Galvano-Zirkel - network of manufacturers and partners in the electroplating industry

The 5th Galvanozirkel took place on November 16 at Leuchtenbau in Leipzig. The host was Mazurczak GmbH. In addition to the thermal process expert, the companies Sager + Mack, aucos, Linnhoff & Partner, Munk and Harter are also part of the electroplating circle. They take turns in organizing the event and also give the presentations. A visit to the German Museum of Electroplating Technology was also part of the event.

Fig. 1: Lukas Büscher, Munk GmbH, kicked off the lecture event with a presentation on the advantages of a new generation of rectifiers

Lukas Büscher: Advantages of a new generation of rectifiers

The rectifiers are housed in a cabinet system, where they receive optimum device protection and meet the highest safety standards. The system has a redundant design. If a module fails, the galvanic process does not come to a standstill. If necessary, the modules can be replaced by the user within 15 minutes. Energy is saved thanks to improved efficiency, which is also achieved through optimum cooling of the individual modules. This reduces operating costs and_{CO2 emissions}. The possibility of BAFA funding provides an incentive to replace existing rectifier systems with more efficient ones. The actual and target status is determined with an energy consultant, the savings concept is developed and the application is submitted to BAFA. Since January 1, 2024, the order may only be placed once the application has been approved. No applications have yet been rejected (Fig. 1).

Christian Gaugigl: Efficient, safe and clever options for temperature control

For efficient heating, a heat requirement calculation must first be prepared. Mazurczak GmbH offers a PDF questionnaire for this purpose. Once the questionnaire has been completed, customers receive an offer tailored to their heating requirements at short notice. Particular attention is paid to safe heating. Temperature limiters switch off the heating if a maximum temperature is exceeded and the heating must be restarted manually. Bath heaters with an integrated anti-fire system switch themselves off during a drying cycle due to evaporation or loss of liquid, thus minimizing thermal damage to systems and containers. Special glass heaters are available for manganese phosphating to prevent incrustation. However, these cannot be used in zinc phosphating because the glass surface is attacked. Coated plate heat exchangers are used here, which are easy to clean as the incrustations can be easily removed from the surface manually (Fig. 2).

Fig. 2: Christian Gaugigl, Mazurczak GmbH, spoke about efficient, safe and clever options for temperature control

Fig. 3: Andreas Scholz and Florian Wimmenauer, Aucos AG, showed how information from electroplating can be used to realize holistic scheduling

A. Scholz, F. Wimmenauer: Production planning 4.0

An easy-to-operate control system facilitates the workflow on electroplating systems. With the program control, delivery dates are organized and the systems are optimally utilized because optimization solutions are specified even with a high variety of types. The system makes recommendations and can be overwritten by employees. This increases confidence in the system and takes into account employees' many years of experience. The control system is self-learning and creates a digital twin, making the process very dynamic. The systems have been delivered for 4 years. Control systems from other manufacturers can also be optimized with AI. Even with small systems, the AI-optimized control system can pay off because the processes are given stability, quality management and logging or even rack management are simplified. However, the biggest problem is obtaining the data that needs to be entered into the system (Fig. 3).

Marius Neuhaus: Future-oriented product solutions

The drum units can be supplied in stainless steel, titanium or polyethylene for the respective application processes. Individual solutions for the customer are developed together. These are durable products with an effectiveness for the highest demands with a long product life, which are modified according to the latest standards. Neuhaus used an example to explain the process of a project, starting with planning, production including prototype construction, through to series production with quality control and delivery to the customer. "The future depends on what we do today." - with Mahatma Gandhi's saying he ended the presentation (Fig. 4).

Fig. 4: Marius Neuhaus, Linnhoff & Partner GmbH, presented innovative solutions for drum units

Fig. 5: Florian Bosch, Sager + Mack GmbH Co. KG, explained how pumps and filters are designed

Florian Bosch: Designing pumps and filters

First of all, the following information must be compiled for the respective task: whether a vertical or horizontal pump is to be installed, which and how much medium is to be pumped and to what height. Pumps are designed based on this information. Particular attention is paid to the material properties, including the sealing material. Empirical values are very helpful for creating the system characteristic curve. The flow rate of the pump depends on the pipe cross-section and length, the height difference and pressure-side installations such as heat exchangers, filters, Venturi nozzles or diaphragm valves. The right product can therefore be determined for every application (Fig. 5).

Reinhold Specht: Compensation drying based on heat pumps

Using numerous examples, he presented customized solutions. Even sensitive surfaces can be dried in the variable temperature range from 20 to 90° Celsius, whereby compressed air-free blow-off technology can also be switched on. Drying is based on condensation drying using heat pumps (Fig. 6). At low temperatures, extremely dry air is used for drying, which absorbs the moisture from the fabric. Tests are first carried out in the technical center according to the task. This provides the customer with the best possible drying system for their products. The drying systems are so efficient and energy-saving that they are subsidized by BAFA, as proven by the experience of numerous customers.

Fig. 6: Harter GmbH has been offering energy-saving drying technology for 32 years. Reinhold Specht reported on heat pump-based condensation drying as a CO2 and energy-saving technology, which makes solutions for future requirements possible

The time during the breaks was eagerly used to exchange experiences with colleagues or to get to know new colleagues. The guests praised the excellent organization and the pleasant atmosphere in which the event took place.

After the lecture event, a visit to the German Museum of Electroplating was an enticing prospect. The beginnings of electroplating technology are honored here. After all, Leipzig is the cradle of electroplating. The production facility founded by Pfanhauser in Vienna in 1873 and the factory opened by Langbein in 1881 were merged in Leipzig in 1907 to form Langbein-Pfanhauser Werke AG. The many exhibits in the museum show how production used to be and that electroplating is a constant part of our everyday lives and is irreplaceable in many branches of industry.

Photos: C. Bäßler