email: info@hartfordfinishing.comphone: (262) 673 - 6557. Differences between Anodic & Cathodic e-coating processes? 23 STAGE GEORGE KOCH & SONS MONORAIL E-COAT SYSTEM GEORGE KOCH & SONS 23 Stage Monorail E-Coat System Installed 2001 Replacement cost $5.0 Million + 16-18 carriers per hour Stages 1-18 are pretreatment Stages Cathodic epoxy electrocoatings are the benchmark for corrosion resistance. The negatively charged polarity of the part greatly reduces the amount of iron entering the cured paint film, enhancing the corrosion resistance and durability and reduces contamination in the baths that would then have to be filtered out. finishing costs, have made it a growing technology that will continue long into the future as Complex small parts are well suited for bulk processing. While e-coating is widely used as a primer coat for powder coating or painting, the process has gained popularity as a final finish as well. And finally, for the modern age, E-coating technology delivers a coating process with minimal environmental impact: Iron Phosphate can be used, but it only provides a coating weight of 40 to 90 milligrams per square foot providing about 500 salt spray hours. The process can be performed either way, however there are benefits of having the part grounded (-) and a charge applied to the solution (+) vs. having the parts (+) positively charged and the tank solution holding a (-) negative charge. material to fill the baths, changing material is very costly. or carrying over solution in non-draining voids in parts . The ability to provide very good inter-coat adhesion with most topcoats allows this process We know a powder coating system represents a large expenditure in time, energy and money for any … The e-coat system allows manufacturers of small or medium sized parts to have an in-house e-coating solution without permanently devoting the space, investment, and operational concerns associated with traditional coating systems. A Cathodic Epoxy E Coat Primer is what protects your car from rusting. of surface area required. Therma-Tron-X is an industry leader in the manufacture of custom powder coating systems. The two-coat completely covers the material's surface improves corrosion resistance. This is not the correct method for doing one or two parts a specific color. Zinc coating weights range from 300 to 400 milligrams per square foot giving superior corrosion resistance. Efficiency. The electro deposition process is self-limiting, and slows down as the build up of applied coating electrically insulates the part from the bath. Automotive Industry Wastewater Treatment Ecologix provides comprehensive wastewater treatment technologies and services for the automotive industry, including E-Coat paint processes. AIS, LLC is moving to our new 200,000 sq. E Coating is environmentally friendly. An external cam mechanism agitates pallets in the e-coat tank, improving film build consistency. be precisely controlled, yielding minimal waste unlike powder or paint overspray. Tilting SST®: We offer PPG’s Powercron 6000CX to produce an economical, durable finish that is HAPs free, heavy metal free and lead free. Many manufacturers use e-coat because the After processing, the baskets are transferred back to the monorail conveyor for forced cooling and unloading. (Volatile Organic Compounds), and is RoHS, OSHA and EPA compliant. The metal ions contaminate the coating. over other finishing technologies. The post rinses are than filtered and many parts or products that can be hung at once. Learn More This size affords our customers exceptional flexibility in electrocoating products ranging from whole antique car bodies to small drill bits. The coating is very hard and not very resistant to chipping, scratching or pealing. For the purpose of listing all the different steps throughout the process Hartford Finishing’s line will be used as a reference, but keep in mind not all e-coat lines include all these stages. Allows for a lower cure temperature. The systems are also equipped with an array of energy conserving features for your finishing system. The UV light will break down the coating The thickness of the paint can be controlled and adjusted with electrocoating, making it a perfect choice for small parts like these that require a consistent coating with a durable long lasting finish. Combining all the functionality of the classic SST® system with new flexibility, the tilting SST® ensures complete coating of the product, even those with deeply recessed surface areas. Indexing Cathodic E-Coat System. This phenomenon is known as throwing power and is a critical aspect of the electro coat process. Virtually all cars use e-coat technology as the foundation of their coating system today. High density throughput allows the customer to get more done in the process time that is needed, minimizing labor and handling needs. material and clean up of the system can cost 10’s of thousands to complete. It attracts the negatively charged paint particles in the paint bath. environments such as chemicals used in your laundry room. This process is also referred to as paint deposition. Much like the Ventury effect in powder coating, the paint material does not attract inside an enclosed area. Although there are many ways of applying finish to a component, only one provides the best material coverage: e coatings. Stages 18 thru 21 are a versatility option of another color. 3 post rinses provides excellent rinsing of excess paint for a uniform film, enhanced appearance, and efficient recovery of paint material. Electrophoretic deposition (EPD), electrocoating, e-coating, cathodic electrodeposition, and electrophoretic coating, or electrophoretic painting. Racking is very important for overall line efficiency. Depending upon the type of system utilized (indexing versus monorail) the overall footprint can be relatively small versus other coating systems. Adaptations of the TTX SST® allow for material handling solutions that decrease the footprint of the coating system and streamline production. Stage 8 - Rise Conditioner - The conditioner stage is used prior to the zinc phosphate to promote a heavier and more uniform phosphate film build. It is typically used in applications where both UV durability and corrosion resistance on ferrous substrates are desired. E-coat Dip & Rinses. Barrel coating minimizes touch marks while still providing the uniform, durable finish that is required. If you are going to e-coat, this is the best method. As a rule, E-coating will only cover the inside of a part 2 times the width of the opening. Ecoat does not protect inside tubes. We plan that an efficiently run system can process 600 square meters per 24 hours working. But we start our systems from a size as small as 500 liters which can process 1.4 square meters every three minutes. The E-coat process is a dipping (immersion) system very similar to what is used in metal plating except the finish uses organic paint particles not metal particles in the immersion baths. The higher the voltage, the thicker the film build. E-102: Eisenmann Monorail Cathodic E-coat / Electrocoating System Design: 4’-7” W x 5’-10” H Opening, 6 FPM E-LIL1: Indexing Cathodic E-Coat System AIS HEADQUARTERS - 242 South Pearl Street - PO Box 208 - Berlin, WI 54923 PH. causing it to fail. To learn more about a specific Automotive wastewater treatment application, call on one of our Professional Engineers, schedule a consultation or request a budgetary proposal for your specific requirements. AquaEC 4000 from Axalta Coating Systems is a family of epoxy-based electrocoats chosen by many manufacturers is specifically designed for automotive and general e-coat systems which require greater control of the painting process. How many steps are in the e-coat process? Most e-coat systems are automated, the amount of paint applied to a product can As long as parts to not touch, the entire tank can be E-coating is an immersion wet paint finishing process that uses electrical current to attract the paint product to a metal surface. The thickness of the paint can be controlled and adjusted with electrocoating, making it a perfect choice for small parts like these that require a consistent coating with a durable long lasting finish. The electrical charge seeks out the path of least resistance and coats the exterior portions of the part or parts nearest to the … Custom Small Container E-coat: This system is designed for small parts, fasteners or screws. Electrocoating has long been recognized as an excellent way to apply a high-quality primer or finish coat on metal parts, even very large ones. electrocoat process produces little or no HAPS (Hazardous Air pollutants), VOCs Most lines have 2 but some have 3 post E-coat solids deposit initially in the areas closest to the counter electrode and, as these areas become insulated to current, solids are deposited in more recessed bare metal areas to provide complete coverage. a pump fails, and the paint is allowed to settle, it is junk. Accommodating a 33,500-gallon e-coat tank and six 8,200-lb-capacity programmable hoists, our facility houses one of the largest non-OEM systems in the nation. The e-coat paint covers and protects the entire part or product so that even corners, edges and recessed areas are completely protected. When smaller footprint systems are utilized the ware package (size of part) and annual production rate of the system can be constrained. number of anodes must be installed in order for the tank to cover the maximum amount The product or part is lifted by the load bar and then lowered into each section sequentially. Stage 3&4 - Rinse - 2 Rinse stages give double protection for removing any soils and alkaline residue so the conditioner and zinc phosphate stages can have full and immediate reaction with the surface material. E-Coating. These rinses are filtered continually using Bag filters. Stage 10 - Zinc Phosphate Rinse - Rinses excess phosphate off parts and prepares the surface for the sealer. footage to be coated at one time. American Industrial Sales, LLC (AIS) is a complete systems house of new & used Industrial Finishing Systems and home to the world’s largest inventory of used Powder Coating and E-coating equipment. In cathodic systems, the product or part is negatively charged, which attracts the positively charged paint particles. But here in India the major hurdle used to be the investment in E-coating equipment. Designed specifically to meet the needs of component suppliers and metal stamping companies, this innovative e-coat system allows manufacturers of small- to medium-sized parts to have an in-house e-coating solution without the space, investment, and operational concerns associated with traditional coating systems. Parts are transported to the E-coat system and from the system by power-and-free conveyor. finish that will stand up to outdoor environments such as water and sunlight or indoor With the paint being suspended in the bath, it has to be constantly agitated, if power is lost, Working on the principle that opposites attract, an e-coat system applies an electrical charge to either the metal part, or the fluid in the immersion tank. In fact, today, approximately 99% of all new cars manufactured are E coated then top coated with the color of choice. Immersion ensures 100 percent coverage of complex parts, as well as uniform coating thickness with no runs or sags. This is followed by a water bath that … To apply for a job with Therma-Tron-X, Inc., please fill out our on-line application or send a cover letter together with your resume to. compliance no other finishing method approaches. It is typically used in applications where both UV durability and corrosion resistance on ferrous substrates are desired. One of the other benefits of the new conductive primer arrangement is the ability to recoat parts if a poor ground or other cause leads to a void in the coating. The paint particles build up on all surfaces of the metal part to form an even, continuous, low-profile film over the entire surface. Electrocoating provides a durable and lasting coating. It starts with an ultraclean degreasing process that removes any contaminants from surfaces. TTX has designed SST®'s to handle loads up to 12,000 pounds and lengths up to 40’. Utilizing automatic gun applicators. This system is designed for small parts, fasteners or screws. Custom Small Container E-coat: . to be used as a primer for almost all ferrous applications. The type of conveyor selected for your operation will depend on the weight, size and even the shape of the items being conveyed as well as the type of finishing process being applied. Widely used in the automotive and automotive parts industries, they provide superior salt spray, humidity, and cyclic corrosion resistance. The metal ions contaminate the coating. Able to paint material with E-Coat paint & further enhance the protection of parts with extended hours of salt spray protection with a nylon top coating. Cathodic acrylic electrocoatings are used as a one-coat finish. Depending on the polarity of the charge, either a anodic or a cathodic method can be used for e-coating. The cationic E-coat process is used to provide a more corrosion-resistant film. The versatility of electrocoating is endless because it can be used both as a top coat or primer. ISO/TS 16949, ISO14001 certified electrodeposition (E-Coat) coating services. Small amounts of metal ions migrate from the part into the paint film, limiting the performance properties of these systems. In anodic systems, the part is the anode, positively charged. E-coat racking architecture that is both efficient and capable of producing deposits on the racks' interior that are the same as parts close to the anode A system that optimizes the advantages of thin-film pretreatments. Zinc Phosphate can provide up to 3000 hour salt spray. TTX customers choose electrocoating because of its versatility and durability. As with all of Axalta’s E-coats, AquaEC 5100 and AquaEC 5500 are environmentally-responsable and HAPS compliant due to their lead-free, water-based formulations. Bubbles can be produced by cavitation in the main tanks pumping system. It can be applied in a thin and uniform film with penetration into recesses and excellent corrosion resistance. Electrocoating utilizes 95-99 percent of the coating, with very low VOCs, making it a “green” technology. Large and Heavy Parts: Environmentally friendly lead-free technology paint that is also HAPS free. The plastic industry requires this type of coated filler for many applications. E-Coat System With Three Stage Post Rinses (Ships as one module with Pre Treatment tanks): Stainless Steel E-Coat tank with dielectric liner Three stainless steel post rinse stages 3 New 3 hp mixers with stainless shafts and impellers Ultrafiltration Module Stainless steel bag filter Anodes membranes (new) – 10 Anolyte Flush Tank How much floor space does e-coat take in my plant? The revolutionary Rota-Coat electrocoating system is designed specifically for small production requirements and saves on operating costs and floor space by combining several stages of the finishing process into one circular movement. Electrocoat is a technology used Cathodic ecoat coatings carry very high performance with excellent corrosion resistance. However, the cathodic epoxy technologies generally have low resistance to UV light, requiring a topcoat to protect the epoxy primer from sunlight. What is a two-coat system? By coating fine ground and classified Calcium Carbonate, we can add more value to fillers in the fineness range of 3µm to 45µm. This TTX engineers continually think outside of the box to find the solution that best suits the customer’s need. 10 Minutes inside this oven helps control out-gassing issues with some castings, and parts with hem and flattened areas. Consistent, controlled application nearly eliminates the need for manual touch-ups. This process continues until the desired film thickness is reached. E-coating was developed originally for the automotive industry because it is economical and provides superior coverage, adhesion and corrosion resistance. A. Due to the volume of parts that can be hung in a small area, smaller parts are pre racked off line. Stage 14 - Color #1 E-coat Epoxy Paint Application Tank. The TTX SLIDERAIL SQUARE TRANSFER™’s adaptability allows those who need electrocoating for their part to use it effectively. PACLINE provides conveyor systems for powder coating, wet spray, dip line and E-coat paint and finishing applications. This stage can only be used on Steel due to the acid involved. Small amounts of metal ions migrate from the part into the paint film, limiting the performance properties of these systems. Bulk E-coat: Historically, 90-95% of e-coat lines have used a “zone system” (typically 2-3 zones), in which parts being coated are exposed to 2 or more voltage levels in the tank... and each zone re- quires a separate rectifier. Phone: 920-743-6568, Crystal Lake, Il 60014 Parts are loaded into baskets either automatically or manually. Manufacturers choose electrocoating to provide their products with a durable, lasting Cathodic acrylic electrocoatings are used as a one-coat finish. filled with parts. Stages 6 & 7 - Rinse - double rinses after the pickle stage. An opposite charged part is lowered into the paint bath and the paint particles are drawn to the metal part. This in turn ensures superior corrosion protection. Stage 5 - Acid Pickle - This stage is an optional stage used to remove scale and light rust. 920-361-5208 - Toll Free: 877-503-3303 - Contact: Nick Thoma, Owner It also allows users to rack parts much more densely while still achieving uniform paint thickness. Anodic e-coating: In anodic systems, the part is the anode, positively charged. Several filters and settings would have to change Sturgeon Bay, WI 54235 The system is set The coating is very hard and not very resistant to chipping, scratching or pealing. An integrated PLC system, allows system users to choose a variety of tilting options, making it even easier to achieve the coating you desire. up for one paint product to run constantly. The simple definition of a two-coat system is a method applying two coatings to the same component. The process involves driving charged particles out of a water suspension to a part capable of conducting a charge. E-Coating system is not limited to CaCO3 and can also be used to treat other minerals with different additives such as polymers for example. new uses and technologies are developed. Electrocoating is the most economical way to paint high volume parts. Epoxy e-coats are very susceptible to sunlight. The performance advantages, along with reduced Film thickness is regulated by the amount of voltage differential applied. Depending on the size of the tank, the correct Our unique lineup includes the iron removal system (Flood Spray), high-performance washing system (Parallel Separator), and counter-flow circulation tank in the degrease process, and high-pressure spray water washing processes. Although e-coat provides excellent corrosion protection, it does have two weaknesses for an automotive coating system: inadequate appearance and poor photostability. Parts are loaded into baskets either automatically or manually. This is based on total square Because of the sheer volume of The paint is than attracted by one or the other being grounded. The Rota-Coat utilizes a round tank, separated into different pie-shaped sections. ft facility and is offering our demo “LIL” Indexing E-coat system for sale. It attracts the negatively charged paint particles in the paint bath. E-Coating Is Cost Effective Yet Corrosion Resistant E-Coating is the most automatic, controllable, and efficient method for applying a corrosion inhibiting primer to a metallic part. and the process of doing so is measured in days not hours. All automakers use cathodic epoxy e coat for under hood applications, and as a prime/topcoat. Here, a pallet of Nissan frames prepares to enter stage 1. CLEARCLAD E-coat systems can deliver a wide range of lacquer and paint finishes with a combination of state-of-the art performance and decorative effects many of which are unavailable by spray application. Pretreatment, painting and rinsing is all completed in a small, circular footprint. To save even more space, the Rota-Coat’s oven can be elevated and placed above the tank itself.​ To remedy these issues, new enamel automotive primers were developed in the 1980s. Electro coating applications use paint particles suspended in a fluid bath. Stage 9 - Zinc Phosphate Bath - Zinc phosphate is a crystalline in structure, providing excellent adhesion. Because e-coat is immersive, coaters are always concerned with trapping air in sealed corners It is now used in many other industries such as Agriculture, Medical, and Electronics as well. This is preformed to utilize as much line space as possible. Stage 12&13 - Reverse Osmosis Rinse - The RO water baths rinse parts in an ultra clean rinse before paint. Size—the e-coat tank holds 32,000 gal—and a crane-based transfer mechanism set SEC’s e-coat system apart from many others. ElectroFin®E-Coat is an automated, computer-controlled process that guarantees complete and uniform encapsulation and 100% coverage. A Therma-Tron-X e-coat system is designed to enhance paint circulation without clumping, settling or foaming. Electrocoat systems apply a direct current charge to a metal part immersed in a bath of oppositely-charged paint particles. worldwide to achieve high-quality, low-cost finishes at a level of efficiency and environmental The part to be coated has a negative charge; the paint bath, a positive charge. Electrocoating is know for its ability to coat assembled products and complex parts using electrical current to … Because opposites attract, the paint is drawn to the metal part and forms an even, continuous film over its entire surface until the coating reaches the desired thickness. Each line is different, but with the correct engineering it is possible to coat as After loaded, the baskets are indexed and transferred to SLIDERAIL SQUARE TRANSFER® load bars. Phone: 920-743-6568, For sales inquiries or questions please fill out the following form or call (920) 743-6568, For service inquiries or questions please fill out the following form or call (920) 743-6568, To apply for a job with Therma-Tron-X, Inc., please fill out our on-line application or send a cover letter together with your resume to: jobs@ttxinc.com. Electrocoating is a specialty, and no one has devoted more energy and focus to this important specialty than Durusa. This can be overcome with a topcoat of paint. It is a rather simple electrical process of positive and negative charges being attracted to each other while like charges repel. these e-coats ideally suited for bulk coating of outdoor equipment. The E-coat system is a programmable hoist arrangement. Stage 1&2 - Alkaline Cleaner - Having 2 cleaning stages allows the ability for independent heating zones, double cleaning, and the versatility of running a “hotter” stage or putting a cleaning booster for processing extremely dirty parts. The total number of steps can vary from line to line depending on the most important part of the entire process, PRETREATMENT and CLEANING. Where a side tank is used for both collection of the e-coat tanks surface bubbles and the addition and mixing of new tank material, a bubble producing problem is possible if the weir shoot tank is: a) Too small. The replacement of the paint any paint collected in the rinse stages is re-introduced back into the application bath. Due to its ability to coat complex parts, electrocoating is used to coat a variety of products, like automotive under-body components, transformers, metal office furniture, military primer, fixtures and marine components. Stage 11 - Sealer - Non-Chrome sealer adds corrosion resistance. Electrocoating (E-Coat) / Paint Line Systems. Material utilization is very high because there is no over spray, and the process generates minimal amounts of VOCs. This process is not widely used due to the degraded corrosion resistance and durability. Electro coating is used on many products you own! TKS offers design, fabrication, and installation of industrial tanks for electro-coat and UF rinses. Stage 15 - 17 Color #1 Post Rinse - Most e-coat lines have 2 post rinses. Rota-Coat E-coat System: rinses to remove any residual paint buildup. 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