Project Descriptions

ITI conducted a metal finishing asset condition assessment for Woodward Corporation of Rockford, IL which included type II and type III anodizing, stainless steel, passivation, copper plating and stripping.

ITI conducted a conventional sulfuric (type II) and hard anodizing (type III) process improvement assessment for Woodward Corporation of Rockford, IL. ITI recommended changes to reduce breakthrough of type II anodize maskant and to improve process utilization eliminating the short term need for a planned renovation of the type III anodize line. ITI also develop an experimental design to optimize hard anodizing of 2000 series aluminum parts.
 

ITI developed a metal finishing department renovation master plan of Lisi Aerospace of Torrance, CA which included anodizing, cadmium plating, stainless steel passivation, molten salt descaling, IVD aluminum coating and cetyl lubrication of aerospace fasteners. The primary objectives of the project included:

1.Evaluate opportunities to increase the overall process and/or facility capability, capacity, and reliability

2.Decrease product defects due to equipment design, process chemistry, and/or operational constraints or practices

3.Decrease facility interruptions due to equipment design and/or operational constraints or practices

4.Decrease process operating costs

5.Improve employee health and safety

6.Improve environmental performance and reliability.
 

ITI conducted an audit of metal finishing processes and the industrial wastewater treatment plant at Goodrich Corporation's Landing Gear Division in Oakville, ON and developed a master plan to improve and renovate the industrial wastewater treatment system. The project included process mapping and modeling of wastewater flows, waste stream characterization, development of a process water balance, waste stream segregation planning, and master planning.
 

ITI worked with a confidential client as an expert witness in a dispute between the sellers and buyers of a major aerospace manufacturing company to resolve claims related to environmental costs at one manufacturing site which includes metal finishing operations.
 

ITI worked with Price Industries of Grand Rapids, MI and Metal Improvement's EM Division of Chatsworth, CA to plan, model, and optimize metal finishing processes for a new near zero discharge facility that is currently under construction in China. The plant will perform bulk finishing of aerospace fasteners. ITI assessed production requirements, sized process equipment, evaluated activity based process costs, and designed process rinsing and recovery systems to meet near zero discharge project goals.
 
ITI conducted a feasibility study for Cly-Del Manufacturing of Waterbury, CT with the objective of recycling aqueous cleaning wastewater generated by a rotary screw parts washer. The project included process modeling, evaluation of technology alternatives, technology selection, P&ID development, implementation logistics planning, development of ROM capital and operating cost estimates, and ROI Calculations.
 

ITI conducted a process and facility opportunity assessment (PFOA) for Daido Manufacturing of Thailand with Okuno-Auromex Company (Thailand) Ltd. (OACL) also of Thailand. Daido plates decorative chromium and satin nickel on plastic automotive parts. The primary objectives of this project were to assess opportunities to:

1.Increase the overall process and/or facility capability, capacity, and reliability

2.Decrease product defects due to equipment design, process chemistry, and/or operational constraints or practices

3.Decrease facility interruptions due to equipment design and/or operational constraints or practices

4.Decrease process operating costs

5.Improve employee health and safety

6.Improve environmental performance and reliability

ITI successfully identified opportunities to dramatically improve the facility in each of the above areas, completed a cost-benefit analysis and developed project priorities and an implementation plan.
 

ITI developed conceptual and detailed design of new surface finishing pilot plant for Okuno-AuromexCompany (Thailand), Ltd. (OACL) in Thailand. The scope of work included master plan development, basis of design development, conceptual, preliminary, and final design. The design phases included development of drawings, equipment schedules, and specifications.
 

ITI developed a conceptual design for a new automated decorative anodizing facility for Sritong Electro Chemicals in Thailand with Okuno-AuromexCompany (Thailand), Ltd. (OACL). The project includes manual chemical polishing, automatic sulfuric anodizing, automatic and manual dyeing to twenty-eight (28) different colors, and automatic sealing and rack stripping. The new facility will anodize 24 loads per hour. The work scope included a process assessment, production basis development, equipment sizing, process mapping and modeling, process layout, activity based process costing, and hoist constraint analysis.
 

ITI provided American Airlines with trouble shooting support for diffused nickel-cadmium plating problem.
 

ITI provided Emerson Process and Rowan Technologies troubleshooting support for a gold plating problem.
 

ITI consulted with Hill AFB in Ogden, UT and CH2M Hill to assess and develop conceptual industrial wastewater treatment plant improvements. Our work scope included waste stream characterization, evaluation of alternative technologies to treat chelating agents, and evaluation of up-stream improvements.
 
ITI provided a detailed Scope of Study for the investigation and implementation plan of the facility's ability to consistently achieve future compliance with the effluent limitations for discharge into the Naugatuck River under a new NPDES Permit for Summit Corporation of America in Thomaston, CT. Summit Corporation electroplates copper, tin, silver, gold, and nickel on strip and wire substrates as well as barrel and rack plating of parts with electroless nickel. An Opportunity Assessment was conducted to audit process and wastewater operations and procedures to address problem areas and offer opportunities for improvement in performance. The study identified work required to comply with nitrogen, nickel, copper, cyanide, and aquatic toxicity.
 

ITI designed and constructed a closed-loop chromate conversion coating process for aerospace composite conducting materials including copper and aluminum for Astroseal Products Mfg Corp of Chester, CT. ITI provided design, procurement, and construction management services. The process system included an integrated DI water and vacuum evaporation recycling system without a drain connection to a POTW. The process was developed, including a cascading rinse system, by pilot testing on site and evaluating techniques to reduce drag-out, including vacuum drying and air blow down stations. The field testing provided a unique, ultra efficient rinse system using only 1.8 gph per process line. Submittals were provided to the CT DEP for approval of the ventilation and wastewater systems. Design included P&ID, detailed equipment list, mechanical and electrical drawings. ITI managed approvals, fabrication, on-site electro-mechanical assembly, installation, O & M manual documentation, and start-up.
 

ITI evaluated and modified the metals precipitation and dewatering system for Ansonia Copper and Brass in Waterbury, CT. A 120,000 gallon outside settling basin with rotating sludge rake was damaged and required significant repair. An evaluation of the equipment indicated a better approach would be replacement with an inclined plate clarifier due to reduced flow rates, life cycle, reliability, and maintenance considerations. A plate and frame clarifier was installed to replace a vacuum drum dryer. Improvements were made to the reaction tanks, instrumentation and control systems. Design documentation included P&ID, layout, and tank drawings. An equipment list and specifications were provided for obtaining bids. Construction management included selection of vendors, fabrication approvals, and installation supervision.
 

ITI designed, fabricated, and installed a turn-key, self-contained cleaning station with rinse water recycling system for Sikorsky Aircraft Corporation in Shelton, CT. The station is used for overhaul and repair of helicopter components. The cleaning skid included a polypropylene rotating table for 800 lb load with heated soap delivery system and spent chemical storage system. Design services including P&ID, detailed equipment list, mechanical and electrical drawings. Drawings were presented to the client for approval prior to release to fabrication. The completed assembly was pre-tested and rigged on site. ITI provided design, fabrication, installation, O & M manual documentation, start-up, and training as a lump sum contract.
 

ITI provided a design and specification for heat exchangers for anodizing type II and III operations for Lockheed Martin Space Systems and Tetra Tech Engineering in Denver, Colorado.The design involved special chillers and heat exchange design to produce coolant at 20°F to maintain sulfuric acid bath temperatures at 32ºF. Support included evaluation of customer specifications to enable downsizing of equipment to save capital costs. The system design employed a plate and frame heat exchanger with a glycol pump loop and process chemistry pump loop to handle the heat produced by the anodizing rectifier.
 

ITI designed, fabricated, and installed a turn-key wastewater evaporation system and vibratory recycling system for Hubbell Die Casting, Moultrie, GA. The wastewater contains rinse water from cleaning operations and cooling tower water. The evaporation system eliminates the discharge to the POTW. A wastewater pretreatment system and two gas-fired evaporators operate in parallel at a rate of up to 40 gallons per hour each. The waste volume is reduced by 95% or more, with water removed as water vapor to the atmosphere. ITI also provided a vibratory recycling system to reuse dilute soaps used in vibratory tumbling employing gravity settling with automatic waste bleed and chemical make-up. The system was provided as a modular skid. Substantial savings were realized in chemical, operating, maintenance, and waste treatment costs. ITI design services included P&ID's, detailed equipment list, mechanical and electrical drawings. Drawings were submitted to the client for approval prior to release to fabrication. The completed assembly was pre-tested and shipped tom the site for installation. ITI provided design, fabrication, O & M manual documentation, start-up, and training.

 
ITI provided a feasibility study, in support to DemVal, Inc., for water reuse within the Tinker Air Force Base Metals Finishing Facility. The feasibility study included the use of process modeling to evaluate potential water use scenarios, the preparation of potential water reuse and water use improvement alternatives, and the implementation of water use improvement measures, including installation of rinse water conductivity controls. ITI provided capital and operating cost estimates for each alternative, and provided an assessment on the impact of each alternative on operations, cost, and water use. In addition to the feasibility study, ITI provided project oversight during facility modifications.
 
ITI provided professional services, in support to DemVal, Inc., related to an Advanced 14 Meter Test Cell procurement, including preparation of a detailed Requirements Document (RD), a Basis of Design (BOD) summarizing engine specific design data for the 14 meter test cell, and a study of public/private partnerships that provides a road map to alternatives besides MILCON financing. ITI reviewed global world-class test cells in the 14 Meter size range, discussing approaches and features with test cell providers, engine manufacturers, and end-users to develop a project approach and to define requirements.
 
ITI provided engineering services, in support to DemVal, Inc., related to the evaluation and implementation of a low temperature cure (LTC) powder coat process as a replacement of solvent based polyurethane paints. ITI prepared a test program consisting of a series of physical test to provide a comparative study of key properties including adhesion, erosion and hardness testing on both test coupons and targeted part assemblies. ITI identified potential expansion of applications for the LTC powdercoat, and drafted alternate technical order (TO) language to allow substitution of LTC powder in lieu of polyurethane paints. In addition, ITI prepared specifications for a powder coat system purchase, evaluated bids, and made recommendations for system implementation including the preparation of a depot-wide implementation plan.
 
ITI provided lead engineering services, in support to DemVal, Inc., to implement handheld laser welding at Tinker Air Force Base as a technology that provides repairs for otherwise non-repairable parts and to provide a streamlined in-situ repair to in-theatre aircraft. Under the Foreign Comparative Test (FCT) program, ITI evaluated technology vendors and conducted initial process qualification testing. In addition, ITI completed a detailed process safety analysis using the Operational Risk Management (ORM) approach and developed a refined process qualification test plan. More detailed process qualification testing is ongoing. Upon successful completion of process qualification, ITI will prepare operator qualification and training programs, a detailed health and safety plan, expansion of HHLW applications and assist with equipment purchase.
 
ITI managed and provided expert metal finishing process support implementation of TrueChem software for laboratory sampling and analysis and process improvement for a metal finishing shop at a confidential leading prime aerospace manufacturer. The TrueChem software provides: schedule management for sampling, analysis, maintenance activities, and corrective actions; automatic result computation, statistical analyses and trending; rule and notification capability (based on specific results or statistical trends); notes and documentation links; chemical inventory management; and dashboard graphical status overview. The TrueChem database was populated with client process tank and chemistry information; a SQL version of the software was installed on the client network; and software training was provided, including executive overview training, basic TrueChem training and a customized training for information technology staff.

ITI provided principal consultant input to CH2M HILL Plateau Remediation Company for a high-level cost steering committee assembled to review and recommend approaches to enhance site remediation cost estimating tools and procedures for the multi-billion dollar Hanford environmental remediation project. ITI was lead author for a draft cost guidance chapter in a CERCLA project manager's guidance document. Hanford remediation project managers will use this guidance to develop defensible decision documents to support environmental cleanup.


ITI conducted a Process Equipment and Systems Asset Management Planning (PESMP) audit for Sonaca NMF, an aerospace structural component manufacturer, in Montreal, Quebec.The on-site audit was performed for a chromic acid anodizing process line consisting of eleven tanks, approximately 50´ long x 4´ wide x 10´ deep, and accessory equipment, ventilation system, hoist system, and wastewater treatment system. Process Equipment and Systems Management Planning (PESMP) is a comprehensive strategy and process directed toward achieving greatest effectiveness and profitability from production and manufacturing equipment assets. The PESMP is a unique evaluation tool developed by Integrated Technologies, Inc. to assess the physical condition and operational efficiency of existing equipment and system design and to provide recommendations for improvements. The assessment included an analysis on the present condition of equipment and systems, and the ability of an asset.The audit consisted of equipment and system inspections, including visual inspections, use of analytical equipment were applicable, and interviews with system operators and maintenance staff.Equipment condition bases that were assessed included structural condition, corrosion, wear, and fabrication defects.In addition, the equipment application was evaluated.Materials of construction, equipment selection and overall process design was evaluated for the given application. An Assessment Rating was assigned for the condition, system design application, and area and level of impact.Each piece of equipment and the system is identified with a written description of the defect and rated. A risk table is utilized to categorize the various components and system defects to establish a level of risk or importance based on the ratings and level of impact.A detailed audit report was generated for the wet process line and wastewater treatment system.
 
ITI provided project scoping and review support for services to Ducommun Technologies, Inc. for process improvement and Nadcap compliance for a chromate conversion coat process and related process operations and systems. ITI's support included assessment of rinsing, process solutions and maintenance, part preparation and handling, laboratory methods and testing (chemical analysis and salt spray testing) and wastewater treatment. ITI provided recommendations for improvement to achieve process quality goals and selected training/process improvement implementation support.
 
ITI provided process modeling and capital cost estimates for the design of a new Chromate & Anodizing Line for Southwest United Industries, Tulsa, OK. The process design included state-of-the-art, fully automated, lean process systems for surface finishing for aerospace components. A detailed process design was prepared for two automated wet process lines and ancillary process systems, water and wastewater treatment and ventilation and air pollution control systems. The design incorporates advanced technologies, optimizes processes while minimizing water consumption, utility requirements, energy consumption, and wastewater treatment requirements. Wet processes include alkaline cleaning; Type I, IC, II and III anodizing; aluminum preparation and chromate conversion coatings. ITI prepared detailed process design and bid package deliverables including 2D and 3D drawings; tank schedules; equipment schedules; electrical feeder schedule; process line, wastewater treatment, and chiller water PID's; specifications for wet process and support equipment; automatic hoist production analysis; and contractor scope breakdown package. (ITI plans to provide construction management services in the developing stages of the project). ITI's automated wet process line design and push-pull ventilation design including automated tank covers to minimize ventilation loading. ITI utilized the commercial process modeling software, Plato's Process Planner® to optimize processes and develop a basis of design. ITI developed an integrated water and wastewater design to cost effectively conserve water. Other deliverables included preparation of capital cost budgets for process equipment and construction at various stages of the project.
ITI built a custom application to help Global Ionix track and graph testing results for a new product coming to market. ITI Information Technology staff built an application using Excel automation to import data directly from the testing equipment output, formatted it to be meaningful, and created a graphing capability. The result was to reduce the burden on valuable technical staff, provide valuable information sooner, and make that information easy to understand.
ITI provided process design services to the architectural firm, KZF Design Inc, for the design of a new Advanced Metal Finishing Facility (AMFF) for Robins Air Force Base in Warner Robins, GA. The process design included state-of-the-art, fully automated, lean process systems for surface finishing related to the overhaul and repair of C-5, C-130, C-17 and F-15 aircraft body and structural components, propeller components, and potential future workload .
ITI prepared a detailed process design for eight automated wet process lines and ancillary process systems, water and wastewater treatment and ventilation and air pollution control systems. A performance-based process design and preliminary layouts were prepared for dry processes and non-destructive inspection processes. ITI's process design work was closely coordinated with a performance-based building design by KZF Design Inc. The advanced metal finishing facility design incorporates advanced technologies, optimizes processes while minimizing water consumption and wastewater treatment requirements. The process design includes features to provide Robins Air Force Base with capability to become a Tier 1 metal finishing operation to achieve a facility that is NadCap and Leadership in Energy and Environmental Design (LEED) certifiable.

Wet processes in ITI's design include alkaline cleaning; Type I, II and III anodizing; aluminum preparation and conversion coatings; chemical milling of aluminum and titanium alloys; chromium, nickel, cadmium, titanium-cadmium, copper electroplating; electroless nickel plating; and other surface finishing operations including zinc and manganese phosphating; black oxide; magnesium treatment; stripping of anodize, cadmium, chromium, nickel coatings; temper etch inspection; and Type II passivation. Dry processes in ITI's design include High Velocity Oxygen Fuel (HVOF) and Magnetron Sputtering, and other support processes such as ovens for hydrogen embrittlement relief baking, both glovebox and walk-in rooms for abrasive blasting for depaint and parts cleaning and preparation. Non-destructive inspection (NDI) processes in ITI's design include fluorescent penetrant inspection (FPI) and magnetic particle inspection (MPI),

ITI prepared detailed process design and bid package deliverables including 2D and 3D drawings, tank schedules, equipment schedules, detailed specifications for wet process and support equipment, performance specifications for dry and non-destructive inspection processes. ITI's automated wet process line design and push-pull ventilation design with enclosures provides for maximum worker safety. ITI utilized the commercial process modeling software, Plato's Process Planner® to optimize processes and develop a basis of design. ITI developed an integrated water and wastewater design to cost effectively conserve and reuse water.

Other deliverables included: documentation of the basis of design in the form of a process narrative; development of process flow diagrams of relevant surface finishing operations based upon Mil Specs and US Air Force Technical Orders; preparation of facility Best Management Practices (BMPs) and post design implementation steps; preparation of a draft Operational Risk Management (ORM) analysis; and preparation of capital cost budgets for process equipment and construction at various stages of the project.
ITI provided process consulting and design services for several projects at CP Tech, Division of Technimeca International Corp., an aerospace component manufacturer in Montreal, Quebec. CP Tech is a specialty surface finishing and testing job shop that provides services in aerospace, military, telecommunications, transportation and other industries. ITI worked with CP Tech to prepare a Process Specific Opportunity Assessment (PSOA) to strategically pursue manufacturing and process improvement. Overall project goals included improved process flow within the facility, reduced waste generation, and improved process capacity/capability. ITI consultants spent three weeks onsite at CP Tech collecting data and gaining a thorough understanding of CP Tech's processes and operations. ITI evaluated process control procedures and recommended improvements to increase process quality, efficiency and safety.

ITI developed a production basis and input data for use in the commercial process model, Plato's Process Planner®, to evaluate baseline and optimized facility configurations to assess process improvement opportunities. ITI developed a general process map to evaluate process arrangement and information flow. ITI recommended changes to the overall process arrangement and information flow to make processes leaner and reduce operating costs.

ITI also evaluated the condition of major equipment and systems, and applied a qualitative rating of asset condition to create an asset condition report. CP Tech used this to assess the relative risk of business interruption and environmental and safety impacts.

ITI provided process design services for CP Tech to construct a new right-sized aluminum finishing line and a new automated chromium, cadmium, and titanium-cadmium plating line. The new aluminum finishing line includes aluminum surface treatments including Type I (Chromic), II and III anodizing, etching, and aluminum chromating. ITI worked with CP Tech to tailor the designs to meet overall project goals of improved process flow within the facility, reduced waste generation, and improved process capacity/capability. ITI's conceptual designs for the new lines included tank and equipment schedules, layout drawings and a performance specification. These were combined with instructions to bidders and general conditions to form separate RFPs for the construction of the new aluminum surface treatment and new chromium, cadmium and titanium-cadmium surface treatment lines.

ITI provided process design services for CP Tech for a new paint line and a new wastewater treatment system. ITI worked with CP Tech to tailor the designs to meet overall project goals of improved process flow within the facility, reduced waste generation, and improved process capacity/capability. The new paint system consists of a new paint line with a manual conveyor system, a UV/IR oven and two paint booths, and related process ventilation and air pollution control systems. The new wastewater treatment system consists of a new fully automated chromium reduction system, cyanide oxidation system, chelated metals treatment, solids removal via microfiltration, final pH adjustment and oily waste treatment. In addition, ITI developed concepts for water recycle and up-the-pipe technologies to decrease hydraulic and contaminant mass loadings to the wastewater treatment system. ITI's design scope included equipment schedules, layout drawings and a performance specification.

ITI managed and provided expert metal finishing process support implementation of TrueChem software for laboratory sampling and analysis and process improvement for the metal finishing shop at Hill AFB, Ogden, UT. The TrueChem software provides: schedule management for sampling, analysis, maintenance activities, and corrective actions; automatic result computation, statistical analyses and trending; rule and notification capability (based on specific results or statistical trends); notes and documentation links; chemical inventory management; and dashboard graphical status overview. A software implementation plan was developed, a TrueChem database was populated with Hill AFB process tank and chemistry information, a SQL version of the software was installed on the Hill AFB network and software training was provided, a follow-up training and support trip was completed and three HTML-based status dashboards were developed and deployed to provide broad based, graphic overview and detail result parameter and schedule status.

ITI prepared metal finishing design concepts and evaluations for a proposed new state-of-the-art manufacturing plant in Mexico for a confidential Tier 1 aerospace components manufacturer. ITI developed design concepts for two metal finishing lines processing aluminum, magnesium, steel and stainless steel parts. ITI also developed design concepts for prime/paint processing.Processes included in the design concepts were:anodize type I and II, cadmium plate, chemical film (Aluminum Chromate), fluorescent penetrant inspection (FPI), magnesium treatment type II, passivation type VII, and prime/paint.The design concepts were developed to facilitate lean workflow, high quality production, good worker safety and Nadcap certification.

ITI participated in three days of process scoping workshops with the client to arrive at a basis for concept design. ITI reviewed production workload projections based on existing and anticipated future workload scenarios and evaluated metal finishing process needs to meet process specific production requirements.ITI developed process flow diagrams for individual metal finishing process sequences and for overall substrate-specific work flow. ITI developed three layout scenarios accommodating a broad range of maximum part envelope sizes with tanks ranging from 4 feet to 32 feet from front to back. ITI provided preliminary scoping input for process support systems including: heating and cooling systems, laboratory, part racking/fixturing/handling, paint kitchen, process water supply/treatment, rectifiers, ventilation and air pollution control, wastewater treatment/recycle, miscellaneous mechanical systems, and instrumentation and control systems.

ITI prepared a summary report including data collected and process concepts and evaluations.The summary report included implementation recommendations and a series of capital and operating and maintenance (O&M) cost estimates for different maximum part size and production level scenarios.

ITI also prepared metal finishing design concepts and evaluations for the same confidential Tier 1 aerospace components manufacturer for a proposed new state-of-the-art manufacturing plant to be located in the US either in the Northwest or Midwest.The ITI work scope and deliverables were similar to the Mexico plant, except with initial focus on aluminum finishing only.

ITI consulted with AAI Services, ARINC, USAF Egyptian Depot Program and the Egyptian Air Force in Cairo, Egypt. ITI provided engineering services and operations support to the Egyptian Air Force (EAF) related to the startup and commissioning of an F-16 Overhaul & Repair Depot Surface Treatment Facility (STF). The STF processes include temper etch; black oxide, bronze, cadmium, chromium, copper, electroless nickel, lead, tin, nickel, silver, and zinc plating; wax/dewax; chromate conversion; anodizing (Type I, II & III); manganese phosphate; thermal spray; abrasive blasting; shot peening; and stripping (both inorganic and organic coatings). ITI's work scope also included start up and commissioning of all surface treatment processes as well as auxiliary facility processes including water treatment, air pollution control, and wastewater treatment systems.

ITI's responsibilities included implementation and management of all process control functions. Process control functions included: development/validation of analytical techniques, routine solution analysis, wastewater testing, initial process commissioning and routine physical testing of specimens required to assure compliance with applicable specifications. Laboratory data is managed with a Laboratory Information Management System (LIMS) and ITI implemented process improvements on a continuous basis. ITI also developed a model of all wet processes utilizing Plato's Process Planner® to evaluate major enhancements to the facility.

ITI was responsible for researching component repair requirements and developing and documenting process procedures. ITI also designed required fixtures. Our responsibilities also included training EAF operators in the established procedures and the operation and maintenance of all equipment/systems.

ITI also provided engineering and construction management services for facility upgrades.

ITI consulted with Heroux Devtek,Longueuil, QC to develop master plans for the lean renovation/expansion of existing surface finishing operations. ITI is currently supporting the implementation of the first phase of a multi-phase surface finishing facility renovation program designed to dramatically improve information, material and work flow and increase the capacity and capability of the facility. Phase one processes include aluminum finishing (type I, II, and III anodizing, etching, and chromate), titanium etch and passivation. ITI has assisted Heroux is currently planning phase two project details for the following processes: temper etch, stripping, cadmium, TiCd, and chromium plating. ITI is also working with Heroux to improve process methods which have resulted in significant productivity improvements.
 
ITI consulted with Rolls Royce, Indianapolis, IN to support improvement of process control for over 100 surface finishing process solutions used in manufacturing processes for aircraft turbine engines at Rolls Royce's largest North American manufacturing plant. Scope of work includes reviewing process solution control and process limits and process solution sampling and analytical methods for process solution constituents and contaminants. Recommendations were made for improving surface finishing process solution sampling and analytical methods, for setting effective control limits within solution specific process limits, and for planning and deploying software and systems for statistical process control (SPC) and for managing, documenting, and reporting of sampling and analysis activities.
 
ITI consulted with Warner Robins AFB, MACTEC and CH2M Hill to develop a green plating master plan to guide FY 06 surface finishing renovation. The work scope included development of the following deliverables: Project Action Plan, Process and Production Basis and Optimization Approach, Plato's Process Planner® Modeling and Updates, LEAN Workflow and Automation Assessment, Pollution Prevention Assessment, Integrated Project Scoping, Process Equipment and Support Systems, Structural/Architectural Approach, Project Delivery Basis, Budgetary Cost Estimate.

ITI consulted with GM Electromotive Division and Western Remanufacturing to identify the failure mode for chromium plated crankshafts used in locomotive engines.

ITI consulted with Tobyhanna Army Depot (TYAD) and Conti Environmental to commission surface finishing processes. ITI provided on site support to TYAD for 18 months to implement the commissioning plan developed with Burns & McDonnell. The work at TYAD included new method development, optimization, process validation, fixture design support, and operator training.

ITI consulted with Tobyhanna Army Depot and Burns & McDonnell to develop a commissioning plan for surface finishing processes. Processes include abrasive blasting, painting, powder coating, chromate conversion coating, zinc phosphate, acid cadmium, hard coat anodizing and sulfuric acid anodizing, nickel plating, electroless nickel plating, non-cyanide copper and silver plating, steam cleaning, ultrasonic cleaning, and black oxide.

ITI consulted with Heroux Devtek,Longueuil, QC to support NADCAP certification. ITI supported Heroux Devtek in achieving successful NADCAP certification. Our work scope included process audits, and method development and improvement.

ITI consulted with Heroux Devtek,Longueuil, QC in the implementation of lean manufacturing methods in their surface finishing operations. ITI’s work scope included process mapping and Kaizen event leadership and support.

ITI consulted with Heroux-Devtek, Longueuil, Quebec to assess the relative feasibility of renovating the current surface finishing operations vs. constructing a new integrated surface finishing facility. Surface finishing operations include hard chromium plating, sulfamate nickel, electroless nickel, cadmium plating, anodizing (hard, sulfuric, and chromic), chromate (cadmium and aluminum), phosphate (zinc and manganese), passivation, masking, demasking, baking, grit blasting, shot peening, magnetic particle inspection (MPI), fluorescent penetrant inspection (FPI), aqueous and solvent cleaning, and stripping of chromium, cadmium, and nickel. New processes include HVOF.

ITI consulted with IMICornelius, Minneapolis, MN, San Antonio, TX and Renosa, Mexico in the conceptual and detailed design and relocation of surface finishing operations from San Antonio, TX to Renosa, Mexico. Processes include aqueous and solvent cleaning, passivation and electropolishing of beverage dispensing machine heat exchanger tubing and blocks.

ITI consulted with Goodrich Aerospace, AIP; Colorado Springs, CO and CH2M Hill in the conceptual design, specification, vendor selection and services during construction including design review for a new surface finishing facility. Processes include electroless nickel, cadmium plating, anodizing (hard and sulfuric), chromate (cadmium and aluminum), zinc phosphate, passivation and electropolishing.

ITI developed a comprehensive wet process model for Warner Robins AFB with CH2M Hill of Warner Robin’s surface finishing operations using Plato’s Process Planner to identify process improvement opportunities and optimize surface finishing processes and wastewater treatment operations.

ITI consulted with Concurrent Technologies Corp., CAI Resources, MMTC and CAMP as a partner in US EPA’s Environmental Technology Verification Program for Metal Finishing, ETV-MF. Completed verification testing of a Hadwaco MVR evaporator operating as a zero discharge process on copper pickling rinsewater. Currently planning for test of a QVF PCR evaporator operating as a closed loop process on chromic-sulfuric acid etching of automotive plastics prior to electroplating.

ITI consulted with Goodrich Aerostructures Group, Chula Vista, CA and CH2M Hill in the conceptual design and implementation of surface finishing, water and wastewater improvements.

ITI developed a Capsule Report onApproaching Zero Discharge in Metal Finishing for US EPA.

ITI developed a comprehensive wet process model for Boeing, Frederickson, WA with CH2M Hill of Boeing’s surface finishing operations using Plato’s Process Planner to identify process improvement opportunities and assess alternatives for capital improvement planning.

ITI developed a conceptual design and cost estimate for Blount, Oregon Chain Division, Portland, OR with CH2M Hill for a new surface finishing facility. Processes included hard chromium, cleaning and pickling.

ITI developed a conceptual design for GE Aircraft Engines, Lynn, MA with CH2M Hill for an improved wastewater control system for vibratory finishing waste streams.

ITI consulted with General Motors, Arlington, TX to assess opportunities to reduce water usage in wet processes including phosphating, electrocoating, top coat overspray control and car washing. Objectives were to reduce water usage by 50%.

ITI developed a comprehensive wet process model for Tinker AFB with CH2M Hill based upon Plato’s Process Planner of surface finishing operations in anticipation of MP&M effluent guideline requirements to optimize surface finishing processes and wastewater treatment operations.

ITI developed a Capsule Report on Managing Cyanide in Metal Finishing for US EPA.

ITI consulted with Raytheon, Andover, MA in the development of a phased renovation and consolidation of surface finishing operations in their Waltham, MA and Andover, MA facilities. Processes include nickel plating, copper plating, solder plating, chromating, anodizing, phosphating, and passivation.

ITI consulted with EG&G Pressure Science (Perkin Elmer) in the development of a multi-phase renovation plan of surface finishing operations in their Baltimore, MD facility including electropolishing and nickel, silver, gold, lead, tin, indium electroplating. Work included development of pollution prevention and control strategy, conceptual and preliminary engineering, including ventilation and air make-up system design specifications, and hazardous materials and waste storage.

ITI consulted as senior process engineer in the preliminary and detailed design phases of a new metal finishing facility for Pratt & Whitney Aircraft, North Berwick, ME as part of the northeast corner renovation project. Processes include nickel plating prior to brazing, masking and demasking, nitric acid cleaning to remove residual low-melt alloy from fixturing process, and acid and alkaline cleaning. Preliminary design also included anodizing and stripping of metallic coatings for overhaul and repair.

ITI developed a conceptual design for Universal Metal Finishers, Chicago, ILwith CH2M Hillfor a new, fully automated 50,000-sq. ft. anodizing facility. Processes include hardcoat and decorative anodizing. Project elements included process engineering, utilities planning, pollution prevention and control, facility layout, and costing.

ITI developed a conceptual design for Imagineering Enterprises, South Bend, IN with CH2M Hillfor a new, state-of-the-art surface finishing facility. Processes include electroless nickel, phosphating, and passivation. Project elements include process engineering, utilities planning, pollution prevention and control, and wet process layout.

ITI developed a conceptual design for Praxair - Treffers Precision, Phoenix, AZ with CH2M Hillfor a new, fully automated surface finishing facility. Processes include Type I, II and III anodizing. Project elements include process engineering, utilities planning, pollution prevention and control, and wet process layout.

ITI developed a WEB based process model for the simulation of metal finishing processes for NCMS, Ann Arbor, MI.andUS EPA.

ITI consulted with Goodrich Aerostructures Group, San Marcos, TX in the assessment of solution maintenance practices and alternatives for a titanium chemical milling process.

ITI consulted with Hagar Hinge, Montgomery, ALand CH2M Hillin the development of an integrated pollution prevention and control plan which included recommendations for process improvements that significantly reduced the mass and hydraulic load on wastewater treatment operations. The project included conceptual design of a new wastewater treatment plant and development of a budget for capital improvements.

ITI consulted with Boeing Commercial Airplane Group, Portland, OR and CH2M Hillin the development of best management practices for the maintenance and/or treatment of concentrated metal finishing solutions.

ITI consulted with the US Naval Air Command and CH2M Hillin the assessment of aircraft engine washing operations at 12 bases across the US.

ITI consulting with Pratt & Whitney Aircraft, North Berwick, ME in the implementation phase of northeast corner renovation project. The scope of work includes procurement and installation of four surface finishing lines (sulfamate nickel plating, acid and alkaline cleaning, and wax/dewax operations) and pollution prevention equipment.

ITI consulted with Pratt & Whitney Aircraft, North Haven, CT and conducted a plant wide (1.5MM sq. ft) audit of all wet processes (approx. 150) in the North Haven facility. Data collected was assembled in a computer model in order to characterize waste streams, evaluate segregation practices and potential process improvements. We developed evaluation criteria to prioritize pollution prevention and control projects and recommended projects for implementation. Processes included aqueous cleaning, nondestructive testing, acid stripping and cleaning, electroplating, electrochemical machining and vibratory finishing.

ITI consulted with Pratt & Whitney Aircraft, North Haven, CT and provided process and environmental engineering services during conversion of this facility to product centered manufacturing cells. Provided concurrent engineering and construction management during a fast track project to relocate aqueous cleaning, nondestructive testing and vibratory finishing processes.

ITI developed and implemented a testing and evaluation program for Pratt & Whitney Aircraft, North Haven, CT to clean complex airfoils using alternative aqueous cleaning equipment and replace chlorinated solvent vapor degreasing. Equipment included ultrasonic cleaning, spray cleaning, spray-under-immersion and immersion cleaning.

ITI consulted as a principal process engineer in the conceptual engineering and development of a complete metal finishing facility renovation plan for McClellan Air Force Base. The facility includes more than 100 processes and more than 250 tanks ranging from 100 to 5,000 gallons.

ITI consulted with McClellan Air Force Base during an investigation of all ozone depleting substances on base. This investigation encompassed solvent cleaning and included investigation of solvent cleaning alternatives and technology including hermetically sealed vacuum vapor degreasers, alternative solvents, semi-aqueous and aqueous cleaners.

ITI consulted with McClellan Air Force Base in the evaluation of alternative bath maintenance technologies including selective ion exchange, membrane electrolysis and crystallization to support surface finishing operations.

ITI consulted with McClellan Air Force Base in the evaluation of a zero discharge wastewater treatment system.

ITI consulted with ITT Electronics in the development of pollution prevention and control plan to reduce the hydraulic load on the existing sulfide precipitation based wastewater treatment system. Audited manufacturing operations to evaluate and classify residual wastes generated by all processes.

ITI consulted with BF Goodrich Aerospace, Simmond’s Precision Aircraft Systems, an avionics equipment manufacturer as principal process engineer in the conceptual and preliminary design of a new world class metal finishing facility which included wastewater treatment, crystallization of caustic etch solutions, and evaporative recovery of chromic anodizing, caustic etch and nickel electroforming dragout. Processes include chromic and sulfuric anodizing, chromate conversion, nickel, tin, passivation and nickel electroforming. Reduced water usage from 30,000 GPD to 3,000 GPD. Evaluated a zero discharge option for economic viability.

ITI prepared an audit of four printed circuit board and hard disk drive manufacturers in the San Jose area to identify means to reduce the mass outfall of copper and nickel to the San Jose POTW.

ITI consulted with a confidential client in the assessment and development of “lifetime finish” coating technology for lighting fixtures to replace an existing coating process that is dependent on VOC emitting solvent-based coating process. Objectives of the project were lifetime corrosion resistance, world class decorative coating on unpolished substrate, cost effective and environmentally compliant coating process, high process yields (improved first time quality) and increased capacity.

ITI consulted with Pratt & Whitney Aircraft, East Hartford, CT on a multiyear, multi-plant, U.S. Air Force sponsored Industrial Modernization Incentive Program (IMIP) project to minimize waste in four areas: metal finishing, ECM, coolants/lubricants, and solvents. Plants included in the study were East Hartford, North Haven, Middletown, and Southington. Acted as Senior Technical Advisor for all areas and Project Manager for the metal finishing study. The processes involved in this study included alkaline cleaning, acid pickling, chromium plating, sulfamate nickel plating, cadmium cyanide plating, chromating; chromic acid anodizing, copper cyanide plating, stripping of cadmium, copper, chromium and nickel, and chemical milling of titanium and nickel alloys. The solvent work covered investigation of alternatives to conventional solvent cleaning and dewaxing including totally enclosed vacuum vapor degreasers, semi-aqueous and aqueous cleaning, alternative hand wiping alternatives, alternative solvents and dewaxing alternatives. The project included program development, research and development, conceptual engineering, and pilot testing. Technologies evaluated include acid retardation, ion exchange, reverse osmosis, ultrafiltration, microfiltration, atmospheric and vacuum evaporation, electrodialysis, membrane electrolysis, diffusion dialysis and electrowinning.

ITI consulted with Pratt & Whitney Aircraft, North Haven, CT on a multiyear, plant wide basis in the areas of pollution prevention and control and surface finishing process engineering. Assistance included program development, conceptual and detailed engineering, construction management, process start up, and operator training. Projects include the start up of new advanced plating lines, plating line renovation, wastewater recovery and conservation, wastewater treatment plant evaluation, noncontact cooling water reuse and process troubleshooting.

ITI consulted with Pratt & Whitney Aircraft, North Berwick, ME and provided conceptual engineering of a countercurrent acid cleaning process and recovery of 200,000 pounds of nitric acid per year.

ITI consulted with Pratt & Whitney Aircraft, East Hartford, CT to evaluate and characterize coolant management, recycling, treatment, and disposal practices at the East Hartford, North Haven, and Middletown facilities.

ITI consulted with US EPA’s Office of Policy, Planning & Evaluation on itsSustainable Industry Project to identify barriers and incentives to environmental stewardship in the metal finishing sector.

ITI consulted with the National Defense Center for Environmental Excellence operated by Concurrent Technologies Corporation in the conceptual and preliminary design, and procurement of process and environmental systems for a zero discharge (effluent) surface finishing demonstration factory which includes mobile (point source) and central pollution prevention and control technologies. Processes include alternative cleaning; inorganic coatings including electroplating, electroless plating, phosphating, and ion vapor deposition; alternative stripping including water jet stripping; organic coatings including powdercoat and electrodeposition.

ITI consulted with New York Air Brake in the development of a phased renovation and expansion plan for the surface finishing operations in their Watertown, NY facility. Processes include chromating, anodizing, phosphating, passivation, and impregnation. Work to date includes development of revised process procedures, conceptual and preliminary engineering, specifications, and proposal review.

ITI consulted with General Dynamics (formerly Lockheed Martin) to assess pollution prevention and control options and energy reductions through reduced and improved process ventilation and process improvements. Developed a complete software model for the surface finishing operations in their Burlington, VT facility. Developed solution contaminant and rinsewater quality standards. Processes include abrasive blasting, aqueous parts washing, vibratory finishing, spindle polishing, abrasive flow machining, magnetic penetrant inspection, chromic, sulfuric and phosphoric anodizing, chromating, chemical deburring, chemical polishing, electropolishing, chromium plating, manganese phosphating, black oxide, electroless nickel and nickel plating.

ITI consulted with General Dynamics to a conceptual design for a near zero discharge wastewater recycle system based upon reverse osmosis and ion exchange. Developed preliminary specifications to assemble budgetary level capital costs.

ITI consulted with General Dynamics to review manufacturing process instructions (MPI) and solution control practices, including laboratory procedures, for surface finishing operations. Developed test plans and conducted testing to support changes to MPIs that streamlined operations, implemented good operating practices and improved process control.

ITI provided process engineering support within the development of pollution prevention and control options for wet processes at Teradyne tosupport the expansion of multilayer printed wiring board manufacture in their Nashua, NH facility.

ITI consulted with Colt Manufacturing Company as principal process engineer in the conceptual design of a new advanced metal finishing facility West Hartford, CT.  Processes include black oxide, manganese phosphate, electropolishing, chromium plating, hard coat anodizing, electroless nickel and electroless nickel/Teflon plating, nickel plating, nickel alloy plating, solid film lubricant, etc.

ITI acted as principal process engineer with Burns & McDonnell in the preliminary design and detailed design of a new advanced metal finishing facility for Tobyhanna Army Depot’s industrial operations facility in Tobyhanna, PA. Processes include abrasive blasting, painting, powder coating, chromate conversion coating, zinc phosphate, acid cadmium, hard coat anodizing and sulfuric acid anodizing, nickel plating, electroless nickel plating, non-cyanide copper and silver plating, steam cleaning, ultrasonic cleaning, black oxide, etc.  Developed waste stream characterization and simulation, assessed pollution prevention options and developed conceptual design of point source wastewater recovery, process solution maintenance, centralized wastewater recycle, and batch treatment of blowdown.

ITI acted as principal process engineer with Burns & McDonnell in the preliminary design of centralized process control system for multiple plating tanks within multiple reel-to-reel plating line at Molex inLittle Rock, Arkansas.

ITI teamed with CAI Engineering to perform a survey for the National Center for Manufacturing Science and the National Association of Metal Finishers to assess pollution prevention and control technology in use at U.S. Plating Operations and secondly surveyed suppliers of technology to generate application and cost data.

ITI was principal process engineer on two projects in the conceptual and detailed design of a new advanced metal finishing facility for Textron-Lycoming's (Allied Signal) turbine engine facility in Stratford, CT. Processes include chromium plating and stripping, copper plating and stripping, chromic and sulfuric acid anodizing, nickel plating, manganese and zinc phosphate, black oxide, etc.

ITI consulted with Klock Company, a Connecticut manufacturer specializing in heat treating, brazing, shot peening and plasma coating in the development of a waste minimization program and to audit all manufacturing processes.

ITI developed compliance program for a 60,000 gpd, oily wastewater stream generated by an automatic, alkaline aqueous parts washer for Cly-Del Manufacturing Co., Inc., a large manufacturer of deep drawn metal stampings.  Work resulted in full compliance through implementation of minor changes at the point-of-process.  Additional work centered on developing systems to recycle alkaline cleaners and eliminate effluent discharges.

ITI consulted as principal process engineer in the conceptual and detailed design of a zero discharge wastewater treatment system for Lockheed Advanced Development in Burbank, CA. Waste generating processes included chromate conversion coating and phosphating.

ITI provided design services to Environmental Health and Safety Services of N.E. for Birken Manufacturing, a Connecticut-based manufacturer of aerospace components, to simultaneously decommission an existing and design a new plating department including: chrome, woods nickel strike and sulfamate nickel, cadmium cyanide, and silver cyanide plating; chromic and hardcoat anodizing; titanium cleaning and chromating. The work scope included development of a phased renovation plan and project management for conceptual design through start-up. In addition to plating process design, responsible for design of wastewater recovery and treatment systems and spill control. All processing lines are operational.

ITI performed a toxicity reduction audit and evaluation for Plainville Electro Plating, a job shop specializing in the aerospace industry in Plainville, CT, which encompassed over 100 processes plus wastewater treatment operations. The project focused upon up-the-pipe waste reduction and control measures to eliminate downstream toxic effects. Cyanide wastewater was reduced from +20,000 GPD to 600 GPD. Toxic components were isolated by process source and control measures were implemented on small segregated streams. Wastewater treatment systems controls were improved to minimize the use of treatment chemicals and reduce toxic load.

ITI performed a combined toxicity reduction audit and waste minimization study for Quality Rolling and Deburring, a large commercial job shop plater in Thomaston, CT.  This project also focused upon up-the-pipe waste reduction and control measures.  Nickel plating (barrel) was close-looped and copper bearing chemical polishing and burnishing wastewaters were polished with an ion exchange system; volume was reduced from +20,000 GPD prior to implementing ion exchange.  Proprietary cleaning and burnishing materials (more than 60) from approximately 25 suppliers were evaluated and recommendations for materials substitutions were prepared with the help of suppliers; required materials were reduced from +60 to 12 and six suppliers.

ITI evaluated closed-loop plating concepts for chrome, nickel, cadmium and copper plating and assisted with toxicity reduction strategies for Har-Conn Chromium, a Connecticut job shop specializing in the aerospace industry. Also provided consultation for improved shop layout to reduce wasted floor space and improve workflow.

ITI consulted with The Torrington Company, a division of Ingersoll Rand, a manufacturer of bearings and other industrial components.  Responsible for developing conceptual designs of recovery systems for black oxide, cadmium cyanide, copper cyanide, and chromium plating, as well as cyanide-based stripping of copper.

ITI consulted in the design of new plating facility for National Chromium, a Connecticut job shop specializing in hard chrome plating.  Work included conceptual design of wastewater recovery and contaminant control systems for two hexavalent chrome plating lines and for one nickel/trivalent chrome plating line.

ITI developed preventive maintenance and process control program for Grant Hardware, a manufacturer of furniture hardware with 12,000-gallon acid zinc and 7,000-gallon alkaline zinc automatic plating machines.  This work has reversed a 100 percent reject rating to a more than 95 percent acceptance rating on both lines.

ITI designed a compliance program for Computer Circuit Technology, Inc., a printed circuit board manufacturer in upstate New York, which included evaluating recovery/disposal options for over 950 drums of accumulated processes waste.  Compliance was achieved through waste minimization and material recovery techniques and a minimal reliance upon wastewater treatment and the generation of secondary sludges.

ITI designed wastewater management systems and overall compliance program for Precision Photo Fabrications, Inc., a start-up chemical milling facility in upstate New York.  Responsibilities ranged from design through implementation of wastewater collection, treatment, and recovery systems.  Additional work included development of a Release Prevention Control and Counter-measures Plan and a Systems Operation and Maintenance Manual for all installed systems.
ITI performed a waste management audit for Pan Graphics, a manufacturer of photoengraved rotogravure rolls and screens in New Jersey.  The work scope included evaluation of existing systems and conceptual design of improvements, including waste minimization and recovery, wastewater treatment, and development of a solvent management plan.  Additional work at this facility included assistance with Worker and Community Right to Know programs.