CO2-reduced degreasing at the deep-drawing specialist
Mark Metallwarenfabrik GmbH puts its faith in the recyclates and expertise of Richard Geiss GmbH
The process took a year and a half, but the result was worthwhile: Mark Metallwarenfabrik GmbH, based in Spital am Pyhrn in Austria, has changed its in-house degreasing system and now uses solvent recyclates. As a result, the deep-drawing specialist saves approximately 21 tonnes of CO2 emissions per year. Mark manufactures deep-drawn components of between 2 and 80 mm in diameter, which primarily go into use in the automotive industry, for example in airbags. In this area, a high degree of component cleanliness comes first. To ensure a smooth changeover, Mark sought the support of Richard Geiss GmbH. The solvents specialist from Offingen, Bavaria supplied not only the recycled perchloroethylene (PER), but also the expertise.
“For us, taking the step towards solvent recyclates was both logical and consistent with our strategy and values in terms of sustainability and reduced CO2 emissions,” explains Christian Schneeberger from the Sustainability Management team at Mark Metallwarenfabrik GmbH. “We are actively addressing reducing our ecological footprint in all areas, calculating our CO2 emissions and focusing on a circular economy. We also wanted to take these efforts into our degreasing process,” added Christian Schneeberger.
CO2 savings in degreasing
The results have been impressive: last year Mark has already saved 21.26 tonnes of CO2 emissions in the area of in-house metal degreasing. And this is just the start, as the changeover in the cleaning system is taking place gradually. Although Mark still uses its existing stocks of new products, solvents are now delivered in the form of recyclates only.
Deep-drawing specialist: everything from one single source
The company Mark Metallwarenfabrik GmbH in Spital am Pyhrn is the technology centre for forming technology of the Mark Group. Here, the know-how and technology of the Austrian specialist for deep-drawing are continuously developed further. Mark manufactures deep-drawn components with diameters between 2 and 80 mm, a material thickness between 0.1 and 2.5 mm and a maximum length of 150 mm. The deep-drawing specialist offers everything from one single source: from in-house tool and prototype construction, to the fully-automated assembly and control by means of eddy current or camera systems. In addition to the automotive industry, Mark also supplies the medical technology, electrical engineering sectors as well as the cosmetics industry.
Sustainable and stable degreasing process
It is naturally the case that the Mark Metallwarenfabrik assumes the task of the degreasing and cleaning of its metal components. Approximately 300 wash baskets per shift pass through the company’s own degreasing process at Mark; the system operates in three shifts. The components are cleaned of cooling lubricants and particles – thanks to the solvent recyclates from Richard Geiss GmbH, this is now done on an especially sustainable and low-CO2 basis.
“In switching to recyclates, we initially feared that we would have to stabilise the solvent bath in our system to a far greater extent. That hasn’t been the case, though. We are still able to rely on a stable degreasing process,” emphasises Wolfgang Krenn, Head of Surface Technology at Mark Metallwarenfabrik GmbH. Approximately 2.3 billion precision steel components leave the plant in Upper Austria per year.
Recyclates in new product quality
The recyclates from Richard Geiss GmbH – such as the perchloroethylene used by Mark – are in no way inferior to new products, they actually offer more. “Our recyclates achieve 100 percent of the quality of the original goods while also offering an environmental benefit,” assures Bastian Geiss, CEO of Richard Geiss GmbH. The solvent recyclates can be almost infinitely recycled in the distillation plants in Offingen, which reduces the need for newly-manufactured solvents and therefore saves valuable resources.
Pilot system and boil tests
Before the changeover of the in-house degreasing process at Mark, the parts cleaning with the recyclates was tested on site on a similar system at Spital am Pyhrn. The exact need for solvent recyclates and stabilisers was determined individually by the specialists of Richard Geiss GmbH. “We analysed all the oils that are present in the degreasing system at Mark in our own laboratory in Offingen with the use of boil tests,” explains Manuel Huihui, a member of the Technical Support and International Sales team at Richard Geiss GmbH.
Mark will continue to use the laboratory service and solvent expertise of Richard Geiss GmbH after the changeover. “We want to be chlorine-free with our oils and cooling lubricants by 2025. We’re testing various alternative oils in this area, and whenever an oil comes up for consideration, Richard Geiss carries out the oil compatibility tests at their lab. Their support is great,” says Wolfgang Krenn enthusiastically.
System in an extended production hall
The modern degreasing system, which now cleans using recyclates, is located in the production hall of the Mark Metallwarenfabrik, which was extended in 2017. With the 10,000 m2 extension made at that time, Mark doubled the size of headquarters in Spital am Pyhrn with a 30 million euro investment. In addition to the new production hall, the extension also included an automatic high-bay warehouse as well as offices, a technical centre and a shipment area.
All signs point to sustainability
Mark, the deep-drawing specialist with more than 100 years of industry experience, is committed to achieving greater sustainability in its various areas, of which the switch to using solvent recyclates in in-house metal degreasing is also part. From its production through to external supply chains and logistics, the company transparently calculates its CO2 emissions with the aim of continuously reducing them. A photovoltaic system supplies some of its own electricity and the building is cooled by well cooling without the use of climate-damaging refrigerants. By ensuring efficient production processes, Mark also minimises waste and thus conserves resources. “By using solvent recyclates in our degreasing, we are also supporting the concept of a circular economy,” emphasises Christian Schneeberger.
About Mark Metallwarenfabrik GmbH
Mark has more than 100 years of industrial experience and is currently one of the world’s leading companies in metal forming technology. The company supplies its products to leading customers in the automotive, medical, shoes and leather industries as well as the electronics, electrical engineering and consumer goods sectors. Mark offers solutions from one single source: it develops and manufactures deep-drawing tools for precise deep-drawing components with diameters of 2 to 80 mm in its in-house workshop. The deep-drawn components are processed directly into the required assemblies on the fully-automated assembly line. An eddy current and/ or camera system control ensures the highest quality. Mark also has its own department for prototyping and development for enabling the company to meet new requirements.
Mark Metallwarenfabrik GmbH has approximately 520 employees at three locations and trains more than 40 apprentices at the “MARKademie”. The Mark Group last generated a total sales revenue of more than 100 million euros (16/04/2024).
About Richard Geiss GmbH
Richard Geiss GmbH is one of Europe’s leading specialists in solvent recovery, based in Offingen in the district of Günzburg. The company produces high-purity distillates from solvent waste by distillative processing. Richard Geiss GmbH supplies solvents for industrial surface cleaning, textile cleaning, and the chemical and pharmaceutical industries. Contract cleaning rounds off the range of services as the fourth business area. Richard Geiss GmbH employs approximately 110 people in Offingen. The company has an approved processing capacity of 50,000 tons of solvents per year, which are processed into high-purity distillates and is certified according to ISO 9001, ISO 14001, ISO 45001, ISO 50001 as well as a waste management specialist. Richard Geiss GmbH was founded in 1959 by Richard Geiss and today Bastian Geiss manages the family business in its third generation.
Info:
Richard Geiss GmbH
Lüßhof 100, 89362 Offingen, Phone + 49 8224-807-0, info@geiss-gmbh.de, www.geiss-gmbh.de
Press contact:
Bettina Nilius, Marketing
Tel. 08224-807-91, bettina.nilius@geiss-gmbh.de
