For many industries, including canning, standard tank plating remains the go-to option. Yet challenges still exist with this technology, not least the need to break down parts and ship them out for repair resulting in costly downtime. It’s why SIFCO ASC, the global leader of selective electroplating, provides the SIFCO Process®, a selective brush plating application method of applying metal deposits to localised areas without using an immersion tank.
SIFCO ASC’s Southwest Territory Sales Manager, Tony Arana, who helps customers successfully identify and implement solutions using the SIFCO Process®, explains how those operating within the canning industry will quickly benefit from switching to selective plating. Covering everything from enhanced repair efficiency to reduced operating costs, he also describes the unique role the SIFCO Process® plays in reducing downtime and improving component performance.
No disassembly required.
Downtime is costly at any stage of the manufacturing process. During the highspeed canning operation, a bearing spins on the shaft of the press, creating areas with excessive wear and pitting that, in time, require repair. Wear areas, or areas scored by grit and foreign materials, can cause the press to leak hydraulic fluid or not form the mold properly – potentially triggering a catastrophic event. Removing, breaking down and shipping these parts isn’t simply just time-consuming, it directly results in increased operating costs.
Traditional repair methods call for disassembling the press and removing the crankshaft or press tool before assessing whether to replace the component or weld the damaged areas – both options requiring substantial expense and downtime. With selective brush plating, metal deposits can be applied to localised areas in-situ, enabling stationary parts that are either difficult to move or disassemble to be efficiently plated. With repair work completed entirely on-site the need to ship out parts is avoided, resulting in less downtime and in turn reduced operating costs.
For example, a shaft of 3.53-inches in diameter had a 2.5-inch area of wear. SIFCO ASC determined it needed 0.012 inches of Nickel to plate it back to size, with minimal disassembly of the press and no need to remove the shaft or post machining. This repair was completed in-situ in just five hours – less than one working shift.
Manufacturing is continually looking for ways to extend the operational lifespan of equipment and selective plating provides fast and efficient turnaround times. Industries like aerospace, marine and energy already benefit from the SIFCO Process® and significantly improve wear resistance on critical components prolonging the life of their equipment.
SIFCO ASC is able to evaluate what components need to be repaired and devise a plan that allows this work to be completed both in-situ and around shutdowns, minimising costly disruption. Furthermore, once the repair work is done the machinery can immediately be used again – saving additional downtime for reassembly.
Another benefit of brush plating is that it counts on minimal masking, which is a process that involves protecting areas on the components where plating should be avoided with special tapes and paints. Brush plating is designed to treat those specific areas of a component, with a high level of accuracy enabling in-situ repair and enhancement that is typically faster than alternative surface coating methods.
Machine components need to be properly maintained across all industries, including canning, given that the machines are subjected to wear and tear as a result of the exposure to harsh elements, corrosion and damage. If these components are not properly maintained, then there is a risk they will need to be scrapped which can prove very costly.
Positive environmental impact.
The scrapping of parts and components not only affects company overheads but there is the environmental issue to think about. The question of sustainability is one that is continually discussed. Worn-out, corroded or damaged parts contribute to the million metric tons of ferrous metal, and millions more tons of non-ferrous metals and stainless steel in the U.S. scrap rate.
This can be significantly reduced if site managers and manufacturers can find a way to head off component failure and remove the need for scrapping equipment. This is where remanufacturing comes into play, returning OEM parts back to original specification, or better, for a longer, more reliable lifespan.
With tank plating the parts need to be submerged throughout the process. In some cases the tank can be large depending on the size of the part to be plated. Some tanks can hold up to 1000’s of gallons of chemical solutions, whereas a standard brush plating repair can use less than two litres of solution.
Finally, due to the large volume of toxic material involved in tank plating, expensive and complex effluent systems are required in order to treat the liquid prior to it entering the public waste water system. With brush plating, since the amount of solution is very small, the damage to the environment is significantly reduced, therefore providing a healthier working environment.
The SIFCO Process®.
SIFCO ASC is unrivalled when it comes to engineering capabilities for the selective plating industry. As the global leader in selective plating technology, they have provided practical, cost-effective brush plating solutions for both OEM components and parts requiring refurbishment in the aerospace, oil and gas, general industry and power generation sectors for over 50 years. And at the heart of everything there lies the SIFCO Process® – the leading method of selectively electroplating localised areas without the use of an immersion tank.
In addition to improving component performance, minimising downtime and reducing manufacturing costs, the SIFCO Process® also provides access to SIFCO ASC’s technical expertise from the initial concept and design phase right through to production and beyond. Procurement and logistics teams also ensure that supplies and equipment are readily available when and where they are needed.
In conclusion, it’s clear that SIFCO ASC’s selective brush plating provides those operating within the canning process with a proven, efficient and cost-effective alternative to standard tank plating. This, coupled with the company’s 50 years of expertise and unique SIFCO Process® methodology, will ensure technicians are able to safely repair and plate parts in-situ at rates that are 30 to 60 times faster than tank plating.
For a closer look at SIFCO ASC’s time-saving, efficiency enhancing selective plating systems visit www.sifcoasc.com/canning
About SIFCO ASC
SIFCO Applied Surface Concepts (SIFCO ASC) is the global leader in selective plating solutions. A Quaker Houghton company, SIFCO ASC provides practical, cost-effective selective brush plating solutions to improve part performance and reduce manufacturing costs through corrosion protection, increased wear resistance, increased hardness, improved conductivity, anti-galling or slip.
SIFCO ASC surface enhancement technologies and brush plating services have been used for over 50 years on both OEM components and on parts requiring refurbishment in the aerospace, oil and gas, general industry and power generation sectors. Visit www.sifcoasc.com to find out more.
About Quaker Houghton
Quaker Houghton (NYSE: KWR) is the global leader in industrial process fluids. With a robust presence around the world, including operations in over 25 countries, our customers include thousands of the world’s most advanced and specialized steel, aluminum, automotive, aerospace, offshore, can, mining, and metalworking companies. Our high-performing, innovative and sustainable solutions are backed by best-in-class technology, deep process knowledge and customized services.
With 4,000 employees, including chemists, engineers and industry experts, we partner with our customers to improve their operations so they can run even more efficiently, even more effectively, whatever comes next. Quaker Houghton is headquartered in Conshohocken, Pennsylvania, located near Philadelphia in the United States. Visit www.quakerhoughton.com to learn more.
Media Contacts
James Tomlinson, Senior PR & Content Manager
Wyatt International
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Allison Furlong, Marketing Manager
SIFCO ASC
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+1 216 524 0099 ext 120
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