CASE STUDIES

Company

Colorado company that manufactures circuit boards

Waste Stream Targeted

D001 Ignitable Wastes (isopropanol, flux, fuse oil) in the Solder Coating Process.

Original System

Circuit boards were micro-etched (removes thin layer of copper), triple rinsed with water, dipped into an isopropanol tank (IPA, de-watering device before flux), dipped into a flux tank (HCl reacts with copper, for solder bond), and finally, into the solder pot (1000 lb. molten solder dip). A thin layer of fuse oil was then coated over the lead. The IPA and flux tanks had to be dumped once/2 weeks (50 gallon tanks).

New System
(with P2 Modifications)

On a conveyor system, circuit boards are micro-etched, triple rinsed, hot air dried (replaces IPA drying), and automatically fluxed with a flux applicator (roller applicator, makes and applies flux), which eliminates flux waste (thin coat applied is used up on the solder). This system eliminated the 45-gallon flux tank change out. A Hot Air Leveler automatically applies the solder with fuse oil, eliminating the fuse oil waste.

The new system cost ~ $150,000.00 (including installation).

Material Cost Savings

Under the new system, company saves ~$6600/yr in material costs.

Waste Disposal Cost Savings

Under the old system, 56 barrels/year of D001 (blend) waste was disposed of @ $275.00/barrel. This waste was eliminated with the new system at a waste disposal cost savings of $15,400/year.

Total Cost Savings

$22,000/year

Payback Period

6.8 year

Major Benefits

Total cost savings of ~$22,000/year.
Reduced hazardous waste generation and regulatory requirements. Increased quality, and improved business image.

Obstacles

High capital costs.

Key to Success
in Making this
P2 Modification

Management commitment to spending money on pollution prevention.