The training of qualified specialists in the industry is in a tight spot: the number of people training to become surface coaters is falling steadily, and with it the number of electroplating technicians in the two-year full-time training program at the Schwäbisch Gmünd trade school, among others. Electroplating" met highly motivated young people there, ready to enter a professional world that also offers numerous new fields of activity. In order to meet future demand, however, companies in the sector are in particular demand.
Electroplating - an indispensable economic factor
Sustainability through electroplating is not just an empty phrase. Since the beginning of industrialization, technology with electroplated surfaces has protected machines, vehicles, infrastructure and countless everyday objects from destruction, thus ensuring their functionality. It is estimated that surface technology - and electroplating processes in particular - reduce the damage caused by corrosion in Germany by up to 40 percent, amounting to 120 to 160 billion euros per year. Electroplating technology thus ensures the preservation of resources and is therefore in line with the essence of a sustainable economy: machines can produce for decades with its protection, power plants can reliably and safely generate and transmit energy, taps can perform their service beautifully and hygienically for generations, supplied by corrosion-protected water and wastewater pipes. The wet-chemical separation of metals is an indispensable economic factor. What's more, batteries, electrolysers and microprocessors are key technologies on the road to decarbonization and climate neutrality - technologies that rely on electroplating. The components installed in them must be conductive, durable or adhesive, and electrochemical processes also play an important role in batteries and electrolysers.
Declining figures despite greater importance
However, the increasing importance of the technology founded by Luigi Galvani in the 18th century is in stark contrast to the low number of trainees in this key technology. In 2023, over 1,000 young people in Germany were still being trained as surface coaters (435) or process mechanics for coating technology (655). However, the numbers of surface coaters in particular have been falling sharply since 2018. This is now also having an impact on advanced technician training, where the number of participants has also fallen sharply.
The specialist level is about to submit their technician thesis: Axel Aichele, Heinrich Uhlmann, Benjamin de Vries, Paul Rienäcker and Jannik Fritsch (from left to right)
Searching for causes: demographics, clichés, companies
How did it get this far? On the one hand, there is the shortage of skilled workers in the industry due to weakening demographics, which is causing the numbers to fall, as electroplating technicians can only become electroplaters if they have previously completed training as a surface coater. Secondly, the profession of surface coater is hardly known, according to Dr. Christa Hannak, Head of the Surface Coating Department at the Gewerbliche Schule Schwäbisch Gmünd. "And if it is, then only through old clichés," she adds. Unfortunately, the presentation of the profession in careers advice and schools is still unable to convey the innovative potential that lies in this technology.
However, the most decisive lever for training electroplating technicians is the companies themselves. They are the main motivating factor for their employees to pursue further training as technicians. But why is it that companies do not push ahead with the technical training of their workforce more decisively and do not ensure that their own specialists are able to find solutions for a changing economy and answers to new coating requirements? Whether the answers are economic uncertainty, higher wages for skilled workers or bureaucratic hurdles: Germany's industry needs more qualified electroplating technicians.
Volker Rogoll, specialist teacher for electroplating technology at the vocational school, is well aware of this. This is because "sustainable electroplating and surface technology is becoming increasingly technologically demanding, especially in locations such as Germany. But also because the demands on production planning and resource efficiency, including documentation, continue to rise," says the man who was a project engineer at the Research Institute for Precious Metals and Metal Chemistry (fem) for many years, but was also Managing Director of the German Society for Electroplating and Surface Technology (DGO). He also confirms: "The transformation process towards the decarbonization of industry cannot be achieved without electroplating and surface technology." At the same time, the career opportunities for electroplating technicians are better than ever due to the shortage of engineers in the industry. "You should perceive independently working and thinking specialists in the company as an asset," Dr. Christa Hannak promotes a change of mindset in the industry. A qualified employee is also someone who pursues and drives forward a goal. "Standing still is falling behind," recalls the doctor of engineering.
Tablets are now a standard part of training - for both surface coaters and technicians
It's no longer about the how - but the why
Some companies, including Umicore and Schlötter, encourage their employees to attend technician training in Schwäbisch Gmünd. The local trade school is considered one of the most important technical schools for electroplating technology in Germany. Electroplating vocational qualifications have been available here since 1927 and more than 1000 technicians have passed through the school since then.
A lot is demanded of the students: they have to spend two years full-time at the school. During this time, they are taught a great deal. In addition to a profound understanding of chemistry and electroplating processes, the curriculum includes environmental technology, business administration, business communication, industry-specific English, personnel management and trainer aptitude. The subject of electroplating technology is no longer just about how something works, but why it works the way it does. "We delve deeper into scientific issues, for example in the technicians' final thesis," explains Dr. Hannak, adding: "This is why the technicians' thesis is carried out as a scientific project in a practical setting in industry."
Birka Schunter, who herself grew up in a family of electroplaters, teaches the technical processes. After studying surface technology at Aalen University and working as an engineer at Umicore and hard chrome platers, she switched to teaching in 2008. "I teach the students processes that go beyond the everyday: Chemical polishing, electropolishing, special chrome processes, hydrocyclone technology." Her credo: "The students should understand processes, not just carry them out."
The equipment in the training workshop is modern and safe. Technicians have the opportunity to repeat and deepen the content of their training here
Basic level: advanced specialist knowledge required
This is also what the current generation of prospective electroplating technicians in Schwäbisch Gmünd have in mind. The young people aged between 20 and 37 are eager to learn and highly motivated. Many have made a conscious decision to become state-certified technicians - not because their employer told them to, but mainly of their own accord. Like Elena Feil, who knew after her training at high-voltage technology expert Rosenberger in Friedolfing, Upper Bavaria: "I want to know more and understand what I'm actually doing." She is one of the few women on the technician training course, but that doesn't bother her: "I would recommend the profession to any woman interested in technology," says the 21-year-old. Her classmate Leandro Anderutti from Switzerland, who is the same age, came to Schwäbisch Gmünd of his own accord and is financing the training himself. There is no technician training in his home country - only a master electroplater. Several colleagues at his employer Hofstetter PCB in Küssnacht on Lake Lucerne recommended the German technical college to him. "I wanted to go deeper. The versatility in electroplating is enormous - from research to the laboratory to production." He has no regrets about swapping the idyllic town of Küssnacht for the dormitory in Schwäbisch Gmünd. However, whether Leandro, like around 70 percent of electroplating technicians, will go on to train as a master electroplater is still up in the air. The reason: "In Switzerland, technicians are more highly regarded than master craftsmen."
Michael Ferahyan, on the other hand, grew up in the industry - his father worked as an electroplater in an anodizing company. At first, the 26-year-old had reservations about following in his father's footsteps: "He talked a lot about assembly line work. But when I did an internship at Schlötter, I realized how varied the job really is," he says. Today, he particularly appreciates the combination of chemistry, technology and precision. Like Elena and Leandro, Michael is in the basic level, i.e. the first year of the two-year training course, which this year consists of just nine students.
Surface coating apprentices and participants in the advanced technician training course come from all over Germany and from neighboring countries. Many live in the modern school dormitory
Specialist level: enthusiasm for electrochemical coating
Many young electroplating technicians have a similar background: many began training as surface coaters after completing their general schooling - and discovered their passion during internships or in the company. It is no different when looking at the technical level, the final year of further training for technicians, which has twelve participants this year.
Jannik Fritsch (22) from Ravensburg, for example, worked at Liebherr Aerospace in Lindenberg, where he coated zinc-nickel, silver and copper. Today he is a trainee technician - and recently signed a contract as a trainer with his former employer. His classmate Axel Aichele (24) comes from Schwäbisch Gmünd. After completing his apprenticeship at a smaller company in Böbingen, he moved to Umicore in anode production. "It was clear to me from the start that I wanted to become a technician as soon as I felt ready," he says. In 2023, he started his technician training on his own initiative. He quickly received his career advancement BAföG grant, but other funding options such as housing benefit are still to come. Paul Rienäcker (26), on the other hand, followed an unusual career path: he trained as a metal wind instrument maker in Vogtland, Thuringia. He discovered his enthusiasm for electrochemical coating in the electroplating department of his training company. After his apprenticeship and a year of work experience, he decided to become a technician. Paul is flexible and can imagine a future at Umicore in Schwäbisch Gmünd as well as at semiconductor manufacturer Global Foundries in Dresden, for example.
Benjamin de Vries (26) initially wanted to become a chemical laboratory technician in Solingen, but was unable to find a job here and then followed a tip from a friend to complete his training at a fittings company with a large electroplating department. Today he lives in Schwäbisch Gmünd. "I wanted to see something new. The school here impressed me with its reputation." Heinrich Uhlmann (36) has the most professional experience. After starting a degree in chemistry, he worked in the emergency services, where he left due to an accident at work. He later spent seven years as a shift supervisor at the Technology Center for Surface Technology and Environmental Protection (TZO) in Leipzig. "I wanted to show that I could do more than just monitor a plant," he says. The logical next step: further training as a technician in Schwäbisch Gmünd.
Corridors with high window facades characterize the school and give it a modern learning ambience
Electroplating as an industry of the future
All eight of the young electroplating technicians interviewed from the basic and technical levels agree that electroplating is an industry of the future. Their arguments: Sustainability, resource conservation, miniaturization, electromobility, medical technology. "Almost every technical product has a coated surface," says Elena Feil. Many see the fact that coatings will become thinner, more efficient and more precise in the future as a challenge - also for their own technical work, the topics of which are already crystallizing in the technical level: Paul Rienäcker is writing together with Heinrich Uhlmann about saving material and energy, Jannik Fritsch about aluminum coatings. Benjamin de Vries is working on minimizing hydrogen embrittlement in the silver plating process and Axel Aichele is writing a thesis on the fluoride-free pre-treatment of titanium. The technician training course cannot meet the standards of a degree course, but the specialists of tomorrow clearly have a scientific approach and advanced specialist knowledge. And at the end of their training, the path to a university is also open to them with the advanced technical college entrance qualification acquired at the same time. And how do they see their school? Unanimously positive. The teachers are considered committed, the content sheds light on procedures and contexts, the atmosphere is collegial. "Everyone is motivated here - that promotes learning," says Leandro. And Paul sums it up: "I couldn't have imagined a better school."
Gewerbliche Schule Schwäbisch Gmünd has an excellent reputation in the industry, but suffers from continuously falling training numbers
Conclusion: recognizing the signs of the times
If you listen to the young people in the electroplating industry of tomorrow, the dawn of a more sustainable world with the help of electroplating technology is already here. They are not worried about career opportunities. "If Germany wants to maintain its position as an industrial location, remain at the cutting edge of technology and exploit the potential of the energy transformation process, we need to train more surface coaters and technicians," Dr. Christa Hannak is convinced. In order to boost training again, companies need to go into schools, raise awareness of the profession and bring it back into the consciousness of school leavers. After all, as Volker Rogoll emphasizes, "electroplating technology in particular offers the best opportunities for a professional career up to higher levels with attractive annual incomes".
The mood in the country is worse than the situation. Many entrepreneurs in the industry agree on this, as the industry survey at the Leipzig specialist seminar in February showed. Global developments are pointing in the direction of a return to Germany as a business location. Self-sufficiency and independence are more important than ever in recent decades. It is now important to recognize the signs of the times and to share the enthusiasm of young people who want a successful future in electroplating. If you want a future, you have to train - and show courage, confidence and perseverance in your training efforts!
