At Kairos Poland, we believe that every implementation starts with a conversation. In the case of Steel-Pol from Nowa Sól, a company with many years„ experience in the fencing and carport industry, we met partners with a clear goal from the outset, which was not to find a ”magic formula', but a solution that would realistically improve their day-to-day work. The surface preparation process - crucial before powder coating - worked well, but was too complex. Long cycle times, high energy consumption and emerging corrosion on the welds effectively made it difficult to maintain stable quality. Our common goal became simplifying the process without compromising on the end result.
Challenge
In its previous process in a three-stage Libra spray washer, Steel-Pol used acid etching with wash additives in the form of two products. Although the technology was proven, in practice has caused several unacceptable problems:
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long, more than 30 minutes processing cycle,
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high energy consumption - bath maintained at 40°C,
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corrosion of welds and bare steel despite long cleaning process,
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the lack of a conversion layer, so important for the adhesion and resistance of the coatings.
Together with the client team, we decided to test whether the new technology Kairo-SURF PF AR can become an alternative to the existing process - not only more efficient, but also more user-friendly on a day-to-day basis.
Implementation in practicee
We conducted the first run at a concentration of 0.7% and a temperature of 25°C - already then a difference could be seen. After adjusting the parameters to 1%, we achieved a stable process and an even surface effect. The total cleaning cycle was shortened from 31 to 17 minutes, which immediately translated into efficiency and energy consumption.
During tests on aluminium, zinc and steel components surfaces covered with a characteristic gold conversion layer - a signal that the process was going well. Subsequent tests - notch grid, bending and impact test - confirmed the full GT0 adhesion, which we document in the video below.
Joint problem solving
It was not without its challenges, but at Kairos Polska we like them very much. In the course of testing the coating on aluminium components, we noticed their inaccurate washing, which resulted in poor adhesion of the coating. A brief investigation revealed, that the lightweight aluminium components were „escaping” under the spray due to their low weight. Together with the Steel-Pol team, we quickly came up with a solution: stabilising and adding weight to the components and slightly adjusting the nozzle setting in the washer. The result? The problem disappeared and the process became fully repeatable for aluminium as well.
Maintaining the correct performance of the Kairo-SURF PF AR product is far simpler than in the phosphating process, based on topping up one product based on simple titration. But even so, the Steel-Pol crew has been trained and given the instructions, training video and refill calculator, which makes day-to-day parameter control even easier.
Results of cooperation
Technology Kairo-SURF PF AR not only simplified the process, but also significantly improved its efficiency, as can best be seen in the table below:
| Indicator | Prior to implementation | Once implemented | Change |
|---|---|---|---|
| Total cleaning cycle | 31 minutes | 17 minutes | ⬇ approx. 45% shorter |
| Line performance | base | +82% | ⬆ increase in efficiency |
| Bath temperature | 40°C | 25°C | ⬇ energy saving |
| Number of products | 2 | 1 | simplifying the process |
| Conversion layer | no | present (golden opalescence) | quality improvement |
How did we calculate the performance increase by 82%?
Increase in line capacity by 82% results directly from reduce cleaning cycle time from 31 to 17 minutes. This calculation is based on the simple mathematics of production line throughput. The key to understanding this increase is the number of cycles that can be completed in a given time:
Before implementation:
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Cycle time: 31 minutes
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Number of cycles per hour: 60 ÷ 31 = 1.94 cycles/hour.
Once implemented:
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Cycle time: 17 minutes
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Number of cycles per hour: 60 ÷ 17 = 3.53 cycles/hour.
Efficiency gains
Performance increase = [(3.53 - 1.94) ÷ 1.94] × 100% = 82,4%
In other words, in the same amount of time (e.g. an 8-hour shift) the line can process:
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Before: ~15.5 lots of elements
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After: ~28.2 lots of elements
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The difference: +12.7 additional batches per shift
Summary
The implementation at Steel-Pol is an example of how partnership approach and joint testing can translate into real results. It was not just a matter of exchanging chemistry, but of adjustment of the whole process - from the bath parameters, to the geometry of the washer, to the way the workpieces are clamped. Today Steel-Pol is working with a stable, shorter and energy-efficient process, and we are pleased to see that the Kairo-SURF PF AR is realistically supporting their quality and production goals. With the line's capacity increased by 82%.
