Automatic Galvanic Zinc Plating Line

Project description

The automatic galvanic line of drum-suspension galvanizing is a production complex that provides the application of protective and decorative zinc coatings on products made of ferrous and non-ferrous metals in bulk in a drum or individually on hangers with subsequent surface passivation.
The uniqueness of this production complex is the possibility of simultaneous galvanizing of the outer and inner surfaces of pipe-type products, due to the introduced anode.
Passivation processes include chromating or phosphating operations, depending on the surface requirements.

The design capacity of the galvanic line is not less than60000 m2per year.
Applied thickness of zinc coating:up to 22 μmfor various types of products and surfaces.
The operation of the equipment and the operation of the technological process are carried out by software in automatic mode under the control of an automated control system developed by IVES specialists.

This galvanic line was implemented as part of the project of technical re-equipment of the enterprise with the concomitant modernization of auxiliary production.

The customer put forward the following requirements:

1. Maximum energy efficiency of production equipment;
2. Development and implementation of modern electroplating technology aimed at environmental safety of production;
3. Implementation of an electroplating line on limited production areas;

Work done

In the course of the project, IVESS specialists performed a set of works on the design and manufacture of equipment and applied technical solutions that made it possible to meet all the established requirements of the Customer:

• Assistance was provided to the Customer in determining the requirements for the production line and technology, taking into account productivity, nomenclature, overall dimensions and weight of products, types of coating, processing methods and productivity;
• Optimal design, technological and engineering solutions aimed at minimizing the consumption of raw materials, materials, heat and energy resources have been developed and applied;
• A set of specialized technological equipment was designed and handed over to the Customer for manufacture;
• The technology and technological process of electroplating were developed: the compositions of working solutions and electrolytes of process baths were selected with an indication of the manufacturers of reagents, modes of the process, the required energy consumption, recommendations were provided on the number of line personnel with an indication of qualifications;
• Design work has been carried out to create the main and auxiliary capacitive equipment using specialized programs, which ensures the optimal design of galvanic baths, in accordance with international quality standards;
• The required design and technological documentation has been developed;
• Requirements for the construction part of the project were developed and provided to the Customer;
• Manufacturing and comprehensive equipment of technological equipment using structural materials and components of the world's leading manufacturers was carried out;
• Software for the automated control system of the production line was developed;
• Installation and commissioning, running and production tests of the line equipment were carried out, and training of production personnel was carried out.

The commissioning of an automatic galvanic line made it possible to:

1. to organize modern galvanic production, which allows to significantly improve the quality and ensure the optimal cost of products;
2. to increase productivity and ensure the implementation of the Customer's production plans;
3. Minimize manual labor of personnel and eliminate the "human factor"
   in the production process, thereby minimizing the number of defects and the associated costs;