Client profile:
Metbox Kurpas Sp. J. - manufacturer of specialist trailers for transporting animals, including the award-winning „Silesian Thing” dog transport trailers with sleeping annexes. The company ships its products all over the world and therefore requires maximum repeatability, durability and the complete elimination of the risk of complaints, which - with deliveries to such distant countries as Canada - would be extremely costly.
Baseline situation
Metbox had been using low-temperature phosphating technology for years. The key limitation was low power connection, significantly narrowing the options for heating the bath. The company therefore began to look for an alternative that:
- operates at a low temperature,
- ensures high surface adhesion and cleanliness,
- limits the number of parameters to be controlled,
- gives process stability for production aimed at global markets.
The reason for contacting Kairos Poland was twofold:
- Willingness to test modern market solutions.
- Value convergence. The client, after reviewing the website, stressed that it was the declaration to act according to Christian moral principles and ethical values that inspired his confidence.
Implementation of Kairos technology
The implementation process proved to be extremely fast and intuitive.
On arrival at the plant we found perfectly cleaned washer, completely prepared after the previous technology. The mains water in the working bath had neutral pH, which made it possible to proceed to the configuration of the operating parameters without further adjustment.
Process settings:
- working concentration: 1%,
- solution temperature: 25°C,
- spraying time: 5 minutes,
- drip: 2 minutes,
- rinsing: 2 minutes,
- re-draining: 2 minutes.
The entire implementation process - from entry to full configuration - took approximately two hours.
The paint shop operator has been trained to handle the new chemistry and to control the parameters. In day-to-day practice, this comes down to:
- one simple titration,
- pH measurement,
- replenishing the concentrate according to the measurement results.
Significantly, on the day of implementation, there were no details to be produced at the plant. The Kairos team declared that they could come for the first wash at any time - but this was not necessary.
The technology proved so simple and fault-tolerant that the client without the slightest problem carried out the first processes himself, making sure only that the concentration was 1%.
Optimisation of hangers and workpiece flow
As part of our full technical support, we also advised on the appropriate suspension of components:
- so as to increase loading efficiency,
- while eliminating dead zones prone to under-drying,
- resulting in a more uniform and predictable surface preparation prior to powder coating.
Result
Metbox gained:
- stable, reproducible and low-temperature process, ideal with limited connection power,
- minimum number of parameters to be checked,
- a process that operators mastered immediately,
- clean and homogeneous substrate for a high-quality coating,
- full elimination of the risk of international complaints.
Metbox continues to manufacture with Kairos technology, serving global markets with the highest standards of quality and paint durability.
Find out how much you can gain from Kairos technology
Each line of surface preparation is different, but one thing remains common - the potential for real savings from switching to a modern surface preparation measures Kairos.
Our calculator will quickly show how reduced temperatures, reduced process steps and lower chemical consumption
can translate into concrete financial benefits in your production.
