Automatic Rack Plating Line Zn/Zn-Ni

Automated technological production equipment for the electrolytic deposition of zinc and zinc-nickel coatings.

Layout and Handling
• Configuration: Double-row line with two transverse transfers, installed at floor level (±0.00 m).
• Loading/Unloading: 4 manual stations for racking and unracking.
• Handling System: 10 automatic transporters (hoists) with a lifting capacity of 750 kg.
• Material Feeding: Goods are loaded using electric-drive trolleys with lifting capabilities.

Technical Parameters and Performance
• Working envelope (Rack size): 2,730 x 200 x 1,450 mm.
• Internal tank dimensions: 3,000 x 500–2,300 x 1,800/1,850 mm.
• Cycle time (Takt): 4 minutes.
• Maximum throughput: 119.25 m²/hr (average 93.3 m²/hr).
• Batch weight: Max. 500 kg (including rack tooling).

Technological Equipment and Process
• Plating Baths: Capability for plating in acid Zn or acid Zn-Ni.
• Agitation: Eductor nozzles for most baths; passivation and rinses agitated by low-pressure air.
• Heating: Electric heating elements; dryers equipped with automatically controlled lids.
• Cooling: Closed-loop system with a cooling unit and heat exchangers (registers) in the tanks.
• Filtration: Continuous filtration for degreasing, zinc plating, Zn-Ni, passivation, and sealing.
• Anodes: Membrane insoluble anodes used in the Zn-Ni process to stabilize ion concentration.

Ecology and Savings (BAT - Best Available Techniques)
• Air Scrubbing: Harmful vapors from pickling are treated in a multi-stage spray absorber (air scrubber).
• Water Management: Three-stage counter-current rinsing, water recycling from the wastewater treatment plant (WWTP), and regeneration via ion exchangers.
• Rectifiers: Modern transistor power supplies with efficiency exceeding 90%.
• Emissions: Conveyors in the pretreatment section feature an exhausted enclosure and drip trays.

Control System and Software
• Control Unit: Siemens S7 with AK-system PLUS software.
• Visualization: AK-system Visual for process monitoring and data archiving.
• Operator Panels: Small input panels at the entry point for batch code entry.

Additional Components
• Homogenization Tanks: For acid baths (2 x 6.6 m³).
• Oil Separation: Gravity-coalescence oil separators and belt skimmers.
• Air Handling: KLMOD 50 air conditioning unit with hot water heating to provide makeup air for the exhaust system.
• Piping: Polypropylene (PP) pipe distribution systems.