Work Process

Jigging

The transferred materials are opened (unbundled) and checked by the Jiggers for damages and for determining the type of cleaning requirement.

For Heavy Oxide Film/Rust on the material, if observed, the sections are buffed with M 14 Cup brush. For Slight Oxide Film/Rust on the material, if observed, the sections are buffed with p 180 Grit sandpaper and buffing machine. For dust, dirt, oil, grease etc. on the sections, the jigger wipes them with Jotun thinner No.2 and cotton cloth until properly cleaned.

If any material is to be returned (rejected) due to poor quality, they are kept aside and PS/PF is informed. PS/PF reviews the possibility for rectification or rejects and records in the PSF and PM is informed. The accepted materials after required cleaning are buffed with a buffing machine and P 180 Grade sand paper to smoothen the surface further.

The sections are then jigged (hanged) by the jiggers in appropriate frames on Flight Bars, in such a way as to have complete coverage on the aesthetic sides/all sides of each of the sections.

Pre Treatment

Stage 1- Alkaline Etch (AD De Greaser/Etcher Alkaline Medium) The Degreaser/Etcher removes the Rust, dirt, oil etc on the sections and make them clean and also removes a layer of Aluminium surface (not more than 1gm/Sq.m) and makes the surface smoother.

Stage 2- Water Rinse The Alkaline chemicals on the Aluminium from stage 1 are cleaned by dipping in water.

Stage 3- Acid Etch (AD Etcher Acid Medium) The Acid etcher further removes a layer of Aluminium surface (not more than 1gm/Sq.m) and makes the surface smoother. This chemical also neutralizes the alkaline chemicals carried over on the Aluminium surface from the preceding stages.

Stage 4- Water Rinse The Acid chemicals on the Aluminium from stage 1 are cleaned by dipping in water.

Stage 5- DI (De ionized ) Water Rinsing The sections are dipped in De- Ionized Water maintained at less than 100 micro siemens to ensure the cleaning off the Acid from the preceding stage and for proper formation of Chrome film from the succeeding tank

Stage 6- DI (De ionized ) Water Rinsing The sections are dipped in De- Ionized Water maintained at less than 30 micro siemens to ensure the cleaning off the Acid from the preceding stage and for proper formation of Chrome film from the succeeding tank

Stage 7- Adhesion and Anti Corrosion (AD Pre- Coat Chrome Free) This stage provides a protective film on the sections and ensure anti corrosion and a better adhesion of Powder to the surface. Drier The moisture form the pretreatment is dried off in the drier maintained at 130 degrees..

Powder Coating

Powder coating is applied automatically with automatic guns and the operator provides manual touch up (Optional) if required at Faraday cage areas and or on complex sections wherever powder is not covered with the auto guns. A single coat of Powder manufactured by M/s Jotun as prescribed by the customer will be provided during coating. The coating thickness should be not less than 60 microns for PE-F and PE SDF products and should not be less than 50 microns for Durasol products on the aesthetic sides. However the range may vary from 60- 120 microns.

Curing

The powder coating oven will be set so as to achieve a temperature of 200 degrees on the metal for 10 minutes. The Powder Coated Loads passes through the pre set heated oven and gets cured as per time provided by Powder manufacturer. (10 minutes at 2000 C).

Off loading

After curing, the Loads are offloaded by Offloading personnel and transferred from the conveyor to the unloading Jacks.

Online QC Checking

QCI checks the loads for conformation to quality standards. And records the values in Online Quality Inspection Report GALCO-QC/03 and in Online Quality Inspection Consolidated Report GALCO-QC/04.

Quality Control

All Quality control checks are done in par with the requirements of the powder manufacturer and Qualicoat 11TH Edition standards.

Packing and Delivery

The Coated items are packed either individually or as per customer requirements and in a proper manner to avoid any damages.