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Utica Metal Products partnered with the New York State Pollution Prevention Institute (NYSP2I) to uncover innovative strategies for minimizing waste and reducing solvent use. As a trusted manufacturer of automotive emblems, fuel doors, and wheel caps, the company recognized the importance of balancing high production standards with environmental responsibility.

The Challenge: Addressing Solvent Use, Water Consumption, and Chemical Waste

Like many manufacturers, Utica Metal Products had to balance high-quality standards with minimizing environmental impact. The team identified key areas for improvement within their metal finishing, plating, and wastewater treatment operations that demanded attention.

• Hazardous Solvent Use: The company consumed 110 gallons of N-Propyl Bromide (nPB) annually for cleaning processes. While effective, nPB posed significant environmental and health risks and generated hazardous waste requiring costly disposal.
• Excessive Water Usage: In 2022, Utica Metal Products used approximately 449,000 gallons of water. This level of consumption highlighted the need for improved recycling methods to reduce wastewater output and associated chemical treatment costs.
• Chemical Waste: The wastewater treatment system’s reliance on excessive chemical dosing contributed to high waste generation and unnecessary expenses, particularly in managing hazardous sludge.

Utica Metal Products knew there was a better way to balance environmental goals with operational efficiency, so they partnered with NYSP2I for expert guidance.

The Solution: Innovative Strategies for Sustainable Operations

Through meticulously evaluating the company’s processes, NYSP2I developed customized solutions that targeted the root causes of solvent dependency, water waste, and chemical overuse. The improvements included:

1. Replacing Hazardous Solvent with Aqueous Cleaning

NYSP2I explored advanced cleaning technologies such as Vacuum Cycle Nucleation (VCN) and ultrasonic cleaning methods. After rigorous testing, a cost-effective alkaline aqueous cleaner was selected as a direct replacement for nPB. The aqueous solution maintained the same level of cleaning performance while:

• Eliminating hazardous solvent use.
• Removing the need for hazardous waste disposal.

This simple yet impactful change enhanced workplace safety and reduced environmental risks.

2. Optimizing Water Use in Anodizing Operations

Water quality and usage were carefully monitored to identify opportunities for conservation. NYSP2I recommended targeted modifications to the anodizing line’s rinse system, leading to:

• A 50% reduction in water consumption, cutting annual usage nearly in half.
• Implementation of a water recycling system that redirected treated water for reuse, reducing wastewater volumes.
• Reduced chemical treatment requirements by minimizing the flow into the wastewater system.

These changes addressed both environmental and operational inefficiencies, allowing Utica Metal Products to conserve water while reducing costs.

3. Minimizing Hazardous Waste with Precise Chemical Dosing

The wastewater treatment system was overdue for an upgrade. NYSP2I dug deep, running extensive jar tests to pinpoint the exact amount of treatment chemicals needed. The changes were dramatic:

• A 63% reduction in treatment chemical usage, dropping consumption from eight pallets annually to just three.
• A dramatic decrease in hazardous sludge generation from 47,000 lbs/year to 25,000 lbs/year.

By addressing chemical waste at its source, Utica Metal reduced both disposal costs and environmental impact.

The Results: Measurable Environmental and Financial Gains

The collaboration between Utica Metal Products and NYSP2I didn’t just deliver improvements—it created measurable, impactful change:

• Elimination of Hazardous Solvents: The shift to aqueous cleaning eliminated the need for nPB solvent purchases and hazardous waste disposal—removing two drums of waste annually.
• 50% Reduction in Water Use: Water-saving modifications in the anodizing process significantly reduced annual consumption and wastewater output.
• Optimized Wastewater Treatment: Precision chemical dosing cut chemical usage and hazardous sludge generation by over half.
• Annual Cost Savings: Combined improvements resulted in an estimated $40,000 in savings annually.

These achievements didn’t just make Utica Metal Products cleaner—they made us stronger.

Leading by Example: A Blueprint for the Future

Utica Metal Products has proven that sustainability doesn’t have to mean sacrifice. By rethinking our processes and embracing innovative solutions, we’ve shown that waste reduction, cost savings, and operational efficiency can all go hand in hand.

This journey highlights what’s possible when companies commit to doing better—for the planet, their teams, and their bottom line. Visit our website to learn more about Utica Metal Products’ ongoing commitment to sustainability and innovation.