Automotive supplier discovers pioneering solution for its PU foam production.
Polyurethane Case Study: Manufacturer switches to water-based release agent.
WHAT WE ACHIEVED.
We helped one of the top automotive parts suppliers in the world shift to Chem-Trend’s water-based product, creating remarkable changes. Total VOC emissions were reduced. A better, safer working environment was achieved. And due to reduced product needs, they saw a 12% reduction in costs. All without significant impact to production efficiency.
HOW WE GOT THERE.
The customer was using a traditional solvent-based release agent solution. For several reasons, including sustainability and new regulations, the transition to a water-based solution became necessary. Their fears were that the shift would come at the expense of greater cost and reduced productivity.
At Chem-Trend, we embraced the challenge: create a water-based solution capable of reducing VOC emissions and improving the working environment. All while maintaining total cost.
While investigating the situation to determine the best product solution, we had the opportunity to identify an application issue: they were consistently overspraying. Through hands-on training, we were able to work with them to recognize a significant reduction in release agent used.
We partnered side by side to coach the operators to properly apply the new release agent before we started the trial run. We also communicated with the process engineer to get his support to let us train the operators shift by shift. We adjusted their new equipment to better utilize the release agent. Ultimately, we helped improve their process, achieving all of their stated goals with almost no change in production efficiency.
In addition, thanks to Chem-Trend’s global reach and local presence, we were able to provide training, consistency, and supply chain efficiency throughout their organization.
At Chem-Trend, we pride ourselves on our long history of sustainability efforts. However, it is our effect on our customers’ processes that provides the greatest impact. It goes beyond our global Footprint; it is our even wider Handprint.
Here, we achieved the following:
- Total VOC emissions were reduced
- Reduced release agent consumption, leading to reduced transportation and shipping needs
- We were able to meet/exceed regulations