High performance - precise metering guarantees process reliability

With its new FlexKorr process, the company has been providing flexible surface coating for the last two years. Due to increasing demand, the existing plant was upgraded and production capacity more than doubled: The new plant, reequipped with its flexible corrosion protection production facilities, was inaugurated on 19.01.2010. The Holzapfel Group developed the new FlexKorr process in close cooperation with a process supplier and a customer. Treated materials, for example piping and tubing can be formed and bent. The corrosion protection provided by the coated surfaces remains completely in place.

Maximum effort was required from all those involved to ensure that the inauguration and, in particular, production could start-up by the end of January 2010. A particular challenge in upgrading the coating plant was the short delivery period. The decision to upgrade the plant was only taken in November 2009, and the target was production by the end of January 2010. This is where ProMinent demonstrated delivery reliability bar none. Two metering systems (skids), equipped with six metering pumps from our delta product range plus five from the gamma /L range, were custom-finished and it was possible to supply and install them after just four weeks.

Better for the environment
As far as Holzapfel are concerned, the most important innovative technology claim they make is that of environmental sustainability. Water-based coating processes without any organic solvents or heavy metals in the varnish are used. And the new metering pumps play their part in this environmental protection. The decision in favour of the delta diaphragm metering pumps was based on their regulated optoDrive solenoid drive. Its main benefit is the provision of a slow pressure stroke. As the pressure stroke can be executed very slowly, it means that the chemicals can be metered almost continuously, e.g. feeding of sodium hydroxide into the dipping tank. The metering leads to excellent through-mixing without any need for additional mixers, which in turn means that fewer chemicals are required.
 Another advantage of the delta is its trouble-free connection to higher-level controls via Profibus.
Mr. Aydin, an electroplating technician with Holzapfel explained that "This, as well as the accuracy of the pumps and the quality of the ProMinent products, were the decisive factors." He went on to say, "The delta was also impressive thanks to its visually appealing design."
A metering pump is used for each dipping tank in the coating process. The metered chemicals include organic additives as well as sodium hydroxide (NaOH), hydrochloric acid (HCL), nitric acid (HNO3) and sulphuric acid (H2SO4).

Strength: competent, partnership-based consulting
A partnership-based, mutual consulting service is the strength of the surface specialist. ProMinent can attest to this through cooperation in the development of a solution for continuous quality control with a high requirement in respect of metering. In close cooperation with Holzapfel, the Heidelberg manufacturer developed and refined the metering processes so that precise metering of the electroplating liquid using metering pumps can be achieved. The pump capacity is so stable that the time frame for metering could be markedly reduced even as early as the installation and test phases. The performance of the pumps means process reliability is increased. Simultaneously, the existing high quality standards are maintained thanks to continuous quality control.
Holzapfel and ProMinent have been working together for more than 20 years, during which time some 100 metering pumps have been installed, not only in the electroplating process but also in the waste water treatment system in all plants.