Ferro Powder Coatings Presentation


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  • Welcome
  • Ferro Powder Coatings Presentation

    1. 1. Welcome to the world of * Ferro * Ferro Industrial Products is a dynamic South African manufacturer and supplier of Vedoc Performance Surface Coatings for Industry, Masterbatch polymer additives to the Plastic Industry, Ceramic and Glaze Coatings for tile, tableware and sanitaryware manufacturers, thermosetting glass colours for decorating the glass and bottle Industries and Porcelain Enamel to a diverse marketplace. With Worldwide experience we offer specialized coatings benefiting thousands of end users with improved efficiencies, higher output and improved profits.
    2. 2. Welcome to the world of * Ferro cont’d… With our feet on the ground………………….. We aim for solid commercial success together with our customers We will develop our resources with creative vision We will lead by innovation We will listen to our customers needs We will provide quality products at affordable prices We will develop and empower our people This will enable us to strengthen our position in the marketplace
    3. 3. 1919 …With a total investment of $1000 Harry D. Cushman incorporates Ferro Enamelling Company producing porcelain enamel frit in a plant at East 56th Street in Cleveland Ohio. Frit is a complex ingredient in porcelain enamel. 1920 …Robert A. Weaver establishes Ferro Enamel & Supply Co. to market products manufactured by Cushmans organization. 1923 …Weaver begins publishing the Enamelist, the first trade journal in the porcelain enamelling industry. 1926 …To assist customers to do a complete enamelling job, Weaver designs and patents porcelain enamel furnaces 1932 …A Ferro employee J.E,Hansen publishes Advanced Techniques of Porcelain Enamelling which became accepted as the authority in the Industry. 1946 …Ferro initiates research into a revolutionary frit composition based on titanium dioxide and amplifies Ferro leadership. 1946 …Ferro South Africa is established and the brand grows 1948 …Ferro expands its colour division by developing inorganic pigments for ceramics and plastics in addition to porcelain enamel. 1969 …Ferro answers the prayers of homemakers by developing a specialized porcelain enamel coating which continuously cleans household ovens. Ferro continues with its Global network drive by expanding into most countries and into the 21st century where Ferro remains the leader in technology and supply Ferro History
    4. 4. Business Units <ul><li>Ferro Vedoc Powder </li></ul><ul><li>Performance Surface Coatings </li></ul><ul><li>Overview </li></ul><ul><li>Why Ferro </li></ul><ul><li>What is powder coating </li></ul><ul><li>Automotive </li></ul><ul><li>General Metal Finishing </li></ul><ul><li>Architectural and Industrial </li></ul><ul><li>Consumer Durables </li></ul><ul><li>The Vedoc Range </li></ul><ul><li>Colour Accuracy </li></ul><ul><li>Consultancy and Training </li></ul><ul><li>Problem solving </li></ul><ul><li>Coverage Chart </li></ul><ul><li>Terms </li></ul>
    5. 5. Performance Surface Coatings Overview Ferro Vedoc performance powder coating is one of the leading global providers of high quality, cost effective powder finishing materials for a wide range of general, industrial and specialized applications. With more than 40 years experience supplying and supporting powder coatings to the Industry, our rich heritage brings a proud history of business integrity, product consistency, customer care, innovation and generally environmentally friendly coatings. Our expertise is enhanced by; our global network of business and technology professionals, state of the art integrated supply and manufacturing systems, commitment to quality and safety standards consistent and unprecedented excellence in customer service Ferro Vedoc Powder
    6. 6. Powder Coatings are Corrosion <ul><li>Basically ‘solid paint’ </li></ul><ul><li>Thermosetting or thermoplastic </li></ul><ul><li>Environmentally friendly </li></ul><ul><li>Extremely efficient </li></ul>
    7. 7. The Product and Partner of Choice As the global technology leader in powder coatings innovation and quality, we manufacture the broadest range of products for the complete finishing market. We serve the full range of Automotive, architectural, consumer durables, general metal finishing and industrial goods markets, providing a choice of powder coatings suitable for applications as diverse as anti graffiti surfaces in trains, ceiling tiles and shopping carts in supermarkets, auto and truck wheels and exterior automobile trim, patio furniture and garden care equipment. Why * Ferro Vedoc
    8. 8. <ul><li>PREPARATION OF </li></ul><ul><li>ALUMINIUM </li></ul>
    9. 9. Aluminium Finishing Company and Technology Overview Key Industry: Aluminium Finishing
    10. 10. Examples of Aluminium Applications <ul><li>Automotive </li></ul>Cold Forming Coil Automotive Components Aerospace General Industries Architectural Aluminium Packaging
    11. 11. Key Industry Aluminium Finishing Key Industry: Aluminium Finishing
    12. 12. <ul><li>Architectural Aluminium </li></ul>Extruded aluminium sheets and profiles for outdoor and indoor application. Spray - dip - cascade applications
    13. 13. <ul><li>Pre-treatment prior to paint </li></ul>
    14. 14. Pre-treatment Prior to Paint <ul><li>Cleaners (acid, alkaline) </li></ul><ul><li>Etching (acid, alkaline) </li></ul><ul><li>Conversion (green, yellow chromate and chrome free) </li></ul><ul><li>For standard, short and long cycle, dip, spray and cascade application </li></ul>
    15. 15. Typical chromate pre-treatment cycles - Spray / Dip / Cascade Short Cycle Standard Cycle Long Cycle Alkali degrease Rinse Alkali etch Rinse Rinse Acid etch Rinse Rinse Chromate Rinse Alkali degrease Rinse Rinse Acid etch Rinse Rinse Chromate Rinse DI Rinse Acid etch clean Rinse Rinse Chromate Rinse DI Rinse Hot Air Drying Hot Air Drying DI Rinse Hot Air Drying
    16. 16. Chrome Pre-treatment Benefits <ul><li>Traditional process. </li></ul><ul><li>Suitable for use on several substrates. </li></ul><ul><li>Large number of industry approvals. </li></ul><ul><li>Easy to see pre-treatment layer (yellow). </li></ul><ul><li>Coating thickness can be measured easily analytically. </li></ul><ul><li>Easy to control. </li></ul><ul><li>QUALICOAT and GSB approved process. </li></ul>
    17. 17. Non-Chrome Pre-treatment Benefits <ul><li>Newly introduced to the market place. </li></ul><ul><li>Improved worker safety. </li></ul><ul><li>Reduced environmental impact. </li></ul><ul><li>Reduced wastewater pre-treatment costs. </li></ul><ul><li>Non-chrome pre-treatments available for all aluminium alloys. </li></ul><ul><li>Satisfies current and future legislative demands. </li></ul><ul><li>Off-line methods available for measuring coating thickness. </li></ul><ul><li>Yellow colour pre-treatment is available (chemical reaction on the surface). </li></ul><ul><li>QUALICOAT and GSB approved and pre-approved processes. </li></ul>
    18. 18. <ul><li>Qualicoat: GARDOBOND ® X 4723 - Approval Nr. A-001 </li></ul><ul><li>GARDOLENE ® D 6899 - Approval Nr. A-011 </li></ul><ul><li> GARDOBOND ® X 4670 - (provisional A-023) </li></ul><ul><li>GARDOBOND ® X 4707 - (provisional A-024) </li></ul><ul><li>GSB: GARDOBOND ® X 4707 – Approval Nr. 304A </li></ul><ul><li> GARDOBOND ® X 4670 – Approval Nr. 304B </li></ul>Product Approvals
    19. 19. <ul><li>Cleaners: </li></ul><ul><li>Gardoclean ® T 5374 </li></ul><ul><li>Gardoclean ® 501 </li></ul><ul><li>Gardoclean ® S 5201 </li></ul><ul><li>Gardoclean VP 4857 </li></ul><ul><li>Gardacid ® 614 </li></ul><ul><li>Alukleen 840/1 </li></ul>Line Card <ul><li>Deoxidisers/Etchants: </li></ul><ul><li>Gardacid ® P 4326 </li></ul><ul><li>Gardacid ® P 5244 </li></ul><ul><li>Gardacid ® P 5244/1 </li></ul><ul><li>Gardacid ® P 4307 </li></ul><ul><li>Gardacid ® P 4307ES </li></ul><ul><li>Gardacid ® P 4345 </li></ul><ul><li>Green Chromate </li></ul><ul><li>Gardobond ® K 701 </li></ul><ul><li>Yellow Chromate </li></ul><ul><li>Gardobond ® 723 </li></ul><ul><li>Gardobond ® C 4703 </li></ul><ul><li>Non- Chrome </li></ul><ul><li>Gardobond ® X 4723 / Gardolene ® D 6899 </li></ul><ul><li>Gardobond ® X 4707 / Gardobond ® </li></ul><ul><li> Additive H 7067 </li></ul><ul><li>Gardobond ® X 4670 </li></ul>Conversion Coatings:
    20. 20. Anodising
    21. 21. Anodising <ul><li>Cleaners (acid, alkaline) </li></ul><ul><li>Long life etch additive </li></ul><ul><li>Desmutting </li></ul><ul><li>Anodising additives </li></ul><ul><li>Electro-colouring (tin based) </li></ul><ul><li>Sealing (cold, medium, hot) </li></ul>
    22. 22. Anodising Process Mechanical Polishing Brightening Rinse Rinse Rinse Rinse Alkaline Cleaner Alkaline Stripping Desmut Anodising Sealing Rinse Long Life Etch Additive In-/Organic Dyeing Electrolytic Colouring Rinse Rinse Rinse
    23. 23. Chemical Brightening Anodising Rinsing after Anodising Natural Colour
    24. 24. The Chemetall Difference <ul><li>Complete range of Chemicals. </li></ul><ul><li>Approvals by Qualicoat and GSB. </li></ul><ul><li>World-wide network of subsidiaries. </li></ul><ul><li>ISO TS 16949:2002 certified facilities around the world. </li></ul><ul><li>Sophisticated analytical laboratories and experienced personnel to provide high level global support. </li></ul><ul><li>Technology Centers of Excellence around the world support the business at both a local and international level. </li></ul><ul><li>Product and applications support available throughout the world. </li></ul><ul><li>A different approach to the Aluminium Business </li></ul>
    25. 25. The Friendly Expertise <ul><li>Assistance in the engineering of new or modification of existing lines </li></ul><ul><li>Evaluation of pre-treatment processes and selection of respective products </li></ul><ul><li>Selection of the right pre-treatment processes </li></ul><ul><li>Assistance in the start-up of lines, new or modified processes </li></ul><ul><li>Training of personnel (in-house or in special training programs) </li></ul><ul><li>Continuous servicing of the process during the entire period of application (on demand: defined service package) </li></ul><ul><li>Optimisation of processes / process control </li></ul><ul><li>Assistance in environmental, safety and quality issues </li></ul><ul><li>Provision of laboratory capacity for analyses, test series, etc. </li></ul><ul><li>Elaboration of customised problem solutions with reference to product, process, application techniques, etc. </li></ul><ul><li>One stop shopping – Chemical management </li></ul>
    26. 26. Examples of Reference Accounts
    27. 27. Chemetall Support Around the World
    28. 28. <ul><li>A TYPICAL </li></ul><ul><li>FERRO </li></ul><ul><li>CUSTOMER </li></ul>
    29. 37. Ferro Powder coating is a dry form of paint containing most of the ingredients of a typical paint without the solvent. They are universally recognized to be more application efficient than liquid coatings, and provide many benefits for the coater, end user and environment, including: - Solvent free- no VOC emission - Applied by electrostatic application or by dip application in a fluidized bed - Low fire hazard risk - Waste powder can be recycled providing >95% recovery - Low cost of application due to ease of process resulting in one of the least expensive methods of coating available - Economical one coat application - Increased durability of finishes on the final product - Superior temperature, corrosion, wear and chemical resistance of the final product - Diverse product range to suit all applications What is * Ferro powder coating and what are the advantages
    30. 38. The characteristics of Ferro powder also include: - Superior corrosion resistance acting as a barrier to corrosive chemicals and moisture - Superior chemical resistance of the finished film when in use - Superior Heat resistance when specifically developed for elevated temperatures - Superior Abrasion resistance for applications such as office furniture - Impact Resistance is a measure of the coatings toughness. Ferro powders are formulated to withstand high impacts on lawn mowers, automotive components and children’s toys - Excellent Abrasion resistance and Mar resistance characteristics are included in the formulations of the coatings. What is * Ferro powder coating and what are the advantages cont’d…
    31. 39. Powder Coatings can be applied to Metal Wood, Wood Substitutes, Ceramics, Glass, Plastics
    32. 40. Advancing automotive design and component performance Our world class products are engineered to meet the unique and rigorous performance requirements of global automotive manufacturers and tier suppliers and enhance hundreds of car parts. Ferro has powder for all our customers needs from wheels, coil springs, brake and suspension components, interior and exterior trim, oil filters, under hood components, and more. Automotive
    33. 41. Our technical innovations in the automotive market have lead to many new practical applications. We have produced powder coatings with outstanding weatherability characteristics, developed unique materials with exceptional corrosion resistance for functional components such as high tensile steel springs and brakes, and married corrosion resistance with clarity for cost effective, high quality aluminium wheel finishes. We offer unique and consistent quality products and in partnership with our customers deliver cost savings coupled with performance characteristics required by the automotive industry. Custom coaters and metal fabricators depend on us for high quality products that meet the customers exacting appearance and performance requirements adding value Automotive cont’d…
    34. 42. Quality and value…when you need it You can depend on our products to be consistent from batch to batch. Our selection of stock products are readily available in a vast array of colours, appearances , performance characteristics and chemistries through our network of distribution depots throughout the country. This means that our customers get what they need when they need it. Our expertise in process optimization and application efficiency also allows us to help our customers reduce their applied costs and improve usage efficiencies adding value through every step of the process. Our customers can benefit directly from our work with Industry and Trade regulatory bodies, OEMs and various industry specifiers to develop products to meet tomorrow in this fast growing industry. General Metal Finishing
    35. 43. The Vedoc Hi-Q advanced polymer coating is designed as a superior exterior coating for architectural aluminum extrusions and panels, offering; - additional external protection with added UV - ability to withstand the harsh extremes of the climate - light fast colour range - warrantees, when applied by approved applicators Architectural and Industrial Goods
    36. 44. Ferro is renowned for innovation in support of industrial applications and has pioneered low temperature curing, thin film applications and superb, durable coatings. Whether for building and construction products, office and institutional furniture, industrial and agricultural machinery or electrical and telecommunications equipment we set records for developing cost performing coatings for specific applications. Architectural and Industrial Goods cont’d…
    37. 45. The * Ferro range of coating are fashioned to suit the changing trends in colour and performance in this sector. Our expertise and creativity is in serving the consumer. Our team of experts understands the economics, trends and performance needs of the changing consumers and delivers powder coating technology tailored for all applications and uses as varied as household appliances, furnishings, healthcare, leisure, electronic equipment and lawn mover parts. Ferro powders are increasingly demanded for products that require attractive fashionable finishes with the maximum durability for both interior and exterior uses. Tough coatings…resistance to scratching…resistance to fading and wear…lightfast That’s Ferro powder Consumer durables
    38. 49. Production of powder coatings Raw materials Dry blending Extrusion Grinding Sieving Application Wax
    39. 50. VEP Epoxy Polyester This range of powder exhibits excellent corrosion protection and chemical resistance when applied to properly pretreated metal substrates.It is suitable for application to iron, aluminium, zinc and magnesium castings as well as sheet metal, aluminium and electrogalvanising for interior and certain limited exterior applications. VP HI-Q Polyester… SABS 1578 This Superior UV resistant Vedoc range is formulated specifically for use in the architectural aluminium industry where strong resistance to exterior exposure is required. This range carries a 15 year guarantee when applied to specification by a “Ferro Vedoc Approved Applicator”. The *Ferro Vedoc Powder Range
    40. 51. VX Polyester Vedoc VX polyester powders are suitable for exterior exposure. They are recommended where superior UV resistance is required and may be applied to suitably pretreated aluminium and mild steel. They are not recommended for Aluminium extrusions for Architectural use. VPU Polyurethane Vedoc VPU powders is formulated as a superior polyurethane system for many external applications in the automotive industry . The *Ferro Vedoc Powder Range cont’d…
    41. 52. VPC Vedoc VPC powders possess high chemical resistance and are recommended for fusion……..like pipelines, valves and fittings. VE Vedoc Epoxy powders are manufactured for internal use only. The *Ferro Vedoc Powder Range cont’d…
    42. 53. The Ferro Vedoc choice of finishes - Smooth finish in Gloss, Semi Matt or Matt - Ferrotex textured finish used to hide substrate irregularities - Vedoc Hammertone finish. - Vedoc Ferrograin provides a fine texture. - Vedoc Clear powder is available where additional protection is required. Also available Vedoc Speckled, Wrinkled, Metallic and Fluorescent powders. The *Ferro Vedoc Powder Range cont’d…
    43. 54. Application I
    44. 55. Application II - Corona Charging
    45. 56. Application III - Tribo Charging
    46. 57. Application IV
    47. 58. Powder Coating Formulations I
    48. 59. Some Characteristics <ul><li>Average particle size 40 µm </li></ul><ul><li>Average baking cycle 15 min at 180°C </li></ul><ul><li>Average film thickness 60 µm </li></ul>
    49. 60. Powder Coating Chemistries <ul><li>Epoxy </li></ul><ul><li>Hybrid (Epoxy/Polyester) </li></ul><ul><li>Polyester (Polyester/TGIC) </li></ul><ul><li>Polyurethane </li></ul><ul><li>‘ Primid’ </li></ul><ul><li>Acrylics </li></ul>
    50. 61. Powder Coating Statistics I
    51. 62. Powder Coating Statistics II
    52. 63. Powder Coatings Statistics III
    53. 64. Powder Coatings Statistics IV
    54. 65. Worldwide Consumption of Powder Coatings Consumption in Tonnes Per Annum Growth in %
    55. 66. Powder Coatings Consumption/Regions 2000
    56. 67. Powder Coatings Consumption/Applications 1999
    57. 68. Vedoc Colour accuracy <ul><li>Every colour that is manufactured is sprayed, compared, analysed using “state of the art” technology, adjusted if necessary under the expert eyes of the colour specialists until a perfect match is achieved </li></ul><ul><li>Chose your colour from one of the following </li></ul><ul><li>Ferro Vedoc Colour chart </li></ul><ul><li>Ferro Vedoc Hi-Q colour chart </li></ul><ul><li>RAL colour chart </li></ul><ul><li>SABS colour chart </li></ul><ul><li>NCS colour chart </li></ul>
    58. 72. Consultancy <ul><li>Our technical consultants provide advice on all aspects of powder coating to ensure that maximum efficiency is achieved from the product. </li></ul><ul><li>Surface preparation..film thickness..oven temperatures..baking schedules..spraying facilities</li></ul><ul><li>…… this is our business </li></ul>
    59. 73. Training……. People make the difference <ul><li>* Ferro provides “on site” training from our technical consultants and certified training courses for spray operators at the * Ferro Training Centre at Brakpan. </li></ul>