Following design of the Brompton Folding Bicycle by Andrew Richie MBE in 1975 initial low volume ad hoc production commenced in London, with the product subsequently then achieving recognition by way of the Best Product Award at the Cyclex event at Olympia in 1987. Full time production followed from the first railway arch facilities in Acton to a factory in Brentford in 1988 with the company then achieving Royal recognition with the Queens Award for Export Achievement in 1995.
Today the company employs over 230 staff, currently producing over 45,000 bicycles per year, exporting to 45 countries and maintaining a commitment to quality and excellence with Managing Director, Will Butler Adams being appointed an OBE in the 2015 New Year’s Honours List.
The company use the latest leading technologies from rapid 3D prototyping through precision machining, skilled brazing, co-ordinate measurement and electrostatic powder coating.
However, until recently, despite applying production disciplines, the company were conducting somewhat inconsistent and uncontrolled vibratory finishing processes to clean, de-scale and remove unwanted deposits from brazed sub-assembly components prior to powder coating. The processes were using conventional ceramic processing media in conjunction with a citric acid pickling agent which was producing inconsistent results with large irregular amounts of chemical being required. The subsequent inhibition stage of the processes also required uncontrolled amounts of compound to be used and in conclusion far too many variables were being employed in a non-uniform manner.
Moreover, the processes were producing an unacceptable toxic effluent and consent limits set by the local water authority were unable to be met. Post process effluent was therefore being collected in IBC containers and being removed from site by a specialist hazardous waste company for treatment at very high cost of £1,800 per week. Two existing suppliers were unable to offer better methods or provide operational and technical support. Therefore, taking full responsibility and observing a duty of care, Tony Hobbs ( Factory Manager ) contacted Walther Trowal for advice and recommendations.
A full site evaluation of the processes being used was undertaken to include collection of sample components for alternative process trials and effluent for chemical analysis.
The process trials by Walther Trowal were carried out free of charge and established that an improved method could be adopted using a fraction of the citric acid and that an improved surface finish and appearance could be produced consistently and with the uniform use of materials and additionally reducing the cycle time from 1 hour to 30 minutes.
Furthermore, by the introduction of a centrifugal effluent treatment system, the process liquid could be re-cycled, within a so called closed loop system, based around a ZM 03 – FL model machine, whereby its small footprint permitted the machine to be fitted into the current layout with no major alteration being required. The unit serves eight vibratory finishing machines and the re-cycling system allows Brompton to save up to 90 % of the water and compound consumption compared to the previous processing method, reducing waste effluent removal to one IBC every three months.
Following installation the system has operated efficiently in full production resulting in multiple savings and providing a quick return on investment and much improved working environment.
