Surface Treatment

Surface Finishing and Plating plants are used mainly for Plating, Phosphating and Cleaning Systems for a broad range of automotive, aircraft, appliance hardware, electronics and machinery components made out of metal or ABS.

We have developed PLC / HMI / SCADA based solution with following salient features

Sequential handling of flight bars, barrels, baskets including barrel rotation, basket/flight bar tilting, dunking.
Time optimisation and achieving desired dip times
Single line, multiple lines with cross trolleys, multiple transporters, round automatic plants.
Random selection facility for different types of loads in a single plant
Dryer, Oven integration
Conveyor / Pick-n-place integration
Web based reporting
Remote access for quick response to resolve technical issues

Our Automation solutions help you achieve

• High Accuracy • Consistency • Reduction in Labour Cost • Repeatability • Reduction in rejection • Traceability

We have serviced Surface Finishing & Plating Industry with providing Automation Solutions for more than 100 plants for different processes.

We specialise in

ABS Plating
Anodising
Aqueous Cleaning
Blackodising
CED Painting
Copper Plating
Chrome Plating

Hard Chrome Plating
Nickel Plating
Nickel-Chrome Plating
Phosphating
Silver Plating
Zinc Plating (Acid / Alkaline) and with different Passivations

We also have expertise of developing software for ETP (Effluent Treatment Plants) used for metal finishing plants.

Salient Features of our Solution (applicable to each plant)

Three different modes of operation for individual wagon viz
- Auto Mode: For regular production
- Manual Mode: Useful for Plant setup before start of Auto Cycle, carrying different trials, rectifying errors etc.
- Service Mode: Useful for Maintenance/Settings, rectifying errors.
Provision to run Auto Cycle with following combinations making running of Plant versatile and increase uptime and thereby productivity of the plant dramatically.
- All Wagons running (default)
- 1 Wagon under maintenance: Run the plant with remaining wagon/s.
- 2 Wagons under maintenance: Run the plant with remaining wagon/s.
- 1 Wagon only
- Bypass of any Plating/Process Tank
Etching Dip Time settable from HMI/SCADA (say range from 1 to 30 secs) for operational flexibility.
Facility to extend cycle time from HMI to achieve higher plating time if required (say range from 1 to 600 secs)
HMI/SCADA screens with better diagnostic features for
- I/O testing: Very useful in maintenance.
- Events & Alarm messages: Very useful for monitoring & quick error diagnosis thereby reducing operational & maintenance related downtime.
- Plating/Process Tank selection/bypassing: Useful in event of problem with plating tank / plating rectifier thereby increasing plant uptime and productivity thereof.
- Drip time setting: Useful to reduce carryover if required, reducing consumption of chemicals.
We provide interlocks for Plating Rectifier healthiness. This ensures that operator has switched on corresponding rectifier & it is in healthy condition avoiding reprocessing.
Control outputs are sent to Plating rectifiers in such a way that rectifiers start after load is kept in plating tank & stopped before load is lifted from plating tank or plating time is elapsed thereby avoiding heavy spark at time of lifting/lowering load in a plating tank & extra thickness in the event of load remaining for extended time in plating tank.

Monitoring of Barrel Rotation/Dunking: Useful when you want to reject/reprocess loads in case rotation/dunking did not happen as desired.
SMS Alert: Get critical alerts on Plant Stoppages, Delays etc. immediately as SMS and remain updated to last minute.
SCADA Features
Ampere-Hour or pH based dosing
Temperature, Level and Conductivity Control
Connectivity using industry standard protocols such as Modbus, Profibus, Profinet, Ethernet IP, ModTCP etc over RS232 / RS485 / TCP networks.
Wireless communication for ease of maintenance and reduced cabling.
Rectifier control using Modbus/Profibus connectivity for high accuracy.