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METALWORKING

» With the upgrade to PRIMETREAT™ SZR 101/SU nanotechnology there was improvement of safety for the operators since PRIMETREAT™ SZR 101/SU has a lower risk classification compared to the previous technology used

» Increase in corrosion protection (salt spray test) performance

» Reduced work temperature and maintenance for the complete line

» Elimination of sludge in the conversion stage

CONVERSION COATINGPRIMETREAT™ SZR 101/SU

THE SOLUTION

Quaker introduced PRIMETREAT™ SZR 101/SU which uses nanotechnology instead of the traditional zinc phosphate technology. As a first step, Quaker prepared standard panels to evaluate the corrosion resistance in a Salt Spray Chamber (SSC). Customer specification was 400 hr (SSC).

In the meantime the Health & Safety profile of the product was approved by the customer’s Safety Department. Following successful lab tests, the second step was to perform a preliminary industrial trial on 200 refrigerators, using a rinse bath with demi water in the conversion stage. Three months later, the line was started with the new technology. As a result the following savings were achieved:

CHALLENGESThe Italian factory of a global home appliance company producing refrigerators was looking for a supplier to help:

» Reduce the costs maintenance

» Eliminate the sludge coming from their traditional Zinc Phosphate process

» Reduce the working temperature for cost saving

» Reduce the general risk classes of the chemicals used in the pretreatment area

PREVIOUS TEchnOlOgy PRIMETREAT™ SZR 101/SU

cost of chemicals for pre-treatment 0,027 €/m2 0,029 €/ m2

Total cost of chemicals for pretreatment 800.000 pieces x 4 m2/Refr. x 0,027 €/m2 = 86.400 €/year

800.000 pieces x 4 m2/Refr. x 0,029 €/m2 = 92.600 €/year

cost of energy 76.200 €/y 4.000 €/y

cost for maintenance in the conversion stage

200 h/year x 25 €/h = 5.000 €/year 0

cost of Demi water 0 1.800 €/year

Treatment of sludge 16.000 €/year 0

Total costs 183.600 €/year 94.400 €/year

Savings 183600 – 94400 = 89.200 €/year

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METALWORKING

CONVERSION COATINGPRIMETREAT™ SZR 101/SU

THE PRODUCT

PRIMETREAT™ SZR 101/SU is a water-dilutable, Zirconium-based nanotechnology conversion coating for pre-painting (in this case for powder paint).

» Concentration range 1,5 - 4% » Work Temperature 25 - 35°C » Work Pressure 0,5 - 1,5 bar » Work Time 45 sec. - 180 sec. » Make-up water hardness: Demi water

The benefits of this product are:

» Lower risk classification » Use at room temperature (25°C) » No sludge / no maintenance » Performance equivalent to Zinc phosphate

technology

THE EXPERTISE

Surface treatments represent a very minor part of the total steel processing cost, typically less than 1%. This case illustrates the importance of the correct selection of the surface treatment. The impact of the fluid can be a multiple of its costs, making the price of surface treatment insignificant. That is why Quaker focuses on developing fluids with the highest performance without compromise. Fluids that sharpen your competitive edge.

PROCESS AND EQUIPMENT

InDUSTRIal PRE-TREaTmEnT lInE

materials 100% cRS

Operation conversion coating

Pressure 1 bar

Temperature 55°c

Total Vol. of degreasing baths 7 m3

Water hardness Demi water

concentration 25 g/l