Henkel has introduced a new process control system that addresses key challenges in metal pre-treatment as customers are increasingly seeking to implement data-driven Industry 4.0 solutions. In combination with the company’s New Generation Conversion coatings (NGC) for multi-metal substrates, the BONDERITE® E-CO digital multi-channel (DMC) controller enables maximum corrosion performance and sustainability at minimised overall process costs.
Bonderite E-CO DMC is a process control system that allows users to run complex metal pre-treatment lines with up to fifteen or more stages. It features an intuitive touch screen PLC interface and supports fully digitalised process control with flexible communication and remote access functionality.
Thanks to its adaptive open system architecture, the new digital multi-channel control system easily integrates in to customers’ existing conversion processes and automation concepts. Together with New Generation Conversion coatings, it maximises the benefits derived from Henkel’s sustainable metal pre-treatment technologies and process expertise.
Bonderite E-CO DMC minimises chemical usage, water and power consumption as well as waste. In addition, it helps to avoid manual work and chemical exposure in metal pre-treatment. All equipment and process setup, adjustment, control and monitoring can effectively be managed by the controller, including bath preparation and refill. The multi-channel system supports both single and multiple production lines in one and the same or neighbouring buildings. It can control a virtually unlimited number of process parameters and devices.
Furthermore, Bonderite E-CO DMC is equipped with an internal memory that stores all parameter data and events for creating numerical, graphic and consumption reports as well as maintaining a historical database. The controller’s comprehensive connectivity easily links the system to other resources in local area networks and provides access for remote devices, such as tablets and smartphones. It enables alerts with discrete data to be sent to selected recipients by SMS or email and can be integrated in cloud-based data-driven solutions.
The system underscores Henkel's total solutions approach and commitment to supporting customers as they implement Industry 4.0. Users can run automatic parameter checks and even automate the dosage of chemicals in the tanks by using a special function to correlate analysed data with outputs – all without involving any personnel on site.
While the performance benefits of Bonderite E-CO DMC can be tapped into with any of Henkel’s existing metal pre-treatment process, including conventional phosphating, the technology unfolds its maximum sustainability in combination with the company’s New Generation Coatings. As zirconium-based alternatives for multi-substrate metal conversion and corrosion protection, these NGC contain neither phosphates nor heavy metals, simplify water management and can reduce process steps, contact times, energy consumption and sludge. Leaving only a nano-thin, non-toxic coating layer on substrates, Henkel helps customers to optimise the cost, control and reliable quality of production.
The Bonderite E-CO DMC system is available throughout Europe and North America, and belongs to a complete range of application, control and support equipment for Bonderite metal pre-treatment processes from Henkel.
For more information, please visit www.bonderite-solutions.co.uk
Henkel operates globally with a well-balanced and diversified portfolio. The company holds leading positions with its three business units in both industrial and consumer businesses thanks to strong brands, innovations and technologies. Henkel Adhesive Technologies is the global leader in the adhesives market – across all industry segments worldwide. In its Laundry & Home Care and Beauty Care businesses, Henkel holds leading positions in many markets and categories around the world. Founded in 1876, Henkel looks back on more than 140 years of success. In 2016, Henkel reported sales of 18.7 billion euros and adjusted operating profit of 3.2 billion euros. Combined sales of the respective top brands of the three business units – Loctite, Schwarzkopf and Persil – amounted to more than 6 billion euros. Henkel employs more than 50,000 people globally – a passionate and highly diverse team, united by a strong company culture, a common purpose to create sustainable value, and shared values. As a recognized leader in sustainability, Henkel holds top positions in many international indices and rankings. Henkel’s preferred shares are listed in the German stock index DAX. For more information, please visit www.henkel.com
Henkel’s portfolio of products for the hot dip galvanising (HDG) market now includes a number of new-to-the-UK, best-in-class surface solutions for many stages of the process, including acid/alkaline cleaning, pickling and pickling inhibitors, passivating or conversion coating prior to painting.
Cleaning is the vital first stage in any HDG process. For acid-based cleaning, which typically take place at temperatures up to 45°C, Henkel now offers BONDERITE® C-IC HDG 21 Plus, a high-efficiency, low consumption, mono-component cleaner that offers easy management for users. Similarly, for alkaline-based cleaning, which takes place at temperatures of between 45 and 80°C, BONDERITE® C-AK 4181L is a high efficiency cleaner that has the capability to accelerate the subsequent pickling stage. Again a single part product offering easy management, C-AK 4181L can remove rust, paints, greases and carbon residues from ferrous and chrome nickel alloys, as well as titanium, when used as directed.
After cleaning and rinsing, pickling and inhibitors form the next phase of most HDG processes. Although acids are used typically to remove oxide in the HDG process, these attack base materials and cause metal loss and reduced strength. The solution lies in the use of inhibitors, which not only reduce metal loss, but acid consumption and hydrogen development (bubbles during pickling), thus offering extended bath life. In short, inhibitors reduce attacks and impede embrittlement caused by the absorption of hydrogen. The most recent development in this area is the introduction of BONDERITE® S-AD 60500, a high concentration product suitable for use in baths up to 80°C. This advanced inhibitor is formulated specially to deliver cost-saving dependability, without slowing production.
With regard to pickling bath additives, Henkel can now offer the easy-to-use BONDERITE® C-AD N, which reduces and controls fume emissions from tanks by up to 80%. The upshot is a healthier environment for workers and less structure corrosion.
Following another rinse stage, material then enters the flux tank, which prepares the surface for HDG deposition and protects against flash rust and thermal shock. Products such as BONDERITE® C-AD HDG 35 provide benefits that include a reduction in salts consumption, homogenous deposition of salts, pH stabilisation and homogenous Zn deposition/consumption.
After galvanising and mechanical cleaning, the final stage in most HDG processes is passivation or conversion coating, which protects the HDG coating against corrosion. Here, BONDERITE® M-NT 5992 is free of both Chrome-VI and organic compounds, and offers the potential to be used as a conversion coating of the formed layer. Furthermore, the product has a wide working temperature range (up to 45°C) and offers low consumption thanks to a proportionally small working concentration – all with better performance than Chrome-VI passivation.
All of these BONDERITE® HDG products from Henkel have been proven at installations across Europe. For instance, the introduction of BONDERITE® C-IC HDG 21 Plus cleaner at one particular plant led to a host of benefits, including very low consumption rates of around 1kg per 1000kg of material processed. In addition, the customer enjoyed further cost reductions due to lower inventory levels on chemicals and automatic dosing, while sludge levels were also reduced.
Elsewhere in Europe, a customer needed to export 70 tonnes of galvanised material to South America by sea, with a requirement for no white marks upon arrival. By adopting BONDERITE® M-NT 5992 passivation/conversion coating, not only was this requirement met, but tank life was extended to in excess of one year.
Ultimately, the BONDERITE® range of HDG products from Henkel is designed to enhance product performance, increase reliability, improve the overall manufacturing process and reduce costs – as increasing numbers of plants are discovering.
Henkel operates worldwide with leading brands and technologies in three business areas:
Laundry & Home Care, Beauty Care and Adhesive Technologies. Founded in 1876, Henkel holds globally leading market positions both in the consumer and industrial businesses with well-known brands such as Persil, Schwarzkopf and LOCTITE. Henkel employs almost 50,000 people and reported sales of 16.4 billion euros and adjusted operating profit of 2.6 billion euros in fiscal 2014. Henkel’s preferred shares are listed in the German stock index DAX.