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FluxcleaningFluxcleaningbyby
IndufinishIndufinish
FluxcleaningFluxcleaningbyby
IndufinishIndufinish
Wim BrandsemaWim Brandsema Managing Director, Owner of
Indufinish 25 years of experience HDG Board member branch
organization
Wim BrandsemaWim Brandsema Managing Director, Owner of
Indufinish 25 years of experience HDG Board member branch
organization
We are an innovative full service-oriented manufacturer in the surface treatment industry, with a unique combination of market knowledge Galvanizing, Powder Coating, Anodizing, Electroplating and E-coat.
Based on 25 years knowledge and experience, we provide quality, sustainable solutions, cost effective technical and logistical solutions and lean processes.
We are an innovative full service-oriented manufacturer in the surface treatment industry, with a unique combination of market knowledge Galvanizing, Powder Coating, Anodizing, Electroplating and E-coat.
Based on 25 years knowledge and experience, we provide quality, sustainable solutions, cost effective technical and logistical solutions and lean processes.
Short story of companyShort story of company
Our company in Emmen, The Netherlands
Our company in Emmen, The Netherlands
Grounded in 1991 Owned by Wim Brandsema & Han Kleijn 40 full time employees Company surface 7.500 m² R&D budget 2-3% of annual turn-over Installations throughout Europe.
Grounded in 1991 Owned by Wim Brandsema & Han Kleijn 40 full time employees Company surface 7.500 m² R&D budget 2-3% of annual turn-over Installations throughout Europe.
FactsFacts
Powered by Dutch technologyPowered by Dutch technology
Powered by Dutch technologyPowered by Dutch technology
Intelligence, Dynamic, Driven Passionate about their company and
products Development power 40 ambitious people to improve
constantly
Intelligence, Dynamic, Driven Passionate about their company and
products Development power 40 ambitious people to improve
constantly
ISO 9001 DVS, Deutsche Verein für
Schweißtecnik TÜV, Anerkennung Fachbetrieb Continuous training of employees
ISO 9001 DVS, Deutsche Verein für
Schweißtecnik TÜV, Anerkennung Fachbetrieb Continuous training of employees
QualityQuality
Linkedin Twitter You Tube
Linkedin Twitter You Tube
Social mediaSocial media
Galvanizing Powder Coating Anodizing Plating E-coat
Galvanizing Powder Coating Anodizing Plating E-coat
PortfolioPortfolio
GalvanizingGalvanizing
pre treatmentpre treatment
GalvanizingGalvanizing
pre treatmentpre treatment
Pre-treatment plantsPre-treatment plants
Pre-treatment plantsPre-treatment plants
LiningsLinings
SpinningSpinning
Fluxcleaning Fluxcleaning 1.01.0
Fluxcleaning Fluxcleaning 1.01.0
Getting the Iron out Compact unit Easy to maintain & service Transportable Online servicing
Getting the Iron out Compact unit Easy to maintain & service Transportable Online servicing
GoalsGoals
The unitThe unit
Protoype 6 months trial Still up & running Learning curve
Protoype 6 months trial Still up & running Learning curve
ResultResult
Standard chemistry No overdosing H2O2 No sludge in your tank Fe on constant level
Standard chemistry No overdosing H2O2 No sludge in your tank Fe on constant level
FactsFacts
Fluxcleaning Fluxcleaning 2.02.0
Fluxcleaning Fluxcleaning 2.02.0
Process controlProcess control&&
Quality improvement Quality improvement of galvanized steelof galvanized steel
Process controlProcess control&&
Quality improvement Quality improvement of galvanized steelof galvanized steel
Temperature Concentration and Ratio pH Fe content Surface tension
Temperature Concentration and Ratio pH Fe content Surface tension
Flux parametersFlux parameters
Important but not influenced by flux treatmentMinor drop during proces in external unitHeater can be installed in unit
Drying is very important!Reduces splatter
Important but not influenced by flux treatmentMinor drop during proces in external unitHeater can be installed in unit
Drying is very important!Reduces splatter
Flux parameters temperatureFlux parameters temperature
Concentration in between 200-550 g/l total saltAlthough lower concentrations are mentioned
Ratio
Mono, double, triple, quadra salts
Influenced by flux treatmentNH4OH pH correction will influence ratio and densityCorrection with ZnCl2 is necessaryPossible through ZnCl2 solution or stripping acid!
Concentration in between 200-550 g/l total saltAlthough lower concentrations are mentioned
Ratio
Mono, double, triple, quadra salts
Influenced by flux treatmentNH4OH pH correction will influence ratio and densityCorrection with ZnCl2 is necessaryPossible through ZnCl2 solution or stripping acid!
Flux parameters concentrationFlux parameters concentration
The “least” discussed parameterWhat is your pH? 4,5
Why pH 4,5?Because we’ve done so for agesLess agressive/active flux less Fe built up
What are the benefits of pH 2,3?More active fluxWill “polish” the surfaceFe building is not an issue with a flux treatmentBetter circumstances in the flux treatmentDry filter cake, faster reaction, no Zn oxidation
The “least” discussed parameterWhat is your pH? 4,5
Why pH 4,5?Because we’ve done so for agesLess agressive/active flux less Fe built up
What are the benefits of pH 2,3?More active fluxWill “polish” the surfaceFe building is not an issue with a flux treatmentBetter circumstances in the flux treatmentDry filter cake, faster reaction, no Zn oxidation
Flux parameters pHFlux parameters pH
Drag in of Fe gives higher dross and ash production
Iron content < 5 g/l is recommendableHard to achieve without flux treatment
Main reason to start with flux treatment!Concentrations < 1 g/l are achievableAmount of rinses between pickle and flux can be 1 or even none
Oxidation with hydrogen peroxide is most common
Drag in of Fe gives higher dross and ash production
Iron content < 5 g/l is recommendableHard to achieve without flux treatment
Main reason to start with flux treatment!Concentrations < 1 g/l are achievableAmount of rinses between pickle and flux can be 1 or even none
Oxidation with hydrogen peroxide is most common
Fe contentFe content
Important for an equally fluxed surface Modern wetting agents are stable
towards H2O2 Automated dosing of wetting agent in
small amounts is recommendable and can be performed in the flux treatment
Important for an equally fluxed surface Modern wetting agents are stable
towards H2O2 Automated dosing of wetting agent in
small amounts is recommendable and can be performed in the flux treatment
Surface tensionSurface tension
1. Case 1, proto type Dutch general galvanizer 7 metres
2. Case 2, crash barriers, extremely high Fe content German crash barrier galvanizer 13 metres
3. Case 3, advantages low pH German general galvanizer 15 metres
1. Case 1, proto type Dutch general galvanizer 7 metres
2. Case 2, crash barriers, extremely high Fe content German crash barrier galvanizer 13 metres
3. Case 3, advantages low pH German general galvanizer 15 metres
Quality improvementQuality improvement
Prototype Fluxcleaner Dutch general galvanizer 15.000 tons/year capacity 30 m3 flux
pH at start 3,9 Fe content 19 g/l Colour at start coffee brown Start up at October 27th 2007, no cure no pay Started with iron removal at 1 g/l program Stable situation from february 2008
different programs (removal rate) changed pump
Prototype Fluxcleaner Dutch general galvanizer 15.000 tons/year capacity 30 m3 flux
pH at start 3,9 Fe content 19 g/l Colour at start coffee brown Start up at October 27th 2007, no cure no pay Started with iron removal at 1 g/l program Stable situation from february 2008
different programs (removal rate) changed pump
Quality improvement, case 1Quality improvement, case 1
Status April 2008 pH 2-3 Color coffee brown Iron content < 5 g/l Filter press is emptied once a week Customer purchased unit
Savings 30 m3 new flux Disposal of 30 m3 old flux Disposal sludge from flux tank Overall impression of better quality
Status April 2008 pH 2-3 Color coffee brown Iron content < 5 g/l Filter press is emptied once a week Customer purchased unit
Savings 30 m3 new flux Disposal of 30 m3 old flux Disposal sludge from flux tank Overall impression of better quality
Quality improvement, case 1Quality improvement, case 1
Extremely high Fe content German crash barrier galvanizer 25.000 tons/year capacity 48 m3 flux
pH at start < 0,5 Fe content 78 g/l Color at start pitch black Start up February 2009
Corrected pH to > 1 Started iron removal at 5 g/l program Filter press is emptied multiple times a week
Extremely high Fe content German crash barrier galvanizer 25.000 tons/year capacity 48 m3 flux
pH at start < 0,5 Fe content 78 g/l Color at start pitch black Start up February 2009
Corrected pH to > 1 Started iron removal at 5 g/l program Filter press is emptied multiple times a week
Quality improvement, case 2Quality improvement, case 2
Status June 2009 pH 2,3 Fe content < 1 g/l Color coffee brown
Savings 48 m3 of new flux Disposal of 48 m3 heavily contaminated flux Disposal of sludge from flux tank Lower dross production (from 0,35% to 0,24%) Lower ash production (from 0,54% to 0,48%)
Status June 2009 pH 2,3 Fe content < 1 g/l Color coffee brown
Savings 48 m3 of new flux Disposal of 48 m3 heavily contaminated flux Disposal of sludge from flux tank Lower dross production (from 0,35% to 0,24%) Lower ash production (from 0,54% to 0,48%)
Quality improvement, case 2Quality improvement, case 2
Advantages low pH German general galvanizer 35.000 tons/year capacity 92 m3 flux
pH at start 4,5 Fe content 1,3 g/l Color coffee brown Test to see if the expected advantages of
pH 2,3 are found in praxis Test for 7 months using identical, numbered products
Advantages low pH German general galvanizer 35.000 tons/year capacity 92 m3 flux
pH at start 4,5 Fe content 1,3 g/l Color coffee brown Test to see if the expected advantages of
pH 2,3 are found in praxis Test for 7 months using identical, numbered products
Quality improvement, case 3Quality improvement, case 3
Test followed the following steps;Filtration at pH 4,5Iron removal at pH 4,5Lowering pH to 2,3 combined
with iron removal5 months of testing to ensure quality improvement is stable
ConclusionsDistinguished quality improvement after lowering pH (over X-mas)
Less pickle and roughness Less ashes, different type of ashes
Test followed the following steps;Filtration at pH 4,5Iron removal at pH 4,5Lowering pH to 2,3 combined
with iron removal5 months of testing to ensure quality improvement is stable
ConclusionsDistinguished quality improvement after lowering pH (over X-mas)
Less pickle and roughness Less ashes, different type of ashes
Quality improvement, case 3Quality improvement, case 3
As iron was already low specific attention wasgiven to dross production.
A higher dross production related to lower pH was not found.
Higher dross production was identified and originating from change of products
Conclusion in a, by the galvanizer written, report was that a lower pH gives a considerable quality improvement but can’t be achieved
without a Fluxcleaner
As iron was already low specific attention wasgiven to dross production.
A higher dross production related to lower pH was not found.
Higher dross production was identified and originating from change of products
Conclusion in a, by the galvanizer written, report was that a lower pH gives a considerable quality improvement but can’t be achieved
without a Fluxcleaner
Quality improvement, case 3Quality improvement, case 3
Status June 2013pH 2,3Fe content < 0,5 g/lColour coffee brownCustomer purchased the unit
Savings Slightly cheaper then sludge removal from the tank
The improved quality meant less after work, the savings on this labour were not calculated but estimated to be at least one FTE!
Status June 2013pH 2,3Fe content < 0,5 g/lColour coffee brownCustomer purchased the unit
Savings Slightly cheaper then sludge removal from the tank
The improved quality meant less after work, the savings on this labour were not calculated but estimated to be at least one FTE!
Quality improvement, case 3Quality improvement, case 3
Indufinish propositionIndufinish proposition
www.fluxcleaning.com
Compact Lowest chemistry consumption Usage of basic chemistry only Corrosion resistance, only plastic Will clean up existing flux with high iron content Best ROI Fully automated Easy to maintain Short delivery times 35 units in the European market Knowhow and experience with the unit since
2006
Compact Lowest chemistry consumption Usage of basic chemistry only Corrosion resistance, only plastic Will clean up existing flux with high iron content Best ROI Fully automated Easy to maintain Short delivery times 35 units in the European market Knowhow and experience with the unit since
2006
Indufinish propositionIndufinish proposition
Thank you for
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Thank you for
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