Product category:
Washing and pretreatment
News Release from: Stowlin Croftshaw | Subject: Croftshaw Cool-Phos surface preparation system
Edited by the Manufacturingtalk Editorial
Team on 22 March 2001
Surface preparation 'key' to a good
finish
To provide a good, reliable and consistent 'key' for powder coating, communications OEM, RW Data, installed a Cool-Phos open surface combined degreasing, phosphating and drying system.
The use of modern communication devices is increasing at a breathtaking rate Cabling infrastructures are designed to support voice, data, video and other building communication services such as cable, TV, video conferencing and other security applications
This article was originally published on Manufacturingtalk on 7 Mar 2001 at 8.00am (UK)
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Formed in 1988, RW Data are specialists in the design, development and production of structured cabling systems and associated components, and was the first company to manufacture Category 5 structured cabling products in the UK.
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Finishing the job - a recipe for growth
Sheet Metal Products carried out a thorough process and market investigation before installing new preparation and coating equipment.
A fine finish at the point of sale
The installation of the largest UK Cool-Phos combined degreasing, phosphating and drying system is critical to finishing process at Jack Sayers Products.
Cleans, phosphates and dries in one process
A pre-treatment process that combines the benefits of vapour degreasing and aqueous phosphating produces a better key for paint or powder coating and also protects the parts against corrosion.
However, a fast turn around of product is also vital in the communications industry and RW Data have recently sought to control the complete manufacturing process, building a bespoke finishing cell in the winter of 1998.
'The Powder Coat Division was the brainchild of Production Director, Neil Weatherley.' stated Works Manager, Mike Wye.
'We used to output our finishing operation to a local trade finisher, who used a spray phosphate-tri-chloroethylene tank cleaning method.
'With business being dictated by a fast turn around of product, we found a bottleneck appearing in the subcontract finishing operation.
The quality of finish was also of increasing concern and reject rates were rising.
To alleviate this problem we decided to build our own finishing line, controlling both the finish and accelerating product time-to-market.' Today, a Cool-Phos 2.5 x 1.2 metre open surface combined degreasing, phosphating and drying system, installed by pretreatment specialists Croftshaw Solvents, comfortably feeds two bespoke drying/paint cells containing a PED Contraflow Gas Oven, with a Nordson manual 2-station paint booth and a PED four-zone infra-red oven with a Nordson 4-station automatic and manual reclaim booth.
Both are fed by overhead motorised track systems, with maximum feed speeds of 1 metre/min.
An average days throughput can see 2,000 units finished, utilising the Croftshaw, Cool-Phos system for only three hours.
Mixed batch sizes and a variety of machined component - predominantly Alpha Snap Category 5 and 6 interconnect systems - are designed in-house by R.W Data, with the base metalwork being fabricated by a local subcontract engineering company.
'Tight tolerances in the machining of the components are matched by the tolerances in the paint finish, 2 to 6 thou, allowing a 'good fit' of the plastic accessories that are fitted in the assembly process.
As a result the surface preparation is critical.'said Mike Wye.
Machined parts are 'jigged' where appropriate, enabling an easy >hook-up= in the spray booth, and loaded into a basket, ensuring that the parts are positioned to allow a good flow of Cool-Phos solution.
Loaded baskets are placed into a motorised hoist cage and are lowered into the tank.
Held in the vapour zone above the boiling Cool-Phos solution, vapour condenses on the components until the temperature equalises at 381degC.
This degrease's the surfaces and removes loose dirt as it is flushed off by the condensed Cool-Phos.
Dipped into the solution for 2 - 3 minutes, a phosphate conversion coating, a thin crystalline bond that is integral with the metal substrate is added.
The phosphate coating increases the surface areas available and provides an excellent >key= for paint, powder and other finishes.
Additionally, Cool-Phos presents a physical barrier against moisture, thus inhibiting rust in the event of a damaged surface.
After dipping, the coating basket is raised into the vapour zone where it is spray-rinsed for 30-seconds with cooled Cool-Phos distillate to remove traces of phosphoric acid.
Residual condensate flash evaporates as the basket is removed from the tank.
The whole cycle takes only six minutes.
'Parts are cool to handle and if not immediately required for coating, they can be crated and held in a waiting area without fear of rusting.
The pre-treatment of every metal surface is critical,' continued Mike Wye, 'and to date the Cool-Phos process has never failed to produce a pristine finish.
It is also safe, environmentally friendly and economical.
The specific gravity and optimum water content of the Cool-Phos solution is also regularly monitored.
A monthly sample is sent to Croftshaw for analysis and a report is issued.' 'Our attention to the finish extends to the powder coating.
For example, a Courtaulds Interpon coating is favoured where we have to reference parts, using screen printing techniques after spraying.
However both Herbert and Interpon coatings are used on the lines in general.
The cell is now profitable, our finishing operation is completely under control and we have the capacity to also operate as a trade finisher, content in the knowledge that the Croftshaw, Cool-Phos process, will always provide a clean surface for a good paint/powder adhesion.' concluded Mike Wye. Request a free brochure from Stowlin Croftshaw ...
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