Modern solutions in surface processing - innovation in the Szamotuły district
In the Szamotuły district of Wielkopolska, one of the leading manufacturers of components for the heating industry has implemented our state-of-the-art solution in surface preparation technology. The company decided to low-temperature surface preparation technology for painting in the form of Kairo Surf PF AR. This innovation has resulted in significant savings, improved quality and reduced environmental impact.
Surface treatment process to date
Prior to the implementation of the new product, the company was using classic methods such as iron phosphating in a standard configuration of a modular three-stage washer:
- Washing with iron phosphating at temperatures above 50°C.
- Rinsing with process water.
- Rinsing with demineralised water.
This process, although standard, generated a number of problems. The high operating temperature was associated with high energy consumption, and the resulting phosphate sludge deposited in the tanks and on the washer components, leading to frequent cleaning downtime. Maintaining operating parameters also required significant chemical top-ups - on average as much as 2,500 litres per year.
Innovation with Kairo Surf PF AR products
Once the measures have been implemented Kairos Surf PF AR the company has achieved impressive results. Key developments include:
- Reduction in operating temperature to 25°C - The previous 50°C generated high energy costs, and now power consumption has fallen by up to 10 times.
- Lower operating concentration - The new measures work effectively at a concentration of just 0.5%, a fourfold reduction compared to the previous 2%.
- Extended bathing life - The process requires changing chemicals twice as often, which translates into savings and less waste.
- No phosphate sludge - problematic deposits are gone, reducing cleaning and disposal costs and extending the life of the washer.
- Improving the quality of cleaning - Previously, damp patches on decorative elements in black mat were visible under the paint layer, forcing them to be repainted. Today, the surface quality is much higher and the amount of paint used in the painting process has decreased.
- Improved thermal resistance of coatings - The new products can withstand drying temperatures of up to 230°C, while iron phosphating allowed a maximum of 130°C.
- Reducing chemical consumption - toppings have fallen by a factor of five, generating further savings.
- Neutral odour - The agents are virtually odourless, which improves working comfort.
Business and environmental benefits
Implementation of Kairos products Surf PF AR is a milestone for the company from the Szamotuły district. Lower energy and chemical consumption and no sludge reduce environmental impact, while reducing costs operational. Higher quality machining eliminates manufacturing defects and an improved surface preparation process increases competitiveness in the market.
The company, thanks to innovative solutions, gains not only a technological advantage, but also significantly improves production efficiency, which is crucial in the rapidly growing industries in which it operates.
