Spaleck Oberflächenveredlung GmbH recently switched from the previous chromium(VI) process to the more environmentally friendly chromium(III) process from surface specialist SurTec in an automatic electroplating machine.
When chrome-plated fittings gleam or the handles on cupboards and doors continue to shine for years to come, this is often thanks to Spaleck Oberflächenveredlung GmbH from Greiz in Thuringia. Twenty-five years ago, the company, founded in 1991, intensively expanded the field of decorative frame electroplating. Today, 45 employees are busy applying top-quality coatings to surfaces made of die-cast zinc, brass or steel. The decorative finishes not only give the components a high surface quality, but also provide protection as required - even for complex requirement profiles. In addition to chrome plating, the product range also includes copper plating, nickel plating and gold plating, each available in bright, pearlescent or aluminum finishes.
High quality and environmentally friendly
Spaleck Oberflächenveredlung GmbH attaches great importance to the consistent use of environmentally friendly materials and processes. This includes in particular the substitution of substances that are classified as harmful to the environment and health according to the REACh regulation. This also includes chromium (VI) electrolytes, which are still widely used in electroplating.
In order to improve the ecological compatibility of electroplating technology as well as the occupational health and safety of employees and to be able to continue to produce in compliance with the law in the future, the company has converted the chromium deposition in its rack electroplating machines to a high-performance chromium (III) process developed by SurTec for chromium (VI) replacement. The process is particularly suitable for small parts in large quantities of 1,000 components or more. In order to guarantee full reproducibility of the production results at all times, all electroplating technologies are stored on a part-specific and customer-specific basis. The corresponding process parameters are documented for each batch produced.
Complete replacement for chromium(VI) processes
The consistent appearance of the deposited chrome layer was therefore a decisive criterion for Spaleck Oberflächenveredlung GmbH when choosing a supplier to switch to the chromium(III) process. This requirement is met by SurTec 883 XT, an innovative chromium(III) process developed by SurTec for decorative applications, which represents a one hundred percent chromium(VI) replacement in terms of color and function.
SurTec's extensive experience in the production of large series using the chromium(III) process was also convincing. Among other things, SurTec enabled the experts from Spaleck Oberflächenveredlung GmbH to visit an existing chromium(III) series plant so that they could gain a practical impression of the application.
In order to integrate the process into the existing electroplating plant, the plant had to be converted, the old tanks removed and new electrolyte tanks for chromium deposition integrated. The waste water treatment had to be adapted to the chromium(III) electrolyte, which is associated with higher costs. The entire conversion was to be realized with as little production downtime as possible.
SurTec chromium(III) process convinces
SurTec 883 XT is an innovative sulphate-based chromium(III) process for decorative applications that offers a 100% replacement for chromium(VI) in terms of color and function. Corrosion protection and color properties are identical to chromium(VI) bright chrome. The process already has several approvals, including from well-known companies in the automotive industry.
Chromium(III) processes from SurTec are already replacing the previously used chromium(VI) applications in all decorative areas worldwide. Customers include plastic (POP) and metal coaters as well as the sanitary industry. In total, more than half a million liters of chromium(III) electrolytes are in use. SurTec's latest developments in this area include chromium(III) electrolytes in all color variants from light (L* value 85) to dark (L* value below 40). In addition, SurTec is currently working on a process to make the pre-treatment of plastic components completely chromium(VI)-free and thus meet REACh requirements.
The coating costs of the new process are higher at the beginning compared to chromium(VI) and stabilize over the course of using the chromium(III) electrolyte. At the same time, no energy is required for cooling the electrolyte and the chromium(III) process enables faster deposition and higher loading of the product carriers with correspondingly powerful direct current sources.
Integration in just 48 hours
The new approach with SurTec 883 XT was a complete success: the integration of the process with SurTec 883 XT into the previously converted electroplating plant was completed within just two days and chromium(III) production was started in less than 48 hours after the new chromium(III) electrolyte was prepared. SurTec provided intensive support to train the employees of Spaleck Oberflächenveredlung GmbH and to teach them how to handle the chromium(III) electrolyte. The analysis is carried out by a partner laboratory in addition to the internal analysis.
