Finishing - September-October 2023
As we reach the end of summer which has not been the greatest in terms of weather it will be interesting to see which way the wind is blowing in regard to the environment as the next general election approaches. I live close to London and the ULEZ extension has been on top of the agenda for many people. The statistics on London’s air quality are extremely worrying with the WHO saying that air pollution far exceeds limits. Do we ignore the evidence and continue to put lives at risk? I would imagine we would not like a polluting business near our home or place of work and it is impressive that finishing companies are stepping up and taking on board their environmental responsibilities. We are all aware that there is a cost involved, but it seems a small price to pay for a healthy future. John Hatcher, Editor
As we reach the end of summer which has not been the greatest in terms of weather it will be interesting to see which way the wind is blowing in regard to the environment as the next general election approaches.
I live close to London and the ULEZ extension has been on top of the agenda for many people. The statistics on London’s air quality are extremely worrying with the WHO saying that air pollution far exceeds limits. Do we ignore the evidence and continue to put lives at risk? I would imagine we would not like a polluting business near our home or place of work and it is impressive that finishing companies are stepping up and taking on board their environmental responsibilities.
We are all aware that there is a cost involved, but it seems a small price to pay for a healthy future.
John Hatcher, Editor
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<strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
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www.finishingmagazine.co.uk
www.finishingmagazine.co.uk CONTENTS 3<br />
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<strong>September</strong>/<strong>October</strong> <strong>2023</strong> – Volume 47 Number 5 – ISSN no. 0264 2506<br />
In this issue...<br />
As we reach the end of summer which has not been the greatest in terms of<br />
weather it will be interesting to see which way the wind is blowing in regard to<br />
the environment as the next general election approaches.<br />
I live close to London and the ULEZ extension has been on top of the<br />
agenda for many people. The statistics on London’s air quality are extremely<br />
worrying with the WHO saying that air pollution far exceeds limits. Do we<br />
ignore the evidence and continue to put lives at risk? I would imagine we would<br />
not like a polluting business near our home or place of work and it is<br />
impressive that finishing companies are stepping up and<br />
taking on board their environmental responsibilities.<br />
We are all aware that there is a cost involved, but it seems<br />
a small price to pay for a healthy future.<br />
News<br />
Newsdesk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4<br />
Features<br />
Surface World <strong>2023</strong> . . . . . . . . . . . . . . . . . . . . . . . . . .10<br />
Optimum efficiency . . . . . . . . . . . . . . . . . . . . . . . . . .16<br />
Smart robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20<br />
Solvent advantage . . . . . . . . . . . . . . . . . . . . . . . . . . .32<br />
Going the distance . . . . . . . . . . . . . . . . . . . . . . . . . . .34<br />
Programme delivers jobs . . . . . . . . . . . . . . . . . . . . . .38<br />
Hot off the press . . . . . . . . . . . . . . . . . . . . . . . . . . . .42<br />
Gently does it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44<br />
Sustainable innovation . . . . . . . . . . . . . . . . . . . . . . . .56<br />
Regulars<br />
Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30<br />
Workshop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66<br />
Classified listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67<br />
<strong>Finishing</strong> (formerly <strong>Finishing</strong> Industries) was established in 1947 and incorporates Metal<br />
<strong>Finishing</strong> journal, Electroplating & Metal <strong>Finishing</strong>, The Plant Journal, Surface Coatings, and<br />
Industrial <strong>Finishing</strong> & Surface Coatings. <strong>Finishing</strong> is a member of the Metal <strong>Finishing</strong><br />
Association, a sustaining member of the Institute of Metal <strong>Finishing</strong> and the UK representative<br />
of the Groupement International des Revues de Traitements de Surfaces.<br />
<strong>Finishing</strong> – <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
4 NEWS www.finishingmagazine.co.uk<br />
Major redevelopment<br />
Manchester Galvanizing, part of Wedge Group Galvanizing, has<br />
undergone major redevelopment at its Heywood site which has seen it<br />
replace its old galvanizing bath, and introduce new equipment aimed<br />
at boosting productivity, quality, and sustainability efforts.<br />
Mark Waters, commercial manager at Manchester Galvanizing,<br />
explained: “Over the last few months we’ve been working on these<br />
improvements to ensure we can continue to keep up with growing<br />
demand and deliver a high quality, sustainable service.<br />
“Our new bath replaces our old one which has come to the end of<br />
its life. This enables us to process steelwork for projects as varied as<br />
small sculptures and commissions, through to large structural<br />
steelwork and components for industries as diverse as rail, marine, and<br />
construction.<br />
“Our new furnace and heat exchanger will also enhance our<br />
efficiencies and further improve the quality and capabilities that we can<br />
provide to customers. It’s been a long few months and much hard<br />
work but we’re thrilled to now be back up-and-running as normal.<br />
We’d also like to thank our customers for their continued patience,<br />
and to our sister plants for stepping in and supporting our workload<br />
during our downtime.”<br />
Environmental commitment<br />
Interpon powder coatings from<br />
AkzoNobel have received an<br />
Environmental Product<br />
Declaration (EPD) for a third<br />
time, confirming the company’s<br />
continued commitment to full<br />
transparency in the sustainability<br />
of its products and aligned to its<br />
own sustainability goals<br />
including a 50% carbon<br />
footprint reduction by 2030.<br />
An EPD is an independently<br />
verified assessment of a<br />
product's environmental impact<br />
across its whole lifespan, from<br />
initial production to end-of-life<br />
disposal or recycling. It<br />
contributes benefits to some of<br />
the leading green building<br />
schemes, such as LEED<br />
(Materials and Resources) and<br />
BREEAM (Materials) certified<br />
building projects.<br />
Interpon D became the first<br />
powder coating to achieve an<br />
EPD in 2015; this was renewed<br />
in 2018. The latest EPDs are<br />
valid for a further five years with<br />
global geographical scope<br />
considering 11 representative<br />
powder coating production sites.<br />
Bob Dirks, global segment<br />
manager architectural<br />
AkzoNobel Powder Coatings,<br />
says that Interpon continues to<br />
be the stand-out performer in<br />
every sense: “This EPD renewal<br />
shows how we are committed to<br />
providing total transparency<br />
concerning the sustainability<br />
credentials of the raw materials,<br />
manufacture and transportation<br />
associated with creating Interpon<br />
D,” she explains.<br />
Innovation boost<br />
Innovations are boosting sustainability in a wide range of industries<br />
and processes – and along the entire value chain. Customers of<br />
Henkel’s Adhesive Technologies business unit recently recognized this<br />
important positive impact by presenting three prestigious awards for<br />
metal pretreatments to the company: the Paint Sustainability<br />
Innovation Award from ArcelorMittal, the Global Supplier Award from<br />
Novelis, and Best Project of 2022 from B/S/H.<br />
International steel producer ArcelorMittal presents its Paint<br />
Innovation Award to celebrate projects that open up exciting<br />
opportunities for innovative future products. Novelis, a company that<br />
produces flat-rolled aluminum products, honors outstanding<br />
partnerships and high-quality solutions that drive sustainability with its<br />
Global Supplier Award. And the Best Project award from household<br />
appliance manufacturer B/S/H recognizes outstanding suppliers who<br />
support progress toward its ambitious sustainability goals.<br />
For many years, Henkel Adhesive Technologies have been working<br />
to optimize processes in the metals industry and to reduce the sector’s<br />
impact on the environment. Even in the future the company aims to<br />
lead with technologies enabling sustainability. “We are proud to receive<br />
recognition for our contributions to our customers’ process efficiency<br />
and sustainability,” says Volker Mansfeld, vice president metals EIMEA<br />
at Henkel Adhesive Technologies. “We see these awards as a<br />
motivation to keep improving our CO2 footprint, as well as to<br />
enabling our customers to rethink their applications, processes and<br />
products – to become even more sustainable in the future.”<br />
The bank’s all here<br />
HMG Paints recently had the privilege of welcoming representatives<br />
from the Bank of England to their Riverside Works headquarters in<br />
Manchester. The visit, held on 12th July, provided an opportunity for<br />
an insightful discussion on various aspects of HMG Paints' operations,<br />
SME’s role in the economy, manufacturing and the broader economic<br />
landscape.<br />
Mike Jennings, HMG finance director said of the visit “The visit<br />
provided a valuable opportunity for us to share our perspectives and<br />
experiences and gain insights into the broader economic landscape.<br />
We appreciate the Bank's interest in our operations and look forward<br />
to further collaboration in the future."<br />
During the visit, the Bank of England representatives explored a<br />
range of topics that held significant importance for both HMG Paints<br />
and the wider economy. Following HMG’s recent recognition as<br />
Manufacturing Family Business of the Year by Family Business United,<br />
the representatives were keen to get HMG’s insight on the current<br />
manufacturing landscape and future outlook.<br />
<strong>Finishing</strong> – <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
Unit 10, Southlink Business Park,<br />
Hamilton Street,<br />
Oldham, OL4 1DE
6 NEWS www.finishingmagazine.co.uk<br />
The BCF has announced the nominees for its award ceremony<br />
being held later in the year<br />
Seal of approval<br />
Vertik-Al says it remains the only applicator in the UK and Ireland to<br />
hold the GSB International Master Seal for Approved Coater<br />
Aluminium after successfully passing its latest audit. The powder<br />
coating specialist has held this status since 1994.<br />
GSB International awards quality seals in different levels of quality.<br />
Recipients are tested annually for adherence to the prescribed quality<br />
requirements. Vertik-Al met the demands of GSB QR AL 631 for<br />
aluminium coating companies.<br />
“Being the only coater in the UK to hold the GSB International seal<br />
is a great honour. In a challenging market, it gives us the edge over<br />
our competitors as businesses seek competent and reliable supply<br />
chain partners,” comments group managing director, John Park-Davies.<br />
“Quality seals such as this promote confidence. All participants in<br />
the supply chain are assured of the quality and performance of the<br />
coating. By demonstrating compliance our customers know that they<br />
can trust our coatings for many years to come, a fact that can be<br />
shared and appreciated by everyone involved – from architects and<br />
façade designers to facilities management and maintenance teams.”<br />
Intent to supply<br />
BASF and Zhejiang Guanghua<br />
Technology (KHUA) have signed<br />
a Letter of Intent (LoI) for the<br />
supply of Neopentyl Glycol<br />
(NPG) from BASF’s Zhanjiang<br />
Verbund site to KHUA. This<br />
agreement marks a significant<br />
milestone in the long-term<br />
partnership between both<br />
parties.<br />
KHUA is planning to build a<br />
100 kilotons per annum (KT/a)<br />
production plant for high-end<br />
powder coatings resins in<br />
Donghai Island, Zhanjiang<br />
Economic & Technological<br />
Development Zone, where BASF<br />
is building a world-scale NPG<br />
plant with an annual production<br />
capacity of 80,000 metric tons.<br />
Vasilios Galanos, Senior Vice<br />
President, Intermediates Asia<br />
Pacific, BASF, said, “We are<br />
pleased to strengthen our longstanding<br />
partnership with KHUA<br />
through co-location. We are<br />
confident that this strategic<br />
move will create synergies that<br />
benefit both parties, including<br />
enhanced collaboration and<br />
supply reliability, faster delivery,<br />
access to shared resources, and<br />
reduced costs. In addition, this<br />
partnership will help to meet the<br />
growing demand for ecofriendly<br />
powder coatings in<br />
China and the wider Asia Pacific<br />
region.”<br />
The British Coatings Federation<br />
(BCF) is pleased to announce<br />
the shortlisted entries for the<br />
<strong>2023</strong> Awards. Following a<br />
series of judging days<br />
conducted by an independent<br />
panel of judges in each<br />
category, they have reached a<br />
carefully selected shortlist from<br />
a wide variety of high-quality<br />
entries.<br />
The winners will be<br />
announced at the Awards<br />
dinner on Thursday 19th<br />
<strong>October</strong> at The Grand Hotel in<br />
Birmingham.<br />
Sustainable Innovation:<br />
Multinational Award shortlist:<br />
Organik Kimya<br />
Sun Chemical<br />
Siegwerk<br />
BASF plc<br />
AkzoNobel<br />
Sustainable Innovation: SME<br />
shortlist:<br />
Little Greene<br />
Terrafend<br />
Race to Net Zero Award<br />
shortlist:<br />
Crown Paints<br />
BASF plc<br />
GDB Paint & Coatings<br />
Customer Service Award<br />
shortlist:<br />
AkzoNobel - Dulux<br />
Crown Paints<br />
Pulse Printing Products<br />
Excellence in Training Award<br />
shortlist:<br />
HMG Paints<br />
AkzoNobel<br />
Anstey Wallpaper<br />
AkzoNobel – Dulux<br />
Diversity and Inclusion Award<br />
shortlist:<br />
PPG<br />
Sherwin-Williams<br />
Young Leader of the Year<br />
Award shortlist:<br />
Molly Kershaw, PPG<br />
Architectural Coatings UK&I<br />
Nathan Featherstone,<br />
hubergroup UK<br />
James Davis, A-Chem Limited<br />
Chris Morton, Crown Paints<br />
Olly Sheppard, Pulse Printing<br />
Products<br />
Corporate Social Responsibility<br />
Award shortlist:<br />
Banner Chemicals<br />
PPG Architectural Coatings UK<br />
Crown Paints<br />
Marketing Campaign of the<br />
Year Award shortlist:<br />
Farrow & Ball<br />
HMG Paints<br />
AkzoNobel - Dulux<br />
Axalta Coatings Systems<br />
Apprentice of the Year Award<br />
shortlist:<br />
Kris Richens, AkzoNobel<br />
Katie Sterrett, AkzoNobel<br />
Brandon Morgan, hubergroup<br />
UK<br />
Melissa Strowbridge, HMG<br />
Paints<br />
Richard Morgan, AkzoNobel -<br />
Dulux<br />
Sean Kelly, Anstey Wallpaper<br />
Student of the Year Award<br />
shortlist:<br />
Courtney Turner, Tor Coatings<br />
Patrycja Zuchowska, PRA World<br />
Rebecca Jones, Beckers<br />
Melanie Brogden, Belzona<br />
Polymerics<br />
The shortlisted companies for<br />
both Coatings Care Awards will<br />
be announced in <strong>September</strong>.<br />
<strong>Finishing</strong> – <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
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8 NEWS www.finishingmagazine.co.uk<br />
Qualicoat member will be out in force at Surface World<br />
Back to China<br />
SFCHINA<strong>2023</strong> will open its gates on November 15 - 17 at Halls E1<br />
and E2 of the Shanghai New International Expo Centre (SNIEC), P.R.<br />
China, with a total gross exhibition area of more than 17,000 square<br />
meters. After 4 years of absence at Shanghai, 227 exhibitors from 16<br />
countries / regions (as of August 31, <strong>2023</strong>) are going to display a wide<br />
spectrum of processes, materials, equipment and solutions in 2 exhibit<br />
zones, namely ‘Electroplating & <strong>Finishing</strong> Technology’ and ‘Coating<br />
Applications & Coating Products’. Besides, SFCHINA<strong>2023</strong> Online<br />
Show will be held from November 1 to December 31, allowing visitors<br />
from anywhere to participate digitally.<br />
A series of concurrent Technical Programmes will be organized<br />
alongside the exhibition. Industry experts and renowned<br />
manufacturers are going to present cutting-edge technologies,<br />
products and applications, offering opportunities for face-to-face<br />
learning, networking and business cooperation.<br />
New partnership announced<br />
PMD Chemicals has announced<br />
its new partnership with Chicago<br />
based Techevon LLC. Techevon<br />
is a vertically integrated chemical<br />
manufacturer for the anodising<br />
industry and offers a highperformance<br />
range of dyes and<br />
chemicals for the aluminium<br />
anodising process. This<br />
partnership is set to cement<br />
PMD Chemicals stronghold<br />
within the process chemistry<br />
industry.<br />
“Techevon is excited to partner<br />
with PMD chemical as we<br />
continue to grow our anodizing<br />
chemistry solutions globally.<br />
PMD Chemical's best-in-class<br />
operations and sales network will<br />
help us bring our industry leading<br />
anodizing dyes, chemistry, and<br />
technical knowledge to new<br />
customers in the United Kingdom,<br />
the Middle East and Asia, ”<br />
commented Tej Patel, director<br />
Techevon LLC<br />
The dyes offer high alkaline<br />
resistance, nickel-free seal<br />
chemistry and are bleed and<br />
chrome free. Cosmetic enhancers<br />
and brighteners also feature in<br />
this range of stable dyes.With<br />
Techevon Technology, every dye<br />
colour is offered along with a<br />
bespoke colour matching service.<br />
Each product is fully supported by<br />
our in-house laboratory and<br />
technical service team.<br />
“We are really pleased we can<br />
formally announce our<br />
agreement to represent the<br />
Techevon range of Anodising<br />
Dyes and additive chemistry<br />
here in the UK. With all products<br />
produced and stocked here in<br />
the UK we feel with the<br />
excellent quality and second to<br />
none customer support offered<br />
by PMD Chemicals and<br />
Techevon LLC we can fully<br />
service the needs of our UK<br />
Anodising customers,” said<br />
Graham Pemberton, managing<br />
director, PMD Chemicals.<br />
Membership of the UK &<br />
Ireland Association continues to<br />
grow as the QUALICOAT<br />
Specification continues to be<br />
adopted by architectural powder<br />
coaters, powder manufacturers<br />
and pretreatment systems<br />
companies. Now with 44<br />
members across the region, the<br />
aim of the Association remains<br />
the adoption of the most up to<br />
date methodologies and<br />
specifications to ensure the very<br />
best in architectural powder<br />
coating for specifiers in the<br />
construction industry.<br />
QUALICOAT Members will<br />
be on hand on stand A20 at<br />
the forthcoming Surface World<br />
exhibition which takes place on<br />
the 4th & 5th <strong>October</strong> in Hall<br />
11 at the NEC in Birmingham.<br />
If you are attending please drop<br />
by to meet us and discuss any<br />
issues you may have or possibly<br />
discuss with us your potential<br />
membership. Tickets for the<br />
show are available from the<br />
surfaceworld.com website.<br />
The Association aims to<br />
communicate two of the USP’s<br />
of the QUALICOAT<br />
Specification.<br />
The Specification is ‘the only<br />
globally recognised specification<br />
for architectural powder<br />
coating’. This means that as a<br />
specifier you can specify<br />
QUALICOAT for any project,<br />
anywhere and it will be<br />
supported with a local, licensed<br />
supply chain.<br />
The Specification is also ‘the<br />
only third party accredited<br />
specification for architectural<br />
powder coating’ services.<br />
Powder coating Members are<br />
visited, unannounced, twice<br />
yearly by an independent test<br />
house who inspects current<br />
processes and checks records to<br />
ensure the Specification is being<br />
followed. Failure to follow the<br />
Specification can lead to a<br />
Member losing their<br />
QUALICOAT licence allowing<br />
them to use the quality label.<br />
The history of the Association<br />
makes interesting reading. In<br />
1986 several national<br />
associations encompassing<br />
coaters of architectural systems<br />
formed a quality label<br />
organisation and called it<br />
QUALICOAT. Their goal was to<br />
raise and standardise the level<br />
of quality of powder coating<br />
throughout Europe, laying<br />
down rules applying to their<br />
industry. Today, companies from<br />
all five continents have now<br />
become licensees and the<br />
number of national and<br />
international associations has<br />
continued to grow. Through the<br />
efforts of Members over the<br />
past few decades, QUALICOAT<br />
has continued to play a key role<br />
in assuring the quality of<br />
coatings on aluminium systems<br />
used in architecture.<br />
Architectural aluminium powder<br />
coaters, powder suppliers and<br />
manufacturers of pretreatment<br />
chemical systems have been<br />
represented on the<br />
QUALICOAT committees from<br />
the outset, thereby ensuring an<br />
exchange of ideas and<br />
information between coaters<br />
and their suppliers. These<br />
committees and working group<br />
undertake research and<br />
determine agreements that<br />
form the basis of the constantly<br />
updated QUALICOAT<br />
Specification we know today.<br />
The current QUALICOAT<br />
Specification is freely available<br />
for download via the Association<br />
website, qualicoatuki.org and<br />
offers an up-to-date list of<br />
licensed UK and Ireland Powder<br />
Suppliers, Pretreatment<br />
Suppliers and Applicators.<br />
Telephone support is available<br />
from QUALICOAT UK &<br />
Ireland Head Office in<br />
Birmingham on 0330 236<br />
2800, the Association can also<br />
be followed on Twitter<br />
@Qualicoatuki or on LinkedIn<br />
www.linkedin.com/company/qua<br />
licoat-uk-&-ireland.<br />
<strong>Finishing</strong> – <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
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Contact<br />
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enquiries@wagner-group.com
10 SURFACE WORLD 2022<br />
Surface World <strong>2023</strong><br />
Surface World Live is returning to the<br />
NEC, Birmingham. Registration is open,<br />
and entry is free. The organiser’s are<br />
look forward to seeing you in <strong>2023</strong>!<br />
The exhibition is the UK’s only event<br />
Exhibitors<br />
dedicated to the surface treatment, product<br />
finishing and coatings industry. It provides a<br />
major showcase for the very latest technology<br />
and developments in this important and<br />
expanding area.<br />
ADEPT PURE WATER<br />
D22<br />
AEROFIN LABORATORIES<br />
E22<br />
ARUM 3D SOLUTIONS<br />
E10<br />
AUTOMATED WATER & EFFLUENT A12<br />
BANNER CHEMICALS<br />
E2<br />
B & M LONGWORTH<br />
F22<br />
BURNTWOOD SPRAYBOOTHS H8<br />
CC HYDROSONICS<br />
E2<br />
CHEMETALL - BASF<br />
B12<br />
CORRODERE<br />
G2<br />
DEFELSKO CORPORATION C20<br />
DFT INSTRUMENTS (UK)<br />
C20<br />
EFFPARK COATINGS<br />
G4<br />
ELCOMETER<br />
B20<br />
ELCOMETER<br />
J4<br />
ELECTRON<br />
C2<br />
EPIFATECH<br />
C6<br />
EUROMASK – FINISHING GROUP D18<br />
EUROSIDER<br />
C8<br />
FISCHER INSTRUMENTATION K12<br />
FREILACKE<br />
K18<br />
GALVATEK<br />
G8<br />
GEMA<br />
D6<br />
GLOBAL MASK INTERNATIONAL K6<br />
HADLEIGH ENTERPRISES<br />
J18<br />
HARRY DALBY ENGINEERING A6<br />
HANGON<br />
J12<br />
HENKEL ADHESIVE TECHNOLOGIES D16<br />
HMG POWDER COATINGS B2<br />
HODGE CLEMCO<br />
C4<br />
INDUSTRIAL PHYSICS<br />
A2<br />
INSTITUTE OF MATERIALS FINISHING<br />
JACQUET WESTON ENGINEERING E8<br />
JURGEN EMPTMEYER<br />
E14<br />
KEMET INTERNATIONAL<br />
K2<br />
KLUTHE UK<br />
C14<br />
KRAFT POWERCON<br />
A14<br />
MCM CONVEYORS<br />
H2<br />
MECWASH SYSTEMS<br />
E6<br />
METALLTECHNIK (UK)<br />
K4<br />
METAVATE<br />
D4<br />
MINDON OVENS<br />
H8<br />
NORDSON (UK)<br />
B8<br />
OTMK PLATING LINE<br />
D14<br />
PANGBORN<br />
B10<br />
PEARSON PANKE<br />
PHOENIX TM<br />
PRECIOUS PLATE<br />
PURITE<br />
QUALICOAT UK & IRELAND<br />
RAILTECHNIEK VAN HERWIJNEN<br />
RIBBLE TECHNOLOGY/HILIAN<br />
SCIMED<br />
SHERWIN WILLIAMS<br />
SHOTBLAST TECHNOLOGY<br />
SIEBEC UK<br />
STEWART GILL CONVEYORS<br />
STRAALTECHNIEK UK<br />
THERMASET<br />
TURBEX<br />
UNITECH MACHINERY<br />
WAGNER SPRAYTECH UK<br />
D8<br />
D24<br />
D2<br />
A4<br />
A20<br />
H14<br />
J2<br />
F24<br />
F18<br />
E24<br />
G6<br />
H14<br />
C12<br />
F2<br />
G8<br />
H8<br />
J8<br />
WESTBURY<br />
K10<br />
WILL GREEN PLATING LINE ADVICE E18<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
12 ENERGY<br />
Are you ready for the green effect?<br />
With energy prices skyrocketing all over<br />
Europe the question of lowering your<br />
energy consumption has never been<br />
more urgent. But there might be an easy<br />
solution with an enormous hidden potential –<br />
cutting costs and increasing profit while at the<br />
same time making the coating industry<br />
greener.<br />
The coating industry is very energy<br />
demanding. This is a fact that has been<br />
known to us for long, but we never knew<br />
exactly how much energy that escapes during<br />
the process. Now we know.<br />
We are meeting up with Petter Törefors,<br />
CEO and owner of HangOn AB, a Swedish<br />
developer and manufacturer of solutions for<br />
hanging, masking, and handling, solutions that<br />
today are distributed to more than 40<br />
countries around the world. For starters the<br />
business idea was mostly about helping<br />
customers to increase efficiency and<br />
profitability in their coating process, a mission<br />
in which they have succeeded. But the<br />
question that has been eating away during the<br />
last couple of years, ever since HangOn<br />
conducted a life cycle analysis (LCA) on their<br />
own products 20 years ago, is the question of<br />
sustainability. All while visiting customers and<br />
exploring their needs for further development.<br />
– And it is obvious that finding the right<br />
solutions for sustainability in the coating<br />
industry by increasing hanging density is the<br />
most important thing we can do for our<br />
customers, Törefors says.<br />
Sustainability – a top priority<br />
In the coating industry for the last decades,<br />
sustainability has been a top priority when it<br />
comes to limit emissions, preventing air and<br />
water pollution and putting effort to<br />
reformulate and produce environment-friendly<br />
coatings. Furthermore, the coating industry<br />
has gone long ways to explore the<br />
development of bio-renewable technologies to<br />
reduce the carbon footprint. An array of<br />
certified environmentally preferable paints and<br />
coatings are available, which all together have<br />
much lower levels of toxicity, while also<br />
having recyclable content. Some of these<br />
paints are not only environmentally friendly,<br />
but also more cost-effective than conventional<br />
paints.<br />
Energy consumption in the<br />
coating line<br />
But consumer awareness keeps putting<br />
pressure on reaching further. Today,<br />
specifically OEM companies in general and<br />
the automotive industry in particular need to<br />
be looking to impact the entire value chain in<br />
terms of sustainability aspects. One essential<br />
question to be investigated has been to<br />
establish numbers on the energy consumption<br />
and the energy losses in a coating line.<br />
– We decided to find the answer, Törefors<br />
explains.<br />
The idea that Petter Törefors and the team<br />
at HangOn started out with was to<br />
understand in depth what the energy<br />
consumption in a coating line really looks like.<br />
To achieve this, they conducted a thorough<br />
study in five different standard powder coating<br />
line set-ups, assisted by surface treatment<br />
expert Anders Jansson, Meyer & Hjort AB.<br />
What the study rather surprisingly revealed,<br />
was that regardless of how much goods you<br />
fill the line with the energy consumption is<br />
constant up to between 80 and 90 percent.<br />
For example, increasing the goods flow times<br />
five per hour with HQC-hanging instead of<br />
regular hooks, will only increase the total<br />
energy consumption with 18 percent, Törefors<br />
says.<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
continues on page 14
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14 ENERGY<br />
On the HangOn website you can compare<br />
the numbers of different coating cost<br />
calculations in standard scenarios in five<br />
standard coating lines. You can also fill in the<br />
blanks with your own numbers if you like, to<br />
check the facts.<br />
A great way for validation of the numbers<br />
your own coating facility, Törefors says.<br />
Using the energy wisely by<br />
increasing hanging density<br />
No matter what, there will be energy losses<br />
in the outer surfaces, ventilation, and heat<br />
leakages through openings. So, Törefors says,<br />
you need to be smart and use the energy<br />
wisely:<br />
– By hanging the goods in a more efficient<br />
way you can cut your costs up to 75 percent if<br />
you count the cost of energy consumption per<br />
coated detail.<br />
Hanging the goods is mainly a task that is<br />
handled on the workshop floor, but this matter<br />
should be addressed all the way up to<br />
management, according to Petter Törefors.<br />
Because the question of hanging density<br />
makes a difference, not only on reducing costs<br />
and increasing profit, but it definitely makes a<br />
difference in reducing energy consumption<br />
and thereby contributing to a greener coating<br />
industry.<br />
You can actually cut costs up to 48 percent<br />
on the coating process as a whole, going from<br />
0,28 kWh per coated product down to 0,07<br />
kWh per coated product if you choose to<br />
increase the hanging density. This is really<br />
important for the decision makers to<br />
understand, Törefors says.<br />
A Green Effect with enormous<br />
hidden potential<br />
So, lets juggle a few more numbers. A<br />
medium sized automatic coating line with a<br />
conveyor speed of 2 metres per minute and a<br />
conveyor length of 293 metres and an object<br />
size of 3000 x 600 x 1500 mm (LxWxH) that<br />
transports about 850 kg goods per hour uses<br />
about 470 kWh per hour. Of this the pretreatment<br />
uses about 200 kWh, the drying<br />
oven about 85 kWh, the powder application<br />
around 40 kWh and the curing oven 145<br />
kWh.<br />
Running the coating line with HQC-hanging<br />
and a density of 3 550 kg per hour of painted<br />
goods instead, it would use 580 kWh per<br />
hour.<br />
A full year of running a medium sized<br />
coating line in 3-shift with daisy-chain<br />
hanging, amounts to about 2,5 million kWh<br />
per year. With dense HQC-hanging you can<br />
paint the same amount of goods while using<br />
about 800 000 kWh per year, Törefors says.<br />
Numbers that make a huge difference on<br />
the last line of accounting with energy prices<br />
skyrocketing all over Europe.<br />
– The energy saved by this would be<br />
enough to supply 170 average EU households<br />
with energy for a whole year.<br />
And if you take this further to a global<br />
scale, there is an enormous hidden potential to<br />
save energy and make the coating industry<br />
greener.<br />
This is what we at HangOn call the double<br />
Green Effect, Törefors says.<br />
Real numbers in real life<br />
Realizing that the numbers might sound<br />
overly positive, Petter Törefors takes the Swedish<br />
company Skeppshult as an example. This is one<br />
of Sweden´s most well-known bicycle brands<br />
that has taken capacity utilization to a whole<br />
new level. All manufacturing has been done in<br />
their own workshop in southern Sweden since<br />
1911, and to make their production even more<br />
sustainable they wanted to increase efficiency in<br />
their coating process with special hangers. In<br />
one specific coating case they went from 54 pcs<br />
per hour to 180 pcs per hour with the new<br />
solution. The green effect was summed up in<br />
HangOn conducted a life cycle analysis (LCA) on all the hooks produced for the Swedish market.<br />
Everything was counted in, from the energy consumption when the steel was made to the energy<br />
consumption in the process where the hooks are used. The numbers above show the result. “That´s why it<br />
is so important for us at HangOn to do everything we can to provide our customers with sustainable<br />
solutions that can reduce their energy consumption”, Petter Törefors says.<br />
66 percent energy savings and a total coating<br />
cost savings of 53 percent. In another of<br />
Skeppshult´s coating cases they went from 216<br />
pcs per hour to 864 pcs with the new solution,<br />
resulting in 75 percent energy savings and a<br />
total coating cost savings of 63 percent.<br />
And this is exactly what the Green Effect is all<br />
about – lowering your energy consumption and<br />
increasing your profit. You will have an<br />
enormous Green Effect by increasing the<br />
hanging density in your coating process,<br />
Törefors says.<br />
Reduced energy consumption of<br />
utmost importance<br />
As previously stated, going green and<br />
prioritizing matters of sustainability is an<br />
important goal for all manufacturing industry,<br />
with increased customer awareness and<br />
continually strengthened requirements from all<br />
European governments, all by the lead of EU<br />
regulations. From February 10 to March 16,<br />
earlier this year the team at HangOn made a<br />
market study which garnered responses from<br />
250 participants in 11 countries, representing a<br />
range of regions, company sizes, coating<br />
processes and professional roles.<br />
This study shows that the impact of issues<br />
concerning sustainability in the coating industry<br />
is significant. 85 percent agrees that<br />
sustainability is important to their company. The<br />
same number of respondents agrees that issues<br />
related to energy consumption will become<br />
more important over the next five years.<br />
So, what are, according to the respondents,<br />
the most important means to improve<br />
sustainability?<br />
Reduced energy consumption is deemed as<br />
the most important factor, followed by reduced<br />
powder consumption, and reduced chemical<br />
and pre-treatment usage, Törefors says.<br />
Increasing hanging density – an<br />
easy step to undertake<br />
And when it comes to the most important<br />
means to reduce energy consumption, a<br />
majority of the respondents agree that the secret<br />
lies within increasing line utilization, such as<br />
maximizing the number of coated items per<br />
hour.<br />
And to improve coating line utilization,<br />
increasing hanging density is the most important<br />
factor, according to 30 percent of responders.<br />
This is a fairly easy step to undertake, compared<br />
to other costly investments, when pressured to<br />
become more sustainable while still delivering<br />
profits, Törefors says.<br />
At the HangOn production site in Hillerstorp,<br />
Sweden, efforts are continually made to reduce<br />
their own energy consumption, ranging from<br />
developing more energy efficient production<br />
processes to installing solar cell panels and LED<br />
lighting.<br />
But improving the efficiency in our<br />
customers´ coating lines is by far the biggest<br />
impact we can make for sustainability, Petter<br />
Törefors says<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
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16 CASE STUDY<br />
Optimum efficiency<br />
To function properly and last for a long<br />
time in the human body, orthopedic<br />
implants require precisely defined<br />
finishes on different surface areas. For the<br />
targeted surface finishing of femur<br />
components in its new high-tech plant in<br />
Malaysia Smith+Nephew is utilizing two<br />
manufacturing cells, each containing three R<br />
6/1000 SF drag finishers from Rösler. Two fully<br />
automatic Z1000 centrifuges, equipped with<br />
the digital process water management system<br />
“Advanced” from Rösler Smart Solutions,<br />
ensure that the process water is reliably and<br />
efficiently cleaned and recycled. Another<br />
indispensable contribution towards the stability<br />
of the finishing operation is the continuous<br />
monitoring and classification of the grinding<br />
and pre-polishing media.<br />
The mission of Smith+Nephew, a globally<br />
leading medical technology company, is to<br />
replace defective body parts and, thus,<br />
improve the quality of life for the patients and<br />
extend their life expectancy. The company<br />
employs around 18,000 people in more than<br />
100 countries. With the development and<br />
application of innovative technologies they<br />
work diligently to improve the products of the<br />
company’s three global business divisions<br />
“orthopedic reconstruction,” “modern wound<br />
care management” and “sports medicine.”<br />
This commitment to excellent medical<br />
solutions is reflected in Smith+Nephew’s new<br />
high- tech plant in Penang, Malaysia. The new<br />
plant, as part of the “orthopedic<br />
reconstruction” division, produces primarily<br />
endoprosthetic knee and hip implants.<br />
Optimal surface finishes – a key<br />
quality criterion<br />
Jürgen Preiser, senior manufacturing<br />
engineer at Smith+Nephew explains: „For<br />
each of our implants we have specifications<br />
that precisely define the required quality of<br />
their surface finish. In the new Penang plant<br />
he is coordinating the establishment of the<br />
surface finishing manufacturing cells for the<br />
knee implants made from cobalt chrome<br />
alloys. For example, the inner surface areas of<br />
femur components must have a precisely<br />
defined surface roughness to promote optimal<br />
integration into the bone. On the other hand,<br />
the outer surface areas must have a very<br />
smooth, polished surface finish to prevent<br />
friction causing premature wear. Therefore,<br />
some targeted outer surface areas of the<br />
femur components must undergo an<br />
extremely demanding finishing operation with<br />
absolutely consistent results.<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
continues on page 18
18 CASE STUDY<br />
Drag finishing – the solution for<br />
targeted surface grinding and<br />
polishing with no part-on-part<br />
contact<br />
For this demanding task the customer chose<br />
the Rösler R 6/1000 SF drag finishers. These<br />
are special mass finishing systems that were<br />
developed for the precise and targeted surface<br />
finishing of high-value and delicate work<br />
pieces with complex shapes. Extremely<br />
important is that the femur components do<br />
not touch each other during the surface<br />
grinding and polishing operation. All process<br />
parameters, precisely adapted to the stringent<br />
finishing requirements, are stored in the PLC<br />
control panel. This guarantees absolutely<br />
repeatable and consistent results. Jürgen<br />
Preiser explains the decision for Rösler as<br />
follows: „Since our plant in Memphis, USA, is<br />
using identical finishing processes and<br />
machines for the same application, we have<br />
plenty of experience and know-how. This<br />
facilitates and expedites the approval for the<br />
respective equipment and finishing processes<br />
significantly. Another point in favor of Rösler<br />
was the company’s global presence with, for<br />
example, a distributor in Singapore. Moreover,<br />
Rösler develops and produces all its products<br />
in-house. This allows the optimal adaptation of<br />
equipment and consumables and guarantees a<br />
stable source of supply.<br />
Two manufacturing cells – each<br />
containing three drag finishers<br />
To date the plant on the Malayan peninsula<br />
is equipped with two manufacturing cells. Each<br />
cell contains three drag finishers for the<br />
process stages pre-grinding with ceramic<br />
media, pre-polishing with plastic media and<br />
dry polishing with a specially prepared organic<br />
polishing medium. To prevent any disruptions<br />
of the surface finishing operation, all drag<br />
finishers can be used for running the dry<br />
polishing process. Furthermore, four of the six<br />
drag finishers are suitable for the pre-grinding<br />
and pre-polishing as well as the dry polishing<br />
operation.<br />
Optimized work piece clamping<br />
system results in 50 % higher<br />
work piece throughput<br />
The drag finishers consist of a processing<br />
bowl with a diameter of 1,000 mm and a<br />
carousel with six rotary spindles. These are<br />
equipped with specially designed work piece<br />
fixtures, to which the femur components are<br />
mounted. The design of the fixtures allows<br />
clamping of the work pieces in a position that<br />
allows the finishing of precisely defined surface<br />
areas. A redesign of the fixtures now allows to<br />
increase the number of femur components<br />
clamped to one fixture from two to three<br />
without jeopardizing the all-around treatment<br />
and finishing quality. Jürgen Preiser comments<br />
on this design change enthusiastically: „We are<br />
now able to process 18 femur components in<br />
one single batch compared to only 12 we<br />
processed in the past. This increases our<br />
throughput by around 50 %, a truly<br />
remarkable boost of our productivity”.<br />
During the start phase of the grinding and<br />
polishing process the rotating carousel is<br />
lowered. This causes the work pieces attached<br />
to the rotating spindles to be immersed into<br />
the media contained in the stationary<br />
processing bowl. The built-in immersion depth<br />
control system ensures that the specified<br />
immersion depth for the various work piece<br />
types is precisely maintained. Separate,<br />
independently controlled carousel and spindle<br />
drives allow the optimal adaptation of the<br />
processing intensity to the various femur types.<br />
The Rösler drag finishers, including the drives<br />
for the carousel and spindles, are very sturdy<br />
by nature. Therefore, no design change was<br />
necessary to cope with the higher operating<br />
load caused by clamping three work pieces to<br />
a spindle instead of two. Achieving all<br />
processing parameters, including the<br />
immersion depth of the work pieces, was no<br />
problem whatsoever.<br />
Monitoring of the media level<br />
and media classification<br />
guarantee good finishing results<br />
When it comes to consistently achieving<br />
high finishing qualities, maintaining the<br />
optimal media fill level in the processing bowl<br />
and the optimal media operating mix is<br />
extremely important. The media level is<br />
monitored visually as well as with special<br />
sensors. A message is displayed in the control<br />
panel, whenever an action by the operator is<br />
needed. “In addition, to maintain a consistently<br />
high finishing quality, we installed a media<br />
classification system, consisting primarily of a<br />
vibratory screening unit. Once per week we<br />
pass the ceramic and plastic media through<br />
the screening unit, where all undersized media<br />
are discharged from the operating mix“,<br />
comments Jürgen Preiser.<br />
Digital process water<br />
management system improves<br />
overall process stability<br />
For cleaning and recycling of the process<br />
water from the “wet” pre-grinding and prepolishing<br />
operations in the two manufacturing<br />
cells Smith+Nephew purchased two fully<br />
automatic Z1000 centrifuges. Jürgen Preiser<br />
explains: „The dual centrifuge concept allows<br />
us to operate two separate process water<br />
cycles, one for the finishing operations with<br />
ceramic and one for the operations with plastic<br />
media. Maintaining two separate water cycles<br />
helps us prevent all kinds of problems, for<br />
example, foaming issues.” The control panel of<br />
each centrifuge is equipped with the digital<br />
process water management system from<br />
Rösler Smart Solutions. This innovative,<br />
interactive software allows the monitoring, data<br />
collection and evaluation of up to 14,<br />
individually selectable, process parameters.<br />
These include the compound concentration,<br />
pH value and microbiological contamination.<br />
The parameter target values and their<br />
respective tolerance range are stored in the<br />
software, and the actual values are entered for<br />
comparison purposes. Whenever one or<br />
several parameters are drifting out of the predefined<br />
range, the system displays an error<br />
message and issues easy-to-understand<br />
recommendations allowing a quick return to<br />
the specified tolerance range. This ensures a<br />
consistent high quality of the process water.<br />
Jürgen Preiser comments: „With the digital<br />
management system we not only control the<br />
process water cleaning and recycling operation<br />
a lot better. In addition, it helps us with the<br />
training of those employees who know very<br />
little or nothing about how to handle the<br />
process water.” Moreover, the recording of the<br />
parameters over a longer time period helps<br />
identify long-term trends in the process water<br />
so that necessary process water changes can<br />
be precisely scheduled with minimal<br />
disruption of the manufacturing operations.<br />
The digital process water management system<br />
also significantly reduces the consumption of<br />
compound and fresh water. And finally, the<br />
careful recording of all relevant water<br />
parameters represents an excellent tool for<br />
documenting the process quality and stability<br />
for quality audits and documentation<br />
purposes.<br />
Jürgen Preiser summarizes: “The first two<br />
manufacturing cells are currently undergoing<br />
the mandatory validation phase. The start of<br />
full-scale production is foreseen in spring<br />
<strong>2023</strong>. At the moment we are planning two<br />
additional manufacturing cells for the same<br />
products and finishing processes.”<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
AT<br />
Pull-Off Adhesion Testers<br />
Measure the adhesion of coatings to<br />
metal, wood, concrete and more<br />
Automatic Features<br />
n Impact and scratch resistant color Touch Screen display with keypad<br />
n Wirelessly connect the PosiTest AT-A to your smart device using our free app<br />
n Record the results as pass/fail and the nature of fracture —<br />
cohesive, adhesive and glue failures<br />
WiFi<br />
AT-A<br />
Automatic<br />
Model<br />
We are<br />
exhibiting at<br />
Surface World Live<br />
4 & 5 Oct <strong>2023</strong><br />
See us on<br />
Stand C20<br />
Also available<br />
AT-M Manual Model<br />
DFT Instruments UK LTD<br />
16A Long Drive, Meadway, Berkhamsted, Herts HP4 2PN<br />
t: 01442 879494 f: 01442 879595<br />
www.dftinstruments.co.uk e: sales@dftinstruments.co.uk<br />
Proud supplier of DeFelsko Inspection Instruments
20 ELECTROPLATING<br />
Smart robot<br />
In many applications surface coating such as<br />
electroplating is an important part of the<br />
manufacturing process and if performed<br />
manually, will require a considerable amount<br />
of space and human resources. However, a<br />
good example of the benefits of advanced<br />
automation and robotics is the development<br />
of an innovative robot cell which enables fully<br />
automated electroplating and has proven to<br />
be a big benefit to Swiss automation company<br />
Roth Technik.<br />
A three-way collaboration between the<br />
customer, surface coating specialist Collini<br />
based in Dubendorf, near Zurich, with<br />
automation company Roth Technik and sensor<br />
specialist BAUMER, has resulted in the<br />
development of a fully automatic system for<br />
plating racks. Minimal space was a key factor<br />
for the customer which is why they were<br />
looking for a space-saving solution that would<br />
enable a fast and reliable way of hanging<br />
small parts on racks in preparation for transfer<br />
to the electroplating bath.<br />
Marco Fuchs, Head of Product Engineering<br />
at Collini explains, “Boxes containing small<br />
metal parts were stacked in a narrow niche<br />
with barely enough space to manoeuvre a<br />
single pallet between the wall and the liquid<br />
tanks. Behind this assembly are rows of tightly<br />
packed electroplating tanks and this lack of<br />
space was a key factor in why we were<br />
looking for a space-saving solution that would<br />
deliver a fast, reliable way of hanging small<br />
parts on racks for the electroplating bath”. The<br />
conventional method of loading the racks by<br />
hand requires lots of space and human<br />
resources because several racks need to be<br />
loaded at the same time. Collini confirmed,<br />
“This is why we wanted to switch to a new<br />
automated coating system. However, this type<br />
of system had yet to be created so we<br />
embarked on a search for pioneering<br />
companies that we could collaborate with to<br />
take up the challenge”. The search resulted in<br />
a collaboration between Collini, automation<br />
specialists Roth Technik, which in turn relies<br />
on smart sensor solutions from Baumer.<br />
Working together, the team began the<br />
development of a fully automatic and compact<br />
loading line. At the heart of the loading line<br />
are 4 robots that automatically load parts onto<br />
the empty hooks on the racks, with the<br />
biggest challenge being that no two racks are<br />
the same. The hook positions are not located<br />
in exactly the same place on the welded racks<br />
and some hooks may be bent or missing<br />
entirely. Whilst this isn’t a problem for a<br />
manual system, it is a big challenge for robots<br />
that require precise positioning data.<br />
Furthermore, the huge variety and high<br />
throughput of parts presented other<br />
challenges. So how did the ‘team’ solve the<br />
problem of rack positioning accuracy, enabling<br />
the robots to ‘learn’ the exact positions of the<br />
hooks for each rack?<br />
A simple, yet effective solution from<br />
Baumer, the ultra-compact OXM200 profile<br />
sensor proved to be a key component in the<br />
efficacy of the system. Mounted on the robot<br />
arm, the sensor detects the exact position of<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
continues on page 22
22 ELECTROPLATING<br />
each individual hook as it moves down the<br />
rack and reports this data back to the robot<br />
control. With the help of a camera, the robot<br />
then picks up one part after the other from<br />
the separating carousel and hangs it on a<br />
hook. The robot uses the position coordinates<br />
previously collected by the profile sensor to<br />
finely adjust the position of the part and this<br />
enables the profile sensor to guide the robot<br />
precisely and quickly on the electroplating<br />
rack.<br />
Markus Roth, CEO of Roth Technik,<br />
explains, “Whilst the process might sound<br />
simple it requires the sensor to deliver an<br />
outstanding performance, we had to install a<br />
sensor that detects and precisely measures<br />
very thin hooks, not just in 2-dimensional<br />
space but in a 3-dimensional one too”. Initially,<br />
the Roth Technik team tested various camerabased<br />
systems and other laser-based scanners,<br />
but eventually decided that the sensor was the<br />
way to go. Markus confirmed, “In the end, we<br />
chose the Baumer OXM200 profile sensor<br />
because it was the best solution for our strict<br />
requirements regarding accuracy, ultracompact<br />
design and ability to detect objects”.<br />
The OXM200 offers another major<br />
advantage, thanks to powerful, integrated<br />
measuring tools, the sensor outputs the<br />
measured values for the X and Z coordinates<br />
directly in mm, significantly reducing the<br />
number of calculations in the control. This<br />
resulted in less integration work on software<br />
and enabled the project to be up and running<br />
faster.<br />
Also, thanks to Power over Ethernet (PoE) a<br />
single cable is all that was needed to connect<br />
the sensor to the control and supply it with<br />
power, an important detail when it comes to<br />
mounting the sensor on a mobile robot arm.<br />
Further time savings are achieved by<br />
scanning the hook positions only once when<br />
the rack is inserted and as the control stores<br />
all the hook positions, the racks don’t have to<br />
be scanned each time. The result…two robot<br />
cells enable a throughput of 15 million parts<br />
per year using minimal space whilst<br />
eliminating the issues associated with a<br />
manual system.<br />
We are exhibiting at Surface World Live • 4 & 5 <strong>October</strong> <strong>2023</strong> • See us on Stand C20<br />
Affordably measures uncured powder coatings using<br />
non-contact ultrasonic technology to predict<br />
a cured thickness<br />
• Dedicated stand-alone unit is ready to measure right out of the box<br />
• Fast measurement speed—ideal for moving lines and swinging parts<br />
• Scan Mode continuously takes measurements—ideal for<br />
analyzing large areas<br />
Powder Checker<br />
Non-contact Uncured Powder Thickness Gauge<br />
• Storage of 999 readings with onscreen averaging. Stored readings<br />
can be downloaded to PosiSoft Desktop Software<br />
Powder Inspection Kits<br />
Complete solutions for measuring<br />
powder coating before and<br />
after cure are available<br />
£1950.00<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
16A Long Drive, Meadway, Berkhamsted, Herts HP4 2PN<br />
t: 01442 879494 • www.dftinstruments.co.uk • e: sales@dftinstruments.co.uk
Surface <strong>Finishing</strong><br />
is our DNA<br />
Mass <strong>Finishing</strong><br />
Efficient systems engineering and<br />
innovative technologies – powerful<br />
and economical<br />
Shot Blasting<br />
Individual systems engineering and<br />
intelligent process solutions –<br />
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AM Solutions<br />
The full solution provider for<br />
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and 3D printing services<br />
Rösler UK | 1 Unity Grove | Knowsley Business Park | Prescot | Merseyside | L34 9GT<br />
Tel: +44 (0)151 482 0444 | Fax: +44 (0)151 482 4400 | rosler-uk@rosler.com | www.rosler.com
24 MEASUREMENT<br />
A gloss guide<br />
Uniform and consistent gloss are an<br />
essential quality criterion for a variety of<br />
products. Therefore, gloss needs to be<br />
objectively measured. Only what can be<br />
objectively measured, can be controlled and<br />
can be optimized which is of importance in<br />
product development as well as in production<br />
control. Especially in case of multi-component<br />
products a uniform gloss is an expression of<br />
“high quality”. Variations in gloss look like<br />
something is wrong and the end-user will<br />
perceive it as a defect. Therefore, gloss limits<br />
and tolerances are defined based on<br />
application and customer expectations.<br />
The technical performance of the gloss<br />
meter used to objectively measure gloss is<br />
essential to obtain reliable data. Therefore,<br />
BYK-Gardner glossmeters are developed with<br />
focus on excellent technical performance<br />
under any circumstances.<br />
Technical performance:<br />
Essential for reliable data<br />
Repeatable gloss data<br />
Goal is to meet the target value within a<br />
defined tolerance. Therefore, the glossmeter<br />
used should deliver repeatable measurement<br />
results i.e., excellent short- and long-term<br />
repeatability. (Fig. 1)<br />
Otherwise, you don’t know<br />
0,5<br />
0,3<br />
0,0<br />
-0,3<br />
0<br />
50<br />
Repeatability dif 60 o<br />
100<br />
150<br />
200<br />
1,0<br />
0,5<br />
0,0<br />
-0,5<br />
-1,0<br />
0 50<br />
Inter-Instrument Agreement<br />
Medium Gloss Standard 68.7 GU<br />
100<br />
150<br />
Instruments Tolerance + Tolerance -<br />
Fig. 2: Inter-instrument agreement of BYK-<br />
Gardner micro-gloss instruments: ±0.5 GU<br />
delivered the “part with the correct gloss<br />
level”.<br />
Gloss measurement independent of<br />
temperature changes<br />
Depending on the season temperature in<br />
the production area can change. The<br />
temperature during day and night shift can be<br />
considerably different. The temperature in the<br />
lab might be controlled at 23°C, while in the<br />
production area the temperature is much<br />
higher due to baking ovens or other<br />
production machines.<br />
Therefore, it is essential that the glossmeter<br />
used is not influenced by temperature<br />
changes and the gloss data is independent of<br />
the temperature. (Fig. 3)<br />
If gloss values are only stable within<br />
100<br />
99<br />
98<br />
97<br />
96<br />
200<br />
Temperature Stability<br />
85<br />
250<br />
300<br />
-0,5<br />
Fig. 1: Short- and long-term repeatable gloss data<br />
with BYK -Gardner micro-gloss: ±0.2 GU<br />
95<br />
94<br />
93<br />
92<br />
91<br />
60<br />
20<br />
whether the gloss change is due to a<br />
glossmeter drift or a true product variation.<br />
Reproducible gloss data from<br />
glossmeter to glossmeter<br />
Reproducibility is as important as<br />
Repeatability as every production is part of a<br />
supply chain process. Gloss values need be<br />
communicated and exchanged within a<br />
supply chain. Gloss levels of various<br />
production facilities or several production lines<br />
need be consistent to achieve a uniform gloss<br />
within defined tolerances. (Fig. 2)<br />
Otherwise, a multi-component product will<br />
look like patchwork and the various<br />
component suppliers will always discuss who<br />
90<br />
10 o C 20 o C 30 o C 40 o C 30 o C 20 o C 10 o C<br />
Fig. 3: Temperature stability between 10°C – 40°C<br />
– 10°C<br />
laboratory conditions, data cannot be<br />
compared. Temperature stability is as<br />
important as repeatability and reproducibility<br />
because you don't know what the<br />
temperature conditions are at different<br />
production sites.<br />
A glossmeter needs “health<br />
check”<br />
Production environment is often rough and<br />
dusty which can affect the performance of<br />
your glossmeter as optics can accumulate dust<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
continues on page 26
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The installation of a conveyor<br />
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• Increase productivity<br />
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Tel: 0116 259 3175 Fax: 0116 259 2820 Email: enquiry@mhel.co.uk<br />
www.mhel.co.uk
26 MEASUREMENT<br />
on the lenses. Therefore, the “health status” of<br />
the used gloss meter is an important factor<br />
and needs to be checked. The BYK-Gardner<br />
micro- gloss instruments have an “autodiagnosis”<br />
which checks the actual<br />
performance of the instrument and gives you<br />
instant feedback:<br />
• Auto-diagnosis is OK<br />
• Please clean standard<br />
• Optics need cleaning Send in for<br />
service/recertification<br />
The auto-diagnosis is your insurance for<br />
reliable measurement data.<br />
High gloss, semi gloss, matt -<br />
what geometry is best?<br />
The answer is easy: micro-TRI-gloss. The<br />
universal glossmeter to measure high,<br />
medium and low gloss finishes accurately.<br />
Three different illumination angles (Fig. 4) are<br />
required to achieve good differentiation of the<br />
Fig. 4: Standardized geometric conditions<br />
85°<br />
60°<br />
20°<br />
100<br />
90<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
1<br />
2<br />
Low Gloss<br />
3<br />
4<br />
5<br />
6<br />
Semi Gloss<br />
20 0<br />
60 0<br />
85 0<br />
entire range from high to low gloss surfaces:<br />
• 20° high-gloss surfaces - 60° semi-gloss<br />
surfaces - 85° low gloss surfaces<br />
The 60° illumination is used as a general<br />
geometry for a wide range of applications with<br />
gloss values between 10 and 70 gloss units. If<br />
gloss data is higher than 70 GU or lower than<br />
10 GU, this measurement geometry is no<br />
longer effective in showing differences as<br />
shown by the flat portion of the curve. Thus,<br />
the 60° geometry would show little or no<br />
difference in this range, while visually there is<br />
a clear difference. (Fig. 5)<br />
How many measurements should<br />
be taken or the importance of<br />
statistics<br />
Here our answer is “ONE reading is like NO<br />
7<br />
8<br />
9<br />
10<br />
High Gloss<br />
Fig. 5: Specular gloss values dependent on<br />
measuring angle<br />
11<br />
12<br />
13<br />
reading”.<br />
In order to get a representative value of your<br />
product finish a minimum of 3 readings should<br />
be taken. And to evaluate the uniformity of<br />
your product’s surface finish the average with<br />
“std.dev. or range (min – max) should be<br />
recorded.<br />
The micro-gloss instruments offer a statistic<br />
mode (Fig. 6) that can be defined by the user:<br />
A single reading does not give a true picture<br />
SAMPLE 012<br />
MEMORY 001<br />
20 o<br />
60 o x<br />
69.3<br />
88.2<br />
range<br />
4.1<br />
1.5<br />
n = 03/05<br />
stdev<br />
2.3<br />
0.9<br />
of the uniformity which is particularly important<br />
when evaluating larger surface areas.<br />
Gloss measurement digitalized<br />
Everyone is talking about digitalization. Why<br />
do you still write down gloss values or enter<br />
data manually in Excel?<br />
The micro-gloss instruments come with the<br />
software smart-chart which allows you to<br />
transfer, save and analyze the data in easy-tointerpret<br />
trend charts. The saved data can be<br />
used for production monitoring with<br />
documentation in standardized reports as PDFfile<br />
or for transfer to other programs. Always<br />
ready for audits and optimization.<br />
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INNOVATION FOR ALL YOUR WASHING NEEDS<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
Call 01543 675800 or visit our website www.unitechwashers.uk.com
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28 BRAKES<br />
Dust reduction<br />
system<br />
The forthcoming Euro 7 emission standard<br />
will drastically reduce particulate matter<br />
levels for all new vehicles - regardless of<br />
the type of drive. As a result, brake systems<br />
are coming under increasing scrutiny. The<br />
solution: brake discs with low-wear hard<br />
coatings, because less wear means less<br />
particulate matter.<br />
NAGEL is well prepared for this<br />
development. All the technologies for the<br />
environmen-tally friendly brake discs of the<br />
future are already available at the Nürtingen<br />
plant in the form of 2 prototype lines.<br />
These include laser cells for coating using<br />
the high-speed LMD process and finishing on<br />
high-precision double-sided surface grinding<br />
machines. Fine dust emissions are reduced by<br />
80% or more after machining. NAGEL<br />
supplies the entire process, i.e. the complete<br />
lines for coating and grinding with all<br />
peripheral equipment, e.g. for handling the<br />
coating powder, for extraction, cooling or<br />
rinsing agent preparation.<br />
Also very important: precision systems for<br />
continuous quality control. When it comes to<br />
measuring, NAGEL can draw on a wealth of<br />
experience in fine and ultra-fine machi-ning.<br />
Not all coatings are the same. Different<br />
requirements call for individual coating thicknesses,<br />
coating compositions and surfaces.<br />
NAGEL's process development guaran-tees the<br />
right result for every purpose and can create<br />
coating systems on the two existing prototype<br />
lines and qualify them together with the<br />
customer. Thanks to the in-house development<br />
of abrasives, surface topographies can also be<br />
achieved in any desired quality.<br />
The customer orientation continues with the<br />
automation. NAGEL supplies every conceivable<br />
configuration to increase productivity<br />
to the desired level, e.g. line linking or<br />
industrial robot solutions. Thanks to the<br />
modular design, the systems can be scaled<br />
very easily and quickly. Machine production,<br />
peripheral assembly and customisation are all<br />
carried out under one roof at the main factory.<br />
Customers receive a complete package "Made<br />
in Germany".<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
DEVELOPERS AND MANUFACTURERS OF SPECIALIST<br />
ELECTROPHORETIC COATINGS<br />
The Hawking name has been associated with the development and<br />
marketing of specialist electrophoretic<br />
coating systems since 1985.<br />
Hawking Electrotechnology Ltd is at the forefront of technological<br />
advancements in this field and supplies its products<br />
through a distribution network that extends<br />
into some 35 countries worldwide and growing.<br />
• UV/LED Radiation cure coatings<br />
• Friction control applications<br />
• Super durable Architectural finishes<br />
• Anti-bacterial / Anti-viral systems<br />
• Outstanding colours and effects<br />
• Unrivalled matting technology<br />
‘If it conducts electricity we can<br />
coat it, protect it, enhance it’<br />
Hawking Electrotechnology Ltd<br />
T: +44 (0) 1384 483019<br />
sales@hawking.co.uk<br />
www.hawking.co.uk
30 INSTALLATIONS<br />
A hard choice<br />
One of the largest service hardening plants in Spain has purchased a<br />
Vector vacuum furnace from SECO/WARWICK. It will be the third<br />
SECO/WARWICK solution for this Partner.<br />
The Client has been cooperating with SECO/WARWICK for many<br />
years, along with Arrola , who provides service support to the Spanish<br />
market on behalf of the SECO/WARWICK Group.<br />
Local service is one of the reasons why SECO/WARWICK is the<br />
partner’s first choice. SECO/WARWICK has always thought globally<br />
and acted locally. On the Iberian Peninsula, customer service is<br />
provided by Arrola, and this local support is praised by this service<br />
hardening plant, a long time SECO/WARWICK customer.<br />
“We are happy to have a local partner who knows our furnaces<br />
very well and is close to our customers. Arrola understands customer<br />
expectations and has been providing comprehensive services to our<br />
partners for years. It is a very good and convenient system that works<br />
efficiently. Thanks to local support, we can propose a comprehensive<br />
offer including fast support,” said Maciej Korecki, vice president of the<br />
vacuum segment, of the SECO/WARWICK Group.<br />
Watre based rust converter<br />
HMG Paints has announced the relaunch of Ferrozinc, a water-based<br />
rust converter. With its exceptional performance and ease of use,<br />
Ferrozinc is the go-to solution for rust conversion in areas where shot<br />
blasting, or complete rust removal is impractical or impossible.<br />
“Ferrozinc has been a popular product for our customers for a<br />
number of years and we’re proud to introduce the new 250ml size”<br />
commented James Burton of HMG. “It’s such a handy product for<br />
users in a number of industries from decorators and industrial<br />
applicators to agricultural and classic vehicle restoration.”<br />
Traditionally, rust removal has been a laborious and time-consuming<br />
process, involving hours of wire brushing or the use of strong acidic<br />
chemicals that pose significant safety hazards. With HMG's Ferrozinc<br />
rust converter, however, this arduous task becomes a thing of the past.<br />
This is the perfect solution to anyone working in the decorative or<br />
industrial markets, and even classic car enthusiasts!<br />
Users only need to remove loose debris and poorly adhered surface<br />
rust, followed by a degreasing step to eliminate any contamination that<br />
may interfere with the chemical reaction. Afterward, a thin coat of<br />
Ferrozinc is applied to the rusted area, and within 30 minutes, the<br />
surface transforms into a black/navy colour, indicating the successful<br />
rust conversion. Any excess product can be easily wiped off, and after<br />
just +3 hours, the treated surface is ready to be overcoated with the<br />
user's preferred coating system.<br />
Turning waste into new product<br />
Beckers Group is collaborating with suppliers to incorporate raw<br />
materials, made from recycled plastic, into its paints. The ability to turn<br />
waste plastic into new raw materials will promote circularity and reduce<br />
emissions.<br />
Beckers is working in collaboration with BioBTX and the research<br />
institute Symeres to create a supply chain for sustainable aromatic<br />
monomers made from plastic waste. BioBTX has developed a method<br />
for turning waste plastic into BTX (benzene, toluene and xylene) which<br />
Symeres then take and oxidise the xylenes into aromatic phthalic<br />
monomers which Beckers can use to create resins.<br />
The pilot involves processing mixed plastic waste into sustainable<br />
chemical building blocks and finally high-value products, using multiple<br />
advanced sustainable chemical conversions. This includes Integrated<br />
Cascading Catalytic Pyrolysis (ICCP) technology to convert mixed waste<br />
plastics and biomass into aromatics such as benzene, toluene and<br />
xylenes. Beckers is particularly interested in xylenes, which can be<br />
oxidised to produce monomers, such as phthalic anhydride, to be used<br />
Testing, testing<br />
Heraeus Noblelight has installed a new test line, featuring an infra-red<br />
booster in front of an electric convection oven, at its Applications<br />
Centre. This will allow customers to trial the dual technology system on<br />
their own products under practical and controlled conditions to<br />
establish its suitability before committing to further investment.<br />
Infra-red boosting before convection heating allows significant<br />
benefits. Infra-red heating brings products to the target temperature<br />
very quickly and electric hot air ovens ensure homogenous heating of<br />
products, even those of complex geometry. Consequently, there is fast<br />
and efficient energy transfer, which both reduces process times and<br />
optimises the carbon footprint.<br />
The new test line brings together the expertise and decades of<br />
experience of Heraeus in infra-red and Weiss Technik in electric hot air<br />
ovens. In initial in-house tests on powder-coated metal tubes, it was<br />
demonstrated that heating times for curing were reduced by up to<br />
80% when the infra-red booster was used before the oven. Similarly, a<br />
significant reduction in process time, as well as homogenous heating,<br />
was also demonstrated when curing a black powder coating on a<br />
stainless-steel ball.<br />
<strong>Finishing</strong> – <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
PROTECT<br />
YOUR VALUABLE<br />
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32 DEGREASING<br />
Solvent advantage<br />
Fluorinated solvents, also known as<br />
fluorocarbon solvents, offer several<br />
advantages in various industrial and<br />
scientific applications, including being highly<br />
suited for vapour degreasing. Here are some<br />
of the key advantages of using fluorinated<br />
solvents:<br />
Environmental Compatibility:<br />
Fluorinated solvents are often chosen as<br />
alternatives to more hazardous solvents due to<br />
their relatively low impact on the environment.<br />
They have low ozone depletion potential<br />
(ODP) and negligible global warming<br />
potential (GWP). Additionally, they have low<br />
toxicity and are not classified as hazardous air<br />
pollutants (HAPs).<br />
Chemical Stability:<br />
Fluorinated solvents exhibit excellent<br />
chemical stability, making them highly<br />
resistant to degradation and reactions with<br />
other chemicals. They are compatible with a<br />
wide range of materials, including metals,<br />
plastics, and elastomers. This stability allows<br />
for their use in challenging environments and<br />
with reactive substances.<br />
Solvency Power:<br />
Fluorinated solvents have strong solvency<br />
power, meaning they can dissolve a wide<br />
range of organic and inorganic compounds.<br />
This property makes them effective in<br />
applications such as cleaning, degreasing, and<br />
precision cleaning, where the complete<br />
removal of contaminants is crucial, such as<br />
cleaning to oxygen standard.<br />
Nonflammability:<br />
One of the significant advantages of<br />
fluorinated solvents is their non-flammable<br />
nature. Under testing to ASTM D 93 they will<br />
not flash and therefore do not support<br />
combustion, making them safer to use<br />
compared to many traditional solvents. This<br />
property reduces the risk of fire hazards in<br />
various industrial processes and applications.<br />
Dielectric Properties:<br />
Fluorinated solvents have excellent dielectric<br />
properties, making them ideal for applications<br />
that require electrical insulation and heat<br />
transfer. They are commonly used in<br />
electronic and electrical industries for tasks<br />
such as cleaning electrical components,<br />
cooling electronics, and as a dielectric fluid in<br />
transformers and capacitors.<br />
Thermal Stability:<br />
Fluorinated solvents can withstand a wide<br />
range of temperatures without decomposing<br />
or losing their properties. This thermal stability<br />
allows them to be used in high-temperature<br />
applications, including heat transfer fluids,<br />
lubricants, and as coolants in various industrial<br />
processes.<br />
Surface Tension Control:<br />
Fluorinated solvents have the ability to<br />
modify the surface tension of liquids, enabling<br />
them to spread evenly and improve wetting.<br />
This property makes them useful in<br />
applications such as coatings, adhesives, and<br />
printing, where uniform and controlled<br />
wetting is required.<br />
Zero Ozone Depletion Potential (ODP) and<br />
very low Global Warming Potential (GWP)<br />
solvent cleaner for high performance vapour<br />
degreasing<br />
ProSolv 5408e has been developed to<br />
provide superior critical cleaning performance<br />
for manufacturers of electronic and electrical<br />
components. High Solvency (KB Value 98) for<br />
removal of organic residues, compatible with<br />
organic and synthetic oils and most plastics<br />
and metals.<br />
ProSolv 5408e is a high-performance<br />
solvent cleaner used for sustainable and<br />
future proof vapour degreasing. It has a<br />
GWP of less than 1, with a 100 year<br />
Integrated Time Horizon (ITH). Soft on the<br />
environment and safe for users, it offers<br />
improved cleaning at lower costs.<br />
ProSolv 5408e ticks all the boxes and is<br />
the perfect profile for a modern vapour<br />
degreasing solvent. Exceptionally low surface<br />
tension to penetrate micron sized holes and<br />
close contact surfaces. Sustainable and secure<br />
for the future. Non-carcinogenic, low boiling<br />
point, economical with energy with low<br />
solvent losses, faster production, reduced<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
gemapowdercoating.com<br />
High-quality solutions<br />
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We are<br />
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T +39 02 48 400 486<br />
Gema Europe Srl – UK Branch<br />
Tel: 0044 1202 763 942<br />
Email: uk.sales@gema.eu.com
34GALVANIZING<br />
Going the distance<br />
Humber Galvanizing Ltd have jumped<br />
into action alongside local fabricators to<br />
ensure a bespoke piece of art will stand<br />
the test of time.<br />
Driffield-based SA Fabrications were earlier<br />
this year commissioned to create a bespoke<br />
life-sized steel horse sculpture by local farmer,<br />
Paul Temple.<br />
Stephen Albinger, Founder and Owner at<br />
SA Fabrications, said: “Originally inspired by a<br />
performance of War Horse, Paul Temple and<br />
his wife, Liz, commissioned a bespoke horse<br />
sculpture to take pride of place in their<br />
garden. Spurred on by Liz’s passion for the<br />
animals, she provided four horse shoes to be<br />
included in the final framework.<br />
“After much deliberation and creative<br />
consideration, we decided the equine beast<br />
would be in a majestic mid-jump pose. The<br />
sculpture, which took around four weeks to<br />
create, stands at an impressive 2.3m high and<br />
2.5m long, and weighs around 450kg. After<br />
fabrication, I enlisted the support of Humber<br />
Galvanizing, who I’ve worked with for over<br />
twenty years, to ensure it could withstand the<br />
elements when located outside.”<br />
At Humber Galvanizing, the horse was<br />
entirely immersed and hot-dipped into a<br />
large molten zinc bath. Coating the steel<br />
completely, the process allows it to be<br />
protected from corrosion for up to 70 years.<br />
“When the piece returned from the<br />
galvanizers, safe in the knowledge that it<br />
would be rust-free, I used an antique copper<br />
and black powder coating to add more<br />
depth and detail to the framework,” Steve<br />
added.<br />
Tony Linsley, Sales Manager at Humber<br />
Galvanizing Ltd concluded: “We’re proud to<br />
have been able to assist Steve in ensuring the<br />
longevity of this striking horse sculpture using<br />
the galvanizing process. We thoroughly enjoy<br />
working with SA Fabrications, and look<br />
forward to the exciting projects they bring to<br />
us. We can’t wait to see what’s next!”<br />
Humber Galvanizing is part of Wedge<br />
Group Galvanizing Ltd, the largest hot-dip<br />
galvanizing organisation in the UK with a<br />
history dating back over 150 years. With 14<br />
plants strategically placed across the country,<br />
the firm offers a truly national galvanizing<br />
service.<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
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Covering the UK in Powder Coating<br />
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NOVEMBER<br />
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www.cwst.co.uk | eurosales@cwst.com | 01635 279621<br />
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FINISHING is published by Turret Group Ltd, Cardinal Point, Park Road, Rickmansworth, Herts, WD3 1RE • Tel: 01923 432705 • Online at: www.finishingmagazine.co.uk<br />
Editor: John Hatcher - E-mail: j.hatcher@turretgroup.com • Display & Classified Advertising: Stewart Freshwater - E-mail: s.freshwater@turretgroup.com • Production: Carol Baird - E-mail: c.baird@turretgroup.com<br />
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I SAT SUN MON TUES WED THUR FRI SAT SUN MON TUES WED THUR FRI SAT SUN MON TUES<br />
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17 19324<br />
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Greenwich Mean<br />
Time begins<br />
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N. Ireland<br />
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& Scotland)<br />
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siebec_1 panel_<strong>2023</strong>-24.indd 1 12/09/<strong>2023</strong> 22:56<br />
DECEMBER<br />
gema_1 panel_2019-20.indd 1 14/09/2022 14:56<br />
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15/09/<strong>2023</strong> 10:28
36 GALVANIZING<br />
Furnace control<br />
Set to completely revolutionise the<br />
galvanizing industry, Hasco-Thermic Ltd<br />
has developed world-leading furnace<br />
control technology, transforming how burners<br />
are controlled, and allowing businesses to<br />
totally enhance sustainability efforts.<br />
Not only does the innovative technology aid<br />
efficiency, longevity, and future-proof<br />
galvanizing plants, but it’s set to also save time<br />
and costs for companies – savings most<br />
welcome during this period of rising energy<br />
costs.<br />
Wedge Group Galvanizing Ltd is the first to<br />
implement this pioneering technology,<br />
gradually introducing across their 14<br />
nationwide plants. To date, they’ve reported an<br />
average 15% saving on gas, and depending<br />
on the technology level of existing equipment,<br />
this is providing a payback of between four to<br />
10 months. Not to mention a significant<br />
reduction in carbon emissions, enhancing<br />
Wedge Group’s sustainability credentials.<br />
Angela Curtis, managing director at Hasco-<br />
Thermic, said: “When we came up with the<br />
original idea of Smart Firing, we hadn’t fully<br />
appreciated the potential savings that could be<br />
made - and they’ve been much higher than<br />
we anticipated. By the end of the year, we’ll<br />
have successfully converted almost all of<br />
Wedge Group Galvanizing’s 14 plants and are<br />
incredibly keen for the business to benefit<br />
from this technology as soon as possible to<br />
maximise the magnitude of savings available.”<br />
With a genuine passion to make the<br />
industry more sustainable, Angela recently<br />
presented this new technology and<br />
decarbonisation in the galvanizing sector at<br />
the annual European conference in Salzburg<br />
in June.<br />
She added: “Following the immense<br />
success that Wedge Group Galvanizing has<br />
reported since implementing this technology,<br />
we’re hoping to be able to offer it to the<br />
wider galvanizing industry – and even other<br />
businesses within the metals sector – very<br />
soon. We’re keen to support companies to<br />
save time, money, and resources, but also to<br />
provide a more eco-friendly solution.”<br />
David Nobes, technical services director at<br />
Wedge Group Galvanizing, concluded: “This<br />
innovative furnace technology has made a<br />
significant impact to the Wedge Group,<br />
helping to reduce both energy usage and<br />
costs. Over the next few months, we<br />
endeavour to have this fully functioning<br />
company-wide, to totally take advantage of<br />
the benefits.<br />
“The new technology contains many<br />
remote monitoring and analysis benefits,<br />
combined with alarms and automated<br />
notifications for our on-site leadership teams.<br />
Not only have our operations been more<br />
efficient, but it’s also a significant step in our<br />
progress towards government CO2 reduction<br />
targets and our ultimate objective to be a Net<br />
Zero business.”<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
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38 INNOVATION<br />
Programme delivers jobs<br />
One of the UK’s most successful<br />
industrial business support programmes<br />
comes to an end in June after helping<br />
the manufacturing sector to create or<br />
safeguard 12,435 jobs since 2016.<br />
The Manufacturing Growth Programme<br />
(MGP), which is designed and delivered by<br />
Oxford Innovation Advice, will see funding<br />
from the European Regional Development<br />
Fund end and is now urging the Government<br />
and local authorities to ensure that tailored<br />
advice for manufacturing SMEs is quickly put<br />
in place.<br />
A recent independent evaluation* of the<br />
programme found that MGP has delivered<br />
excellent value for money and achieved real<br />
results.<br />
The report revealed that over 95% of<br />
companies surveyed expected their business<br />
to grow in the next five years because of<br />
receiving support from the programme, with<br />
63% identifying the development of new<br />
products as one of the key areas.<br />
In addition, 63% said they had already seen<br />
an increase in turnover, while 52% cited<br />
improved productivity as the main outcome of<br />
the support received.<br />
MGP was established in <strong>October</strong> 2016 to<br />
address some of the main barriers to growth<br />
experienced by SME manufacturers.<br />
Since then, it has been providing grant<br />
funding for business improvement/capital<br />
projects and specialist mentoring from<br />
industry experts, with 4564 companies<br />
assisted across the East and West Midlands,<br />
Yorkshire & Humber and the South East.<br />
Its dedicated team of Manufacturing<br />
Growth Managers has delivered more than<br />
£13.9m of grants that, in turn, have unlocked<br />
over £25.7m of private sector investment.<br />
Importantly, it also generated £42,073 Gross<br />
Value Added (GVA) per employee in the<br />
companies it supported.<br />
Jane Galsworthy, MANAGING DIREctor of<br />
Oxford Innovation Advice – the leading<br />
provider of business support programmes for<br />
SMEs - explained: “This independent<br />
evaluation further demonstrates that specialist<br />
business support programmes like the<br />
Manufacturing Growth Programme play a<br />
crucial role in supporting companies to<br />
overcome everyday challenges and barriers to<br />
growth.<br />
“With the new UK Shared Prosperity Fund<br />
(UKSPF) dividing up funding for business<br />
support at a very local level, there is a risk that<br />
businesses will only be able to access generic,<br />
low-quality support which delivers lower value<br />
for money and less measurable impact on<br />
businesses and the economy.”<br />
She went on to add: “We’ve proven over<br />
the last seven years what targeted support can<br />
do for SME manufacturers, helping them<br />
accelerate growth, improve productivity and<br />
create jobs. With funding for MGP coming to<br />
an end, this creates a significant hole in<br />
specialist high-quality support for smaller<br />
manufacturers.<br />
“The results of our own survey** of<br />
manufacturers revealed reinforces this, with<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
continues on page 40
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40 INNOVATION<br />
91% of companies admitting they do not<br />
know where to turn for business support once<br />
this programme completes.<br />
“Manufacturing is critical to the UK<br />
economy as it accounts for around half of all<br />
UK exports and nearly 10% of the country’s<br />
overall economy (GVA)***. We are keen,<br />
therefore, to engage with government<br />
agencies and local authorities to see how<br />
funding can be best utilised to provide<br />
continued specialist support for<br />
manufacturers.”<br />
The Manufacturing Growth Programme is<br />
the UK’s largest and leading business support<br />
programme for SME manufacturers, delivering<br />
consistent, tailored support across 183 local<br />
authority areas. The findings of this latest<br />
evaluation report have proved that the MGP<br />
model has worked effectively to address<br />
market failures.<br />
The report additionally highlighted how<br />
Oxford Innovation Advice adapted the<br />
programme during Covid-19 and Brexit to<br />
continue delivering high quality business<br />
support and effectively assist manufacturing<br />
SMEs through these difficult circumstances.<br />
Jane said: “In the current economic climate,<br />
where businesses face multiple pressures from<br />
inflation, high energy prices, supply chain<br />
challenges and reduced consumer spending,<br />
the programme and its objectives are still as<br />
relevant now as they were back in 2016.<br />
“It is now more important than ever that<br />
businesses have access to high-quality<br />
business support services and specialist<br />
expertise to help them achieve their growth<br />
potential. This, in turn, will enhance the<br />
economy, create job opportunities, and ensure<br />
the prosperity of our local communities.”<br />
Verity Davidge, Director of Policy at Make<br />
UK, concluded: “Manufacturing is central to<br />
the future of the UK economy as a provider of<br />
high skill, high value jobs, especially in<br />
emerging technologies, digitalisation, and the<br />
move to net zero. SMEs are the absolute<br />
backbone of the sector employing the vast<br />
majority of people and it’s vital that support<br />
programmes are maintained to ensure they<br />
can grow and prosper.”<br />
We are<br />
exhibiting at<br />
Surface World Live<br />
4 & 5 Oct <strong>2023</strong><br />
See us on<br />
Stand K12<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
We are exhibiting at Surface World Live • 4 & 5 <strong>October</strong> <strong>2023</strong><br />
Come and visit us on Stand B12
42 PROFILE<br />
Hot off the press<br />
With a £10 million investment,<br />
Wallwork Group is establishing a<br />
state-of-the-art Hot Isostatic Pressing<br />
(HIP) centre at their Bury, North Manchester<br />
site. Housed in a newly prepared 2500 square<br />
metres facility, the first of their new HIPs is<br />
expected to be fully operational in <strong>September</strong><br />
<strong>2023</strong>. The company also has sites in<br />
Cambridge, Birmingham and Newcastle.<br />
Quintus Technologies are currently<br />
completing the installation of the first of<br />
Wallwork’s HIPs. They are the global leader in<br />
high pressure technology and have over 2000<br />
systems working worldwide in industries<br />
including aerospace, energy, medical implants,<br />
space, automotive, additive manufacturing,<br />
castings and food processing.<br />
“As the UK’s premier independent heat<br />
treatment, vacuum brazing and advanced<br />
ultra-hard coatings company, this is a<br />
significant expansion of Wallwork’s thermal<br />
processing services and is part of a<br />
commitment to invest £20 million over the<br />
next five years. It cements our position as the<br />
UK one-stop shop for component<br />
manufacturers. All secondary processes are<br />
easily accessible on this site or another<br />
Wallwork site and backed by our national<br />
pickup/delivery transport fleet,” said director,<br />
Simeon Collins.<br />
Wallwork director, James Bailey and David<br />
Loughlin (HIP Business Manager) are heading<br />
the new Wallwork HIP Centre, along with<br />
Andy Day in sales. David joins the company<br />
to take on the new role and brings with him<br />
his extensive experience in running a HIP<br />
facility in Europe, and understands customer<br />
expectations on high service, competitive<br />
pricing and quality.<br />
David explained, “The demand for HIP is<br />
growing quickly, in part driven by the leaps<br />
forward in additive manufacturing technology.<br />
HIP is extremely efficient at removing the<br />
porosity from AM parts made from metal<br />
powders – this densification process is often<br />
the only way for AM builds to fulfil their safety<br />
critical potential. With the Quintus URC<br />
system to reduce cycle times and high<br />
pressure capability, we are set to meet<br />
customer demand and expectations in these<br />
developing areas. Compared to the US and<br />
Europe, the UK has been lagging behind in<br />
HIP capacity. This investment, and those<br />
planned by Wallwork, will go a long way to<br />
rectify that. In addition to Wallwork’s focus on<br />
quality, service and value added, I’m looking<br />
forward to developing some new relationships<br />
for the company.”<br />
James added, “The Quintus Technologies’<br />
HIP operates at pressures from 40 to 207<br />
MPa (5,800 to 30,000 psi) and temperatures<br />
up to 1250°C. The new unit being installed<br />
has the latest technology capable of rapid<br />
cooling and also the ability to increase cycle<br />
pressures to aid with new engineering<br />
advances particular in additive manufacturing.<br />
This requires some major engineering and<br />
civil works, hence the high investment we<br />
need to make to enter this growing market.<br />
The ability to improve material fatigue<br />
properties, ductility, structural integrity and<br />
fracture toughness applies to AM, castings,<br />
forgings and subtractive engineered<br />
components. Components with complex<br />
geometries can also be processed to near-net<br />
shape, saving customers additional machining<br />
steps and therefore cost.”<br />
Simeon Collins concluded, “Beginning the<br />
design phase for the first of our HIPs during<br />
the pandemic presented many unforeseen<br />
challenges for Wallwork and the team at<br />
Quintus Technologies. This has forged a solid<br />
working relationship and gives us great<br />
confidence in their support for the technology<br />
going forward as we continue to invest. As the<br />
Bury site is already the largest single-site UK<br />
heat treating facility with an aerospace scope<br />
covering nine Nadcap check sheets, we<br />
expect to be adding new certifications and<br />
approvals for HIP as quickly as possible. We<br />
also have a dedicated online customer portal<br />
in development that will aid load scheduling.”<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
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44 PROFILE<br />
Gently does it<br />
At the Deburring Expo <strong>2023</strong> Walther<br />
Trowal is introducing its new mass<br />
finishing systems for deburring, surface<br />
grinding and polishing of high-value metal<br />
components. For the combined grinding,<br />
polishing and drying of small work pieces the<br />
company presents a fully automatic machine.<br />
Bigger components can be processed in the<br />
largest multivibrator finishing system ever built<br />
by the company during its 90-year history.<br />
The applications for Walther Trowal mass<br />
finishing systems are very diverse. The<br />
technology is equally effective for deburring<br />
turbine blades for jet engines, deburring and<br />
edge radiusing of stampings for the<br />
automotive industry and finishing of<br />
orthopedic implants for medical engineering.<br />
Small work pieces<br />
The new TT Turbotron centrifugal disk<br />
finishing machine from Walther Trowal allows<br />
the surface smoothing and polishing of small<br />
work pieces in one single machine. This helps<br />
to significantly streamline a broad range of<br />
surface finishing operations. The TT 280-A/2C<br />
operates fully automatically – from loading the<br />
raw work pieces into the processing bowl to<br />
discharging the polished and dried<br />
components. A typical application is the<br />
finishing of piston rods used in dampening<br />
systems for hinges, for example, in kitchen<br />
appliances, such as ovens and dishwashers,<br />
and furniture doors.<br />
<strong>Finishing</strong> times reduced<br />
The new Multivibrator MV 50 is the largest<br />
of this machine type ever built by Walther<br />
Trowal. It cuts the cycle time for finishing the<br />
surface of big components from several days<br />
to just a few hours. With an internal diameter<br />
of the processing bowl of 1,600 mm this<br />
machine allows the fully automatic surface<br />
finishing of components with a diameter of up<br />
to 1,300 mm in one single operation. For<br />
example, the MV 50 can handle extremely<br />
complex components utilized in jet engines<br />
and wind power turbines. It is equally suitable<br />
for finishing turbine disks, blisks and forging<br />
tools. The first MV 50 system is about to be<br />
delivered to a customer in the aerospace<br />
industry.<br />
Solutions for a broad spectrum<br />
of surface finishing tasks<br />
The mass finishing equipment program at<br />
Walther Trowal ranges from stand-alone rotary<br />
vibrators to fully automatic finishing systems<br />
that include work piece loading and unloading<br />
devices. They can be easily integrated into<br />
continuous flow manufacturing operations.<br />
The company utilizes a broad range of<br />
grinding and polishing media, for example,<br />
specially developed grinding media that allows<br />
the effective deburring of work pieces without<br />
removing too much material from the work<br />
piece surface. Especially in the case of<br />
components with complex shapes and internal<br />
passages, such as undercuts and drilled holes,<br />
the media allows the finishing of surface areas,<br />
which would not be possible with manual<br />
deburring.<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
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46 EXHIBITIONS<br />
Taking part counts<br />
Companies from every sphere of<br />
industrial manufacturing need to<br />
continuously improve their product<br />
quality and cost efficiency, while<br />
simultaneously cutting down on the<br />
consumption of energy and resources. Here,<br />
optimized and tailored cleaning processes can<br />
make a significant contribution. Parts2clean<br />
features the relevant solutions, trends and<br />
know-how. The 20th edition of the leading<br />
international trade fair for industrial parts and<br />
surface cleaning is being staged from<br />
<strong>September</strong> 26 to 28 <strong>2023</strong>, at the Stuttgart<br />
Exhibition Center in southern Germany.<br />
Whether it involves degreasing, classic<br />
component cleaning or high-purity<br />
applications – as varied as those tasks may be<br />
– technological and social trends are<br />
introducing new requirements to parts<br />
cleaning. This has resulted in the situation that<br />
higher cleanliness specifications need to be<br />
met in virtually all cleaning applications,<br />
especially when it comes to residual filmic<br />
contamination. In order to offer competitive<br />
products in the long run, cleaning must also<br />
be as economical, energy-efficient and<br />
resource-efficient as possible. In a growing<br />
number of cases, the stability of the cleaning<br />
processes must also be verifiable. “As the<br />
world’s foremost information and procurement<br />
platform for industrial cleaning technology,<br />
parts2clean offers ideas, solutions and services<br />
for adapting all of the steps involved in parts<br />
and surface cleaning to meet this increased<br />
set of demands and make them future-proof,”<br />
explains Christoph Nowak, Project Director at<br />
the Deutsche Messe group of companies. “In<br />
the same vein, effective knowledge transfer<br />
for parts cleaning that meets these<br />
requirements and is both process-secure and<br />
sustainable is the focus of the supporting<br />
program at the 20th leading international<br />
trade fair,” he adds.<br />
Innovations and product<br />
refinements in all display<br />
sectors<br />
One proof of this is the presence of<br />
practically all market and technology-leading<br />
companies from the industrial cleaning<br />
technology sector at the event. “Many of<br />
these exhibitors will be using the anniversary<br />
edition to introduce new and refined products<br />
and services to an international trade<br />
audience,” reports Nowak. This includes new<br />
and optimized system concepts for degreasing<br />
and classic cleaning tasks as well as for<br />
precision cleaning and high-purity<br />
applications, such as those increasingly<br />
encountered in the optical and semiconductor<br />
supply industry, electromobility and medical,<br />
pharmaceutical, sensor, measurement and<br />
analysis technology. “Due to the steadily<br />
growing importance of these applications, the<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
continues on page 48
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• Combine with Ervin Amasteel and Stainless<br />
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We are exhibiting at<br />
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See us on Stand C12<br />
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48 EXHIBITIONS<br />
classic core areas of parts2clean have been<br />
expanded at the anniversary event to include<br />
the highlight topic of High Purity,” adds<br />
Nowak. However, this is not only<br />
demonstrated by plant and process<br />
engineering solutions for cleaning high-tech<br />
components, but also by the broad range of<br />
products for setting up, equipping and<br />
optimizing cleanrooms.<br />
The event features exhibitors with<br />
innovative and adapted process technologies<br />
as well as solutions for cleanliness control,<br />
doing justice to the trend towards ever-higher<br />
particulate and filmic cleanliness requirements<br />
that are present in most industries. Energyefficient<br />
drying alternatives will also be<br />
presented for greater resource efficiency in the<br />
operation of wet-chemical cleaning systems.<br />
Whether for the removal of contaminants over<br />
the entire surface or selectively, the<br />
importance of dry individual parts cleaning is<br />
increasing from the point of view of<br />
cleanliness technology and energy as well,<br />
which is also reflected in the range of products<br />
on display at parts2clean.<br />
Another topic covered by exhibitors<br />
consists of the use of artificial intelligence (AI)<br />
in the field of industrial parts cleaning. When it<br />
comes to cleaning media, bath monitoring and<br />
care, water treatment, corrosion protection and<br />
packaging, as well as cleaning and transport<br />
containers, companies are appearing with new<br />
and refined products.<br />
Supporting program delivers effective<br />
knowledge transfer – High Purity included<br />
“Complementing the exhibitors' crosstechnology,<br />
cross-material and cross-industry<br />
presentations, the sophisticated supporting<br />
program offers visitors a wealth of knowledge<br />
and know-how on current topics in<br />
component cleaning and a range of trends in<br />
growth industries,” reports Nowak. The special<br />
show “Process Chain Technical Cleanliness”,<br />
organized jointly with the CEC (Cleaning<br />
Excellence Center), will demonstrate ways of<br />
implementing the required component<br />
cleanliness in line with requirements and in a<br />
sustainable manner, including accompanying<br />
quality assurance based on the use of<br />
innovative technologies.<br />
The exciting program of lectures and<br />
presentations on trends and new<br />
developments at the action area of the<br />
Fachverband industrielle Teilereinigung e. V.<br />
(FiT) will be impressively complemented by<br />
the presentation of the FiT2clean Award,<br />
worth 10,000 euros, on the third day of the<br />
trade show.<br />
A highlight of this year's parts2clean<br />
bilingual Expert Forum program is the keynote<br />
lecture by Dr. Nicole Smits, Cleanliness Expert<br />
at ASML Netherlands B.V., which will kick off<br />
the High Purity lecture series. She will provide<br />
information on the importance of cleaning and<br />
the cleanliness requirements for EUV<br />
technology and how these can be achieved.<br />
Other topics in this session will deal with<br />
requirements and solutions for medical,<br />
pharmaceutical and microtechnology, precision<br />
optics and sensor technology, among others.<br />
No less interesting are the presentations by<br />
high-ranking experts from industry, research<br />
and science on the topic blocks “Fundamentals<br />
of Industrial Cleaning Processes”, “Monitoring<br />
and Controlling Cleaning Processes”,<br />
“Cleaning in Electrical Engineering/Electronics”<br />
and “Monitoring and Analyzing Cleaned<br />
Surfaces”. All presentations will be<br />
simultaneously translated (German English).<br />
Participation in the parts2clean Expert Forum<br />
is free of charge for trade fair visitors, and the<br />
complete program is available on the website<br />
www.parts2clean.de/en.<br />
Hi-Tek<br />
PRODUCTS LIMITED<br />
2a Dawkins Road Industrial Estate, Hamworthy, Poole, Dorset BH15 4JP<br />
Telephone : 01202 661300<br />
www.hitekproducts.com<br />
jane@hitekproducts.com or kirsty@hitekproducts.com<br />
We are suppliers of masking products across a multitude of industries working closely with metal<br />
finishing and powder coating companies. Established over 50 years ago, we bring a wealth of experience<br />
from our family run firm. No order is too small and samples are available on request. All stocked sizes<br />
of tapes, caps, plugs, bungs and pull throughs can be seen on www.hitekproducts.com. If you have a<br />
bespoke size request, please e-mail kirsty@hitekproducts.com or jane@hitekproducts.com or ring our<br />
professional team on 01202 661300.<br />
We are the sole UK distributor for the Tolber range of masking<br />
lacquers. We also stock PTFE lubricant.<br />
Samples of all lacquers are available on request.<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
Plastratum Ltd<br />
100 Armoury Road<br />
Birmingham B11 2RH
50 ELECTROPLATING<br />
Making a selection<br />
Selective brush plating is used for chrome<br />
plating repairs or restore worn or<br />
damaged metal surfaces. It involves the<br />
application of a metal coating to the affected<br />
area using an electroplating process. This can<br />
be done without disassembling the<br />
component or structure, making it a highly<br />
efficient and cost-effective repair method.<br />
In the mining industry, selective brush<br />
plating can be used to repair or restore a<br />
range of components, from large machinery<br />
to small parts. This includes everything from<br />
hydraulic rods, rams, and cylinders, bearings<br />
to conveyor belts, and valves. The technique<br />
can repair damage caused by wear and tear,<br />
corrosion, or erosion and even build up worn<br />
or undersized surfaces.<br />
Equipment Longevity and<br />
Efficiency<br />
One of the key benefits of selective brush<br />
plating in the mining industry is its ability to<br />
extend the life of equipment and components.<br />
By repairing and restoring worn or damaged<br />
surfaces, mining companies can reduce the<br />
need for parts to be sent away for stripping<br />
and re-chroming or costly replacements, which<br />
can be both expensive and time-consuming.<br />
This can help to minimize downtime and<br />
increase productivity, which is essential in a<br />
highly competitive and cost-sensitive industry.<br />
Selective brush plating is also highly<br />
versatile, allowing for repairs to be made to<br />
various materials, including ferrous and nonferrous<br />
metals and some plastics and<br />
composites. This makes it an ideal solution for<br />
mining operations' diverse components and<br />
structures. Another advantage is its ability to<br />
be used in situ, without disassembling or<br />
removing the component. This can reduce the<br />
time and cost involved and minimize the risk<br />
of damage during disassembly and<br />
reassembly. This is particularly important in<br />
the mining industry, where large and complex<br />
equipment can be challenging to move and<br />
repair.<br />
Selective brush plating can help to improve<br />
the safety of mining operations. The risk of<br />
failure and subsequent accidents can be<br />
minimized by repairing or restoring worn or<br />
damaged components before failure or a<br />
catastrophic event. This can help protect the<br />
health and well-being of mining workers and<br />
reduce the risk of damage to equipment and<br />
the environment.<br />
A More Sustainable Solution<br />
In addition to its practical benefits, selective<br />
brush plating can be a more sustainable<br />
solution than traditional repair methods.<br />
Reducing the need for replacements and<br />
minimizing waste can reduce the<br />
environmental impact of mining operations.<br />
This is particularly important given the<br />
significant impact that mining can have on<br />
local ecosystems and communities.<br />
Overall, selective brush plating is an<br />
essential technique for the mining industry,<br />
providing a range of efficiency, costeffectiveness,<br />
safety, and sustainability benefits.<br />
By using this method of repair and restoration,<br />
mining companies can extend the life of their<br />
equipment and components, reduce the risk<br />
of failure and accidents, and minimize their<br />
environmental impact. As such, selective brush<br />
plating should be considered an essential tool<br />
for any mining operation looking to improve<br />
its performance and minimize its effects.<br />
The Portable and Fully<br />
Automated Electroplating<br />
System<br />
In the realm of plating automation,<br />
innovation continues to advance at an<br />
impressive rate. The most recent breakthrough<br />
manifests as a completely portable automated<br />
electroplating system. SIFCO ASC’s Advanced<br />
Solution Control System (ASCS) boasts stateof-the-art<br />
dripless functionality, eliminating the<br />
need for drip trays and ensuring that all<br />
chemicals are returned to the machine. As a<br />
result, it creates a cleaner, more<br />
environmentally friendly, and safer working<br />
environment.<br />
While this system is suitable for many<br />
applications, SIFCO ASC also offers custom<br />
robotic automation for frequent, repetitive<br />
repairs. This revolutionary development<br />
significantly enhances throughput and<br />
productivity while reducing manual handling.<br />
It proves ideal for tasks that require swift<br />
turnaround without the ergonomic risk.<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
We are exhibiting at<br />
Surface World Live • 4 & 5 Oct <strong>2023</strong><br />
See us on Stand F18<br />
COMPLETE RANGE OF INDUSTRIAL COATINGS<br />
• Waterborne • Solventborne • High Solid<br />
• Powder • E-Coat<br />
SERVING A RANGE OF MARKETS<br />
• General Finishes • Heavy Equipment • Design<br />
• Architectural • Transportation • Energy • Rail<br />
• Furniture • Electronics • Military<br />
Inver® and Syntha Pulvin®<br />
are brands of<br />
The Sherwin-Williams Company<br />
CONTACT<br />
The Sherwin-Williams Company, Goodlass Road, Speke,<br />
Liverpool, L24 9HJ, United Kingdom<br />
T: +44 (0)151 486 0486 | liverpool.sales@sherwin.com<br />
oem.sherwin-williams.com | www.synthapulvin.com
52 POLISHING<br />
The dry way<br />
The field of surface finishing is<br />
characterized by demands for higher<br />
quality with, at the same time, an<br />
increasing need for process consistency,<br />
traceability and resource efficiency. Frequently,<br />
this requires new finishing methods. With the<br />
DryLyte system Rösler Oberflächentechnik<br />
offers an innovative system for<br />
electropolishing metal components that must<br />
have a perfect finish. Contrary to classical<br />
electro-chemical polishing methods DryLyte is<br />
a dry process that utilizes solid particles<br />
containing electrolytes. Acid baths or other<br />
process liquids are completely eliminated.<br />
Benefits of this revolutionary technology are<br />
an excellent surface finish, a high geometrical<br />
consistency of the work pieces, a lower CO2<br />
footprint and lower costs for waste disposal.<br />
The costly and complex treatment of used<br />
process liquids is completely eliminated, and<br />
the finished work pieces are discharged from<br />
the system perfectly clean.<br />
Whether for cosmetic or functional reasons<br />
– the providers of surface finishing solutions<br />
are confronted with numerous challenges. On<br />
the one side demands for lower surface<br />
roughness values and geometrical consistency<br />
of the finished work pieces must be met,<br />
whereas on the other side the finishing<br />
processes must be cost-efficient and ecofriendly.<br />
Issues such as energy requirements,<br />
consumption of valuable resources, prevention<br />
of potentially hazardous substances and waste<br />
disposal are becoming more important. In<br />
addition, the customers are demanding<br />
absolutely consistent results and processes that<br />
can be perfectly reproduced. All these<br />
requirements can only partially be met with<br />
manual finishing or traditional electropolishing<br />
methods with liquid electrolytes. With its<br />
innovative DryLyte polishing technology GPA<br />
Innova, a partner of Rösler<br />
Oberflächentechnik, offers an excellent<br />
method for finishing geometrically complex<br />
components made from conductive metals.<br />
From deburring to high gloss<br />
polishing – a sustainable and<br />
highly efficient technology<br />
The fully automatic DryLyte system<br />
simplifies and helps standardize different<br />
surface finishing tasks such as deburring,<br />
surface smoothing, surface grinding, high<br />
gloss polishing and, even, post processing of<br />
3D printed components. Depending on the<br />
initial surface conditions und the specified<br />
finishing results, dry electropolishing can be<br />
utilized as stand-alone process or in<br />
combination with known mass finishing, shot<br />
blasting and other pre-grinding methods.<br />
The DryLyte technology is based on the<br />
principle of electro-chemical material removal<br />
from the surface of components. However, the<br />
technology does not use liquid electrolytes but<br />
a multitude of polymer pellets in different<br />
sizes containing electrolyte media that are<br />
precisely adapted to the respective finishing<br />
task. In contrast to the traditional<br />
electropolishing systems no hazardous vapors<br />
are generated requiring energy-intensive<br />
exhaust systems and special protective gear<br />
for the operator. Since the material removed<br />
from the work piece surface is absorbed by<br />
the electrolyte medium, no dust or metal<br />
particles are getting into the environment, as<br />
happens with manual grinding and polishing<br />
operations. High-quality, consistent processing<br />
results are achieved throughout the usable life<br />
of the electrolyte medium. This must only be<br />
replaced once the dry electrolyte has been<br />
saturated with the metal removed from the<br />
work piece surface. The waste disposal of the<br />
saturated electrolytes is similar to the disposal<br />
of grinding media. The saturation rate is<br />
monitored by the machine so that the<br />
operator is always up-to-date and informed<br />
about the remaining usage time. This<br />
guarantees absolutely stable, and consistent<br />
finishing results and the optimal utilization of<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
continues on page 54
We solve our customers filtration,<br />
chemical transfer and treatment needs.<br />
Contact us<br />
SIEBEC UK Ltd, Stafford<br />
+44 (0) 1785 227700<br />
sales@siebec.co.uk<br />
www.siebec.co.uk<br />
PUMPS & FILTERS<br />
L SERIES | Medium flow rate filter<br />
P SERIES | Ultra-high flow rate filter<br />
A SERIES | Mechanical seals pump<br />
M SERIES | Magnetic drive pump<br />
T SERIES | Vertical pump<br />
[...]<br />
FILTER MEDIA<br />
L-TECH | Pleated cartridge<br />
BAGTECH | Filtration bag<br />
QUALITHERM | Extruded cartridge<br />
QUALIBOB | Wound cartridge<br />
ANODTECH | Anode bag<br />
[...]<br />
SPECIAL SYSTEMS<br />
ACIDPURE | Acid recycling<br />
EASYPURE | Fluid recycling<br />
IONPURE | Ionic filtration<br />
ACIDVAC | Acid draining vacuum<br />
EDUCTORS | Bath agitation<br />
[...]<br />
We are exhibiting at Surface World Live • 4 & 5 <strong>October</strong> <strong>2023</strong> • See us on Stand G6<br />
Reach the UK's metal<br />
finishing market<br />
<strong>Finishing</strong> magazine is a specialist<br />
bi-monthly for the UK’s metal<br />
finishing community.<br />
Read by decision makers in features<br />
technical papers, news, views and<br />
debate on all aspects of metal<br />
finishing and surface coating.<br />
To subscribe call the<br />
Circulation Department on<br />
T. +44(0) 20 3409 2974<br />
circulation@dimensionsuk.com<br />
DALIC SELECTIVE<br />
ELECTROPLATING<br />
ADDEV MATERIALS IS THE UK OUTLET<br />
FOR ALL DALIC ELECTROPLATING<br />
MATERIALS AND SERVICES<br />
All the required consumables including<br />
anodes and bonnets plus training courses and<br />
technical services. Dalic’s unrivalled application<br />
systems including rectifiers and the patented<br />
“closed loop” Dalistick Station for full control<br />
of the application and no exposure to<br />
hazardous metals.<br />
BRUSH PLATING SOLUTIONS<br />
Anodising<br />
Cadmium, Cobalt,Zinc, Nickel<br />
Copper, Tin, Gold, Silver<br />
Turret Group Ltd, Cardinal Point, Park Road,<br />
Rickmansworth, Herts, WD3 1RE, UK.<br />
T. +44 (0)1923 432705<br />
E. info@turretgroup.com<br />
ADDEV MATERIALS AEROSPACE<br />
2 Bordon Trading Estate Old Station Way, Bordon, Hampshire GU35 9HH<br />
T. +44 (0) 1428 651246 F. +44 (0)1428 661471<br />
sales.emea@addevmaterials.com<br />
www.finishingmagazine.co.uk<br />
www.addevmaterials-aerospace.com<br />
addev_quarter pexa_quarter page.indd page_fng-m-a23.indd 1 1 14/03/<strong>2023</strong> 05/11/2020 12:41<br />
11:23
54 POLISHING<br />
the electrolyte. It also helps minimize the costs<br />
for labor and waste disposal. Finally, because<br />
of the efficient resource utilization the CO2<br />
footprint is reduced..<br />
A precise and gentle finishing<br />
process that maintains the<br />
geometrical integrity of the<br />
work pieces<br />
During the dry electropolishing process the<br />
work pieces, mounted to a fixture, are slowly<br />
moving through the dry electrolyte. This<br />
ensures complete coverage of the entire<br />
surface. If required, internal surface areas can<br />
also be finished by using special electrodes.<br />
The DryLyte method removes primarily the<br />
roughness peaks from the surface. Therefore,<br />
the metal removal rate is minimal, and the<br />
overall process is very gentle. The finished<br />
work pieces have a highly homogeneous<br />
surface with no pressure points or an orange<br />
peel effect. Even in the case of delicate work<br />
pieces with complex shapes no damage in the<br />
form of scratches or breakage occurs.<br />
The targeted and “controlled” processing<br />
ensures that in case of precision components<br />
like machining tools or tools for the<br />
pharmaceutical industry their geometrical<br />
integrity is not affected, and their edges are<br />
not radiused. In addition, the highly effective<br />
smoothing effect on the surface prevents<br />
micro cracks and pitting. This improves the<br />
corrosion resistance and “fatigue”<br />
characteristics and, thus, extends the usable<br />
life of the components. Compared to<br />
components treated with traditional<br />
electropolishing, dry- electropolished<br />
components corrode 4 to 15 times slower as<br />
proven in corrosion tests in a saltwater solution<br />
containing 30 grams/liter NaCL. In the case of<br />
gear components used in mechanical systems,<br />
dry electropolishing increases the material load<br />
ratio, reduces friction and guarantees the<br />
optimal distribution of lubricants on the work<br />
piece surface. The improved surface conditions<br />
result in a lower wear rate and, at the same<br />
time, reduce the noise level.<br />
Another significant benefit of the DryLyte<br />
technology are the relatively short cycle times.<br />
Depending on the finishing application, initial<br />
surface roughness and required results, they<br />
can vary between a few minutes and 1.5<br />
hours. The process creates not only a<br />
smoother surface but, if needed it can also<br />
produce a high gloss polish in one single<br />
process. For post processing of 3D printed<br />
components with their typically very high<br />
surface roughness, the electropolishing<br />
operation is preceded by a mass finishing<br />
process utilizing abrasive grinding media.<br />
Easy adaptation to many<br />
finishing applications<br />
The unique, patented dry electropolishing<br />
technology was initially developed for finishing<br />
prototype castings and dental crowns made<br />
from cobalt chrome and titanium. In the<br />
meantime the dry electropolishing method<br />
from GPA Innova is used for finishing stainless<br />
steel, steel, hard metals as well as nickel,<br />
aluminum and copper alloys along with other<br />
conductive metals. Today the process is used<br />
whenever high finishing qualities are required<br />
in industries such as aerospace,<br />
pharmaceutical, machine building as well as<br />
luxury and consumer goods. Because of the<br />
proven biocompatibility of the finished<br />
components dry electropolishing is also used<br />
in medial engineering for the production of<br />
implants and instruments.<br />
Process development and definition of the<br />
process parameters for the respective finishing<br />
application takes place in the customer<br />
experience center at Rösler. For this purpose,<br />
the CEC is equipped with different machine<br />
types allowing fully automatic operation. This<br />
approach guarantees that the finishing<br />
processes for the customer components are<br />
always based on precisely defined and<br />
validated parameters.<br />
Gas Process Burners<br />
Lanemark gas burner systems offer users reliable, high efficiency,<br />
process heating solutions.<br />
FD-C high turndown oven/<br />
dryer air heating burners.<br />
Midco HMA high efficiency,<br />
high turndown, air replacement<br />
or “make-up” air heating burners.<br />
FD-GA modulating gas + air<br />
process air heating burners.<br />
FD-E low cost high turndown<br />
oven/dryer air heating burners.<br />
TX high efficiency small diameter<br />
immersion tube tank heating<br />
systems.<br />
FD Series Packaged Oven/Dryer Burners<br />
• Specifi cally designed for process air heating applications in convection<br />
ovens and dryers<br />
• High turndown/short flame lengths providing accurate process<br />
temperature control<br />
• High effi ciency gas + air modulation, gas only modulation and simple<br />
high/low control options<br />
• Heat Input Range: 9 kW – 1550 kW<br />
TX Series Gas Fired Process Tank Heating Systems<br />
• High effi ciency (80%+) heating of all types of spray and dip process tanks<br />
• Compact high effi ciency small diameter immersion tube heat exchangers<br />
occupying minimum tank space<br />
• Accurate performance modelling using Lanemark TxCalc design software<br />
• Heat Input Range: 15 kW (1½") – 1150 kW (8")<br />
Midco HMA Series Air Replacement or “Make-Up” Air Heating Burners<br />
• Direct fired, high effi ciency burner systems, for high volume air heating<br />
applications such as paint spray booths, ovens and dryers.<br />
• Supplied either as Midco burner heads for OEM system integration or<br />
as Lanemark DB or FDB complete packaged systems including modulating<br />
gas valve trains and controls<br />
• Wide range of firing rates to suit alternative temperature rise and air<br />
velocity system requirements<br />
• DbCalc system design software<br />
Lanemark Combustion Engineering Limited<br />
Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom<br />
Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: info@lanemark.com<br />
www.lanemark.com<br />
COMBUSTION ENGINEERING<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
X4620 Lanemark Ad SDAW.indd 1 31/08/2016 09:04
HodgeClemco<br />
We are exhibiting at Surface World Live • 4 & 5 <strong>October</strong> <strong>2023</strong> • See us on Stand C20<br />
Oven Temperature Logger<br />
Measures and records oven<br />
temperature profiles<br />
• 6 K-type thermocouple ports<br />
• High temperature stainless steel barrier box for<br />
long run times<br />
• Download, view, and analyze data using PosiSoft Desktop Software<br />
or export to .CSV<br />
NEW<br />
Prices starting at:<br />
Oven Temperature<br />
Logger..........£1895<br />
Temperature<br />
Probes............£100<br />
Wide variety of spring clamp and<br />
magnetic temperature probes available<br />
Customizable PDF Reports<br />
16A Long Drive, Meadway, Berkhamsted, Herts HP4 2PN<br />
t: 01442 879494 • www.dftinstruments.co.uk • e: sales@dftinstruments.co.uk
56 PROFILE<br />
Sustainable innovation<br />
Sustainability and the environmental<br />
impact of manufacturing processes are<br />
driving innovation across all industries<br />
including surface finishing. Incumbent<br />
component finishing technologies are well<br />
understood and provide the required surface<br />
finish but are reliant on practices that<br />
generate operational difficulties through high<br />
manual input, the use of toxic materials, lack<br />
of flexibility and the use of several non-value<br />
added steps.<br />
With this in mind, TextureJet, a UK based<br />
company originally spun-out from the<br />
University of Nottingham, developed its Stat<br />
technology. The machines utilise a highly<br />
localised variant of electrochemical machining,<br />
known as electrochemical jet machining<br />
(EJM). Stat can readily finish any metallic<br />
component without affecting the surface<br />
integrity and only using green chemistry<br />
electrolytes. This vitally eliminates the use of<br />
any toxic and dangerous chemicals, such as<br />
hydrofluoric acid, which are still prevalently<br />
used in the finishing of Titanium and other<br />
difficult materials. In addition, TextureJet’s<br />
electrolytes are recaptured and reused in a<br />
closed loop system, which drastically reduces<br />
total waste generation by > 80%.<br />
In contrast to legacy processes, Stat has the<br />
flexibility to apply a variety of different surface<br />
finishes using the same technology. Whether<br />
this be, roughening to prepare the surface for<br />
bonding or coating, super polishing to reduce<br />
friction and wear properties (0.1μm to 30μm<br />
Ra range), applying complex patterns for<br />
aesthetics and part marking using a direct<br />
write method or de-coating for reworking<br />
purposes. The EJM process is also unique in<br />
that it enables targeted finishing and so does<br />
not require masking to create any of the<br />
different surface finishes.<br />
TextureJet developed Stat to be versatile<br />
and automation agnostic, so it can be readily<br />
used in any industry without the need for a<br />
highly specialist workforce. This is<br />
demonstrated by TextureJet’s current line of<br />
expansion units, which offer a range of<br />
automation, precision and flexibility to suit the<br />
needs of each application. This includes:<br />
• JetWrite, a manually operated handheld<br />
device that requires minimal setup and<br />
operator skill. Ideal for on-site repairs and<br />
touch-ups on small-scale production runs, and<br />
de-coating applications.<br />
• PrecisionJet is a 3-axis gantry system,<br />
which is perfect for precisely controlled<br />
surface finishing operations and larger<br />
production runs, offering key increased<br />
automation capabilities such as interpreting g-<br />
code natively.<br />
• Robot Cell, which offers flexibility to do<br />
anything from one-off bespoke parts to<br />
production line integration. The robot system<br />
is perfect for scaling production and its highly<br />
articulated nature simplifies automation for<br />
complex geometries and access to hard-toreach<br />
areas.<br />
TextureJet’s technology offers unparalleled<br />
benefits in both sustainability and targeted<br />
flexible surface finishing, by eliminating toxic<br />
chemicals, drastically reducing waste<br />
generation and providing a multitude of<br />
different surface finishes. In the ongoing<br />
challenge to achieve sustainable<br />
manufacturing, Stat represents the game<br />
changing next generation surface finishing<br />
solution that the industry so desperately<br />
needs.<br />
If you would like to learn more about<br />
TextureJet and discuss your surface processing<br />
needs, please get in touch with us at<br />
sales@texturejet.com<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
www.sfchina.net<br />
Pre-Register Now at<br />
The <strong>Finishing</strong> Industry will<br />
Re-connect in Shanghai!<br />
15-17.11.<strong>2023</strong> Shanghai • Online Show 1.11-31.12.<strong>2023</strong><br />
Shanghai New International Expo Centre (SNIEC)<br />
Halls E1 & E2<br />
Co-Located Show<br />
The China International Exhibition for Surface <strong>Finishing</strong> and Coating Products (SFCHINA<strong>2023</strong>)<br />
www.chinacoat.net<br />
SFCHINA<strong>2023</strong> will open its gates to visitors once again<br />
since our last show being held there in 2019. The show<br />
to be held on November 15-17 at the Shanghai New<br />
International Expo Centre (SNIEC) will be joined by over<br />
230 Exhibitors from 16 Countries and Regions. It will be a<br />
leading show of its kind not to be missed.<br />
SPONSORING EXHIBITOR<br />
232 Exhibitors from 16 Countries/Regions*<br />
75 New Exhibitors<br />
Exhibit Area Exceeds 17,000 sqm<br />
Covering 2 Exhibit Zones: Electroplating & <strong>Finishing</strong> Technology;<br />
Coating Applications & Coating Products<br />
* Exhibitor data as of Sep 5, <strong>2023</strong> Booth No.: E1.E01<br />
www.sfchina.net<br />
www.sfchinaonline.net<br />
(852) 2865 0062 info@sinostar-intl.com.hk
58 SPRAY BOOTHS<br />
Spray analysis<br />
The new Dalby Evolution EQ combination<br />
spray booth oven incorporates the very<br />
latest technology, providing the optimum<br />
paint application environment, whilst<br />
minimising running costs.<br />
The 'Pro Active' control system constantly<br />
monitors the activity within the spray booth<br />
and automatically adjusts airflow, temperature<br />
and lighting to optimise overspray clearance<br />
and bake performance as efficiently as<br />
possible.<br />
The control system allows the booth to<br />
operate in Performance, Smart and Economy<br />
modes. With invertor controlled automatic<br />
pressure balancing, the airflow is automatically<br />
controlled to provide power consumption as<br />
low as 1kW in Economy mode. This unique<br />
spray booth technology will provide your<br />
business long term cost savings without<br />
compromising the quality or performance of<br />
the equipment.<br />
With the high visibility LED mode indicator<br />
and countdown timer display fitted above the<br />
3 leaf, large vision panelled doors, the booth<br />
operating mode and count down timer is<br />
easily visible across any workshop.<br />
The factory-built air handling unit<br />
incorporates the fans, dampers and pilotless<br />
burner into a single unit, enabling a fast<br />
installation and unrivalled levels of reliability.<br />
Access to the plant for maintenance is gained<br />
from inside the EQ booth. This allows for<br />
corner positioning within the workshop with<br />
no side or rear access required. This space<br />
saving design helps maximise usable<br />
floorspace and is a major benefit for clients<br />
with limited room.<br />
With rear extraction as standard, there is no<br />
requirement for a pit. However, if you prefer,<br />
the Dalby EQ can also be supplied with<br />
downdraft air movement via pit extraction or<br />
with an internally ramped raised floor.<br />
Pro Active Energy Saving<br />
Technology<br />
The Dalby ‘ProActive’ touch screen control<br />
system enables full control of all the booth’s<br />
functionality and allows the user to switch<br />
between modes at a touch of the screen.<br />
PERFORMANCE mode, is ideal for spray<br />
and flash off processes where maximum<br />
airflow is required. PERFORMANCE mode<br />
will offer 20,000m 3 / hour airflow whilst<br />
ECONOMY mode will deliver 10,000m 3 /<br />
hour, dramatically reducing the energy<br />
consumption, saving you money.<br />
SMART mode enables the booth to actively<br />
reduce energy consumption without affecting<br />
productivity. This is done by targeting periods<br />
when the booth is running without spraying<br />
activities taking place. The Dalby control<br />
system constantly monitors operations inside<br />
the booth and will actively switch between<br />
modes to reduce electricity and gas<br />
consumption where possible. The EcoSave<br />
mode further reduces power consumption<br />
with active use of stop/start technology when<br />
the booth is not being used for spraying or<br />
curing activities, such as when masking up or<br />
paint mixing is taking place.<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
SPRAY BOOTHS 59<br />
PIR control saves energy by ensuring that<br />
the lights dim and then turn off when no<br />
movement is detected in the booth cabin, and<br />
instantly turn on when an operative enters the<br />
booth.<br />
Cost Per Job Analysis<br />
The Dalby evolution booths now have game<br />
changing technology which can monitor the real<br />
time running costs of your booth. New software<br />
means you can now track the usage of the<br />
booth, recording data against each individual or<br />
job reference number and monitor how long<br />
the booth is operational in each mode giving<br />
you accurate energy costings per job.<br />
This data is displayed on screen and can also<br />
be downloaded onto your laptop for more<br />
detailed performance analysis. With the rapid<br />
cost of energy increases we have seen recently<br />
this is an innovative, new way to monitor costs<br />
in real time and see where operational<br />
improvements can be made to make further<br />
energy savings.<br />
The ‘ProActive’ control system has a number<br />
of other innovative features designed to optimise<br />
the performance and efficiency of the booth.<br />
These include:<br />
Automatic Pressure Balancing, this<br />
automatically maintains the negative pressure<br />
balance in the booth cabin.<br />
Integrated Mist Clearance Indicator. When<br />
spraying has finished, the ‘ProActive’ control<br />
displays the mist clearance time remaining.<br />
Automatic Filter Condition Monitoring. The<br />
control system warns you when the input and<br />
extract filters require replacement.<br />
Maintenance Scheduler, this gives you<br />
advance warning of when the next scheduled<br />
service is due.<br />
Fault Finding and Diagnosis. The ‘ProActive’<br />
control system provides fault diagnosis<br />
information in the event of a breakdown.<br />
Customisable Display. You can also select<br />
from a library of car images to customise your<br />
display.<br />
“HighLight” LED Lighting System<br />
with PIR Control<br />
The EQ booth has The Dalby “HighLight”<br />
LED lighting system fitted as standard. This<br />
system significantly reduces power<br />
consumption, with typical power savings in<br />
excess of 60% versus traditional lighting<br />
systems.<br />
The “HighLight” LED light boxes are<br />
mounted at corner roof level and shine<br />
through our unique, laser cut, highly efficient<br />
light shaping diffuser to provide diffused light<br />
inside the booth which replicates daylight. The<br />
diffused light reduces spotting and decreases<br />
vision issues as operators do not see the<br />
individual LEDs.<br />
With average light levels at the spraying<br />
face in excess of 1400 lux and with excellent<br />
colour rendering, the “Highlight” LED lighting<br />
creates an optimally lit spraying environment.<br />
With heat control designed into the light,<br />
the “Highlight” LED lighting has a much<br />
greater life span that traditional fluorescent<br />
lighting leading to very low ongoing<br />
maintenance costs and minimal reduction in<br />
light output.<br />
Spray Booths Manufactured In<br />
the UK<br />
Harry Dalby Engineering is proud of its<br />
tradition of manufacturing in the UK.<br />
Operating from our two factories in Leicester<br />
with a combined area of 49,000 sq ft, we<br />
manufacture almost every part of our spray<br />
booths in house. The process starts in our<br />
drawing office where, using the latest 3D CAD<br />
software and our modular design concepts, we<br />
specify each and every spray booth to suit our<br />
client’s individual requirements. The designs<br />
are then issued to our factory floor where,<br />
using state of the art CNC machines such as<br />
our Fibre Laser, CNC Punches, 6 Meter CNC<br />
Press Brake and Robot Welders, we manage<br />
production from start to finish.<br />
We manufacture in house all the major<br />
components such as the insulated booth<br />
enclosure panels, vehicle and personnel<br />
doors, fans, dampers, control system<br />
(including state of the art PLC controls), direct<br />
gas fired burners, and we even have our own<br />
ducting shop and spiral duct forming<br />
machine.<br />
By manufacturing these components inhouse<br />
we are able to constantly evolve our<br />
designs to ensure that every part of each<br />
spray booth is perpetually reviewed and<br />
optimised for its function within a paint<br />
application environment, thus ensuring the<br />
highest performance and long term reliability<br />
of our Spray booths.<br />
Dalby spray booths are recognised by<br />
many of the UK’s major OEM’s and Tier 1<br />
industries who work with Dalby because of<br />
our reputation for Quality, Technological<br />
Innovation and the ability to offer a complete<br />
package from concept to installation and<br />
commissioning.<br />
<strong>Finishing</strong> – <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
60 POWDER COATING<br />
Swiss precision<br />
V-ZUG is the leading Swiss brand for<br />
household appliances. For over 100<br />
years, V-ZUG AG has been developing<br />
and producing household appliances for the<br />
kitchen and washroom at its main production<br />
site in Zug, Switzerland, and, since 2013, also<br />
in the refrigeration sector in Arbon and, more<br />
recently, in Sulgen, Switzerland. In Zug,<br />
everything is produced in-house - from the<br />
sheet metal to the finished product. According<br />
to the premium claim, ovens, steamers,<br />
dishwashers, washing machines and tumble<br />
dryers are located in the upper price segment.<br />
Quality and functionality are top priorities for<br />
all products. To further develop this standard,<br />
the company invested in a new powder<br />
enamelling system. "We chose ASIS because<br />
they credibly proved in the run-up of the<br />
project that they can build and manage such<br />
a plant," says Roland Häfliger, Project<br />
Manager Parts Manufacturing & Surface<br />
Technology V-ZUG. "ASIS was also one of the<br />
few suppliers that offered to be the general<br />
contractor for the entire plant."<br />
Growth<br />
The V in the company name V-ZUG still<br />
comes from the founding days as a<br />
galvanizing plant. Since then, the town on the<br />
scenic Lake Zug has developed around the<br />
company. Due to the limited space available,<br />
production can only grow upwards. The plan<br />
is to produce twice as much in the future on<br />
almost half the space. All plant components of<br />
the approx. 1,400 m² coating center have<br />
been designed to fit into the second floor of a<br />
modern wooden building. The renewable<br />
resource wood is not only sustainable, it also<br />
creates a pleasant atmosphere in the so-called<br />
Zephyr Hangar, which is unusually positive<br />
compared to other industrial production halls.<br />
40-50 different components can be coated<br />
automatically from batch size 1. The range<br />
includes four basic types of baking cases and<br />
various flat goods, such as hot-air or baking<br />
trays.<br />
Automatic pickup<br />
The ovens come out of the welding line<br />
every 50 seconds and are automatically<br />
transferred to a flat conveyor belt. Their first<br />
station is the clips and hanger station. There,<br />
clips are automatically applied. These cover<br />
certain areas to protect them from the enamel<br />
powder so that they remain coating-free for<br />
further processing. Hangers are then<br />
automatically attached and transferred to the<br />
Power & Free conveyor system by a transfer<br />
robot. The flat goods are fed in at a separate<br />
manual station.<br />
Pretreatment<br />
At the 5-zone spray pretreatment, all parts<br />
are cleaned of drawing oil and dirt for<br />
optimum coating quality. The spray pumps of<br />
the two-lane system are not controlled via<br />
butterfly valves as usual, but via frequency<br />
converters. This enables consistent integration<br />
into the PLC system control, and the most<br />
ideal operating state in each case, such as<br />
pause switching, can be set. The spray<br />
pressure is kept constant via electronic<br />
pressure pipe monitoring. Special attention<br />
has been paid to economical rinsing agent<br />
consumption with cascade control. After the<br />
blow-off zone, the workpieces are dried in the<br />
adhesive water dryer above so that no water<br />
remains on the surface.<br />
Application combination<br />
All powder applications take place in an airconditioned<br />
housing. The baking cases and<br />
the flat goods are coated in a total of three<br />
powder booths. ASIS' experience in the<br />
household appliance industry has shown that<br />
the combination of robots and linear axes is<br />
an ideal setup. The economical linear axes<br />
coat the vertical, flat surfaces here, while the<br />
robots powder edges and interior areas. Two<br />
booths handle the basic powder application,<br />
while the third powder booth is for the special<br />
coating of steam cookers. Sensors detect<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
continues on page 62
HoldTight 102 - Half Page Advert.qxp_HoldTight 102 Half Page Ad 07/07/2017 12:05 Page 1<br />
HoldTight 102 ® is a wet blasting<br />
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Suitable for a variety of industries:<br />
MARINE l INDUSTRIAL<br />
OFFSHORE l INFRASTRUCTURE<br />
With over 85 years in the Corrosion Prevention Industry,<br />
Winn & Coales (Denso) Ltd. have been long time suppliers of<br />
the ultimate surface preparation solution. To extend the service<br />
life of your coating, contact a Denso representative now!<br />
LEADERS IN CORROSION PREVENTION<br />
& SEALING TECHNOLOGY<br />
Sole Distributor in the United Kingdom:<br />
Winn & Coales (Denso) Ltd<br />
Tel: 0208 670 7511 l Web: www.denso.net<br />
A MEMBER OF WINN & COALES INTERNATIONAL<br />
We are exhibiting at Surface World Live • 4 & 5 <strong>October</strong> <strong>2023</strong> • See us on Stand F2
62 POWDER COATING<br />
which part is currently entering and the<br />
parameters and programs are optimally set<br />
accordingly.<br />
Challenge accepted<br />
"V-ZUG's requirements were very high<br />
right from the start, and a lot of attention was<br />
paid to automation and digitalization," recalls<br />
Dietmar Binder, Project Management and<br />
Sales ASIS. "One challenge was that we<br />
wanted to use only one conveyor technology<br />
system, the Power & Free conveyor, and only<br />
one uniform carriage and hangers to run<br />
through the plant." This makes sense, of<br />
course, as the overall process is simplified and<br />
no additional sorting functions are needed in<br />
the plant. This was realized with a transfer<br />
robot and a carrier cleaning system designed<br />
by ASIS. The transfer robot removes all<br />
workpieces from the carriers, which are also<br />
covered with powder during the application. In<br />
the meantime, these are cleaned in the carrier<br />
cleaning system and the robot can transfer the<br />
workpieces to the same clean carriers, which<br />
then travel to the enamel baking oven.<br />
The enamel powder is baked at a<br />
temperature of 850 °C. The specially built<br />
scale plate conveyor drags the wagons of the<br />
Power & Free conveyor through the oven<br />
without damage and then returns them. The<br />
flexible scales close off the top of the oven at<br />
all times so that no energy is lost and at the<br />
the conveyor chain, which are not designed<br />
for these temperatures. The still-hot baking<br />
chambers that are moving out radiate their<br />
energy onto the workpieces that are moving<br />
in. There are nine firing zones with different<br />
temperatures in the oven, which are heated by<br />
16 burners. At the moment, the baking oven<br />
is still operated with natural gas, but a<br />
changeover to hydrogen is being worked out.<br />
Shiny black, like Swiss dark chocolate, they<br />
leave the oven and line up in the empty<br />
drawing buffer to cool down further.<br />
You could almost think that they are now<br />
ready for assembly. Some parts are further<br />
enhanced according to the customer's wishes.<br />
In another booth, a permanent non-stick<br />
coating is applied by a robot and then dried at<br />
250 °C in a convection dryer.<br />
Digitization and sustainability<br />
"We chose ASIS because we place great<br />
value on functionality and quality, which<br />
includes the complete traceability of quality<br />
data during the processes," says Roland<br />
Häfliger. This is made possible by the Surface-<br />
Analytics 4.0 software. All process data of the<br />
plant are recorded in a central data storage.<br />
The user accesses it via smartphone, tablet or<br />
laptop. In addition to important key figures<br />
and reports for optimizing plant performance,<br />
each individual part can also be fully traced.<br />
Only a few components that do not meet<br />
same actongate time protect - address the wagon alts.qxp_Layout above as well 1 20/05/2022 as the high 12:06 quality Page requirements 1 in the first step<br />
are then brought up to top level in the rework<br />
booth. Of course, everything is recorded<br />
transparently and traceably via touch panel.<br />
Reworking instead of throwing away - this is<br />
also sustainability in the production process.<br />
Precise pre-planning<br />
The entire plant was set up digitally in<br />
advance. In addition to classic reachability<br />
studies, the robots were of course also<br />
simulated and their programs created offline.<br />
The robot simulation of all individual stations<br />
and the entire material flow in the plant were<br />
linked in an overall simulation. The different<br />
process times of the stations were taken into<br />
account. In this way, it is possible to make<br />
precise predictions about the design of the<br />
conveyor system with buffer sections, sources<br />
of error in the individual areas, zones working<br />
in parallel and the throughput to be expected.<br />
"The highlight of the plant is difficult to<br />
determine, in fact it is the plant as a whole,"<br />
Roland Häfliger sums up. "The entire plant in<br />
its functionality is unique." Each individual<br />
process was precisely coordinated, automated<br />
and linked with uniform control technology<br />
like Swiss clockwork. German engineering<br />
meets Swiss precision - through customeroriented<br />
preliminary planning, robotics<br />
expertise and the use of digital solutions, the<br />
world's most modern enameling plant in<br />
Switzerland was created.<br />
Acton Gate Systems Limited - Tel: 01902 249299<br />
1 Nightingale Place, Pendeford Business Park, Wolverhampton WV9 5HF<br />
web: www.actongate.co.uk - email: enquiries@actongate.co.uk<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
Coating Thickness Gauge for Non-Metal Substrates<br />
NEW Design and Features<br />
Non-destructively measures paint thickness<br />
over wood, concrete, plastic and more using<br />
proven ultrasound technology. Advanced<br />
models measure up to 3 individual layers<br />
with graphics.<br />
n Ready to measure—no adjustment required for most applications<br />
n Responsive transducers provide fast, accurate readings<br />
n Max Thick Mode displays the deepest ultrasonic echo<br />
eliminating the need to adjust the Lo Range—ideal for<br />
ignoring unwanted surface echos.<br />
n Conforms to ISO 2808 and ASTM D6132<br />
Ideal for measuring<br />
polyurea and other<br />
thick protective<br />
coatings on<br />
concrete<br />
We are<br />
exhibiting at<br />
Surface World Live<br />
4 & 5 Oct <strong>2023</strong><br />
See us on<br />
Stand C20<br />
DFT Instruments (UK) Limited<br />
Long Drive, 16A Meadway, Berkhamsted, Herts HP4 2PN<br />
t: 01442 879494 f: 01442 879595<br />
www.dftinstruments.co.uk e: sales@dftinstruments.co.uk<br />
Proud supplier of DeFelsko Inspection Instruments
64 LASERS<br />
Laser cleaning for corrosion<br />
Industries have been fighting a war against<br />
corrosion in metal infrastructure,<br />
equipment, and products at great expense<br />
for generations. “The global cost of corrosion<br />
is estimated to be US$2.5 trillion, which is<br />
equivalent to 3.4% of the global Gross<br />
Domestic Product (GDP) (2013), according to<br />
a NACE International IMPACT study to<br />
examine the current role of corrosion<br />
management in industry and government and<br />
to establish best practices.<br />
Given the massive industrial outlay,<br />
proactively controlling corrosion is imperative<br />
and can have an equally impressive ROI.<br />
“By using available corrosion control<br />
practices, it is estimated that savings of<br />
between 15 and 35% of the cost of corrosion<br />
could be realized, i.e., between US$375 and<br />
$875 billion annually on a global basis…The<br />
fact that corrosion control provides a cost<br />
benefit is a lesson learned over and over<br />
again by industry, often too late and following<br />
catastrophic events,” continues the NACE<br />
International IMPACT study.<br />
However, traditional methods of removing<br />
corrosion can be messy, laborious, time<br />
consuming, and can even pose serious health<br />
hazards.<br />
Today, one of the easiest to use and most<br />
effective alternatives in the war against<br />
corrosion is the increasingly important<br />
category of industrial-grade, clean technology<br />
lasers.<br />
With this approach, precision laser-based<br />
systems are used to remove corrosion,<br />
contaminants, paint, and residues with a highenergy<br />
laser beam that leaves the substrate<br />
unaffected. Preparation and cleanup time are<br />
minimal, and the low-maintenance equipment<br />
can last decades. The technology minimizes<br />
operator exposure to potential environmental<br />
health hazards. In addition, no consumables<br />
are necessary.<br />
Corrosion and the Limits of<br />
Conventional Control<br />
Any industry with metal infrastructure,<br />
processing equipment, or products exposed to<br />
water, fluids, moisture, or atmospheric<br />
humidity continually fights corrosion, which<br />
causes the deterioration and loss of a material<br />
and its critical properties due to chemical,<br />
electrochemical reactions of the exposed<br />
surface with the surrounding environment.<br />
Corrosion affects the microstructure,<br />
mechanical properties, and physical<br />
appearance of the materials.<br />
The direct cost of corrosion includes a loss<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
LASERS 65<br />
of materials, equipment, and production, plus<br />
the cost of repair, maintenance, and<br />
replacement. Additional losses can result from<br />
accidents, injuries, and even loss of life as well<br />
as payments to repair environmental damage.<br />
Within the continual struggle against<br />
industrial corrosion, one important niche area<br />
of corrosion control involves the pretreating of<br />
metal surfaces to remove corrosion and<br />
contaminants before coating or welding.<br />
Although metal surface pretreatment is a<br />
small portion of industrial corrosion control, it<br />
is crucial to ensure the safety, performance,<br />
and longevity of products and structures.<br />
Insufficient coating pretreatment can lead to<br />
inadequate protection from the environment,<br />
leading to potential coating failure, moisture<br />
entry, and accelerated corrosion as well as<br />
increased maintenance, early replacement, and<br />
warranty issues. Similarly, insufficient weld<br />
pretreatment to remove corrosion and<br />
contaminants can lead to weakened or failed<br />
welds and necessary rework as well as<br />
substantial safety, liability, and litigation risk.<br />
A More Effective Weapon to<br />
Eliminate Corrosion<br />
In many industries, it is necessary to remove<br />
corrosion, residue, oil, grease, or paint before<br />
coating a product or infrastructure to improve<br />
coating adhesion.<br />
Toward this end, laser-based systems have<br />
significant advantages over traditional<br />
methods, starting with ease of use.<br />
“With laser-based systems, an operator<br />
simply points and clicks a high-energy laser<br />
beam at the surface. The substrate is not<br />
affected by the laser, and the systems do not<br />
create any mess or byproducts. The approach<br />
is eco-friendly, energy-efficient, and completes<br />
the job in approximately half the time of<br />
traditional methods when preparation and<br />
cleanup are considered. Also, no consumables<br />
are required,” says Wayne Tupuola, CEO,<br />
Orlando, Florida-based Laser Photonics, a<br />
leading provider of patented industrial grade<br />
CleanTech® lasers for cleaning and surface<br />
conditioning. The company’s systems function<br />
either as mobile standalone units or can be<br />
integrated into production lines.<br />
In the case of Laser Photonics, the laser<br />
systems are available in portable and<br />
stationary models ranging from 50 to 3,000-<br />
watts (a 4,000-watt version is in development)<br />
with chamber sizes from 3’ x 3’ in size to 6’ x<br />
12’. The systems can also be installed in<br />
manufacturing lines in cabinets or operated by<br />
a robotic arm.<br />
In industry, the laser pre-treatment of metal<br />
surfaces can be used to streamline various<br />
manufacturing processes. For instance, it has<br />
been used to remove rust from hundreds of<br />
automotive transmissions per day. It has also<br />
been utilized to eliminate corrosion from<br />
conveying system components.<br />
The CleanTech lasers are also used to<br />
refurbish industrial infrastructure, such as<br />
when removing a previous coating along with<br />
any corrosion to facilitate the new coating’s<br />
adhesion to the surface.<br />
Another common laser application involves<br />
pre-weld treatment to remove corrosion, mill<br />
scale, residue, and any impurities on the<br />
surface of the base material that would<br />
compromise the weld’s effectiveness. It is<br />
essential to avoid any such contamination on a<br />
weld’s surface, which could otherwise lead to a<br />
weakening of the weld’s mechanical<br />
properties, requiring rework.<br />
Laser treatment is also used for post-weld<br />
cleaning to increase the life expectancy and<br />
corrosion resistance of a welded joint. Postweld<br />
cleaning is important for stainless steel as<br />
well. Welding can cause a “heat tint,” a<br />
discolored, thickened top layer on the stainless<br />
steel around the weld bead within the heat<br />
affected zone that compromises corrosion<br />
resistance. Removing the heat tinted top layer<br />
is necessary to restore stainless steel’s full<br />
corrosion resistance and aesthetic value.<br />
A further benefit of the laser systems is that<br />
some of the most advanced units are designed<br />
to last for decades. For example, CleanTech<br />
laser systems can last for 50,000 to 100,000<br />
hours. In addition, virtually no maintenance is<br />
needed after purchase and no consumables<br />
are required.<br />
Given the devastating cost of corrosion to<br />
industry and the inherent limitations of typical<br />
control methods, lasers are becoming a best<br />
practice technique to combat it in facilities and<br />
in the field. Laser treatment effectively<br />
removes corrosion for many industrial<br />
applications, minimizes cleanup time and<br />
operator exposure to potential environmental<br />
health hazards, lasts for decades, and requires<br />
no consumables.<br />
<strong>Finishing</strong> – <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
66WORKSHOP<br />
Two new solutions<br />
Ingelfingen-based valve specialist GEMÜ is launching two new<br />
solutions for connecting single-use multi-port valve blocks.<br />
The first solution means that it is now possible to control the<br />
pneumatic locking of the valve block via locking cylinders thanks to a<br />
valve block sunk into the skid surface. The second solution consists of<br />
using a valve block placed onto the skid surface, where the valve body<br />
is manually connected to the actuator unit via a detachable hand lever.<br />
This second type offers greater flexibility for the spigot layout. The<br />
connection between the actuator and the diaphragms welded onto the<br />
valve block is created reliably within a few seconds using the familiar<br />
clamping principle of the GEMÜ SU40 SUMONDO. The blocks<br />
themselves are produced by machining and can therefore be tailored<br />
to each specific application.<br />
There are several benefits to using single-use technology: Eliminating<br />
the need for conventional cleaning cycles and the associated costs for<br />
power, cleaning media, waste disposal and peripherals while increasing<br />
protection against cross contamination between different manufacturing<br />
drives. It also minimises downtimes in factories, which significantly<br />
improves the flexibility and effectiveness of single-use solutions in the<br />
medical and pharmaceutical technology sectors in comparison with<br />
conventional solutions.<br />
Made to measure<br />
Digital Metrology Solutions,<br />
provider of measurement<br />
software, consulting, and training,<br />
has introduced TraceBoss+<br />
(TraceBoss Plus) software,<br />
integrating surface texture and<br />
crosshatch measurement in a<br />
single package.<br />
"Last year Digital Metrology's<br />
TraceBoss software changed how<br />
people see, save, and<br />
understand data from surface<br />
roughness gages,” said Mark<br />
Malburg, president of Digital<br />
Metrology. “Since then, we’ve<br />
had many requests to add<br />
crosshatch measurement to the<br />
software, as well as the ability to<br />
view torn and folded metal, a<br />
key indicator of how a honing<br />
process is running. TraceBoss+<br />
adds both of these functions, as<br />
well as introducing new tools to<br />
analyze, save, store, export, and<br />
output all of these results<br />
together. This complete toolset<br />
greatly helps anyone working<br />
with engine components to see<br />
their data and explore their<br />
surfaces.”<br />
TraceBoss+ software interfaces<br />
with most portable surface<br />
roughness gages. A user can<br />
take a measurement, view the<br />
results and graphics full screen,<br />
save data, and reload it for<br />
comparison and statistical<br />
process control. It reports most<br />
common roughness parameters,<br />
showing at a glance whether a<br />
surface passes or fails userprovided<br />
limits.<br />
Floor finishing is here<br />
HMG Paints has launched HydroPro Floor Paint. This cutting-edge<br />
water-based floor paint is designed to transform floor finishing with its<br />
cross-linking formulation that ensures exceptional durability and a<br />
superior finish for both internal and external applications.<br />
HydroPro Floor Paint boasts a formula that combines the strength of<br />
cross-linking technology with the convenience of water-based<br />
application. This innovation results in a tough, hard-wearing mid-sheen<br />
finish that's ideal for a variety of spaces, from domestic garages and<br />
workshops to light-industrial environments. Once cured, HydroPro<br />
Floor Paint becomes resistant to oils, grease, and light industrial traffic,<br />
providing a long-lasting solution for a number of areas.<br />
High quality<br />
with expertise<br />
Unitech prides itself on both the<br />
high quality of its products and<br />
its expertise and industry<br />
knowledge. With Five decades<br />
of experience, the company<br />
offers customers the peace of<br />
mind that comes with working<br />
alongside a market leader.<br />
The company offers<br />
innovative state-of-the-art<br />
solutions to companies across<br />
market sectors ranging from<br />
Automotive OEM and<br />
Commercial Vehicles to<br />
manufacturing and aerospace.<br />
Through its consultative<br />
approach and experience, the<br />
company provides advice on<br />
design, specification functionality<br />
and the needs of existing or<br />
future processes. From initial<br />
planning and CAD/3D design to<br />
manufacturing and installation<br />
Unitech’s team of specialists<br />
support the project through to<br />
completion.<br />
In the next issue<br />
Wet paint<br />
Water & effluent treatment<br />
Powder coating<br />
<strong>Finishing</strong> – <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
Products & Services<br />
Stewart Freshwater<br />
mobile: 07746 373 545<br />
email: s.freshwater@turretgroup.com • web: www.turretgroup.com<br />
Leading manufacturers of<br />
Jigs, Racking systems, Baskets, Heaters, Coils and many other<br />
products for the Anodising & Electroplating industry<br />
T: 01283 529314 • E: Sales@Supreme-Eng.com • W: www.supreme-eng.com<br />
abrasive blast cleaning equipment<br />
abrasives<br />
Abrasives<br />
Blast Rooms<br />
Blast Cabinets<br />
Spares<br />
PPE<br />
Servicing<br />
Training<br />
Recycling<br />
0114 254 8811<br />
www.hodgeclemco.co.uk<br />
We deliver results<br />
beyond the surface<br />
abrasive blast cleaning equipment<br />
HEAVY DUTY<br />
SHOTBLAST MACHINES<br />
LARGEST UK STOCKS<br />
NEW MACHINES<br />
PLATE & SECTION CLEANERS<br />
TABLE & SPECIFIC MACHINES<br />
HOOK / HANGER MACHINES<br />
BARREL & TUMBLER MACHINES<br />
AIR BLAST ROOMS & CABINETS<br />
EXTRACTION / DUCTWORK SYSTEMS<br />
OVER 60 MACHINES IN STOCK<br />
DOUG BOOTH UK LTD<br />
(Est 1971)<br />
SPECIALIST ENGINEERS<br />
Tel: 01924 274887<br />
Fax: 01924 262219<br />
M/C Sales 07850 744377 Txt/WhatsApp 24hr<br />
Email: paul@dougbooth.co.uk (machines)<br />
jonny@dougbooth.co.uk (parts & service)<br />
Website: www.dougbooth.co.uk<br />
SURPLUS & TRADE IN MACHINES WANTED<br />
AGENTS/FINDERS REQUIRED<br />
abrasive media<br />
Steel Shot (High & Low Carbon)<br />
Steel Grit<br />
Stainless Steel Shot and<br />
Stainless Steel Grit (Cr & Cr/Ni)<br />
Chilled Iron Grit • Glass Bead<br />
Ceramic Bead • Fused Alumina<br />
Cut Wire<br />
www.ampereabrasives.com<br />
sales.uk@ampereabrasives.com<br />
Tel: 0121 244 1809<br />
17 School Hall, Hall Green<br />
Birmingham B28 8JG<br />
To advertise please call<br />
boilers<br />
Stewart Freshwater<br />
s.freshwater@turretgroup.com<br />
abrasives<br />
coating applications<br />
coatings<br />
Delivering highly<br />
engineered, critical<br />
function products<br />
and services to<br />
the commercial,<br />
industrial, defense<br />
and energy markets<br />
n Shot Peening<br />
n Laser Peening<br />
n Coating Services<br />
n Analytical Services<br />
Please contact us on:<br />
01635 279621<br />
www.cwst.co.uk<br />
E/M Coating Services<br />
Engineered coating solutions:<br />
● High lubricity/low friction<br />
rdm_4x1_FNGCLASS 15/7/14 14:06<br />
complete finishing plant<br />
(paint or powder coatings)<br />
R.D.M. Engineering Ltd, Est. 1951<br />
Stakehill Lane, Stakehill,<br />
Middleton,<br />
Manchester M24 2RW<br />
Tel: 0161 643 9333<br />
Fax: 0161 655 3467<br />
Web: www.rdmengineering.co.uk<br />
E-mail: sales@rdmengineering.co.uk<br />
Contact: Mr R. Horwich<br />
spraybooths • rooms • ovens •<br />
conveyors • pretreatment • powder<br />
plant • air replacement units<br />
computer systems<br />
Do you know what your production<br />
line is doing? ORPHEUS DOES!<br />
ORPHEUS... Proven Production<br />
control software<br />
Barcode technology provides<br />
TOTAL ORDER TRACKING and<br />
TRACEABILITY<br />
Interested?<br />
Why not give us a call for a<br />
demonstration.<br />
Mark Dimmock<br />
Acton Gate Systems Ltd,<br />
Wolverhampton, WV9 5HF<br />
01902 249299 actongate<br />
www.actongate.co.uk • enquiries@actongate.co.uk<br />
conveyor systems<br />
Overhead Conveyors<br />
& Lifting<br />
Equipment<br />
T. 01926 813111<br />
sales@niko.co.uk<br />
www.niko.co.uk<br />
●<br />
Anti-corrosion<br />
High Carbon Steel Shot and Grit.<br />
Medium Carbon Steel Shot and Metal<br />
Bead. Stainless Steel Cr and Cr/Ni.<br />
High Chrome Grit.<br />
Aluminium Oxide.<br />
Full Technical Support.<br />
Tel: 01952 299777 Fax: 01952 299008<br />
Email: sales@pometon.co.uk<br />
Modern Coil Type Steam<br />
Generators & Fire Tube Boilers<br />
• 100Kg/h – 25,000Kg/h<br />
• High efficiency – up to 96%<br />
• Low overall emissions<br />
• Improved safety<br />
• Simplicity of control<br />
• Quiet, clean & cool in operation<br />
Tel: 020 8953 7111<br />
info@babcock-wanson.com<br />
www.babcock-wanson.com<br />
●<br />
●<br />
●<br />
Resistance to erosion/galling<br />
Chemical/environmental<br />
protection<br />
EM/RF shielding<br />
A business unit of Curtiss-Wright Surface Technologies<br />
Please contact us on:<br />
01386 421444<br />
www.emcoatingsuk.co.uk<br />
CALDAN Conveyor Ltd.<br />
Kirkleatham Business Park<br />
Redcar • TS10 5SH<br />
Tel. +44 1642 271118<br />
salesuk@caldan.dk<br />
www.caldan.dk<br />
Caldan Conveyor Solutions -<br />
simply perfect.<br />
<strong>September</strong>/<strong>October</strong> <strong>2023</strong> - <strong>Finishing</strong>
68 for all your classified needs call Stewart Freshwater on: 07746 373 545<br />
drying racks & spray tables<br />
effluent treatment plants<br />
infra red emitters<br />
DRYING RACKS<br />
FILTERS<br />
To advertise<br />
please call<br />
Stewart Freshwater<br />
on<br />
07746 373545<br />
or email<br />
s.freshwater@turretgroup.com<br />
hooks & jigs<br />
SPRAY TABLES<br />
SPRAY-SHOP-SUPPLIES.CO.UK<br />
01920 822 404<br />
INFO@GIBBSFINISHING.COM<br />
www.neutralac.co.uk<br />
TENNANTS<br />
TENNANTS DISTRIBUTION LIMITED<br />
Polypropylene Tanks<br />
PVC Tanks<br />
PVC/GRP Tanks<br />
Bund Tanks<br />
Tank Linings<br />
Rubber Linings<br />
HDPE Tanks<br />
electrophoretic coatings supplier and applicator<br />
Established 1976<br />
Fume Scrubbers<br />
Fume extraction<br />
Pipework<br />
Ducting<br />
Repairs & Refurbishment<br />
Flexible PVC Linings<br />
Guards in all materials<br />
Bespoke & Custom built Fabrications<br />
Tel: 01543 462 802<br />
Email: plasbrun.plastics@outlook.com<br />
Web: www.plasbrunplastics.co.uk<br />
MANUFACTURERS AND<br />
APPLICATORS OF SPECIALIST<br />
ELECTROPHORETIC COATINGS<br />
• A TRULY UNIQUE FINISHING SERVICE<br />
• SIMULATED BRUSHED NICKEL, CHROME AND STAINLESS STEEL<br />
EFFECTS APPLIED DIRECTLY ONTO BASE METAL SUBSTRATES.<br />
• BESPOKE COLOURS AND EFFECTS TO CUSTOMER SPECIFICATIONS<br />
• ALL FINISHES AVAILABLE WITH ANTI-BACTERIAL CAPABILITY<br />
Hawking Electrotechnology Ltd<br />
T: +44 (0) 1384 483019<br />
E: sales@hawking.co.uk • W: www.hawking.co.uk<br />
electroplaters<br />
COPPER n CHROME n POLISHING n IRIDITE NCP n GOLD and SILVER<br />
BRIGHT ACID TIN n MANGANESE PHOSPHATE<br />
n CHEMI BLACK COLD and HOT n ZINC and CLEAR/COLOUR/BLACK<br />
NICKEL BRIGHT/DULL n ANODISING CLEAR/COLOUR/BLACK/HARD<br />
Units 1 & 2, Dawkins Road Industrial Estate, Hamworthy, Poole, Dorset BH15 4JP<br />
Tel: 01202 677939<br />
jane@dorsetware.com<br />
t Bruest ATEX-certified<br />
Flameless Gas<br />
Catalytic Infrared Heaters<br />
t Gas-saving industrial ovens<br />
t “CATBOX” box ovens for<br />
wood-finishing<br />
t Servicing, spares & repairs for<br />
most brands of catalytic heaters<br />
Unit 1b Brown Lees Road Ind. Est. Forge<br />
Way, Knypersley, Staffordshire ST8 7DN<br />
Tel: + 44 (0) 1782 511880<br />
www.thermocatalytic.com<br />
thermocatsys@aol.com<br />
To advertise please email<br />
Stewart Freshwater at<br />
s.freshwater@turretgroup.com<br />
lacquers<br />
T: 01202 661300 jane@hitekproducts.com<br />
www.hitekproducts.com<br />
Hi-Tek stocks not only an extensive range of<br />
masking products including plugs, tapes, caps and<br />
discs, but also has the distinction of being the<br />
European distributor for the US based TOLBER<br />
range of lacquers and<br />
associated products. Hi-Tek<br />
imports bulk supplies from<br />
Tolber and converts or<br />
decants into commercially<br />
usable volumes for the UK,<br />
and European trade. The<br />
association with Tolber has<br />
evolved over many years.<br />
finishing systems<br />
jigs & baskets<br />
Masking • Hooks • Jigs<br />
HangOn Ltd<br />
Leintwardine, Craven Arms,<br />
Shropshire, SY7 0NB, UK<br />
Tel. +44 (0) 1547 540 573<br />
Fax. +44 (0 1547 540 412<br />
Email. sales@hangon.co.uk<br />
Web. www.hangon.co.uk<br />
• Water wash spraybooths<br />
• Water treatment chemical additives<br />
• Paint separation solids removal systems<br />
• Dry filter spraybooths<br />
• Fixed or portable spraybooths<br />
• Sprayroom enclosures<br />
• Air replacement systems<br />
• Full installation and commissioning<br />
• After-sales service and maintenance<br />
• Spray process engineering<br />
Product complies fully with current environmental<br />
protection and health and safety legislation<br />
Unit 4 Brook Road Industrial Estate,<br />
Wimborne, Dorset, BH21 2BH<br />
T: 01202 840900 • F: 01202 889477<br />
www.dynaclean.co.uk • sales@dynaclean.co.uk<br />
• Automotive • Aerospace<br />
• Oil & Gas<br />
• Petrochemical<br />
• Defence • Medical<br />
• Precision Engineering<br />
Specialist manufacturers in:<br />
Jigs • Baskets<br />
Coils • Heaters<br />
Fasteners • Tanks<br />
0121 622 3887<br />
info@saltandsadler.co.uk<br />
www.saltandsadler.co.uk<br />
Leading manufacturer of Jigs,<br />
Racking systems, Baskets, Heaters,<br />
Coils and many other products for the<br />
Anodising & Electroplating industry<br />
www.Supreme-Eng.com<br />
Tel: 01283 529314<br />
Fax: 01283 529316<br />
Sales@Supreme-Eng.com<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong>
for all your classified needs call Stewart Freshwater on: 07746 373 545<br />
69<br />
nylon colours_3x2_FNGCLASS 17/5/11 16:29 Page 1 serfilco_5x1_FNGCLASS 18/11/13<br />
masking<br />
nylon coating powders<br />
pump & filtration specialists<br />
Hi-Tek Products Ltd<br />
2A Dawkins Road Industrial Estate<br />
Hamworthy, Poole,<br />
Dorset BH15 4JP<br />
Tel: 01202 661300<br />
E-mail: jane@hitekproducts.com<br />
Web Site: www.hitekproducts.com<br />
Contact: Jane McMullen<br />
Masking Caps • Tapes/Discs • Tapered<br />
Plugs • Tubing • Pull-Through Plugs<br />
• Custom Design • Stopping-Off<br />
Lacquers • PTFE Lubricant<br />
To advertise email<br />
Stewart Freshwater<br />
s.freshwater@turretgroup.com<br />
metal finishers<br />
Specialist in Metal <strong>Finishing</strong>, Electro<br />
Coating with Acid Pickle & Zinc<br />
Phosphate, Powder Coating with<br />
3 Stages, Cleaning including Iron<br />
phosphate. We provide high quality,<br />
fast and cost effective polishing<br />
operation for a wide cross-section of<br />
component and parts.<br />
ISO9001-2015 Certified.<br />
Tel: 01902 871311<br />
sales@hitchfinishing.co.uk<br />
www.hitechfinishing.co.uk<br />
metal plating and polishing<br />
Tel: +44 12 96 43 37 54<br />
Fax: +44 12 96 39 22 85<br />
Email: sales@nyloncolours.co.uk<br />
powder coating<br />
gemapowdercoating.com<br />
High-quality solutions<br />
for powder coating<br />
powder coating manufacturers<br />
NYLON<br />
A TOUGHER COATING<br />
Nylon Colours Ltd manufactures<br />
Nylon Coating Powders for<br />
Electrostatic or Fluid Bed.<br />
A wide range of colours including<br />
metallics is available.<br />
Nylon Colours is also the UK distributor<br />
for RILSAN range of Nylon Powders.<br />
The latest and<br />
greatest from<br />
the leading<br />
powder<br />
coating<br />
equipment<br />
provider<br />
Gema Europe Srl<br />
– UK Branch<br />
T: 0044 1202 763 942<br />
E: uk.sales@gema.eu.com<br />
precision cleaning & degreasing<br />
●<br />
●<br />
●<br />
●<br />
SERFILCO<br />
Pumps, Filters<br />
and Agitation<br />
Systems<br />
TITAN Auto Backwash Filter<br />
Carbon Purification & Cartridges<br />
Premier Washed & Pleated Reusable<br />
Drum and Air Diaphragm Pumps<br />
● Electric Immersion Heaters<br />
Tel: 0161 775 1910<br />
Fax: 0161 775 3696<br />
SERFILCO delivers<br />
clear solutions<br />
E: sales@serfilco-international.com<br />
www.serfilco.co.uk<br />
rectifier equipment<br />
Switchmode and SCR DC Power Supplies<br />
for any metal finishing process.<br />
Options include:<br />
Local / Remote control.<br />
Constant Current / Constant Voltage.<br />
PLC controllable. Touchscreen control.<br />
Process timer. Ampere hour / minute meter.<br />
Digital meters. Outputs fully recordable.<br />
Outputs from 10 Amp x 6 V to 6000 Amp x 200 V.<br />
Prices available on request<br />
For more information please contact us on:<br />
Tel: +44 (0) 121 526 6847<br />
Fax: +44 (0) 121 568 8161<br />
e-mail: sales@britishelectrical.co.uk<br />
Website: www.britishelectrical.co.uk<br />
salt spray salt<br />
UKAS/NADCAP CERTIFIED SALT<br />
FOR SALT SPRAY TESTING<br />
Supplied in 5Kg and 25Kg Packs<br />
The Sherwin-Williams Company<br />
To meet the requirements of:<br />
ASTM B117 • ISO 9227 • DIN 50 021<br />
and all other standards.<br />
Full traceability guaranteed.<br />
pumps & filters<br />
SPECIALIST LAB SALT LTD<br />
Paytoe Lane . Leintwardine . Craven Arms.<br />
Shropshire . SY7 0NB<br />
Telephone: 01547 540573<br />
Email: sales@specialistlabsalt.com<br />
Website: www.specialistlabsalt.com<br />
To advertise email<br />
Stewart Freshwater<br />
s.freshwater@turretgroup.com<br />
ptr treatment<br />
To advertise<br />
rdm_4x1_FNGCLASS 15/7/14 14:06 Page 1<br />
oven stoving & curing<br />
R.D.M. Engineering Ltd, Est. 1951<br />
Stakehill Lane, Stakehill,<br />
Middleton,<br />
Manchester M24 2RW<br />
Tel: 0161 643 9333<br />
Fax: 0161 655 3467<br />
Web: www.rdmengineering.co.uk<br />
E-mail: sales@rdmengineering.co.uk<br />
Contact: Mr R. Horwich<br />
spraybooths • rooms • ovens •<br />
conveyors • pretreatment • powder<br />
plant • air replacement units<br />
Aqueous Cleaners/Degreasers<br />
Metal Brightening Solutions<br />
Alkaline and Acid Etches<br />
Desmuts/Deoxidisers<br />
Chrome passivates and treatments<br />
Qualicoat Approved Non-Chrome<br />
treatments<br />
Phosphates and Non-phosphate<br />
treatments<br />
Pickling Solutions<br />
Paint Strippers<br />
Special Formulations<br />
and Approved Systems<br />
Supplied with technical support<br />
and advice<br />
Tel: + 44 (0) 1978 660 297<br />
Fax: + 44 (0) 1978 661 104<br />
E-mail: info@almetron.com<br />
Web: www.almetron.co.uk<br />
please call<br />
Stewart Freshwater<br />
on<br />
07746 373545<br />
<strong>September</strong>/<strong>October</strong> <strong>2023</strong> - <strong>Finishing</strong>
70 for all your classified needs call Stewart Freshwater on: 07746 373 545<br />
spray booths<br />
spray nozzles<br />
web design<br />
The shoemaker’s<br />
son always goes<br />
barefoot.<br />
Excellent surfaces<br />
WAGNER offers a wide range<br />
of systems and products for<br />
perfect coating solutions in<br />
liquid and powder.<br />
Applying<br />
Feeding<br />
spray nozzles<br />
thermal fluid<br />
Thermal Fluid<br />
Heating<br />
Technology now<br />
for the future<br />
• Up to 50% energy savings<br />
• Compact size<br />
• Easy & safe to use<br />
• Works up to 350°C<br />
• Low exhaust emissions<br />
• High efficiency<br />
• Requires no specialist<br />
knowledge<br />
It’s the same in many industries,<br />
we never get the time to look<br />
after ourselves.<br />
We’ve been far too busy<br />
creating beautiful websites<br />
and building successful email<br />
campaigns for clients that our<br />
site relaunch has been pushed<br />
back again.<br />
This is not a complaint though,<br />
it’s what we at Reva call a nice<br />
problem, plus it shows that<br />
with us the customer indeed<br />
does come first.<br />
If you would like to push our<br />
website further down our to<br />
do list contact us for a chat.<br />
R<br />
V<br />
E<br />
A<br />
Web Design<br />
& Development<br />
surface finishing & effluent<br />
technologies<br />
Tel: 020 8953 7111<br />
info@babcock-wanson.com<br />
www.babcock-wanson.com<br />
T. 01932 567505<br />
chat@reva.co.uk<br />
Mixing<br />
Controlling<br />
Booths & Systems<br />
Wagner Spraytech (UK) Ltd.<br />
Tel. 01327 368410<br />
enquiries@wagner-group.com<br />
www.wagner-group.com<br />
<strong>Finishing</strong> - <strong>September</strong>/<strong>October</strong> <strong>2023</strong><br />
AUTOMATIC & MANUAL<br />
METAL FINISHING<br />
PLANT EQUIPMENT<br />
Fume Extraction<br />
Effluent Treatment<br />
DI Water Generation<br />
TEL: +44 (0) 121 314 1191<br />
enquiries@plastratum.com<br />
www.plastratum.com<br />
Plastratum Ltd<br />
100 Armoury Road<br />
Birmingham B11 2RH<br />
tanks & protective linings<br />
Polypropylene Tanks<br />
PVC Tanks<br />
PVC/GRP Tanks<br />
Bund Tanks<br />
Tank Linings<br />
Rubber Linings<br />
HDPE Tanks<br />
Established 1976<br />
Fume Scrubbers<br />
Fume extraction<br />
Pipework<br />
Ducting<br />
Repairs & Refurbishment<br />
Flexible PVC Linings<br />
Guards in all materials<br />
Bespoke & Custom built Fabrications<br />
Tel: 01543 462 802<br />
Email: plasbrun.plastics@outlook.com<br />
Web: www.plasbrunplastics.co.uk<br />
Editorial Calender<br />
Each issue of <strong>Finishing</strong> Magazine includes the<br />
following regular columns:<br />
4 News and views 4 Products<br />
4 Business and technical issues<br />
4 Personnel changes 4 Company focuses<br />
4 Questions & answers 4 Special reports<br />
4 Employment legislation<br />
4 Plus monthly special features<br />
NOVEMBER/DECEMBER <strong>2023</strong>:<br />
n Robotics n Anti Corrosive <strong>Finishing</strong><br />
n Advanced Surface Technology<br />
n Precious Metal <strong>Finishing</strong> n Annual Review<br />
PLUS FINISHING INDUSTRIES YEARBOOK 2024<br />
For Editorial enquiries please contact:<br />
John Hatcher, EDITOR<br />
E: j.hatcher@turretgroup.com
<strong>Finishing</strong> First!<br />
Experts in Metal <strong>Finishing</strong> Chemistry!<br />
Schloetter Co Ltd provides metal<br />
finishing solutions and personal<br />
support to our customers, including:<br />
• Cleaners and pre-treatment<br />
• Zinc, Zinc Alloy and Passivates<br />
• Tin and Tin Alloys<br />
• Electrolytic and Electroless<br />
Nickel<br />
• Bright levelling Copper<br />
• Precious metal processes:<br />
o Gold<br />
o Silver<br />
o Rhodium<br />
o Ruthenium<br />
o and others<br />
Providers of Printed Circuit Board<br />
chemistry from start to finish!<br />
Schloetter have recently expanded<br />
our PCB supply range, and can<br />
now offer:<br />
• Established pulse and DC<br />
copper plating solutions,<br />
insensitive to build-up of<br />
organic constituents<br />
• Easy-to-use Tin or Tin Alloy<br />
etch resists<br />
• ENIG and ENEPIG processes<br />
• New Direct Metallisation<br />
process; SLOTOSIT PCB 3500<br />
Tailored paints made to order!<br />
In the UK, Schloetter also produce a<br />
wide range of paint products, made to<br />
order, for various applications:<br />
• Glass<br />
• Ceramics<br />
• Metal<br />
• Plastics<br />
We also offer custom colour-matching,<br />
and can provide different finishes and<br />
effects, dependent on user<br />
specifications.<br />
Schloetter Co. Ltd.<br />
Abbey Works<br />
New Road<br />
Pershore Tel: +44 (0)1386 552 331<br />
Worcestershire, WR10 1BY<br />
info@schloetter.co.uk<br />
United Kingdom<br />
www.schloetter.co.uk<br />
Solutions for every surface