Iron Phosphate Bath

I have an iron phosphate bath and I would like to reduce the formation of sludge. Is there any way to reduce it?

Iron phosphate baths can be built up several ways, if yours is sodium phosphate based maybe you could change to an ammonium based one. The sodium in these baths is not used in the coating, it falls out as sludge. In the ammonium ones, the by-products are liquids and gases, so less sludge.

Really the first thing you should look at is the monitoring and replenishment habits of the operators of the system. Good bath maintenance is usually the key to controlling sludge. Also remember that anything you clean off the part has to go somewhere, so if this is a cleaner-coater type process then you may be happier than you think.