Merritt Industrial’s Multi-Method
E-Coating Removal Project
Restoring Efficiency at a High-Volume Manufacturing Plant
When a large automotive manufacturing plant approached Merritt Industrial during their year-end shutdown, they needed a contractor capable of delivering high-precision industrial cleaning, e-coating removal, and equipment restoration across multiple systems—all within tight night-and-weekend windows. The job demanded more than routine cleaning. It required a team capable of adapting methods, deploying multiple technologies, and handling sensitive components without disrupting equipment integrity.
Merritt Industrial was selected because we offer exactly that:
Scalable manpower. Advanced cleaning technologies. And the ability to adjust methods to the environment—not the other way around.
Understanding the Challenge: What Makes E-Coating So Difficult to Clean?
E-coating primer (electro-coat) is engineered to be incredibly durable. It provides corrosion resistance, strong adhesion, and uniform coverage—ideal for protecting automotive chassis and components. But those same qualities make overspray and process buildup extremely difficult to remove once cured.
Historically, the facility relied on manual scraping and large crews who chipped away at hardened e-coat using chisels, scrapers, and hand tools. This method was time-consuming, inconsistent, and created unnecessary labor costs. On the crane system, the facility previously used 40,000 PSI water blasting, which produced secondary waste, created safety concerns, and risked damaging electrical components.
When production efficiency, cleanliness, and equipment longevity began to suffer due to e-coat accumulation, the plant needed a smarter, safer, more efficient solution.
Merritt Industrial’s Multi-Method Cleaning Strategy
To complete this complex shutdown cleaning project, Merritt Industrial implemented a three-tiered approach—leveraging dry ice blasting, media blasting, and targeted manual cleaning to ensure every component was restored to operational readiness.
1. Dry Ice Blasting: Non-Abrasive Removal for Sensitive Equipment
Dry ice blasting served as the primary cleaning method for areas where protecting equipment surfaces and electrical components was critical.
Applications Included:
- E-coat removal from oven roller systems
These rollers transport frames and bodies through high-temperature ovens. E-coat buildup had begun to impair rotation and efficiency. Dry ice blasting removed contamination without abrasion or heat distortion. - Crane system cleaning
The crane transports parts through the e-coat process. Historically cleaned with 40k PSI water blasting, this system was vulnerable to overspray, electrical damage, and excessive secondary waste. Dry ice blasting provided a no-water, no-chemical alternative, restoring cleanliness without risk to wiring or sensors. - Chain drives and mechanical assemblies
Dry ice allowed technicians to reach into tight areas and remove accumulated primer and grease safely.
Because dry ice sublimates instantly, no secondary waste was produced—critical when working above sensitive equipment and confined spaces.
2. Media Blasting: White-Metal Finishes Where Needed
While dry ice blasting is ideal for non-abrasive cleaning, some components require more aggressive removal methods.
The plant’s metal floor grates had years of heavy e-coat accumulation that dry ice could not remove efficiently. Merritt Industrial evaluated the situation and selected crushed glass media blasting to strip the grates down to a clean, white-metal finish.
This decision underscores the Merritt advantage:
We are solutions-based, not equipment-restricted. We use the right method for the job—not the only method we sell.
3. Manual Cleaning & Debris Removal:
Supporting Production Uptime
While two dry ice blasting machines and our media blasting unit were operating, our additional technicians were:
- Hand scraping heavily impacted areas
- Prepping and staging downstream zones
- Cleaning pits and removing dislodged debris
- Supporting confined-space operations
- Ensuring all work areas remained safe and operational
This combination of mechanical, media-based, and manual cleaning demonstrates Merritt Industrial’s scalability and ability to deploy resources strategically.
Systems Serviced During the Shutdown
Over the course of the three-weekend operation, our team cleaned and restored:
- Oven roller systems
- E-coat crane and transport systems
- Conveyor systems and chain drives
- Floors, trenches, and pits
- Tooling, dies, and fixtures
- Metal walkways and grates
The buildup was causing visible performance degradation. Our cleaning restored baseline operating efficiency and reduced unplanned maintenance.
E-Coating Removal Project video library
Why an Experienced Contractor Was Critical
Cleaning e-coat buildup—especially on sensitive oven systems—requires specialized knowledge. Damage to an oven floor panel or crane track can result in:
- Production shutdowns
- Expensive replacement components
- Extended maintenance downtime
Our technicians were trained to work:
- At height
- In confined spaces
- Around high-temperature metals
- On sensitive electrical systems
The project was completed without damage, without contamination, and without delaying restart schedules.
Project Stats
- 3 weekends + ½-day Fridays
- 6 technicians deployed
- 12-hour working days
- 8,700 lbs of dry ice used
- Substantial square footage cleaned (multiple systems across the facility)
- Zero secondary waste produced on dry ice operations
The Merritt Advantage: Adapting to the Job, Not the Other Way Around
While Merritt Industrial is known for our dry ice blasting capabilities, jobs like this highlight the broader truth:
We are an industrial cleaning company first—not a “one-machine, one-method” service.
We adapt, evaluate, and select the right approach for each phase of the job to maximize:
- Cleaning effectiveness
- Production uptime
- Equipment longevity
- Plant safety
Our technicians are trained for high-stress environments, elevated work, confined spaces, and complex system cleaning. Whether we’re removing e-coat from rollers, blasting grates to bare metal, or hand-cleaning pits, the end result is the same:
A cleaner, safer, more efficient manufacturing environment.
Outcome & Impact
By combining multiple cleaning technologies, Merritt Industrial delivered measurable improvements:
- Restored equipment efficiency
- Extended lifespan of existing components
- Reduced downtime due to buildup-related failures
- Improved operator visibility and cleanliness
- Eliminated high-pressure water blasting and its risks
- Achieved a deeper, safer clean with no chemicals and zero secondary waste
This is what modern industrial cleaning looks like.
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