Technology and chemical pretreatment

Chemical pretreatment

 

Chemical pretreatment is the foundation for the success of any powder coating. That’s why, at our Albixon Powder Coating facility, we place significant emphasis on it. The basis of our success and the quality of surface treatments lies in our specific chemical pretreatment technology. You can review the exact process below, where it is detailed step-by-step. After chemical pretreatment, the product must be thoroughly dried, followed by the actual powder coating process. Technological procedures in chemical pretreatment also vary depending on the material of the treated surface. You can also read about the procedures for the chemical pretreatment of aluminum and steel below.

Below, we present a list of top-notch technology that constitutes our manufacturing secrets and know-how.

 

• I. Chamber Pretreatment (5 Chambers) - In this section of the line, goods made of aluminum, steel, and zinc can be pretreated in individual steps according to the instructions of the control system and the recommendations of NABU, the supplier of chemical products. Liquid replenishment is automated, and each chamber allows for a tilt of the hanger to accelerate fluid runoff.

• II. Residual Water Dryer - This section dries any remaining fluids from the pretreated material. The dryer operates at temperatures up to 130 °C.

 

• III. WAGNER Automatic Box - This coating equipment enables the painting of items with maximum dimensions of 9000 x 2200 x 500 mm (L x H x W) at a conveyor speed of 1.5 meters per minute. The equipment includes two manipulators with long-stroke lifts, seven automatic horizontally mounted guns on each manipulator, one manual pre-spray gun, and one manual post-spray gun.
   
• IV. CLEANROOM – Clean Space for Coating Booth - This is an enclosed area for the automatic booth, approximately 20 x 10 meters in size, equipped with a cooling unit and air handling system.
   
• V. Curing Oven with Indirect Air Heating - Sufficient capacity with a gelling zone ensures quality curing of items within the designated time and cycle. The optimal line cycle is 5-6 minutes.
   
• VI. Suspended Double-Track Conveyor - The transportation of materials throughout the entire line is facilitated by a Power&Free conveyor with dropping stations for hanging and unhooking. The maximum weight capacity of the conveyor is 400 kg per hanger.
   
• VII. Control System - The entire line is managed by a system with supervisory visualization and a touchscreen interface. The system has four levels of access and is equipped with a modem for remote service connectivity. The control system monitors the entire process of the line and reports any malfunctions to the operator.
   
• VIII. Wastewater Recycling - Wastewater recycling occurs in a closed loop using an ion exchange station and vacuum evaporators. The entire system ensures a minimum water reuse rate of 93%. This equipment is also connected to the line's control monitoring system.
   
• IX. Automatic Packaging Equipment for Profiles - This equipment automatically packages profiles in plastic film using an ultrasonic system.

Technological procedures

 

Aluminum

• Degreasing – Pickling – NABUDUR STI/152S
• 1° Rinsing
• 2° Rinsing
• 3° Rinsing - DEMI
• 4° Rinsing - DEMI
• Passivation Ti – NABUTAN STI/310
• Drying
• Applying PP
• Gelling
• Curing

 

Steel

• Degreasing – Phosphating – NABUPHOR LKI/80
• 1° Rinsing
• 2° Rinsing
• 3° Rinsing - DEMI
• 4° Rinsing - DEMI
• Drying
• Applying PP
• Gelling
• Curing

 

In the case of a decor, the entire process is complemented by applying a special decorative pattern and sealing this pattern in a vacuum oven.