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UK'S NEW GALV PLANT GOES LIVE

One of the UK’s most innovative new galvanising plants is now fully operational at Carrington Wire where the £1M purpose built 2,400 sq metre facility has achieved efficiency gains yet still improved quality standards.

Close attention has been paid to the quality, health and safety and environmental aspects of the product and the plant by the team of in-house specialists who designed the plant after an industry and company wide consultation was carried out. The new environmental measures incorporated into the design of the plant include improving the chemical circulation, automatic chemical additions and re-designed tanks to prevent leaks and spillages. The new facility also incorporates a dedicated effluent treatment plant.

Carrington believes it is the only plant in the UK, and one of the first in Europe, to offer passivation after electrogalvanising of wire. This can increase the service life and corrosion resistance of the wire by up to 500%. Independent corrosion tests have proven that Carrington’s product is more corrosion resistant and its surface finish is also brighter, more durable, flexible and smoother compared to traditional wiped hot dip galv which is also twice as heavy at 70 grams per square metre.

Through the development of new electrolyte chemistry, Carrington has also developed its own unique glistening finish which uses an acid electrolyte which, compared to the more commonly used alkaline methods, also has additional environmental benefits.

Coloured galv is also a potential new option for customers where the basic colour spectrum of clear, straw, red, blue, yellow and green can be personalised providing a new branding opportunity for companies.

Chemical usage has been reduced by 50 % through the introduction of knife air blowers, among other measures, which use high velocity air to remove residual chemicals from the wire as its goes through the process which also reduces contamination. This not only recycles the chemicals but also contributes to a 10% reduction in chemical inconsistency.

Whilst flexibility and efficiency have been built into the new plant, quality standards have not been compromised. The plant capability spans low and high carbon from 1.20mm to 6.00mm across more than 20 lines resulting in reduced lead times and greater product scope.

Darren Rhodes, Carrington Wire’s Product Manager, said: "The new galvanising plant is the result of listening, not only to our customers, but also to the market and our own employees. We have built a plant that matches the needs of many stakeholders including our customers who want high quality product with short lead times and the market generally which demands flexible and agile production facilities as well as our employees who need a safe working environment.

He added: "It is an addition to our customer offering that helps strengthen and consolidate our position as the market leader in the UK by pro-actively challenging the import market and at the same time further developing our international sales.