Specialist in M.S, Aluminium & S.S Powder Coating

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1 Specialist in M.S, Aluminium & S.S Powder Coating

2 About Us Why Us Raj Fabricators has been established in the powder coating set up since 2003 in Thane, Rabale district of Maharashtra, India. It has since then been a provider of excellent state-of-the-art services to our valuable customers. With utilizing the most modern of technologies and quality assessing machinery we are now able to start our division in GIDC, Savli - Manjusar in Vadodara Gujarat in the name of Raj Powder Coating Co. We at Raj Powder Coating offer our clientele industry leading facilities right from pretreatment plants with automatized conveyor belts, curing ovens and powder coating booths. Our aim is to offer quality and efficiency to add value to products at very competitive prices. Successful powder coating involves more than just powder coating and curing in an oven. The pre-treatment determines how much more refined the outcome of the process becomes. Quality is the ultimate aspect in any field and is also the case in our powder coating plants. We offer the best solutions with ultra-modern conveyorised system that runs throughout our plant minimizing manual labor thus increasing efficiency. It goes through our auto wash pre-treatment system, then our powder spray booth and finally into our camel back oven. RAJ POWDER COATING IS BROUGHT TO YOU BY RAJ FABRICATORS - INDUSTRIAL POWDER COATING

3 Pre-treatment auto wash system A pretreatment process consists of 3 main steps: a) Degreasing b) Derusting c) Phosphating Our auto wash pre-treatment system is a 10 tank process suitable for all MS (mild-steel) materials. The 10 step process is as follows: 1) Hot Degreasing:- During the manufacturing of any metal based component there is an addition of oil or grease or light grease.this stage of pretreatment process helps to remove the oil stains from the manufactured component. 2) Water rinse 3) Derusting: - Before manufacturing of any metallic component or product, the raw material to be used is normally stored. Due to the laying of material one above the other and not being used for a long duration, rust is observed on the metal surface. Thus air and moisture in air tends to create rusty and corrosive surfaces on the product, making it unsuitable for further coating. This stage of the pretreatment process removes the rust making it free from corrosive areas resulting in an optimum surface finish. 4)Desmutting:- This is a process of etching alloy additions, left on surface after degreasing and etching aluminium ( with usage of a strong acid or a mordant to cut into the unprotected parts of the metal ) 5) Water rinse 6) Chromating:- In this process aluminium and aluminium alloys are treated by a corrosion resistant conversion coating known as chromate coating or chromating. These coatings are highly corrosion resistant and provide excellent retention of subsequent coatings. Along with the above features, this coating helps increases visual desirability with the help of chromium ions. 7) Activation:- This ensures a compact and uniform coating of alkaline phosphating in the next tank 8) Hot phosphating:- Once the surface treatment of the product is done, the phosphate liquid forms a phosphate coat on the metal surface which in turn becomes an integral part of the product. This phosphate coat developed on the metal surface makes the surface more adaptive to the powder to be sprayed on it. 9) Water rinse 10) Hot Passivation:- It seals the pores of phosphating. * Our water rinse tanks after each process provides superior quality by ensuring no chemical from the previous tank is carried forward. PLC Controlled Transpoter This is used for complete automation of handling of cages in the pretreatment process. It has a wide load carrying capacity (200 to 1000 kg). PLC based control is provided for integrated plant management system.

4 Quality Control Laboratory Our fully equipped laboratory ensures top grade quality control processes involved in powder coating from start to finish. Here is a list of all our equipments: 1) Portable Gloss Meter 45: A gloss meter measures the specular reflection. The light intensity is registered over a small range of the reflection angle. 2) Pencil Hardness Tester: The pencil hardness test, also referred to as the Wolff-Wilborn test, uses the varying hardness values of graphite pencils to evaluate a coating s hardness. 3) Hand Operated Scratch Tester 3mm: A test panel is clamped to a slide which slowly withdraws the panel while a needle scratches the surface. Tests are conducted either on a go/no go basis using a single specified load or by increasing the load to determine t h e minimum load at which the coating is penetrated. 4) Conical Mandrel Tester: The varying mandrel diameter (1/8 to 1.5 inches, 3.2mm- 38.1mm) stretches a coating through a gradient of distension, allowing precise determination of adhesion characteristics. Batch oven / Drying Oven The whole batch after pre-treatment then is transferred to the batch oven which dries the material and prepares it for the powder coating booth. Powder coating booth: Powder coating booth is mainly divided in two categories. (i.e. Powder Coating booth working area & Powder Coating booth recovery unit). In our cyclone based powder booths, over sprayed powder gets collected in the hopper and due to high velocity-suction it gets carried to the cyclone. In the cyclone, due to spiral action, powder gets collected in the container and air goes out through the ducting. This collected powder in the powder coating booth can be reused thus making it economical for us and our valued customers. Camel-back Oven: This specially designed elevated oven is suitable for loading heavier and bulky items and is able to give accurate history of the time and temperature of the job. Effluent Treatment Plant: GO GREEN In keeping with our GO GREEN concept at GIDC, we at Raj Powder Coating Co. make use of the latest effluent treatment plant which releases crystal clear water free from contamination back into Mother Nature s lap. It s essential to purify the water coming out of our industries to ensure that no chemicals or any other harmful material proves toxic to the environment. 5) Cross Hatch Cutter 2mm 6 Blades: Cross Hatch Cutter for adhesion tests provides an instant assessment of the quality of the bond to the substrate. Due to its rugged construction this cross hatch gauge is ideal for thin, thick or tough coatings on all surfaces. 6) Tubular Impact Tester 2 LB: Many surface coatings are subject to the risk of damage by impact. Impact testers allow reproducible conditions of impact to be defined. The 807 allows pass/fail limits to be established and a classification of the coating to be achieved. 7 )Digital Coating Thickness Gauge: Digital coating thickness gauges (also known as paint meters) are the most widely used due to their high level of accuracy and they can be used to measure the coating thickness on almost any substrate, whether ferrous or nonferrous.

5 Specialist in M.S, Aluminium & S.S Powder Coating