Challenge
The company where we had the pleasure of presenting our technology specialises in the production of cold-rolled steel shelving and faces technological difficulties typical of the industry. First and foremost, the problem is the low service life of the chemicals used, which necessitates frequent bath changes and increased operating costs. In addition, the plant consumes a significant amount of gas to maintain the temperature of the chemical bath at 45°C. Another major issue is sludge, which causes pump failures and increases infrastructure maintenance costs. Furthermore, the chemical concentration currently used is ten times higher than that required for Kairos technology.
Technological challenges
A key concern was to ensure that a high quality paint finish could be achieved while ensuring that the chemistry required for the surface preparation process would last longer than at present, and to reduce the sludge that causes pump failures. Due to the high operating costs, it will also be necessary to reduce the cost of the gas required to heat the chemical bath.
Running the tests
In order to verify our solution, we conducted tests according to the following steps:
- We filled the mobile washer with mains water, eliminating the need for specialised installations.
- We added a measured amount of concentrate Kairo- Surf®, highlighting the ease of preparing the solution.
- We obtained a working solution of 0.5%, which shows how little preparation is needed for effective treatment.
- We have made industrial washing details to be tested, thoroughly removing contaminants.
- We rinsed the surface with mains waterwhich allowed the residual product to be effectively removed.
- We dried the parts and passed them on for paintingto assess the adhesion quality of the coating.
Technological results and benefits
The tests carried out showed a clear and visible improvement in the quality of surface preparation. The workpieces were covered with a characteristic iridescent conversion layer, demonstrating the effectiveness of our solution. Importantly, the reduction of the chemical concentration to 0.5% means a significant reduction in operating costs, and the elimination of the need to maintain high temperatures translates into lower gas consumption. In addition, the elimination of sludge deposition has eliminated the risk of pump failure, improving process stability.
Summary and further research
The results obtained confirm that Kairos technology provides an effective and environmentally friendly alternative to traditional surface preparation methods, saving costs and increasing the quality of paint coatings.
If you would like to find out more about how our innovative technologies can improve your company's processes, get in touch!
