Engineering Environment Surface Finishing Engineering / Engineering / Surface Finishing Surface Finishing Automation Automation is greatly preferred in bulk plating operations, predominantly for the following reasons: Consistency Reduction in labour costs Elimination of human error Reduced operational costs Regulated inputs Effective control of production Versatility Traceability Automation features Modern plating plants are designed with various options to minimise pollution and help in maintaining clean environment in the work space. Plant engineering has evolved to offer highly efficient dedicated systems for specific plating processes. Some of the features are: Load as you like for Rack and Barrel plants Automatic current and temperature control as per process requirement Auto level and conductivity control of rinsing water Auto dosing as per ampere-hour consumption Production and event data recording On line process monitoring Event warning by SMS Voice alarms Barrel Rotation sensing by current Monitoring Bar Scanner for parts indentification Data Logging (SCADA) is an integral part of automation and has become a necessary tool for all plating plants. Data logging helps in: Online monitoring of status of Transport Wagon, Tanks and Equipment Abnormalities in the process conditions will generate immediate alarm Accurate control of process parameters like temperature Day/Shift/Load wise production report generation Recording of all errors and abnormalities Unlimited LAN access for control and monitoring of plant with multi level password protection Generation of Trend screens of all process parameters with reference to real time Maintenance alertness for all predefined mechanical, electrical and chemical parameters. Equipment BARRELS Small components having high volumes are handled in barrels for purpose of Pickling, Polishing, Phosphating and Plating. Depending on the process, the material of construction can be MS, SS, Plastic-Acrylic or Polypropylene. The capacities of barrels can be varying from 3kg to say 100kg, with sizes as large as 1200mm l x 500mm a/f. Barrels for Long Bolts: These barrels are specifically manufactured for consistent plating on Long Bolts using special anodes in the barrel. Spokes Plating Barrels: Specially designed Barrels dedicated to Spokes of bicycle/motor bike with pocket configuration in each barrel for accommodating Spokes. Auto lid opening/closing can be provided at loading/unloading station(s). CONTINOUS-PLATING-PLANT Continuous plating systems are designed for high speed operations, more specifically for plating of strips, wires and tubes. They comprise of a complex material handling system in keeping with the plating requirements, in an extremely dynamic state of movement. Straight line configurations are made up of a shallow active tank through which singular or multiple strands of the workload is carried at high speeds with specifically designed D.C. contact system. The pre-treatment modules may consist of brush cleaning facilities typical to such processes. The entire conveying system has to synchronise with the spooling drive which is often provided by the customer. DRYING After all wet operations, articles need to be quickly and effectively dried to reduce possibility of staining/corrosion. Different types of equipment are available for this purpose, like conveyorised drying ovens for large components and basket/barrel configured dryers for smaller parts as well as centrifugal dryers. Manual Dryer: It is operated through a foot pedal and incorporates a safety interlocking arrangement which prevents the top-lid from opening while in operation. Adequate supply of hot air is provided by fully enclosed electrical heating elements mounted on the side of the machine; ideal for high single loads at frequent intervals. Automatic Dryer: It follows a preset operating sequence, thereby reducing labour and ensuring consistent quality and higher productivity. A self contained unit, this dryer has its hydraulic aggregated control panel for sequential operation of all functions. This can handle large loads per batch as compared to manual operations. Unloading is automatic after production based preset cycle. All sequential operations are interlocked. Barrel Dryer: This is recommended for specific components not amenable to drying by centrifugal action, or liable to be damaged during discharge into a centrifugal dryer. Air heaters on either side of the barrel along with a circulation fan at the bottom create a steady flow of hot air over components in barrel, thus dry by evaporation. Centrifugal Dryer: Growel supplies a state of the art on line centrifugal dryer with stainless steel basket, also used in passivation lines. The lid opens with pneumatic cylinder & hot air is fed through a special blower with heating system. The basket is static dynamically balanced & rotates for complete removal of water from components. Brake motor provides easy start and stop operations. Basket capacities are in two ranges of 50-75 kg or 75-100 kg. FILTERS We supply a wide range of filters and filtration systems. They are suited for virtually all filtration requirements in plating industry. Filtration demands of today's plating industry are diverse and stringent, prompting the need for a wide range of filtration systems. Specific applications call for plate type filtration, cartridge type filter candles or bag type elements. Pleated filter cartridges are also finding increasing use. We offer a wide range of pumps in metallic and polymer constructions, magnetically coupled, or with internal mechanical seals. Flow rates range from 500 lph to as much as 30,000 lph. GRAUER & WElL offers complete range of filtration systems engineered to provide removal of particulates or organic impurities from a variety of chemicals or electroplating solutions. A combination of compatible components ensures internal and external resistance to corrosive or oxidising solutions. PVC, polypropylene, teflon, polycarbonates and similar materials are increasingly being used to handle problems associated with solution compatibility. In addition to basic systems, piping and valve arrangements are designed on a custom built basis where special filtration duties such as online carbon treatment, to filter chamber bypass are envisaged. Growel offers both disc type and cartridge type systems to cater to specific applications and working conditions. Some of the best of the Growel range of sturdy and dependable heavy duty filter units are: A) Hercules: This model is designed to cater to very high filtration area requirement up to 30,000 lph. It is a two-stage filtration system with the option of carbon treatment in parallel. The combination of bags and cartridges as the filtering media makes this system more versatile. B) Guardian / Atlas: They are compact, corrosion resistant and extremely simple to operate Cartridge filters, available in flow rates ranging from 8,000lph to 20,000lph. Choice of construction material allows use with most liquids, including harsh chemicals at elevated temperatures. As a further option, separate carbon chamber for simultaneous filtration and purification can be designed with appropriate flow control valve arrangements. PAINTING Systems at GROWEL are engineered to offer world class finish of paint. Importance and knowledge of right type of paint, proper surface preparation, right application technique, limiting pollutants/disposal for cleaner environment & proper material handling are meticulously considered in the engineering of surface pre-treatment, Cathodic electrocoat equipment and Zinc-flake coating equipment. The systems thus designed by the finishing experts, meet the world standards of application technology and offer the customer a green & clean system. GROWEL sells not the hardware but a total concept. Environmental awareness has in recent years encompassed the globe, and increasingly stringent laws are being enacted to regulate toxic substances. Among others, the use of hexavalent chromium, a substance hitherto widely used as an effective coating for the prevention of rust, is likely to be regulated and phased out under the new environmental regulations (chiefly those being adopted in the U.S. and Europe). Responding to this trend, Growel, in collaboration with NOF Metal Coatings Japan, is offering GEOMET, the rust preventive coating technology that has been perfected through 30 years of real-world appreciation. The new chromium-free coating technology is now being offered to the Indian industry, in addition to DACROMET, which is already available with us. ROTAMATIC PLANT This is an ideal system for semi automatic electroplating needs. Components to be processed are hung on conductive hooks system which moves at settable conveyor speed, based on process timings. Conveyor chain and supporting system are made from 304 stainless steel to restrict corrosion for prolonged life. Components pass through several process tanks, lengths calculated corresponding to individual station timings. Distance between anodes and cathodes (components) is always constant. Precise and controlled current is provided via conveyor chain to copper hooks. Loading and unloading is at same point. Material of construction of tanks is usually Polypropylene and that of anode baskets Titanium. A centralized control panel displays conveyor speed with an installed VFD, current & temperatures of various electrolytes. TRANSPORT WAGONS There are numerous variants of motorised transport system. Different types of transport wagons are available to suit specific requirements. Transport wagons facilitate hoist and traverse movement of Racks and Barrels and can have special functions like dunking, tilting, barrel rotation and drip trays for reduced solution carry overs. Transport wagons can be guided in: Ceiling suspended tracks Floor mounted portal structures – TYPE D In a laterally arranged track system (guidance above tank) - TYPE Skid In a laterally arranged track system (guidance below tank) - TYPE BU. Transport Wagons can be precisely stopped at desired position by using proximities, laser or linear positioning systems. Drip tray arrangement helps in reduction of carry-over of solution at each station by directly placing a pneumatically operated or rack and pinion type tray below the barrel, while it is being lifted out of a tank. Most of the collected solution is directed back to its main process tank to substantially reduce wastage as also minimise cost of effluent treatment. Growel has designed wide range of transport wagons capable of operating with traverse speeds of upto 50m/min and pay loads of upto 8 Tons. Types of Transport Wagons a) TYPE D: Transport wagons type D with its derivatives DI or Dll J are designed for heavy loads with higher span widths. They work on an overhead track system and allow for the transportation of heavy payloads. The overhead track system comprises of runway, guide wheels, catenary cable track, etc. The track systems can either be mounted directly on the ceiling of the building or on a self-supporting floor mounted portal structure depending upon space availability. b) TYPE BU: This skid type transporter is available in different sizes. It is ideal for construction oflight weight applications. The transporter has a bridge typedesign, providing maximum stability during movement and accu-rate positioning. Due to itsindependent modular design, it is possible to assemble such systems at our works and offerinspection of dry runs before dispatch. a) TYPE Skid: The transport wagon, guided on a laterally arranged track Type BU system, is mounted on a self-supporting floor structure above the tank level,incorporating the bus-bars and the cable ducts (otherwise generally similar to the BU system) for loads up to 150 kilograms. a) TYPE PC: This is generally recommended for labora-tory application like small barrels for precious plating lines or small size Jigs / Baskets. It is guided on a mono track, mounted on a self-supporting structure or can be suspended from the ceiling or roof truss. Hoisting is through a geared motor. Synthetic Polymer Belt, which winds and unwinds on a drum, enables speed change during vertical movements. Traverse is by a special brake geared motor. This design is more suited to semi-automatic operations where high speed throughputs are not required; it is basically economical and space saving. Transport wagons are designed to handle right from 150 kgs upto 5000 kgs based on customers specific requirement. Close X Know More Industries Our service offerings include plants for : Brief History 2 wheeler & 4 wheeler and Bicycle Industry Forging Sheet Metal Front Forks Hydraulic Cylinders Aluminum & Steel Industry Tubes Wire Rods Aluminium Sections Hardware Fasteners Nuts Hand Tools Door Handles & Fittings Bathroom Fittings Defence & Aerospace Gun Barrels Aircraft Components Other Industries Imitation Jewellery Electrical & Electronics Textile components Switch gears Processes Processes Our service offerings include plants for : Brief History Electroplating Nickel, Electroless Nickel Bright Chrome & Hard Chrome Acidic and Alkaline Zinc & its Alloys Copper, Brass, Tin Gold , Silver Cadmium, etc. Others Pickling, Phosphating Anodising Hot Dip Galvanizing / Lacquering Zinc Flake Coating Powder Coating Painting Close X Know More Close X Know More DISCLAIMER : Our recommendations are made in good faith and are based on our skills. However , since the conditions of use of these product s are beyond our control, this information is given on the express condition and agreement that Grauer & Weil (India) Limited, will not be liable to any person by reason thereof. Nothing herein shall be deemed to be a recommendation to use any product in violation of any existing patent rights.