirements.

Where required, laboratory evaluations, practical testing or production line trials are performed. This ensures that opportunities for sustainability improvements are assessed against the technical and quality requirements of the process.

Part of the AD International sustainability approach

AD Chemicals is part of AD International. In addition to supporting improvements at customer sites, AD International is working to improve its own operations in areas including energy, water, waste streams, packaging, safety and value chain cooperation.

Information about the 2024 sustainability baseline, the management approach and the four ambitions towards 2030 is available on the corporate Sustainability page.

Request a technical process assessment

Would you like to identify opportunities within your pretreatment process to reduce energy, water, chemical consumption, VOC emissions, employee exposure or maintenance? AD Chemicals specialists can evaluate the existing production line and discuss which improvements are technically feasible.