ZERMEG II – Zero emission retrofitting method ... - Fabrik der Zukunft

7.5 Rotoform GmbHRotoform produces printing cyclinders for the graphic business with 20 employees. Rotoformuses a new standard galvanic-line for the cylinder processing. After the copper plating or thechromium plating, the cylinders run through a surface-processing machine.For the processing of the copper surface the processes gravure and etching are used. Forthe gravure two machines are available. As patterns opal-films or electronic data carrier areused. The etching is an autotype process, which consists of several process steps.The wastewater from the galvanic plants and from the corrosion is separated into alkalineand acid solvents, then collected and detoxified in a neutralisation plant. A batch treatmentfor the chrome reduction and for the precipitation of the metals is used. A filter press and anion exchanger are also involved in this process.The finished cylinders are delivered to printers. The old cylinders, which have to be deliveredfor new orders, have to be cleaned and de-chromed first, before the surface can be shaped.During the production of printing cylinders the problematic materials are copper, chromiumand nickel. The chrome cycle is mainly closed, and the small amount of chromeVI, whichgets lost through the exhaust system, is totally reduced to chrome III in the neutralisationplant.Via the nickel and copper baths the respective sulphates get into the neutralisation andwaste water treatment plant. Because of the fact, that sulphate only can be broken downdifficultly, the company is searching for a possibility to reduce the sulphate portions in thewastewater.The rinsing water amount per print cylinder was calculated. For the calculation of the waterconsumption of the spray-rinses the formulas from literatures were used (Fresner, 2004 c).25