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Automated EN Plating
Line Increases Capabilities
Barrel Plater Customizes Controls to Fit its Needs
POWDER Pivoting with industry
COATING demands – 10

Enabling hydrogen fuel

PRETREATMENT cell vehicles – 22

Algae-based coatings
TECHNOLOGY capture CO2 – 30

SHOW PREVIEW FABTECH 2024 – 34

A property of Gardner Business Media AUGUST 2024 / VOLUME 88 / NO. 11

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 PRODUCTS FINISHING

CONTENTS
VOLUME 88 / NO. 11 / AUGUST 2024

22
22 CLEAN CHEMISTRY FOR FUEL CELL
TECHNOLOGY
Leading efforts to improve hydrogen fuel cell efficiency,
this Indiana company has developed chemistry that
cleans the inorganic contaminants from inside a vehicle’s
radiator, resulting in cleaner coolant and a more
efficiently run hydrogen fuel cell.

26 Plating Automation Turns Controls Up a Notch 26 30

Cincinnati-based plater experiences 33% improvement as a
result of investing in automated electroless nickel line.

30 Algae-Based Coating Enables Modular

Carbon Capture Removal System
Bio-based coatings harness the natural CO2-capturing
capabilities of live algae.

TECHNIC AL EXPERTS NEWS / COLUMNS

48 Powder Coating / Rodger Talbert, Consultant 6 From the Editor / Scott Francis
Factors Affecting Job Shop Profitability The Role of Surface Finishing in Modern Manufacturing
Powder Coating Chipping on Aluminum Extrusion
10 Top Shops Insider
49 Automation / Nicolas Gervaise, Carlisle Fluid Technologies Powder Coating Top Shop Pivots With Industry Demands
Powder Coating Automation Can Reach ESG Goals
for Automotive Parts 12 Finishing Industry News
The Powder Coating Institute Announces 2024 Hall of Fame Inductees
50 Plating / Mark Adams, Columbia Chemical
The Benefits of Electroless Nickel Plating 53 Never Finished / Matthew Kirchner
The Disconnected American Worker
52 Tanks / Asa Halliday, Tri-Mer Corp.
Selecting High-Capacity Anodizing Tanks 54 Gardner Business Index / Jan Schafer
Overall Finishing Activity Accelerated Contraction in June,
Closing at 44.0

34 FABTECH 2024
CCAI’s FINISHING Pavilion and Conference continues to grow
at FABTECH, offering insights and innovations covering all
aspects of industrial surface finishing.

PRODUCTS FINISHING (ISSN 0032-9940) is published monthly and copyright The information presented in this edition of Products Finishing is believed to be
2024 by Gardner Business Media Inc. 6915 Valley Ave., Cincinnati, OH 45244-3029. accurate. In applying recommendations, however, you should exercise care and
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2 AUGUST 2024 — PFonline.com

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 FROM THE EDITOR

The Role of Surface Finishing in Modern

Manufacturing: Trends and Best Practices
The entire manufacturing process for any part can benefit from considering the
final finish early in the process. This article discusses trends in surface finishing
with the goal of facilitating better communication with potential partners.
The fall trade show season offers numerous opportunities, such as the SCOTT FRANCIS / EDITOR-IN-CHIEF
International Manufacturing Technology Show (IMTS), to explore [email protected]
where areas of manufacturing intersect. Increasingly, manufacturing
professionals in all areas of the process chain are learning the impor-
tance of considering the final finishing of parts at earlier stages of the
production process. The traditional approach of merely machining
parts and sending them to a metal plater is outdated and should be
left in the past. To achieve the highest quality, it’s essential to collabo-
rate closely with every partner in the process chain, including surface
finishing experts.
What are the current trends when it comes to surface finishing?
Industry professionals are focusing on several key areas that
shouldn’t come as a surprise.
GrayMatter Robotics provides artificial intelligence
1. A.I., machine learning and IoT solutions (AI)-driven software designed to enable robots to
Much like other areas of manufacturing, finishers and coaters are program themselves to perform surface finishing
seeking ways to streamline their processes. Today, finishers are and surface prep operations for a wide variety of
increasingly exploring robotics, artificial intelligence (AI) and machine part sizes and shapes. Source: GrayMatter Robotics
learning to tackle challenges such as workforce shortages, quality
control and repeatability.
Historically, finishing operations have been slower to adopt IoT and
automation solutions due to the high mix of parts typically processed
by job shops, but various factors including workforce trends and
demands for environmentally responsible and sustainable processes
are accelerating the need to find new efficiencies.
Discover how one company is using AI to make finishing processes for
a high mix of parts of varying geometries as easy as the push of a button.
short.pfonline.com/graymatterAI
These lattice cubes were 3D printed from clear resin
2. 3D Printing using stereolithography, then coated by RePliForm
Additive manufacturing is growing exponentially. As this technology with electroless nickel, copper and layers of ductile
continues to move from the realm of R&D and short-run production to and hard nickel to improve their compression perfor-
full-scale production, an increasing number of fabricators are looking mance. Source: Additive Manufacturing
to various finishing methodologies to not only protect parts or provide
aesthetics but in some cases to increase functionality.
Check out a story about how one company is using electroplating to
enhance the physical properties of additively manufactured parts.
short.pfonline.com/repliform3D

3. Electroless Nickel Plating and EVs

The advent of electric vehicles (EVs) seems to have finally arrived.
With a growing number of automotive OEMs investing in new capabili-
ties to grow their EV and hybrid offerings, finishes will be needed for a EVs present exciting new opportunities for additional
range of parts from electrical motor components to batteries. growth in the use of electroless nickel plating in the
One example is electroless nickel (EN) plating. EN has been used automotive market for several critical components.
in the automotive industry for decades. Applications include piston Source: Getty Images

6 AUGUST 2024 — PFonline.com

 FROM THE EDITOR

heads, carburetors and fuel injection components, slip yokes and trans-
mission components. Today, EVs present exciting new opportunities for
additional growth of EN in the automotive market with the finish being
used for several critical components used in electric vehicles.
Learn more about the role EN is playing in the developing EV market.
short.pfonline.com/ENandEV

4. Environmental Considerations
Contrary to some perceptions, environmental concerns are a priority
in the finishing industry. As one of the most heavily regulated sectors
in manufacturing, compliance is essential for the industry’s sustain-
ability. For years, metal finishers have been engaged in negotia-
tions with environmental groups to address issues related to air
quality and wastewater treatment. The industry has been proactive Powder coating overspray can be reclaimed and
in seeking alternatives to potentially harmful hexavalent chromium reused. Source: Innovakote
finishing technologies, exploring safer options like trivalent chro-
mium-based processes. The evolving regulatory landscape will
continue to influence the available finishing technologies and their
application methods.
This Products Finishing Ask the Expert column discusses the environ-
mental considerations driving some of these regulations.
short.pfonline.com/hextotrichrome
In terms of coatings, powder coating has always been a low volatile
organic compound (VOC) approach to coating parts, and powder
overspray is a reclaimable material. Despite its already environmen-
tally friendly nature, new ways of making powder coating even more
sustainable are being explored.
Check out this story about two companies that have found novel
approaches to reclaiming powder. short.pfonline.com/reclaimpowder

5. Plating on Plastics
Plating on plastics (POP) isn’t new. Electroplating on plastic typically
involves the process of depositing a thin layer of metal onto a plastic
substrate using an electrochemical process after first preparing the
plastic for the metal to adhere. Advances in plating on plastics, as well
as the introduction of new materials aimed at producing lightweight
parts are creating opportunities beyond traditional POP applications,
which are often decorative in nature. Today, POP is being explored
for use in diverse industries, including aerospace, automotive and
electronics. The ability to electroplate on high-performance resins,
lightweight composites and additively manufactured parts opens
new avenues for innovation, making plating on plastic an option for
enhancing functionality of parts in addition to providing esthetics.
Learn more about new innovations in plating on plastics. This 3D printed radar array is PAEK plated with layers
short.pfonline.com/GreenPOP of copper and electroless nickel using a plating on
plastic activation chemistry known as GreenPOP.
Finishing today and tomorrow Source: Alliance Finishing and Manufacturing
The finishing industry is integral to the broader manufacturing land-
scape. Consumer needs and buying trends shape not only what we
produce but also the methods we use. To ensure the highest quality
for your parts, engage with your surface finishing partners early
in the production process. Leverage their expertise to achieve the
best possible surface finish, aligning with industry standards and
consumer expectations.

8 AUGUST 2024 — PFonline.com

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 TOP SHOPS INSIDER

Top Shop Pivots With

Industry Demands
Moving from cars and motorcycles to its current aerospace and
architecture customer base, this California powder coating
shop has evolved and grown with the changing market.

BY LORI BECKMAN SENIOR EDITOR

When the small powder coating shop now known as Andrews today. Since then, the company has expanded to three build-
Powder Coating Inc. (APC) opened for business in 1980, ings, invested in a lot of equipment as well as put in the hard
powder coating was so new that it was not yet well known. work to obtain certifications such as ISO 9100 and architec-
But through the years, the coating technology has caught on tural-grade certifications.
across many industries and continues to do so today. However, “It has been a difficult journey, but an exciting and
it has survived through volatile market trends since then, rewarding one,” Andrews says. She started with the company
adapting to changes and learning to be flexible. in 2000 and, as a long-time, dedicated employee, she recog-
Initially serving the car and motorcycle industry, and espe- nizes and appreciates APC’s success.
cially bearing fruit through the motorcycle boom of the early
2000s, the coatings shop in Chatsworth, California, could not Quality shop creates quality products
have predicted the business would be affected when CARB Luckily for this Products Finishing 2024 Top Shop, Andrews
(California Air Resources Board) regulations abruptly trans- is not the only long-time employee. The majority of its
formed the market in the mid-2000s. 15-employee staff has been with the company since its begin-
“CARB prohibited motorcycle builders from registering ning, providing the experience and skills necessary to achieve
more than one custom built motorcycle in a lifetime, unless it high-quality work. In fact, Andrews attributes earning the Top
was a serialized Harley Davidson frame and motor,” explains Shops recognition to the team.
Sandee Andrews, APC COO/CFO. “The industry basically “Without them, their collaboration, their ideas and the way
changed overnight, and it forced finishers that were heavily they care, we would not be where we are,” she says.
into those markets to switch gears.” This powder coating team sets high quality standards for
This is when APC decided to take a new direction toward itself, which shows in its less than 1% reject rate (annual). APC
the architectural and aerospace markets, which is where it is ensures its customers are satisfied as well. Andrews says she asks

Above, space lab techs work in APC’s secure aerospace lab. This 2024 Top
Shop has earned its ISO 9100 certification for aerospace, working hard to be
a leader in the powder coating industry.

APC now does a lot of work for its customers in the architectural and
aerospace industries. Pictured (left) is Dave Winge, lead coating technician
at APC, working on the architectural aluminum extrusion line. Source (all
photos): Andrews Powder Coating Inc.

10 AUGUST 2024 — PFonline.com

 TOP SHOPS INSIDER

customers for quarterly report cards so they can give feedback on Not only is robotics a big market segment that the company
the projects the shop has completed for them. is beginning to service but the company would like to inte-
High quality can only be achieved with reliable equipment. grate robotic methods to help automate its production floor.
Therefore, the shop has invested in a number of new machines Andrews says she’s actively researching ways to do this
and tools. With its relocation six years ago to a large building that without spending $1 million on a robot.
needed to be filled, Andrews says that except for a couple of items,
everything was newly purchased, including a pretreatment tank, Zirconium as a safe alternative
two ovens and two spray booths. APC is also cognizant about its sustainability and environ-
Then, last December, it replaced the air compressor that runs mental impact, especially because California is a national
throughout the shop and installed a humidity controller. Its leader for environmental standards, Andrews says. For
powder coating application guns were also upgraded at that time. instance, the company’s new pretreatment tank is used for
“We want our people to have the latest and greatest tools so pretreating aluminum as well as other substrates. Although
they can do their job as well as they can and not have to deal using a chromate conversion is common on aluminum,
with archaic equipment that would hinder their performance,” she says those chemicals are harmful and toxic to the
Andrews explains. environment.

When the powder coater installed its pretreatment facility, the team investigated zirco- Since joining APC in 2000, COO and
nium, discovering it is a safe product for the applicator and the environment. Also, it has CFO Sandee Andrews has ridden the
met or exceeded anything that a chromate conversion coating can do. ups and downs, which has helped her
appreciate the company's success.

Technology trends “When we installed our pretreatment facility, we really

With technology quickly advancing, businesses like APC need went a different way and started to investigate zirconium,”
to respond quickly so as not to fall behind the competition. she explains. “Zirconium is safe for the environment, the
The powder coater is doing this with both its digitization of applicator, and it has met or exceeded anything that a
the shop as well as with its customers’ needs. chromate conversion coating can do, so why not use it?”
“Everything is digitizing,” Andrews says. “We are trying
to go paperless. We’re trying to automate and get everything Consulting services
controlled by software. All our equipment is cloud based, so Besides its powder coating business, APC provides consulting
we can monitor 24/7 and provide these reports to our clients services for customers around the world. These services offer
so they are sure that everything is working in good order.” basic powder coating project management for those inter-
Because robotics has become more popular, especially in ested in starting up a business. APC aids them in deciding on
the medical device industry, APC has been forced to insert the equipment needed, and recommends an ideal setup for
itself into this market because it has been doing business maximum process flow on minimal square footage as well as
with companies in that industry for so long. It has already performing the install.
implemented medical-grade coatings into its processes that So far, the consulting business has opened powder shops
conform to those standards. But it is also attempting to market in the U.S., Mexico and one on the Caribbean island of
to the robotics companies, which has been challenging. Tobago.

PRODUCTS FINISHING — pfonline.com 11

 NEWS

The Powder Coating Institute Announces

2024 Hall of Fame Inductees
The 2024 PCI Annual Meeting in Savannah honored new Hall of Fame inductees
for their significant contributions to the powder coating industry.

During the 2024 PCI Annual Meeting in Savannah, Georgia, the

Powder Coating Institute (PCI) celebrated the 2024 PCI Hall
of Fame inductees. The Hall of Fame was initiated in 2001 to
recognize individuals who have made outstanding contributions
to the Powder Coating Institute and the powder coating industry.
Nominated by industry peers, eligible Hall of Fame members
must be retired and have a minimum of 15 years in the industry.
This year, the recipients of this recognition are Tom Grady
and Chris Merritt. “PCI is grateful to Tom and Chris for their
many contributions to PCI and the industry,” says Kevin Cour-
sin, executive director. “We appreciate their dedication and
their induction into the PCI Hall of Fame is well deserved.”
Receiving this merited recognition posthumously, Grady
was an active member of PCI for many years and contributed
heavily to the Education Committee and various training
sessions. He served as chairman of the formerly named ARE
Committee and was a leading contributor for several editions Chris Merritt accepts award from PCI Hall of Fame
of PCI’s Powder Coating Handbook. He spoke at numerous member Marc Fooksman. Source: The Powder Coating
powder coating conferences and events. Institute
At the time of his passing, Grady was the business develop-
ment manager for Sherwin-Williams, leading efforts in metal 40-year career at Gema USA Inc., Merritt served as a PCI
building products with a strong emphasis on establishing committee member and chairman, contributing to the
powder in that market space. He developed powder-specific establishment of industry standards and best practices.
training programs for AAMA and AEC applications, and was His strategic insights and leadership skills earned him
constantly on the road helping people with their powder multiple terms on the PCI board of directors, including
systems. Grady spent his working life helping to grow powder a few terms as president. Merritt was a contributing edi-
as a technology. The award was presented to Grady’s wife and tor to the PCI Powder Coating Handbook and a frequent
daughter at the awards dinner. speaker at PCI industry training events. Special guest, Hall
Merritt’s dedication and passion for the powder coating of Fame member and Gema colleague, Marc Fooksman,
industry have been remarkable. Throughout his nearly presented the award to Merritt.

Ronatec Continues to Expand

In a move that strengthens its position in the industry, Ronatec
(Oceanside, California) — a provider of metal finishing chemi-
cals, equipment, products and services — has announced the
acquisition of ICF.
This acquisition marks a significant step forward in
Ronatec’s ongoing expansion strategy, enabling the company
to better serve its customer base.
ICF is known for its brand of specialty products, which cater
to niche markets within the industry. By integrating ICF’s
product line into its expanding portfolio, Ronatec will be able in. This acquisition underscores Ronatec’s commitment to
to offer a wider range of solutions to its customers. growth and excellence. The combined expertise and resources
This strategic move is expected to solidify Ronatec’s market of both companies are expected to drive significant advance-
position, particularly in the niche markets that ICF specializes ments in the industry, benefiting clients across North America.

12 AUGUST 2024 — PFonline.com

 NEWS

IHEA Announces Keynote at Industrial Heating Decarbonization Summit

The Industrial Heating Equipment Association (IHEA) is Shultz leads IEDO’s
pleased to announce Dr. Avi Shultz, director of the U.S. strategy to accelerate the
Department of Energy’s Industrial Efficiency and Decarbon- innovation and adoption of
ization Office (IEDO), will provide the keynote address at its cost-effective technologies
first Industrial Heating Decarbonization Summit to be held that eliminate industrial
Oct. 28-30, at the Conrad Indianapolis. greenhouse gas emissions.
Shultz will open the Industrial Heating Decarbonization He also works with DOE
Summit with a keynote address that will lay the groundwork leadership and interagency
for embracing ways to start the decarbonization process. The partners to position IEDO
Summit is designed to assist everyone using heat technolo- and the department for
gies to understand and overcome important concerns and the greatest impact across
provide potential solutions as manufacturers plan for a America’s industrial sector. Source: IHEA
sustainable future. The two-day program
IHEA national board member Michael Stowe of Advanced contains a lineup of topics that will inform and guide
Energy, says, “IHEA and DOE have had a long and successful attendees in their journey to decarbonization, along
history of working together on industrial process heating. In with a tabletop exhibition where attendees can visit with
recent years, both IHEA and DOE have also adapted to include suppliers to learn more about the products and services
the critical topic of decarbonization into the forefront of their that will help them navigate the decarbonization efforts.
missions. I am pleased that we can continue this tradition of The IHEA approach to sustainable solutions is a compre-
cooperation by having the leader of the newly named DOE hensive mix of currently available technologies as well
Industrial Efficiency and Decarbonization Office (IEDO) to be as developing technologies that will enable companies
the keynote speaker at our upcoming Industrial Heating Decar- to reduce carbon footprints now while planning for the
bonization Summit. This is both an honor and very timely.” future.

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 NEWS

FINISHING INDUSTRY

Registration Open for IHEA 2024 Fall Seminars

ON THE MOVE in South Carolina
The Industrial Heating Equipment Association (IHEA) con-
During the 2024 CCAI Annual Meeting in tinues to educate the thermal heat processing industry with
Savannah, Georgia, the Chemical Coaters training seminars.
Association International held its annual This fall, IHEA will conduct its annual Combustion and
awards ceremony to honor the 2024 James Safety Standards and Codes Seminars on Sept. 17 and 18, at
F. & David J. Wright Lifetime Achievement the Westin Poinsett in Greenville, South Carolina. The semi-
Award recipient and recognize the CCAI nars also feature a joint tabletop exhibit and reception on
Sclafani Chapter Users and Suppliers of the Year. Tuesday, Sept. 17. This enables attendees of both seminars the
This year’s recipient is CCAI’s Past President chance for additional one-on-one interaction with suppliers
Tony Sclafani of AR Iron and the Las Vegas Chap- from across the industrial heating marketplace.
ter. Sclafani has been awarded for his com- IHEA’s Combustion Seminar features 16 sessions designed
mitment to CCAI and the finishing industry at to give attendees exposure to combustion technology. Some
large. He has been a CCAI member since 2012 of the topics covered include chemistry and efficiency of com-
and has been instrumental in launching and bustion, flame safety requirements of combustion systems,
assisting with multiple CCAI chapters west of process and ratio controls with exposure to microprocessor
Warren the Mississippi. equipment, types of industrial burners available, supply and
The West Michigan Chapter recognized Bob control of the fuel and air for systems and preheated combus-
Warren as “Chapter Member of the Year” for his unwavering sup- tion air and furnace recuperators. The seminar also now fea-
port and service over the numerous years to the chapter. In addi- tures a session on hydrogen combustion and decarbonization.
tion, Warren was recognized for his contributions to CCAI, the West The Safety Standards and Codes Seminar provides a com-
Michigan Chapter, CCAI’s Finishing Education Foundation (FEF) and prehensive overview of the NFPA 86 standard. The seminar will
the industry as a whole with the announcement of the annual Bob highlight the recent updates that appear in the 2023 edition
Warren Scholarship Award. This award will provide $2,500 each of NPFA 86 Standards for Ovens & Furnaces. This class will be
year to a student selected by the CCAI FEF board of directors. taught by several instructors who were involved with the 2023
revision and will include discussion of the updates as well
Carlisle Fluid Technologies has hired Jer- as an extensive explanation of several critical safety topics.
emy Renwand as technical sales specialist Sessions will cover the required uses of the American National
for the northeast U.S. and northeast Canada. Standards governing the compliant design and operation of
Renwand has more than 25 years of finishing ovens and furnaces
experience in the Tier One automotive and Attendees can register now for either seminar at ihea.org/Fall24.
industrial industries. Most recently, he was
Renwand paint operations manager at Inoac.

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14 AUGUST 2024 — PFonline.com

 NEWS

Dürr, GROB and Manz Present Concept Factory for Battery Production
In 2022, Dürr (Southfield, Michigan), GROB (Bluffton, Ohio) and solution, enabling end-to-end visibility of all battery produc-
Manz (Reutlingen, Germany) formed the first European part- tion steps. This includes control and planning of the entire
nership in lithium-ion battery production technology. Their production process, as well as analysis and traceability. The
goal is to become a leading European supplier of complete result is high overall system efficiency and lower operating
battery production systems. This year, the three companies costs, primarily achieved through reduced energy consump-
are showcasing their jointly developed concept factory at the tion and a smaller overall plant footprint.
Battery Show Europe in Stuttgart, Germany. The factory high- The first joint customer project, a system for electrode pro-
lights end-to-end process automation, coordinated interfaces duction and battery cell assembly, is already underway. The
and integrated, holistic digita- single-source approach saves the customers from complex
lization solutions. project management, as processing interfaces have been
These three compa- streamlined. Dürr, GROB and Manz offer smooth implemen-
nies possess most of tation following proven project management stan-
the necessary machinery dards and have an extensive supplier network
and plant technology to cover at their disposal.
the entire process chain from electrode
production to cell assembly and from
module to pack assembly. Since the part-
nership began, they’ve focused on developing a
concept factory for battery production. In six defined
workstreams, particular emphasis was placed on achieving
above-average process efficiency during the planning phase.
Both technical and digital interfaces between the three
partners are crucial to development. Dürr’s subsidiary iTAC,
an expert in process digitalization, contributes its MES/MOM

90
Years of
Finishing
Experience

Metal Finishing Industry

Expert William W. Corcoran
Passes Away
William W. Corcoran (Dec. 17, 1944 -
May 22, 2024), Nadcap auditor and
finishing industry expert, has passed
away at the age of 79.
Corcoran’s experience in the finishing
industry began in 1999 as owner and
CEO of Katahdin Industries, a Boston
area finishing shop. Following the
sale of the company in 2007, Corcoran
continued his involvement in the metal
finishing industry as a consultant and
auditor. He started Nadcap auditing
with the Performance Review Institute
(PRI) in 2009 and has served many
businesses, both in the technical and
business areas of metal finishing.

PRODUCTS FINISHING — PFonline.com 15

 NEWS

AkzoNobel Opens World-First Testing Facility for Wind Turbine Blades

The world’s first purpose-built wind turbine blade testing
facility — which is capable of running simulations at half
the speed of sound — has been opened by AkzoNobel at its
Felling plant in the U.K. The multimillion euro investment
will support the development of the company’s Interna-
tional protective coatings brand, which supplies wind farms
around the globe.
Researchers at the new facility — which can simulate harsh
weather conditions from around the world — will be able to
triple the number of rain erosion tests that can be run every
week. At full speed, the so-called “helicopter” test is capable
of running at 176 meters per second.
“Today marks an exciting new chapter in our long history
of supporting sustainable innovation and product develop-
ment,” says Ralph Slikkerveer, R&D director of AkzoNobel’s
Marine and Protective Coatings business. “Bringing this type To support the ultrahigh speed tests, the new facility has
of testing in-house — where we can immediately generate been fitted with a 1,000-liter water recycling tank. During test-
the data, analyze results and prolong testing periods — will ing, the water flow rates, and both the water and air tempera-
transform our contribution to innovation in the wind energy tures, can be adjusted as required.
sector. We’ll be able to participate in a more meaningful “The protective coatings we’ll be testing will help to future-
way in lifetime prediction discussions on protective coating proof our customers’ blades so they can withstand the most
systems for wind turbine blades.” extreme weather conditions,” Slikkerveer adds.

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16 AUGUST 2024 — PFonline.com

 NEWS

HeaterTek Expands Capabilities

for Metal Finishing Market NASF Technical Papers
Edited by Dr. James Lindsay, NASF Technical Editor
Electric immersion heater provider HeaterTek LLC (Evansville,
Indiana) has announced the acquisition of Industrial Heating
Systems (IHS, Boise, Idaho). The strategic move is part of NASF/AESF Foundation Research Project #122:
HeaterTek’s commitment to expand its presence and capabili- Electrochemical Approaches to Treatment of PFAS in
ties into the metal finishing sector. Plating Wastewater - 12th Quarterly Report
“This strategic move not only reinforces our commitment to Qingguo (Jack) Huang and Yuqing Ji, College of Agricultural and
serving the metal finishing industry but also positions Heat- Environmental Science, University of Georgia, Griffin, Georgia
erTek for continued growth and success,” says Chris Brack,
In our previous 11th quarterly report, we described our work on
president of HeaterTek LLC. performance and effect of surface fluorinated Ti4O7 anodes on
The acquisition of IHS brings a wealth of expertise in metal PFAS degradation in reactive electrochemical membrane (REM)
finishing processes, further complementing HeaterTek’s capa- mode. This quarter, our experiments involved utilizing porous
bilities in providing heating solutions tailored to the industry’s Ti4O7 plates serving both as anodes and membranes. Tests com-
specific needs. pared pristine and F-18.6 Ti4O7 anodes at current densities of 10
mA/cm2 and 40 mA/cm2. This 12th quarterly report discusses the
mechanisms of the effects on EO performance by anode surface
fluorination. The full paper on this work can be accessed and
printed at short.pfonline.com/NASF24Aug1.

For more information

or to become a member,
visit nasf.org.

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 NEWS

Henkel Opens Second Application Center in North Vietnam

Henkel, a global provider of adhesives, sealants and func-
tional coatings, has launched a second application center in
Thanh Hoa, North Vietnam, to expand its support for leading
sports and fashion brands in Asia-Pacific and China.
The application center will complement Henkel’s existing
center in Bien Hoa, Ho Chi Minh, to advance local capabilities
and create further opportunities for collaboration and acceler-
ate impactful innovation with customers.
“Our expansion from the south to the north of Vietnam
with a second application center enhances our proximity with
customers and reinforces our commitment as a strategic long-
term partner to providing innovative solutions and robust
support,” says Corbett Wallace, corporate vice president of
Consumer Goods at Henkel.
The application center will collaborate closely with Henkel’s
customers to develop new products and solutions to meet their manufacturing excellence, we look forward to the opportuni-
needs and drive rapid progress in sustainability and innovation. ties this center will bring and remain committed to driving
Spanning over 500 square meters, the center is equipped speed to market, cost efficiency and sustainable growth to-
with a lab, application room, customer experience room, an gether with our partners.”
office and dedicated focus rooms for collaboration. It also of- Through the center, Henkel will also assist partners in
fers leading automation facilities such as auto spray applicators sustainability by educating them on best practices, facilitating
and PUR jet spray solutions to elevate production efficiency. the adoption of alternatives such as water-based products,
Dharmesh Shah, regional head of Consumer Goods in and implementing process simplification measures to reduce
Asia-Pacific Emerging, says, “As the industry shifts its focus to waste and energy consumption.

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18 AUGUST 2024 — PFonline.com

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 NEWS

CCAI Foundation Awards Scholarships

The Chemical Coaters Association International Finishing Scholarship, awarded to the
Education Foundation (CCAI FEF) has awarded this year’s highest scoring applicant.
scholarships. Since 1992, the Matt Heuertz Scholarship Congratulations to all the
Fund has provided financial awards to students enrolled in recipients of a 2024 Matt
programs that could lead to a career in coatings and finish- Heuertz Scholarship:
ing. The scholarships are awarded through the CCAI FEF, a • Rodger Barnard,
501 (c)(3) tax-exempt charitable organization. Applications Michigan Technological
from qualified students were reviewed by the CCAI FEF University
board of directors, which determined this year’s scholar- • Nicholas Boss,
ship winners. University of Alabama
The organization awarded a total of $17,000 in scholar- • Jordan Clabaugh, Scott Andreae, Jim Gallagher
ships to 11 students this year. “The number of applica- Iowa State University CCAI FEF scholarship winner.
tions received in 2024 quadrupled from 2023. While such • Jackson Davis, Source: CCAI FEF
an increase can make it challenging to select recipients, it LeTourneau University
also signals that more students are pursuing degrees that • Nathaniel Ehlinger, University of Iowa
could lead to a career in industrial finishing. We are excited • Samuel Hanson, South Dakota State University
to provide financial support to the academic pursuits of • Madeline Kehoe, Michigan Technological University
these promising students,” notes Sheila LaMothe, CCAI FEF’s • Chloe Lustila, University of Wisconsin-Green Bay
executive director. • Ander Nordin, University of Central Florida
In addition to cash awards sent to the student’s school • Ailey Smith, University of Florida
account, each scholarship recipient receives a one-year
student membership in CCAI. CCAI FEF accepts scholarship applications each year begin-
The board of directors selected Scott Andreae, University ning in January. Applications can be submitted online at
of Wisconsin-Stout, as the recipient of the Jim Gallagher ccaiweb.com.

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20 AUGUST 2024 — PFonline.com

 PRETREATMENT

Clean Chemistry for

Fuel Cell Technology

Leading efforts to improve hydrogen We are living in a time where an abundance of energy
resource exploration is underway. Engineers are engaged
fuel cell efficiency, this Indiana company in developing the cleanest and most efficient power which
is also affordable, durable, available and of high perfor-
has developed chemistry that cleans mance. Hydrogen fuel cell technology, a new power source
that is still being developed for high efficiency, is the
the inorganic contaminants from cleanest form of energy, as it has very low to zero emissions
compared to combustion engines. One coatings company
inside a vehicle’s radiator. This results is collaborating with automotive Tier One suppliers that
manufacture heat exchangers for vehicles operating with
in cleaner coolant and a more efficiently hydrogen fuel cells to keep them running as clean and effi-
ciently as possible.
run hydrogen fuel cell. While Circle Prosco Inc. (Bloomington, Indiana) has
been supplying lubricants for stamping radiator header
plates and the thin fins that zig zag between the tubes
BY LORI BECKMAN SENIOR EDITOR
for 30 years, its technical team has earned a reputation
for problem solving. When its Tier One customers were
required to meet a higher internal cleanliness specifica-
tion for radiators built for hydrogen fuel cell vehicles, they
ABOVE: Circle Prosco Inc. has developed chemistry that
asked the company for help. Now it is applying its 50 years
cleans difficult-to-remove contaminants on aluminum parts
of metal finishing expertise to meet the stringent cleaning
in heat exchangers for hydrogen fuel cell vehicles. The new
chemistry is a pretreatment/conversion coating which is specifications of new energy heat exchangers. The new
corrosion resistant, providing the long life necessary for chemistry cleans the inorganic contaminants inside a heat
hydrogen fuel cells. Source (all photos): Circle Prosco Inc. exchanger and forms a pretreatment/conversion coating

22 AUGUST 2024 — PFonline.com

 FUEL CELL TECHNOLOGY

which also keeps the coolant clean that runs through the cells, the new cleaning chemistry is ready to be implemented,
system. When all components are clean, the fuel cell runs more although R&D is ongoing.
productively and its life is increased.
Specializing in chemistry used in high-volume automotive Stages of the cleaning process
applications, Circle Prosco is designing its latest formulation Circle Prosco works together with its customers to move their
to clean these parts in a short amount of time, making the projects from feasibility testing to prototyping, process valida-
solution commercially viable. tion and the start of production. In general, its new cleaning
“One of the challenges of this project is that the major chemistry is designed to be implemented in the first step of
contaminant must be cleaned from within the small passages the radiator’s cleaning process.
of the fully manufactured radiator,” says Bill Morton, product Morton explains that this cleaning solution will circulate
application manager, lubricants/aluminum coatings at Circle through the radiator parts with standard chemically compat-
Prosco. The standard automotive heat exchanger manufac- ible piping, hoses and pumps. “It is not so exotic that it can’t be
turing process leaves a lot of residual inorganic material on implemented by our customers as we move forward,” he says.
the interior of the heat exchanger. He adds that like any chemical process, concentration of
“The contaminant is very tenacious and hard to clean,” chemistry, time of exposure and temperature will control the
Morton continues. “It’s been sitting on aluminum, and reaction which occurs during this stage.
aluminum can be damaged and degraded by strong acid
chemistry and strong alkaline chemistry.”
Fuel cells produce electricity and heat if fuel (hydrogen)
Despite the obstacles, Morton has been successful in
is supplied. FCEVs are powered by compressed hydrogen
leading efforts to create an aluminum-safe cleaning chem- gas that feeds into an onboard fuel cell stack that doesn’t
istry that has taken three years of R&D. After the project that burn the gas, but instead transforms the fuel’s chemical
began with close collaboration with customers and simulta- energy into electrical energy. This electricity then powers
neous developments in the heat exchangers for hydrogen fuel the vehicle’s electric motors. The fuel cell emits only water
vapor and warm air.

PRODUCTS FINISHING — PFonline.com 23

 PRETREATMENT

Fuel Cell EV Functionality

The benefits of hydrogen fuel cell technology for vehicles for developing this energy source for their brands, according
seem exceptional at first glance, compared with the to Morton. While automotive OEMs are envisioning all the
offerings of internal combustion engines. After all, benefits of hydrogen fuel cells, further government support
hydrogen fuel cells produce zero emissions and are more must occur before the technology is adopted for most
reliable, efficient and quiet. And although they contain applications. For instance, there is still a lot of infrastructure
an electric battery, these vehicles, also called fuel cell development that is required to support hydrogen stations.
electric vehicles (FCEVs), do not require their batteries to Also, the expense of this energy is currently much higher
be recharged or replaced. than gas.

How does a FCEV work? Fuel cells produce electricity The heavy-duty trucking industry especially can benefit
and heat if fuel (hydrogen) is supplied. FCEVs are from hydrogen fuel cell technology. In fact, it is putting forth
powered by compressed hydrogen gas that feeds into the biggest effort in the vehicle sector because, in general,
an onboard fuel cell stack that doesn’t burn the gas, these semitruck owners are most likely to take care of their
but instead transforms the fuel’s chemical energy vehicles with the objective of vehicle longevity. Not only do
into electrical energy. This electricity then powers the hydrogen fuel cells offer longer life but they are a cleaner
vehicle’s electric motors. alternative to running a gas engine cross-country. The use of
hydrogen is practical for long-haul trucks as well because it
With hydrogen fuel cell R&D being federally funded, most takes the same amount of time to refuel hydrogen as it does
automotive OEMs are taking advantage of the support a petroleum gas tank.

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24 AUGUST 2024 — PFonline.com

 FUEL CELL TECHNOLOGY

Then, the rinsing step is next, which is typical of a metal is self-limiting, so you can leave it on a part for 10 minutes
finishing process. in a phosphate-free zirconium stage, and you’ll get the same
The passivation step is the third step, which imparts a thin coating you get after 1 minute. But the iron phosphate is going
corrosion-resistant coating that’s between 25 and 30 nano- to keep building and building.”
meters and reacts to the aluminum surface. “We want it to After the passivation process, another rinse cycle occurs.
coat all the interior surface evenly and Then, the product is ready to be
completely, but we don’t want the film presented to the customer per its
to be so thick that it would impede the criteria, which will be either a fully dry
heat exchange capability or close off the or not fully dry subassembly, Morton
passages through this heat exchanger,” Not only do hydrogen explains.
Morton explains. fuel cells offer longer life,
Passivation provides the surface with R&D continues
a corrosion-resistant coating. As a result, but they are a cleaner Circle Prosco persists in its R&D work
part longevity and clean coolant will be alternative to running a gas on the cleaning step chemistry and the
compatible with the fuel cell, giving it engine cross-country. process design. The application process
long life as well. and results will depend on different
Morgan Fraga, director of sales and variables in the heat exchanger which
marketing at Circle Prosco, adds that the is still undergoing development and
thin nano coating layer uses the same incremental changes.
technology that is in zirconium pretreatment chemistry for The company will continue to develop its passivation
steel. “The longer your iron phosphate touches a product, the process alongside of the evolution of hydrogen fuel cell
more coating will develop,” she says. “The zirconium coating technology.

PRODUCTS FINISHING — PFonline.com 25

 PLATING

Plating Automation Turns

Controls Up a Notch
This Cincinnati-based plating company When a business witnesses growth in certain industry segments
that it services, it behooves the company to respond quickly
has experienced a 33% improvement as and to the best of its ability to satisfy customer needs. Varland
a result of investing in a new electroless Plating, a family-owned barrel plating job shop based in
Cincinnati, Ohio, has made it its mission to do that and more:
nickel line. It continues to tweak the the business goes above and beyond for its customers. It recently
expanded its offerings to react to an increase in demand for its
control technology to create the most electroless nickel plating services — its automotive customers
were experiencing an immediate increased demand for EN,
effective coating for its customers’ needs. and the company’s management predicted near-term demand
from its firearms and electrical customers as well. With only one
BY LORI BECKMAN SENIOR EDITOR
manual EN line, it was time to add another line.
As of late 2023, the company has been running production
work on the new line from Corrotec Inc. (Springfield, Ohio),
ABOVE: Varland Plating’s new EN line from Corrotec Inc.
which runs mid-phosphorous EN and electrolytic flash for acti-
automates functionality that controls barrel movement,
vating plating on copper and brass. The line was also designed
bath level control, drainage, chemistry feed systems,
variable frequency drives (VFDs) for exhaust, and controls for the ability to add aluminum and boron nitride over EN in
for heat and circulation pumps. Since implementing the the future, if the need presents itself.
automated line, the company has experienced a 33% “With the addition of our new EN line and our existing
improvement in its EN plating process. automated electrolytic line, Varland has significantly boosted
Source (all photos): Products Finishing our overall nickel capacity and efficiency to better meet our

26 AUGUST 2024 — PFonline.com

 ELECTROLESS NICKEL

customers’ needs,” says

Andrea Varland Wilson,
marketing manager/admin-
istrative specialist and a
third-generation employee.
Although the new equip-
ment is already bearing
fruit for the business, the
line is still in the process
of being tweaked and
adjusted to meet Varland’s
specifications.

A focus on continuous
improvement
Since its opening in 1946,
Varland Plating has been
committed to continuous
improvement and exceeding
customer needs, according
to President Brian Mangold.
The 2023 Products Finishing
Top Shop has six plating lines, four of which are automated. The automated EN barrel plating line took several years of
Besides EN plating, it also offers zinc, zinc-nickel, tin-zinc, design planning prior to its installation in late 2023. With
bright and matte tin, nickel, copper, brass and cadmium the line now up and running, the team could not be more
plating. Its two manual lines are used for small-volume excited and proud of the new system’s capabilities and
applications in addition to R&D testing of new processes for how it is helping its customers by expanding offerings.
possible expansion.
Varland also provides antiquing, baking, bead blasting and
oil dipping services. Joel Perrine, V.P. of operations at Varland, was heavily
As a job shop, the company plates thousands of different involved in designing the automated EN line. He says the
parts, with sizes ranging from less than an inch to as long as company thoroughly trains its EN plating line operators
12 inches, for hundreds of customers across many industries. prior to having them run the new line. They must be highly
Varland, which has several second-, third- and fourth-gener- skilled and understand the plating process well.
ation employees, has developed value-added services over
time, including detailed quotations, plating thickness testing,
salt spray corrosion testing, hardness testing, Production Part
Approval Process (PPAP) documentation and others.

Digging deep into automation

When determining specifications for the new EN line, there
was no question the system would involve automation.
Automated systems are recognized as being more efficient,
accurate, repeatable and lower cost than manual lines.
Although the automated line meant a higher expense on the
front end and a more complicated installation, Varland was
committed to investing in an adaptable line that could handle
a multitude of controls.
Even before customer parts make it to a plating line, auto-
mation at the shop begins when an order is received. These
orders are immediately entered into a proprietary produc-
tion control system and assigned an order number. The
order number tracks the part throughout the entire process
and includes a detailed plating procedure/recipe. This

PRODUCTS FINISHING — PFonline.com 27

 PLATING

custom recipe is then downloaded to a

programmable logic controller (PLC)
that controls and monitors every aspect
of the automated line.
The PLC in the new EN line auto-
mates functionality which controls
barrel movement, bath level control,
drainage, chemistry feed systems,
variable frequency drives (VFDs) for
exhaust, and controls for heat and
circulation pumps. Here is a brief
description of what the automation
entails:
• Flextime wet process line control
from GPR: Controls barrel
movement through a built-in
recipe. This regulates order of
operations along with time in stations, the current/ The automated EN plating line runs mid-phosphorous EN
voltage on rectified stations and barrel rpm in each and electrolytic flash for activating plating on copper and
station. brass. The line was also designed for the ability to add
• Level control: The soak cleaner, electrolytic nickel and aluminum and boron nitride over EN in the future, if the
EN plating baths have auto level control. This saves labor need presents itself.
and helps keep the plating baths at the right chemical
concentrations. years later. Varland partnered with Plating Specialists (Fort
• Recipes that control barrel drainage when moving from Thomas, Kentucky), a supplier of plating lines, to create a
one station to the next: The drain time can be adjusted as design requirement. Corrotec handled the engineering and
well as how the barrel turns, the speed at which it turns, installation of the line.
how long it turns and how long it drains after turning “We have been doing business with (Plating Specialists
stops to reduce chemical loss and drag out. President) Bob Greene for a very long time,” Mangold says.
• Specially designed single-station rinse tanks: These “He has been an amazing business partner over the years,
function like normal two-station rinses but in half the and the value in having his experience can’t be overstated.”
footprint. These rinses reduce the number of rinse tanks Greene recommended the Corrotec line because he had
required, while also maximizing rinsing effectiveness and worked with that company on many installations and was
minimizing the amount of water used. confident the plating system provider had the appropriate
• Automatic feed systems for liquid nickel sulfate, the staff on hand to complete the installation.
hypophosphite component and ammonia (if using a Mangold explains that the Varland team was set on
non-pH regulating chemistry): The chemical additions customizing the system as much as possible. Therefore, with
are accurate to within 25 cc. all the adaptations made, he explains it is still too early in
• VFDs: As with all the company’s other lines, the exhaust the life of the plating line to finalize the system. He believes
systems use VFDs that enable the slowdown of exhaust it will take years to settle on all the right equipment and
and consume less energy when tanks are cool and not accessories.
being used. Not only does this reduce the electrical usage “We’re still reengineering some replacement aspects of
of the exhaust but it also translates into less cold being the lower control system that was installed that didn’t work
pulled into the plant in the winter which would then right,” Mangold says. “We’re in the process of updating that
need to be heated. to something else.”
• Scheduling system: The line has a scheduling system for The team is particular about the controls on the automatic
startup that controls heat and circulation pumps. The EN line and prefers the ability to tweak them, which made
circulation pumps start and stop when heat is turned installation even more challenging than a system that did
on/off, which also helps reduce energy consumption. not demand such customization.
“Everything does not run on the same cycle through our
Installation process and challenges automatics,” Mangold says. “For example, at one time we
Like anything worth implementing, installing the automated had 64 different cleaning cycles for different amounts of
line was challenging and time-consuming. Installation began time, acids and cleaners. The parts we run have different
during the COVID-19 pandemic and was completed two cleaner voltages, amperage and rinse cycles.”

28 AUGUST 2024 — PFonline.com

 ELECTROLESS NICKEL

Integrating new software for the line was another chal- Benefits realized
lenge. Varland was accustomed to designing everything Varland has experienced a 33% improvement in its EN plating
internally via Opto 22. But when the new line came in, process since implementing the automated line. Besides
the IT department was forced to learn how to implement enjoying the expected advantages that come with automa-
the new programming software. Ultimately, after working tion, such as higher repeatability and accuracy as well as the
with Allen Bradley ladder logic, the company realized the need for less manpower, the plater also has the newfound
advantages it offered and decided ability to increase its load sizes of larger
to migrate to a similar architec- parts, according to Perrine.
ture called CODESYS in future From the beginning, Because of the tightly programmed system
system upgrades. Varland was committed to that controls the process down to the minute
Now that months have gone by investing in an adaptable without operator intervention, the automatic
since integrating the new line, the system saves the company time and material
biggest challenge for management line that could handle a cost, he says.
is training EN operators across multitude of controls. Mangold adds, “We can have really long
all shifts to keep the line up and programmed barrel drain times on our
running as long as possible for automatics to reduce solution dragout and
efficiency. costs. Whereas handline operators feel pressure to get work
Joel Perrine, V.P. of operations at Varland, who was heavily through, and the demands on them are higher because they
involved in designing the new EN line, says its EN line opera- have different things to focus on.”
tors are highly trained and skilled at what they do. “We start
them out on learning how to run the manual barrel line, Preparing for the future
which gives them a good basis for understanding the plating Varland has received multiple requests for silver plating from
process. Then, they graduate to training on the automatic EN existing customers. Therefore, the shop is in the process of
line for quite some time, where they learn the ins and outs of setting up a small prototype line that it hopes to have up and
the software and controls.” running later this year or in early 2025.

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 COATINGS TECHNOLOGY

Algae-Based Coating
Enables Modular Carbon
Capture Removal System

Reactive Surfaces, an innovator in bio-based coatings, works on development of Carbon

Capture Coatings, which harness the natural CO2-capturing capabilities of live algae.
BY HANNAH MASON SUSTAINABILITY CORRESPONDENT

What will it take to meet global climate change targets? and clay to absorb CO2 and release oxygen; and lime-based
Reducing carbon emissions during manufacture and paints said to reabsorb carbon emissions from the construc-
product use, certainly, but another key technology area tion process.
that many are working on is the industrialization of carbon One company working on this is leveraging its experience
capture — in other words, technologies that remove and in coatings to create a paint inspired by nature — specifi-
sequester already emitted carbon from the air or directly cally, lichen.
from the point of emissions.
As it turns out, coatings could be a vital component in Developing Carbon Capture Coatings
these efforts. For more than 20 years, coatings business Reactive Surfaces
There are a number of paint and coating technologies (Austin, Texas) has considered itself to be “an innovator in the
available or in development today that claim to have carbon paint and coatings space,” says Beth McDaniel, president.
removal capabilities, including a purifying, graphene-based Specifically, the company’s team of microbiologists and
“eco-paint” said to capture CO2 and other toxins; research biochemists work to “merge biotech with materials science to
into coatings based on living cyanobacteria mixed with latex create functionality of surfaces. We work with biomolecules
that have a functionality in nature, and put that into a coating
ABOVE: Biochemical coatings specialist Reactive Surfaces
system. Then, we apply that coating to a particular surface,
has turned its attention to use of algae-based coatings
and that surface becomes functional,” McDaniel explains.
within modular, carbon capture removal systems
(pictured), with future uses to include painted exterior Examples of the company’s functional additives and
structures or other applications. coatings include its DeGreez self-cleaning enzymatic coating
Source (all images): Reactive Surfaces additive, WMDtox coatings for detoxifying surfaces

30 AUGUST 2024 — PFonline.com

 CARBON REMOVAL

additive, WMDtox coatings for detoxifying surfaces One of these embodiments, spurred by Reactive Surfaces’
contaminated with certain organophosphorus pesticides or involvement in the ongoing XPrize Carbon Removal compe-
nerve weapons, and ProteCoat antimicrobial coating addi- tition (they are called Team Lichen, of course), is a stack-
tives for eliminating microbes including some viruses. Of able module for concentrated carbon removal.
the latter, McDaniel notes, “This is very different from, say,
a spray-on product like a disinfectant, which only lasts until Algae-based carbon removal
the surface gets fouled again. This coating’s functionality is The technology starts with growing algae from pellets, which
designed to be active for the life of the coating.” She adds is then used to inoculate sheets of a cellulose-based matrix —
that Reactive Surfaces’ additives are also naturally occur- which are flexible, porous materials that act like the fungus in
ring and nontoxic. lichen and provide a surface area for the algae to grow on.
Since 2018, the company has been working on extending The inoculated polymeric panels are then carefully
its experience in bio-based coatings and coating additives draped in modular, 4-square-meter repurposed cargo
to meet the need for carbon capture removal technologies. containers that, McDaniel says, “act as a terrarium” for the
“You see statistics all the
time about where we’ll be
in eight years or 20 years if
everything stays the same, and
we felt like this was an urgent
problem and there was no
time to waste. We wanted to
use our experience in coatings
and biological systems to add
a tool to the climate change
toolbox,” she says.
The company took its
idea from lichen, a plant-
like organism consisting of
algae and fungi coexisting
symbiotically, forming a
growth that spreads across
surfaces like rocks and trees.
Lichen captures CO2 from
the atmosphere naturally, by
providing a fungal surface Reactive Surfaces’ Carbon Capture Coating was designed to functionalize surface coatings
area for photosynthetic, with live, CO2-capturing algae.
CO2-absorbing algae to spread
out and work their magic.
Starting from this idea, the
company first developed an
algae-based coating — “this
time, not using a biomol-
ecule, but rather a living
organism, a blue-green algae,
actually,” McDaniel clarifies
— “with the idea of creating
a paint that harnessed the
natural role of algae in
nature, which is to capture
carbon dioxide, and that
could be spread on surfaces
the way lichen works. This
worked well and has evolved
into several embodiments of
the technology.”

PRODUCTS FINISHING — PFonline.com 31

 COATINGS TECHNOLOGY

algae on the sheets, enabling the algae to access needed For its first commercial product, as part of the XPrize
gas exchange and light. Specially-formulated coatings and Carbon Removal competition, the company is inoculating
surface treatments, such as those that help absorb ambient polymeric sheets with its algae coating — mimicking lichen
moisture, can also be used to enhance the efficiency of in nature — into stackable carbon capture modules.
the carbon capture process. “The idea is to create a whole
bunch of surface area within these modules to do the work
of photosynthesis,” McDaniel says.
The modules can either be installed in an open environ-
ment — for direct air capture — or directly next to a facility
that emits carbon dioxide as part of its operations — to
capture industrial point-source emissions.
At that point, the algae does what it does best, and
begins naturally capturing carbon dioxide from the air.
How is the carbon removed and sequestered? Reactive
Surfaces installs monitoring systems in each module to track
humidity and temperature data to determine when the algae
has captured enough carbon for “harvesting.” The sheets
are removed and wrung out — the liquid, containing algae
and water, is saved and reused to inoculate new sheets. The
wrung-out sheets, containing now only the base cellulose/
polymer material and the captured CO2 caught in the mate-
rial’s pores, are dried out in a solar-powered oven and then
pyrolyzed down into biochar.
“Biochar is a widely recognized way of sequestering CO2
and is a very valuable byproduct,” McDaniel explains, which
can be added to soil to help retain water. She adds that
The company has installed its first carbon capture pilot
producing biochar is also a less risky and costly solution plant, and continues to work on optimizing both its carbon
compared to some other carbon capture removal technolo- removal technologies for ambient and point-source emis-
gies that result in gaseous or liquid carbon which is piped into sions capture, and its algae-based coatings for adding carbon
underground wells. “This is a fully encapsulated system and a removal technology to architecture and other surfaces.

32 AUGUST 2024 — PFonline.com

 CARBON REMOVAL

permanent carbon removal process,” McDaniel emphasizes. At the same time, the company continues to develop its
How much does it cost? McDaniel notes that the total cost carbon capture technology and algae-based coatings. “We’re
— including capital expense, operating expenses and mainte- still optimizing and automating everything, it’s still a work-in-
nance — is less than $500 per ton of CO2 removed, less than progress,” McDaniel says.
half of what some similar technologies cost. “Cost compari- Looking ahead for the carbon capture modules, she envi-
sons aren’t quite apples to apples at this point, but we know sions fields of modules — “think like a wind farm, except full
it’s a cost-competitive technology and we’re still of direct air capture modules,
working to optimize it further,” she says. “The idea is to create a powered by solar energy” — as
well as source-point emissions
Next steps: Pilot plants, optimization, whole bunch of surface installed at steel plants and
surface coatings area within these other manufacturing operations
Currently, the company has a pilot plant full of that produce carbon emissions
modules to do the work of
carbon capture modules up and running next directly. “And there are a lot of
to a desalination plant in California, capable of photosynthesis...” other possibilities in between,
capturing either ambient or point-source CO2. It such as infrastructure for indi-
takes approximately 33 1m3 modules to capture a ton of CO2, viduals to install in their backyards, for example. We plan to
McDaniel says, and the company plans initially to scale up to create a blueprint for this to make it accessible for companies,
multiple sites to capture at least 1,000 tons of CO2. farmers or individuals to set up systems themselves,” she says.
McDaniel emphasizes, “This could work with industrial Beyond the modules themselves, Carbon Capture Coatings
emitters of CO2. We’ve been working with manufacturers in have potential in and of themselves as a coating system for
hard-to-abate industries — like oil and gas or steel manufac- architecture and construction applications and beyond. “For
turing — to work out how we might design a system for them. our first product, we built the modules to cram as much
The system is modular and they can be stacked up in order to dedicated surface area as possible for these, but in future
optimize the amount of CO2 capture per site. We could build we’ll develop more versions that can be used to capture
these around, say, a big steel manufacturer for instance, and emissions in other environments and on other surfaces,”
they could pipe in their CO2.” McDaniel says.

ENGINEERED SOLUTIONS
HISTORY OF
EXCELLENCE
RTT Engineered Solutions has emerged
as a market leader in paint booths, powder
booths, ovens, washers, air make-up
units, RP Arrestors, and other finishing
system components for use in the
industrial, automotive, truck and large
equipment, and woodworking markets.

PRODUCTS FINISHING — PFonline.com 33

 FABTECH 2024

FABTECH 2024
Heads to Orlando

CCAI’s FINISHING Pavilion and Conference continues to grow at FABTECH,

offering insights and innovations covering all aspects of industrial surface finishing..

BY SCOTT FRANCIS EDITOR-IN-CHIEF

Are you looking to explore the latest surface finishing technol- Conference meeting rooms this year. It makes it easy for
ogies, share knowledge, network with industry peers and gain attendees to get from the show floor to conference sessions
insights into manufacturing trends that will help you prepare and back to the show floor.”
for what’s on the horizon? FABTECH 2024 is the place to be. Training and education have always been at the forefront
This year, FABTECH will take place in Orlando, Florida, from of CCAI’s mission, and the conference program features 23
October 15 to 17. Now in its 15th year as a FABTECH partner, sessions with expert-led presentations covering a range of
The Chemical Coaters Association International (CCAI) technical topics for all finishing professionals.
FINISHING Pavilion and Conference offers a look at the latest FABTECH 2024 also features the seventh edition of CCAI’s
surface finishing innovations, products and services, and FAB to FINISH Production Experience, a popular program
provides a wealth of educational opportunities. offering attendees a first-hand opportunity to participate in a
“We’re excited to take FABTECH to one of the best part’s production from fabrication to finishing. The produc-
convention centers in the country,” says CCAI Executive tion route follows a souvenir part being laser cut and bent,
Director Anne Goyer. “It’s great to have our FINISHING and then through a finishing production route to participating
Pavilion located directly across from our FINISHING CCAI corporate member exhibitor booths, where the part
will be cleaned, powder coated and cured. Some routes will
ABOVE: FABTECH 2024, North America’s largest metal feature paint stripping. Don’t miss out!
forming, fabricating, welding and finishing event, will take For show updates and conference and registration informa-
place in Orlando, Florida, from October 15-17. Source: CCAI tion, visit fabtechexpo.com.

34 AUGUST 2024 — PFonline.com

 FABTECHEXPO.COM

General Information

DATES | OCT. 15-17, 2024

LOCATION | Orange County Convention Center,
Orlando, Florida
REGISTRATION | fabtechexpo.com

SHOW DATES & HOURS

TUESDAY, OCT. 15 | 9:00 AM - 5:00 PM
WEDNESDAY, OCT. 16 | 9:00 AM - 5:00 PM
THURSDAY, OCT. 17 | 9:00 AM 4:00 PM

FEES AND CCAI MEMBER DISCOUNTS

Enter promo code FBCCAI for free admission to the expo.

FINISHING CONFERENCE SESSION DISCOUNT

Registration for the conference sessions is separate and
open now. Visit fabtechexpo.com/conference.

HOTELS
FABTECH has negotiated the lowest hotel rates for exhibitors
and attendees at the most popular and convenient hotels
in Orlando. Reserve rooms now through onPeak, the official
hotel provider for FABTECH. Visit fabtechexpo.com and click
“Hotel & Travel” at the top of the homepage.

CCAI’s FINISHING Pavilion and Conference offers

insights into all aspects of industrial surface finishing.
Source: CCAI

FABTECH 2024 features CCAI’s popular FAB to FINISH produc- FABTECH 2024 will feature more than 170 exhibitors.
tion experience, enabling attendees to experiment with Source: CCAI *
finishing processes on the show floor. Source: Products Finishing

PRODUCTS FINISHING — PFonline.com 35

 FABTECH 2024

FABTECH 2024 FINISHING CONFERENCE PROGRAM

For registration details, session descriptions and more visit fabtechexpo.com and click on the Conference tab.

TUESDAY, OCT. 15 TUESDAY, OCT. 15

10:00 – 11:30 AM 1:00 – 2:30 PM
C11: All Aboard: An Interactive Trip Through C21: ABCs of Finishing System Design
the Powder Coating Process John Sudges|Midwest Finishing Systems Inc., Frank Mohar|Nordson
Steve Houston|Vitracoat Powder Coatings Corp., Mike Withers|Axalta Coatings
John Cole|Parker Ionics
Brian Korecky|Bulk Chemicals C22: Choose Your Own Adventure: Selecting a Chemistry
For Your Pretreatment
C12: Enhancing Productivity and Precision: Optimal Diana St Jacques and Max George|DuBois Chemicals
Masking and Racking Strategies
• Line Density: The Rest of the Story C23: Optimizing Operations Using Advancements in
Ryan Allen|Gema USA Inc. Transfer Efficiency and Low Cure Powders
• Innovating Masking Designs and Materials • Technology in Powder
Cliff Shephard|Echo Engineering Kyle Vinther|Sames
• Accelerating Toward a Net Zero Carbon Future: The Role
C13: Sustainability & Decarbonization for Industrial of Low-Bake Powder Coatings Technology in Sustainable
Finishing – is it on Your Company’s Radar? Manufacturing
Scott Bishop|EPRI Aric Yarosz|Akzo Nobel Coatings Inc.

TUESDAY, OCT. 15
3:00 – 4:30 PM
C31: Use Your Tools Wisely
• Tools of the Trade
Josh Gilmore and Kyle Vinther|Sames
• The Importance of Proper Inspection Lighting on the Quality
of Product Finishing
Jerry Trostle|Wenker Inc.

C32: Evaluating Oven Efficiencies and Curing Solutions

• Gas Catalytic Infrared: Hypothesis or Noteworthy Science?
Eric Bellon| Vulcan IR Systems
• Improving Oven Performance Through Self-Auditing
Lee McWhorter|TITAN-Catalytic

C33: How Sustainability Drives Powder Coating Usage

• Powder - The Sustainable Choice for Corrosion Protection
Matthew Rush|USCA PPG
• Furthering Sustainability in Powder
Sameer Shaikh|Arkema

Engineering Turnkey Finishing

Systems For Over 30 Years
Pretreatment Washers • Dry-off & Cure Ovens
Material Handling Systems • Environmental Rooms

MidwestFinishing.com
574-257-0099 | Mishawaka, Indiana

36 AUGUST 2024 — PFonline.com

INDUSTRIAL FINISHING EQUIPMENT EXPERTS

Your Best Finish

Starts With Us!

ECOAT | POWDER | LIQUID

Visit Booth W2301

Finishing Systems
Heat Processing Solutions
Material Handling Innovations
Customer Service | Spare Parts
Advanced Water Recovery Technologies

THERMA-TRON-X, INC.
 FABTECH 2024

WEDNESDAY, OCT. 16 THURSDAY, OCT. 17

8:00 – 9:30 AM 8:00 – 9:30 AM
C41: Batch vs. Automated Finishing Systems: C71: Maintaining Your Finishing Line
Which is Right for You? • Enhancing In-House Paint Removal for Sustainable Operations:
Nick Dawson|Koch Finishing Systems, Frank Mohar|Nordson Corp. Boosting Productivity and Reducing Operational Costs
Stephen Taylor|Atotech - An MKS Brand
C42: Forging New Frontiers: Robotics and Automation on • Innovations in Conveyor Chain Lubrication, Maintenance
Finishing Lines & Monitoring
• Are We Ready For Collaborative Paint Robots Justin Anderson|LubeCon USA
in the Finishing Industry? • Descaling a Washer
Barton Faylor|FANUC America Polly Higgins|Henkel Corporation
• Investing in Powder Automation
Micky Ricard|Sames C72: Water Conservation Through Reuse Solutions
• Water Reuse in the Finishing Industry
C43: Color Change Flexibility: To Infinity and Beyond! Thomas Neeley|Koch Finishing Systems
Jeff Hale and Ryan Allen|Gema USA Inc. • Conserving Resources - Driving Operational Savings to the
Bottom Line
WEDNESDAY, OCT. 16 Jeff Blain|Circle-Prosco Inc.
10:00 – 11:30 AM
C51: Down and Dirty: Cleaning Up Your Pretreatment C73: New Generations of Powder Coating Technology
Processes Sarah Mueller|PPG
• Minimizing Contamination in Your Pretreatment System
Mike Pypiak|Circle Prosco Inc. THURSDAY, OCT. 17
• Unlocking Cleaner Futures: Membrane Filtration 10:00 – 11:30 AM
for Profitability and Sustainability C81: See It, Touch It, Fix It
Carm Fernando|Hubbard-Hall David Schimpff|DuBois Chemicals Inc.

C52: How to Choose the Right Protective Coating C82: Technology Today to Prepare for Robotics in Finishing
Matthew Rush, Christopher Graniero and Sarah Sisley|PPG Tomorrow
Derek DeGeest and Brad Ruppert|DeGeest Corp.
C53: An Interactive Exploration of Infrared Curing for
Finishing Applications
Scott Bishop|EPRI

WEDNESDAY, OCT. 16
1:00 – 2:30 PM
C61: Consistency Across Unconventional Substrates:
Achieving Your Specification Goals
• You Want to Powder Coat WHAT?
Josh Gilmore and Micky Ricard|Sames
• Optimizing Coating Uniformity: Advanced Analysis and
Precision in Powder Application Processes
Marlon Boldrini|coatingAI, Aric Yarosz|Akzo Nobel Coatings Inc.

C62: You Don’t Know Me from Atom(ization)

• Understanding and Controlling Chaos in the
Atomization Process
Colin Horne|Carlisle Fluid Technologies
• Ultrahigh Transfer Efficient Rotary Atomizer Technology
Justin Hooper|Carlisle Fluid Technologies

C63: Consolidating Data for Effective Process Management

Jeff Halonen | Steelhead Technologies, Julian Carpenter | Bean’s Best LLC

38 AUGUST 2024 — PFonline.com

 FABTECHEXPO.COM

FABTECH 2024 Finishing Exhibitor List

Listed below are exhibitors in the Finishing Pavilion (as of July 1) along with corresponding booth numbers.

3D.aero GmbH .........................W2781 ECO Burn-Off Ovens ..................W2344 Luoyang Xincheng Precision Sherwin-Williams ......................W2612
4JET Technologies ....................W2212 Ecoclean Inc. .............................W2310 Machinery Co. Ltd..................W2487 Smak Handling ..........................W2550
Accudraft Paint Booths .............W2854 Elcometer Inc.............................W2255 MacDermid Enthone South Atlantic Galvanizing .......W2590
Airblast AFC ...............................W2755 Electron......................................W2670 Industrial Solutions...............W2884 Southern Fluid Systems ............W2253
AIS Finishing Systems ...............W2374 Elektrim Motors .........................W2445 MacDermid Envio Solutions .....W2886 Southern Systems
Akzo Nobel Coatings Inc. ..........W2634 Empire Abrasive Equipment Co.W2891 Magic Rack / Production International LLC...................W2548
Alabama Washer and Oven...... W2352 Epner Technology Inc................W2246 Plus Corp. ..............................W2409 Spray Systems Inc. ...................W2451
Amiberica Inc. ............................W2273 Ervin Industries .........................W2564 Mankiewicz Coatings ................W2270 Spray Tech Junair ......................W2675
Anest Iwata USA Inc. .................W2664 FAMIS Inc.................................... W2475 Marpol ........................................W2385 Sprimag Inc. ..............................W2447
ATL .............................................W2289 FANUC America Corp – Marvel Industrial Coatings ........W2806 Steelhead Technologies ............W2332
Atmospheric Plasma Solutions W2245 Paint Booth ............................W2729 Matech Makina ..........................W2388 Surface Engineering
Atotech / An MKS Brand ............W2313 Filter Junkie (Filterjunkie.com) W2485 Micron Fiber Tech ......................W2269 & Alloy Powders Inc ...............W2391
Axalta Coating Systems............. W2401 Fischer Technology Inc. ............W2874 Midwest Finishing Systems.......W2429 SurfacePrep ...............................W2365
Ayrven ........................................W2233 Frank Lowe ................................W2271 Mighty Hook Inc......................... W2508 System Technologies Inc. ........ W2441
AZZ Metal Coatings.................... W2304 Galv-Pro Products .....................W2364 M-Tek Spray Booths ..................W2474 TCI Powder Coatings .................W2201
Baril Coatings ............................W2481 GAT Finishing Systems ..............W2413 Narran Laser Cleaning............... W2288 Technic.......................................W2240
Bayco Ovens ..............................W2204 Gema USA Inc. ...........................W2620 NikoTrack ...................................W2844 Tecnofirma America Inc. ...........W2852
BCI Surface Technologies General Fabrications Corp. .......W2220 Nitrex Metal Inc..........................W2287 The Electrocoat Association .....W2247
(Bulk Chemicals Inc.) ............W2465 Global Finishing Solutions ........W2235 Nordson .....................................W2600 Therma-Tron-X Inc..................... W2301
Belco Industries Inc. .................W2355 Goff Inc.......................................W2771 Pangborn ...................................W2351 Thermion ...................................W2850
Blast Cleaning Technologies.....W2421 HafcoVac ....................................W2532 Parker Ionics ..............................W2715 TITAN-Catalytic..........................W2705
Blastec Inc. ................................W2471 Heatmax Heaters.......................W2292 Patriot Powder Coating.............W2260 Total Finishing Systems ............W2648
BlastOne International .............W2309 Hebei Hanna PEM Inc ......................................W2461 Trimac Industrial Systems ........W2707
BOCE Industrial Systems ..........W2208 Technology Co. Ltd. ...............W2688 Pollution Control Troy Chemical ............................W2249
Brush Research Manufacturing W2375 Hedson Technologies Products Co. ..........................W2215 Ultimate Linings ........................W2490
CALDAN Conveyor .....................W2280 North America .......................W2254 Polyhose - ExitFlex ....................W2293 United Finishing Systems .........W2348
CAPLUGS / SHERCON ................W2261 Henkel ........................................W2405 Porcelain Enamel Institute .......W2284 VaporTech ..................................W2544
Cardinal Paint and Powder .......W2241 Hentzen Coatings ......................W2504 Powder Coated Tough................W2749 Variable Inc. ...............................W2248
Carlisle Fluid Technologies .......W2640 HERR Industrial Inc. ..................W2368 Powder Coating Institute ..........W2749 Ventilation Solutions Inc...........W2753
Catalytic Industrial Systems .... W2433 IFS Coatings Inc. ........................W2721 PPG ............................................W2775 Vitracoat Inc...............................W2335
CESCO ........................................W2285 INTEK Corp. ...............................W2205 Prismatic Powders Cerakote ....W2890 Vulcan IR Systems .....................W2216
Chemical Coaters Association IntelliFinishing ...........................W2221 Products Finishing Magazine .....W2228 Vulkan Blast Shot Technology ..W2880
International.......................... W2341 IPCM International Paint Pulverit ......................................W2692 Wagner Industrial Solutions .....W2654
Circle-Prosco Inc. ......................W2574 & Coating Magazine ...............W2384 Railtechniek van Herwijnen ......W2390 Washington Mills Ceramics .......W2250
Clearclad Coatings ....................W2812 Jiangsu Renhe Environmental RAMPF Group Inc. ......................W2470 Webb-Stiles Co. .........................W2308
Colonial Coatings ......................W2213 Equipments Co Ltd. ...............W2275 Reliant Finishing Systems .........W2680 Wenker Inc. ................................W2371
Combustion and Systems Inc. ..W2209 Koch Finishing Systems ............W2701 RGI Spraybooths.Net.................W2761 Wheelabrator Group .................W2660
Daifuku America Corp. ..............W2370 Kresco Solutions Inc..................W2274 RHODIUS Abrasives ...................W2789 Winoa .........................................W2200
Decalcorama..............................W2291 KTA-Tator Inc. ............................W2244 Richard’s Paint........................... W2787 WolfRayet................................... W2846
Decoral .......................................W2381 KYZEN.........................................W2810 Richards-Wilcox Inc. ..................W2236 Worldwide Finishing
DeFelsko Corp............................ W2741 LDPI Inc. .....................................W2554 Rohner Finishing Systems LLC.. W2435 & Supply Inc. ..........................W2870
Diamond H2O ............................W2745 LestaUSA Integrated RollSeal Inc. ...............................W2814 Xiamen Daxing Industry ............W2888
Diamond Vogel Paint by DeGeest.............................W2317 RTT Engineered Solutions ........W2480 Zhengzhou Liyuan Haina
& Coatings..............................W2800 Linde Advanced Material Ruthman Companies- Gusher, Rectifier Co. Ltd. ....................W2588
Digilube Systems .......................W2484 Technologies .........................W2234 RAE and Process Systems’ Deming Zhongshan Tensun Welding
DI-MA..........................................W2366 Lineage Metallurgical ................W2386 VTP Pumps ............................W2252 Equipment Co. Ltd. ...............W2819
Dinamec Systems ......................W2412 LPI Lift Systems .........................W2455 Sames ........................................W2628 ZonePro .....................................W2286
DuBois Chemicals...................... W2229 LS Industries Inc. .......................W2361 Sata Spray Equipment ..............W2804
Dürr Systems Inc. ......................W2329 LubeCon.....................................W2265 SFX Laser....................................W2491

PRODUCTS FINISHING — PFonline.com 39

 FABTECH 2024 ON DISPLAY

Thermoset Powder Coatings Custom Turnkey Finishing Systems

For the past 76 years, Vitracoat has been a trusted family-owned Midwest Finishing Systems will
international manufacturing business and has become the larg- highlight its turnkey systems
est independent supplier of quality thermoset powder coatings for powder and liquid coating.
in the Western Hemisphere. With state-of-the-art research and Midwest delivers washers,
innovation centers, one of the largest powder production facili- ovens, environmental rooms,
ties in the world, and satellite locations in the U.S. and South material handling systems and
America, Vitracoat builds the products of today but are also dedi- system controls that are cus-
cated through research to develop the products of tomorrow. tom engineered and manufac-
Visit Booth W2335 to learn more about Vitracoat’s innovative tured to meet each customer’s
technologies, fast response and delivery, extensive stock color specific requirements. Midwest will also feature its unique
offerings, small batch capabilities, unmatched applied cost, finishing solutions for large, heavy and oversize parts, which
proprietary manufacturing processes, field technical service include batch and automated system options. Midwest Finishing
experts and national distribution centers. provides complete project management with its own in-house
Vitracoat Inc. | 888-778-5994 | vitracoat.com | W2335 engineering team and fabrication, transportation, installation
and service crews. From sales
to start-up, all operations are
Pretreatment Process Demonstration managed by 100% company
DuBois Chemicals is a one-stop shop for all your specialty chemical needs. DuBois’ Fab to employees. Equipment is
Finish demo will feature two of its outstanding products: Spirit 221, a low-odor, aliphatic solvent delivered on the company’s
degreaser; and DuraTEC 602, a zirconium treatment technology. Utilizing innovative accelerators, own truck fleet.
the DuraTEC 602 produces a dense, deep zirconium coating. Its industry-leading performance on Midwest Finishing Systems |
steel makes it the option for heavy equipment manufacturers’ pretreatment. The DuBois team 888-281-0099 |
looks forward to demonstrating its highly effective pretreatment process from start to finish. powdercoating.com |
Make sure to stop by and check out all the solutions for manufacturing DuBois has to offer. W2429
DuBois Chemicals | 800-438-2647 | duboischemicals.com | W2229

Trimac Paint & Powder Coating Systems

The Best in Innovative System Engineering & Technology.

Trimac manufactures best-in-class systems technology - with

1000’s of convection, gas catalytic and electric infrared ovens
and washers designed and installed worldwide, we are the
leader in high quality and energy efficiency in the paint and
powder coating industry.

Explore all the features and benefits of using a Trimac Custom

Turnkey System to wash, dry and cure your parts FAST!

– Reduce your floor footprint

– Reduce your CO2 footprint
– Reduce your production time
– Reduce your operating costs

trimacsystems.com 1-800-830-5112

40 AUGUST 2024 — PFonline.com

 FABTECHEXPO.COM

Powder Application Equipment Wastewater Treatment with Outstanding Water Recovery

Parker Ionics will have on display its latest Transform wastewater challenges with TTX Envi-
generation of powder application equip- ronmental. For surface finishers facing limited ac-
ment, the Proficy Series. Sales engineers will cess and strict municipal wastewater regulations,
be available to discuss how our Pulse Power TTX provides a groundbreaking solution. TTX’s
Advanced Corona Charging Technology will advanced industrial flow-through system, coupled
save money while improving the coating with Membrion’s electro-ceramic desalination
finish. Keep valuable revenue in your pocket technology, ensures exceptional results. Rigorous
instead of your waste stream. testing has shown dramatic reductions in conduc-
Parker Ionics will also discuss powder tivity and impressive high-water recovery rates.
coating booth requirements and share valu- Looking for a wastewater treatment system
able cost saving concepts. with outstanding water recovery? Contact TTX
A 3-D model of our Compact Configurable Shuttle System will Environmental today for innovative, customized solutions tailored
be on display to help you understand the value of adding this to to your specific needs. Choose TTX for unparalleled performance
your production floor. and reliability — don’t settle for less.
Parker Ionics | parkerionics.com | W2715 TTX | ttxinc.com | W2301

Hybrid Oven Features Catalytic and Electric Infrared Technology

Trimac Industrial Systems will be featuring its new innovation, the Pro-Cat oven. The Pro-Cat’s hybrid de-
sign is a combination of the fastest curing technologies available – the Protherm electric infrared with Gas-
Cat catalytic infrared – resulting in the fastest, most controllable and efficient system available. Trimac is
the only company in North America that manufactures convection, gas catalytic and electric infrared. With
almost 40 years of design history, and thousands of ovens and washers installed worldwide, Trimac has the
experience to design, manufacture and install a turnkey finishing system that meets your requirements.
Trimac Industrial Systems | 800-830-5112 | trimacsystems.com | W2707

PRODUCTS FINISHING — PFonline.com 41

 FABTECH 2024 ON DISPLAY

The Industrial Finishers’ Squad IR Heating Systems Reduce Downtime While

The CPI Solution Squad works chemical magic for some of the Improving Carbon Footprint
biggest brands in the business and for small custom coaters, For powder or liquid coatings,
alike. CPI chemists and technical service experts crawl through adhesive activation, polymeric
the dirtiest tanks, tackle the toughest soils and analyze the most thermoforming and heat sensitive
elusive defects to solve customer’s trickiest problems. If you’re substrates, Vulcan IR Systems are
facing a paint-line problem with no way out, stop by the CPI a must. Globally recognized for
booth. 25-plus years, Vulcan’s chemi-
Circle-Prosco Inc. | circleprosco.com | W2574 cal catalyzation, industrial heating process solutions have proven
effective in markedly increasing throughput yet reducing footprint,
operational costs and downtime, while minimizing carbon footprint.
Immersion Heaters for Finishing As CCAI-FAB to Finish partner members, the Vulcan enhanced ex-
Heatmax Heaters is a US-based company hibit showcases a fully functioning gas catalytic infrared oven, live
specializing in the design and manufactur- powder curing demonstrations and a wealth of expert information.
ing of electric immersion heaters for the Don’t miss Vulcan Technical Sales Manager Eric Bellon’s
surface finishing industry. Its extensive presentation, “Gas Catalytic Infrared: Hypothesis or Noteworthy
metal finishing product range includes Science?” on Tues., Oct. 15, from 3 – 4:30 p.m.
stainless steel, Incoloy, titanium and fluo- Vulcan Technical | vulcanir.com | W2216
ropolymer (PTFE) over the side heaters.
UL/CSA listed, its heaters have been Powder Coating and Batch Systems
trusted and used by professionals in the United Finishing Systems specializes in complete paint and pow-
industry for over 70 years. der coat finishing and batch systems. In addition to paint sys-
Designed to ship quickly and reliably. tems, the company offers design, installation, system modifica-
Visit booth W2292 and ask about lead- tions, system relocations with a full in-house service department.
times and on-time delivery record. United Finishing Systems will “build it the way you need it” and
Heatmax Heaters | 800-321-3574 | will stand by you from the beginning of any project to the end.
heatmaxheaters.com | W2292 United Finishing Systems | unitedfinishing.net | W2348

Going Above and Beyond

Aluminum Finishing issues for Automotive st,
o above
Aluminum is the fastest growing substrate in the automotive industry.
Rely on Luster-On finishes for your automotive applications!

Luster-On Kemo Luster-On

Aluma Blue LQ 490L
Blue dye used Aluminum deoxidizer
to identify which resolves
non-hexavalent AL2024
chromate conversion compliance issues.
coatings.

Luster-On Aluminescent
Trivalent Chromate conversion coating for Aluminum, Mil Spec approved and
RoHS, WEEE and ELV compliant...the most economical TCP!

KEMO ALUMA BLUE MEANS NON-HEX!!!

LUSTER-ON PRODUCTS, INC.
[email protected]
www.luster-on.com

42 AUGUST 2024 — PFonline.com

 FABTECHEXPO.COM

Sames Inocart Systems for Manual Powder Coating Fischer Measurement and Material Analysis Systems
The Inocart VT (vibrating table) system by Sames is a manual For over 40 years, Fischer
powder coating system that pairs the Inogun M spray gun Technology has been provid-
with the Inobox control module for optimal performance. It ing businesses across North
features quick color changes, efficient powder transfer using America with the best in
TEC5 technology and easy operation. This system is ergo- benchtop, handheld and inline
nomically designed, it offers a consistent spray pattern, high automated coating thickness
transfer efficiency and reduced processing time. The system measurement and material
is built for durability and includes advanced features for analysis solutions. See what
easy maintenance and superior finish quality, making it ideal Fischer can do for your business.
for industrial applications. In addition to the vibrating table Fischer Technology Inc. | 800-243-8417 |
system, hopper feed, high flow and non-destructive testing fischer-technology.com | W2874
solutions are offered.
SAMES | sames.com/usa/en | W2628 Custom Engineered Conveyor
and Material Handling Systems
Choose from More Than 400 Powder Coating Options Since 1956, Webb-Stiles Co. has been engineering, fabricating,
Sherwin-Williams new services make it easy for all businesses to installing and commissioning custom conveyor and material han-
access the resources of a global leader. With the Stock Powder dling systems.The company’s equipment and systems are in many
Program, choose from 400-plus powder coating options, from industries including agriculture, appliance, automotive, building
RALs to architectural-grade powder, available to order from one products, finishing, foundry and casting, tire and rubber, the defense
of the company's 90 locations. FASTTrack services offer many industry and more.
liquid products in 1- or 5-gallon pails available for pickup or ship- Floor conveyors to overhead systems, Webb-Stiles Co. does it
ping within 24 hours. all — from turnkey systems to one-off pieces of equipment.
Sherwin-Williams | 800-233-8769 | sherwin-wiliams.com | Webb-Stiles Company | webb-stiles.com | W2308
W2612

Powder Coatings that

Perform,
Innovation that
Transforms,
More Sustainability
for the things that
really Matter.

Contact us at:
[email protected]
Follow us on
Ph: (574) 264-6090
www. vitracoat.com
www.vitracoat .com Toll-Free: (888) 778-5994

PRODUCTS FINISHING — PFonline.com 43

 FABTECH 2024 ON DISPLAY

Energy Efficient SprayWand Going Above and Beyond

Pretreatment System Belco is easy to work with, available 24/7, and has the safest, most reli-
PEM Inc., a leader in providing innovative able and long-lasting equipment. Belco products go above and beyond
batch and automated finishing equip- manufacturing requirements, minimize floor space and offer the low-
ment to OEMs, fabricators and job shops, est operating costs possible. Belco’s commitment to customer support,
will display its SprayWand, FinFlow its diversified product line and willingness to respond to the growing
and SprayLean brands. The company and changing demands of finishers makes Belco an industry leader.
will showcase its new P-450 energy ef- Belco Industries Inc. | belcoind.com | 616-794-0410 | W2355
ficient SprayWand Pretreatment System
and the SprayLean Modular Washer, as well as its new E-300
SprayWand with electric heat. Vulkan Blast Shot Technology
PEM Inc. | 800-969-1601 | pemequip.com | W2461 Vulkan Blast Shot Technology offers high quality products and
technically trained sales reps to assist in making the right choice
for your stainless steel abrasive media requirements tailored to
Industrial Paint Finishing Systems and Equipment your needs. Vulkan customers also receive complementary on-
HERR Industrial Inc. is a site machine / finish evaluations to ensure the highest level of
design-build manufacturer of blasting efficiency and ultimate satisfaction.
industrial paint finishing sys- Vulkan Blast Shot Technology | vulkanshot.com | W2880
tems and equipment. The sys-
tems are customized to meet
the specific requirements of a Masking Solutions
particular product, produc- Whether you need a catalog part or a custom solution, Caplugs/
tion rate and process. The company’s in-house personnel engineer Shercon specializes in reliable, economical masking solutions with
fabricates and installs the equipment, including conveyors, spray short lead times. More than 13,000 masking catalog parts in stock,
washers, booths, ovens, environmental rooms and so on. including caps, plugs, tapes, die-cuts, hooks and more, as well as
Herr Industrial Inc. | 80070043774377 | temperature-resistant options for demanding finishing processes.
herrindustrial.com | W2368 Caplugs | caplugs.com | W2261

Painting excellence
for every surface
Bringing your surface to perfection.
Dürr offers high-quality and easy
to integrate painting solutions from
manual to automatic.

See us at
FABTECH
booth
W2329

www.durr.com

44 AUGUST 2024 — PFonline.com

 FABTECHEXPO.COM

Gema to Display Latest in Powder Coating Technology Reliant Finishing Systems

Gema will display the new Since 2005, Reliant Finishing Systems has designed and manu-
Optigun GA04 automatic guns, factured thousands of appliances for powder coating, industrial
while also demonstrating the painting and thermal processing including blast rooms and blasting
Dynamic Contour Detection laser equipment, multistage pretreatment washers, wash booths, spray
scanner. The laser scanner is wand systems, drying ovens, compressors, conveyors, powder guns,
designed to automatically detect powder coating booths, curing ovens and engineered finishing lines.
object geometries. The OptiSpray Reliant Finishing Systems | reliantfinishingsystems.com | W2680
all-in-one powder application pump will also be on display. It is
the first product to merge Smart Inline Technology, dense phase Products for Applying Sprayed Materials
powder delivery and electrostatics into a single compact unit. Carlisle Fluid Technologies features products for the application of
Explore Gema’s cloud-based digital intelligence tool, Gema- sprayed materials including paints, coatings and powder. New prod-
Connect, and try the OptiFlex Pro manual spray unit, featuring ucts include IntelliFlow RF2 for one-, two- and three-component
the highest charging power in the industry. metering, mixing and flow control, DVX industrial spray gun, the
Gema USA Inc. | 800-628-0601 | IntelliCoat IC24 Powder System and the RMA 600 Series and more.
gemapowdercoating.com | W2620 Carlisle Fluid Technologies | carlisleft.com | W2640

Efficient Solutions for Parts Cleaning and Surface Processing

Ecoclean's EcoCcore system degreases industrial parts with modified alcohols or hydrocarbons in a
closed loop system, offering maximum flexibility and high capacity throughput, with optimized cost ef-
ficiency. The EcoCcompact is compact solution for economical solvent cleaning. This single-cham-
ber cleaning system offers short cycle times combined with a maximum of flexibility for diverse
cleaning tasks. With its flexible modular system (from one to three tank version), the machine is
easily adapted to individual customer needs. The EcoCwave for aqueous parts cleaning is a pow-
erful spray flood cleaning system with a vacuum-tight work chamber, which can be equipped for
either two or three independent cleaning steps.
Ecoclean Inc. | 248-450-2586 | ecoclean-group.us | W2310

PRODUCTS FINISHING — PFonline.com 45

 FABTECH 2024 ON DISPLAY

Explosion-Proof Collaborative Paint Robot RazorStar Line of Belts, Quick-Change and Fiber Discs
FANUC’s new CRX-10iA/L Paint cobot is Saint-Gobain Abrasives will
the first explosion-proof collaborative exhibit a range of abrasives
paint robot for use and sale globally. that optimize the user
The CRX-10iA/L Paint cobot unlocks the experience. Products to
benefits of automation for more com- be featured include the
panies, including high-mix, low volume latest in grinding, cut-off,
operations, in the painting, powder and/ blending and finishing
or gel coating (with fiberglass reinforce- solutions to address today’s
ment) industries. “Easy-teach” features challenging application re-
include drag-and-drop programming quirements. The company
with graphical icons and “lead through will highlight its Norton
teach” capabilities. RazorStar belts, quick-change and fiber discs featuring innova-
The CRX-10iA/L Paint cobot has a tive engineered-shaped ceramic grain, a revolutionary technol-
payload of 10 kg as well as the longest ogy with unbeatable performance and metal removal rates in the
reach in its class, at 1,418 mm and is toughest grinding applications when performing off-hand and/or
lightweight at 45 kg. As with other CRX cobots, this cobot is automated grinding.
maintenance-free for 8 years. Norton Abrasives, Saint-Gobain Abrasives Inc. |
FANUC America | 888-326-8287 | fanucamerica.com | W4817 800-446-1119 | nortonabrasives.com/en-us | W3301

Sustainable Paint Pretreatment and Paint Removal Solutions

Atotech / An MKS Brand is excited to showcase its portfolio of sustainable paint pretreatment and
paint removal products. Its line of UniPrep alkaline cleaners feature long life, low temperature
operation, Master Remover high efficiency paint removal technologies, Interlox P-free multi-metal
pretreatments, and UniPrep AC weld and laser scale removers.
Atotech/MKS | atotech.com | W2313

46 AUGUST 2024 — PFonline.com

 FABTECHEXPO.COM

Find the Wastewater Treatment Solution PosiTector GLS Gloss Meter

for Your Process DeFelsko offers PosiTector and
MacDermid Envio Solutions (MES) focuses on delivering PosiTest instruments includ-
wastewater treatment and recycling systems as well as system ing the PosiTector series of
care and services to its customers and markets. The compa- interchangeable probes for
ny’s goal is to serve customer needs by developing sustainable measuring coating thickness,
products, processes and technologies that meet or exceed en- surface profile, environmental
vironmental standards while providing commercially compel- conditions, salt contamination, hardness, gloss and wall thickness.
ling solutions that markets expect, thus assisting customers Popular products for powder coaters include PosiTector
in reaching their environmental sustainability goals. As part 6000 coating thickness gages, PosiTest OTL Oven Temperature
of a multinational chemical company, MES designs waste- Logger, PosiTest Powder Checker to measure uncured powder
water treatment systems with a complete understanding of thickness and PosiTector GLS Gloss Meter.
the chemical processes its customers operate. Visit the MES The PosiTector GLS Gloss Meter measures gloss, reflectance,
team of experts for guidance in finding the perfect wastewater and haze. Select up to three measurement angles to suit any
treatment solution. application, save readings into memory and transfer them to
MacDermid Envio Solutions | 803-412-3808 | PosiSoft software to archive data and generate reports.
macdermidenvio.com | W2886 DeFelsko Corp. | 800-448-3835 | defelsko.com | W2741

Full-Face Breathing Protection System

The SATA air vision 5000 offers effective health protection and a comfortable way of breathing. With
its modern, ergonomic design, the hood can be adapted to fit almost any head shape, enabling the
adjustment of circumference, height and position.
Painters are exposed to solvents, sanding dust and overspray. It is important to protect their
respiratory tracts as well as their eyes, hair and skin. The supplied-air hood and belt unit contains a
large field of vision, and the soft stream airflow enhances comfort.
SATA Spray Equipment | 800-533-8016 | satausa.com | W2804

Paint or Powder Coat Systems...

WE BUILD IT THE WAY
YOU NEED IT!
Complete paint and powder
coat systems
Individual finishing equipment
Design/engineering
In house installation
System relocation
System modifications/upgrades
Preventative maintenance
training
Project management
Parts and Service
unitedfinishing.net
704.873.2475

PRODUCTS FINISHING — PFonline.com 47

 CLINIC POWDER COATING PFonline.com/zones/asktheexpert

Factors Affecting Job Shop Powder Coating

Profitability Chipping on
Q. We are fairly new in the powder coating job shop business. We have
found that our quoting and process are uneven: we are not really hitting
Aluminum Extrusion
the margins we want on all our jobs. One issue we have identified includes Q. We currently powder coat a variety of parts,
a typical reject rate of around 5%. Some parts have higher yields, but the mostly steel. We have had some opportunities
average is too high. Another issue is the coating thickness. Light coating to coat aluminum extrusions. We clean parts
and orange peel are a major part of our rejects. We also have a hard time with a blast process or three-stage hand wash.
getting the throughput we plan on when we quote a project. Can you ad- We have done a few jobs, but we have seen a
vise us on quoting methods and other issues that affect profitability? few field failures where the coating is easily
chipped off the extrusion. Do you have any
A. This is an interesting question that I have seen examples of before. A lot thoughts on what might be causing this?
to talk about here. Profitability in a job shop begins with the part to be
coated, how it will be hung and how many good parts can be coated in A. Aluminum has a tight oxide layer that can be
a given time frame. Before the part can be quoted, the racking method removed, but oxidation occurs rapidly after
and throughput must be determined. For a conveyor line like you cleaning or blasting. Initial powder adhesion
describe, the racking density is critical. Parts should be close enough might appear to be good, but any exposure
for efficiency but with enough space to easily and accurately reach to heat and moisture can lead to delamina-
and cover all surfaces. Contacts should be clean and the parts kept in tion and failure. Blasting might work, but
a steady position. Racking should be consistent with full racks and the there is no certainty. The only way to get
same position all the time. reliable results with powder on aluminum
First, you need to understand the principles of good racking. As I that will be used outdoors is to use an
mentioned, good density is key. Second, the parts should be positioned so aluminum conversion coating that neutral-
they can be easily accessed and easy to see. They should be held in a stable izes the surface so the oxide cannot rapidly
and consistent position. There should not be any large gaps between racks reform. Traditionally, chromic acid was used
— as long as there is sufficient time to coat the parts based on the line speed to provide good adhesion and long-term
and number of guns. Contacts must always be clean so there is no way a corrosion resistance. Non-chrome products
part can be insulated from earth ground by coating buildup. Good racking is are now available that work very well.
important for profitable coating. I suggest you contact a chemical supplier
Once a good racking density has been determined, you are ready to quote. regarding options that will work in your
The factors are labor, material, variable line burden, fixed cost and scrap shop, and consider the operational issues
or rework. Calculate each total per hour and then divide by the throughput and the cost. You may find a good product
to come up with a piece price. There is a detailed description of the quote that fits. You can test these products with
method in a previous edition of Products Finishing called Calculating the a wet adhesion test as described in AAMA
Cost of Powder Coating: short.pfonline.com/powdercalculator. 2604 or 2605. The surface is cross-hatched
Once you have the job and begin production, you will need to measure and subjected to boiling demineralized
and record the setup of the spray equipment and quality results. First-pass water for 20 minutes. After removal from the
yield with powder coating should typically be in the high 90s. If you find water, a tape pull test can be used to confirm
that you have a lot of issues (light coat, heavy film, orange peel), you should adhesion. If this test is successful, the part
examine the racking and gun setup to determine what issues are at the root should be good. If it consistently fails, the
cause. For example, if the issue is light coating, you may need more manual product is not adequate for your parts. The
operator training, more guns, more flow or something else to pick up the wet adhesion test is also a good quality
film thickness. This assumes you have good earth ground. Poor ground will control measure.
radically affect film uniformity and cover.
Work on your racking and think of the rack as a tool, not just a hook.
Maintain racks at all times. Get the line operators the tools, time and training RODGER TALBERT
they need to do good work. Measure and react to the film thickness, Consultant
coverage and first-pass yield. Keep everything clean and in good working
order. Finally, if a job is not making any money and you conclude it is Rodger has more than 30
years of experience in the
quoted too low, raise the price or stop doing those parts. You cannot run
powder coating industry.
parts well below margin without serious losses.

48 AUGUST 2024 — PFonline.com

 CLINIC AUTOMATION PFonline.com/zones/asktheexpert

Powder Coating Automation Can Reach

ESG Goals for Automotive Parts
Q. Our company is working to strengthen our corporate environmental, social and governance (ESG) goals.
I have been asked to identify opportunities within our process. Is there anything new for the automotive
industry that can help improve our ESG, primarily focusing on our primer line?

A. A few new processes can impact your material consump-

tion. Powder is an alternative to improve material
consumption because powder can be reclaimed, unlike
liquid material.
Some automotive plants use robotic process auto-
mation (RPA), a quick-disconnect robot-mounted
powder applicator, primarily to apply powder prime.
The applicator has no moving parts, so its maintenance
cost is minimal. The bell-like pattern enables wide,
flexible pattern size and can provide bell or gun-like
patterns, meaning it can be used on both broad areas
and cut-in areas. With minimal impact fusion, the
applicator can reduce gun spits. The gentle powder
handling permits better powder with fewer issues,
while providing superior film build uniformity and
improved patterns.
By adopting the RPA powder applicator, a plant can
make significant savings for both the environment and Source: Getty Images
the bottom line. With its increased flow rates of up to
800 g/min, an application will require fewer robots or
machines, leading to lower capital costs and reduced
operating expenses. The applicator’s lack of moving parts SHOW OFF
also contributes to additional savings.
While the RPA powder applicator offers increased flow
YOUR WORK!
rates, it requires a dense-phase powder delivery system
to meet its demand. However, this system also brings
numerous benefits, including no powder damage, implicit
closed-loop mass flow control, smooth powder flow (zero
pulsation), and ± 2-gram repeatability, ensuring precise
and efficient powder application.
While this type of powder system might not be
suitable for every application, it offers numerous
benefits, particularly when considering new processes
to align with your company’s ESG goals. The poten-
tial environmental impact of this choice can inspire a
positive change in your operations, making it a compel-
ling option to consider. Products Finishing is looking for reader photos to
highlight in our popular column, Photo Finish.
SUBMIT BY EMAIL TO:
NICOLAS GERVAISE [email protected]
Carlisle Fluid Technologies
OR SCAN HERE
Nicolas Gervaise is global product
manager – powder for Carlisle Fluid
Technologies. Visit carlisleft.com.

PRODUCTS FINISHING — PFonline.com 49

 CLINIC PLATING PFonline.com/zones/asktheexpert

The Benefits of Electroless Nickel Plating

Q. We have a well-established customer offering us an opportunity to get into electroless nickel work with an
available line we have. Can you provide an overview of the benefits of electroless nickel plating, including the
different categories, and the differences and applications of each?

A. Electroless nickel plating is a coating process that deposits

a nickel-phosphorus alloy onto a substrate without the use
of an external current source. This barrier coating process
adheres to a variety of substrates and protects the substrate
by sealing it off from the environment, rather than by tradi-
tional galvanic or sacrificial action. It is worth noting that
electroless nickel plating can also deposit a nickel-boron
alloy onto the substrate, but for the purposes of this article,
we will limit our focus to the nickel-phosphorus alloy, which
is more commonly used throughout the plating industry.
Key benefits of electroless nickel plating include
uniform coating, durability and corrosion resistance.
Electroless nickel’s coating capability is well known for
depositing an even layer across complex geometries. From
Source: Getty Images
a durability standpoint, high hardness and wear resis-
tance are important considerations for industry applica- this coating typically ranges from 600-700 Vickers (HV) as
tions, with the coating having an ability to achieve up to deposited, which can increase to approximately 850-1,100
1,100 Vickers (HV) when properly heat-treated. Finally, Vickers (HV) after a post-plate heat treatment.*
the amount of nickel-phosphorus alloy in the EN coating Medium-phosphorus electroless nickel plating contains
has the ability to provide superior corrosion resistance a range of 6-9% phosphorus and is the most popular choice.
and hold up well in harsh environments. Lubricity is an It is commonly selected by engineers and applicators as
additional benefit of electroless nickel coatings, and is it is the most well balanced and versatile of the three,
especially applicable for hydraulic applications, valves and providing both excellent hardness and corrosion resistance
other moving parts where friction reduction is necessary. for a variety of industry applications, such as oil and gas
From an overall industry perspective, electroless nickel equipment, automotive engine components, industrial
is commonly used in the oil and gas field for drilling equip- machinery and tools, aerospace landing gear and more.
ment, valves and pumps as it offers excellent durability, The hardness of this coating typically ranges from 500 to
wear resistance and protection against harsh environ- 600 Vickers (HV) as deposited. A post-plating heat treat-
mental conditions. In the automotive industry, it is used ment can increase it to approximately 800-1,000 Vickers
for engines, fuel systems and additional components that (HV). Medium-phosphorus electroless nickel offers strong
require high wear resistance. A similar workhorse environ- performance benefits and is more cost effective than high-
ment where it can be found is in the aerospace industry phosphorus coatings. It is widely used and known to be easy
where electroless nickel’s durability and protection is to implement and control for various industrial settings.
needed for the extreme conditions to which engines, High-phosphorus electroless nickel contains a range of
turbine blades and landing gears are subjected. The process 10-12% phosphorus. Its primary performance feature is its
is also used in the medical and electronics industries. superior corrosion resistance in highly acidic or corrosive
Electroless nickel is broken down into three categories (such as marine and chemical processing) environments.
of high, medium and low phosphorus-containing deposits. It has a lower hardness value (only 450-525 Vickers HV
The varying amounts of the phosphorus contained in the as deposited), but can be heat-treated after plating to
deposits dictate the specific wear resistance, hardness and improve hardness properties (to 850-950 Vickers HV).
corrosion protection properties of each, which can help
determine the suitability for various applications.
MARK ADAMS
Low phosphorus electroless nickel plating falls into
Columbia Chemical
the range of 2-5% phosphorus and offers the highest wear
resistance and hardness. Performance-wise, it has lower
Mark Adams, CEF, CFS, is a technical
corrosion resistance and contains magnetic properties. It is account manager at Columbia Chemical.
often suitable for hydraulic cylinders, pistons and other parts For more info, visit columbiachemical.com.
that routinely endure abrasive conditions. The hardness of

50 AUGUST 2024 — PFonline.com

 PLATING CLINIC

*The heat treatment process is performed in a controlled of the electroless nickel process is not overly complex.
atmosphere and typically involves heating the plated compo- Pretreatment cleaning and activation prior to plating are
nents to temperatures between 300°C and 400°C (572°F to critical steps to ensure proper adhesion. As previously
752°F) for 1-2 hours. The exact temperature and duration mentioned, heat treatment can be applied after plating to
can be adjusted based on the desired hardness and the specific increase hardness and wear resistance. Good filtration,
application. The choice of substrate can influence the effective- routine bath analysis and replenishment are also important
ness of heat treatment. components of managing the process. Some electroless
When looking at the three categories of electroless nickel systems contain cadmium and lead while others on
nickel, it is also helpful to consider the end-use environ- the market are cadmium and lead free. RoHS compliance
ment of your application from an acidic versus alkaline can also be a determining factor for applicators. Be sure to
standpoint to further determine the phosphorus content work with a knowledgeable chemistry supplier who can
needed. For highly acidic environments, high phos- help you select the proper type and optimize your line for
phorus electroless nickel is the preferred choice based maximum efficiency.
on its corrosion-resistant properties. For alkaline or To summarize, electroless nickel plating provides
mildly acidic environments, medium phosphorus elec- a uniform barrier coating which can offer strong wear
troless nickel is a good and versatile choice, offering resistance, excellent corrosion resistance and enhanced
the right balance of corrosion resistance, hardness and hardness, all of which make it a highly desirable choice in
cost-effectiveness. Medium-phosphorus is suitable for a various industrial applications. These performance attri-
broad range of industrial applications where exposure to butes will vary based on the amount of phosphorus in the
alkaline substances is common. Low-phosphorus coatings coating, and heat treatment can be used to further enhance
offer good performance in alkaline conditions, but are the hardness of electroless nickel coatings. Reviewing the
less effective in acidic environments. performance requirements, applications and environmental
As you consider the option of putting in an electro- factors the coating will be subject to, as well as selecting
less nickel line, know that applicators often appreciate the phosphorus content that will meet those specific needs
electroless nickel for its fast deposition rate, excellent will help you ensure the protection and longevity of your
bath stability and long solution life. After setup, operation finished components.

33rd Annual
Anodizing Conference & Exposition
Anodizing: The Finish Register
R gister by

October 1–3, 2024 Sept.

ept. 3rd
to Save!
Hilton Cleveland Downtown • Cleveland, Ohio USA

Two General Sessions &

12 Breakout Sessions
provide a wealth
of education and
information to advance
your company and
career to the next level !

Focus & General Sessions • Anodizing EXPO • School for Anodizers • Networking

Visit Anodizing.org/AnodizingConference for more details!

PRODUCTS FINISHING — PFonline.com 51

 CLINIC TANKS PFonline.com/zones/asktheexpert
p t

Selecting High-Capacity Anodizing Tanks

Q. We need high-capacity anodize tanks for a busy shop. How can we make sure they’re made right,
won’t leak and won’t cause a disaster if someone backs a fork truck into one?

A. Process tanks subject to high temperatures and corrosive

compounds, in factories with elevated potential for mechan-
ical damage, need careful qualification to be successful long
term — and by “long term,” I mean decades. The expected
service life of a properly qualified anodize tank, used contin-
uously or nearly so, is north of 20 years.
To achieve that longevity, chemical compatibility, oper-
ating temperatures (and peak temperatures) and durability
are the buyer’s first priorities. Durability, of course, includes
several factors related to structural design, including
compressive stress potential and the specific gravity (relative
density) of the tank contents. Thermal expansion (linear
and volumetric) is also an important design factor.
Source: Tri-Mer Corp.
Given those considerations, the four most effec-
tive material options are homogeneous thermoplastics, bends or showing other chemical damage. It was usually easy
including polypropylene, co-poly and CPVC*, and steel to see that the tools used to make those tanks were not up to
alloys. Coated mild steel and lined carbon steel are workable the task demanded by an industry where solvents, acids, alkalis
for lighter duty applications, but generally don’t have the and heavy metal solutions are commonplace. The direct costs
staying power required for commercial anodizing. of draining and decontamination — and downtime — caused
Homogeneous thermoplastics are favored because the by these occurrences were always consequential.
material has a high strength-to-weight ratio, is corrosion- One side note about tank damage: on several occasions, the
resistant and highly resilient. Tanks are easily repaired if cause of those tank emergencies was not obvious — and the list
there is a wayward forklift; properly patched thermoplastic of possibilities was as long as the number of fingers pointing.
tanks maintain their integrity throughout their service life. Was it valve vent failure? Thermostat malfunction?
They’re also easy to install in the field. Overheating of fluids that precipitated a vapor release? When
The highest quality thermoplastic tanks are fabricated from the cause is unclear, it pays to have partners. Our longstanding
virgin material. That material, however, has a requirement relationship with the manufacturer of our thermoplastic sheet
of its own for best results: fabrication machinery and tooling material enabled us to quickly arrange for a detailed assess-
that can perform the secondary fabrication processes required ment by that manufacturer’s lab. That association, and our
while maintaining the structural integrity of the material. ability to guarantee there would not be a repeat of the issue
Extrusion welders, butt welders and CNC machines are with the new tank we built, established a 3-way relationship
the three most necessary tools for fabricating sheeted ther- that all the affected shop owners found valuable.
moplastics destined for heavy service. Extrusion welding is a Process tanks are literally the foundation of finishing.
continuous, rather than “stop-start” process that minimizes There’s no substitute for thoughtful design and selecting a
the risk of air pockets forming in the material and ruining a vendor based on their experience, fabrication resources and
weld. It also eliminates the need for workers to scrape off the others they can add to your team — whether the RFQ is for a
contaminants that can compromise weld quality. Butt welds single pretreat tank or a 14-stage anodize line.
provide total fusion of the filler material and are generally *CPVC - Chlorinated Polyvinyl Chloride - is a thermoplastic
stronger than the materials they’re joining. Butt welds are used with corrosive fluids at temperatures up to 210°F. It has
the permanent leak preventive for thermoplastic tanks; they a low affinity to scaling and chemical resistance equivalent to
also minimize distortion. In the hands of experienced design standard PVC.
engineers, CNC machines and software produce tanks with
the closest tolerances and most precise finishes.
There are other tools and processes needed to fabricate ASA HALLIDAY
Tri-Mer Corp.
tanks from less-common thermoplastics, including CPVC*;
we can explore these separately.
Asa Halliday is sales manager
As sales manager for Tri-Mer Corp., I’ve had numerous
for Tri-Mer Corp. Visit tri-mer.com.
“emergency” visits to finishing facilities where tanks — often
not very old — were weeping chromic acid, leaking at the

52 AUGUST 2024 — PFonline.com

 NEVER FINISHED

The Disconnected American Worker

Virtual meetings and the ability to work remotely have created new
flexibility in how we work, but at what cost?

Having lived through the workplace transformation that thick lines between work
took place during and following the pandemic many have life and personal life it
lost perspective on how profoundly the world of work has fosters and encourages
changed in the last four years or so. The experience of a the overlap of the two MATTHEW KIRCHNER
close friend recently brought this into focus for me. in the daily life of its Host of the TechEd Podcast
Following an extremely successful career he sold his team members. During [email protected]
company pre-COVID and retired at a young age. Earlier this time individual
this year, when a company in which he had invested direly team members can share a bit about their personal life and the
needed his expertise and leadership, he reentered the work- team learns more about their teammates.
force. In a conversation a few days following his return he Get Social. I’m a big fan of integrating social activities into
marveled to me at the way the company was able to pull work events like trade shows and conferences. When a good
together a virtual meeting of senior leaders on quite short portion of the team is traveling together, taking time off for
notice. Separately, he was amazed that he could participate gourmet cuisine or an afternoon at a high-tech driving range
in a virtual meeting with a colleague and see the person and can let members get to know each other in a more casual
materials being presented at the same time. Of course, what environment and thereby become more connected to one
appeared miraculous to him seems mundane and obvious another. A personal example: Last November while in Phoenix,
to almost anyone in today’s workplace but to him it was all Arizona I joined a group of teammates for a hike up Camelback
quite novel. His experience provides a stark reminder of Mountain. The experience left the group with a sincere sense
how much we’ve changed in the past half decade. of accomplishment and built camaraderie in ways a virtual
These changes are not all for the better. While the icebreaker never could. Including employees who otherwise
advancements and transitions in the way we work have might not be in attendance for team dinners and business
provided unprecedented improvements in efficiency and travel is a great tactic as well. In our distribution companies
employee flexibility, they are taking a toll on the workforce, it’s not uncommon to see our administrative team, customer
as highlighted by a recent article in the Wall Street Journal service reps, accounting staff and interns join the sales and
entitled “The Loneliness of the American Worker” (Te-Ping senior leadership teams at trade shows, conferences and
Chen, May 27, 2024). The article cites a 2023 survey by customer dinners. The resulting connection they can build to
Bright Force indicating that 40% of fully remote workers the company and its stakeholders is invaluable.
go days without leaving the house and per Cushman & Encourage Outside Friendships. I love hearing stories
Wakefield those of us who do go to the office spend nearly a about our team members having dinner together, taking care of
25% of our time in virtual meetings while there. each other’s pets to accommodate personal travel and building
Loneliness has myriad causes, but there’s plenty of friendships along the way.
research indicating that a sense of disconnectedness ranks Focus on Wellbeing. Take time in senior leadership
high among them. Remote workers trapped in the house for meetings to talk about the wellbeing and connectedness of
days? 25% of our time in virtual meetings even when we’re team members, especially the newer ones or individuals who
in the office? Is it any wonder the American Worker feels might be at risk of feeling disconnected.
disconnected and thus lonely? Get Out of Your House. Practice what you preach and get
While the contributors to loneliness certainly go deeper into the office and out in the field with team members and
than what happens during work hours, employers can do customers. Leaders who expect team members to be social,
plenty to alleviate the problem. outgoing and connected but spend their own time tied to
Connect the team to its mission. One team I know well virtual meetings on a home computer are missing the point.
takes time in its weekly meeting to share how their activi- Leaders get the behaviors they exhibit, expect and tolerate.
ties and those of their teammates reflected the words in Protect Your Culture. Finally, be a staunch protector of
the company’s mission statement. This activity not only a culture that fosters connection and respect among team-
reinforces the importance of the organization’s mission, it mates. Constructive feedback and suggestions are encouraged,
provides team members with a nice opportunity to interact personal attacks or a lack of consideration for another’s dignity
on a topic beyond the nuts and bolts of the weekly meeting. should be sternly corrected on the spot.
Share examples of work-life integration. Iowa’s A place of employment should be one of connection, shared
Mission Learning Systems emphasizes work-life integration mission and friendship for our team members. Let’s all do what
as part of its culture. In other words, rather than drawing we can to fix the problem.

PRODUCTS FINISHING — PFonline.com 53

 GARDNER BUSINESS INDEX: FINISHING

Overall Finishing Activity Accelerated

Contraction in June, Closing at 44.0
Finishing activity accelerated contraction for the second month in a row,
down 2.5 points from May. Two months does not a trend make, but it
does suggest that some degree of softening is real. Because contraction
is common across industry segments reinforces that likelihood. JAN SCHAFER, MBA
Director of Market Research
The Gardner Business Index (GBI): Finishing activity has taken a turn inline with other
Gardner Intelligence
industry segments, contracting faster like we last experienced about a year ago.
Jan has been an essential part of
• Most contracting components contracted faster in June, employment being the
Gardner Intelligence for over five
exception that remained the same.
years, and has led research and analysis
• Production and backlog contracted faster for the first time in months, each
in various industries for over 30 years.
dropping more than two points.
[email protected]
• New orders contracted faster for the second month in a row, also by more than
two points.
• Exports continued a slowly accelerated decline.
• Supplier deliveries continued to lengthen at about the same rate as May,
for some non-obvious reason since volume is not stretching supply.
• Expectations of future business (not part of the GBI calculation) are still
positive, having leveled off in May and staying the same in June.

THE GARDNER BUSINESS INDEX (GBI): FINISHING Finishing activity contracted

70
70
at an accelerated rate in
June.
60
60
50
50 70
40
40
70
44.0
44.0
60
60 50
30
30 50 40
Jun '19
Jun '19 Jun
Jun '20
'20 Jun
Jun '21
'21 Jun
Jun '22
'22 Jun
Jun '23
'23
40 Jun '24
Jun '24 30 44
30 Jun '19 Jun '20 Jun '21 Ju
Jun '19 Jun '20 Jun '21 Jun '22 Jun '23 Jun
KEY COMPONENT ACTIVITY Production and backlog
accelerated contraction,
70 70
driving contraction in the
70 60
overall Finishing index.
60 60 50
50 50 40
40 30
40 30 Jun '19 Jun '20 Jun '21 Ju
30 Jun '19 Jun '20 Jun '21 Jun '22 Jun '23 Jun
Production (3-MMA)

Jun '19 Jun '20 Jun '21 Jun '22 Jun '23 Jun '24 Backlog (3-MMA)

Production (3-MMA)
Production (3-MMA) Backlog (3-MMA)
Backlog (3-MMA)

Stay ahead of the curve with Gardner Intelligence.

More information about the Finishing Index can be found at gardnerintelligence.com.

54 AUGUST 2024 — PFonline.com

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PRODUCTS FINISHING — PFonline.com 55

 AD INDEX

This issue of Products Finishing is being sent to more than 26,400 subscribers
in 18,500 plants — the largest audience in the finishing industry.
Aluminum Anodizers Council ................................................... 51 MicroCare Corp .......................................................................... 21
Atotech USA LLC .......................................................................... 1 Midwest Finishing Systems ....................................................... 36
biganodes Inc. ........................................................................... 55 Nordson Industrial Coating Systems ........................................ 14
Bionomic Industries .................................................................. 55 Parker Ionics ................................................................................ 5
Bulk Chemicals Inc ...................................................................... 4 Parts Cleaning Conference ...............................Inside Back Cover
Columbia Chemical Corp .......................................................... 45 Powder Coating Institute .......................................................... 24
Custom Fabricating & Supplies Inc. .......................................... 46 Production Plus Corp. ............................................................... 19
DeFelsko Corp ........................................................................... 16 Reliant Finishing Systems ........................................................... 7
Durr Systems Inc. ...................................................................... 44 RTT Engineered Solutions ........................................................ 33
Endura Corp............................................................................... 17 Sames North America Corp ...................................................... 20
FABTECH ...................................................................................... 9 Steelman Industries Inc. ........................................................... 25
GPB Distributing ........................................................................ 18 The Solvents Co ........................................................................... 3
Hubbard-Hall .........................................................13, Back Cover Therma-Tron-X Inc..................................................................... 37
IMC Metals America LLC ............................................................ 19 Tri-Mer Corp. .............................................................................. 29
IntelliFinishing ........................................................................... 17 Trimac Industrial Systems ........................................................ 40
Koch Finishing Systems ............................................................ 15 United Finishing Systems LLC................................................... 47
Lanco Corp................................................................................. 55 Univertical LLC .......................................................................... 41
Luster-On Products Inc. ............................................................ 42 Venjakob Maschinenbau GmbH & Co. KG ................................ 20
MacDermid Enthone ....................................... Inside Front Cover Vitracoat America Inc. ............................................................... 43
Magic Rack. ................................................................................ 19 Water and Wastewater Equipment Co...................................... 55
Met-Chem Inc. ........................................................................... 55

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56 AUGUST 2024 — PFonline.com

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