automotive sector report
Cold Formed Products (CFP) installed a new universal degreasing machine at the end of the
production line at its Plaistow factory, which is already cleaning approximately 1 million
aluminium impact-extruded parts a month for automotive and aerospace industry customers.
Solvent solution
OVER 45 years CFP has become a thriving, 40employee
second-tier automotive supplier. The
impact extrusion process it employs can deliver
up to 3000 parts per hour; and it also offers
subsequent CNC machining to supply finished
parts. For degreasing CFP had been using an
ageing open-top solvent tank. This had to change
when the EU’s Solvent Emissions Directive (SED)
came into force in October 07.
‘We heard about the impending legislation
three years ago,’ says technical director David
Binks. He looked first at replacing solvents with
aqueous-based methods but trials were
unsatisfactory, so he revisited solvent cleaning -
specifically hermetically sealed systems. His
solvent supplier suggested Pero machines, he
contacted Kumi and opted for the Pero V1
machine after successful trials in Germany.
CFP has developed its own methods for
measuring part cleanliness that replicate
customers’ procedures. Binks says that a factor in
favour of the Pero V1 was its vacuum system, used
to remove residue from the chamber. Many
competitor systems use a regenerative carbon
stack, which can be a time consuming alternative.
Pero machines employ almost any type of
solvent, from chlorinated hydrocarbons - such as
trichloroethylene and perchloroethylene -
through to methylene chloride, modified alcohols
- such as Dowclene 1601 - and any standard
hydrocarbons - for example, A3 category products
with a flash point in excess of 55°C. A V-Series
system can be changed from one solvent type to
another in as little as one day.
The V-Series machines are hermetically sealed
to provide ‘near zero’ emissions to comply with
the new SED. They are run under partial vacuum
conditions, which helps to lower the boiling point
of the solvent; advantages include improved
energy efficiency, reduced solvent consumption
and the ability to clean more delicate materials
such thermoplastics and coated parts. Solvent
Form follows function
JOONAS Vartola’s Kota design concept was awarded Best Individual Design accolade at the Corus-sponsored private view of the Royal College of Art’s Vehicle
Design Department ‘Connections project held at the RCA in December. The winning design concept was selected from a line up of 15 international students
on the MA vehicle design course at the world’s only wholly post-graduate university of art and design. The four-month ‘Connections’ project tasked students
to generate innovative mobility solutions for those living in rural areas.
The ‘Kota’ concept features highly experimental and advanced structural design to create a vehicle that can be physically connected with other similar
vehicles to provide meeting places in rural communities whenever and wherever required. Jon King, director Corus Automotive Engineering and member of
the judging panel comments: ‘Joonas’ project was very complete and well executed. It has evolved from the idea started in April but has remained true to the
original concept. The feature, structure and form of the project were all excellent and well thought through and Joonas’ presentation was also top class.’
Professor Dale Harrow, Head of Vehicle Design Department at the RCA and member of the judging panel adds: ‘Although Joonas was a deserved winner,
the judging panel was very impressed by the general high level of design on show and our congratulations must also extend to all the students. Our students
have benefited greatly this year from the extensive materials know-how that Corus has been able to provide and this support has helped them to generate the
technically innovative designs we have enjoyed at the show.’
King concludes: ‘Corus is delighted to have sponsored and supported the Connections project in 2007. During the design project, Corus has been on-hand
to provide the students with an insight into the impact of future technologies, and the most effective use of steel materials and technologies. It is great for
Corus to participate in an initiative alongside a world-renowned design institution such as the RCA, which explores the boundaries of car design and brings
together a pool of industry representatives, to help nurture the growth and talent of the next generation of car designers.’
www.automotivepr.com www.corusautomotive.com
56 MWP march 2008
Each basket takes between
150 and 2,000 units
depending on component size
condition is monitored automatically with solids,
oil and water separated as part of the process.
The Pero V1 was commissioned (using
perchloroethylene) within two days with no
interruption to production. ‘So far it has
performed very well’ says Binks. ‘We make around
1 million parts a month here and they all go
through it.’ Cycle times are typically 6 minutes,
but the loading system, which accommodates
four baskets on the conveyor, means ‘the machine
looks after itself for 24 minutes at a time.’
Depending on the size of component, CFP puts
between 150 and 2000 units in each basket. The
machine runs for 10 hours a day, five days a week.
‘In total the Pero machine cleans 2.5 tonnes of
aluminium a day - 25% more than we could do
previously. Furthermore, it only requires cleaning
once every three weeks; we had to clean our
previous open top tank every week without fail -
and the process was much more labour intensive.’
www.kumi-solutions.com
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