Sustainable switch to solvent recyclates at Mark Metallwarenfabrik

Solvent recyclates CO₂-reduced degreasing

2024-12-05 A guest contribution by Sabrina Deininger | Translated by AI 4 min Reading Time

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The process took a year and a half, but the result was worth it: Mark Metallwarenfabrik GmbH, based in Spital am Pyhrn (Austria), has switched its in-house degreasing to solvent recyclates. This allows the deep-drawing specialist to save around 21 tons of CO_2e per year.

CO2-reduced degreasing: In the cleaning system at Mark Metallwarenfabrik, PER recyclate is now used instead of fresh material.(Image: Ingo Jensen/Richard Geiss) — CO2-reduced degreasing: In the cleaning system at Mark Metallwarenfabrik, PER recyclate is now used instead of fresh material.
(Image: Ingo Jensen/Richard Geiss)

Mark manufactures deep-drawn parts with diameters ranging from 2 to 80 millimeters (approx. 0,04 to 3,15 inches), which are later primarily used in the automotive industry, for example in airbags. High component cleanliness is the measure of all things here. To ensure a smooth transition process, Mark has sought support from Richard Geiss GmbH. The solvent specialist from Offingen (Germany) provides not only the recycled perchlorethylene (PER) but also the expertise.

"For us, it was only logical and consistent to take the step towards solvent recyclates, in terms of sustainability and CO₂ savings," explains Christian Schneeberger from sustainability management at Mark. "We actively address our ecological footprint in all areas, calculate our CO₂ emissions, and rely on circular economy. We wanted to incorporate these efforts into our degreasing process as well," Christian Schneeberger continues.

Gallery

Around 300 wash baskets per shift go through the in-house degreasing process at Mark Metallwarenfabrik.(Image: Ingo Jensen/Richard Geiss)

Sustainable and stable degreasing process: The parts are freed from coolants and particles.(Image: Ingo Jensen/Richard Geiss)

The result is impressive: Last year, Mark already saved 21.26 tons of CO_2e in its in-house metal degreasing. And this is just the beginning, as the transition in the cleaning system is happening gradually. Mark still uses existing fresh material, but only recyclates are delivered as solvent supplies.

Everything from a single source

Mark Metallwarenfabrik is the technology center for forming technology of the Mark Group. Here, the know-how and technology of the deep-drawing specialist are continuously developed. Mark produces deep-drawn parts with diameters ranging from 2 to 80 mm (approx. 0,08 to 3,15 inches), a material thickness between 0.1 and 2.5 millimeters (approx. 0,004 and 0,10 inches), and a maximum length of 150 millimeters (approx. 5,91 inches). At the deep-drawing specialist, everything comes from a single source: from in-house tool and prototype construction, to fully automated assembly, to inspection using eddy current or camera systems. In addition to the automotive sector, Mark also supplies the medical technology, electrical and electronics, and cosmetics industries.

Sustainable and stable degreasing process

It is clear that Mark Metallwarenfabrik also handles the degreasing and cleaning of its metal parts. Around 300 wash baskets per shift go through the in-house degreasing process at Mark; the system operates in three shifts. During this process, the parts are freed from cooling lubricants and particles—and thanks to the solvent recyclates from Geiss, this is now particularly sustainable and CO₂-efficient.

"Initially, we feared that switching to recyclates would require much more stabilization of the solvent bath in our system. But that is not the case. We can still rely on a stable degreasing process," emphasizes Wolfgang Krenn, Head of Surface Technology at Mark. Overall, around 2.3 billion precision steel parts leave the plant in Upper Austria annually.

Recyclates in fresh material quality

The recyclates from Geiss, like the perchlorethylene used by Mark, are in no way inferior to fresh products—on the contrary. "Our recyclates achieve 100 percent of the quality of the original product and score with an environmental plus," assures Bastian Geiss, managing partner of Geiss. The solvent recyclates can be reprocessed almost indefinitely in the distillation facilities in Offingen, reducing the need for newly produced solvents and thus conserving valuable resources.

Pilot plant and cooking tests

Before the final transition of in-house degreasing at Mark, the cleaning of parts with recyclates was tested on an identical system on-site in Spital am Pyhrn. The need for solvent recyclates and stabilizers was determined individually by Geiss. "We analyzed all the oils used in Mark's degreasing system in our in-house laboratory in Offingen, using boiling tests," explains Manuel Huihui, who works in technical support and international sales at Geiss.

Mark continues to use the laboratory service and solvent expertise even after the transition. “By 2025, we want to be chlorine-free with our oils and coolants. We have various oil alternatives in a test run here, and whenever an oil is a consideration for us, we have oil compatibility tests conducted in the lab. This is great support,” Wolfgang Krenn is satisfied.

The modern degreasing system, which now cleans with recyclates, is located in the area of the production hall of Mark Metallwarenfabrik that was expanded in 2017. With the expansion of 10,000 square meters (approx. 11.960 square yards) at that time, Mark doubled its headquarters in Spital am Pyhrn and invested 30 million euros ( 31.581.000 USD) in it. The expansion includes not only the new production hall but also an automatic high-bay warehouse, office spaces, a technical center, and a shipping area.

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Signs point to sustainability

Mark, the deep-drawing specialist with over 100 years of experience, is committed to greater sustainability in various areas – the switch to solvent recyclates in in-house metal degreasing is part of this. From production to external supply chains and logistics, the company transparently calculates its CO₂ emissions with the aim of continuously reducing them. A photovoltaic system provides part of the self-generated electricity, and the building is cooled using well cooling without the use of climate-damaging refrigerants. Through efficient production processes, Mark also minimizes waste, thus conserving resources. "By using solvent recyclates in degreasing, we also promote the idea of a circular economy," emphasizes Christian Schneeberger.

Solvent recyclates CO2-reduced degreasing