Processes

 

The ALRO GROUP has state-of-the-art production lines and processes. They offer high quality organic paint coatings: wet painting, powder coating and cataphoresis (KTL). We continually invest in new production processes in order to satisfy your specific requirements. The result of this will be seen in the flexibility as well as in the coating quality.

We carry out these processes for you in our 5 coating companies that are located in Western and Central Europe. We offer an impressive range of options and available capacities: around 20 coating installations process more than 100,000 products each day in 1,000 different colours

Wetpainting

Exterior components: many of the metal or plastic objects assembled on the exterior of a vehicle require a perfect paint coat. This is possible in a high variety of bodycolours or in specific contrast colours.

Interior components: the interior of your vehicle is extremely important. That is why many of the plastic products have a paint coat that not only provides your product with a different colour, but a different feel as well. Apart from special effect paints, we also use soft paints that provide a gentle feeling of comfort.

The wet painting process consists of various stages:

  • Placing the products on a transport system
  • Pre-treatment: power wash (degreasing and rinsing with demineralised water) in a spray tunnel
  • Drying
  • Flame treatment: activation of certain specific plastics (optional)
  • Discharging static electricity
  • Applying primer coat using robots or manually + drying (optional)
  • Applying the colour coat using robots or manually + drying
  • Applying varnish coat using robots or manually + drying
  • Remove the products from the transport system
  • Quality control
  • Packing

For each product, the structure of the various layers is determined in advance. This may be from 1 to 4 different paint layers. The paints used are 1-component or 2-component systems, based on water or solvents. Depending on the application, these are primers, uni colours, metallic colours, mica colours, soft paints or transparent varnish. The paint coats can be applied using conventional as well as electrostatic spray guns. This is done using robots or through manual application.

Electrocoating

One of the best techniques for protecting metal is electrocoating (cataphoresis). In this process, an anti-corrosion layer and an organic paint layer is applied after cleaning is done. This layer can be used as a final coat in specific applications, but in most cases, it is the ideal primer coat on which subsequent wet painting or powder coating finishing layers may be applied. Cars undergo this first process at the manufacturer’s works.

Electrocoating is done in the following manner:

  • Placing the products on a transport system
  • Pre-treatment in the automatic car wash: degreasing, activating, application of the conversion layer (for example, phosphating using Zn-Mn-Ni fluorides), passivation, rinsing with demineralised water
  • Electrical deposition of the organic paint coat (± 20 μm or +/- 40μm) in the cataphoresic dip immersion bath
  • This is followed by rinsing with ultrafiltrate
  • Drying at high temperatures
  • Remove the products from the transport system
  • Quality control
  • Packing

Another name for electrocoating is ‘Cathodic Dip Painting’ (KTL).

Powder coating

Powder coating is also a much used method of coating metals. This powder based coating can be used as a primer coat or as a finishing layer. We can offer you a range of options: colour, structural effect, the gloss level, etc.

Apart from conventional powder coating, the ALRO GROUP is one of the few that can apply a high gloss black acrylic powder of the very best quality. This is primarily used to achieve high gloss ‘piano black’ on the outside of metal car-window profiles.

In many cases, a prior electrocoating treatment provides the required corrosion resistance.

The powder coating process comprises various stages:

  • Placing the products on the transport system
  • Degreasing
  • Applying the conversion layer (optionally if products still have an anticorrosive layer)
  • Rinsing with demineralised water
  • Drying
  • Electrostatic application of the powder layer by means of automatic spraying machines
  • Baking on the powder layer in an oven
  • Remove the products from the transport system
  • Quality control
  • Packing

The powders used are based on epoxy, polyester or acrylic technology. Epoxy is used as a primer coat for further processing with wet paints. Polyester is the basis for most of the finishing layers, except for specific sections that require a higher depth of gloss and scratch resistance. In that case, we use acrylic powder

Assembly

After coating, we can further assemble your products into full assemblies. This is done through specific assembly operations. Thus for example, we can do this manually using assembly tracking systems, as well as automatically in assembly units with or without robots.

If so required, we can even provide the engineering and development of the required tools and automations.

We can also purchase the assembly components directly from manufacturers, thereby relieving you of the management of the related goods and financial flow.

You can rely on us to directly deliver fully finished modules to your end customer, with all possible care.

Recycling

The ALRO GROUP company RECITECH is an approved waste treatment company for hazardous and non-hazardous waste.

RECITECH detoxifies, neutralises and recuperates heavy metals, cyanides and other inorganic components from wastewaters using the most advanced physio-chemical techniques in an automated processing station.

Organic components are recycled through vacuum distillation.

RECITECH operates not only from its own location but also provides cleaning at customer sites. In this connection, efforts are directed toward achieving a closed loop solution using membrane technology, ion exchangers and adsorption columns.

Paint stripping

RECITECH can strip coatings from metal products using two different processes: thermally or chemically.

Thermal paint stripping is done through indirect heating of the oven. The components to be stripped  are heated according to a specific temperature curve until the organic paint layer gradually starts smouldering. RECITECH has pyrolysis ovens that can strip the paint off components of various dimensions and different types of paints and coating thicknesses. After the pyrolysis process, components are covered with a layer of inorganic ash. To remove the ash layer, RECITECH will provide an appropriate post-treatment, depending on the required quality. The possible post-treatments include blasting, which can be used to remove stubborn ash layers, and high-pressure spraying, which is suitable for removal of ashes of powder coatings. The treated parts can also be provided with corrosion protection.

In chemical paint stripping, the paint is broken down in an alkaline environment using automatic spraying systems. This technique is ideal for stripping light-weight metals as it has no impact either on the material quality or on the thermal and mechanical properties of the parts. The main advantage of this technique is its high quality in terms of cleanliness and dimensional tolerances.

Recycling Laboratory

The RECITECH analytical laboratory lays down the acceptance criteria for deliveries of your waste materials.

Using the state-of-the-art equipment, it is excellently equipped for the process follow-up of a variety of installations such as surface treatment, pre-treatment baths, and water treatment plants.

Based on their years of experience, our laboratory team can professionally explain the analysis results.

Top