Need to start a Zinc Plating Plant

A. Short answer, you need to do some research on your own first, then you probably need a consultant.

James Totter, CEF - Tallahassee, Florida

A. Hi, Arvind.

You must start with a knowledge of what type of parts you will be plating so that you can determine a pretreatment sequence (cleaning, activation, and possibly initial plating layers like zincate, alkaline copper, or Wood's nickel based on the material of the substrate). Then the plating sequence (acid vs. cyanide vs. alkaline zinc plating, for example). Then you select the required post treatment (probably a RoHS-compliant chromate, perhaps followed by a sealer topcoat, or a wax or a water soluble oil).

Next you consider such factors as whether you will barrel plate the articles or rack plate them, and whether the line will be manually operated or automatic. With this information and the production rate, you can begin sizing the process tanks and ancillary equipment. I have seen small production plating lines put together from used equipment for $50,000, whereas I was involved in one plating line where the concrete foundation cost $6.5 million before we began setting the first tank :-)

You may possibly find a process supplier and/or equipment supplier who will help you through the entire design, but many years (or decades) of experience are required to make the right early decisions. So, as James says, you should probably retain a plating consultant before attempting to go further.

The best way to determine cost per kg is to request quotes from a couple of local plating shops. Best of luck.

Regards,

Ted Mooney, P.E. RET finishing.com Brick, New Jersey

A. Hi Jigar. Try to search for a supplier of plating processes in Gujarat and ask them to send a technical sales representative to see you. Armed with brochures and an hour or two of his/her time, I think you'll have a very general idea of what is involved, so that you can continue to study on your own for a while. You'll see recommended plating books on our "must-have books" page.

After you have the general idea, plus a little book knowledge, you'll be able to talk to a consultant and do initial planning on the installation. Good luck.

Regards,

Ted Mooney, P.E. RET finishing.com Brick, New Jersey

A. Hi again, Jiger. We may be having a little bit of language difficulty, but I don't quite understand what you want. If you are asking for the general sequence of operation, it is usually soak clean, electroclean, acid activate, zinc plate, chromate conversion coat, seal (necessary with some trivalent chromate processes) -- with rinsing between each step.

But there are entire 1000-page books just on the zinc plating process, just on the installation and maintenance of plating equipment, just on troubleshooting plating problems. So, in between my one-sentence description of the plating process, and thousands of pages of "the full process" in plating books, what exactly can we help you with? Thanks.

Good luck.

Regards,

Ted Mooney, P.E. RET finishing.com Brick, New Jersey