Valley Chrome Plating’s Journey To
Environmental Compliance through E.M.S.
Valley Chrome Plating
Company History
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Founded 1961
Originally Job Shop
 Car bumper routes
Production Decorative
Electro-Plating
Family Owned
Ray Lucas
President: Valley Chrome Plating Inc.
Director- at- Large: NAMF Membership Chair
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Manufacturer of Truck Bumpers
Zero Discharge Hoist Plating Processes
1st Plating Shop in U.S. to be permitted for
Nickel Air Emissions.
Participant in Environmental Management
Systems
In application process for OSHA VPP Star
Program
Valley Chrome Plating Inc.
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High-level of environmental compliance
prior to implementing an EMS
EMS was the catalyst for achieving the
next level of environmental compliance
and significant $$ savings
Regulatory Changes
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Clean Water Act of 1977
 Catalyst
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Increased Public Scrutiny
 High
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for Inspections
Profile Cases
Expanded Regulations
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Discharge limits 3.5ppm -1.3 ppm
Ion Exchange
Closed Loop Technology
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Nickel
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Counterflow Rinsing
Filtration
Carbon Treatments
Trial & Error
Spray Rinsing
Chrome
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Counterflow Rinsing
Evaporation
Porous Pots
Dummying
Nickel Process Changes
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Carbon Anodes
 Reduction
of Nickel Metals
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Re-Use of Nickel (post generation)
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Dead Rinses
 Allows
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for re-use of chemical
Each rinse improves water quality 100%
Pre-Plating Improvements
Necessary to Achieve Zero
Discharge & Waste Reduction
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Ultraviolet light
Filtration
Ozonator
Counter flow rinsing
Weirs & Oil Superator
Evaporation
Batch Treatments
Effects of Achieving Zero Discharge
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Positive Side Effects
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Saving H2O
No discharge to POTW
Re-use of Chemicals
 Resulting in $$ savings
Negative Side Effects
Poor Rinse Quality
 Higher reject rate (in house/in field)
 Higher Waste Treatment Costs
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Environmental Compliance /
Reduction of Discharge
Sleep Factor
Amount of Sleep
(used w ith permission -Jim Miille Chemical Solutions Inc.)
VCP Environmental Goals
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Water Reduction
Waste Reduction
Scrap Metal Reduction
Electricity Reduction
Storm Water Runoff Capture and Use
E.M.S. = Water Reduction
1999
2002
3,200,000
3,500,000 986,000
2003 *
3,200,000
615,500
Gallons
3,000,000
2,500,000
2,000,000
986,000
1,500,000
615,500
1,000,000
500,000
0
1999
2002
Annual H20 Use
2003 Projected
Waste Reduction
Waste Hauled by Year
180,000
170,379
157,336
160,000
124,253
120,000
105,164
99,500
100,000
80,000
60,000
40,000
20,000
2003 P
2002
2001
2000
0
1999
Lbs of Waste
140,000
Scrap Steel Reduction
Scrap Steel Generation
1,400,000
1,312,480
1,148,050
1,200,000
Lbs
1,000,000
800,000
600,000
400,000
200,000
0
2001
Year
2002
Kilowatt Reduction
1,800,000
1,600,000
1,479,120
1,400,000
kw per year
1,260,724
1,115,902
1,200,000
1,137,732
1,024,332
1,000,000
800,000
600,000
400,000
200,000
0
2000
2001
2002
2003 P
Co-Gen Oct 03
Storm Water –The Next Goal
Capture & Re-Use
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Capture & Re-use of all rain
water landing on our facility
Environmental Lawsuits will
require metals
and other limits in runoff.
Use of runoff will help reduce
plant water usage.
Elimination of permit and
regulatory reporting
requirements
EMS 2003 Projected Net Savings
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Hazardous Waste
= $45,000
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Water
= $ 2585
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Scrap
= $25,000
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Electricity
= $25,000
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Total Projected Savings
$97,585
Valley Chrome’s Future
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Role Model For Industry
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Sharing of Knowledge
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Waste Reduction
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ISO 14000
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Voluntary Protection Program
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100% Capture & Use of Rain H20
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Safety Hour
Capture H20 from air
US EPA Performance Track
Plating Industry Future
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Sharing of Resources & Solutions
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Coordination Between Agencies
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Survive together or die together
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Increased scrutiny by regulators and public
Disintegration of supplier base.
Disintegration of customer base
 Other modes of coating