Automation is greatly preferred in bulk plating operations, predominantly for the following reasons:
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:
Data Logging (SCADA) is an integral part of automation and has become a necessary tool for all plating plants. Data logging helps in:
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).
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.
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.
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.
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.
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.
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.
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:
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.
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.
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.
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:
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
Transport wagons are designed to handle right from 150 kgs upto 5000 kgs based on customers specific requirement.
Our service offerings include plants for :
2 wheeler & 4 wheeler and Bicycle Industry
Aluminum & Steel Industry
Defence & Aerospace
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.