From TCE to Safer Solvents at New Method Plating

In this webinar, Nicholas Cappello, Co‑President of New Method Plating Co., discusses the company’s transition from TCE to a modified alcohol vacuum degreasing system, sharing lessons learned and results achieved—working with Alliance Manufacturing to meet TURI standards.

Transcript:
Nicholas Cappello:
Thank you very much for having me speak today. My name is Nicholas Cappello. I am Co‑President of New Method Plating in Worcester, Massachusetts. I was asked to speak about our process—really the whole experience—from making the decision to move away from trichloroethylene to where we are now.

We were established in 1931 by my grandfather and are a third‑generation business. My brother Chris and I now run the company. We’ve been using TCE for over 50 years. Like many chemical users, it was a case of “if it isn’t broken, don’t fix it.” It always worked well and delivered successful cleaning results, but we also knew it was on the endangered list and posed health concerns.

That made this a difficult decision. We were concerned about quality issues, production issues, and whether an alternative chemistry could truly perform as well. We specialize in production plating—primarily zinc, cadmium, and nickel plating—and vapor degreasing is critical to both our internal process and as a service we provide to customers.

One of the main motivations for change was aging equipment. We were dealing with failures, production disruptions, maintenance issues, and some quality concerns. There was also the reality that TCE is going to be banned—it’s not a question of if, but when. Waste removal costs were another major driver. Those costs have gone up tremendously.

Energy and maintenance reduction were also key. We were running two machines and a high‑pressure steam boiler, which required a lot of electricity and maintenance. Reducing that energy usage was very important to us.

As a job shop, one of our biggest challenges is that we don’t always know what’s coming in. We handle a wide variety of parts—screws, cylinders, delicate components, threaded stainless parts—and many arrive with unknown oils. Finding equipment and chemistry that could adapt to that variability was a major concern.

We ultimately replaced two older machines with a single ILSA IK‑40E vacuum degreasing system using a modified alcohol solvent, Dowclene 1601. The machine is manufactured in Italy, with representation and support here in the U.S. through Alliance Manufacturing.

One of the biggest advantages for us was going from two machines to one. The new system handles all of our production, takes up roughly the same floor space, and significantly reduced maintenance requirements. Alliance Manufacturing worked with us to customize the equipment, including modifying the machine height so it would fit in our building and adapting it to work with our existing baskets.

Selecting the right chemistry was critical. We worked closely with TURI and our suppliers, conducted trials, reviewed safety data, and even tested equipment at other facilities. That testing phase was essential. Picking the right equipment was just as important as selecting the right solvent.

Implementation took time. This is not off‑the‑shelf equipment. From purchase order to delivery, it was close to a year. My advice is simple: don’t wait. Do your research early, because there are many considerations when purchasing a vacuum degreasing system.

Waste removal costs really put things into perspective. Our last drum of oil mixed with TCE cost nearly $1,650 to dispose of—a 159% increase. Today, the waste oil from the new system is non‑hazardous and costs about $160 per drum. That difference alone was shocking.

In terms of results, part cleanliness has improved. Parts aren’t just clean—they’re coming out shiny, especially stainless steel. The system is fully automated, with touchscreen controls and built‑in safeguards. Cycle times adjust automatically based on cleanliness, heat, and drying requirements, removing guesswork from the process.

We have not had to add any solvent since startup. The system recovers and recycles the solvent internally, separating oil in the still. We typically drain one to two gallons of oil per month.

Energy usage has dropped significantly. We’re now running one machine instead of two, without the steam boiler, and overall runtime has decreased because the system is more efficient.

Perhaps most importantly, customer feedback has been extremely positive. We informed customers that we were switching to a greener cleaning process, and there was no pushback—only positive responses. Many noticed improved cleanliness and less residue right away.

Overall, the transition has been a success. It took planning, testing, and collaboration, but we are confident we made the right decision.

If you’re planning a move to cleaner solvent chemistry, contact Alliance Manufacturing to discuss your options:
https://alliancemfginc.com/contact