Surface pre-treatment with chemical and technical products can neither be carried out using a very limited number of standard products, nor should those treatments be disregarded that frequently consist of several processes. Here is where our product responsibility for interlinked treatment processes applies: we determine the optimal product and process sequence and the best type of application for you to achieve the optimum efficiency and economy.
HAKUFORM und HAKUFLUID
For metalworking processes, the most frequently used products are cooling lubricants (CL). This type of lubricant must have both lubricating and cooling properties. In addition, the liquid should take away the metal abrasion produced during the machining process. To avoid corrosion on the work piece, tool and on surfaces of the processing machine, these lubricants must have distinct corrosion protection properties. Furthermore, the cooling lubricant must contain special additives to prevent any excessive tool wear or any premature tool breakage.
Cooling lubricants are subdivided into two major groups. The most important distinctive feature is their water miscibility. Non-water-miscible cooling lubricants, so-called metalworking oils, are also often called cutting oil, drawing oil or grinding oil. Water-miscible cooling lubricants are mixed with water and the resulting emulsion or solution is used for the metalworking process. Mineral-oil-based cooling lubricants form an emulsion when they are mixed with water. Mineral-oil-free, fully synthetic cooling lubricants form a clear solution in water.
We develop, produce and sell cooling lubricants under the HAKUFORM and HAKUFLUID product names.
HAKUFORM stands for water-miscible and non-water-miscible cooling lubricants, which can be used for both cutting and forming operations. HAKUFLUID is exclusively used to designate fully synthetic cooling lubricants soluble in clear water, which are used for metal cutting operations.
Advantages for the User
The product range includes water-miscible and non-water-miscible qualities for cutting operations and forming processes. HAKUFORM and HAKUFLUID cooling lubricants can be used in both large central plants and individually filled machines. Our cooling lubricants cannot be purchased “off the shelf”. When selecting our products, we are responsive to the conditions existing in the individual case and take the respective framework conditions into account.
Cooling lubricants are strictly regulated. Our cooling lubricants are regularly adapted to the latest requirements and are in compliance with any laws and regulations.
The water-miscible cooling lubricants must be reviewed on a regular basis. To ensure process reliability, the concentration must never fall below a specific minimum value. In addition, the pH values and nitrite concentrations are to be measured at weekly intervals (requirements of the Technical Rules for Hazardous Substances 611). We conduct these investigations in our laboratory, thus relieving our customers of stressful work.
Once the metalworking process has been completed, the cooling lubricants are washed off again. To do so, we use a large number of different industrial cleaners. Subsequently, the work pieces often have to be preserved to protect them against corrosion. When selecting the cooling lubricants, we take account of the follow-up processes and recommend perfectly matched cleaners and corrosion protection products. The different products are optimally matched to one another.
Water-Soluble Cooling Lubricants for Cutting Operations
HAKUFLUID cooling lubricants are free from mineral oil, boron and formaldehyde donors. The employees and the environment of the processing machines are not impacted by oil vapor and oil mist. The products have a good skin tolerability. HAKUFLUID cooling lubricants are extraordinarily efficient. The quantities consumed can be reduced by up to 30% when changing from an emulsion to HAKUFLUID, and by up to 90% when changing from a machining oil to HAKUFLUID.
Emulsifiable Cooling Lubricants
The cooling lubricants of the HAKUFORM A series are free from formaldehyde donors and critical amines like monoethanolamine, dicyclohexylamine and the like.
The emulsions of the HAKUFORM A cooling lubricants can achieve very long service lives. The separate addition of correction chemicals like biocides is usually not necessary.
Non-Water-Miscible Machining Liquids on the Basis of GTL Oil
These machining oils are fully synthetic and have a very high viscosity index. HAKUFORM L offers significantly low mist and evaporation losses.
Moreover, the product range also comprises other water-miscible and non-water-miscible cooling lubricants for forming processes, e.g. for the manufacture of tubes and profiles, the production of beverage cans, etc.
Furthermore, volatile punching oils, minimum quantity cooling lubricants, cold impact extrusion and drawing oils are also part of the comprehensive product portfolio.
HAKUPUR & CEKASIN
HAKUPUR stands for water-based acidic, neutral or alkaline cleaning products around the globe.
HAKUPUR products are often used to clean metallic materials. Once the metalworking process has been completed, any residues of water-mixed or also non-water-miscible cooling lubricants are cleaned off using HAKUPUR. The HAKUPUR cleaner is used here as an intermediate cleaner, i.e. prior to any further processing of the work pieces, or as a final cleaner.
Additional applications for HAKUPUR further include plastics cleaning, the cleaning and preserving in one working operation using emulsion cleaners, the cleaning of UF membranes and much more.
HAKUPUR cleaners are usually processed in the form of a 0.2-15% solution in water. The processing temperature is between 20 and 70°C. A small number of products are used in the condition as delivered.
CEKASIN is a specialty used to clean microfiltration and ultrafiltration membranes. The CEKASIN UF cleaners are acidic, neutral or alkaline. The use of the corresponding product depends on the contamination to be removed.
Advantages for the User
The tasks of an industrial cleaner are very multifaceted. Besides cleaning, they also have to be characterized by an optimal work piece compatibility. Finally, the metals to be cleaned must not be liable to rusting. Moreover, the cleaning solution must not tend to foam, and the follow-up processes, e.g. any heat treatment, should not be adversely affected. The HAKUPUR range of cleaners offers suitable products for every application.
The type of contamination to be removed is fundamentally different. Its variety is very large and ranges from very easily removable residues of a water-mixed cooling lubricant to problematic polishing pastes and release agent residues. We use our technical center to run cleaning tests. These ensure that the most suited cleaner will be determined for the process in question. Furthermore, our laboratory is used to analyze cleaner bath samples of our customers and thus contribute to process reliability.
Industrial Cleaners Following Metalworking
Once processing has been completed, metal parts with a water-mixed cooling lubricant, a low-viscous or also a high-viscous machining oil as well as metal abrasion are contaminated. Besides ferrous metals such as grey cast iron, steel or stainless steel, HAKUPUR can also be used to clean very different light and non-ferrous metal alloys.
The machining processes very often include cleaning in spray processes. Moreover, HAKUPUR cleaners are also processed in dipping, ultrasonic, flood and water jetting methods.
Other Water-Based Cleaners
Apart from the industrial cleaners used after a metalworking process, the HAKUPUR range of cleaners comprises a multitude of additional cleaning products. These include plastic cleaners, maintenance products such as floor and machine cleaners, but also products used to clean tankers. The product portfolio is completed by emulsion cleaners and substitute products for solvent-based cold cleaners.
CUSTOS, HAKUDREN und PLASTELOX
Corrosion-sensitive metals such as grey cast iron, standard steel, but also galvanized steel surfaces have to be protected against corrosion before they are stored over a longer period of time or transported. For this purpose, corrosion protection products are very often used to protect metal surfaces against corrosion.
From dewatering fluids (Hakudren) through to corrosion inhibitors (Custos) to melting dip masses (Plastelox), we offer many different products. These qualities leave protective films and/or layers on the metal surfaces, protecting them against corrosion up to considerably more than one year and can be easily removed again, if necessary.
Advantages for the User
The “standard requirement” placed on any temporary corrosion protection media is always the same: the thinnest possible and easily removable protective films to guarantee corrosion protection for as long as possible! Taken in isolation, these requirements are, of course, contradictory. Finally, the best corrosion protection results can be achieved with a thick and very adhesive film.
Using the CUSTOS HAKUDREN and PLASTELOX corrosion protection products, however, we come very close to the “ideal corrosion protection product”. Most of the products leave wafer-thin protective films with very good corrosion protection properties. These protective films often no longer have to be removed. If the films have to be removed, however, e.g. before the metal surface is lacquered, cleaning will be very easy, and our water-based HAKUPUR cleaners are optimally matched to this cleaning task.
Our laboratory and technical center provide for modern testing facilities. They can be used to test the corrosion protection properties under specific storage conditions, e.g. under temperature fluctuations or changing humidity levels. Our customers often provide us with the work pieces to be preserved. We then run comparative trials and finally recommend the most appropriate corrosion protection product.
By dipping water-wet work pieces into a HAKUDREN dewatering fluid, they can be dried and preserved at the same time. In doing so, the water film adhering to the metal parts is displaced by the metal surface and the water is separated at the bottom of the immersion container. Once the dewatering has dried up, a thin protective film remains, protecting the treated work pieces against corrosion for a certain period of time.
Corrosion Protection Products, Solvent-Based
Solvent-based CUSTOS and HAKUDREN corrosion inhibitors are still widely used. This type of product can be very easily processed by dipping, flooding or spraying. Depending on the consistency and on the percentage of the film former contained in the product, oily, Vaseline-type or waxy protective films remain once the corrosion inhibitor has dried up.
Solvent-Free Corrosion Protection Oils
Corrosion protection products which do not contain any volatile hydrocarbon solvents and are thus VOC-free, are increasingly gaining in importance. These products of the CUSTOS series are highly fluid, have flash points of more than 100°C and leave very thin protective films once they have dried up, protecting metal surfaces against corrosion for more than 12 months.
Water-Soluble Corrosion Inhibitors
Water or aqueous solutions are mixed with corrosion inhibitors to ensure that metals, which are in contact with water, will be protected against corrosion. Typical applications of this type of product include purge baths used, for example, to verify the impermeability of specific components. Moreover, our CUSTOS corrosion inhibitors are also mixed with water-mixed cooling lubricants or neutral cleaner solutions to improve the corrosion protection properties of these products. Certain water-soluble corrosion inhibitors are used instead of a neutral cleaner. Afterwards, the metal surfaces cleaned in this way will be protected against corrosion for several months.
Emulsifiable Corrosion Protection Oils and Corrosion Protection Emulsions
The emulsifiable corrosion protection oils of the CUSTOS series are usually processed in the form of a 5-15% emulsion at 50-60°C in spray processes. Using these emulsions, metal components can be cleaned in one working operation, protecting them against corrosion.
The ready-for-use corrosion protection emulsions are free from organic solvents and are processed in dipping or spraying processes. Once the emulsion has dried up, a protective film remains which is characterized by a high water resistance.
Melting Dip Masses
Under the product name PLASTELOX, we offer thermoplastics processed at 150-170°C in immersion containers. In this temperature range, the PLASTELOX melt is a highly viscous liquid. By dipping the metal work pieces in the melt, they are coated with PLASTELOX. Subsequently, the parts are protected against mechanical damage and corrosion by a transparent, plastic coating. If necessary, the coating can be removed again by simply peeling it off.
The surface treatment of metallic work pieces is one of the key steps in our customers' value added chain. The components elaborately manufactured beforehand with different materials and forms are finished by applying a decorative lacquer coating. Our pre-treatment products of the DECORRDAL series protect the metal surfaces against corrosion and ensure that our customers' components will have a long intrinsic value. The parts should not present any corrosion or fail prematurely due to the poor adhesion of the coating – even under the harshest of climatic conditions. Tailored to the respective application technology and the metal substrates to be treated, there is always an appropriate procedure.
Advantage for the Customer
In addition to traditional phosphating products (iron and zinc phosphating), we also offer new ecologically and economically viable alternatives. The heavy-metal-free pre-treatment systems from our DECORRDAL ZT series are state-of-the-art. They combine the high protection of the components' surface with low make-up concentrations and low consumption quantities. Furthermore, DECORRDAL products can, in principle, be combined with any coating systems around the world. Of course, our portfolio also includes the right products for other applications which are in line with the latest legal requirements, e.g. substitute products for chromium (VI) applications.
A decisive factor for success is the selection of the right product. To select the most suitable product, we pre-treat original parts in our technical center and also coat them with coating systems. Besides the application for powder coating, we also perform electrophoretic dip coating.
For quality assurance and quality control purposes, we carry out the corresponding tests for the customers using manufactured sample components (salt spray test,...).
You will be provided with technical documentation for the process in order to manage it accordingly. Moreover, we have technically trained staff ensuring direct support on site and perform personal employee training courses.
In order to select the right product, detailed knowledge of the respective process is indispensable. We elaborate this knowledge within the framework of a personal consultation. To provide both our customers and interested visitors of our website with an opportunity to obtain information, we have structured our pre-treatment products by the corresponding procedures specified below.
The simplest type of pre-treatment to date is traditional alkali phosphating, also called iron phosphating, as it deposits a layer of iron phosphate on steel surfaces. This procedure is a system combining degreasing and phosphating. Both steps take place simultaneously (in an active zone). The products are easy to handle and can be run without any problems using a pH-value-controlled dosing pump. Thanks to the combination of different ingredients, it is possible to treat steel and iron work pieces, but also aluminum surfaces and electro-galvanized steel surfaces. The corrosion protection results achievable in a SST (salt spray test) range between 100 and 240 h. Iron phosphating is often used before powder coating. Today, alternative procedures also exist in the scope of application of iron phosphating which are no longer based on phosphoric acid, but zirconium. The application method is analogous, but the produced layer is completely different.
In the automotive industry, zinc phosphating trication (low-zinc phosphating) can still be regarded as the state-of-the-art procedure. This procedure basically works on the principle of the deposition of metal phosphates as well as iron phosphating. In this case, however, zinc, nickel and manganese phosphates are deposited as a conversion layer. The crystalline layers are considerably thicker and denser than the ones of iron phosphating. This makes it possible to achieve significantly better corrosion protection results. In the automotive sector, zinc phosphating is often combined with cathodic dip-paint coating, but powder coating or wet coating are also possible without any problems and achieve good results. For steel, the corrosion protection values achievable with such systems range between 750 and 1,000 h in the salt spray test, with disbonding being < 1 mm.
Besides the nickel-containing zinc phosphating trication, steel surfaces can also be pre-treated using nickel-free procedures. Here, too, a crystalline zinc phosphate layer is deposited, which increases corrosion protection and improves lacquer adhesion. The products of the DECORRDAL 500 series have been developed for use in pure steel making plants. The components phosphatized in this way can be lacquered with different coating systems. Here, too, cathodic dip-paint coating is the most common type of coating. Besides, the procedure is also combined with powder coatings. The achievable corrosion protection requirements range between 750 and 1,000 h in the salt spray test, with disbonding being < 1 mm.
To ensure that the phosphate layer will be optimally developed, irrespective of whether or not it contains nickel, an appropriate activator (rinse conditioner) will be required. For this purpose, we offer the corresponding products, e.g AKTIVATOR 1 or AKTIVATOR CT. Using these products, important layer properties such as crystal size and layer weight can be very well influenced/controlled.
Thin-Film Technology/Zirconium Technology/Phosphate Substitute Procedure
In addition to the long-standing phosphate-based procedures, new procedures which are free from phosphate and based on zirconium have existed for a number of years now. Such procedures have very different names. Starting out from the position of zirconium in the periodic table, they are called “TMCs” for Transition Metal Coating. A likewise widely used term for such pre-treatment agents is “thin-film technology”, which relates to the thickness of the conversion layer. All procedures share the common feature that they produce a very thin conversion layer on steel which consists of oxides and zirconium and is deposited on all metal surfaces.
Chromium-Free / Chromium (III) Technology
The state-of-the-art procedure in the pre-treatment of light metals such as aluminum or magnesium, but also galvanized steel is the chromate-free pre-treatment process. Due to the forthcoming prohibition of the use of chromate compounds, the last remaining products will disappear from the domain of surface technology in 2017. There are different alternative products which can be used to treat the aforementioned metal surfaces.
On the one hand, pre-treatment systems containing chromium (III), such as DECORRDAL ZN 320 or DECORRDAL AL 325. Both are characterized by a robust application method. Compared with the likewise available chrome-free ones which do completely without chrome, however, they also have crucial advantages as regards blank corrosion protection, i.e. in all cases where no organic coating is applied to the surfaces. The chrome-free products include DECORRDAL AL 230 A, which has already been in use for many years and has been certified by the GSB or QualiCoat quality associations.
Cleaning and Pickling Products
Pre-treatment is not only one single product, but always an entire process, which does not only include the main materials used to produce a conversion layer, but also further processes. The most important step to prepare the metal surface is degreasing. Here, the adhering contaminations from upstream machining processes are removed, e.g. machining oils, emulsions, metal chips and atmospheric dirt. Since it is not only used to process edged or punched metal sheets, but also welded constructions, scaled and partially corroded surfaces, it may also be necessary to include an acidic pickling step into the process. Here, the alkaline degreasers of the HAKUPUR series, acidic pickles of the DECORRDAL 29 series or DECORRDAL 35 series and some special products can be named.
The paint-processing industry uses a technically highly complex application technology to apply very different coating technologies on likewise differing surfaces. These different coating technologies, e.g. solvent-based high-solid lacquers or also water-based top coats with metallic effect, require the use of specific flushing media.
We are proud to say that our NIKUTEX purges are the most innovative and effective products in the market.
Thanks to the NIKUTEX range, we have specific flushing media for almost every painting process to optimally clean paint application components, such as coating-transferring tubing, valves, mixers, atomizing bells, etc.
Our flushing media are divided into two basic groups:
- NIKUTEX hydro purges used to flush/remove water-based coating systems
- NIKUTEX purge thinners used to flush/remove solvent-based coating systems
Advantages for the User
Besides our long-term experience in the field of hydro purges and purge thinners of more than 50 years, we have a large range of products at our disposal to meet the most different requirements and to offer the greatest process reliability possible. Furthermore, our product portfolio comprises VOC-reduced and VOC-free products, which are in no way inferior to the efficiency and effectiveness of conventional products.
A decisive factor for our customers' success is, inter alia, the selection of the right product for the painting process used. In order to select the best possible product from our portfolio here, we carry out very different laboratory tests.
Especially for the area of hydro purgers, we can conduct trials on a high-speed rotating atomizer in our technical center. This enables us to create extremely practical trial conditions and direct the development of new and the further development of existing products onto the right track.
Our customers are provided with a laboratory elaboration for the trials conducted to be able to understand the selection of products. Moreover, we have technically trained staff ensuring direct support on site.
Purges for Water-Based Paints
The product range of hydro purges comprises products on the basis of organic solvents, surfactants, amines and other additives. NIKUTEX hydro purges are used to remove/flush fresh or partially dried-on/cured water-based paints. The main area of application is the flushing of entire paint shops (e.g. in the automotive industry), the associated system components and the application equipment.
- paint guns
- atomizing bells
- coating-transferring tubing
- valves / mix blocks
- mixers (e.g. Kenics mixers)
The VOC-free NIKUTEX hydro purges are characterized by their good paint compatibility, an excellent dissolving/flushing capacity, a low concentration, a very low foam tendency, a comparatively low pH value and their mild, pleasant odor.
Purges for Solvent-Based Paints
The product range of purge thinners comprised products on the basis of different organic solvents. NIKUTEX purge thinners are used to remove/flush fresh or partially dried-on/cured solvent-based paints. The main area of application is the flushing of entire paint shops (e.g. in the automotive industry), the associated system components and the application equipment.
- paint guns
- atomizing bells
- coating-transferring tubing
- valves / mix blocks
- mixers (e.g. Kenics mixers)
The VOC-reduced NIKUTEX purge thinners offer an excellent dissolving/flushing capacity.
Furthermore, NIKUTEX purge thinners are characterized by their good paint compatibility and a comparatively mild odor.
Paint and Adjustment Thinners for Solvent-Based Paints
The product range of paint and adjustment thinners comprised products on the basis of very different organic solvents. HAKU paint and adjustment thinners are used to adjust coating systems to a specific processing viscosity. Depending on the application and the application technology used, paints have to be adjusted to the corresponding viscosity before they can be used to achieve an optimal coating result. The drying behavior likewise plays a major role, e.g. regarding the gloss level, and can be positively influenced by the use of the right paint thinner.
HAKU paint and adjustment thinners are available for all common types of paints, e.g.:
- synthetic resin paints
- EP paints
- PU paints
HAKU paint and adjustment thinners are particularly characterized by their consistently high quality, the high dissolving capacity and their universal applicability.
Cold Cleaners & Thinners
Cold Cleaners / Cold Degreasers
The product range of cold cleaners or also cold degreasers comprises products on the basis of aromatic as well as aliphatic hydrocarbons, i.e. products of the HAKU 1025 series are based on organic solvents. HAKU 1025 cold cleaners are used to degrease/de-oil mostly metallic surfaces. Cleaning can be carried out manually by wiping or brushing, but also using dipping, ultrasonic or other application methods. As a rule, the objective is to get a surface which is clean enough and/or suited for further processing, e.g. coating.
HAKU cold cleaners are available in different versions, e.g.:
- highly/slowly volatile
Depending on the product, HAKU cold cleaners are characterized by a particularly mild odor, a high dissolving capacity towards oils and fats or also a high flash point.
The product name ISOFLEX stands for water-based peelable coatings. They are processed by spraying, brushing or rolling and protect the treated surfaces against contaminations. If required, the peelable paints can be easily removed again by simply peeling it off together with the adhering contaminations.
Advantage for the User
ISOFLEX peelable coatings are often processed in paint shops. The coating of the paint booth walls or even of the floor eliminates the need to expensively remove the paint contaminations using aggressive solvents or paint stripping products.
The product range comprises both white pigmented qualities and products forming transparent films. All ISOFLEX peelable coatings are water-based and free from organic solvents.
The painting process is inevitably followed by the regular stripping of paint off the auxiliary tools such as varnished suspension frames, hooks and grates to enable them to be used in the process again. Even parts coated with errors or used parts intended to be used again must be stripped of paint before being re-coated. Furthermore, application devices such as paint tubes and paint guns have to be cleaned at regular intervals and paint contaminations in the paint booth and on floors have to be removed. Removing graffiti from buildings and vehicles for rail transport also falls within the scope of paint stripping.
The product portfolio of Chemische Werke Kluthe includes the right paint stripping agents for any de-coating tasks and meet the requirements for effectiveness, economy and occupational safety. The products can be subdivided into 3 groups:
CONTROX E hot paint stripping agents:
Under the name CONTROX E we offer hot paint strippers for steel, aluminum and other metals as well as the associated additives.
CONTROX cold paint stripping agents:
For any de-coating work which cannot be performed in heated systems, there are different cold paint strippers available.
CONTROX B stripping pastes:
The paste-type paint stripping agents are used to remove paint contaminations in paint booths, on floors and for graffiti removal. They are also suitable for bulky parts or wooden parts, which cannot be stripped of paint in dipping or spraying systems.
Our product range includes all paint stripping agents required for the technically and economically successful stripping of paint off different materials. Tailored additives and/or accelerators for the respective products ensure a uniform paint stripping effect and guarantee long service lives. For the water-free organic paint stripping agents, users have the possibility to recycle consumed media in our premises and to recycle them back into the process.
A decisive factor for our customer's success is the selection of the right product. To find the optimal product, we use original parts to carry out paint stripping tests in our laboratory in compliance with the process conditions defined by the customer. If required, we support our customers with technically trained staff directly on site and verify that the processes are managed correctly.
CONTROX E Hot Paint Stripping Agent
The product range of hot paint stripping agents comprises water-free organic paint stripping agents for aluminum and other NF metals, aqueous-alkaline paint stripping agents for ferrous metals as well as different paint stripping accelerators and additives. The products can be used in dipping or spraying systems.
The organic products are applied undiluted and primarily used for stripping paint off aluminum parts coated with errors. Depending on the product and requirements (type of paint, layer thickness, time), the application temperatures are at about 80°C; in individual cases, significantly lower or higher temperatures are likewise possible (approx. 40-120°C).
If certain requirements are met, consumed media can be taken back and used again in the paint stripping process as freshly defined recyclate instead of fresh goods.
Prior to their application, the aqueous products are generally diluted 1:1 with water and are thus particularly suitable for the economic removal of large amounts of paint. The application temperatures are usually about 90°C.
Advantages of the CONTROX E types in practice:
- high paint stripping performance
- long bath service lives
- recyclable organic products
- free from NEP, NMP and other SVHC (substances of very high concern)
- VOC-free products
CONTROX Cold Paint Stripping Agents
For any de-coating work which cannot be performed in heated systems, there are liquid cold paint strippers available. Application takes places in dipping or spraying systems at room temperature (approx. 20°C). Due to the lack of thermal support, however, de-coating proceeds much more slowly in most cases than with hot paint stripping agents.
Products containing methylene chloride are only available for industrial users on presentation of an end-user certificate.
CONTROX B Stripping Pastes
Paste-type products are used outside paint stripping systems to de-coat and/or clean large surfaces (graffiti removal, cleaning in paint booths) and to strip paint off bulky parts. They are applied using brushes, rollers or airless spray guns at room temperature (approx. 20°C)..
The selection of the products mainly depends on the base material to be de-coated (e.g. aluminum, steel or other metals) and on the pre-defined process parameters (e.g. dipping or spray process, achievable temperature, time available). Special requirements for occupational safety and environmental protection can also play a role (e.g. VOC, SVHC).
The goods undergoing paint stripping remain in the paint stripping system until the paint has completely detached from the surface or can at least be easily removed in the following flushing process.
Subsequent cleaning of the stripped parts is usually carried out with water. To prevent any paint residues from adhering to the surface again, the parts should not be flushed in dip-painting tanks, if possible, but sprayed under pressure.
The used flushing water has to be transported to a waste water treatment plant to neutralize it and to remove any paint residues. Suitable waste water treatment products are available in our T 400 product group.
The paint stripping medium should be regularly inspected and complemented, where required, to keep its effect on a consistently high level. Any post-dosing is performed using either new goods or additives specially tailored to the respective products.
To achieve long service lives, the paint stripping medium should be regularly desludged, as this slowly decomposes the detached paint residues in the liquid while consuming the paint stripping product.
Paint sludge and consumed paint stripping medium are to be deposed of as hazardous waste. Organic paint stripping agents offer the possibility of being recycled in our premises.
ISOGOL & T 400
The overspray produced in the application of paint in spray processes is separated via air washers in the recirculating water of the paint shop. The coagulation agent dosing tailored to the ongoing painting process ensures that the paint particles are bound and can be discharged from the recirculating water via an automatic discharge system. The paint coagulation thus ensures that the overspray is continuously disposed of from the paint shop and is important for the smooth operation of the painting process.
Depending on the origin of the waste water, different types of contaminants have to be removed from the water in the waste water treatment process, e.g. oils from metal processing and cleaning waste waters or heavy metals from the pre-treatment process. Only in a few cases, this process is a circuit water treatment similar to paint coagulation. As a rule, the waste water is channeled once it has been treated and has to comply with the limits set by the public authorities for discharge.
Paint coagulation and waste water treatment operate with similar chemical-physical mechanisms. The products used are thus partially related to one another or complement each other.
The ISOGOL product group comprises the paint coagulation agents for the treatment of the recirculating water in water-flooded paint booths. There are products for all paint systems and plant engineering circumstances available: coagulation agents for both solvent-based paints and water-based paints and for the joint coagulation of both paint types in one system. The resulting paint sludge can be made sedimenting or floating, using additional doses of suitable additives from the T 400 series, where appropriate, and thus removed from the recirculating water with different discharge systems.
The product name T 400 summarizes flocculants and precipitants used both in waste water treatment and as additives in paint coagulation processes. The basis of these products are adsorptively acting substances, polymers and salts which are combined for the different tasks.
Different paint systems, different types of systems, varying process conditions: the requirements for paint coagulation processes can be very varied and can therefore change quickly.
This requires a portfolio of modern coagulation products ensuring high process reliability thanks to their universal properties.
Products tailored to paints and plant engineering enable an economic mode of operation and reduce the cleaning effort, inter alia by keeping the solid body content in the circulating water at a permanently low level.
In the field of waste water treatment, we offer intelligent solutions for any chemically/physically removable contaminations. Typical applications of our T 400 products are waste waters from metal processing, cleaning, metal pre-treatment and paint stripping.
Our analytics-based development ensures tailored procedural proposals and high process reliability.
The decisive factors for a smooth process at our customers include both the selection of the right products and the optimal setting of process parameters. To determine the most suitable products, we use our laboratory to carry out tests with the paints to be coagulated and/or the waste waters to be treated, taking into account the process conditions defined by our customers. If required, we offer application engineering support and training courses on site.
Paint Coagulation Process
The selection of products depends on the paints used (e.g. solvent-based or water-based paints) and the plant engineering circumstances (e.g. paint sludge discharge via floating or sedimenting, dosing pumps available).
When using neutral coagulation agents based on adsorptively acting substances, this usually results in a paint sludge with very good floating properties. Nevertheless, our portfolio also comprises products for the sedimentation. The neutral coagulation agents are suitable for the coagulation of both solvent-based paints and, in combination with emulsion-breaking additives, water-based paints. It is not necessary to check or adjust the pH value in the recirculating water, with the salinity of the recirculating water not being increased either.
Due to their strong emulsion-breaking effect, coagulation agents based on metal salts are ideally suited for the coagulation of water-based paints and are characterized by their low consumptions. By adding debonding additives, they can also be used for the coagulation of solvent-based paints. In most cases, however, they require regular pH checks due to their low pH value and simultaneous dosing of a pH correction agent.
All process variants usually require further additives to be dosed.
Defoaming agents are used for combating foam in the recirculating water, especially when adding water-based paints.
Flotation agents enhance the floating properties of the paint sludge and improve its extractability by increasing the flakes.
Biocides prevent the growth of bacteria and odor formation in the recirculating water.
Hardeners favor the flocculation of the neutral coagulation agents in soft recirculating water (water hardness below 20°dH).
ISOGOL Coagulation Agents
Due to their high adsorption capacity, our neutral coagulation agents for solvent-based paints do not only provide an excellent debonding effect, but also distinct water-purifying properties. In combination with a suitable additive from the T 400 series, they are thus also suited for the coagulation of water-based paints and for the mixed coagulation of water-based and solvent-based paints in one single system. Moreover, the products are free of salt and especially chloride and thus cause no incrustations or corrosion in the exhaust air system and in the water-bearing parts of the system.
The products specially developed for water-based paints are characterized by their yield and foam-damping effect.
In most cases, the coagulation process requires dosing of several components (coagulation agents, flocculants, defoamers, further additives). The combination of harmonized products forms the basis of an economic mode of operation.
Waste Water Treatment Process
Product selection and process sequence are determined by laboratory tests using representative waste water samples.
If the treatment process takes place in batch operation, the use of a reaction release agent in powdered form containing all of the active agent components required is often preferred. As a result, this only requires neutralization using an acid or alkali and dosing of another product. Nevertheless, powder products require a stirring time of approx. 15-30 min. in the waste water before its ingredients have dissolved completely and come into full effect.
Liquid products dissolve very quickly and are thus mostly used in tunnel systems passed through by a continuous waste water stream. The combination of different active substances in liquid products is possible only to a limited extent, which is why it is usually necessary to dose several components when they are used.
T 400 Flocculants and Precipitants
Depending on the tasks, there are different products available for waste water treatment processes, be it for the precipitation of heavy metals and various anions (e.g. phosphate, fluoride), for the splitting of emulsions and for the separation of oils, for the flocculation of turbidities and the purification of water.
Depending on the requirements, it is possible to use products having a specific effect on certain pollutants or reaction release agents combining several different mechanisms of action.
The purified water can either be fed to the sewer system or re-used in specific cycle processes (e.g. paint coagulation, vibratory finishing).