Numerous companies and industries worldwide rely on SurTec's chromium(III) process to replace chromium(VI) applications without compromising on resistance, hardness and color. In 2017, the surface technology expert SurTec began a successful collaboration with mbw GmbH Metallveredelung in this application. The SurTec 883 XT chromium(III) process was established in production at the plant in Sömmerda, Thuringia. The mbw Group has been active in the nickel-chromium sector since 1992 and the Sömmerda plant has since developed into a leading provider of surface finishing in this area.
Together with SurTec, surface finishing for the highest demands
The SurTec sulphate process implemented at mbw offers several advantages: It ensures color stability even during 24/7 production, and the amount of metal required is reduced by half, which reduces material consumption. In addition, fewer electrical currents are required, the plant remains cleaner and the chemicals used are less aggressive, which protects the plant and reduces the environmental impact. Thanks to the successful implementation of new equipment, which was realized in cooperation between SurTec, mbw and the plant manufacturer AST, the site was able to further expand its expertise in the field of decorative steel components for automotive interiors. Components finished by mbw can be found in almost all well-known car brands.
Components for the highest demands
Mr. Seifert from SurTec GermanyThembw plant in Sömmerda primarily produces for the automotive industry. It offers surface finishes such as nickel and chrome coatings. These processes are mainly used for steel parts used in automotive production, the construction and fittings industry, merchandise and mechanical engineering in order to meet high requirements in terms of aesthetics, corrosion protection and wear resistance. The mbw group produces at 6 locations with over 20 production facilities and other strategic coating processes for many other industries. While the main focus is on corrosion protection and functionality, color properties and coating uniformity are also important for applications in the automotive and electrical industries where appearance is important.
35 million components per year
In 2018, a second trivalent chrome plant was jointly converted, followed by the construction of a third plant in 2024, which offers an impressive fabric window of 8 m². mbw Sömmerda produces around 500,000 m² of trivalent chrome components annually, which corresponds to around 35 million components per year. The exclusive cooperation with SurTec, as a system supplier, has ensured an economical and stable process for the coating of trivalent decorative chrome components in the automotive interior sector.
The SurTec chrome(III) process - convincing innovation for decorative applications
With SurTec 883 XT, SurTec has developed a high-performance chromium(III) process that is a 100% replacement for chromium(VI) in terms of color, function and quality. The sulphate-based technology offers identical corrosion protection and color properties as conventional chromium(VI) bright chrome and has already been approved by leading companies in the automotive industry. The surfaces coated in this way have identical color values to chromium(VI) surfaces and achieve the required results in terms of color and corrosion resistance when mixed with components made from chromium(VI) processes.
The right equipment is the most important basis for trouble-free, efficient production. The recommendations can vary greatly depending on experience. When switching to chromium(III) electrolytes, the suggestions of the chemical companies should be implemented accordingly.
An essential aspect for the optimum performance and quality of the chromium(III) process is the selection of the correct MOX anode and its proper maintenance.
One advantage of the SurTec 883 XT process is that the existing chromium(VI) rectifiers can generally be used, which reduces investment costs and facilitates the changeover. Rectifiers between 12 and 15 volts are sufficient. The optimum current density is 3.5 - 5.5 A/dm².
In addition to the right equipment, reducing the liter load per square meter of surface to be chromium plated can reduce the consumption of chromium(III) solution and other chemicals, resulting in cost savings and a lower environmental impact. New projects and installations are designed up to > 0.7 A/liter. This corresponds to a calculation similar to the chromium(VI) process, but without cooling!
Economical and sustainable
The SurTec 883 XT processAlthoughthe coating costs are higher, they stabilize over the course of using the chromium(III) electrolyte. In addition, there are no costs for cooling the electrolyte, and the process enables energy-efficient and faster deposition as well as higher loading of the product carriers. The waste water treatment can be carried out in existing systems for chromium(III). SurTec 883 XT therefore offers not only a sustainable, but also an economically attractive solution for the future of decorative coating.
Users include plastic and metal coaters as well as the sanitary industry, furniture and household goods. A total of over half a million liters of chromium(III) electrolytes are already in use. The latest innovations include the development of chromium(III) electrolytes in a wide range of colors, from light to dark shades.
SurTec is currently working intensively in cooperation with Okuno Chemical Industries on the development of a process that enables the pretreatment of plastic components to be completely chromium(VI)-free in order to meet the strict REACH requirements and further reduce the environmental impact. As one of the market and technology leaders in Asia in the field of chemical specialties for surface treatment, Okuno is an innovative partner, especially for plastic coaters and the electronics industry.
Chromium(VI) practically on the brink of extinction
The chromium(VI) process is already heavily regulated in many countries and regions and there are efforts to further restrict or completely ban the use of chromium(VI) in various applications. In the European Union, for example, chromium trioxide is classified as a hazardous substance and there are strict regulations on the use and handling of this chemical substance.
REACH Regulation: Under the EU's REACH Regulation (Registration, Evaluation, Authorization and Restriction of Chemicals), companies must report the use of Substances of Very High Concern (SVHC), which includes chromium(VI). Efforts are underway to restrict or ban the use of chromium(VI) in certain applications.
ECHA recommendations: The European Chemicals Agency (ECHA) has issued recommendations on the restriction of chromium(VI) in various applications. These recommendations may lead to certain uses of chromium(VI) being banned in the near future.
Global trends: There is also a trend outside the EU towards stricter regulations for hazardous chemicals. Countries such as the USA and Canada have also taken measures to regulate the use of chromium(VI).
Overall, it is likely that the use of chromium(VI) will be further restricted in the coming years. Specialists such as SurTec are helping companies like mbw to proactively prepare for these changes and switch to less harmful alternatives. Sustainability is also a key focus here.
Contact:
SurTec Germany GmbH
SurTec-Straße 2
64673 Zwingenberg
Phone: +49 6251 171700
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