S04 E17 - Jason Potts & Shane Moore - Reducing Rejects Without Slowing Production

S04 E17 - Jason Potts & Shane Moore - Reducing Rejects Without Slowing Production

Inconsistent coating performance, plating defects, and costly rework often start long before parts ever reach the plating bath. In this episode of Seen & Solved, experts from Hubbard-Hall and Pavco discuss the upstream causes of rejects in metal finishing operations — and how manufacturers can improve quality and consistency without sacrificing throughput. Many shops struggle with process drift, contamination, poor rinsing practices, changing oils, bath imbalance, inadequate cleaning, and rushed production speeds that quietly create downstream quality issues. Drawing from decades of field experience, the conversation explores practical ways to troubleshoot plating lines, stabilize production, and reduce scrap across both automated and manual finishing operations.   The conversation covers: ·      Process drift and reject reduction ·      Plating bath troubleshooting ·      Cleaning and pretreatment performance ·      Rinsing, contamination, and bath control ·      Hull cell testing and diagnostics ·      Production speed vs. coating quality ·      Root causes of plating defects and roughness   Jason Potts (Hubbard-Hall) and Shane Moore (Pavco) also share practical examples from the field, including troubleshooting zinc contamination, paraffin wax issues, improper bath temperatures, inadequate activation, and common “quick fixes” that often create even larger downstream problems. Whether you work in electroplating, decorative plating, retreatment, industrial cleaning, or surface finishing, this episode provides practical insights into improving consistency, stabilizing production, and reducing costly rework without adding unnecessary complexity.   Learn more about Hubbard-Hall’s cleaning, pretreatment, plating, and wastewater chemistry at https://www.hubbardhall.com [https://www.hubbardhall.com]

S04 E16 - Mike Valenti - Why Most Cleaning Failures Aren’t Chemistry: Equipment, Throughput & Process Control

When parts aren’t coming out clean, the first instinct is to change the chemistry. In many cases, that’s not where the problem starts. In this episode of Seen & Solved, Tim Pennington talks with Mike Valenti about what actually drives cleaning performance in a metal finishing operation. It’s a practical look at a common issue across shops – trying to solve systemic problems with chemistry, when the limitation is really equipment, capacity, or how the process is being run. Mike walks through why most cleaning challenges trace back to equipment, not the cleaner itself, and how factors like throughput, part geometry, and soil loading determine whether a system will hold or break down. From immersion and spray systems to ultrasonics, the conversation covers where each approach works and where it doesn’t. They also get into what you can see on the floor when things aren’t right: rinse stages that can’t keep up, oil carrying through the line, tanks being changed too frequently, or systems that were sized for a different level of production. As more operations move from solvent to aqueous cleaning, those gaps become harder to ignore, especially with complex parts and tighter performance requirements. The takeaway is straightforward. Cleaning isn’t a single variable, it’s a system. Spray pressure, coverage, time, temperature, rinsing, and oil removal all have to work together. If the equipment isn’t set up or maintained to support that, no chemistry change will stabilize the process.

S04 E15 - David Govoni - Choosing the Right Aqueous Cleaner - The Chemistry Behind Clean

Choosing the right aqueous cleaner isn’t always straightforward. Metal type, soil load, equipment, temperature, and wastewater considerations all influence performance—and small missteps in cleaning can lead to bigger problems downstream. In this episode of Seen and Solved, Dave Govoni, Senior Chemist at Hubbard-Hall, shares practical insight from years of hands-on experience in metal finishing. He walks through how to approach cleaner selection based on real-world conditions, from degreasing and oxide removal to managing sensitive metals like aluminum, copper, and brass. The conversation covers how pH and temperature impact cleaning performance, why rinsing and bath monitoring are often overlooked, and how surfactants, emulsifiers, and inhibitors work together to deliver consistent results. Dave also highlights common causes of staining, residue, and adhesion failures—and what to look for on the line before those issues show up later in the process. There’s also a practical discussion on extending bath life, stabilizing performance, and reducing waste treatment impact through better process control and operator awareness. If you work in metal finishing, surface preparation, powder coating, plating, or industrial manufacturing, this episode offers straightforward guidance you can apply directly to your process.

S04 E14 - Jason Potts - Breaking Through Paraffin: Removing Wax-Based Oils from Metal

Paraffin-based rust preventatives are some of the most stubborn soils in metal finishing. When they’re not removed properly, shops pay the price — in labor, solvent cost, safety concerns, and poor adhesion. In this episode of Seen and Solved, a finishing facility was forced to wipe every single part with acetone before cleaning just to remove a tenacious paraffin-based oil. The manual step slowed throughput, increased chemical spend, and exposed employees to unnecessary solvent fumes. Instead of accepting the process as “the way it’s always been done,” Hubbard-Hall Technical Representative Jason Potts investigated the root cause — identifying the oil as paraffin-based and reformulating the cleaning stage using AquaEase® PL 918, a high-performance alkaline cleaner designed to remove heavy oils at lower operating temperatures. Within one week: • Acetone wiping was eliminated • Labor and solvent costs were reduced • Line throughput improved • Adhesion risks were minimized • Workplace safety improved If you’re dealing with: • Paraffin-based rust preventatives • Adhesion failures in plating or coating • Excessive manual cleaning steps • High-temperature alkaline cleaning limits (160°F max systems) • Slow production throughput in finishing lines This episode walks through how to identify the chemistry challenge and correct it without adding complexity. Serving metal finishers, electroplaters, powder coaters, and manufacturers across the U.S., Hubbard-Hall helps facilities improve cleaning performance, surface preparation, and overall finishing efficiency.

S04 E13 - Travis Hilton - Getting Proper Ratios on Tin/Lead Deposits

In this episode of Seen and Solved, Travis Hilton, Operations Manager at Hubbard-Hall, discusses one of the most critical controls in electronics and specialty metal finishing: achieving and maintaining the proper tin-lead plating ratio. Tin-lead electroplating is still widely used in aerospace, medical, military, and electronics applications where solderability, ductility, and corrosion resistance are required. Maintaining consistent alloy ratios—such as 60/40 or 90/10 tin-lead—depends on tight control of bath chemistry, current density, temperature, agitation, and preventative maintenance. This episode covers:- How modern methane sulfonic acid (MSA) tin-leadplating baths are formulated- How tin and lead concentrations are measuredusing titration and atomic absorption (AA)- Why deposit ratios can shift even when solutionchemistry is in control- How current density influences alloy compositionand coating performance- The effect of tin-rich vs. lead-rich deposits onsolderability, ductility, and brittleness- Common issues such as stannic tin formation,organic contamination, and bath instability- Filtration, anode maintenance, and processcontrols to extend bath life- Waste treatment and disposal considerations forlead-bearing plating chemistries For plating engineers, process managers, and quality teams working with tin-lead electroplating for electronic components, connectors, and wire bonding, this discussion explains how chemistry control and operating discipline directly impact deposit ratio, reliability, and long-term performance.