The goal of each business activity is: added value.
This goal can be reached by:
Economic efficiency, quality, productivity and profitability.
In the galvanizing the pretreatment is the most important factor, in order to obtain optimal quality.
To achievie the maximum productivity the galvanizer has to know the pretreatment baths composition.
This information he gets trough regular wet chemical analysis. Based on the analytical results he gets the chance to keep the quality on a high level or to change the process as far as necessary.
Trough these measures he achieved his goals:
Best quality and customer satisfaction
Thus, the regular wet chemical analysis is the significant key point for
the four above mentioned targets to reach the ultimate goal,...
In terms of quality assurance here an excerpt of the "Handbook galvanizing Fire" (section 8.3.5).
The product monitoring and process monitoring are the two key areas of quality assessment. The product monitoring covers the entire in-house testing of the
The individual steps of monitoring the product have to be done as early as possible in order to discover possible mistakes and to take corrective action.
Errors which discoverd at the end of the production process need to be remediate by means of high costs; eventually a high number of pieces of a product galvanized with the same error.
The monitoring process must ensure that all the parameters which influence the galvanizing quality are fully monitored. Permanent and perriodic tests are necessary since the etching baths changes its chemical character after a certain time.
The process monitoring must cover the whole process. Starting from the incoming raw material to the outgoing product.
Wet chemical analysis of pre-treatment facilities of fire galvanizing plants.
Why analysis of acids?
1st Optimization of etchant line management.
2nd Monitoring and compliance with the desired stain terms of an optimal etchant range (see curve according G. Haensel).
3rd Monitoring and compliance with the desired parameters for a correct
4th Counter-balancing work in case of deviations.
5th Cost saving due to points3 and 4.
6th Optimal new set-up trough knowledge of the values and
7th Short exposure time of the material in the bath of in case the values are correct.
8th Official documentation for authorities.
Why analysis of sink baths?
1st To avoid enrichment of zinc , so that the wash water can be used again.
2nd To avoid enrichment of iron to prevent iron is carried into the flux.
3rd Official documentation for authorities.
Why analysis of flux bath?
1st Optimization of the composition (salinity, salt ratio, pH).
2nd By point 1 optimizing the effectiveness in surface preparation.
3rd c galvanizing with the correct parameters.
4th Official documentation for authorities.
Optimum pre-treatment - Optimum galvanizing!
Analysis of cooling lubricants
Why analysis of the cooling lubricant?
1st Compliance with statutory requirements:
Technical Hazardous Substances Directive No. 611 (TRGS 611)
2nd Avoiding concentration fluctuations
Under-concentration: Risk of rust and higher abraison.
Over-concentration: Avoidable costs! Risk of skin irritation.
3rd Perfect results with optimum values
Longer- life cycle of the tools.
4th Prevention of bacterial infection at optimum values.
Protection of employees.
5th Conservation of the machines at optimal values
No downtime= higher process safety
6th QM- documentation
Optimum cooling lubricant - Smooth production process!