The Environmental Evolution of a Metal Stamper

The plant uses progressive die operations to manufacture precision parts for the medical, aerospace, firearms and defense industries worldwide. It also operates accurate, repeatable and powerful slide forming machinery that is ideal for the economical production of intricate springs, stampings, and wire forms.  Slide forming machines produce parts that may cost substantially less than parts produced from power press tools. Tooling is also substantially less expensive.

Complex forming operations that add cost to progressive tooling can be formed easily on slide forming machinery. Parts produced using slide forming machinery include welded medical bands, surgical staples, wire formed clamps, retention spring clips, blade locks, clutch springs, and float wires.

The slide forming machinery, including Fourslide, Multislide and Vertislide systems, do not need a carrying web like that needed by progressive tools, resulting in significantly reduced material scrap. When the cost of materials is high, minimizing waste is key to running the part cost-effectively. This advantage is particularly pronounced in parts made of stainless steel, Inconel, copper, some brasses, and beryllium copper, where scrap can range from 20 percent to 50-60 percent.

“While an older technology, slide forming machines are still an extremely cost effective option for the right combination of material, part configuration and number of parts needed,” states Steve Dicke, the vice president of sales and marketing. “We have had excellent success using Fourslide equipment to produce parts going into medical devices that connect internal workings, as well as blade locks found in jet engines, and even float wires in gas tanks that connect back to a sensor. Where material can be as high as $60-70 per pound, reducing waste is important.”

“We do not ship anything that is not environmentally compliant, nor do we allow any chemical in the plant that is dangerous to employees or hazardous,” adds Thomas. “We do not even allow samples into the plant without first doing a MSDS review.” He explains that every hazardous substance brought into the plant increases the possibility of a spill, or emissions to the air or land, or exposure to workers. He gives the example of acetone, which is not allowed in the plant.

On a couple of occasions, CSS has turned away business when the customer insists upon using a particular hazardous chemical rather than a suggested substitute. Overall, the company believes it has gained more business than it has lost by being so attuned to environmental and hazardous waste concerns. Thomas adds that CSS is always looking for newer and better options for chemical substitutions, but is careful to make sure that new options are thoroughly vetted before being accepted for use.

According to Thomas, CSS used to require sewer permits to allow discharge of processed water into the sewer system, but now all processed water is evaporated into clean steam. Also, sludge is no longer placed in the sewer system but is removed by an environmental disposal firm.

In addition to the attention paid to hazardous waste substitutions, and the reduction in wastewater disposal and air emissions, Thomas conducts weekly and monthly audits for storm water runoff, spill prevention control, drum area inspection, and spill preparedness. Reuse and recycling of corrugated packaging materials is also an integral part of the facility’s operations.

As a certified trainer, Thomas trains 40 people internally for annual hazardous waste materials certification, including such topics as hazardous communications, solvent safety, hazardous waste management, spill response, and DOT security. “We are continually looking to the next advance in environmental compliance, which is becoming increasingly important to many Fortune 500 companies,” says Thomas. “In addition to U.S. rules, we comply with European Restriction of Hazardous Substances Directive (RoHS), as well as REACH (Registration, Evaluation, Authorization and Restriction of Chemical substances) standards as part of our cost of doing business.”

Connecticut Spring and Stamping Corporation, 48 Spring Lane, Farmington, CT 06034, 860-677-1341, www.ctspring.com.