Electroplating Plant

Engineering play an  important role in modern plating plant for highly efficient  and  operator friendly. Being the specialized in line, we offer a wide range of electroplating plants and associated equipments from manual to fully automatic plant.
Our plant can meet all your needs for plating, be it on any metal or a plastic component ( ABS Component).

1. TANKS

Type                      Capacity                                             Lining
M.S.                      upto  20,000 Liters                              Lead, PVDF, PVC, Rubber, FRP

P.P.                        upto  10,000 Liters                              ---------

PP+FRP                upto  20,000 Liters                              ---------

SS                          upto  20,000 Liters                              ---------

(a)     MILD STEEL TANK

1. M.S. Tanks are constructed with HR Sheet of appropriate thickness with suitable M.S. reinforcement.
2. Epoxi painted / FRP coating from outside as is necessary.
3. Tanks are welded with arc weld for robust.
4. Thermal insulation is provided wherever necessary.
5. Tanks cover is provided wherever necessary.

(b)     Polypropylene Tank (P.P. Tank)

1. P.P. Tanks are constructed with high density P.P. duly reinforced  with coated steel and P.P. supports.
2. The large capacity tanks are welded with extrusion welding machine ensuring homogenous bonds and higher joint strength.
3. State of art machine are used for fabrication process like welding, cutting, bending etc for quality and durability .

(c)      P.P. + FRP TANKS
1.     Tank are constructed with PPGL duly reinforced with coated steel / seasoned wood duly coated with
         FRP on it with ISOthellic / Bisphenol / Venyl Ester Resin as is required.

(d)     S.S. TANKS

1. Tanks are constructed with SS-304 or SS-316L grade sheet.
2. Tanks are welded with argon or arc welding for very robust.
3. Thermal insulation is provided wherever is necessary.
4. Epoxi painted or FRP coated from outside as required.

Features

1. All tanks are provided with slope in bottom to provide ease of cleaning .
2. Adjustable leg supports for proper alignment (if desired by the client).
3. P.P. / C.I. “V” block for flight bar resting on tanks.
4. Phosphorous Bronze “V” block are provided on electrolytic tanks.
5. Special type of P.B. “V” block with cooling arrangement are provided on Etching tank & chrome plating tank.
6. Al. “V” block are provided on Anodizing Tank.
7. Fume extraction is done by means of lip ducts provided on the rim of the tank, made out with 3mm PPGL / 3mm PVC duly FRP coated on it or made out in PVC+FRP on it as per demand of project.
8. Electrolyte tanks are provided with electrolyte grade copper bus bar.
9. Air Agitation coils are provided in PP/PVC/SS as per process requirement.
10. Heating coil in SS/Ti or heater in SS / Titanium/Glass/ Teflon are provided as per process requirement.
11. Cooling coils in SS/Ti or Plate type heat exchanger is provided, if process require it
12. Temperature sensor is provided in tank in SS or Titanium as process bath requirement.
13. Educator is provided in tank if process require more agitation or cathode rod movement system is provided for mechanical agitation for satin Ni or other bath if required.
14. To reduce the load on E.T.P. we recommend two stage or three stage cascade rinse and thus reduction in water consumption.
15. Drain connections of appropriate sizes are provided in tanks except precious metal tanks.
16. For manual type plant we provide temperature display and time display alongwith timer on tanks.
17. In manual type plant we provide rectifier On-Off with ampere hour meter display on tanks wherever required .

2. MATRIAL HANDLING SYSTEM

(A)      TRANSPORT WAGON
Type                                        Capacity
Cantilever Type                       50-100 Kgs.
D Type                                    100-1000 Kgs.

The following configurations  are available based on layout / space availability.
(a) Straight Line :-                   Plating Plant with load / unload same side.
(b) Straight Line:-                   Plating Plant with load / unload on opposite side.
(c) Parallel Lines:-                   Plating Plant with traverse cross transport wagon.

 Features

1. Operation :- Manual / Semi automatic / Automatic.
2. Robust design.
3. Frame:- M.S. , SS-304 construction with epoxi paint.
4. High efficiency geared motor with brake suitable for continuous duty.
5. Speed upto 15 mtr. Per minute for hoisting and upto 30 mtr. per minute  for traverse.
6. Step-less speed  regulation through frequency A.C. drive.
7. Hoisting with nylon belt / chains.
8. Vulcolan wheel  suitable for  corrosive atmosphere and anti skidding  function for traverse movement.
9. Horizontal  and vertical movement transmission of direct gears.
10. Combination of proximity and limit switches for enhancing of safety & reliability.

(B)     TRACK AND SUPPORT
(a)   Different type of section in MS/SS are used for robust type structure for running of transport wagon on it.
(b)   Tank support structure is provided for resting of tanks on it on uniform level.
(c)    The station  cams are provided on track for sensing the station.
(d)   All the structure is painted with epoxi painted to reduce the corrosion chances.

Features

1. We provide robust structure.
2. Adjustable leg supports in SS/MS are provided for alignment of track if required.
3. Epoxi Painted.

(C)    FLAT CABLE DRAGGING ARRANGEMENT
            (a) Lapp make flat cable are used for better life.
            (b) Special type robust  cable trolleys are used for smooth running of cable.
            (c) Proper track is provide for running of trolley on it.

Features

1. Low noise in movement of cable.
2. Better life of the system.
3. Low maintenance  cost and easy to replace defective trolley.

(D)    AUTOMATION:-

1. Consistency and improvement in quality.
2. Increase production under optimum conditions.
3. Reduction in production bottlenecks.
4. Reduction in  chemical costs.
5. Reduction in labour and operational cost.
6. Elimination of human error.
7. Regulated inputs.
8. Reduction in inspection.
9. Maintenance of operating efficiency.
10. Effective control of production.
11. Versatility and quality consciousness.

With the advent of computers and industrial logic controllers, the material handling systems of  plating plats have become far more flexible with unending possibilities, limited only by commercial prudence. Important parameters like raw material control, data logging of production and other MIS systems can be incorporated. The PLC which is the most vital part of automation itself can be interfaced with a main computer to integrate with the automatic production line.

PLC can also provided with necessary auxiliary driver cards with I/O’s ( analog / digital ) wherever required and software packages for controlling parameters like process temperature, PH, plating current, ampere hr./ consumption etc.

(E)     BARRELS

S.No.	Model	Moc	Capacity	Shape
1	Plating (Custom Built).	PP/Acrylic	5 to 50 Kgs.	Hexagonal
2	Phosphating  (Custom Built )	MS/SS	20-80 Kgs.	Round
3	Manual Plating (Custom Built )	PP	30-80 Kgs.	Hexagonal
4	Spoke Barrel (Custom Built )	P.P.	10-15 Kgs.	Hexagonal Multi Chamber.

Features

1. Unloading Chute: Funnel shaped chute made out of PP/SS that provide easier unloading of material into a basket from the barrel .
2. Drip Tray:- This  arrangement helps in reduction of carry over of solution at each station, by directly placing a pneumatically operated or rack and pinion type tray below the barrel, while it is being lifted out of a tank, the collected solution is then drained into a pipe manifold and sent directly to the ETP. This substantially reduces the contamination at each station by over 10%.
3. Drip Accelerator:- This feature helps in a faster drip of the solution from the barrel, hence reducing the drip time at each station and the time decreasing the carry – over of solution by over 30%.
4. Direct drive / Chain drive :- Drive mechanisms are designed, depending on the operational requirements.

(F)     FLIGHT BAR

1. Flight bar are designed with suitable size copper section in electrolyte grade.
2. Special type of male part is  designed for proper contact in “V” block at electrolyte tanks to reduce the energy losses hence increase the profitability.
3. Proper reinforcement in SS / MS is provided with S.S. hardware to increase the robustness of the flight bar.

Features

1. Due to special type design of male part proper contact area is provided on both end of the electrolyte tanks. So that the current flow from both ends remain uniform for uniform plating on all components.
2. Better life due to robust in nature.

(G)    JIGS & FIXTURES(CUSTOM BUILT)
(a)        Jigs & Fixture are developed in frame type shape with suitable size electrolyte grade copper section of appropriate current carrying capacity and as per requirement of component to be plated.
(b)        Both side hooks provide with P.B. spring tension strip for better contact for current flow.
(c)        Special type plastocized coating is used on jigs.
(d)       S.S. hardware is used for firm contact and strength of jig.

Features

1. Robust in nature.
2. Better contact area on flight bar reduces the energy loss hence increase the life of jig and save the energy lost in heat.
3. Uniform plating.
4. The contact points are provided with spring tension from the material like Copper, P.B., S.S., Titanium depending upon the current requirement & nature of process.

3. AUXILIARY EQUIPMENT

(A)      RECTIFIER

1. All electro chemical deposition require D.C. current which is supplied by rectifier. It converts A.C. supply into D.C. output.
2. All electroplating require low ripple content  not more than 5% except in chrome plating which require only 3% ripple content in supply.
3. Power factor more than 85%.
4. Winding of coils with electrolyte grade copper wire.
5. Indicating  lamps, digital or analog meters are provided for display of out put –voltage and current.
6. Normally three type of rectifiers are in common use:-
7. Conventional (Variac).
8. Thyrostorised.
9. Solid State.

(B)     FILTERS
The filtration plays a vital role in plating process, we provide effective and efficient  filters for  purification of baths with minimum down time. In our filter unit, we provide higher filtration surface area per unit volume to enabling better performance and ease of maintenance. We provide our filter unit with chemical dosing chamber.
We carefully choose the material of construction to with stand corrosion and acid fumes in the plant, typical in plating industry.

Normally two types of filter units are used in plating industry.

1. Plate Type.
2. Cartridge Type.

(C)    AGITATION BLOWER
In plating industry, the agitation is used in electrolyte bath to change the cathode film which reduces the polarization hence enhance the current density means fine grains are deposited at higher plating speeds.
In rinsing tanks agitation improve the power of cleaning the component and minimize the time of rinsing and quantity of water needed for cleaning , hence reduces the  load at E.T.P. and reduces the polluted water treatment cost.
Normally twin lobe blower or tubo blower  with low pressure 2 to 6 PSIG with appropriate capacity depending upon the plant size are used in plating industry.

(D)    DRYING OVEN
After wet processing, component need to be dried immediately to prevent from the possibility of staining or corrosion .
Different type of equipments are used for the purpose including centrifugal driers, batch type conventional oven, canveyarised drying oven, automatic lid openable drying oven for automatic plant etc.

(E)     AUTO TEMPERATURE CONTRO SYSTEM
In plating industry the temperature  consistency of bath play an important role hence temperature is maintained in a specific range.
To achieve this target temperature indicating cum controller are used for On-Off the heaters of the bath or to OPEN-CLOSE the flow of steam / hot water through heating coils in the bath through three way motorized or pneumatic operated valve.
Normally bypass arrangement is provided to make the system maintenance friendly.

(F)     CHILLING UNIT
If the plating process require low temperature like in Anodizing, Electropolishing, Chrome & Zinc Plating, the chilling plant alongwith cooling tower is provided of appropriate capacity depending upon the load requirement of the plant.

(G)    TITANIUM ANODE BASKETS
Titanium baskets are widely used in plating industry to put the anode in the basket particularly in nickel plating due to its excellent property like:-

1. High corrosion resistance.
2. High mechanical strength.
3. High wear resistance.
4. Provide constant anode area hence providing constant current density.

The basket is custom built depending upon the size of tanks made out with expanded mesh of titanium reinforced with Ti Sheets of 1.2mm thick.
The hooks are provided with lifting arrangement for ease of maintenance. The P.P. filter bags of 3 to 4 micron is provided with the basket to elimate the impurity of anodes, if any.

(H)    LEAD-TIN ANODES
Lead Tin Anodes are provided for chrome tank with 8% of Tin for better current flow and strength. The anodes are developed in such a way to increase the surface area of contact in unit volume of electrolyte separate.

(I)      OIL SEPARATION
Degreasing operations separate oil and lubricants along with allied contaminations from the surface of the components and float on top of the cleaning liquid. This floating contamination needs to be continuously removed so that it does not carry over to the next operating station, and also increase the life of the cleaner.

Various types of oil skimmers are under use, the most popular in present day’s applications are the disc type. The rotating disc with a scraper separates oil from the fluid surface when the cleaning machine is not in use or it can work continuously if attached to a separate chamber. The oil skimmer prolongs the life of the bath 2-5 times and ensures good cleaning results.

(J)     CENTRAL CONTROL PANEL
Main control panel is provided for all the controls of rectifiers, filters, blowers, chillers, heaters & other load of the plant except transport wagon with all safety protection.

4. SERVICES

1. Steam / Hot water pipe line with insulation and cladding which is designed on the basis of heating load of the plant.
2. Air Pipe Line in GI / P. P. is provided from Bower to Plant.
3. Raw Water / DI Water Pipe Line is provided in GI / S. S. / P. P./CPVC depending upon the plant requirement.
4. Drain Pipe Line is provided in P.P./ PVC/ HDPE of  appropriate size, separate for Acid / Alkali Rinse, concentrate acid and concentrate Alkali between both ends of plant.
5. Cabling is provided in  cable trays from main control panel to different equipments of the plant having connected with proper size of cable lugs / thimbles.
6. Working platform  is provided for operator movement made out in M.S. with epoxi painted and having FRP ( Acid proof) grating on it.

5. SPARES

TANKS

1. Cooling Coil – MS / SS /  Ti.
2. Heating Coil – MS / SS /  Ti
3. Temperature Indicator cum controller.
4. Temperature sensor / probe.
5. Inlet Valve & Drain Valve.
6. V-Block – C.I. / Cu-Alloy/P.P.
7. Insulating washer / sleeve.
8. Lip ducts
9. Air agitation piping system

FILTER

1. Mechanical Seal for Pump.
2. Pump delivery / suction casing, pump impeller & nut.
3. Pump Shaft.
4. Pump Rubber Packing.
5. Pump with  / without motor.
6. Filter Plate,  Filter Cartridge.
7. PP Filter Plate & Cloth.
8.  Filter Paper.
9. Central pipe.
10. Filter stack complete.
11. Canister Housing & Cap.
12. Air vent assembly.
13. O ring.
14. Gasket for valve / lid.
15. Pressure Gauge.
16. Drain valve PP/CIRL/SS.

BARREL:-

1. Rubber bush for contact pin.
2. Contact strips, Pads & Pins.
3. Contact pin mounting plate.
4. Danglers.
5. Gear box / motor.
6. PP gear pinion / drive / driven.
7. Starter with MPCB.

RECTIFIER

1. Filter Choke.
2. DC voltmeter.
3. DC ammeter.
4. Indicating lamp.
5. Raise / lower switch.
6. HRC fuse.
7. Resistor.

TRANSPORT WAGON

1. Station cam.
2. Vulcolan traverse wheel.
3. Idler wheel.
4. Roller pin.
5. Carriage rollers.
6. Side thrust rollers
7. PP hoisting belt.
8. Lifting Arm.
9. Drive / driven gear.
10. Hoist gear / box with motor.
11. Traverse gear box with motor.
12. Frequency inverter.
13. Break for motor.
14. Rectifier for motor.
15. Catenary cable.
16. Cable carrier trolley.
17. Limit switch
18. Proximity Switch
19. Drive / driven shaft.
20. Spur gear assembly.

PLC

1. DC power supply.
2. CPU
3. Battery
4. Digital INPUT / OUTPUT
5. Pin Connector.

SWITCH GEARS

1. MCB.
2. Power MCCB.
3. Overload contactors
4. Mechanical relay
5. Interlock
6. CVT
7. Choke.
8. Relay Card
9. Control Contactor
10. Relays.
11. Selenium rectifiers.
12. 11 watt Tube.
13. Control Transformer.
14. Panel Air Filter.
15. Panel Exhaust Fan.
16. Pus Button.
17. Selector Switch.
18. A.C. Drive.