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04
2025
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12
Unsure about the right pretreatment process for your coating line?
Author：
Chuangzhi Coating
"If pretreatment is not done well, even the best coating is useless" — this is a consensus in the coating industry. However, many enterprises still take detours in process selection: following the trend to adopt phosphating process, but causing large-area peeling of aluminum alloy workpiece coatings; plastic parts only undergo simple degreasing, leading to chalking and cracking of the surface coating after half a year; investing heavily in equipment, but the capacity utilization rate is less than 60% due to mismatching between process and production capacity. There is no "one-size-fits-all template" for pretreatment processes for coating lines, which need to be accurately matched according to workpiece materials, industry standards and production requirements. As a professional coating line equipment manufacturer, we focus on customized pretreatment systems and match them with exclusive coating pretreatment equipment to help enterprises get out of the misunderstanding of selection and lay a solid foundation for coating quality.
1. "Match by Material": Core Process Selection for Different Substrates
The core of pretreatment processes for coating lines is to "adapt to substrate characteristics". We customize exclusive solutions for three major mainstream materials:
Metal workpieces (such as auto chassis brackets, hardware parts): Adopt a five-tank process of "pre-degreasing + main degreasing + pickling + surface conditioning + phosphating". The coating pretreatment equipment is equipped with an intelligent temperature control system (precise temperature control of degreasing temperature at 50-60℃), the phosphating film thickness is stably maintained at 3-5μm, the coating adhesion reaches cross-cut test level 0, and the salt spray resistance is increased to 1000 hours; Aluminum alloy workpieces (such as door and window profiles, home appliance casings): Abandon traditional phosphating, adopt "chromium-free passivation + silane treatment" environmental protection process. The equipment is equipped with a closed-loop spray pressure control (pressure ±0.02MPa) to avoid corroding the substrate. After treatment, the coating salt spray resistance reaches 800 hours, meeting the RoHS environmental protection standard; Plastic workpieces (such as ABS casings, instrument panels): Adopt "plasma activation + static elimination" process. The customized pretreatment system improves the surface tension to more than 45dyn/cm through high-frequency plasma, increasing the coating adhesion by 3 times and solving the problem of easy peeling of plastic workpiece coatings.
2. Customized Pretreatment Systems: Matching Industry Standards and Capacity Requirements
In addition to substrates, industry standards and production capacity are also key to selecting pretreatment processes for coating lines. Customized pretreatment systems can achieve "on-demand adaptation":
Automotive industry: For workpieces with high-strength requirements such as engine blocks, strengthen the "high-temperature degreasing + multi-layer phosphating" process. The equipment integrates an on-line film thickness detector to monitor the phosphating film thickness in real time (deviation ±0.5μm), meeting the IATF16949 standard; Home appliance industry: Focus on appearance requirements, optimize the "low-temperature degreasing + phosphorus-free conversion" process. The coating pretreatment equipment is equipped with a precision filtration system (filtration accuracy 5μm) to avoid impurities affecting the coating gloss. The color difference ΔE of the treated workpieces is ≤0.4; Small-batch customization enterprises: Design compact systems, adopt "batch processing tank + rapid liquid change module", shorten the changeover time to 15 minutes, support flexible production with a minimum batch of 10 pieces, and increase the capacity utilization rate to 90%. After customizing the system, a home appliance enterprise reduced the coating defect rate from 15% to 0.6%, saving more than 340,000 US dollars in annual rework costs.
3. Case: From "Process Mismatch" to "Quality Benchmark"
A new energy auto parts factory once fell into trouble due to wrong pretreatment process selection: using the traditional phosphating process to treat aluminum alloy battery trays, the coating adhesion was poor, and bumping and peeling occurred during transportation. The rework rate reached 20%, and the loss caused by delayed order delivery exceeded 50,000 US dollars. After our intervention, we first determined its core needs of "environmental protection + high adhesion" through material testing and working condition analysis, customized the pretreatment process for coating lines of "chromium-free passivation + silane treatment", and matched it with intelligent coating pretreatment equipment (including plasma activation module and on-line detection system). After transformation, the coating adhesion of the battery tray increased to more than 5MPa, the salt spray resistance reached 1200 hours, the rework rate dropped to 0.3%, successfully passed the OEM certification, and the order volume increased by 40%.
4. Full-Process Services: Worry-Free Support from Diagnosis to Implementation
We provide full-cycle services of "diagnosis - design - implementation - operation and maintenance" to help enterprises accurately select the right process: In the early stage, the technical team visits the site to test the workpiece material, analyze the production capacity (such as 2,000 pieces per day) and quality standards (such as weather resistance requirements), and issue a "Process Matching Report"; In the design stage, customize the customized pretreatment system according to needs, and optimize the equipment layout (such as U-shaped flow line reducing the floor area by 20%); During the installation stage, engineers are stationed on-site for commissioning and train the operation team to master parameter adjustment skills; After-sales service includes 1-year free maintenance, equipped with a remote fault diagnosis system that responds to problems within 30 minutes to ensure stable operation of the process.
Conclusion
Selecting the right pretreatment process for coating lines means half the success of coating quality. We do not promote "general processes", but only provide "accurate matching" — adapting to diverse needs with customized pretreatment systems, ensuring process implementation with coating pretreatment equipment, helping enterprises avoid selection misunderstandings and achieve "one-time investment, long-term benefits". Whether you produce metal parts, plastic parts or composite material workpieces, consult now to let the professional team customize an exclusive pretreatment plan for you and build the first line of defense for coating quality.
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