Finishing - September-October 2020

September/October 2020

THE PREMIER UK JOURNAL FOR SURFACE TECHNOLOGY

Innovation in Thru-Process

Automotive Paint Monitoring

Safe ATEX Certified Temperature Profiling

Intrinsically Safe

• 20 measurement

channels

• Paint & Powder coating

• Includes Phoenix Factor

cure index calculation

New Optic Video Profiling System

During Production

• Detect paint runs, drips

and defects

• Spot transport problems

• Identify oven damage

Phoenix Temperature Measurement

T:01353223100 E:sales@phoenixtm.com www.phoenixtm.com

www.finishingmagazine.co.uk

THE

POWER

OF

MEMBERSHIP

THE SEA HAS ALL THE ATTRIBUTES YOU NEED

Save money

Save time

Keep a step ahead with industry updates

Enhance your reputation

Gain political clout and expertise

SURFACE

ENGINEERING

AWARDS

FRIDAY 19 th MARCH 2021

PARK REGIS BIRMINGHAM

Visit www.sea.org.uk/2021-awards for

sponsorship opportunities; if you wish

to enter; or should you just wish to

attend and support your industry.

SEA

SUPPORT

MEMBERS

SEA members are working hard in the

manufacturing supply chain, supporting

programmes to improve the working lives

of those on the frontline in the NHS as

well as the comfort and survival of those

suffering from Coronavirus in hospitals across

the world. This includes parts produced for

the UK Ventilator Challenge and 3D printing

straps for masks, amongst many other things.

Some of the SEA members involved:

Aalberts Surface Treatment

Abbey metal Finishing

A-Gas Electronic Materials

Amphenol Invotec

Ashton & Moore

Electrolytic Plating Co.

Frost Electroplating

Poeton

Riley Surface World

Stainless Plating Ltd

South West Metal

Finishing

For further details of how the

Surface Engineering Association

can support you, please contact

Michaella Mais on 0121 237 1123

or email michaella.mais@sea.org.uk

Surface Engineering Association

Federation House

10 Vyse Street Birmingham

West Midlands B18 6LT

+44 (0)121 237 1123

info@sea.org.uk

www.sea.org.uk

A

www.finishingmagazine.co.uk CONTENTS 3

Editor

John Hatcher

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Carol Baird

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Managing Director

Ian Garmeson

Circulation

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Printed by Stephens & George

September/October 2020 – Volume 44 Number 5 – ISSN no. 0264 2506

In this issue...

At the moment it appears that no one in the UK knows what is ahead of us in the

coming months, with mixed messages coming from the UK Government on the

pandemic, Brexit and international trade agreements.

I don’t think anyone could have predicted the path of the last few months and with

the furlough scheme set to end it will certainly be an interesting time for British industry.

It would be good to get some feedback from the Finishing industry on how it sees the

future.

I suspect there may be some difficult times ahead, but hopefully I will be proved

wrong and there is certainly some optimism in the pages of this months issue. Keep

your news and opinions coming in and keep safe as we enter the

winter months.

News

Newsdesk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Features

Do you know what happens in your paint oven? . . .10

Selectively speaking . . . . . . . . . . . . . . . . . . . . . . . . . .12

Think big: powder coating on heavy duty parts . . . .16

Integrating robotics . . . . . . . . . . . . . . . . . . . . . . . . . .20

All members of the SEA

automatically receive Finishing Magazine

Extraction units launched . . . . . . . . . . . . . . . . . . . . . .26

Precision boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Getting the drop . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Precious process . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Doubling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

© Copyright Turret Group Ltd 2020

All Rights Reserved

All rights reserved. No part of this publication

may be produced in any material form (including

photocopying it or storing it in any medium by

electronic means and whether or not transiently

or incidentally to some other use of this

publication) without the written permission of

the copyright owner except in accordance with

the provisions of the Copyright, Designs and

Patents Act 1988. Applications for the copyright

owner's written permission to reproduce any

part of this publication should be addressed to

the info@turretgroup.com

Regulars

Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Workshop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Classified listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Finishing (formerly Finishing Industries) was established in 1947 and incorporates Metal

Finishing journal, Electroplating & Metal Finishing, The Plant Journal, Surface Coatings, and

Industrial Finishing & Surface Coatings. Finishing is a member of the Metal Finishing

Association, a sustaining member of the Institute of Metal Finishing and the UK representative

of the Groupement International des Revues de Traitements de Surfaces.

Finishing – September/October 2020

4 NEWS www.finishingmagazine.co.uk

New service could generate income from assets

Manufacturers, building

managers, local councils and

other large energy users could

generate thousands of pounds of

income from their assets thanks

to a new service launched by SSE

Enterprise’s distributed energy

business.

SSE Enhance is a smart grid,

aggregation and trading platform

that allows users to get paid for

helping to balance supply and

demand across their local

network and the electricity

network. The platform will give

customers access to the

Wholesale market, Balancing

Mechanism, and Ancillary

Services.

Companies, public sector

organisations and other

customers can receive

payments/make savings for

reducing their electricity demand

during peak periods, or they can

Three year deal

Leading national supplier of

metalworking and maintenance,

repair and operations (MRO)

products and services, MSC

Industrial Supply Co. (MSC), has

won a three-year contract with

Sulzer, a global leader in fluid

engineering.

The contract, which covers

Sulzer’s 25 UK facilities, sees

MSC appointed as Sulzer’s

preferred supplier for

metalworking and MRO

categories including tooling, PPE

reduce their own peaks through

optimising and automating local

demand against

generation/storage. This will help

customers manage local

constraints, increase security of

supply and optimise asset

performance.

Customers could also be paid

to feed excess electricity from

their own assets – like combined

heat and power units, solar

panels, wind turbines or energy

storage batteries – into the grid

to help cope with spikes in

demand.

Customers can set the

parameters for the platform –

such as the times of day that

they’re prepared to vary their use

of electricity on site – and then

SSE’s market-leading optimisation

software, coupled with its

experienced trading team, will

optimise and/or trade those assets

and general consumables,

alongside the provision of

engineering support.

MSC was awarded the contract

following a competitive tender

involving five suppliers.

Primarily, MSC will devise and

implement vending solutions at

five of Sulzer’s largest UK

manufacturing sites, in

Birmingham, Leeds, Hungerford

and two facilities in Aberdeen. It

will then roll-out bespoke solutions

at Sulzer’s other UK sites.

in response to market events.

Users also receive access to a

round-the-clock support and

monitoring desk.

This new platform forms the

basis of SSE Enterprise’s wider

suite of services, that will enable

them to partner with

Global service

extended

AMETEK Surface Vision has

extended its global service and

technical support for industrial

customers to ensure operations

continue safely and effectively.

The pandemic has seen an

increased demand in critical

industries such as nonwovens,

paper, and food packaging.

AMETEK Surface Vision has

fast-tracked its enhanced plans

for remote support to ensure

maximum productivity and

efficiency in these areas.

Surface Vision’s two surface

inspection and monitoring

product lines, the SmartView

and SmartAdvisor systems, are

in use by customers around the

world, requiring continual

support in a range of industries

including metal, paper, plastics,

and non-wovens.

In particular, the company

has seen an increase in

requests to optimize systems

detection and classification as

industrial mills have changed

their product mixes in response

to the pandemic. Surface Vision

provides a full-featured remote

organisations to support them on

their journey to Net Zero carbon

emissions.

SSE Enterprise’s distributed

energy business is currently

adding specific customers’ assets

to the system so that they can

begin trading their energy.

support platform to facilitate

these requests, allowing mills to

adapt to changing priorities.

With travel restrictions in

place due to the COVID-19

pandemic, Surface Vision

customer support engineers are

working more remotely, which

has allowed the team to be

more responsive as they are

available online for longer.

Yamina Lansari, global

manager of technical services at

AMETEK Surface Vision,

comments, “The pandemic has

prompted us to evaluate how

effectively we deliver services to

our customers.

“Our support service is built

as a partnership with our

customers, who often have

mission-critical systems that

need our help. Our service

engineers are well versed in,

and available for, remote

service delivery. On-site service

is also available to supplement

and augment our remote

offerings where it is businesscritical

and where regulations

allow.”


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The BCF looks at how the UK will cope once we fully leave the EU at

the end of the year

Technical data service

Bitrez has launched a new service to provide customers with technical

data on a broad portfolio of specialist resins used in the formulation of

advanced coatings, adhesives and composites via the free, members

only, section of their website, My Bitrez.

Providing a hub of knowledge, My Bitrez offers the user everything

they need to know about the latest developments such as REACH

compliant alternatives; from green bio-epoxy curing agents which

mitigate the use of Mannich based formulas used in marine and

construction to BPA free phenolic resins used to coat food packaging.

My Bitrez offers some of the most in depth product presentations and

data sheets available free online, providing descriptions, applications,

key properties and specifications.

Dominic Hopwood, Bitrez’s resin sales manager, says: “After decades

of intensive R&D, working with academia, research institutes and some

of the largest companies in the world, we have been able to create this

library of information of specialist resins. This has allowed us to share

our research in an easy to use format, with concise data sheets and

technical information all in one place.”

New sales manager

BOFA International has

appointed Douglas Gray as

international sales manager to

support the company’s growing

success in overseas markets.

Douglas has more than 20

years’ experience in industrial

sales, the last 15 of which have

been with companies in Asia,

Europe and the Americas.

In his new role, he will focus

on developing sales to OEMs in

all BOFA markets worldwide,

other than North America,

where the company operates

through its subsidiary business,

BOFA Americas, Inc. He will be

working closely with new

customers to develop long-term

relationships while also providing

support to existing clients,

particularly those with a focus on

printing applications.

Douglas commented: “The

most striking thing about BOFA

is the calibre of the team and

the reputation of their products

– and these qualities provide a

strong foundation in markets

around the world. I am very

much looking forward to

meeting new and existing

clients, whether that be remotely

in the current circumstances or

face-to-face as and when

lockdowns start to ease around

the world.”

The British Coatings Federation has increasing concerns at how plans

for post-Brexit trade with the EU will have a substantial negative

impact on its membership in future.

In a letter to the UK Prime Minister, BCF CEO Tom Bowtell cited

lack of progress on UK-EU Free Trade Agreement talks, as well as

how current plans for future regulation of chemicals in the UK –

particularly a UK version of REACH - would create substantial extra

financial and regulatory burdens for business. These conditions could

lead to global companies moving their manufacturing to sites in

Europe threatening the UK’s status as a net-exporter. The letter also

highlighted fears of job losses across the UK if workable solutions for

trade beyond the Brexit transition period were not found.

Examples of extra regulatory burdens on the coatings and printing

inks industry included UK-based companies that want to continue to

export to the EU having to set up legal entities in the EU and

operate under dual labelling regimes. On top of those issues of redtape

are the much-talked-about concerns over the setting up of a

separate UK REACH system, duplicating the requirements of the

existing EU REACH. In the letter to the PM, BCF explained how

additional costs to chemical manufacturers re-registering chemicals in

the new UK chemicals database within a two-year period are

conservatively estimated at £1 billion. Moreover, EU companies may

deem it uneconomic to register some substances in the new UK

system at all. That would mean UK manufacturers would not have

access to the same raw materials as their EU counterparts or, in order

to make sure they can continue to have access, UK downstream

manufacturers, like those in the coatings sector, would have to take

on the re-registration costs themselves.

The letter goes on to urge the Prime Minister to secure a

comprehensive FTA that maintains tariff-free trade, high standards

and consistency in chemicals regulation, and does not create

substantial extra cost and bureaucracy or animal testing. It also calls

for the current duplications inherent in the planned UK REACH

system to be rethought, to reduce the additional costs that it would

currently mean for business.

Commenting on the letter, Tom Bowtell said: “The BCF has, along

with many other organisations, worked closely with Government to try

and ensure a workable transition for industry post-Brexit. However,

with the clock ticking, and FTA talks making very little progress, we

feel that there remain significant – indeed growing – risks that what is

currently planned will significantly and detrimentally impact on our

members’ future business. Put simply, if a key point of Brexit was to

reduce bureaucracy for business, this will not end up being the case

in the coatings or wider chemicals sector as things stand.

“We still believe the best way to prevent the issues outlined in our

letter from damaging UK business would be for the UK to remain as

an associate member of the European Chemicals Agency. However, if

the UK Government has definitively ruled that option out, we

support attempts to negotiate access to the EU chemicals database

for the UK regulator through an FTA chemicals annexe. However,

even then, there would be extra obstacles and costs to trade between

the UK and EU our members will have to deal with. We therefore

also need the UK Government to minimise those added hurdles of

new UK regulations in future, especially where they introduce

duplicate requirements for our industry, as will be the case with UK

REACH.”


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enquiries@wagner-group.com


Two become one

In 2019 Pexa and PSG, both part of the Graytone Group, were

acquired by Addev Materials, the French owned international specialist

in chemicals distribution and custom packaging.

Since then the companies have continued to operate independently

but it has been announced that the two companies will come together

and operate under the name Addev Materials Aerospace & Defense.

This forms part of Addev Materials’ global strategy to gather its

chemicals distribution businesses under this brand and to offer the

market the option of a technically expert supplier with a significant

international reach.

The companies will unite under the Addev Materials brand and the

old Pexa and PSG brands have been “retired”. All literature and other

assets have been reissued with the new logo.

Jim Rowbotham, strategic partnership director said “This is good

news for our industry and our partners, both customers and suppliers.

Due to Covid-19 the whole market has suffered a shock and significant

restructuring of business is underway. Our merger is very timely and

offers customers and suppliers in our market a new solution and a

new approach based on the market as it evolves from here.”

The field sales teams of the two companies have been merged, so

customers now have a single sales contact. All UK stocks and product

mixing capabilities have been located at the company’s site at Bordon,

Hants. In the EU all stocks have been located at the Addev Materials

site at Toulouse, which will form the hub of EU operations and the

main platform for the company’s operations in Europe after Brexit. The

company has merged the Pexa and PSG websites at

www.addevmaterials-aerospace.com and will create an entirely new

website moving into 2021.

New website launched

On the 1st September the Institute of Materials Finishing launched its

new website (www.materials-finishing.org)

What is different about this website is that it will have a new

members section which will allow members of the Institute to access

areas such as webinars, seminars, useful information etc. that nonmembers

will not be able to.

If you are already a member contact Helen Wood

(helen@materialsfinishing.org) to be asked to be allow access to the

this area.

You will need to provide her with your membership number and

email address; you will then be supplied with a generic password

which you will need to reset via the Edit Profile or forgotten password

section.

The membership will gradually be added to the web site from the

1st September, so if you see an email stating you have been added to

the IMF website, read it and login and change your password.

Wedge is Covid approved

A leading firm of UK galvanizers has been officially recognised as meeting

the requirements to earn ‘COVID-secure’ status when operating during

the pandemic.

The accolade for Wedge Group Galvanizing means that steps taken by

the firm to mitigate all potential health and safety risks related to the

spread of coronavirus have been independently assessed and verified.

The company, which has kept its plants open to fulfil urgent and

emergency work associated with supporting the fight against coronavirus,

rapidly implemented safety measures to keep its staff and customers safe

during the crisis.

Adam Gibson, group HR and health & safety manager at Wedge

Group Galvanizing, said: “A huge effort has gone into ensuring all the

risks associated with COVID 19 have been tackled head on in order to

protect our workforce.”

QUALICOAT Specification Update

Companies that form the membership of QUALICOAT recognise

that the association is constantly updating its powder coating

standard for architectural aluminium installations. Irrespective of

country borders, the standard is recognised across the globe for

specification of high quality powder coat applications for

architectural use. Updates to the current standard, now in its 16th

edition, are issued to licence holders who immediately implement

the changes to the processes. The constantly reviewed

QUALICOAT Standard differs to typical country specific standards,

such as British Standards and European Standards, that usually

only get reviewed once every few years.

The 16th edition of the QUALICOAT Standard launched in early

2019 was updated early in 2020 to incorporate the 2019 updates.

A further four updates were announced on the 1st July 2020

which now forms an appendix to the current standard.

With membership of the QUALICOAT association comes

communication and all new updates are discussed during member

meetings prior to implementation into the standard giving

members the opportunity to question and prepare for changes in

production. Three of the recent updates relate to changes in

production testing conducted in powder coating applicators

laboratories and the fourth one related to approval of colours for

Class 3 powders.

The first of the production update sheets, ‘US10’, effective

immediately, removes the ‘cupping test’ from the production line

tests used during powder coat application. This test now replicates

some of the existing tests carried out on production sample plates

and following the guidance from the ‘In-house Control Working

Group’ it was felt this test could be eliminated. Update sheet

‘US11’, effective immediately, refers to minor corrections in the

standard and to maintain correct cross reference to emerging

national standards and charts. Update sheet ‘US12’, effective from

1st January 2021, highlights small but crucial changes in frequency

of production testing proposed by the ‘In-House Control Working

Group’.

Update Sheet ‘US13’, effective from 1st January 2021, defines

which RAL colours are to be tested to meet the Class 3 powders

standard and lists the RAL colours, that as powder coating

technology stands today, do not have sufficient resistance to colour

change after ten years of outdoor exposure to ‘Florida Outdoor

Exposure Testing’. QUALICOAT Class 3 powders are the most

resilient powders available for powder coating, sometimes known

as ‘Hyper- Durable Fluorocarbon Powders’ and are used in areas

of the world where exceptional resistance to UV degradation and

abrasion is required. In the UK Class 1 powders are commonly

used for general applications and many new prestigious projects

are being specified in Class 2 powders for extended durability on

both colour fastness and gloss retention.

Copies of the sixteenth edition of the QUALICOAT Standard,

complete with the amended updates mentioned, are available

through the UK Association website, www.qualicoatuki.org together

with an up-to-date list of licensed UK and Ireland Powder

Suppliers, Pretreatment Suppliers and Applicators. Printed

literature and telephone support is available from QUALICOAT UK

& Ireland Head Office in Birmingham on 0330 236 2800 or email

enquiries@qualicoatuki.org. The Association can also be followed

on Twitter @Qualicoatuki


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TENNANTS

Simon Kelly

Product Manager

T: 0161 205 4454

M: 07970 134 455

simon.kelly@tennantsdistribution.com

10 PAINT

Do you know what happens

in your paint oven?

The basic concept of thru-process

temperature profiling remains very similar

to the systems developed in the 1980’s, a

thermally protected data logger is passed

through a cure oven measuring via

thermocouples the product temperature

throughout its journey to provide a

temperature profile. Evolution and automation

in the automotive manufacture process,

including painting operation, has driven a

constant need for innovation in temperature

profiling and process monitoring.

Safe Monitoring in ATEX

classified areas

Over the year’s regulatory compliance and

health and safety has become a critical aspect

of day to day

manufacturing. One important requirement

of this in the paint operation has been the

need for classification of areas and zones on

the paint line against potential explosive risk

(e.g. ATEX classification in Europe). A need to

identify the explosive risk in key areas and

therefore restriction on the type of equipment

that can be used in that area brings technical

challenges.

To perform a temperature profile on a

solvent or water-based coating line requires

that the profiling system be passed through

zones / areas that are classified as potentially

hazardous. These areas may include the paint

booth, flash off zone and even the paint

curing oven itself. In such areas potentially

explosive gases / volatile organic compounds

(VOC) may be present from solvents such as

Acetone, Toluene and Xylene, used in and

released from the coatings or as cleaning

agents. In a powder coating line, the build-up

of dust layers and dust clouds can also create

an environmental explosive risk.

Phoenix Temperature Measurement

(PhoenixTM) has introduced the Epsilon-x a

unique intrinsically safe 20 channel profiling

system. The PTM1520 data logger is certified

against the ATEX European standards as

Group II category for safe operation in

gaseous and dust environments (ATEX Zone 2

and 22 respectively) allowing safe operation of

automotive paint and powder coating

applications.

The PhoenixTM Finishing monitoring

system allows efficient safe and accurate

monitoring and validation of your paint line.

Choose from magnetic thermocouples for

traditional steel or clamp thermocouples for

Aluminium. A choice of Silicone free thermal

barriers provides the thermal protection you

can trust, typically 3 to 5 hours at 200 °C. The

Thermal View Finishing software allows paint

process conclusions and actions to be made

quickly but with confidence. Including the new

Phoenix Factor index of cure analysis tool,

accurate cure confirmation against paint

supplier specifications for all your different

coatings is now possible. The final profile

report gives you the comprehensive certified

monitoring record to allow fully traceable

validation of your paint operation.

Optical Profiling a products eye

view

Thru-process temperature profiling provides

a great understanding of what temperatures

the product sees travelling through the cure

oven. In terms of paint quality though, in

particular cosmetic finish and paint defects, this

is not the complete story. During the journey

through the oven the painted car body can

experience many problems that are not

temperature related that can affect the quality

of the cured paint. Problems such as paint

runs, drips, paint or rinse entrapment or

condensate contamination can only be

detected post process without any specific

knowledge of the root cause / location of

problem. If only you could see a video of the

car body travelling through the oven to allow

identification and location of such issues.

The PhoenixTM Optic system has been

developed specifically to allow such paint

defect detection using Optical Profiling.

Adapting the thermal barrier technology used

for temperature profiling a high-resolution

video camera can safely travel through the

paint oven with an independent torch

recording video footage of what the product

sees. The system is just like your car ‘Dash

Cam’ the only difference being that the

journey is through a cure oven operating up

to 200 °C. The Optic system can be mounted

on a test body allowing monitoring of the

exterior of a separate production body shell or

potentially directly on a production body itself.

In addition to paint defect detection the

Optic system can be helpful in detecting other

process problems specifically relating to the

oven and conveyor system operation without

physically having to access the oven.

Identifying oven damage, badly adjusted

ducting, faulty fans, failing jerky belt drives can

allow pro-active corrective action and prevent

lengthy down time and lost productivity.

Whether temperature or optical monitoring

PhoenixTM your Finishing Oven to find, fix

and forget those paint cure problems!

Finishing - September/October2020

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Proud supplier of DeFelsko Inspection Instruments

12 POWDER COATING

Selectively speaking

Damage to molds and related tooling for

plastic and metal parts seems to be

inevitable due to foreign object damage,

acidic corrosion, and other causes of wear and

tear. In some cases, small flaws in new mould

tooling causes higher than acceptable scrap

rates. This can mean tearing down the

equipment, removing the mould, and sending

it out for repairs. However, with in-situ

selective plating, mould surfaces can often be

repaired without taking the mould out of the

machine. This greatly reduces repair costs.

The end result is reduced rework and scrap

rates.

Selective Plating Process

Mould and die costs vary widely depending

on size, materials and origin. With costs

ranging from tens of thousands of dollars up

to millions, the last thing a manufacturer

wants to do is buy new tooling. Just the cost

of removing a mould from the machine for

outside repair is substantial, and the cost of

lost production is greater still. These costs vary

depending on the size and depth of the

mould area needing repair. This makes typical

in-situ plating repairs for a one-day job a very

attractive option.

As a general rule, defect depths of up to

about 0.060” are good candidates for this

type of repair. Greater depths are possible and

the decision to proceed with deeper defects

may become an economical one and not

technical. Very large or deep defects can often

be prepared for selective plating by peening

or filling with a metal plug to minimize the

time needed for plating.

If a mould has a lot of corrosion, scratches

and other small surface flaws that result in a

poor finish on the molded part, the

temptation may be to remove the tooling and

send it out for tank electroplating. However,

selective plating can take care of these flaws

without extensive masking and is significantly

faster than tank electroplating.

The general approach for a selective plating

repair is:

• Dish out the repair area to create the

appropriate depth to-diameter ratio

• Apply cleaning and surface treatment

chemicals to prepare for plating

• Use selective plating to fill the depression

with filler metal material (often copper)

• Then selectively plate with a hard cap

metal that matches the performance

requirements of the tool

continues on p14


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14 POWDER COATING

• Do final dimensioning for the required

finish and sizing

Selective plating equipment is portable,

enabling the operator to meet plating and

build-up requirements wherever they arise.

This flexibility is an important cost and time

saver. It minimizes dismantling, downtime,

turnaround delays and shipping charges

usually associated with sending parts out to be

plated.

Automotive Case History

Vehicle manufacturers around the world

continue to increase the use of fiber reinforced

plastic (FRP) components in their cars to

reduce weight, cost and fuel consumption.

Several kinds of fiber and plastic matrixes are

being used in compression and resin transfer

molding (RTM) processes for everything from

body parts to internal components. Carbon

fiber reinforced plastic (CFRP) components

seem to be the choice for many of the body

parts in small, lightweight vehicles. The molds

for these and other FRP parts can be quite

expensive and have long lead times, especially

for the car body parts.

That was the case for one automaker having

problems with a fender mould that was being

used over multiple shifts every day. The

original cost for this mould was approaching

$2 million and was made by an offshore

producer. Because of pitting in an area of

several square inches at the bottom of the

mould, the automaker’s scrap rate was 15 %

and other fenders required post-processing

rework to salvage them. Compared to average

scrap rates of 2 to 4 % for other molded parts,

this was totally unacceptable.

This automaker used an outside shop for

mould maintenance. The maintenance

company tried doing some surface repairs, but

that made the problem worse. Another option

was taking the mould out of service for a

month to do major outside repairs by the

original mould maker. That meant they would

have to stockpile 800-900 fenders in a rented

warehouse—another costly alternative.

At this point the mould maintenance vendor

called in a plating technician to use the SIFCO

Process of selective plating to repair the

mould. The technician arrived at the site with

all the equipment and solutions needed to

complete their part of the repair. After

prepping the pitted area, copper was used as

the fill material. Afterward, a nickel cap was

applied. The final dressing back of the

repaired area to blend with the original mould

surface was then done by the mould

maintenance company.

This entire job was accomplished during

only one operating shift. The selective plating

portion of the repair was completed for less

than $10,000. The mould is now producing

fenders with scrap rates within the

automaker’s acceptable range. All this was

accomplished at a cost far below any of the

other alternatives.

Selective Plating Capabilities

Selective plating, also referred to as brush

plating, techniques were first developed in the

late 1930s, but have been refined with more

modern plating materials and equipment

today. Dozens of pure metal and alloy

solutions are available for use in brush plating

Table 1: Example of Brush Plating Applications for Plastic Molds

to accommodate different mould metals and

finishes. These solutions typically have higher

metal content than those used in tank plating.

Deposits can be produced that are hard, fine

grained, very low in porosity, have low

residual stress and are not prone to hydrogen

embrittlement. Electropolishing and application

of wear-resistant coatings to the mould surface

can also be accomplished using the same

techniques.

The preparatory process used depends on

the base material of the mould and any

plating from prior processing that may be

present. This process can include solutions for

cleaning, etching, desmutting, activating and

preplating. In all cases, preparatory and plating

solutions are applied with a handheld plating

tool wrapped with an absorbent cover material

saturated with the solution. The mould is

attached to the ground lead of a DC power

supply, and the plating tool is connected to

the positive lead to complete the circuit.

As shown in Table 1, selective plating can

solve various mould problems. Nickel and

cobalt are excellent choices for selective

deposition to resize core pins and bushings,

often without post machining. These two

materials have good toughness characteristics,

in addition to excellent wear resistance. If a

harder surface is required, nickel-tungsten,

cobalt-nickel and cobalt-tungsten alloys may

be selectively deposited with a hardness range

of Rockwell C 47 to 60.

Summary

Selective plating is a cost-effective mould

repair technique for a broad array of mould

surfaces. It can be accomplished without

removing the mould from production

machinery and can often be accomplished in a

matter of hours.

Application Metal Deposited Capping Metal

Mould Cavity Damage Nickel or Copper fill Nickel Semi-bright, Nickel-

Flash Correction in Gate

Areas or Parting Lines

Resize Core Pins and

Bushings

Corrosion Protection

Machine Maintenance

a) Hydraulic cylinder repairs

b) Resizing shafts, journal

areas, and bearing fits

Same as above

Nickel or Cobalt

Depending on corrosion

mechanism

Copper

Nickel or Cobalt

Tungsten, or Nickel alloys

Gate Areas: same as above

Parting Line: Nickel Semibright

only

Not Applicable

Not Applicable

Nickel semi bright tin or zinc


16 POWDER COATING

Think big: powder coating

of heavy duty parts

Giga Coating GmbH was founded to

protect trailer and semi-trailer chassis

with a length of up to almost 16

meters from corrosion. The largely

automated, high-performance powder

coating system is also available to external

customers with large components as a job

coater.

Truck semitrailers and trailers travel around

the world and are subject to many years of

hard use. Maximum corrosion protection

plays a central role in the long service life of

these vehicles. System Trailers, a company

based in Germany, relies with great success

on the innovative combination of cathodic

dip painting and powder coating. To this

end, the medium-sized company has

founded its own coating company Giga

Coating GmbH and has built a state-of-theart

plant for surface finishing in two

construction phases.

The challenge: external job

coating as the eye of a needle

Maximum corrosion protection plays an

important role in the durability of trailers and

semi-trailers. To be able to produce them

economically despite high automotive

requirements, System Trailers relies on a

high degree of automation and optimized

manufacturing processes.

After powder coating by a job coater had

become a challenge in production, managing

director Ralf Saatkamp resolved by founding

Giga Coating GmbH in autumn 2015 as an

in-house coating company for large-format

components in automotive quality.

An approximately 8,600 sqm hall was built

on the company premises, in which very

large and very heavy workpieces are made

corrosion-resistant by means of cathodic dip

painting KTL and powder coating. Right from

the start, the capacities were designed to also

process external orders.

The solution: cathodic dippaint

coating and dense-phase

technology - highly automated

Researching for a suitable partner for their

new powder coating system, managing

director Ralf Saatkamp got in contact with

Nordson - and with its dense-phase

technology. The soft powder cloud of

Nordson’s dense-phase technology with the

Encore HD spray system and the patented

HDLV (High Density Low Velocity) pumps

continues on p18


18 POWDER COATING

ensures full coverage in corners, recesses,

and delivers powder to the spray system with

a minimum of air offering the independent

control of the powder and air volumes.

Further advantages of the technology are

maximum process control, a very high

degree of automation and repeatability of the

coating quality at the highest level. "This

gave us the secure feeling of having found

the right partner in Nordson, so that

Nordson was awarded the contract," says Mr.

Saatkamp.

Since the new plant was established in

2018, a sophisticated conveyor system has

been handling the workpieces, which can be

up to almost 16 meters long and weigh up to

9 tons, through the 11-stage pre-treatment

process of blasting, degreasing, zinc

phosphating and cathodic dip painting before

they arrive at one of the two ColorMaxE

powder coating booths, ("E" = Engineered)

built to customer specifications. The

installation of the second powder coating

system followed in 2020, additionally

equipped with the highly efficient Dynamic

Contouring System for complex product

geometries.

Thanks to their compact design, the booths

are engineered for fast color change

processes to minimize lengthy production

interruptions with multiple color changes

(usually batch size 1) per shift. The Nordson

Spectrum HD powder feed center provides a

complete powder management within the

powder coating system. The entire system is

operated via the icon-based touchscreen

interface of the PowderPilot® HD control

system. The operator can call up the status

information of all modules at any time and -

for example in case of a color change - be

shown step by step where his attention is

needed. Thomas Maubach, coating operator

at Giga Coating, says: "With the excellent

coating result, the simple operation and the

fast and very easy color change, it is a

pleasure for me to go to work every day".

In each booth, 22 Encore HD automatic

powder guns efficiently ensure uniform

powder application with maximum process

control over a long period of time.

Two Encore HD manual guns are also

available for coating very special shapes. The

manual coating stations are equipped with

lifting platforms for better access up to 2.7

meter high components. The first booth

without Dynamic Contouring naturally

requires a little more post coating than the

latest booth with the Dynamic Contouring

system.

The second ColorMaxE booth, equipped

with the innovative DCM (Dynamic

Contouring Mover) system, provides even

more precise control of the powder guns -

without any programming. Scanners in the

booth's entry area detect the geometry of the

incoming part. They transmit the data via

PowderPilot HD to the DCM system to bring

the powder guns to the optimum distance

from the workpiece. The result is an even

more consistent coating of the complex

geometries, even lower powder consumption,

less post coating and higher productivity. The

system thus operates up to 95%

automatically.

The system control is also integrated into

the in-house ERP system "Giga-IT".

The customer benefit: Coating

heavy-duty parts economically

in automotive quality

After Giga Coating commissioned the first

of the two powder coating booths in 2018

and the second in spring 2020, managing

director Ingo Wildermann draws a thoroughly

positive conclusion. "The decision to bring

the coating into our own hall and automate it

as much as possible has massively increased

our production. And further optimizations are

being carried out daily. The required powder

quantity per rack is stored in our Giga

Coating ERP system and is analyzed daily.

Mr. Wildermann is also completely convinced

of the coating quality. "We work according to

the strict specifications of the automotive

industry and even exceed them. A salt spray

test, which we carried out here on our own

initiative, we stopped after 3,000 hours

because nothing corroded yet. The DIN EN

ISO 11997-1 standard specifies only 1,000

hours!”

The construction of the powder coating

system worked well right from the start -

even though Giga Coating certainly had to

put in a great deal of effort to get a complete

production line up and running in a short

time. "In the first week after the installation of

the line, we already produced 20 chassis with

the desired coating thicknesses between 80

and 120µ - practically on the side while the

line was being adjusted", Mr. Wildermann

remembers the successful start-up phase.

"We now have the capacity for around 50

trailers per day!"

In the environment of a "batch size 1

production" with maximum powder recovery,

this is only possible if the frequent color

changes, including careful cleaning, can be

accomplished within minutes.

The trouble-free operation of the plant

encouraged Giga Coating to start contract

coating for external customers after only one

year. These are mainly customers who, like

Giga Coating, are looking for fast throughput

times with very high quality and who, with

their large-format, corrosion-prone

components, contribute to good utilization of

the annual capacity of around 1.5 million

sqm of coating in three-shift operation.

In the next issue:

Robotics

Anti-corrosion

Precious metal

finishing


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20 ROBOTICS

Integrating robotics

Advanced automation is nothing new to

Gema, for many years they have been

integrating powder coating systems with

robots for full flexibility and efficiency. Leon

Hogg, Gema UK business manager explains:

‘More recently we have seen an increase in

demand for automation within our customer

base, with businesses looking more to reduce

the labour requirement in the production

environment whilst maintaining the flexibility

of a more traditional system. As we respond

to the increased interest in more advanced

automation we recognise the need for in

depth application trials early in the project

specification process.

“Our lab facilities in St Gallen, Switzerland

have adapted quickly to the challenges

presented with Covid-19, we are pleased to

confirm that are now offering trials using

virtual meetings and video conferencing to

our UK customers whilst travel restrictions

remain in place. Product trials have been an

integral part of the Gema project process for

many years as we demonstrate our

technologies and capabilities, by adapting to

the situation and using a different approach

we can ensure that meet our customer needs.’

The Gema lab has recently undergone a

significant upgrade programme with all of the

existing trial systems upgraded to the latest

Gema technology offering the option to test

the complete range of our technology in a

single trial. They have also recently unveiled

a brand new automation cell, this is a

dedicated powder coating booth system

complete with their state-of-the-art laser

contour system and robot application for both

organic and enamel powders.

As demand increases, Gema are working

on projects that require advanced automation

and data collection with R&D teams constantly

developing and refining their Industry 4.0

compatible systems to maintain their position

as the world leader in powder coating

technology. There is no doubt that the future

will see traditional powder coating give way to

more flexible and efficient robot orientated

applications combined with contour

recognition technology to achieve high

standards of coating on very complex parts

with minimal operator intervention.

As the need for more advanced automation

increases the need for data collection &

sharing become a core requirement. In 2019

Gema launched the new MagicControl 4.0

and with it a range of new advanced features

that have been developed around data and

relevant use of that data. Some of the new

features now offered includes:

• Line management data including

coating time, clean down times, number of

colour changes

• Real time monitoring and recording of

power usage

• Real time monitoring and recording of

compressed air used

• Ambient condition monitoring –

humidity and temperature

• Batch management data with option for

powder weight measuring

• Overall system health monitoring with

consumable parts counters and service due

continues on page 22


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22 ROBOTICS

warnings

When it comes to powder conveying, Gema

says it is the market leaders with its dense

phase SIT pump technology. With more than

800 SIT pumps in operation in the UK alone,

it has become the benchmark product due to

its efficiency and simple design that can be

easily maintained and operated. However,

with the focus starting to move towards

advanced automation the Gema R&D team

also recognised the need to update and

redevelop the traditional technology that still

forms a large part of what they do and

brought them to where they are today. This

allows the Gema sales teams to offer their

customers a range of options when working to

specify a new powder coating facility. The

Gema All-in-One system has been developed

to bridge the gap between traditional injector

technology and the SIT inline dense phase

pump technology.

The All-in-One combines a completely

redesigned powder pump body with the gun

control unit to give a compact system that

offers extremely high quality coating and

powder application control. The All-in-One fits

directly into the Gema OptiCentre platform

without the need for additional gun control or

pump cabinets as found on typical traditional

systems and comes equipped with a range of

standard features:

• No pneumatic pipework associated with

traditional venturi systems – this removes any

time lag when triggering the gun making it an

excellent option when using robots

• Built in FlowCheck powder flow sensor

to detect any powder blockages

• PowerClean function with bi-directional

cleaning through the injector body

• Built in Gema DVC and PCC

technology for best possible powder transfer

efficiency and consistent powder output

through the gun

chemical transfer and treatment needs.

Contact us :

SIEBEC UK Ltd, Stafford

+44 (0) 1785 227700

sales@siebec.co.uk

www.siebec.com

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• Save tank heating costs up to 25%.

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and thickness distribution.

• Improves Throw deposit thickness in blind,

through holes and recesses.

• Permits use of increased current density,

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24 INSTALLATIONS

New plant facility

During the recent pandemic as well as producing goods for use in

ventilator and medical equipment manufacture, Almetron has put time

to good use by building a new Pilot Plant Facility to cover all aspects of

its metal finishing supply operations.

The new facility will play a key role in its future development work

and also be able to offer its customers assistance in any of their

development work.

Attached to the laboratory and product development department the

Pilot Plant is a fully functional anodising line and paint pre-treatment

line which includes a powder coating facility. Combined with our

inhouse corrosion testing suit and adhesion testing facility, means we

can produce specific finishes, powder coat and performance test all at

the Wrexham Site.

Air force on

Following the recent extensive

painting of India’s Surya Kirans

aerobatic display team aircraft,

specialist coating manufacturer,

Indestructible Paint Ltd., has

brought its expertise to a light

combat helicopter operated by

the Indian air force. Products

from the company have now

been re-certified for application

by local distributor, Matcon High

Coats PVT Ltd., by the helicopter

division of Hindustan Aeronautics

Ltd.

“Both new build and overhaul

vehicles have been coated with a

system of high build epoxy

primer-surfacer for the composite

airframe, overcoated with a 2-

component polyurethane finish

in both military and commercial

colours,” says John Bourke,

global sales manager at

Indestructible Paint. The work

has been conducted at many

sites throughout India with more

than 300 Advanced Light

Helicopters and Light Attack

Helicopters painted since the

original certification in 2005.

New launch

from Datacolor

Indian powder plant

A new powder coating extruder at a factory in India has been

commissioned and started-up remotely by Baker Perkins engineers

based in the UK.

This is an extension of existing capabilities where, with the

customer’s permission, Baker Perkins is able to log in to a machine

regardless of location and, providing there is access to the internet,

carry out fault-finding and software updates.

This feature has allowed Baker Perkins to modify equipment

functionality, including the options to add upstream and downstream

equipment to the existing extruder control. These alterations can be

made with minimal cost, as the engineer does not have to leave Baker

Perkins’ office in the UK.

The MPX50 extruder in India is now in full production: a video link

allowed step-by-step guidance from our technician in the UK to the

customer’s engineer on-site. Remote support was achieved using an

Industrial Router mounted in the extruder control panel, which enabled

remote PLC access via a Wi-Fi VPN connection.

Datacolor has launched

SpectraVision V, an addition to

the SpectraVision family that

enables manufactures to

objectively measure and digitally

communicate colour

measurements for the

multicoloured, textured, smallsized

and irregular-shaped

materials. The solution increases

efficiency by reducing the steps

to match and approve colour.

“With the new vertical

configuration and enhancements

to the Datacolor Tools SV

software, we are able to extend

the benefits of objective digital

colour management to multiple

industries and customers.” said

Albert Busch, president and

CEO, Datacolor. “Customers with

previously unmeasurable

materials, whether due to its size,

shape, texture, or applications

can now conduct consistent,

repeatable, objective colour

measurements, result in

increased efficiency, reduced

costs and faster time to market.”

The new vertical

configuration, sample tray and

cup enable customers to

measure a wide variety of

samples, such as plastic pellets,

watch components, electronic

parts, and much more. High

resolution sample image taken

by the hyperspectral

spectrophotometer can also be

leveraged for onscreen colour

evaluation and communication of

colorimetric data.


The Choice for the Professional Powder Coater

Gema UK

01202 763942

uk.sales@gema.eu.com

26 FUME EXTRACTION

Extraction units launched

Developed for professional welders and

yet affordable for newcomers: The new

SmartFil extraction unit from KEMPER

sets a new standard in mobile welding fume

extraction for regular welding. Even in the

basic version, it is the price/performance

winner in its device class. At comparable price

level, the SmartFil offers twice the filter surface

and thus a significantly longer service life

compared with similar systems. An even larger

replacement filter and other accessories enable

welders to further upgrade the extraction unit.

Equipped for the first time with a round filter

insert in this device class, KEMPER has also

optimised the design to create a more

attractive, rounded appearance.

The more different the hazard potential, the

more different the necessary welding fume

extraction: Which extraction unit is suitable for

an individual welding application depends on

both the duration of use and the amount of

welding fumes produced. "Our SmartFil now

provides an extraction unit for a wide range of

hazard intensities – and at the best

price/performance ratio", emphasises Björn

Kemper, CEO of KEMPER GmbH.

Service life twice as long as

comparable models

The new extraction unit is available at a

comparable price level to other industrial

entry-level models but has by far the largest

storage filter. At 25 square metres, the filter

surface is in some cases twice as large as

similar models. This means that even with the

basic SmartFil equipment, welders achieve a

significantly longer service life compared to

conventional models.

And that’s not all: Welders can further

upgrade the SmartFil with optional accessories

if required. The choice for the replacement

filter is between the 25 square meter standard

filter or a storage filter with a filter surface of

42 square meters that again extends the

service life accordingly. In addition, the

SmartFil can be optionally equipped with an

automatic start/stop system and LED

workplace lighting in the extraction hood.

Fit for the future by upgrading

with KEMPER innovations

While the optimised design of the extraction

hood in the original equipment already makes

less tracking necessary, the new KEMPER

extraction hood available at the end of the

year in the extended version in combination

with the new 180 millimeter extraction arm

ensures an even higher capture rate. The

SmartFil is already designed for these

additional accessories: KEMPERbeats, a

Bluetooth loudspeaker for playing your own

music, an LED strip and the integrated volume

flow monitoring also make welding work even

safer and more pleasant.

Round instead of square:

SmartFil with a new design

KEMPER is also setting new standards in

terms of design with the SmartFil. Like many

comparable models, the extraction unit is no

longer square but round. This is possible

because – for the first time in this device class

– KEMPER has integrated a round storage

filter. As part of the housing, welders can

easily remove this SafeChangeFilter from the

extraction unit. This means that its disposal is

completely contamination free.

Thanks to its mobility and the 360-degree

rotating exhaust hood, the compact system

can be used flexibly at changing workplaces.

Welders gain greater reach by integrating

longer extraction arms of up to four meters in

a pipe or flexible hose version. The SmartFil

filters more than 99.5 percent of alveolar dust

particles.


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28 CASE STUDY

Precision boost

Ultra Precision Products Ltd,

manufacturer of high-end precision

machined components, have enhanced

their quality offering by investing in a

MecWash Systems Duo 400, as part of a

£1.5 million series of upgrades.

Ultra Precision’s main business activity is

in precision engineering; CNC milling,

turning, and machining. Based at a purposebuilt

factory in Haverhill, Suffolk, key

operational sectors include aerospace,

medical, oil and gas, subsea, nuclear,

hydraulics and defence.

A 2019 investment programme increased

engineering capacity and provided customers

with parts finished to a world-class level of

cleanliness. As well as cleaning equipment,

the investment also included the acquisition

of new CNC machines.

Replacing the previous labour-intensive

method of cleaning, the MecWash Duo 400

exceeds the requirements to clean machined

stainless steel and aluminium precision

components including rods used in medical

applications, removing soils, oil, coolant, and

swarf. It was essential for the machine to

have the ability to clean and dry products to

a high-quality specification.

MecWash’s Duo 400 has the benefit of

flood / immersion washing, which provides

the highest standards of cleaning by full

solution contact with all component surfaces,

and a re-circulating heated spray rinse, which

provides a superior surface finish by

removing detergent residues left by the wash

solution.The rinse stage can also be used to

apply a longer term corrosion inhibitor for

ferrous components, all finished off with a

hot air dry.

Simon Quick, production manager at

Ultra Precision Products Ltd, said: “Our new

component washing facility from MecWash

has proven to be a great success, hugely

improving the quality of the parts we deliver

in terms of cleanliness, whilst also reducing

the process time to complete the cleaning

operation. This in turn has helped with lead

times and delivery.

“The machine is fully programmable for

any cycle required, with a combination of

flood wash, spray wash, rinse and dry. The

water is filtered and skimmed automatically

to keep the wash solution in the best

condition possible and the dosage of cleaner

is controlled and maintained automatically in

cycle.

“As well as a full rotating wash, more

fragile items can be run on a static wash

where the baskets stay still. A variety of

baskets, dividers and clamps allow us to hold

all parts securely.

Geoff Quick, managing director at Ultra

Precision Products Ltd speaks of Simon’s

decision to choose MecWash:

“Being a British built machine was a factor

in the purchase of the MecWash Duo. This

coupled with the outstanding cleanliness

provided by the Duo made it the top choice

for Simon.

“MecWash’s customers include aerospace,

medical, pharmaceutical, defence and

motorsport. We have an excellent reputation

supplying precision parts into a wide range of

these industries, many of which also have

MecWash machines, so we are aware of the

fantastic cleanliness levels achieved.”

John Pattison, managing director at

MecWash Systems Ltd comments:

“We are always delighted when customers

are recommended our systems from other

suppliers they work with. Ultra Precision

supplies parts into many of the same sectors

that we supply our cleaning systems, so they

have seen how a well developed and

manufactured washing system can surpass

the results they were after.

“We work closely with all of our customers

to ensure the right mix of washing

technology and a bespoke blend of cleaning

chemicals. The Duo’s final wash quality meets

the highest possible standards of cleanliness. I

am positive that the Duo 400 will deliver for

Ultra Precision as they continue to increase

their capabilities and I hope they will return

to us again in the future with any further

cleaning requirements.”


Made in

Great Britain

…used all over

the world

Specialist

manufacturers

of acid proof

equipment

• metal immersion heaters

• fluoropolymer immersion heaters

• temp & level control

• external heating systems

• chemical pumps

• heat exchangers

To see the entire range of Braude

thermal process equipment visit

braude.co.uk

01252 876123

sales@braude.co.uk

click through from our web site to find us

in social media, follow us for latest news

Member of Backer Group

30 FINISHING

Getting the drop

company specializes in drop

forging in the weight range from 2.5

"Our

kg to 20 kg," explains Eng.

Ferdinand Bernhofer, owner and managing

director of technology of Ferdinand Bernhofer

Ges. m.b.H. in Höhnhart (Austria). Production

is mainly in small to medium-sized series with

batch sizes from 500 to 50,000 parts / year.

The parts are delivered machined and ready

for use upon customer request. Customers

include manufacturers of vehicles (i.e. trucks

and agricultural machinery), off-road vehicles

(from construction machinery to dirt bikes) as

well as general mechanical engineering

companies and hydraulic system producers.

Forging is an extremely efficient

manufacturing process in which the material is

used to its full extent, which makes it a highly

sustainable process. In collaborating with its

customer, Bernhofer draws on its competence

in the area of forging technology to support

users when requested in optimizing part

design to ensure process compatibility.

Finishing machining for

customer benefit

"When it comes to delivery, customers are

increasingly expecting complete service

packages from a single source," explains

Bernhofer.

Customers often prefer partnering with a

single provider to assume the overall

responsibility for the entire manufacturing

chain, from delivery to the finished parts or

installation-ready modules. Not having to rely

on and keep track of numerous suppliers

allows a company to concentrate on its core

competencies.

With this in mind, Bernhofer began

ambitiously expanding its range of services

several years ago. Expanding installation-ready

machining to a standard service was a top

priority. This service, which had previously

been purchased externally, would be

implemented increasingly in-house in the

future. To do this, Bernhofer set out to find a

manufacturer of suitable machine tools. Above

all, the machine tools had to be sturdy and

powerful enough to handle three-shift

machining of forged parts that are often highstrength

and therefore difficult to machine.

The parts being machined are combined in

groups so the systems can be changed over

or retooled as quickly and smoothly as

possible. Another criterion was the most

extensive automation possible, in order to

conserve resources through 24/7 operation.

Machining begins with

workpieces for motorcycle

frames

"The first project was a family of parts with


FINISHING 31

six variants made of quenched and tempered

steel for motorcycle frames," explains Christian

Stempfer, regional sales manager for Austria

of Schwäbische Werkzeugmaschinen GmbH.

The goals were fully automatic machining and

product change with no change-over. The BA

322 (a horizontal machining center from SW

with two synchronous spindles), was chosen to

accomplish these goals. The customer was so

satisfied with the system that SW was honored

with the Ferdinand Bernhofer Gesellschaft

Supplier Award 2016 in the same year as the

delivery.

SW machine is ideally suited for

heavy-duty machining of steel

drawbar eyes

"The mutual trust we have built on this

foundation has led us to choose SW again for

the next project," says F. Bernhofer. The new

project involved machining particularly large

drawbar eyes made of different variants of

42CrMo4. The task was made more difficult

by the relatively large number of holes and fits

that had to be machined and was further

complicated by the need for cooling lubricant

to drill the holes. The milling machine type BA

722, which was purchased for this purpose is

structured similarly to the BA 322 already in

use. The larger machining center, also with

two spindles, was needed mainly because

considerably greater quantities will be

motorcycles. Machining must remove up to 3

kg of material from each drawbar eye, which

may weigh up to 18 kg depending on the

variant. Although the allowances range from 5

to 15 mm, no problems were reported for the

"workhorse" BA 722. Its two spindles are quite

capable of removing up to two metric tons of

removed

actongate

through

- address

machining

alts.qxp_Layout

than for the

1 09/11/2016

material

08:51

in an

Page

hour

1

of rough machining, even

with a material as difficult to machine as this

one. Despite this, the system can be used not

only brachially, but also for precision

machining, for example in helical interpolation

of semi-spheres for clutches.

Stellar service and support –

flawless impeccable

"The support provided by SW was beyond

impeccable," recalls F. Bernhofer. In the critical

initial phase of the project, C. Stempfer in

particular was untiring in his dedication to

eliminating initial glitches and optimizing

processes, including time spent outside of

regular working hours. The technical service

provided by the SW technicians stationed

nearby in Austria and their supply of

replacement parts also left nothing to be

desired. Help was also available through

telesupport and online consulting. The

customer rated the support and service from

SW highly and noted that it was refreshingly

uncomplicated. The first system delivered

proved to be so good that a second was

ordered a short time later because the

customer's call-off orders had increased.

Machine availability is excellent despite the

high work load, as summed up by F.

Bernhofer: "I was also so satisfied with the BA

722 that we have already begun discussing

more extensive automation for the coming

year."

Acton Gate Systems Limited - Tel: 01902 249299

Hilton Hall Business Centre, Hilton Lane, Essington, Staffordshire, WV11 2BQ

web: www.actongate.co.uk - email: enquiries@actongate.co.uk


32 CASE STUDY

Transforming the environment

Northern Powergrid, the power network

operator for the North East, Yorkshire

and northern Lincolnshire, is the UK’s

first distribution network operator (DNO) to

adopt an innovative new eco-paint as

standard.

The announcement is the latest in the

company’s commitments to enable it to

deliver cost savings, increase reliability and

improve local air quality for its 8 million

customers. The paint provides a vital

protective coating to electricity network assets

and its unique formula cuts the amount of

material needed to protect a power asset by a

third.

DNOs traditionally use alkyd paints on

transformers and pylons. Traditional solventbased

paints can emit more than half the

liquid-weight as gases, known as volatile

organic compounds (VOC), into the

atmosphere during the drying process. This is

not a problem with the new paint, which is

water based. If rolled out across the UK

electricity industry, the eco-paint could save

more than 5.5 million tonnes of VOCs from

being emitted into local air.

Following a successful trial, Northern

Powergrid will deploy the new paint networkwide

as part of its maintenance programme to

protect its assets. The DNO expects the paint

to reduce asset downtime by 166 days a year,

as its properties mean assets can be painted

more quickly and come back online faster.

Additionally, the reduced asset downtime

increases network resilience by minimising the

risk of power outages, while also enabling

better value for money for customers. The

paint is supplied by North East firm Rosh

Engineering.

“We’re committed to delivering cost-savings

and driving sustainability across every element

of our business. Enabling the switch to

renewable energy and decarbonising transport

are two significant ways we are going green,

but this project demonstrates our commitment

to achieving net-zero carbon emissions in

every way possible,” said Geoff Earl, Northern

Powergrid’s director of safety, health and

environment. “This paint is a stroke of genius.

It is a prime example of out-of-the-box

thinking having a real and measurable positive

impact on our local environmental footprint.”

The roll-out of Rosh Engineering’s awardwinning

Greenovoc paint replaces the need

for toxic white-spirit paints. It will enable the

DNO to increase network resilience by

significantly reducing time taken to carry out

essential maintenance on assets, minimising

downtime and enabling Northern Powergrid’s

expert team to focus on delivering more

customer benefits.

The DNO uses 1,000s of gallons of paint

each year to protect 1,200 transformers across

the North East, Yorkshire and northern

Lincolnshire. It carried out trials with Rosh

Engineering over 20 months from June 2018.

The partners successfully applied the new

formula paint to two large power transformers

in Darlington Grid and Killingworth

Substations. The performance assessment met

all the required criteria, such as protection and

durability, and delivered increased

performance when compared with traditional

alkyd paints.

The new paint offers three interconnected

core benefits to the 3.9 million homes and

businesses that Northern Powergrid serves

across the North East, Yorkshire and northern

Lincolnshire:

1 Drying speed: The eco-paint can dry in

less than an hour, cutting the time taken to

disconnect, paint, and reconnect a transformer

to the network from two days to less than

one. Transformers usually work in pairs so if

one is out of service, the other keeps the

lights on. Taking an asset offline even for

essential maintenance therefore temporarily

reduces security of supply for customers.

Halving the downtime for transformers will

therefore increase network resilience.

2 Drying temperature: Water-based paint is

better for the environment and local air

quality. Northern Powergrid wanted to switch

for some time, but traditional water-based

paints need temperatures of 20°C+ to dry.

The new paint can dry as low as 6°C,

meaning it beats the drying speed of previous

water-based and white spirit-based paints.

3 Raw materials: The new paint needs a

much thinner coat to protect an asset,

reducing raw materials by up to a third.

Ian Dormer, MD of Rosh Engineering, said:

“We are always trying to improve the service

we provide our customers. No other

protective coating has delivered the results

that the Greenovoc Speciality Coatings

innovative paint has, while also being so

environmentally friendly. We are now

planning a new mixing plant for the paint at

our Blaydon on Tyne facility to ensure we can

meet the increased demand going forward.”

The first transformer to be painted as part

of the new agreement is in Peterlee, County

Durham. The rest of Northern Powergrid’s

transformers will be painted with the

innovative new solution as required.


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34 CASE STUDY

Precious process

AYorkshire-based pyrometallurgical

engineering firm has been

commissioned by a world leader in

managing, recycling and fabricating platinum

group metals, to deliver a number of

significant upgrades to its manufacturing plant

in London.

Normanton-based Inprotec will manage the

upgrades to Johnson Matthey’s Brimsdown

plant over the next 12 months as part of a sixfigure

contract.

Inprotec will renew key equipment used

throughout the recovery and production

process in order to improve reliability and

process control and ensure the plant is best

placed to meet constantly evolving demands.

As part of the project, Inprotec has worked

with Scunthorpe-based GWF Engineering to

create a Short Rotary Furnace, 3.5 metres in

length, which will be used for the smelting of

precious metals, supplementing the existing

furnaces at the site.

Additionally, Inprotec is also carrying out

major upgrades to the combustion system that

feeds a series of hard-working smelting

furnaces, known as Top Blown Rotary

Converters.

Commenting on the project, Chris Oldroyd,

managing director of Inprotec, said: “We’ve

provided Johnson Matthey with specialist

pyrometallurgical plant used to recover

precious metals for over 20 years now and

we’re delighted to have been commissioned

to support with this latest raft of hi-tech

improvements.

“As with any hard-working industrial plant,

it’s vital that it’s maintained and upgraded on

a regular basis in order to address any issues

of wear and tear and ensure it remains

efficient and reliable.

“Furnaces and the technologies that power

them lie at the heart of any metal retrieval

process and the significant upgrades our team

of specialists is delivering will ensure Johnson

Matthey continues to be a world leader in

managing, recycling and fabricating precious

metals, such as platinum and gold.”

George Dyer, site manager at Johnson

Matthey’s Brimsdown plant, said: “As part of

our commitment to providing our customers

with quality products that meet a diverse

range of needs, we’re continually investing in

our plant to develop and improve its industry

leading capabilities.

“The expertise, attention to detail and

service Inprotec offers is unrivalled and we’re

delighted to be working with them once again

on this latest round of improvements, which

will ensure we’re able to more effectively and

efficiently manage the metal recovery and

production processes.”

Inprotec is a family-run engineering

business which started in 1977 as G.A.

Oldroyd, named after its founder, Garry. In

2010, Garry’s son, Chris, took over the reins

and renamed the business Inprotec as part of

a rebrand, with the company moving to a

bespoke manufacturing facility in Normanton

shortly afterwards. It specialises in the design

and supply of pyrometallurgical process plant

used to recover lead and precious metals and

works with clients all over the world.


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Performance by design

36 VALVES

Doubling up

GEMÜ is supporting the development of

a new system, which will double

existing ventilation capacities by

enabling two patients to use the same

ventilator, with a pragmatic solution.

The Institute for Manufacturing of

Cambridge (IfM), which is part of the

University of Cambridge's Department of

Engineering, and the Royal Papworth

Hospital in Cambridge are collaborating to

develop a method for splitting a ventilator's

air flow so that two COVID-19 patients can

be treated simultaneously with one ventilator.

Such a device would make it possible to

double the capacities for the safe ventilation

of patients for short periods.

One requirement imposed by medical

professionals was that it had to be possible to

individually measure and control the air flow

to each patient. This was intended to ensure

that a deterioration or improvement in the

breathing of one patient would not affect the

air supply or monitoring of the other patient.

In order to accomplish this, the IfM has

developed a read-out meter, which makes it

possible to measure the tidal volume for each

patient in real time and monitor both the

overall pressure and the air flow on the

device. The individual fine adjustment of the

air flow for each patient requires valves that

can ensure the air/oxygen mixture is

precisely metered and are also easily

accessible.

In order to find a solution for these two

challenges, the scientists collaborated with

specialists from valve manufacturer GEMÜ.

These specialists calculated the optimum flow

rates for the air/oxygen mixture and

recommended that the GEMÜ C67 valves in

the nominal size DN8 be used, as these

valves allow for a high air flow and

simultaneously provide good manual

controllability thanks to their low flow

resistance. The design of the GEMÜ valves

also plays an important role, as the

handwheels are the only parts of the newly

developed device located outside the

housing, allowing doctors to individually

adjust the air flow for each patient.

Tests of the "splitter" with artificial lungs

have so far yielded very promising results, so

that the first details about the apparatus,

which was developed as a portable device,

are now freely available on the IfM website.

The website will be updated with the

complete details of the design and testing

once the device has been approved for use.

This will make it possible to have the

"splitter" copied across the world so that it

can be used as needed, particularly in

countries which, for a variety of reasons, do

not have enough ventilators, to double

ventilation capacities for short periods.

"We are very proud to have been involved

in this project. The device developed by the

Institute for Manufacturing of Cambridge will

save lives, particularly in countries that do

not have the means to procure a sufficient

number of ventilators," says Gert Müller,

managing partner at GEMÜ, about GEMÜ's

contribution and the collaboration with the

IfM.


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38 TOOLS

A common-sense approach to

effective tool management

High levels of safety, security and

organisation has to be paramount when

it comes to the working environment;

and meeting the demand for shadow and

impactful visual communication boards as

companies strive for 5S compliance and lean

operations in the workplace will contribute

significantly to ensuring this. Any effective

workplace, from an office to the factory shop

floor, from the warehouse and logistics centre

to high street store, benefits from a reliance

on visual cues and communication to operate

efficiently and safely.

The advantage of visual workplaces can

drive heightened levels of quality, productivity,

safety and employee morale. Moreover, visual

aids subliminally feed people with the

information they need by answering

questions, identifying equipment and

describing procedures. They also provide

important safety information. And that’s one

reason why we are seeing increasing numbers

of organisations implementing their 5S

programmes.

Developed in Japan, and embodying

orderliness, standardisation and cleanliness

among other attributes, 5S is an inexpensive

management approach that has at its heart a

system of visual aids and tools. These are

designed to help employees positively

contribute to the organisation they work in,

driving through improvements and

advantages across the whole business

environment. Enshrined in the 5S concept are

sort, set, shine, standardisation and sustain.

5S itself can be subject to continuous

improvement, so the adoption of shadow

boards for tools and specialist equipment, will

provide a common sense - and more cost

effective - way to improve the organisation of

the workplace, as part of the overall adoption

of lean processes.

Elimination of waste

Who wouldn’t disagree that the elimination

of wasteful practices has to be an important

consideration in business? So, nullifying the

effect of unnecessary actions can add value

and cut costs in straightened times. Shadow

boards are a proven means to implement

continuous improvement principles because

they are designed to encourage smarter

working practices and drive out waste.

Misplacing workplace equipment can be

frustrating, inconvenient and inefficient. It is so

often the case that it is not until work is

underway and people are reaching for a

specific item, that they realise it has gone

missing. They will inevitably have to then stop

what they are doing and waste valuable time

and effort attempting to locate the item - or if

they are unable to find it, spend needlessly to

replace it.

Experience has revealed that visual solutions

have been found to be more effective than

any other medium communication, even in

distracting environments. When introduced

into the workplace, the impact and advantage

of shadow boards can be manifold.

Equipment can be arranged in order in a

logical position and handy locations, making

them immediately visible and anything that is

amiss – a missing brush, for instance - can be

instantly identified and rectified before other

people become involved.

Shadow boards can be seen as an

embodiment of a common-sense approach to

an effective style of law and order in the

workplace. Shadowing products (or

equipment) has proven effective in helping

people find the right device quickly and

efficiently; less time wasteful. Usage


TOOLS 39

instructions suitably indicated alongside serve

as a subtle reminder every time the device is

used. It is, however, important to use shadow

boards with colours and artwork best suited to

the visibility levels in the workplace.

Colour coded, they can create

standardisation, personalisation and effective

delineation to ensure that the right equipment

is always available, in the right place at the

right time. Users can also reduce operational

costs as workplace standardisation removes

the requirement for designing and installing

expensive and time-consuming custom-made

shadow boards.

No-one can afford to be complacent when

it comes to workplace efficiency, regardless of

the operational environment. It’s clear that

higher visibility of tools and more effective

management of them is an important asset to

staying in step with 5S lean processes.

Specifically designed to ensure compliance

with lean processes, they can help to unlock

higher productivity levels in the workplace.

Ease of location due to clear product marking

provides rapid identification of equipment in a

busy, cluttered industrial shop floor or

warehouse, enhancing production levels and

reducing errors, while minimising the

possibility of cross contamination in hygiene

areas

Undoubtedly, shadow boards can also

transcend the testing environments of today’s

workplace. While a hard copy of instructions

has a short life, difficult to refer, and needs

multiple prints for distribution, details featured

on shadow board systems are here to stay,

unless there are additions or deletions to the

set of devices. Multiple transparent pockets

can hold hard copies of processes/instructions,

with changes updated by simply replacing an

older copy with the latest details. These are

but a few salient benefits of the shadow board

system. Adopting the right design will help

make best of this visual solution.

Different workplaces

It’s important to recognise that each

workplace is different: it has its own particular

set of unique requirements around tool

organisation and management. And this must

be reflected in any solution involving shadow

boards. So, a visualisation strategy must be

tailored to suit individual needs and

requirements – the ones size fits all won’t

always work in an environment where the

optimum flow of productivity is critical.

Workplaces, large or small, require a good

deal of complex planning and product

support, so think about your visualisation

investment in terms of quality, reliability and

performance. Consider also how your supplier

can add value through bespoke planning and

consultancy services. Implementation of

standardised shadow boards such as

Beaverswood’s new Modulean range, can be

innovative, cost effective and time-saving

investment, meeting the demand for impactful

visual communication boards as companies

comply with 5S and Lean in the workplace. It

reflects a comprehensive package of off-theshelf,

ready-to-buy highly visible boards that

can be used effectively individually or as part

of a modular system

40 Q&A

A family affair

ETS Ltd was established in 1996 and is

based in Warrington, Cheshire and cover

work within the North West region. It is a

small family company which means it is able

to focus its attention to quality workmanship

whilst affording a first class personal back up

service. Being a family run company it takes

pride on offering a professional, efficient and

friendly service from the first point of contact

through to the finish.

The company works closely with local

council and NHS bodies on a wide variation

of projects.

Finishing asked Anthony Bate owner of ETS

about his business and the markets that it

works in.

What does ETS do?

Entrance Technology Services manufactures

of aluminium security gates for

industrial/residential application which are

branded as Aligates

How long have you been in business?

ETS commenced 1996 as a family run

business by Kenneth Bate who started by

manufacturing timber based gates,from a

home workshop. Anthony Bate has further

developed the business to become one of the

UK leading gate and security manufactures &

installers

Do you specialise in any particular

process?

In January 2020 ETS moved into their new

18000 sq/ft facility based Warrington a new

state of the art pre treatment process with full

automatic powder coating and sublimation

process was installed for the application of

high quality powder coating finishes and the

wood grain sublimation process

How did you come to specialise in the

sublimation process for wood grain

effect on aluminium profiles?

We currently import wood grained materials

from Australia to fabricate into our gates. We

have complemented this range and adapted it

to suit the UK market with our own profiles

and additional wood grain colours. This has

allowed us to now manufacturer and supply to

installers within 4 weeks of receipt of an order.

Is this process becoming more popular

in the UK and can you give any

examples of people who have used the

process?

The process is uniques to ETS Ltd for their

own manufactured products, the sublimation

wood grain effect is becoming more popular

we can offer 8 varieties of wood grain effects

which we expect to increase due to demand.

What pre-treatment processes do you

use?

We work with Barry Clements Pre

Treatment Solutions Ltd who supplies the

process PHOS - PREP a non chrome pre

treatment for aluminium. The process is set up

to meet the performance requirements of

Qualicoat which we will be applying for.

Do you work with a company on your

pre-treatment processes?

The equipment was installed with TD

Finishing, controls procedures and operational

technical support we receive from Pre

Treatment Solutions Ltd.

How do you see the market going

forward?

I expect the market to increase

exponentially over the next few years and into

the next decade.

ETS Ltd being a family run business is

flexible for dealing with the smallest of

customers as well as the largest blue chip

operations


Celebrating more than 70 years

providing excellence in pumps

and filtration

High Quality German DC

Switch Mode Rectifiers

} DC Rectifiers

} Pulse Rectifiers

} High current rectifiers

up to 10,000A

Pumps up to 250m³/h

} Horizontal

} Magnetic Sealless

} Vertical Sealless

Filtration Systems

up to 60m³/h

} Cartridges

} Bags

} Papers

} Microfibres

For all

applications

} Electroplating

} Anodising

} Hard Chrome

} Reel-to-Reel Plating } E-Coat

For all your product finishing requirements

Hendor-pe UK Ltd, Carrington Business Park, Manchester Road, Carrington, Manchester M31 4DD

Tel: 0161 776 4331 | E: sales@hendor-pe.co.uk | W: www.Hendor-pe.co.uk

42 GALVANIZING

Speeding up the process

SIEBEC principally offers three tried and

tested technologies for the Galvanizing

industry:

• Oil removal from the degreasing baths

• PUSH-PULL agitation of the Acid pickling

bath

• Iron removal from the Flux bath.

The customer has a 60 m³ volume Flux

tank, running at 50 - 60°C. Unfortunately they

experience processing quality issues related to

the variation in iron concentration within the

flux process.

Hot-dip galvanizing pre-treatment requires

the maintenance of two critical parameters.

One being the oxidisation of iron (Fe² to Fe³ )

and the second, iron concentration within the

flux solution that should be maintained below

1 g/l.

The SIEBEC solution was to supply and fit 3

P51-A30 filters, each fitted with 4 L-TECH

50µm pleated cartridges, allowing iron

particles to be extracted from the 60 m³ flux

tank.

Thanks to the SIEBEC designed installation,

our customer now maintains the iron

concentration in the flux process below the

desired 1 g/l and no longer experiences the

quality problems they had been experiencing

prior to the P51-A30 filters being installed.

The solution has proven to be cost effective

as the filter media is very quick and easy to

clean, minimising waste. The L-TECH re-usable

cartridges only need to be replaced every 4 -6

months.

PUSH-PULL agitation

Pumped agitation of HCL Pickle tank.

SIEBEC developed and designed this

technique specifically to create a uniform,

evenly distributed laminar flow of the pickle

acid across the entire surface of the parts

anywhere within the tank. This system has the

additional benefit of increasing the

effectiveness of the pickling solution during

the colder months. When cold, longer pickling

immersion times are required to attain the

same reaction. Alternative technologies are the

addition of air agitation or solution heating but

both of these have an adverse impact on the

environment and the fabric of the building.

Fitting a conventional Eductors system to

achieve the same results is problematic as

anything at the base of a large acid pickle

tank is at high risk of being caught by the

work and dragged out of the tank.

Additionally, PUSH-PULL system demand

significantly smaller pumps and have proven

to be an efficient and a robust solution for

pickling applications.

Benefits of the system

• Faster pickling, especially during low

temperatures when the acid becomes almost

inert.

• Increased productivity, greater throughput

• Improved homogeneous mix of the acid,

within the tank.

• Minimise air entrapment, improving

quality.

Oil removal of floating oils using a coalescer

to skim off the surface of the degreasing tank.

The benefits of removing the oil are that the

degreasing solution will usually last longer and

the oil is not dragged by the work down the

line into other process tanks.

SIEBEC has a comprehensive range of

proven products available for filtering,

pumping, eductor agitation, dosing, filter

media, precious metal recovery, ion exchange,

organics removal, effluent treatment and

vacuuming of process chemistry and waste

water. Many products are stocked and

typically available for next day delivery from

our Stafford factory.


Since 1982 Automated Water

& Effluent Ltd have been

supplying process control

equipment to the metal finishing

and surface finishing industry.

We have an in-house team

of qualified engineers able to

recommend and build control panels

and process equipment specific to fit

your requirements.

• Custom Designed & Built Control Panels

• pH & Redox Controllers & Electrodes

• Conductivity Controllers

• Liquid Level Controllers

• Open Chanel & Magnetic Flow Meters

• Data Loggers

• Dosing Pumps & Tanks

A wide range of our control

instrumentation, dosing pumps

and chemical process equipment is

available on short delivery.

Automated Water

& Effluent Ltd

Get in touch for a quote today!

AWE House, Antom Court, Tollgate

Industrial Estate, Stafford, ST16 3AF awe-ltd.co.uk 01785 254 597

Gas Process Burners

Lanemark gas burner systems offer users reliable, high efficiency,

process heating solutions.

FD-C high turndown oven/

dryer air heating burners.

Midco HMA high efficiency,

high turndown, air replacement

or “make-up” air heating burners.

FD-GA modulating gas + air

process air heating burners.

FD-E low cost high turndown

oven/dryer air heating burners.

TX high efficiency small diameter

immersion tube tank heating

systems.

FD Series Packaged Oven/Dryer Burners

• Specifi cally designed for process air heating applications in convection

ovens and dryers

• High turndown/short flame lengths providing accurate process

temperature control

• High effi ciency gas + air modulation, gas only modulation and simple

high/low control options

• Heat Input Range: 9 kW – 1550 kW

TX Series Gas Fired Process Tank Heating Systems

• High effi ciency (80%+) heating of all types of spray and dip process tanks

• Compact high effi ciency small diameter immersion tube heat exchangers

occupying minimum tank space

• Accurate performance modelling using Lanemark TxCalc design software

• Heat Input Range: 15 kW (1½") – 1150 kW (8")

Midco HMA Series Air Replacement or “Make-Up” Air Heating Burners

• Direct fired, high effi ciency burner systems, for high volume air heating

applications such as paint spray booths, ovens and dryers.

• Supplied either as Midco burner heads for OEM system integration or

as Lanemark DB or FDB complete packaged systems including modulating

gas valve trains and controls

• Wide range of firing rates to suit alternative temperature rise and air

velocity system requirements

• DbCalc system design software

Lanemark Combustion Engineering Limited

Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom

Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: info@lanemark.com

www.lanemark.com

COMBUSTION ENGINEERING

X4620 Lanemark Ad SDAW.indd 1 31/08/2016 09:04

44 WORKSHOP

All gone green

LANXESS has developed a new range of MDI polyether prepolymers

containing renewable, bio-based raw materials. Marketed under the

brand name Adiprene Green, the products are suitable as replacement

for existing fossil based polyether prepolymers to manufacture highly

durable polyurethane (PU) elastomers.

The overall objective to develop Adiprene Green was to create a

range of bio-based prepolymers which allow the PU processor to

produce components with a reduced CO2 footprint. Depending on the

system, a reduction of CO2 between 20 to 30 percent is possible

compared to fossil-based prepolymers due to the use of polyether

polyols based on starch. The share of bio-based raw materials varies

between 30 to 90 percent dependent on the targeted system

hardness. At the same time the existing PU processing capabilities

would remain applicable and the properties of the final polyurethane

elastomer would be similar to established elastomers based on fossil

based polyether or even better.

Big batches

The new metallic colour masterbatches from Tosaf Color Service put an

end to the previously typical and undesirable streaks and similar

surface defects on plastic parts. The key to this lies in the

manufacturer's compounding know-how acquired over the last few

decades in combination with the special effect pigments with a

rheologically optimized geometry that have only recently become

available. As a result, these masterbatches meet the requirements for

the cost-cutting, environmentally friendly use of components with

brilliant metallic finishes in visible areas. The new masterbatches are

available on different carrier systems and, at short notice, in customized

shades. They are suitable for all transparent thermoplastics, whereby

the brilliance increases with the degree of transparency. They can,

however, also be used in opaque plastics such as PC/ABS or PA/ABS

blends.

The further developed pigment technology makes a major

contribution to the considerable reduction in the separation effects that

are responsible for streak formation or color deviations, especially in

critical areas such as weld lines, cross-sectional transitions or with

distinctly three-dimensional, concave or convex contours.

Sample selection

Tektronix has announced the

new 8 Series sampling platform,

a disaggregated modular

instrument series boasting

parallel acquisition, with up to 4

channels per mainframe and the

highest measurement accuracy

for PAM4 optical signals on

multiple inputs simultaneously.

The 8 Series consists of the

TSO820 Sampling Oscilloscope

Mainframe, optical sampling

modules, and TSOVu, a new

software platform that runs

independent of the mainframe

on host PC for both live and

offline processing of acquired

data. Tektronix also introduces

the TCR801, an external optical

Down the tracks

A highly versatile and robust

epoxy coating system has now

been introduced by specialist

manufacturer, Indestructible Paint

with particular benefits for the

rail industry. The development –

centred on the introduction of

the company’s RWIP120 product

– signals the organisation’s

recent focus on the rail sector

and gains from some four

clock recovery module which

covers dual band ranges around

both 26GBd and 53GBd. These

instruments and software

provide a platform solution for

fast acquisition and analysis.

“Our customers are facing

new challenges with the

increased demand for

bandwidth and network

capacity,” says Matt Ochs,

general manager of the

performance portfolio at

Tektronix. “The 8 Series helps

solve critical problems by

delivering a scalable platform

that reduces test times, while

also providing fast, accurate and

repeatable test results.”

decades of experience of coating

technology in many of the most

challenging global environments.

Indestructible Paint’s

RWIP120, which is fully

compliant with CR/PE0102

Repainting of Rail Vehicles

specification, offers a range of

performance benefits and,

significantly, is available as either

a one or two coat system.


Kemet

Precision Lapping | Polishing | Cleaning | Materialography

Sticky Corner?

Kemet can help you get out with Deburring brushes, Precision Polishing

equipment & materials, Ultrasonic Cleaning machines & solutions,

Profile Inspection, and much more.

sales@kemet.co.uk

+44 (0) 1622 755287

www.kemet-enq.co.uk

DALIC SELECTIVE

ELECTROPLATING

ADDEV MATERIALS IS THE UK OUTLET

FOR ALL DALIC ELECTROPLATING

MATERIALS AND SERVICES

All the required consumables including

anodes and bonnets plus training courses and

technical services. Dalic’s unrivalled application

systems including rectifiers and the patented

“closed loop” Dalistick Station for full control

of the application and no exposure to

hazardous metals.

BRUSH PLATING SOLUTIONS

Anodising

Cadmium, Cobalt,Zinc, Nickel

Copper, Tin, Gold, Silver

WEDGE GROUP GALVANIZING

Your Galvanizing Partner

Hot dip galvanizing provides you with long-term protection

against rust and corrosion of steel products.

With 14 plants across the UK, Wedge Group Galvanizing

is the UK’s largest hot dip galvanizing organisation off ering

a national service, collection and delivery and 24hr

turnaround on request. The group can process anything

from small components to 29m structural beams.

ADDEV MATERIALS AEROSPACE

2 Bordon Trading Estate Old Station Way, Bordon, Hampshire GU35 9HH

T. +44 (0) 1428 651246 F. +44 (0)1428 661471

aerospace.emea@addevmaterials.com

www.addevmaterials-aerospace.com

E: Info@wggltd.co.uk

T: 01902 601944 www.wedgegalv.co.uk

@wedgegalv

Head Offi ce: Staff ord Street,

Willenhall, West Midlands, WV13 1RZ

Products & Services

Stewart Freshwater

tel: 01923 437615 • fax: 01923 432770

email: s.freshwater@turretgroup.com • web: www.turretgroup.com

Leading manufacturers of

Jigs, Racking systems, Baskets, Heaters, Coils and many other

products for the Anodising & Electroplating industry

T: 01283 529314 • E: Sales@Supreme-Eng.com • W: www.supreme-eng.com

abrasive blast cleaning equipment

straaltechniek_5x1_FNGCLASS_9x_Lay

abrasive blast equipment

boilers

HEAVY DUTY

SHOTBLAST MACHINES

LARGEST UK STOCKS

NEW MACHINES

PLATE & SECTION CLEANERS

TABLE & SPECIFIC MACHINES

HOOK / HANGER MACHINES

BARREL & TUMBLER MACHINES

AIR BLAST ROOMS & CABINETS

EXTRACTION / DUCTWORK SYSTEMS

OVER 60 MACHINES IN STOCK

DOUG BOOTH UK LTD

(Est 1971)

SPECIALIST ENGINEERS

Tel: 01924 274887

Fax: 01924 262219

M/C Sales 07850 744377 Txt/WhatsApp 24hr

Email: paul@dougbooth.co.uk (machines)

jonny@dougbooth.co.uk (parts & service)

Website: www.dougbooth.co.uk

SURPLUS & TRADE IN MACHINES WANTED

AGENTS/FINDERS REQUIRED

New Wheel Blast & Air Blast Machines

2nd Hand Refurbished Machines

Spares, Service, Inspections & Reports

Dust Extractors & LEV

Technical Support & Advice

Full Range of Abrasive Media

Fabrication, CNC Turning & Milling

Laser & Plasma Cutting

Straaltechniek UK

Unit 8, Valley Works, Grange Lane, Sheffield S5 0DQ

Tel: 01142 571077, Fax: 01142 571075

www.straaltechniek.co.uk

Contact

Stewart Freshwater

Modern Coil Type

Steam Generators & Fire Tube Boilers

• 100Kg/h – 25,000Kg/h

• High efficiency - up to 96%

• Low overall emissions

• Improved safety

• Simplicity of control

• Quiet, clean & cool in operation

Tel: 020 8953 7111

info@babcock-wanson.co.uk

www.babcock-wanson.co.uk

on 01923 437615 or email [6656] Classified Factory Equipment Ads (P&W 16/03/2016 E) - Steam Genorator 12:55 5

s.freshwater@turretgroup.com

cleaning & degreasing equipment

abrasives

abrasive blast cleaning equipment

abrasives

THE POWERFUL FORCE

IN COMPONENT CLEANING

• In-process Cleaning

• Final Cleaning

• Spraywash

• Ultrasonics

01420 544909

sales@turbex.co.uk

www.turbex.co.uk

High Carbon Steel Shot and Grit.

Medium Carbon Steel Shot and Metal

Bead. Stainless Steel Cr and Cr/Ni.

High Chrome Grit.

Aluminium Oxide.

Full Technical Support.

Tel: 01952 299777 Fax: 01952 299008

Email: sales@pometon.co.uk

To advertise

Cleaning & degreasing equipment panel ad 27/09/2019 50x42 - 2020.indd 14:02:50 1

please call

Stewart Freshwater

on 01923 437615 or email


abrasives

coating applications

NEW Products From Equip.

UNW Unitized Wheels

Finishing - September/October 2020

CW Convolute Wheels

Contact us for the latest information on our

NEW unitized and convolute wheels.

T: 01298 22233

sales@equipmidlands.co.uk

www.equipmidlands.co.uk

ball covers floating

Thermal

Insulation Spheres

Frogspawn by

Manufacturing in the UK since 1957

braude.co.uk

Delivering highly

engineered, critical

function products

and services to

the commercial,

industrial, defense

and energy markets

n Shot Peening

n Laser Peening

n Coating Services

n Analytical Services

Please contact us on:

01635 279621

www.cwst.co.uk

for all your classified needs call Stewart Freshwater on: 01923 437615

niko_5x1_FNGCLASS 20/1/12 13:45 Page 1

coatings

conveyor systems

electrophoretic coatings supplier

47

Engineered coating solutions:

● High lubricity/low friction

●

●

●

●

Anti-corrosion

Resistance to erosion/galling

Chemical/environmental

protection

EM/RF shielding

E/M Coating Services

A business unit of Curtiss-Wright Surface Technologies

Please contact us on:

01386 421444

www.emcoatingsuk.co.uk

Overhead Conveyors

& Lifting

Equipment

T. 01926 813111

sales@niko.ltd.uk

www.niko-ltd.co.uk

effluent treatment plants

rdm_4x1_FNGCLASS 15/7/14 14:06 Page 1

complete finishing plant

(paint or powder coatings)

CALDAN Conveyor Ltd.

Kirkleatham Business Park

Redcar • TS10 5SH

Tel. +44 1642 271118

salesuk@caldan.dk

www.caldan.dk

Caldan Conveyor Solutions -

simply perfect.

effluent treatment plants

FM_PSA_2016.indd 1 14/04/16 12.43

finishing systems

R.D.M. Engineering Ltd, Est. 1951

Stakehill Lane, Stakehill,

Middleton,

Manchester M24 2RW

Tel: 0161 643 9333

Fax: 0161 655 3467

Web: www.rdmengineering.co.uk

E-mail: sales@rdmengineering.co.uk

Contact: Mr R. Horwich

spraybooths • rooms • ovens •

conveyors • pretreatment • powder

plant • air replacement units

5x42mm Finishing Magazine.indd 1

computer systems

Do you know what your production

line is doing? ORPHEUS DOES!

ORPHEUS... Proven Production

control software

Barcode technology provides

TOTAL ORDER TRACKING and

TRACEABILITY

electroplaters

Interested?

Why not give us a call for a

demonstration.

Mark Dimmock

Acton Gate Systems Ltd,

Essington, Staffordshire, WV11 2BQ

01902 249299 actongate

www.actongate.co.uk • enquiries@actongate.co.uk

www.neutralac.co.uk

TENNANTS

TENNANTS DISTRIBUTION LIMITED

electrophoretic coatings supplier and applicator

Polypropylene Tanks

PVC Tanks

PVC/GRP Tanks

Bund Tanks

Tank Linings

Rubber Linings

HDPE Tanks

Established 1976

Fume Scrubbers

Fume extraction

Pipework

Ducting

Repairs & Refurbishment

Flexible PVC Linings

Guards in all materials

One off Fabrications and installation

Tel: 01543 462 802

Email: plasbrun.plastics@outlook.com

Web: www.plasbrunplastics.co.uk

MANUFACTURERS AND

APPLICATORS OF SPECIALIST

ELECTROPHORETIC COATINGS

• A TRULY UNIQUE FINISHING SERVICE

• SIMULATED BRUSHED NICKEL, CHROME AND STAINLESS STEEL

EFFECTS APPLIED DIRECTLY ONTO BASE METAL SUBSTRATES.

• BESPOKE COLOURS AND EFFECTS TO CUSTOMER SPECIFICATIONS

• ALL FINISHES AVAILABLE WITH ANTI-BACTERIAL CAPABILITY

Hawking Electrotechnology Ltd

T: +44 (0) 1384 483019

E: sales@hawking.co.uk • W: www.hawking.co.uk

fume extraction

• Water wash spraybooths

• Water treatment chemical additives

• Paint separation solids removal systems

• Dry filter spraybooths

• Fixed or portable spraybooths

• Sprayroom enclosures

• Air replacement systems

• Full installation and commissioning

• After-sales service and maintenance

• Spray process engineering

Product complies fully with current environmental

protection and health and safety legislation

Unit 4 Brook Road Industrial Estate,

Wimborne, Dorset, BH21 2BH

T: 01202 840900 • F: 01202 889477

www.dynaclean.co.uk • sales@dynaclean.co.uk

To advertise

please call

Stewart Freshwater

on 01923 437615

or email

s.freshwater

@turretgroup.com

Orchard Environmental Systems

Unit 2C, Webner Industrial Estate, Ettingshall Road, Wolverhampton WV2 2LD

Specialising in the

Upgrading and Servicing of existing plant equipment

We also design and manufacture:

• Chemical Cleaning Plant • Fume extraction & purification

• Effluent treatment plant • Water purification and recycling

• Turnkey systems are our specialty

Tel: 01902 408766 • Fax: 01902 495032

Email: sales@oesgroup.co.uk

September/October 2020 - Finishing

48 for all your classified needs call Stewart Freshwater on: 01923 437615

heating equipment for corrosive solutions

Specialist manufacturers

of acid proof equipment

fl uoropolymer immersion heaters •

temp & level control •

heat exchangers •

external heating systems •

metal immersion heaters •

chemical pumps •

sales@braude.co.uk

01252 876123

braude.co.uk

hooks & jigs

Masking • Hooks • Jigs

HangOn Ltd

Leintwardine, Craven Arms,

Shropshire, SY7 0NB, UK

Tel. +44 (0) 1547 540 573

Fax. +44 (0 1547 540 412

Email. sales@hangon.co.uk

Web. www.hangon.co.uk

infra red emitters

t Bruest ATEX-certified

Flameless Gas

Catalytic Infrared Heaters

t Gas-saving industrial ovens

t “CATBOX” box ovens for

wood-finishing

t Servicing, spares & repairs for

most brands of catalytic heaters

Unit 1b Brown Lees Road Ind. Est. Forge

Way, Knypersley, Staffordshire ST8 7DN

Tel: + 44 (0) 1782 511880

www.thermocatalytic.com

thermocatsys@aol.com

jigs & baskets

masking

laquers

T: 01202 661300 jane@hitekproducts.com

www.hitekproducts.com

Hi-Tek stocks not only an extensive range of

masking products including plugs, tapes, caps and

discs, but also has the distinction of being the

European distributor for the US based TOLBER

range of lacquers and

associated products. Hi-Tek

imports bulk supplies from

Tolber and converts or

decants into commercially

usable volumes for the UK,

and European trade. The

association with Tolber has

evolved over many years.

metal immersion heaters

Tubular MI heaters

for most process solutions

500W to 12kW

single or 3-phase

masking

Hi-Tek Products Ltd

2A Dawkins Road Industrial Estate

Hamworthy, Poole,

Dorset BH15 4JP

Tel: 01202 661300

E-mail: jane@hitekproducts.com

Web Site: www.hitekproducts.com

Contact: Jane McMullen

Masking Caps • Tapes/Discs • Tapered

Plugs • Tubing • Pull-Through Plugs

• Custom Design • Stopping-Off

Lacquers • PTFE Lubricant

rdm_4x1_FNGCLASS 15/7/14 14:06

oven stoving & curing

R.D.M. Engineering Ltd, Est. 1951

Stakehill Lane, Stakehill,

Middleton,

Manchester M24 2RW

Tel: 0161 643 9333

Fax: 0161 655 3467

Web: www.rdmengineering.co.uk

E-mail: sales@rdmengineering.co.uk

Contact: Mr R. Horwich

spraybooths • rooms • ovens •

conveyors • pretreatment • powder

plant • air replacement units

overhead conveyors

To advertise

please call

Stewart Freshwater

on 01923 437615 or email


jigs & baskets

sales@braude.co.uk

01252 876123

braude.co.uk

SALT&SADLERLTD

Automotive • Aerospace • Oil & Gas • Petrochemical • Defence • Medical • Precision Engineering

Specialist manufacturers in:

Jigs • Baskets

Coils • Heaters

Fasteners • Tanks

0121 622 3887 • info@saltandsadler.co.uk

www.saltandsadler.co.uk


nylon colours_3x2_FNGCLASS 17/5/11 16:29 Page 1

nylon coating powders

Tel: +44 12 96 43 37 54

Fax: +44 12 96 39 22 85

Email: sales@nyloncolours.co.uk

NYLON

A TOUGHER COATING

Nylon Colours Ltd manufactures

Nylon Coating Powders for

Electrostatic or Fluid Bed.

A wide range of colours including

metallics is available.

Nylon Colours is also the UK distributor

for RILSAN range of Nylon Powders.

for all your classified needs call Stewart Freshwater on: 01923 437615

49

powder coating manufacturers

rectifier equipment

spray nozzles

spray booths

Switchmode and SCR DC Power Supplies

for any metal finishing process.

Options include:

Local / Remote control.

Constant Current / Constant Voltage.

PLC controllable. Touchscreen control.

Process timer. Ampere hour / minute meter.

Digital meters. Outputs fully recordable.

Outputs from 10 Amp x 6 V to 6000 Amp x 200 V.

Prices available on request

Page 1

The Sherwin-Williams Company

pre treatment chemicals

BC METAL FINISHING

BC

MF

pump & filtration specialists

●

●

●

●

METAL FINISHING TREATMENTS

FINISHING PLANT AND EQUIPMENT

METAL FINISHING CONSULTANTS

Contact: Brian Carroll

Specialist in Phosphate Pretreatment Chemicals

SERFILCO

Pumps, Filters

and Agitation

Systems

TITAN Auto Backwash Filter

Carbon Purification & Cartridges

Premier Washed & Pleated Reusable

Drum and Air Diaphragm Pumps

● Electric Immersion Heaters

Tel: 0161 775 1910

Fax: 0161 775 3696

SERFILCO delivers

clear solutions

E: sales@serfilco-international.com

www.serfilco.co.uk

pumps & filters

PUMPS and FILTERS

For more information please contact us on:

Tel: +44 (0) 121 526 6847

Fax: +44 (0) 121 568 8161

e-mail: sales@britishelectrical.co.uk

Website: www.britishelectrical.co.uk

salt spray environmental

cabinets

UKAS/NADCAP CERTIFIED SALT

FOR SALT SPRAY TESTING

Supplied in 5Kg and 25Kg Packs

To meet the requirements of:

ASTM B117 • ISO 9227 • DIN 50 021

and all other standards.

Full traceability guaranteed.

SPECIALIST LAB SALT LTD

B C METAL FINISHING SERVICES

Paytoe Lane . Leintwardine . Craven Arms.

7 RAVENSWOOD DRIVE

Shropshire . SY7 0NB

HEATON, BOLTON BL1 5AJ

Tel: 01204 495818

Telephone: 01547 540573

Fax: 01204 845206

Email: sales@specialistlabsalt.com

E-mail: brian1.carroll@homecall.co.uk

serfilco_5x1_FNGCLASS 18/11/13 Website: 12:25 www.specialistlabsalt.com

Page 1

specialised coating supplier

FreiLacke -

System coatings &

application solutions

We develop and produce all conventional

coating systems under one roof.

We are able to offer our customers

not only all the important coating

technologies but can also match these to

the respective coating structure and finish

to optimum effect.

FreiLacke UK Ltd

Tel: +44 (0) 1827 288418

Fax +44 (0) 1827 287912

sales@freilacke.com

spray nozzles

tanks & protective linings

Polypropylene Tanks

PVC Tanks

PVC/GRP Tanks

Bund Tanks

Tank Linings

Rubber Linings

HDPE Tanks

To advertise please call

Stewart Freshwater

on

Established 1976

Fume Scrubbers

Fume extraction

Pipework

Ducting

Repairs & Refurbishment

Flexible PVC Linings

Guards in all materials

One off Fabrications and installation

Tel: 01543 462 802

Email: plasbrun.plastics@outlook.com

Web: www.plasbrunplastics.co.uk

01923 437615

or email


uni-spray_5x2_FNGCLASS 18/1/10 15:22 Page 1

Excellent surfaces

WAGNER offers a wide range

of systems and products for

perfect coating solutions in

liquid and powder.

Applying

Feeding

Mixing

Controlling

first for CHOICE

first for VALUE

UK LTD

SIEBEC UK Ltd

Unit 3 St Albans Road, Stafford

Staffs ST16 3DR

Tel: 01785 227700 Fax: 01785 246006

www.siebec.com

To advertise please call

Stewart Freshwater

on 01923 437615

SPRAY NOZZLE PRODUCTS FOR PRE-TREATMENT

• Quick Release Nozzles

• Quick Release Stand pipe couplers

• Eductors

• Air Knives

• Pipe Supports

• Complete Pipe Systems

Tel No. 01273 400092 • Fax No. 01273 401220

E-mail. info@beteuk.com

BETE Ltd, PO Box 2748, Lewes, East Sussex, BN8 4HZ

Booths & Systems

Wagner Spraytech (UK) Ltd.

Tel. 01327 368410


www.wagner-group.com

September/October 2020 - Finishing

50 for all your classified needs call Stewart Freshwater on: 01923 437615

thermal fluid

web design

The shoemaker’s son

always goes barefoot.


ultrasonic cleaning

Each issue of Finishing Magazine

includes the following

regular columns:

4 News and views

4 Products

4 A-Z company shorts

4 Business and technical issues

4 Personnel changes

4 Company focuses

4 Questions and answers

4 Special reports

4 Company forecasts

4 Industry comment

For Editorial enquiries please contact:

John Hatcher, EDITOR

• E: j.hatcher@turretgroup.com

• T: +44 (0) 1923 437 618

THE POWERFUL FORCE

IN COMPONENT CLEANING

• In-process Cleaning

• Final Cleaning

• Aqueous Ultrasonics

• Precision Cleaning

01420 544909

sales@turbex.co.uk

www.turbex.co.uk

Ultrasonic Cleaning panel ad 50x42 - 2020.indd 27/09/20191

14:01:18

R

V

E

A

Editorial Calendar

wychwood water_v2_5x1_FNGCLASS 18/11/13 11:58 Page 1

water purification

Purified Water Systems

■ Deionisers

■ Reverse Osmosis

■ Filtration

■ Rinse Water Recovery

Fast Responsive Service

Your problems solved

Unit K, Country Park,

Avenue Two, Station Lane,

Witney, Oxon, OX28 4YD

Tel: 01993 892211

Fax: 01993 892212

www.wychwood-water.com

To advertise please call Stewart Freshwater

on 01923 437615 or email


It’s the same in many industries, we never get the time to look after

ourselves.

We’ve been far too busy creating beautiful websites and building

successful email campaigns for clients that our site relaunch has been

pushed back again.

This is not a complaint though, it’s what we at Reva call a nice problem,

plus it shows that with us the customer indeed does come first.

If you would like to push our website further down our to do list

contact us for a chat.

Web Design

& Development

T. 01932 567505

chat@reva.co.uk

4 Plus monthly special features

NOVEMBER/DECEMBER 2020:

n Robotics n Anti Corrosive Finishing

n Advanced Surface Technology

n Precious Metal Finishing n Annual Review

PLUS FINISHING INDUSTRIES

YEARBOOK 2021

JANUARY/FEBRUARY 2021:

n Solvent Recovery n Pre-Treatment Chemicals

n Conveyors n Mechanical Handling and Jigs

n European Legislation

The most important

guide to the UK surface

treatment industry, the

Finishing Industries

Yearbook 2021,

will be published

in November 2020.

Now in its 43rd year

of publication, the

Finishing Industries

Yearbook

has evolved to be

the comprehensive

reference source to this

ever changing market.

The Finishing

Industries

Yearbook 2021

edition will be the

most comprehensive

ever published,

with over 950+

businesses and over

450 products.

The Finishing

Industries Yearbook

2021 will also

contain –

n A comprehensive

A-Z section

complete with full

company contact

details

n An up-to-date

Classified Guide

listing finishing

products by

supplier

n An up-to-date

Regional Guide

listing sub-contract

finishers by their

area of operation.

n Up-to-date

information relating

to the ownership and

description of key Trade

Names.

n Directory of key

Associations representing

the surface finishing

industry.

To advertise contact:

Stewart Freshwater

(Display) on

+44 (0)1923 437615

or

Barbara Williams

(Classified) on

+44 (0)1923 437616

We provide

INDUSTRIAL

SOLUTIONS

for productivity,

quality improvement,

material & cost savings

WORLD LEADER IN

PRECISION SPRAYING SOLUTIONS,

SAMES KREMLIN offers customers

COMPLETE SOLUTIONS FROM PUMPS

TO COMPLETE APPLICATION SYSTEMS.

Our products pursue

the following key objectives for our customers:

PERFORMANCE, PRODUCTIVITY & SUSTAINABILITY

Making Manufacturers More Competitive

Visit our website to know more about our Solutions

Apply your skills

www.sames-kremlin.com

Poison under control.

SLOTOLOY ZN „Generation VX“

The alkaline zinc-nickel processes SLOTOLOY ZN „Generation VX“ are operated with an anode (special anode VX 1)

specially adapted to the process and respective additives. Because of this, the formation of breakdown products and cyanide

on the anode is inhibited. The practical application at customers showed in converted electrolytes that even the cyanide

content is reduced actively.

Advantages of the zinc-nickel

processes „Generation VX”

· No cost-intensive membrane technology necessary.

· Improvement of current efficiency and appearance.

· Simple conversion of existing electrolytes.

· Low additive consumption.

· The formation of cyanide is significantly reduced and

may falls below the detection limit.

· Since there’s less non-active tetracyanonickelate there’s

a lower demand of nickel.

Decrease of the cyanide content after the conversion to

SLOTOLOY ZN „Generation VX“

cyanide content [mg/L]

500

400

300

200

100

0

0 500 1000 1500 2000

bath throughput [Ah/L]

Schloetter Co. Ltd.

Abbey Works

New Road, Pershore

Worcestershire WR10 1BY

United Kingdom

T +44 (0)1386 552 331

info@schloetter.co.uk

www.schloetter.co.uk

Finishing - September-October 2020

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