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The only magazine covering TheUK's UK's only magazine covering the surface ﬁ nishing industry the surface ﬁ nishing industr

OCTOBER OCTOBER2026 2026 WEHAVE HAVEEVERYTHING EVERYTHINGCOVERED COVERED– – WE

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PLATING JIGS PLATING JIGS Full Design Full Designand and Repair Service

www.dacncservices.co.uk www.dacncservices.co.uk

Repair Service TITANIUM JIGS JIGS TITANIUM Anode Cages – Coils Anode Cages–Coils PAINT JIGS JIGS PAINT Compatible with Robot Compatiblewith Robot Programmes

Programmes BESPOKE SOLUTIONS BESPOKE SOLUTIONS Racks Trolleys Racks TrolleysTanks Tanks ON-SITE ON-SITE FABRICATIONS FABRICATIONS CNC MACHINING MACHINING CNC (in house) house) (in HEALTH AND HEALTH ANDSAFETY SAFETY Bespoke Fabrications Bespoke Fabrications and Services Services and PLANT EQUIPMENT EQUIPMENT PLANT ACCESSORIES //ACCESSORIES

D.A.PLATING PLATINGJIGS JIGSLTD LTD D.A.

FULL FULLCOLLECTION COLLECTION AND DELIVERY DELIVERYSERVICE SERVICE

ENGINEERS FINISHERS TRADE ENGINEERSTO TOTHE THEMETAL METAL FINISHERS TRADE

UNIT 66 WHARFSIDE WHARFSIDE BUSINESS ROAD, KINGS NORTON, BIRMINGHAM B38B38 9PN9PN UNIT BUSINESSPARK, PARK,ARDATH ARDATH ROAD, KINGS NORTON, BIRMINGHAM Tel: 0121 451 1742 Tel: 0121 451 1742Mobile: Mobile:07860 07860883092 883092 E-Mail: E-Mail: daplatingcnc@gmail.com daplatingcnc@gmail.com We Weare arean anestablished establishedcompany companythat thathas hasbeen beentrading tradingfor forover over2020years years and are renowned for our services to our customers and are renowned for our services to our customers

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OCTOBER 2026 VOLUME 33 NUMBER 10 MANAGING DIRECTOR & ADVERTISEMENT DIRECTOR Nigel Bean t: +44 (0) 1442 826826 e: nigelbean1@aol.com nigelbean@surfaceworld.com EDITOR & GRAPHIC DESIGNER Jane Soones e: janesoones@aol.com janesoones@surfaceworld.com CIRCULATION & SUBSCRIPTION DEPARTMENT t: +44 (0) 1442 826826 EXHIBITION ORGANISATION t: +44 (0) 1442 826826

COMPANY SPOTLIGHT D.A. PLATING JIGS LTD: ENGINEERS TO THE METAL FINISHERS TRADE. 2

QUALICOAT UK & IRELAND INSTANT VERIFICATION WITH NEW QUALICOAT UK & IRELAND QR CODE.

INSTITUTE OF MATERIALS FINISHING INDUSTRY RECOGNISED TRAINING COURSES FROM THE IMF.

INDUSTRY NEWS Hill Media Ltd, Marash House 2-5 Brook Street, Tring, Hertfordshire HP23 5ED, United Kingdom. The Surface World magazine is published 12 times a year by Hill Media Ltd. Although every effort is made to ensure the accuracy and reliability of material published in Surface World, Hill Media Ltd and its agents accept no responsibility for the veracity of claims made by contributors, manufacturers or advertisers. Copyright in all material published in Surface World, including but not limited to all Hill Media brands, brand logos, trademarks, and associated assets, remains with Hill Media Ltd and its agents. © Hill Media Ltd – 2026 ISSN 1757-367X

ABB ROBOTICS INTRODUCES TWO NEW HIGH-PERFORMANCE ROBOTS FOR PRECISION MANUFACTURING.

THE COMBO RANGE FROM ADEPT PURE WATER.

NEW ECOMETER XS DOSING SYSTEM APPLIES THE SMALLEST QUANTITIES OF ADHESIVES AND SEALANTS.

HMG PAINTS BACKS VOLUNTEERS RESTORING HISTORIC BRITISH BUSES.

Enhanced Ecoclean app: NEW FEATURES AND IMPROVED USER GUIDANCE.

TEXTUREJET AWARDED INNOVATE UK GRANT TO ADVANCE NEXTGENERATION COMPOSITE SURFACE PROCESSING TECHNOLOGY.

A SHOW FULL OF OPPORTUNITIES! The Industry Meets in Guangzhou.

PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING ONE PASS, FOUR PROCESSES: HOW WET BLASTING IS SIMPLIFYING SURFACE PREPARATION. 22

NO ROOM FOR COMPROMISE. QUALICOAT delivers performance, durability and compliance for architectural powder coating in the built environment.

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THE FINISH IS DECIDED BEFORE IT STARTS: PRE-TREATMENT AND THE PREPARED SURFACE.

NEXT-GENERATION, PFAS-FREE VAPOUR DEGREASING SOLVENT FOR MODERN INDUSTRY.

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PAINT & POWDER ADVANCING INDUSTRIAL FINISHING THROUGH ROBOTIC SPRAY-PAINTING AND SMART PAINT SYSTEMS.

MATERIAL & EQUIPMENT SUPPLIERS

COMPANY SPOTLIGHT

D.A. PLATING JIGS LTD: ENGINEERS TO THE METAL FINISHERS TRADE In the metal finishing industry, having the right equipment for the job is essential. From plating and lacquer jigs to paint jigs and specialist fabrications, every application has its own requirements. Understanding these needs and providing practical, costeffective solutions is at the heart of D.A. Plating Jigs Ltd. With more than 20 years of trading experience, the company has built its reputation on providing a comprehensive service to customers across the metal finishing trade. Its approach combines quality manufacturing with customer care and after-sales support, ensuring that solutions are tailored to individual requirements. Working closely with customers, the team aims to identify the most cost-effective options to help maximise productivity and profitability. Whether the requirement is for a new jig, a bespoke design or the repair of existing equipment, D.A. Plating Jigs Ltd offers a flexible service built around the customer’s needs.

Experience That Makes the Difference Designing and manufacturing jigs requires a thorough understanding of both the equipment and the processes in which it will be used. D.A. Plating Jigs Ltd benefits from a team of jig designers with more than 30 years of combined knowledge and experience. This expertise underpins the company’s ‘Right First Time’ approach, with designs developed to suit specific applications and customer requirements. By working closely with customers from the outset, the team aims to deliver practical, efficient solutions that meet the demands of each project. Customer satisfaction remains a priority throughout the process. The company recognises the importance of strong working relationships and dependable after-sales support, providing customers with assistance beyond the initial manufacture and supply of equipment.

Growing to Meet Customer Requirements Over the years, D.A. Plating Jigs Ltd has continued to develop its business and expand its capabilities through strategic acquisitions. In 2017, the company acquired another plating jig business, strengthening its

position within the market. This was followed in 2019 by the acquisition of Titanium Engineering Products, further enhancing its services and establishing D.A. Plating Jigs Ltd as a key competitor in the industry. These developments have helped create a more versatile organisation, bringing together complementary expertise and a broader range of services. This expansion reflects the company’s commitment to meeting the changing needs of its customers and providing a comprehensive service to the metal finishing sector.

A Comprehensive Range of Services D.A. Plating Jigs Ltd offers an extensive range of design, manufacturing and repair services, providing customers with specialist equipment and fabrication solutions under one roof. Its capabilities include the design and manufacture of plating jigs, lacquer jigs and paint jigs, as well as titanium baskets, stillages, trolleys and light fabrications. The company also undertakes production welding, including MIG, spot and TIG welding, supporting a variety of manufacturing applications. For customers working with plastic coating processes, the company manufactures plastic coat jigs in a range

of sizes, from smaller components to larger applications, with a maximum capacity of 6ft 6in.

companies, the Ministry of Defence (MOD) and the decorative sector, including architectural products.

Alongside manufacturing new equipment, D.A. Plating Jigs Ltd offers a full repair service and accepts repair contracts. This allows customers to access specialist support for both new projects and existing equipment, helping them maintain their operations and address their ongoing production requirements.

This breadth of experience enables the company to work across a variety of applications, from volume production runs requiring consistent, reliable equipment to specialist one-off projects where bespoke solutions are essential.

By combining bespoke design, manufacturing and repair services, the company can accommodate a wide variety of projects, from straightforward requirements to more specialised applications.

Whatever the product or market, the company’s focus remains on understanding the customer’s requirements and providing the most appropriate solution. The team is happy to visit customers to discuss potential projects, assess their needs and provide a free quotation.

Serving a Diverse Range of Industries

A Service Built Around the Customer

Although its expertise is centred on the metal finishing trade, D.A. Plating Jigs Ltd works with businesses across a diverse range of industries, supporting organisations both large and small.

For D.A. Plating Jigs Ltd, delivering a quality product is only one part of providing a complete service. Understanding individual requirements, offering practical solutions and maintaining good communication are equally important.

Its customer base includes several aerospace companies, automotive businesses, robotic paint application

With an established track record,

experienced jig designers and an extensive range of manufacturing, fabrication and repair capabilities, the company continues to support the needs of metal finishers across multiple sectors. Its commitment to quality, cost-effective solutions and customer satisfaction remains central to its approach. By working in partnership with customers, D.A. Plating Jigs Ltd aims to provide equipment and support that help businesses maximise productivity and profitability. Whether the requirement is for a new jig, specialist fabrication or a reliable repair service, the team welcomes the opportunity to discuss individual needs and develop a solution to suit. D.A. Plating Jigs Ltd — dedicated to providing quality engineering solutions and a comprehensive service to the metal finishing trade. Contact D.A. Plating Jigs Ltd Telephone: 0121 451 1742 Mobile: 07860 883092 Website: www.dacncservices.co.uk Email: daplatingcnc@gmail.com

QUALICOAT UK & IRELAND

INSTANT VERIFICATION WITH NEW QUALICOAT UK & IRELAND QR CODE QUALICOAT UK & Ireland has added a QR code to its member certificates in a move which transforms a static certificate into a live verification tool. By scanning the code, stakeholders can instantly verify QUALICOAT member credentials for complete traceability and assurance. This investment supports competent decision making, helping to prevent errors and misrepresentation, or non-compliant suppliers being specified, and enables specifiers to select suppliers quickly and with confidence.

QUALICOAT licence, so, we have taken positive action to address this by adding a QR code to each QUALICOAT certificate which links to the member’s profile. “This addition aligns our certification

This initiative forms part of a wider programme of continuous improvement, ensuring the QUALICOAT quality label remains robust, relevant and trusted.

with modern demands. The construction

Chris Mansfield, chair of QUALICOAT UK & Ireland explains: “As a quality label organisation, we value trust and transparency. Possession of a printed or digital certificate alone does not necessarily mean that a company or system currently holds a valid

claims. Our QR code provides practical

industry is under pressure to demonstrate compliance and competency, and decision makers need evidence not just support for those responsible for due diligence and compliance. Better still, verification can now be completed in seconds, saving time across specification, procurement and audit processes.”

Chris Mansfield QUALICOAT UK & Ireland Chair

How it works By scanning the QR code, users are redirected to the relevant record in the QUALICOAT QCT360 database, where the current validity status can be confirmed. If valid, the user can access key information, including License Number and Type, Certification Year and Expiry. This additional transparency also helps specifiers identify established and experienced supply chain partners.

Find a QUALICOAT approved member This QR code initiative also protects our members – compliant, licensed suppliers, by clearly differentiating them from unlicensed or lapsed operators. Search Members via qualicoatuki.org for an up-to-date list of QUALICOAT UK & Ireland members, including powder coat applicators, powder manufacturers and pre-treatment system suppliers.

INSTITUTE OF MATERIALS FINISHING

Become an Acknowledged Leader in Surface Engineering and Materials Finishing:

INDUSTRY RECOGNISED TRAINING COURSES FROM THE IMF To follow on, students can then elect

Are you involved with the application of coatings to enhance and protect your products? Do you need to meet client specifications to ensure the longevity of your components? Does the complex world of surface engineering and materials finishing cause you headaches? If so, the courses offered by the Institute of Materials Finishing (IMF) could be your solution! The IMF have been promoting knowledge in the surface finishing industries, both inorganic surface treatments including plating and the application of organic paints, lacquers and varnishes for many years. Large numbers of engineers and technicians across a multitude of industries have benefitted from the knowledge gained to enhance their careers, their standing within industry and the ability to problem solve the many challenges they face in their daily working lives!

Starting with the Foundation level course, students gain knowledge on all aspects of materials finishing, specifically aimed at their own industry requirements, but to include sections on Health & Safety, the Environment and Surface Finishing and Corrosion Protection. There is no need for a science background to be able to successfully complete a foundation course. The Foundation Course requires study of 15 sections and requires the submission of 2 marked assignments followed by an end examination. The course, conducted by distance learning will take 16 weeks to complete. There are three specific study routes to choose from; electroplating, organic coatings and aerospace finishing. On successful completion, the student is awarded the Foundation Certificate.

to progress to the Technician level modules, which give more in-depth knowledge for key finishing technologies, their application and best practice methods. Again, both inorganic and organic technologies can be studied to match the industry requirements. There is a choice of eight modules, which provide study in applicable areas of surface finishing best matched to your needs. Like the Foundation course, study is by distance learning, and the student is required to complete four marked assignments and pass an examination. Passing two technician modules leads to the award of Technician Certificate; passing four modules leads to the award of an Advanced Technician Certificate.

If you feel your career could benefit from being a recognised specialist in your particular branch of Surface Engineering or Materials Finishing, then contact the IMF today. Speak with our training manager Karen Yates on +44 (0)121 622 7287 or email karen@materialsfinishing.org. Move your career to the next level and join the finishing community and all the benefits that gives through the IMF.

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INDUSTRY NEWS

ABB ROBOTICS INTRODUCES TWO NEW HIGH-PERFORMANCE ROBOTS FOR PRECISION MANUFACTURING New, compact IRB 1700 and IRB 1700ID deliver up to 20% shorter cycle times with higher motion accuracy, higher payloads Meeting growing demand for high-speed and precision manufacturing, from electronics to automotive Lower total cost of ownership by reducing power consumption and in-creasing service intervals ABB Robotics is expanding its industrial robot portfolio with two new compact, high-performance robots, the IRB 1700 and IRB 1700ID, delivering up to 20% shorter cycle times than comparable robots on the market. “Precision manufacturing across sectors from electronics, automotive, to general industries is facing the pressure to produce more, while maintaining quality and reducing operating costs,” said Craig McDonnell, Managing Director, Business Line Industries, ABB Robotics. “The IRB 1700 family addresses these challenges with a new level of speed, accuracy, reliability and energy efficiency. It gives manufacturers and system integrators a flexible platform for high-performance automation.” Offering payloads from 6 kg to 12 kg across five variants and powered by OmniCoreTM controllers, the new robots help manufacturers increase productivity, with up to 20% shorter cycle times, and improve uptime and reduce operating costs, with up to 15% lower power consumption and service intervals of up to 20,000 hours between oil changes. Precise path repeatability of down to 0.03 mm and joint speeds of up to 700 degrees per second make the new robots ideal for high-speed precision tasks such

as material handling, arc welding, deburring, sanding, and machine tending. The highperformance robots are also suited to new electronics applications such as AI server rack assembly, meet-ing the surging demand for AI servers and computing. The new robot offers a footprint 50% smaller than its predecessor, and for even greater packaging efficiency, the IRB 1700ID model features ABB Robotics’ Integrated Dressing (ID) design, routing cables and hoses inside the robot arm, simplifying installation across industrial applications. The IRB 1700 family extends ABB Robotics’ comprehensive mechatronics portfolio and ABB Robotics’ development of more autonomous and versatile robotics (AVRTM), with access to an expanding portfolio of programming

and AI-powered software, including RobotStudio®, AI Robot Trainer, OmniCore EyeMotion and automatic collision-free path planning. The IRB 1700 and IRB 1700ID made their public debut at China International Industry Fair (CIIF), Shanghai, October 12–16, 2026, with a demonstration featuring a fully functional arc welding and sanding application. For more information, visit: go.abb/robotics

INDUSTRY NEWS

THE COMBO RANGE FROM ADEPT PURE WATER As a UK leader in water-purification research and development, Adept’s Combo range offers cost-effective, low-maintenance units for topping up any pure water process that needs <10 μS/ CM quality. One of the most popular models is the Combo 200-800, which provides 200 to 800 litres of permeate water per hour. Yet there is no standardisation around the building and commissioning process. With each client’s unique needs in mind, the result might be anything from the smallest Combo 200 Mini to a multi-membrane unit supplying up to 40m³ of permeate per hour. With ever-increasing regulations around effluent discharges, chlorides and sodium will soon come under standards closer to drinking water. As they are difficult to clean out of water, most companies with reverse osmosis (RO) units have duplex softeners that further contaminate wastewater. The Combo unit does NOT suffer this issue. By re-blending wastewater and permeate water after the Combo process, the end-product is mains water. Cost savings are achieved through: No uncontrolled wastewater going to drain Concentrate that is reusable (the absence of impurities makes it ideal for reuse in water/drag-out rinse tanks) Combo 200-800 Front

No additional chlorides, sodium or boron affecting most effluent systems No sudden solids build-up in the wastewater (many kilos of hardness salts are dumped to drain via softener regeneration) Adept recommends an activated carbon (AC) pre-filter to remove any chlorine or organics. This helps to minimise the build-up of dirt, which eventually makes cleaning ineffective and exhausts membranes. Compared to some other filtration systems, Combos are straightforward and economical to operate and maintain. An in-built HMI/PLC, with touch-screen operation, provides timely data and maintenance updates. Due to huge variations in mains water quality across the UK, no pure water system will function identically, and this is where the Combo really comes into its own. The first process acts very much like a coarse filter, bringing feed water for the final RO process down to between 50–75 μS/CM. Water processed by the RO is far more stable without the fluctuations that mains water, softeners and RO units bring and typical outcomes range from 1-5 μS/CM. Process water becomes repeatable time after time. How important is that to your process? Adept is well-placed to assist new clients in all areas of operation requiring improved water clarity, where softeners, RO and DI processes are looked on as standard for supplying pure and ultra-pure process water for industrial use.

Combo 200-800 Back

As a proud member of ‘Made in Britain’, the trademark for British manufacturing excellence, Adept’s staff work from two UK sites – one in Wellingborough and the other in Kettering, Northamptonshire. The business designs, manufactures, commissions, installs and services a full range of in-house-produced water treatment plant and equipment – from back washable filters and water softeners to reverse osmosis (RO) and deioniser-based systems. No matter the industry, Adept will work to find the best commercial purification/filtration solution for each client. For further information about the Combo 200-800, or any other product manufactured by Adept, you can call +44 (0)1933 677181. Visit: www.adeptpwt.co.uk

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INDUSTRY NEWS

NEW ECOMETER XS DOSING SYSTEM APPLIES THE SMALLEST QUANTITIES OF ADHESIVES AND SEALANTS Dürr is expanding its dispensing technology portfolio with the EcoMeter XS, a compact microdispensing unit that automatically applies very small quantities of adhesives, sealants, and other highviscosity materials. The system primarily serves manufacturers of battery and electronic components, as well as electric motors. The EcoMeter XS supports a broad range of applications, including vehicle battery assembly, power electronics manufacturing, magnet bonding in electric motors, grease and seal applications, and small-volume potting processes. Until now, Dürr has used its EcoShot Meter dispensing technology series for these applications. However, these systems reach their performance limits when manufacturers need to apply extremely small quantities. One example is the spot application for round battery cells, where the material establishes a thermal bridge between the cell and the cooling unit. “One tenth of a cubic centimetre, applied to the front surface of the cell, is enough to establish thermal contact,” says Sebastian Jochum, Product Manager for dispensing technology at Dürr. “With the

EcoMeter XS, Dürr now offers the perfect solution for these specific requirements in the manufacture of battery systems.”

Continuous material flow eliminates refilling times The EcoMeter XS continuously meters and applies the material, eliminating the refilling interruptions associated with conventional piston dosing systems. Building on Dürr’s established large volume continuous-dosing technology used in applications such as vehicle window bonding, the EcoMeter XS brings this capability to microdispensing applications. The system supports flow rates from 0.00005 cm³/s to 1 cm³/s, while allowing users to precisely control the dosing rate when supplying material from cartridges or hobbocks. “With the EcoMeter XS, we are scaling our dispensing technology to the micro range. This allows us to offer the right dispensing solution for virtually any application volume,” says Jochum.

Low weight enables mounting on axis gantries The compact EcoMeter XS weighs between 0.8 and 1.6 kg, depending on the configuration. Its low weight allows users to install the unit on conventional robotic systems, axis gantries, and robots with low payload capacities. The EcoMeter XS therefore is ideally suited for compact production cells for battery and electronics manufacturing, electric servo motor production, and a wide range of sealing applications. A centralised dosing and process control system combines all functions to simplify operation.

Modular design increases flexibility Dürr developed the EcoMeter XS around a modular design to cover the full range of micro-quantity applications. The design supports multiple configurations and variants, allowing users to adapt the system quickly as process requirements change. The modular approach accommodates different application quantities, material viscosities, and component geometries.

EcoMeter XS completes Dürr’s dispensing portfolio The EcoMeter XS completes Dürr’s dispensing technology portfolio. Together with the proven EcoShot Meter and EcoMeter SP piston dosing systems, Dürr now provides automated solutions for applying 1K and 2K adhesives and sealants across the full range – from extremely small quantities to continuous, high-volume dispensing applications. Visit: www.durr.com

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INDUSTRY NEWS

HMG PAINTS BACKS VOLUNTEERS RESTORING HISTORIC BRITISH BUSES HMG Paints, the UK’s leading independent paint manufacturer, has supported the preservation of British Transport history and heritage with its latest donation of specialist coatings to the Town & District Transport Trust. The Trust, a volunteer-led organisation dedicated to restoring and preserving historic vehicles for future generations which cares for a collection of more than 80 historic buses, showcased their work at the Great Harwood Transport Weekend

event held over the 5th and 6th of September, bringing together vehicles and enthusiasts to celebrate decades of British Transport history. Among the vehicles that have been restored by the Town & District Transport Trust is a 1973 Leyland Atlantean, one of this county’s most recognisable doubledecker buses. After being retired from the roads after thousands of journeys the vehicle required care and refurbishment, HMG provided their support through a donation of specialist coatings to the Trust. To help bring the bus back to its historic appearance, HMG Paints donated Acrythane XSC98, a two-pack acrylic coating that is designed to provide a durable, high-gloss finish. Acrythane XSC98 was supplied in RAL 9003 and Ribble Grey, colours which were taken from HMG’s extensive colour archive which contains colours stretching back to as far as 1930. Together, the coatings provided the finish and protection required for the refurbishment, helping restore the bus back to its historic appearance. Following the refurbishment, the 1973 Leyland Atlantean was proudly displayed at the Transport Weekend, giving visitors the opportunity to see the historic vehicle and its restored appearance up close. The renovated bus joined a wide range of heritage vehicles on display across the weekend, celebrating the history of British Transport.

Speaking about the Trust’s relationship with HMG Paints, Ian Amarnani of the Town & District Transport Trust said: “We have received excellent service and support from the HMG team over the last 10 years, particularly with obtaining and matching colour codes to accurately replicate authentic liveries. We look forward to continuing to use HMG products across our future restoration projects.” Previous vehicle restorations using HMG product include a Leyland Olympian, which was restored in a special Platinum Jubilee Livery, as well as a second Leyland Olympian that was given a commemorative redecoration for the Coronation of King Charles III. Additionally, HMG also assisted in the restoration of a Halifax Joint Committee MCW Metrobus MkI, which was colour-matched to its distinctive green appearance, with the shade added to HMG’s ColourBase library and appropriately named ‘Halifax 10 Green’. The relationship between HMG Paints and the Town & District Transport Trust will be continuing beyond the Great Harwood Transport Weekend, with further projects already well underway, including the restoration of a former Ribble Motor Services Leyland Olympian. “Working with Ian and the team over the years has been a pleasure, and we’re proud to play a part in preserving these historic vehicles,” said Martyn Binnington, General Sales Manager of Commercial Transport & Distribution at HMG Paints. “We look forward to continuing our relationship and supporting many more restoration projects in the future.” This project highlights the role specialist coatings continue to play across the transport sector, from the restoration of historic vehicles through to modern commercial transport application. With decades of experience within the sector, HMG remain committed to providing coatings, colour matching services and technical expertise to help protect and maintain vehicles across the UK. Visit: www.hmgpaint.com

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INDUSTRY NEWS

Enhanced Ecoclean app

NEW FEATURES AND IMPROVED USER GUIDANCE cleaning systems visible to every user

With a revised version of the Ecoclean app for iOS and Android, the plant manufacturer is expanding the features of its digital service platform. The application enables structured, cross-site communication between plant operators and Ecoclean Service, as well as more efficient access to plantrelated data, information, and open requests. New additions include enhanced functions for data analysis and documentation, such as for the ultrasonic performance data recorded with the APM-Go measurement solution.

and allowing access to existing inquiries. This eliminates time-consuming duplicate processing and information loss. A clear chat function with intuitive selection fields is available for new messages and status updates regarding the processing status of existing requests. Colleagues can be registered via a convenient invitation function. This creates a virtual network that enables internal communication almost as if in real life. Ecoclean is actively alerted to ambiguous entries, such as a typo in the system serial number, and can automatically verify and correct or confirm them accordingly. When using the innovative APM-Go measurement solution for the reproducible and contactless recording of ultrasonic power in continuous

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simple and direct contact with the service team at the relevant location. In addition, it simplifies spare parts procurement and assists with training requests. A bidirectional real-time connection via chat function is available for this purpose, as well as video and image transmission. The Ecoclean app is now available in an updated version. In addition to a new design, the user interface has been optimized to enable simpler and more

The current version of the Ecoclean app will soon be supplemented with machine documentation. This new feature enables convenient and quick access to the respective system documentation from any device with internet access. The new version of the app for iOS and Android is available for free download in the app stores. It works on smartphones and tablets as well as on desktop web interfaces.

efficient use. This includes, among other

Contact: Ecoclean GmbH,

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www.ecoclean-group.net

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We solve our customers filtration, chemical transfer and treatment needs.

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INDUSTRY NEWS

TEXTUREJET AWARDED INNOVATE UK GRANT TO ADVANCE NEXT-GENERATION COMPOSITE SURFACE PROCESSING TECHNOLOGY TextureJet has secured a £130,000 Innovate UK grant to accelerate the development and commercialisation of its pioneering ArcSlice® surface processing technology designed to improve manufacturing efficiency, quality, and sustainability across high-growth industrial sectors. The funding has been awarded through Innovate UK’s Advanced Manufacturing Supply Chains: Potential High Growth SMEs competition, which supports innovative UK businesses with the potential to strengthen manufacturing capability, productivity and supply chain resilience.

productivity, and resource efficiency, the project aims to help manufacturers meet the demands of Industry 5.0 by achieving higher quality outcomes while reducing waste, processing times, and operational costs.

The nine-month project will focus on advancing ArcSlice, which is a new and disruptive surface finishing technology. The project will enable further development, validation, and customer evaluation of ArcSlice, ahead of future commercial deployment.

“This award is a fantastic endorsement of both our technology and our vision for the future of advanced manufacturing,” said Dr Jonathon Mitchell-Smith, CEO and Founder, TextureJet. “Innovate UK’s support enables us to accelerate the development of a highly promising technology platform with the potential to deliver significant benefits for manufacturers working with advanced materials. As industries continue to pursue higher performance, greater efficiency, and more sustainable production methods, we believe innovations such as ArcSlice will play an important role in supporting that transition.”

Building on TextureJet’s established expertise in intelligent surface engineering, the project will support advanced manufacturing of polymer and composite components by providing a new technology which will address the current industry challenges in the preparation and treatment of such materials. Polymer and composite materials are increasingly being adopted across industries including aerospace, automotive and construction due to their high strength-to-weight ratio and their lightweight, durable and corrosion-resistant properties. By addressing key manufacturing challenges around process consistency,

at TextureJet, added: “Advanced materials such as composites are becoming increasingly important across modern manufacturing, but many production challenges still remain. This project provides an exciting opportunity to further develop and validate our technology while working closely with industry to ensure ArcSlice delivers meaningful commercial and operational value. The Innovate UK award provides vital support to bring that capability closer to market.”

The project forms part of TextureJet’s broader innovation roadmap and reinforces the company’s commitment to developing intelligent, scalable manufacturing technologies that help customers improve performance while reducing environmental impact.

The Innovate UK award marks an important milestone in TextureJet’s innovation journey, accelerating the development of next-generation manufacturing technologies designed to deliver greater efficiency, improved quality and reduced waste. The project will support future commercial adoption while reinforcing TextureJet’s position at the forefront of advanced manufacturing innovation.

Dr Patrick Bointon, Chief Product Officer

Visit: www.texturejet.com

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INDUSTRY NEWS

A SHOW FULL OF OPPORTUNITIES! The Industry Meets in Guangzhou SFCHINA2026 is scheduled to take place in Halls 4.1 and 5.1, Area A of the China Import and Export Fair Complex in Guangzhou, P.R. China, bringing together professionals from across the surface finishing community. Since 1983, SFCHINA has grown into Asia’s leading industry platform, showcasing electroplating, coating applications, anodizing and surface treatment technologies and solutions. This year, the exhibition spans over 14,500 square metres, with more than 250 exhibitors from 13 countries and regions (as of August 2026) presenting their latest products and technologies. SFCHINA2026 is set to provide industry professionals with opportunities to explore innovations, exchange knowledge and expand networks in a dynamic marketplace.

Ideas That Spark Change Technical Programmes held concurrently with the exhibition will offer industry players valuable insights and opportunities for exchange. All programmes are free to attend. For details, please visit www.sfchina.net. Technology Forum: The Full Chain Evolution: Intelligent Coating Solutions Forum will be held on the first day of the exhibition, focusing on industry upgrades under the context of intelligent manufacturing, carbon neutral goals and new VOC standards. The Forum will cover 4 topics: Flexible Intelligent Coating for Large Scale Construction Machinery, Digital Coating Plants for New Energy Vehicles, Smart Energy Management

for Special Purpose Commercial Vehicle Coating Equipment and 5G + AI Intelligent Coating Quality Inspection for Rail Transit Locomotives. Experts from these sectors will present replicable mass production case studies, offering participants practical knowledge and fresh perspectives on intelligent coating. A second Surface Treatment Forum on Lithium ion Battery Copper Foil will be hosted on the second day of the exhibition, with further details to be announced in due course. Technical Seminars and Webinars: Industry experts will address key topics in the surface finishing industry, sharing innovations, practical applications and market trends to help visitors gain meaningful takeaways.

Industry Momentum in Surface Finishing SFCHINA2026 arrives at a pivotal moment for the surface finishing industry. Demand from new energy vehicles is driving lightweight, corrosion resistant finishes; the semiconductor sector is advancing precision plating for next generation chips; aerospace and electronics are seeking higher performance coatings; and sustainable construction is accelerating adoption of eco friendly processes. With the Greater Bay Area prioritizing advanced manufacturing and green materials under the China’s 15th Five Year Plan, the exhibition offers visitors a timely opportunity to engage with our platform to explore solutions, align with regulations and connect with peers.

Early Registration – Special Privileges Register now at www.sfchina.net or via our ofﬁcial WeChat account (ID: ChinaCoat_SFChina). Visitors who complete registration before September 30, 2026 can enjoy early bird discount and will be eligible to enter the Lucky Draw, a special event celebrating the 30th Anniversary of the concurrently held CHINACOAT series of exhibitions. Overseas visitors, including those from Hong Kong SAR, Macau SAR and Taiwan region, will additionally receive a complimentary digital Exhibition Directory and Welcome Gift (while stocks last), along with exclusive access to the onsite VIP Lounge. Stay updated by following SFCHINA on Facebook, X, LinkedIn and YouTube, or contact the Organizer for the latest event highlights.

PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

ONE PASS, FOUR PROCESSES: HOW WET BLASTING IS SIMPLIFYING SURFACE PREPARATION Wet blasting can deburr, degrease, clean and prepare a part for coating in a single pass. The right machine makes that result repeatable Map the route a machined component takes to coating and a familiar chain appears: deburring, degreasing, cleaning, then grit blasting to give the coating a key. Each step adds handling, queuing, floor space and risk of contamination or damage. Wet blasting collapses that chain into a single operation.

How one pass does the work of four Wet blasting suspends abrasive media in water to form a slurry, which compressed air accelerates through a blast gun onto the component. The abrasive removes the fine micro and feather burrs left by machining, with negligible dimensional change when media and pressure are set correctly. Meanwhile, the slurry scrubs away light oils, coolant residues and swarf, degreasing and cleaning the part in the same stroke.

Author: Ryan Ashworth, Head of Sales and Marketing

After a quick rinse and dry, the result is a clean, uniformly textured surface ready for coating, bonding or painting: four processes in one pass, with no dust, no solvents and far less handling.

Why control matters Combining processes raises the stakes. If one pass does four jobs, the variables behind it, from media concentration and air pressure to gun angle, traverse speed and cycle time, must hold steady from the first part to the ten-thousandth. That is where Vapormatt’s Puma+ and Cougar+ come in. The Puma+ is a compact, self-contained system with a 1.47m x 1.38m footprint,

designed for manufacturers stepping up from manual blasting. Radial, vertical, vertical-with-satellites and barrel configurations handle anything from batches of additively manufactured parts to 42 solid carbide tools at once. Up to four Mk3 blast guns, independent pressure control and stored recipes deliver the same result every cycle. The Cougar+ is built for long production runs and heavier work. With 32 standard configurations, a 1,200mm turntable and up to 1,000kg capacity, it suits aerospace components, extrusion dies and precision parts alike. A sight glass monitors media concentration in real time, while hydrocyclone and closed-loop filtration

PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

remove degraded media automatically. Robotic handling can be built inside the cabinet.

The Vapormatt difference Vapormatt has led wet blasting since the process was first developed, operating in its present form since 1978 and selling more than 2,000 machines in over 50 countries. What sets it apart is process control engineered into the hardware. Across its range, that includes a patented elutriation tower that continuously removes broken media, slurry delivery that gives every nozzle an equal supply, and pump drives and nozzle airflow monitoring that compensate for wear. Vapormatt 4.0 logs every parameter for every cycle and enables remote support. Machines can be tested on customers’ own components before leaving the factory, backed by the Vapormatt Promise that they will meet the agreed specification.

About Vapormatt

product performance, consistency and sustainability across manufacturing sectors.

Vapormatt pioneered wet blasting technology and supply robotic, automatic and manual systems for precision industries. With more than 40 years of experience, its solutions help improve

Telephone: +44 (0)1823 257976 Email: sales@vapormatt.com Visit: Vapormatt.com

For manufacturers combining processes, that depth of control is the deciding factor.

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PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

THE FINISH IS DECIDED BEFORE IT STARTS: PRE-TREATMENT AND THE PREPARED SURFACE Every surface process depends on the surface it is given. Electroplating, anodising, conversion coating, painting, powder coating and PVD all need the finish to wet the substrate and bond to it. Adhesive bonding, brazing and welding need sound metal to join. Heat treatment and penetrant inspection need a surface free of anything that will react, stain or hide what lies beneath. Pre-treatment exists to deliver that surface, and it has two distinct jobs: removing what should not be there, and conditioning what remains so that the next process can take hold. The first job is cleaning, and its failures are expensive because they are invisible. A film of oil, a residue of cleaning chemistry or a deposit left by rinse water only a few molecules thick is enough to defeat any of these processes. A contaminated part will usually go through the next process and often pass inspection at the end of the line. The defect appears later: as blistering after humidity exposure, flaking in an adhesion test, corrosion creeping from an edge, a braze joint that has not wetted, or in service, after the part has been shipped and invoiced. By then the finish has concealed the evidence, and the cost has grown with every operation added since. A good many failures recorded as plating, coating or joining defects are pre-treatment defects that have presented late.

The second job is surface preparation, and here pre-treatment goes beyond cleaning. A clean surface is not necessarily a receptive one. Etching removes a thin layer of the substrate itself, taking with it oxides, embedded contamination and the disturbed layer left by machining or forming. What remains is microscopically roughened, giving a coating or adhesive more area to grip and a texture to key into, and chemically more active, with a higher surface energy that the next process can readily wet. Alkaline etching of aluminium before anodising, acid activation before plating and the etch stages ahead of dip-applied hard coatings on optical components all serve this purpose. The etch must be controlled as tightly as any finishing step: too little leaves the surface unreceptive; too much removes material the part cannot spare or

leaves a smut that must itself be removed. Soluble salts show how such a failure develops. A coating behaves as a semi-permeable membrane: water passes through it, but salts trapped beneath cannot pass out, so water is drawn to the interface until the pressure exceeds the adhesion of the film. The salt can come from the line itself, from hard rinse water left to dry or chemistry carried forward by an inadequate rinse, which is why the protective coatings sector measures soluble salts before coating, using methods such as ISO 8502-6 and ISO 8502-9. Effective pre-treatment is therefore rarely a single operation. ASTM B322, the long-established guide to cleaning metals

Shyre Cleanliness as specified, delivered at rate. Automated cleaning systems for automotive and e-mobility components. • • • • •

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PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

before electroplating, starts from the premise that the performance and quality of plated articles depend on surface cleanliness and condition, and sets out a sequence of precleaning, alkaline cleaning and electrocleaning, usually followed by acid activation. The same logic applies whatever the next process is. Organic soils, oxides, particulate, etch products and the residues of the chemistry itself are different problems requiring different treatments, and the order in which they are dealt with matters. Each chemical stage needs a rinse after it, because chemistry carried into the next tank contaminates that tank and, in the end, the part. The chemistry can itself become the contaminant. Surfactants, silicates and phosphates are in a formulation to do work in the tank; on the part, they are residues, and some bond to the surface and are released only slowly, so removing them depends on clean, flowing rinse water and adequate contact time, not simply on another dip. In our own investigation work on precision optics, marking that looked like a cleaning failure was traced to species in the rinse water at concentrations far below anything conductivity monitoring would flag; once dried on, some such deposits cannot be removed by further rinsing at any practical purity. Prevention is the only control. Rinsing and drying are part of the pre-treatment, not an afterthought to it. After an etch, the rinse also stops the

reaction at the intended point. The final deionised rinse exists chiefly to remove the preceding mains water rinse, which removes chemistry well but marks wherever a droplet dries. It should be as pure as practicable, generally below 0.1 µS/cm; staining becomes a risk at around 0.8 to 1 µS/cm. Conductivity monitoring is the right everyday control, though not always sufficient on its own. A slow, controlled withdrawal from the final rinse then lets the water film drain from the surface rather than evaporate on it, and filtered hot air completes the drying without redepositing airborne particulate. A prepared surface does not stay prepared. Handling, airborne contamination and time in storage all degrade it, and a freshly etched surface is at its most receptive, and its most vulnerable, immediately after preparation. Particulate left on a part also becomes harder to remove the longer it sits, because its contact area with the surface grows. The most reliable arrangements prepare the part immediately before the next process, under clean conditions,

with handling engineered out rather than managed. Simple, fast checks are available and should be used. The water-break test, standardised as ASTM F22, detects hydrophobic films down to molecular layers by whether a continuous film of water breaks on the surface, and is widely used before priming, conversion coating, anodising, plating and adhesive bonding. It is a go or no-go check, less sensitive on rough or porous surfaces, and complements rather than replaces testing of the finished part. Its value is speed: a batch found wanting before the next process costs a re-clean; found afterwards, it costs the process, the part and potentially the customer. Unitech Shyre designs and builds automated cleaning, etching and pre-treatment systems for the processes that follow, from plating, coating and joining to inspection and assembly; on our dip coating lines, pre-treatment and coating are built as one machine. In every case the pre-treatment is specified against what comes next: chemistry matched to the substrate and the soil, etch stages controlled, rinse water treated and monitored, and drying controlled. A lasting finish starts with a properly prepared surface. Unitech Shyre Ltd designs, manufactures and supports automated precision cleaning, pre-treatment, dip coating and fluorescent penetrant inspection systems for the optical, ophthalmic, medical, automotive, semiconductor, aerospace, metal finishing and precision engineering sectors.

Visit: www.unitechshyre.co.uk

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Their fully Welded stainless Steel construction and Hygienic Design significantly reduces and minimises the need for extensive and time consuming cleaning operations. The units are mobile, can be fitted with extraction fan or condensate unit (as shown) and feature a self-contained water storage tank and filter tank, which effectively removes gross debris and particulates before draining. If you have similar requirements or are interested in exploring our range of equipment for the Food, Pharmaceutical, and Engineering sectors, please don't hesitate to reach out to us.

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PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

NEXT-GENERATION, PFAS-FREE VAPOUR DEGREASING SOLVENT FOR MODERN INDUSTRY EnviroTech Europe supplies high-performance precision cleaning solvents, manufactured in the UK to the highest standards in accordance with strict quality control procedures. Our customers receive premium quality, cost-effective, safe and sustainable precision cleaning solutions. Suitable for various applications across industries such as automotive, aerospace, electronics, and medical device manufacturing.

ProSolv®5408e is a next-generation, PFAS-free solvent that offers zero Ozone Depletion Potential (ODP) and low Global Warming Potential (GWP below 1), future-proofing your cleaning applications. Effectively removes organic residues and oils and is compatible with most metals and many plastics. Exceptionally low surface tension and strong solvency allows it to reach tight spaces, blind holes and micron-sized holes. It can also be used as a direct replacement for 3M™ Novec™ 72DE and 73DE. ProSolv®5408e is compatible with most solvent cleaning systems including one-tank or multi-tank immersion and vapour degreasing equipment, using ultrasonics or flush cleaning. An excellent choice for removal of a wide range of organic soils by vapour degreaser, ultrasonic cavitation, dip tank, flushing. Energy-efficient, fast processing, low solvent loss, and easy handling, reducing both environmental impact and operating costs.

THE SOLVENT OF CHOICE FOR HIGHPERFORMANCE CRITICAL CLEANING ProSolv®5408e has a unique range of characteristics which make it the vapour

degreasing solvent of choice for critical cleaning applications in the following industries: Avionics and Aerospace Electronics and Electrical Environmental General Cleaning Industrial and Manufacturing Marine and Maritime Mechanical Engineering Medical Device Manufacturing Military

FEATURES AND BENEFITS Free from Per- and polyfluoroalkyl substances (PFAS-free). Global Warming Potential (GWP) of less than 1. Non-hazardous for transportation. Non-flammable (No Flash Point). Not classified as a carcinogen. Fast precision cleaning with short cycle times, fast drying.

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PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

FRASER TECHNOLOGIES ANNOUNCES THE LAUNCH OF THE MIELE EXPERTLINE PLW 8636 Advanced aqueous cleaning for precision, repeatable and controlled industrial cleaning processes Fraser Technologies is pleased to announce the launch of the Miele ExpertLine PLW 8636, a new industrial aqueous cleaning machine available in the UK through Fraser Technologies as Miele’s UK sole partner. Designed for industrial parts cleaning using a wet chemical spray cleaning process, the PLW 8636 combines powerful cleaning performance with precise process control, process monitoring and repeatable results. For manufacturers where technical cleanliness is critical to component quality, performance and durability, the PLW 8636

provides a controlled and flexible platform for developing and maintaining an effective aqueous cleaning process.

Designed around process control The PLW 8636 combines a powerful variable-speed circulation pump with optimised spray arms and precise dosing pumps and sensors. With a maximum circulation rate of 600 litres per minute, cleaning pressure can be adapted to different components and process stages. This allows particulate and film-type contamination to be removed efficiently while providing the flexibility to clean sensitive components more gently. Process monitoring is built into the system, including spray pressure, spray

arm, conductivity and temperature monitoring, helping manufacturers maintain greater control over critical cleaning parameters.

Repeatable cleaning for technical cleanliness The PLW 8636 features a freely programmable PLC, with 26 programmes supplied as standard and capacity for up to 50 freely programmable customer programmes. This allows cleaning processes to be configured around different components, contamination types and production requirements. The machine’s fresh-water system is designed for ultrafine cleaning of precision parts, with Miele highlighting its ability to achieve the desired technical cleanliness reliably and reproducibly.

SAVE THE DATE!

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From first trial to final fluid change we: Evaluate - we evaluate your application, conduct trials and provide a range of solutions to get you the result you are looking for. Supply - your complete solution, not just the equipment but the cleaning chemicals too. Support - we continue to work with our customers on servicing, maintenance agreements, regulatory monitoring and chemical stabilisation if required.

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PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

Powerful cleaning and advanced drying

Optical instruments and glass

The PLW 8636 incorporates DryPlus hot-air drying with HEPA H14 filtration. The HEPA filter has a filtration efficiency of 99.99% according to the supplied specification.

Metalworking

Designed to provide the cleaning and drying performance required for demanding industrial applications, with VDA 19 and ISO 16232 as relevant technical cleanliness requirements for which the machine can form a basis.

Flexible industrial applications The Miele ExpertLine PLW 8636 is suitable for a wide range of industrial applications: Electronics Watch and jewellery manufacturing

Medical technology

High-purity applications 3D printing Optional passivation and an external recycling tank connection provide further opportunities to configure the cleaning process around specific application requirements.

Technical specification The PLW 8636 has a compact 900 mm wide × 1,430 mm high × 700 mm deep

net machine footprint, with the Miele specifying an additional 100 mm wall gap. Its usable wash cabinet measures 470 × 530 × 520 mm, with a 146-litre usable cabinet capacity.

Even Larger Quantities That Need To Be Cleaned? In addition to the PLW 8636, we also offer two other machine series with larger chambers for higher cycle capacities or larger geometries. Fraser Technologies can support manufacturers in evaluating their cleaning requirements, assessing the suitability of aqueous cleaning and developing the appropriate process. Talk to Fraser Technologies about precision aqueous cleaning, process optimisation and the new Miele PLW 8636. www.frasertech.co.uk

Specialists in Material Handling Solutions Product Overview Manual Monorail Systems Unit loads up to 3000kg

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Stewart Gill Conveyors Ltd have been supplying overhead conveyors into all sectors of industry for over 70 years. As a long time member of the Railtechniek van Herwijnen BV Group based in the Netherlands, Stewart Gill Conveyors can offer a comprehensive range of overhead conveyor products which are capable of handling unit loads up to 7000kg. Stewart Gill Conveyors Ltd offer complete manufacture, installation and commissioning, coupled with fully documented instruction, operation and maintenance manuals. We do:  In-House 3D CAD engineering  In-House manufactoring in the UK and EU  In-House design of PLC/PC control systems  Industry 4.0  Worldwide installation and commissioning  Remote support, service & inspection

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PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

GKN AEROSPACE RELIES ON RÖSLER’S MASS FINISHING AND SHOT BLASTING SOLUTIONS FOR HIGHPRECISION TURBINE BLADE PROCESSING For decades, the area around San Diego (CA) has been a center for the US aerospace industry. It offers highly qualified personnel as well as a large network of suppliers. At the same time, the state of California is imposing strict regulations for sustainable and resource saving manufacturing. In 2024 GKN Aerospace, a globally leading manufacturer of high-performance components and systems for the aerospace industry, who supplies customers like Pratt & Whitney, General Electric and Boeing, opened an ultra-modern factory in El Cajon. This location specializes in MRO operations (Maintenance, Repair and Overhaul) for all kinds of aircraft components. The high environmental protection standards in Southern California are in perfect synch with the sustainability offensive of GKN Aerospace. But for suppliers they can pose a real challenge: Every piece of equipment must comply

with the strict environmental standards in the state of California. But in addition, it must offer precise, reliable and highly productive performance. For the relatively complex reconditioning of turbine blades for aircraft engines the customer chose

In Rösler’s robot-guided high-pressure water jet system, the stripping of turbine blades now takes about half the time it used to. In addition, there is a reduction in chemical wastewater and contaminated coating residues.

high-performance surface finishing systems from Rösler, not only for stripping of the used turbine blades but also for the final mass finishing operation. To a large extent this decision was influenced by the positive experience the GKN Aerospace sister company in Malaysia had with comparable Rösler equipment and processes.

Innovative Rösler technologies – in perfect compliance with environmental standards The blades in aircraft engines, be it fan blades, pressure blades or turbine blades, are exposed to tremendous stress, including high temperatures, strong centrifugal force and constant vibration. Over time, such loads can cause material fatigue, micro cracks and unwanted deposits. To ensure the safety, performance and efficiency of aircraft engines, the blades must be periodically checked, cleaned and as needed, overhauled. The required technical procedures are spelled out in the repair manual for the respective engine components issued by the engine manufacturer. It stipulates that prior to visual and x-ray inspection the components must be stripped of all coatings, respectively, deposits. For these stripping operations GKN Aerospace is using a high-pressure water jet system from Rösler that produces perfect results. Since it does not require any processing media or chemicals, the stripping process with pure water is extremely eco-friendly. A further advantage of the water jet system is the automatic process water

PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

Production cells under construction: Twelve tub vibrators for the final finishing of the reconditioned turbine blades were manufactured at Rösler’s main site in Untermerzbach.

Up to six turbine blades can be mounted side by side on the turntable of the high-pressure water jet system and processed one after the other.

cleaning and recycling system that drastically reduces the overall water consumption. The final step of the overhaul operation, surface finishing of the reconditioned components, is also handled by Rösler equipment, namely 12 tub vibrators. Two process water cleaning and recycling systems, each equipped with two centrifuges, are cleaning the process water contaminated with solids and sending the cleaned water back to the mass finishing machines for reuse. A digital monitoring tool from Rösler Smart Solutions is continuously checking the quality of the process water. And in case of deviations from the set values it recommends corrective actions.

Effective and sustainable stripping with a highpressure water jet system To allow an objective evaluation of their condition, in a first step any coatings/ deposits on the blade surface must be removed. Until now, this was done using chemical stripping, which involved substances that had to be disposed of in a complex and costly process. At its sister plant in Malaysia GKN Aerospace has been using a Rösler high-pressure water jet stripping system for several years. Based on the good experience in

Malaysia the plant in El Cajon decided to use the same stripping technology. “For GKN Aerospace we supplied a so-called ALS system, a robotic blast system equipped with a rotary table. Up to six turbine blades can be clamped on the table and are then processed, one after another,” explains Tobias Maaser, Sales and Project Engineer Shot Blasting, and as such exclusively working with customers from the aerospace industry. One stationary and one rotary nozzle ensure effective, all-around treatment of

the titanium components. “The highpressure water jet technology uses a combination of high energy in combination with a liquid medium, namely water. This penetrates the surface and chips away the surface coatings. Water jetting is much faster than the previously used chemical stripping method.” Actually, it is twice as fast and extremely eco-friendly, because it completely eliminated the disposal of numerous batches of chemical waste and coating residues.

Project Engineer Salvador Jaimez-Meneses stands in front of the enclosed mass finishing systems at the GKN Aerospace facility in San Diego, California.

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A look inside the tub vibrators: Each unit can process two parts simultaneously, separated by partitions. The goal of the machining process is to achieve a Ra value of 0.6 µm.

The highly regulated aerospace industry requires not only effective and sustainable equipment technologies; equally important is the complete documentation of all manufacturing processes. The robotic stripping of the turbine blades is fully automated, and the entire process, including the computer managing the robot movements, is controlled by a supervisor system (PC supervisor master). The supervisor monitors all process parameters in real time, including all valves, maintenance components and processes. The entire process status is digitally displayed. Based on their serial numbers a barcode scanner assigns the respective processing program to the components, thus allowing complete documentation of every single process step. Because the PC supervisor monitors all process parameters and makes sure that their values remain within set limits, complete traceability of the entire process and, therefore, absolute process safety is guaranteed. This is particularly critical for shot blast processes, because one faulty operational parameter can damage or even destroy a component.

Ergonomic, precise finishing in tub vibrators with a minimum of resource input For another stage of the reconditioning operation at the El Cajon location, namely the surface refinement of overhauled turbine blades, the customer is also using a Rösler system. With this operation the savings in processing time and use of processing media are even more impressive. Until recently the last step, surface finishing of the reconditioned components, was done in somewhat obsolete machines, supplied by a competitor, and with comparatively low-quality processing media. “The finishing process as such is clearly prescribed, and we were not permitted to make any changes,” explains Michael Striebe, Global Sales Expert at Rösler, who is responsible for managing mass finishing projects in the aerospace industry. “However, we completely replaced the old finishing equipment and are utilizing our own high-quality processing media, with astonishing success: Through the higher efficiency

of our tub vibrators and grinding media perfectly matched to the finishing task, we could reduce the media consumption by 30 percent. And processing times are 50 percent shorter than before.” But the new mass finishing vibrators are not only designed for high efficiency but also offer optimized ergonomics. Pairs of two tub vibrators share one pedestal. This shortens the distance the machine operator has to walk. For noise protection, a key consideration of the project, the mass finishing machines were completely enclosed with suitable noise absorbing cabins. In each tub, equipped with dividers, two work pieces can be processed at the same time without touching each other. With a suitable supervisor system the entire finishing process is monitored and all process stages documented. The specified finishing goal is a surface roughness value of Ra = 0.6 µm (24 micro inches). A big step towards improving the sustainability of the mass finishing operation is the switch from using fresh water for every single finishing cycle to cleaning and recycling the process water.

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PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

For this purpose four fully automatic centrifuges were installed for cleaning the process water and pumping it back to the mass finishing system for reuse. Depending on the actual water demand one or two of these centrifuges can be turned on or off, in line with the “master & slave” principle. Michael Striebe from Rösler comments: “Recycling of the process water had a real positive impact on the CO2 footprint of the entire mass finishing operation. With the twelve finishing vibrators the customer lowers his consumption of fresh water by roughly 1,500 liters every hour. The cleaned and recycled process water has a usable life of about three months, before it must be replaced. This is a real breakthrough for sustainability at GKN Aerospace, and we at Rösler are proud for having played a key role in this project.“ The process water cleaning & recycling system is controlled by the “Advanced” version of the Rösler Smart Solutions (RSS) software. This digital tool checks the condition of the process water and recommends corrective action, whenever predefined values of certain water parameters are out of the

acceptable range. The comprehensive monitoring of the process water conditions resulted in additional savings in consumables consumption, especially the compound usage. Compared to the exclusive use of fresh water the process water recycling system helped reduce the overall compound consumption by around 90 percent.

One supplier, two surface treatment technologies: Rösler supplies total solutions Salvador Jaimez-Meneses, senior manufacturing engineer at GKN Aerospace at the plant in El Cajon explains: “Rösler was chosen for the vibro and HP projects, because the company worked closely with our engineering team to develop solutions that are perfectly adapted to our requirements.” He continues: “While other suppliers only offered standard equipment without consideration of our specific technical needs, Rösler provided professional support during the entire planning and validation phase. The Rösler engineering team was actively involved in adapting

A big step towards improving the sustainability of the mass finishing operation is the switch from using fresh water for every single finishing cycle to cleaning and recycling the process water. For this purpose the plant is equipped with four fully automated centrifuges.

the blast and mass finishing machinery to our requirements, including optimization of the ergonomics of the vibratory tubs. The ergonomic improvements are based on a recommendation by our sister plant in Malaysia, especially, the people who are operating the machines. This active participation of GKN Aerospace personnel helped to ensure that the Rösler equipment fully meets our production requirements and quality standards.” But it was not only the close cooperation with the experts at Rösler that convinced GKN Aerospace to choose this German supplier with its subsidiary company in the United States. The fact that Rösler was the only company that could offer high-pressure water jet blasting, mass finishing machinery as well as the required processing media and services from one single source, also played a key role. Salvador Jaimez-Meneses at GKN Aerospace concludes: “Throughout the entire project Rösler provided exemplary support. If we had to do it all over again, our preferred supplier would be Rösler.” For more information, please go to: www.rosler.com

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PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

TENABLE SCREW ADDS CLEANING FLEXIBILITY WITH MODIFIED ALCOHOL TECHNOLOGY For precision component manufacturers, cleaning is more than just a processing step. Surface cleanliness can influence component quality and functionality, affect subsequent manufacturing processes and, ultimately, determine the performance of the finished component. For UK precision engineering specialist Tenable Screw, meeting demanding cleanliness requirements is an integral part of its manufacturing operations. The family-owned company manufactures millions of high-precision CNC-turned and milled components each year across three UK sites, serving sectors including automotive, aerospace, medical and defence. With a particularly strong focus on electrical connectors, effective degreasing and technical cleanliness are essential to maintaining the quality and performance of its components. The company had already established three closed degreasing systems using DOWPER™* MC, virgin-grade perchloroethylene (PERC), one at each site. As production volumes increased, however, Tenable Screw needed additional cleaning capacity. Rather than simply adding another machine using the same technology, the company saw an opportunity to broaden its process capability with modified alcohol solvents. In March 2024, a Karl Roll RCTS Advantage 2 closed vacuum cleaning system was installed at the company’s London headquarters, operating with DOWCLENE™* 1601 modified alcohol solvent. The decision was driven not by a need to replace PERC, which continues to meet many of the company’s cleaning requirements, but by the value of having

two complementary technologies available. The combination gives Tenable Screw greater flexibility to select the cleaning process according to individual customer and application requirements. DOWCLENE™* 1601 can effectively remove oils and greases as well as certain polar contaminants, including cooling emulsions, and solids such as particles and abrasives. The vacuum system also incorporates distillation for continuous recovery of used solvent, helping to reduce solvent consumption and waste. The intention was initially for the new system to operate as a secondary unit during a six- to twelve-month transition. In practice, the implementation progressed considerably faster, with Tenable Screw moving its primary cleaning workload to the new machine within a month of installation. Operationally, the additional machine has made a significant difference. When the two systems are operated in parallel, Tenable Screw has doubled its weekly cleaning throughput, helping the company keep pace with growing demand while creating additional capacity for planned maintenance. Through SAFECHEM’s COMPLEASE™ chemical leasing model, Tenable Screw

benefits from an integrated service package covering both its existing PERC operations and its new modified alcohol system. For a fixed monthly fee, the package includes solvent supply, used-solvent collection, monitoring, waste management and technical support. The predictable ongoing costs, combined with access to technical expertise to support process efficiency and optimisation, give the company greater confidence in managing its parts cleaning operations. By combining established PERC technology with modified alcohol cleaning, the company has created a more adaptable cleaning operation – one capable of responding to different component, customer and industry requirements while supporting higher production volumes. As precision manufacturers face increasingly varied cleanliness specifications and growing expectations around process efficiency and environmental responsibility, having flexibility within the cleaning process can be as important as the cleaning performance itself. Email: r.starkey@safechem.com Telephone: +44 (0) 1384 296613 Visit: www.safechem.com

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PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

INTELLIGENT SURFACE ENGINEERING BRINGS GREATER CONTROL TO PRECISION DEBURRING Precision deburring continues to present challenges in the manufacture of high-value components, especially when advanced materials and complex geometries, such as intersecting holes, demand dependable cross-hole deburring. For surface engineering professionals, the challenge is not simply removing unwanted material but achieving a consistent edge profile while preserving the integrity of the component. Many deburring operations remain manual, making quality dependent on operator experience while also limiting production capacity. An ageing workforce, widening skills gaps and the inability to run processes unattended are increasing demand for automated alternatives. These pressures are encouraging manufacturers to treat deburring as a controlled surface engineering operation, with repeatability considered alongside productivity. TextureJet is addressing these challenges through software-defined surface engineering. Its integrated technology platform combines hardware, software and AI with electrochemical jet machining (ECJM), enabling manufacturers to automate material removal rather than rely on mechanical force or operator judgement. ECJM directs a controlled stream of

electrolyte onto a precise location while applying an electrical current to dissolve the material. Software-defined toolpaths and process parameters determine where machining occurs and the resulting geometry. This makes the platform readily adaptable to automated production, including repeatable and lights-out processing. The targeted nature of the process brings a further dimension to precision finishing. Rather than applying a general treatment across a component, material removal can be directed to a defined edge or feature. For intricate parts, this creates an opportunity to address local finishing requirements through a digitally controlled process. With no mechanical contact between the tool and workpiece, ECJM avoids mechanically induced deformation and stresses during material removal. It is particularly suited to difficult-to-machine materials, including nickel-based superalloys, where maintaining surface integrity is an important consideration. Recent TextureJet research has demonstrated the advantages of ECJM for edge-break treatments on these materials. Building on its 2024 white paper, the latest study indicates that the technology can achieve up to four times greater precision than manual brush deburring and nearly twice the precision of automated brush processes.

For manufacturers, consistent edge profiles can reduce rework and improve component reliability. The value extends beyond an individual finished part: greater consistency helps make deburring a more predictable stage of production, supporting confidence in the quality of subsequent components and batches. Digital process recipes can be repeated across components and production batches, reducing reliance on individual operator technique. Once an appropriate recipe has been established, manufacturers can apply the same defined toolpaths and parameters to recurring finishing requirements. The electrolyte is continuously filtered and recycled, supporting a more resourceefficient approach to surface processing. This reuse places electrolyte management alongside precision and automation as a practical consideration when assessing the process. By combining hardware, software and AI with accurate, non-contact material removal, TextureJet is positioning surface engineering as an automated, repeatable and digitally controlled element of advanced manufacturing. Visit: www.texturejet.com

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PRECISION WITHOUT COMPROMISE: VIXEN’S EXPERTISE IN WET BLAST CLEANING Repeatable performance across shifts and operators

As industries continue to demand cleaner components, extended service life, and greater process consistency, surface cleaning technology has never played a more critical role. At Vixen Surface Treatments, wet blast cleaning is not an adaptation of existing processes—it’s a proven surface enhancement technology, engineered from the ground up to deliver controlled, repeatable results across a vast range of materials and applications. With over 30 years of experience in the design and manufacture of surface treatment systems, Vixen has become the global leader in wet blast cleaning equipment—providing efficient, environmentally responsible solutions trusted by some of the world’s most advanced manufacturers.

Designed for Cleanliness. Engineered for Control. Wet blast cleaning uses a water borne slurry of fine abrasive to remove corrosion, coatings, oxides, and contaminants, while gently cleaning and conditioning the underlying substrate. The result is a uniform, contamination free surface, free from dust and static build up. Vixen systems deliver: Consistent cleaning quality part after part

Controllable parameters—media concentration, flow rate, and blast pressure Safe, no-dust operation in a sealed, clean environment From aerospace components and turbine blades to automotive parts, stainless fabrications, and precision tooling, Vixen’s technology ensures every surface is prepared for its next stage— whether that’s inspection, coating, bonding, or service.

Advanced Wet Blast Cleaning Systems At the core of Vixen’s portfolio is the Aquablast range, offering manual, semi automated, and fully integrated cleaning systems. Each is engineered for efficiency, long service life, and easy maintenance. Key features include: Balanced slurry flow for even finish distribution High efficiency pumps for consistent media delivery

PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

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Inline and Multi Stage Cleaning Solutions For high volume applications, Vixen provides inline and continuous wet blast cleaning systems, integrating cleaning, rinsing, and drying into a single automated line. Such systems are ideal for: Aerospace and automotive MRO facilities

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Your Partner for Cleaner Performance At Vixen Surface Treatments, wet blast cleaning is more than a process—it’s a partnership built on understanding each customer’s requirements and delivering long term performance. Whether restoring precision components, preparing surfaces for coating, or ensuring ultraclean finishes in production, Vixen continues to set the standard for wet blast cleaning technology worldwide. Discover how Vixen Wet Blast Cleaning can transform your surface preparation process below: www.vixenaquablast.com

PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

PRECISION CLEANING FOR HIGH-VOLUME MEDICAL INJECTION MOULDED COMPONENTS A collaboration between UK plastic injection moulders OGM and industrial cleaning specialist Turbex demonstrates how precision cleaning technology can be integrated into the injection moulding process for medical plastics. The project highlights how scalable cleaning systems can deliver consistent surface cleanliness for high-volume production.

As medical device manufacturing expands, surface cleanliness requirements are becoming increasingly critical. Components produced through plastic injection moulding must often meet strict contamination standards before assembly or packaging, particularly when used inside the human body. A recent project involving UK plastic injection moulders, OGM, and the industrial cleaning specialist Turbex, demonstrates how precision cleaning technology can be integrated into the high-volume production of medical injection moulded components.

Medical Plastics and Surface Cleanliness Oxford-based OGM provides full-service plastic injection moulding, mould toolmaking, assembly and finishing for a range of industries. The company operates Class 7 (ISO 10,000) cleanroom assembly facilities, enabling the manufacture of medical-grade plastics for global OEM customers. When OGM secured a contract to produce a disposable medical device, the project introduced a new requirement within the injection moulding process: post-process precision cleaning.

PRETREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING

Unlike many injection moulded components, which are typically supplied without washing or degreasing, the device required complete removal of processing residues, mould-release oils and airborne particulates. Achieving the required level of cleanliness across thousands of medical-grade plastic parts required a robust, repeatable cleaning solution.

Evaluating Cleaning Technologies

volumes of identical plastic injection moulding components. Instead, testing at Turbex’s Cleaning Technology Centre identified a precision cleaning system combining immersion, ultrasonic energy and basket rotation as the optimal approach. The selected MAFAC Java system integrates washing, rinsing and drying within a single chamber. The rotating basket ensures that all surfaces of the injection moulded components are evenly exposed to the cleaning medium, improving contaminant removal while enabling hundreds of parts to be processed in a single cycle.

The installation requires a significantly smaller footprint—around 2 m² compared with approximately 14 m² for the alternative—and delivers around 20% lower energy consumption. The investment cost is also three to four times lower. Importantly, the modular system allows cleaning capacity to scale alongside production. As the output of medical plastic components increases, additional machines can be installed to support the growing manufacturing programme.

To develop the process, OGM partnered with Turbex to evaluate industrial cleaning methods. Initial discussions centred on a large multi-stage ultrasonic cleaning line.

Efficiency and Scalability

The project highlights how modern precision cleaning technology can meet the stringent surface cleanliness requirements of today’s medical plastics and injection moulding applications.

However, cleaning trials showed that ultrasonic tanks alone would not provide the most efficient solution for large

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ELECTROPLATING, ANODISING & GALVANIZING

ANODISING, ELECTROPLATING OR BLASTING? SPECIFY THE FINISH BEFORE THE PART CROSSES A BORDER A buyer specifies black anodise on an aluminium bracket because the last bracket was black anodised. The part passes goods in, ships to an assembler in Germany, and starts to pit eighteen months into service on a coastal site. Nothing went wrong at inspection. The finish was wrong for the job from the moment someone wrote it on the drawing. You can avoid that by working through four questions in order: substrate, duty cycle, cosmetic requirement and volume.

1. Substrate narrows the list Anodising works on aluminium, titanium and magnesium. Steel will not anodise. Wrought 6000 series alloys anodise clean and take dye without streaking. High silicon die cast alloys such as LM24 and ADC12 come out grey and patchy, because the silicon particles do not oxidise with the aluminium around them. If your cosmetic spec calls for uniform black on a die casting, change the alloy or the finish before you cut the tool. Steel parts go to electroplating, most often zinc or zinc nickel with a trivalent passivate, or to blasting followed by paint or powder. Plastics can take a plated finish too. The plating line etches ABS or PC/ABS, seeds the surface with a palladium catalyst, lays down electroless nickel or copper, then builds copper, nickel and chrome on top. Ask your moulder for a plating grade resin. Glass filled and high flow grades lose adhesion. Blasting on its own gives steel no corrosion protection. Treat it as preparation, or as a texture under anodise.

2. Duty cycle picks the process Wear. Hard anodise (MIL-A-8625 Type III, or ISO 10074) builds 25 to 75 µm of oxide at around 350 to 500 HV. About half of that thickness grows outward from the original surface, so machine bores and threads to a pre finish size or mask them. Corrosion. For steel outdoors, specify zinc nickel with a trivalent passivate and state the hours to red rust in neutral salt spray to ISO 9227. A number gives the finisher and your inspector something to test against.

Load. Steel above about 1,000 MPa tensile strength picks up hydrogen in the plating bath. Specify an embrittlement relief bake to ISO 9588 and put the maximum delay between plating and baking on the drawing. A thickness gauge will not catch a missed bake. The fastener cracks later, under load, in someone else’s plant.

3. Cosmetic requirement sets the tolerance Anodise colour shifts with alloy, bath age and sealing. RAL and Pantone references do not transfer well to dyed aluminium, so agree a physical master sample and a colour tolerance with your finisher. Bead blasting before anodising gives a satin surface and hides extrusion die lines. Chrome on plastic suits trim and bezels where weight matters. Every anodised or rack plated part carries a contact mark where the jig held it. Mark the zones where a contact mark is acceptable. Leave them off the drawing and the finisher chooses, based on what jigs easiest.

4. Volume decides rack or barrel Small steel parts in volume go through barrel plating. Cost per part stays low and every piece carries tumble marks. Cosmetic parts need racking, which adds handling cost to each part. Most anodising runs on racks, so jig design sets how many parts fit per load and where the marks fall. At prototype volumes, finishers often charge a minimum batch, so ask before you split an order into small call offs.

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ELECTROPLATING, ANODISING & GALVANIZING

Decision table Substrate

Main duty

Wrought aluminium (6000 series)

Wear, sliding contact

Wrought aluminium

Indoor corrosion, colour

Finish to specify

Write on the drawing

Hard anodise, MIL-A-8625 Type III or ISO 10074

Oxide thickness, pre finish dimensions, masked features

Sulphuric anodise, MIL-A-8625 Type II or ISO 7599, dyed and sealed

Master sample, seal method, contact mark zones

High silicon die cast aluminium (LM24, ADC12)

Corrosion, uniform colour

Blast, chrome free conversion coat, then powder coat

Alloy grade, blast media, coating spec

Carbon steel

Outdoor corrosion

Zinc nickel with trivalent passivate

Hours to red rust in neutral salt spray to ISO 9227

Steel above 1,000 MPa tensile

Structural load

Zinc nickel plus embrittlement relief bake

Bake to ISO 9588, maximum delay from plating to bake

ABS or PC/ABS

Cosmetic trim

Steel before Coating paint or powder adhesion

Copper, nickel and chrome on plastic

Plating grade resin, adhesion and thermal cycle test

Abrasive blast

Cleanliness grade to ISO 8501-1 (e.g. Sa 2½), profile, media

Pretreatment decides whether the finish holds When a finish lets go in service, trace it back and the cause often sits upstream of the tank. Three prep faults come up again and again at inspection. Residue. Machining coolant, drawing lubricant and die release agent all have to come off before the part meets an anodising or plating bath. On die castings, release agent trapped in porosity bleeds out during processing and leaves blisters or bare patches. Specify the degreasing and etch stages, and ask the finisher for a water break test record on the batch. Cross contamination. Grit used on carbon steel embeds iron in aluminium. After anodising, those particles show as rust spots. Put “dedicated media for nonferrous parts” on the purchase order. Delay. Blasted steel flash rusts within hours in a damp shop. Plan blasting and finishing into the same shift. For steel going to paint or powder, specify the cleanliness grade to ISO 8501-1 and the surface profile, rather than “shot blast” on its own.

Holding traceability when the part crosses a border AS9100D treats anodising and plating as special processes. Clause 8.5.1.2 requires the processes to be validated, and clause 8.5.2 requires you to keep product identified and traceable through every stage. Many aerospace primes also expect Nadcap accreditation for chemical processing. You carry the most risk when a part is finished in one country and assembled in another, because each handover is a chance to lose the link between a part and its process record. Five controls keep that link intact. 1. Cite the standard, type, class and revision. An assembler in the US reads “hard anodise” as MIL-A-8625 Type III. A UK finisher may work to ISO 10074. Put the specification number, type, class, thickness and revision on the drawing so both sides read the same requirement. 2. Require a certiﬁcate of conformity per batch. It should carry the finisher’s approval reference, the line, the process date, thickness readings, seal test result and the specification revision.

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3. Keep lot identity through consolidation. Export packing often merges several releases into one shipment. Bag and label each lot on its own so the assembler can match every part to its certificate. 4. Check the chemistry for both markets. UK REACH and EU REACH have run as separate regimes since January 2021. Hexavalent chromium processes, such as chromic acid anodising and some passivates, need authorisation under the regime where the finishing happens, and a growing number of customers refuse hexavalent treated parts whatever the legal position. Trivalent and chrome free processes remove the question where the duty allows.

team checks thickness and certificates before parts ship. An overseas assembler auditing the chain then works from one supplier’s file instead of chasing three.

5. Repeat ﬁrst article inspection when the ﬁnisher changes. AS9102 treats a change of process source as a trigger for a new or partial first article inspection. Moving work to a cheaper line abroad resets the evidence.

Author Eliot Crossley writes on manufacturing and surface ﬁnishing for Coler Supply Solutions, an ISO 9001:2015 certiﬁed contract manufacturer in Atherstone, Warwickshire. coler.co.uk | 01827 712910 | eliot@coler.co.uk

Coler Supply Solutions quotes casting, machining and finishing on one order from Atherstone. Anodising, sandblasting, plastic electroplating and metal electroplating run at partner plants certified to AS9100D and IATF 16949, and Coler’s own quality

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TESTING & MEASUREMENT

FIRE IT RIGHT! Nail Your Vitreous Enamel Furnace Monitoring Every Time For anyone involved in vitreous enamel (porcelain enamel) a critical need of any firing process is the ability to measure and control both process and product temperature. The temperature control of the firing application, typically between 750 and 950 °C is critical to ensure that the powdered glass “Vitreum” fuses correctly to the substrate. Aesthetic and functional properties of the vitreous enamel surface coating are very temperature dependent. Temperature and rate of temperature change of the product will influence the melt, flow and fusing characteristics of the final coating and its performance. The PhoenixTM ‘thru-process’ temperature profiling system used in the paint and powder coating markets comes with an option specifically designed for the challenges of the vitreous enamel process. The PTM1200 multi-channel data logger (6-20 thermocouples) is able to monitor multiple points on either the product(s) or in the furnace environment with an accuracy of +/- 0.3 °C and sampling rate of down to 0.2 s to give high resolution profile data. The thermal barrier (TS01-125) protects the data logger as it travels through the furnace. With a typical protection of 1 hour at 800 °C the thermal barrier keeps the data logger below its maximum operating temperature of 80 °C to guarantee measurement accuracy and prevent thermal damage. The thermal barrier employs dual thermal protection using a combination of high-performance microporous insulation and a phase change heat sink. Despite the high protection the barrier is compact 125 x 240 x 588 mm (h x w x l) and weighs only 13 kg. Temperature measurement is achieved in-process typically with short type K thermocouples attached, to key parts of the product, record temperature during the journey at specified intervals recording the accurate temperature of the product/ enamel surface interface. The thermocouple of choice for enamel firing is an exposed junction thermocouple. The thermocouple is insulated either by a high temperature Nextel or Mineral insulated sheath protecting the core thermocouple wires. Complying to ANSI-96.1 the thermocouple accuracy is certified to +/-0.4% of the temperature measured or +/- 1.1 °C (whichever is greater). For a vitreous enamel firing temperature of 800 °C the measurement accuracy of the system, which is the sum of data logger accuracy and thermocouple accuracy, is therefore ±3.5 °C.

Thru-process Monitoring Solutions for Paint & Powder Coating Ovens Temperature Profiling Systems

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TESTING & MEASUREMENT

significantly overcome some of the inherent problems experienced by the application and identify the potential root cause(s). A critical component of the vitreous enamel profiling system is the profile analysis software such as Thermal View Finishing software. Designed specifically for the needs of the coating market it allows not only the set-up/download of the data logger but the raw process data to be converted into meaningful information. Such information can be used to understand exactly how the process is operating, allow informed changes and provide certified evidence to prove to others the quality you are providing. From the thermal profile trace a full understanding of the firing conditions experienced by the product can be reviewed and analysed in a clear and accurate fashion. Such information can help

After corrective actions have been completed the temperature profile can be rerun to check that firing anomalies are resolved. Obtaining the thermal profile “Thermal fingerprint” of the product/process gives the production management and or quality team invaluable insight into how the process is performing against specifications to guarantee product quality and efficient furnace operation. PhoenixTM your Furnace to Find, Fix and Forget your Firing problems! www.phoenixtm.com

Automated Water & Effluent Ltd Get in touch for a quote today! Automated Water & Effluent Ltd have been supplying process control equipment to the metal finishing and surface finishing industry.

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TESTING & MEASUREMENT

SAME GLOSS, DIFFERENT FINISH A high gloss powder coated panel can pass its gloss check yet still draw a complaint about how it looks. Dawn King of Rhopoint Instruments explains why that happens and which measurements show the difference.

How a finish is judged A customer judging the quality of a high gloss part examines the reflection in it. A deep, clear reflection is perceived as higher quality, while a rippled or distorted one can be perceived as lower quality.

ACT#4 (left) shows an orange peel ripple in the reflection; ACT#10 (right) gives a straight, clean image. Values are the average of five Rhopoint IQ readings on each panel.

Measuring the reflection DOI: how sharply a reflected image appears. Whether the edge of a light fitting stays crisp in the surface or softens. A high gloss coated alloy wheel.

What a gloss reading does well A glossmeter measures how much light returns from the surface at the mirror angle, traceable to a national metrology institute (NMI). It is the established way to hold a gloss level from batch to batch. What it reports is the quantity of reflected light, while the customer is judging the reflection.

RIQ: how much orange peel distorts the reflection. The ripple that bends a reflected image out of shape. Rspec: how crisp the highlight is. Peak gloss measured over a very narrow angle. It is very sensitive to surface texture and can be used to identify subtle differences between smooth surfaces. All three are measured alongside gloss, so existing gloss specifications still apply.

Why gloss is not enough

From a number to a process change

Orange peel reduces appearance quality without affecting the gloss reading. A rippled part can therefore pass the same gloss check as a good one.

A number for each fault gives the process engineer somewhere to start. Low RIQ usually points to application: coating flow, particle size or cure.

Two panels, one gloss reading At Rhopoint’s factory in St Leonards-on-Sea, two ACT powder coated test panels were each measured five times with a Rhopoint IQ. At 20 degrees, the angle used for high gloss, they gave near identical gloss values of 87.1 and 87.8 GU. At 60 degrees the panel with the poorer finish, ACT#4, averaged slightly higher: 93.5 GU against 92.9. In the reflection, ACT#4 showed a visible ripple of orange peel while ACT#10 gave a straight, clean image. RIQ averaged 57.7 on ACT#4 against 94.1 on ACT#10. Rspec, the peak gloss measured over a very narrow angle, was 42.4 on ACT#4 against 79.8 on ACT#10. ACT#4 was also less consistent. Across its five readings RIQ ranged from 50.2 to 64.1, while ACT#10 stayed between 92.6 and 95.1. On gloss alone, the panel with the visible defect scores as well or better.

The same readings, taken before and after a change to an oven profile, a powder batch or a pre-treatment stage, show whether the change improved the finish. An RIQ limit set beside the existing gloss specification gives the production line a figure to check finished parts against. Gloss remains the right check for gloss level. DOI, RIQ and Rspec describe what the customer sees in the reflection.

Contact - Rhopoint Instruments Ltd Telephone: +44 (0)1424 739 622 Email: sales@rhopointinstruments.com Visit: www.rhopointinstruments.com/product/rhopoint-iq-2060-85-gloss-haze-doi-meter/

PAINT & POWDER

ADVANCING INDUSTRIAL FINISHING THROUGH ROBOTIC SPRAY-PAINTING AND SMART PAINT SYSTEMS Sedco Limited are a UK based company who specialise in automatic and robotic spraypainting systems together with offering paint technicians training courses on application and robot painting. Our facility offers a fully operational paint and coating laboratory together with ABB and Fanuc spraying robots. The robots can be demonstrated using Electrostatic automatic guns or Electrostatic Bells. We are equipped with a full range of application equipment for brand leading suppliers such as Binks, Ransburg and Wagner. Our lab staff have over 100 years collective experience in application technology. The Sedco lab is equipped with almost every type of application equipment available including Airless, Air Assisted Airless, Electrostatics, Gear Pump 2K, Closed Loop 2K together with manual 2K system for all industrial applications. In addition to a full range of application equipment and Robots Sedco also supply and install paint circulating systems and paint pumps, we have installed “Smart”

Paint kitchens that can reduce energy costs and pump maintenance. The importance of a correctly sized and installed paint circulting system can’t be understated. Paint needs to be circulated at a certain speed in order to ensure that the paint stays in suspension, this maintains the properties of the coating and and reduces the shear effect on the paint. Several important parameters need to be considered, in additon to paint circulating speeds, pressure drop also needs to be factored in to ensure the correct pressue is available in the required quantity at the point of use. Telephone: 10942 673184 Email: sales@sedco.co.uk Visit: www.sedco.co.uk

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To advertise in these pages under an existing heading or one of your own choice please call Nigel on 01442 826826 or email nigelbean1@aol.com 72

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Surface World October 2026