A local company instituted a new chemical procedure in their spray phosphating system used in the pretreatment of large components for industrial racking systems. An inorganic conversion coating is deposited on the workpiece surface during phosphating and this prepares the surface to receive an organic top-coat. The organic coating is applied to the workpiece surface in the form of a powder and cured to form a continuous film about 80 u.m thick. The solution chemistry of the phosphating system was monitored by sampling and chemical analysis and taking direct reading instrumental measurements on the process and rinse solutions. The process was also evaluated using the results of a waste minimisation audit. This involved gathering data on composition, flow rates and costs of inputs and outputs of the process. Two types of information were collected and used during the audit, namely chemical monitoring (concentration levels of Na, Fe, Zn, Mo, Mn and Cr and measurements of conductivity, TDS, SS and pH) and water usage data on the Phosphating Line and existing data (raw materials, workpieces and utility inputs as well as domestic waste, factory waste and scrap metal outputs). The data were analysed using four established waste minimisation techniques. The Scoping Audit and the Water Economy Assessment results were determined using empirically derived models. The Mass Balance and the True Cost of Waste findings were obtained through more detailed calculations using the results of the chemical analysis. The results of the audit showed that the most important area for waste minimsation in the Phosphating Line was the (dragged-out phosphating chemicals present in) wastewater stream. According to the scoping audit, water usage had the third highest waste minimisation potential behind powder and steel consumption for the entire powder coating process. While the scoping audit and the specific water intake value showed that water consumption for the process was not excessive, it did not indicate that the pollution level in the rinse waters was high. Further, drag-out calculations showed that drag-out volumes were typical of those found in the metal finishing industry. However the presence of high levels of metal species in the rinse waters was highlighted through the chemical monitoring of the Phosphating Line. The True Cost of Waste Analysis estimated potential financial savings for the effluent stream at about R8000 for a period of 105 days. However this does not take into consideration the cost of the liability associated with this stream when exceeding effluent discharge limits (given in the Trade Effluent Bylaws) or of the chemical treatment necessary to render this stream suitable for discharge to sewer. Intervention using only "low-cost-no-cost" waste minimisation measures was recommended as a first step before contemplating further areas for technical or economic feasibility studies. However, a further study involving monitoring the sludge was recommended in order to establish the potential financial savings offered by this waste stream. / Thesis (M.Sc.)-University of KwaZulu-Natal, Pietermaritzburg, 2005.