Reduction of Scrap in Anodization Process: A Case Study in a Cosmetic Packaging Industry

Abstract

According to the production process conditions in the company case study, in particular the operation of anodization department for coating of the packaging, the defects of the process have been found significantly. Referring to the primary analysis, the defects are caused from inappropriate chemical parameters in anodization process and also inappropriate packaging wash after the anodizing process when the highest amount of paint losses is found in scrap. The scrap value of both matte coating process and glossy coating process is about USD 2,800 per month. The objectives of this research are to study aluminium alloy metal coating process with sulfuric acid under particular conditions and to determine appropriate conditions for material surface coating. The appropriate level of the turbidity is 12.4242 NTU and the concentration is 220 g/L for matte coating process. Glossy coating process can be reduced to the appropriate level of the turbidity at 3.4040 NTU and the concentration is 303.33 g/L. In addition, this can reduce defect on the paint loss packaging from anodizing process, and coating process condition in matte coating process up to 67.77% and glossy coating process is also reduced by 66.02%.