Reducing Hazardous Waste Costs in an Automotive Plating Application
General $6,000 saved Mid-Range ($10K-$100K) HEPA Filtration Product Quality 2026-01-20

Reducing Hazardous Waste Costs in an Automotive Plating Application

Total Filtration Services

Unified ROI Framework

$52,000 total annual cost reduction by eliminating $6,000-per-changeout hazardous disposal fees through metal-free HEPA filters that extend life and remove hexavalent chromium carcinogen handling risks across two plating facilities

Direct ROI
Total Documented
$52,000 annually
Filter Savings
$52,000 total annual reduction across both facilities
Labor Savings
Reduced maintenance frequency — at least one fewer changeout per site per year
Waste Reduction
$6,000 per changeout disposal fee eliminated — hazardous waste cost is the primary savings driver
Operational Excellence
Quality
99.7% HEPA efficiency maintained — no compromise on filtration performance with metal-free design
Safety
Dramatically improved — elimination of metal frames removes hexavalent chromium contamination risk during filter handling; metal-free design reduces worker carcinogen exposure significantly
Soft Savings
Hexavalent chromium is a known carcinogen — employee health protection and OSHA compliance value is significant and long-term
Facility Efficiency
Equip Life
Filter life extended from 2–3 months to 3–6 months per site
Maintenance
At least one fewer changeout per facility per year — reduced regulated waste handling events
ESG Overlay

$52,000 in annual savings comes from eliminating hazardous metal HEPA components, removing hexavalent chromium carcinogen exposure risk and cutting regulated waste disposal costs at two automotive plating facilities

Sustainability
Metal-free HEPA eliminates metal component disposal from the hexavalent chromium hazardous waste stream
Waste
Eliminated metal-framed HEPA from hexavalent chromium hazardous waste stream — significant regulatory and environmental compliance benefit
Hexavalent Chromium ReductionHazardous Waste EliminationWorker SafetyEnvironmental ComplianceOSHA Compliance

The company is a Tier-1 automotive supplier producing exterior trim components for major OEMs including GM, Ford, and BMW. Their plating operations in Evansville, IN and Morehead, KY rely on high-efficiency air filtration to capture particulate associated with hexavalent chromium processes—requiring strict handling and disposal procedures. Total Filtration Services supports both locations through a Vendor Managed Inventory (VMI) program, with on-site visits to review inventory levels, engage maintenance and engineering teams, and proactively identify filtration optimization opportunities.

Challenge

The customer’s plating operations utilized metal-framed HEPA filters with aluminum separators.

Each filter changeout triggered specialized hazardous-waste disposal requirements due to hexavalent chromium contamination and the presence of metal components. Disposal fees averaged $6,000 per changeout per facility, driven by the need for regulated handling and landfill processing.

With approximately four changeouts per year and eight filters per location, disposal costs alone exceeded $48,000 annually, not including the higher unit cost of the filters themselves. Additionally, the frequent changeouts increased labor demands and employee exposure risk during filter handling.

The customer asked TFS to identify a non-metal HEPA filter solution that could eliminate disposal fees while maintaining performance and production consistency.

Leveraging technical expertise and preferred supplier partnerships, TFS recommended the Rensa Superflo® HEPA filter—a metal-free, high-efficiency (99.7% efficient) solution designed for clean-air and plating applications.

TFS worked closely with the customer’s plating engineers to review performance data, validate compatibility, and initiate a controlled trial at the Morehead facility.

During the three-month trial period, filter performance was monitored through pressure and airflow measurements to ensure consistent operation and proper loading behavior.

The trial confirmed that the Rensa Superflo® filters met performance requirements and exceeded expectations for service life. Based on these results, the same solution was implemented at the Evansville facility, and the previous HEPA filters were fully phased out the filtration system.

Explaining HEPA

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RENSA Superflo® HEPA Filter

HEPA is an acronym for "High-Efficiency
Particulate Air" or "High Efficiency Particulate Arresting." This
acronym refers to a mechanical air filter that is manufactured, tested,
certified, and labeled in accordance with current HEPA filter standards. it works by forcing air through a fine mesh that traps harmful particles.

Total Filtration Services partners with multiple trusted manufacturers of HEPA filters and can assist you with selecting the right model for your application.

Connect with a HEPA expert today
  • Eliminated $6,000 per changeout disposal fee by removing metal components
  • Reduced total annual costs by approximately $52,000 across both facilities
  • Extended filter life from 2-3 months to 3-6 months depending on site conditions
  • Reduced maintenance frequency by at least one changeout per site per year
  • Improved employee safety by minimizing exposure during filter handling
  • Decreased overall waste volume through fewer changeouts and simplified disposal

The customer reported that the Rensa Superflo® filters maintained stable airflow and pressure over longer service intervals, improving operational consistency while significantly reducing total cost of ownership.

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