Overhauling an Automotive, Industrial Ecoat System

Photo Credit: PPG

Springco Metal Finishing (Cleveland, Ohio), a finisher for automotive, heavy-duty equipment and industrial markets, installed a PPG Versabond electrocoating system after experiencing long downtimes and rising operational costs from its two e-coat lines.

The problems arose from accelerating dump cycles in the company’s waste treatment process. Springco turned to PPG (Pittsburgh, Penn.), which has reportedly provided the manufacturer with e-coat, powder and pretreatment products since 1983, for a solution to these issues.

Working with Springco’s team to replace the standard zinc-phosphate chemicals they had been using, PPG began trialing its product on one of the company’s two e-coat lines in April 2016. After a successful one-week trial, the PPG Versabond system was approved for processing of automotive parts and steel wheels; then, after two months of positive feedback, it was launched on the company’s second production line.

“PPG has always worked hand-in-hand with us to offer solutions and new products,” says Jason Conn, vice president of Springco. “When we told our rep that we were experiencing rapid sludge development in our zinc-phosphate tank, he suggested we try the PPG Versabond system, which performs at lower temperatures and produces less sludge as a result.”

The right fit

Conn says the PPG Versabond rinse conditioner and zinc phosphate system is a good fit for Springco’s productions lines because its liquid formulation performs more efficiently than the powder chemistry it replaced. “Liquids are much easier to pump out and handle,” he explains. “The product also creates zinc-phosphate crystals faster, so it is possible to increase line speeds and productivity. Operating at lower temperature also means shorter lead times to fire up the system.”

Since switching to the PPG Versabond system, Springco says it has realized a variety of operational benefits, including lower application expenses, less downtime for maintenance, fewer chemical dumps and a significant reduction in waste treatment costs. The company’s line operators also report that the PPG Versabond system, which combines a new zinc-based rinse conditioner with a specially engineered zinc-phosphate concentrate, is easier to control than the standard zinc-phosphate system.

According to Springco, the new system also resolved quality issues tied to the corrosion resistance and physical performance of Springco’s finished parts and improved the company’s on-time delivery.

Several years after the initial trial on its smallest e-coat line, Springco continues to use the PPG Versabond system in all its pretreatment, electrocoat and powder coat finishes. Springco says it operates more efficiently than before and is better equipped to meet the stringent specifications of its most demanding customers.