The Finishing Department has four fully operational e-coat lines that have been purchased new to eliminate downtimes and they are performing very well. We presently operate 3 shifts of production. Our current employment is 140 people and growing.We use OEM approved pre-treatment and paint. offering black, and red catholic epoxy e-coat. We specialize in both small and large parts which often require specific racking to eliminate defects caused by part geometry. Along with our standard e-coat process we offer unique partial coating capabilities. We paint tether and ISO FIX wires which require partial paintings
E-coating is a paint process that uses electricity to coat a metal part with paint. The most common metals used include steel, zinc, brass, aluminum or any other conductive material. After cleaning, the entire part is immersed in the electrodeposition paint tank. The paint bath is comprised of 20% paint solids (the portion that remains on the part) and 80% deionized water.
Upon application of the electrical potential (voltage) the paint solids are transported by electrical current from the bath to the part’s surface one molecule at a time. As the exterior surfaces of the part become coated, an electrical resistance builds. Since electricity always seeks the path of least resistance the electrical current automatically flows to areas of the part not previously coated. This process continues until all surfaces of the part are coated with the same thickness of paint solids. When the entire part is coated with the proper film thickness the flow of electricity will slow to a stop. When the electrical current stops every surface on the part is coated with a uniform thickness of paint solids.
After the paint solids are applied electrically, all runs and drips that could cause an uneven film must be removed in the post rinses. An ultra filter, which separates deionized water from the paint solids, is the basis for the closed loop post rinse system. Rinse water is continuously refiltered and reused. The excess paint, not electrically deposited, flows back to the paint tank where it can be reapplied.
Once the runs and drips have been removed, the part transfers to the dehydration and cure ovens. The dehydration oven is used to remove all water from the electrically applied paint film. After all the water is removed the part enters the cure oven. In the cure oven, the paint film undergoes a molecular transformation. The paint solids that were applied electrically now crosslink with each other and become a smooth, even, layer of acrylic modified epoxy. This epoxy film is extremely dense, thin, smooth and resistant to attack by a wide variety of chemicals.
The Finishing Department paints metal parts supplied by manufacturers who require or choose the e-coat paint process. Because of the efficiency of the e-coat process and the assurance of uniform paint coverage many manufacturers are requiring that their parts are painted using e-coat The advantages to e-coat are numerous. If you are not familiar with the e-coat process, here are just some of the benefits from using the e-coat process for your manufactured parts.
Low VOC (Volatile Organic Compounds) – Water based paint system
HAPS (Hazardous Air Pollutants) Free Products
Using the latest technologies and innovative methods, we have become the forerunner in partial painted parts. We regularly e-coat paint tethers, ISO FIX wires and small stampings which require partial paintings. When you compare the cost of e-coating painting of tethers and ISO FIX wire with other E-Coat operations, you will find that the Finishing Department will consistently be more competitive.
E-Coat painting of tethers, ISO FIX wires, small stampings and other partially painted parts requires special handling, customized equipment and the knowledge to utilize these. The Finishing Department has these abilities.
Dip spin is a process whereby product is placed in a mesh basket, submerged in coating solution and spun to remove excess coating. The temperature and viscosity of the coating, immersion time, spin direction and velocities and the cure method are among the variables that allow users to customize a process recipe and achieve precise, highly repeatable results.
Also notable is dip spin’s ability to minimize the cost of both coating material and waste disposal. This is due to the 98% or greater on average transfer efficiency
The advantage to Dip Spin is the ability to coating a large quantities of small parts at a fast rate. This can keep the cost per piece very low .
In addition, this allows the Finishing Department to use specialized coatings to meet additional customer requirements that cannot be used in the e-coating process.
The Finishing Department has been utilizing Dip-Spin paint coating since 1984. Our experience in this process is a major advantage to our customers . We can analyze the parts that needs coating and use our knowledge and expertise to provide our customer with maximum efficiency for his product, in both quality and cost.
The Finishing Department has 3 automated Dip-Spin lines. This allows us the flexibility to run multiple coatings and a variety of sizes and shapes.
Our new barrel zinc electroplating line was installed in late 2020. The highly automated line features soft handling transfer points, 12 electroplating cells, robotic passivation, and an integrated hydrogen embrittlement relief oven. The automated loading system ensures optimum barrel load size. PLC controlled rectifiers provide precise plating thickness control. The line has two robotic passivation cells. One is before the integrated hydrogen embrittlement relief oven and the second is after the oven. This allows passivation protection for the zinc during the 8 hour 400 degree bake cycle and precise passivation and color control after the bake. We can supply clear bright zinc, bright blue zinc and a very consistent deep gold yellow zinc. After the second passivation, parts can be automatically transferred to a tilt/tumble dip-spin applicator for a dry film lube. The process also allows for parts to bypass the dry film lube step and go to one of our planetary dip-spin coating lines for application of high performance topcoats.