Abstract
The European Commission has an objective of improved resource efficiency in manufacturing enterprises (particularly small- and medium-sized enterprises—SMEs) by structural and technological changes. The aim of this study was to demonstrate the concrete improvements as a result of a systematic resource efficiency methodology applied to an SME in surface coating/painting industry in Turkey which is an EU accession country. Within the context of this study, cadmium plating process was substituted with a less toxic and more environmentally benign alternative coating process (silane-based coating). Therefore, cadmium oxide (CdO) and sodium cyanide (NaCN) consumption was eliminated from the processes of the company. Moreover, degreasing chemical consumption of the company was reduced by 92.9 %. Owing to the improvements in the resource efficiency, the total specific chemical consumption of the company was reduced from 44.07 to 16.01 g/m2, corresponding to a chemical saving of 63.7 %. Total annual cost saving was calculated to be 43,372 $/year. It was determined that the annual cost saving (43,372 $/year) was as high as 8.4 % of annual turnover (512.500 $) of the company. The payback period of the implementations was approximately 8.2 months. Based on the outcomes of this study, it is recommended that the resource efficiency concept should be used as a key strategy in Turkey, an EU accession country, to adopt norms and standards set by the European Commission (e.g., restrictions on the use of cadmium and cyanide in production processes).
Similar content being viewed by others
References
Babu BR, Bhanu SU, Meera KS (2009) Waste minimization in electroplating industries: a review. J Environ Sci Heal C 27:155–177. doi:10.1080/10590500903124158
Barros MC, Torres MT, Bello PM et al (2008) Integrated pollution prevention and control in the surface treatment industries in Galicia (NW Spain). Clean Technol Environ Policy 10:175–188
Baum T, Schiffrin DJ (1997) AFM study of surface finish improvement by ultrasound in the anisotropic etching of Si in KOH for micromachining applications. J Micromech Microeng 7:338–342
Dvarionienė J, Kruopienė J, Stankevičienė J (2012) Application of cleaner technologies in milk processing industry to improve the environmental efficiency. Clean Technol Environ Policy 14:1037–1045. doi:10.1007/s10098-012-0518-x
Envirowise (2002) Surface cleaning and preparation: choosing the best option (No. GG354). Oxfordshire, The United Kingdom. http://www.wrap.org.uk/sites/files/wrap/GG354.pdf. Accessed 13 Mar 2013
Envirowise (2003) Cost-effective paint and powder coating: application technology (No. GG387). Oxfordshire, The United Kingdom. http://ec.europa.eu/environment/air/pollutants/stationary/solvents/activities/pdf/d029_paint_and_powder_coating.pdf. Accessed 17 Apr 2013
European Commission (2006) Reference document on best available techniques for surface treatment of metals and plastics (BREF). Brussels, Belgium. http://eippcb.jrc.es/reference/BREF/stm_bref_0806.pdf. Accessed 21 Mar 2013
European Commission (2007) Reference document on best available techniques on surface treatment using organic solvents (BREF). Brussels, Belgium. http://eippcb.jrc.es/reference/BREF/sts_bref_0807.pdf. Accessed 23 Feb 2013
European Commission (2008) Directive 2008/105/EC of the European Parliament and of the council: Directive on environmental quality standards. Brussels, Belgium. http://eur-lex.europa.eu/LexUriServ/LexUriServ.do?uri=OJ:L:2008:348:0084:0097:EN:PDF. Accessed 31 Jan 2013
European Commission (2010) Europe 2020: A strategy for smart, sustainable and inclusive growth. Brussels, Belgium. http://eur-lex.europa.eu/LexUriServ/LexUriServ.do?uri=COM:2010:2020:FIN:EN:PDF. Accessed 29 Apr 2013
European Commission (2011a) A resource-efficient Europe—Flagship initiative under the Europe 2020 Strategy. Brussels, Belgium. http://ec.europa.eu/resource-efficient-europe/pdf/resource_efficient_europe_en.pdf. Accessed 12 Feb 2013
European Commission (2011b) Roadmap to a resource efficient Europe. Brussels, Belgium. http://ec.europa.eu/environment/resource_efficiency/pdf/com2011_571.pdf. Accessed 22 Jan 2013
European Commission (2011c) Directive 2011/65/EU of the European Parliament and of the council: On the restriction of the use of certain hazardous substances in electrical and electronic equipment. Brussels, Belgium. http://eur-lex.europa.eu/LexUriServ/LexUriServ.do?uri=OJ:L:2011:174:0088:0110:en:PDF. Accessed 10 Apr 2013
Fresner J, Schnitzer H, Gwehenberger G et al (2007) Practical experiences with the implementation of the concept of zero emissions in the surface treatment industry in Austria. J Clean Prod 15:1228–1239
Galitsky C, Worrell E (2008) Energy efficiency improvement and cost saving opportunities for the vehicle assembly industry: an energy star guide for energy and plant managers. Ernest Orlando Lawrence Berkeley National Laboratory, Berkeley
Heimann N, Simpson GT (2005) Surface mineralization as an alternative to cadmium plating and hexavalent chromate treatment for corrosion protection. Navy ISA RUST Conference, Louisville
Hu J-M, Liu L, Zhang J-Q, Cao C-N (2007) Electrodeposition of silane films on aluminum alloys for corrosion protection. Prog Org Coat 58:265–271. doi:10.1016/j.porgcoat.2006.11.008
Jiang L-L, Wu L-K, Hu J-M et al (2012) Electrodeposition of protective organosilane films from a thin layer of precursor solution. Corros Sci 60:309–313. doi:10.1016/j.corsci.2012.03.042
Kliopova I, Bagdonas A (2003) Optimization of electroplating processes in Lithuanian machine and instrument industry. J Environ Res Eng Manag 3:29–37
Koefoed M, Buckley C (2008) Clean technology transfer: a case study from the South African metal finishing industry, 2000–2005. J Clean Prod 16:S78–S84. doi:10.1016/j.jclepro.2007.10.023
Li M, Yang Y-Q, Liu L et al (2010) Electro-assisted preparation of dodecyltrimethoxysilane/TiO2 composite films for corrosion protection of AA2024-T3 (aluminum alloy). Electrochim Acta 55:3008–3014. doi:10.1016/j.electacta.2009.12.081
Liu L, Ma X (2010) Technology-based industrial environmental management: a case study of electroplating in Shenzhen, China. J Clean Prod 18:1731–1739. doi:10.1016/j.jclepro.2010.06.026
Materne T, Buyl F ois de, Witucki GL (2006) Organosilane technology in coating applications: Review and perspectives (No. 26-1402A-01). Dow Corning Corporation. USA. http://www.dowcorning.com/content/publishedlit/26-1402-01.pdf. Accessed 22 Apr 2013
Merrikhpour H, Jalali M (2013) Comparative and competitive adsorption of cadmium, copper, nickel, and lead ions by Iranian natural zeolite. Clean Technol Environ Policy 15:303–316. doi:10.1007/s10098-012-0522-1
Ministry of Environment and Forestry—MOEF (2009) Paint/varnish: Guidance document (No. LIFE06/TCY/TR/000292). http://www.iso.org.tr/tr/documents/cevre/boya_vernik.pdf?redirected=1. Accessed 28 Feb 2013
Organisation for Economic Co-operation and Development—OECD (2012) SME policy index Western Balkans and Turkey: Progress in the implementation of the small business act for Europe. http://www.oecd.org/daf/psd/smepolicyindexwesternbalkansandturkey2012.htm. Accessed 31 Mar 2013
Pandey AM (2007) Identification and assessment of cleaner production technologies and appropriate technology management strategies and methods in South African vehicle industry. Masters of engineering (Technology Management), University of Pretoria, Pretoria
Randall PM (1992) Pollution prevention methods in the surface coating industry. J Hazard Mater 29:275–295. doi:10.1016/0304-3894(92)85073-A
Regional Activity Centre for Cleaner Production (RAC/CP) (2002) Alternatives for pollution prevention in the surface treatment sector. Barcelona, Spain. http://www.cprac.org/docs/tsu_eng.pdf. Accessed 26 Jan 2013
Republic of Turkey Small and Medium Enterprises Development Organization—KOSGEB (2012) Enhancing the competitiveness of SMEs in Turkey: Country report. http://www.comcec.org/UserFiles/File/%C3%BClkeraporlar%C4%B1/28_isedak_%C3%BClke_rap/T%C3%BCrkiye.pdf. Accessed 17 Apr 2013
Telukdarie A, Buckley C, Koefoed M (2006) The importance of assessment tools in promoting cleaner production in the metal finishing industry. J Clean Prod 14:1612–1621
Ulutaş F, Alkaya E, Boğürcü M, Demirer GN (2012) The national capacity assessment on cleaner (sustainable) production in Turkey. Sust Cities Soc 5:30–36. doi:10.1016/j.scs.2012.05.006
United Nations Environment Programme—UNEP (2004) Guidelines for the application of best available techniques (BATs) and best environmental practices (BEPs) in industrial sources of BOD, nutrients and suspended solids for the Mediterranean region (No. MAP Technical reports series No. 142). Athens, Greece
United States Agency for International Development—USAID (2009) Metal finishing: Cleaner production fact sheet and resource guide. Washington DC, USA. http://www.encapafrica.org/EGSSAA/metalfinish.pdf. Accessed 26 Jan 2013
Venkatesan G, Senthilnathan U, Rajam S (2014) Cadmium removal from aqueous solutions using hybrid eucalyptus wood based activated carbon: adsorption batch studies. Clean Technol Environ Policy 16:195–200. doi:10.1007/s10098-013-0628-0
Willumeit T (2010) Caterpillar: OXSILAN—Update. France: Chemetall Group. http://docs7.chomikuj.pl/1584148356,PL,0,0,CAT-OXSILAN-internet.pdf. Accessed 12 Feb 2013
Wymenga P, Spanikova V, Barker A, et al. (2012) EU SMEs in 2012: at the crossroads. Rotterdam, The Netherlands. http://ec.europa.eu/enterprise/policies/sme/facts-figures-analysis/performance-review/files/supporting-documents/2012/annual-report_en.pdf. Accessed 13 Feb 2013
Zimmer M-M, König U, Galant S, et al. (2011) Recommendation for an efficient contribution of SME companies to greater resource efficiency within the supply chain of metal finishing by focusing on interdisciplinary branches like surface finishing. http://ec.europa.eu/environment/resource_efficiency/pdf/Galvano.pdf. Accessed 23 Apr 2013
Acknowledgments
This study was financed by Millennium Development Goals Fund (MDGF) within the scope of United Nations Joint Programme entitled “MDG-F—1680: Enhancing the Capacity of Turkey to Adapt to Climate Change.” The authors would like to thank Ferda Ulutaş and Merve Böğürcü for their constructive comments.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Alkaya, E., Demirer, G.N. Improving resource efficiency in surface coating/painting industry: practical experiences from a small-sized enterprise. Clean Techn Environ Policy 16, 1565–1575 (2014). https://doi.org/10.1007/s10098-014-0732-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s10098-014-0732-9