ecoat finishing

ECOAT FINISHING
Koch designed & installed the FIRST industrial e-coat system in
North America...
Today, Koch has implemented more than
300 high performance systems in a wide
range of industries.
Environmentally Responsible Solutions
In all of our business endeavors, KOCH is committed to providing
equipment and services that respect the environment and use the
least amount of natural resources possible.
Koch Headquarters
USA Tel: 888-873-5624
KochLLC.com
THE ART AND SCIENCE OF ELECTROCOATING
Electrocoating is a process critical
to every segment of metalworking
manufacturing. Advanced
electrocoating systems allow product
designers greater latitude in the choice
of materials. Electrocoating systems
improve the performance and wear
properties of critical components,
and give metals a high quality,
nonporous, high-adhering surface for
the subsequent application of liquid or
powder topcoats where desirable.
The most common applications of
electrocoating include underhood and
underbody components, recreational
goods, cooking and laundry appliances,
HVAC products and aerospace.
Manufacturers of upscale consumer
products widely use electrocoating as a
primer for powder-coated goods.
Electrocoating uses electrical energy
to apply organic finishes. The part is
grounded and immersed in paint that
has been charged with the opposite
polarity. Resin and pigment migrate
to the part, and a uniform film is
irreversibly deposited. The part is
rinsed, then cured.
There are two basic types of
electrocoating processes. Anodic
systems deposit a negatively charged
polymer onto a positively charged part.
In a Cathodic system, the reverse is
true. George Koch Sons, LLC can
demonstrate and help you compare
these fundamental options to select
the best process for your specific
application, your plant, your production
and your future requirements.
Member of
KOCH SYSTEM - Tailored to your needs
KOCH sales professionals will work with you, your paint and chemical suppliers
and other critical suppliers to design a complete system to meet your particular
needs. Our experience with more than 300 systems allows us to guide you
through critical decisions on all system modules, including:
Material Handling
The process by which parts are conveyed through the entire system determines
many other design considerations. KOCH provides both continuous motion
(monorail, power and free, and continuous belt) and indexing (cross-bar, walking
beam, and programmable hoist) systems. Your part characteristics, production
requirements, space utilization and other factors will be carefully explored in
helping you select the best method of material handling.
Surface Preparation
Surface preparation is the first and perhaps most critical step in obtaining a quality
coating on any product, regardless of the coating process.
The cleaning process best suited for your application will be determined through
interaction with your paint and chemical supplier. Spray, immersion and sprayimmersion combination cleaning are available. Single and dual-tunnel washers can
be provided to optimize process requirements and space utilization. Mild steel,
stainless steel, and fiberglass construction are available.
Dry-Off
For select applications, a drying oven is
installed following the surface preparation
stages to dry the ware before it enters
the electrocoating area. Paint and part
characteristics help determine if this step is
required.
low and maintenance downtime to a
minimum. Unique KOCH designs provide
users with exceptional flexibility and efficiency.
Wastewater Treatment
Integrated KOCH systems typically
include collection tanks, treatment
modules, clarifier, sludge thickener,
pH adjust, sand filter and sand filter
transfer, water re-use, and flow
monitoring.
Electrocoating Application
The electrocoating tank is constructed of steel plate with an inner lining made of
a chemically-resistant, dielectric material. The tank itself is electrically grounded.
Current flows from the power supply through an electrode, through the paint to
the part, and through the part back to the power supply. Through this process,
resin and pigment migrate to the part, and a uniform film is deposited. In anodic
systems, the part is positively charged and the paint is negatively charged. The
reverse is true in Cathodic systems.
Typical dwell times in the tank are
from 90 seconds to 120 seconds.
Dwell time and part dimensions
are two of the key factors in
determining the size of the tank.
As parts leave the tank, they
are moved through two or three
counterflow rinse stages to
remove undeposited paint.
Cure Oven
Exclusive KOCH features, including
heat recovery, heat exchange
tunneling and air seals, give
users an important competitive
advantage by keeping operational
costs
KOCH ovens are legendary for reliability, uptime, and temperature profile
performance.
KOCH has extensive experience with all recognized pretreatment processes,
including zinc phosphate, iron phosphate, chromate, and the newest phosphatefree conversion coating
Controls offered by George Koch Sons include simple relays to the most
advanced Programmable Logic Controls (PLCs), as well as specialty devices, such
as those for strategic safety lock-out and electronic data interchange.
If building a new electrocoating line or updating an existing one is in your plans,
we invite you to visit our headquarters. We also encourage you to talk with current
users of KOCH electrocoating systems. Ask one of our sales professionals for a
reference similar to your application. There are more than 300 satisfied KOCH
E-Coat users from which to choose throughout North America and the world.
AUXILIARY E-COAT EQUIPMENT
The Power Supply is an AC/DC converter with adjustable constant voltage
capacity of 50-500. Rectifiers delivering DC of less than 5% ripple factor are
standard.
The Liquid Chiller supplies cooling medium to the heat exchanger in the e-coating
tank in order to control bath temperature.
Paint Replenishment equipment feeds the electrocoating tanks. If the pigment
and resin are furnished separately, the system supplies them, pre-mixed to the
specified ratio by a static mixer which is integral to the system.
Ultrafiltration Membranes pass water and dissolved substances and collect
dispersed paint resins and pigments. The permeate (or ultrafiltrate) is used
to rinse the product as it leaves the electrocoating tank. This rinse recovers
undeposited paint, which cascades back to the tank through counterflow rinsing.
Efficient, well-engineered ultrafiltration allows repeated recycling of undeposited
paint, and a resultant material utilization of 99%+.
COMPACTCOAT™
SYSTEM
BULK E-COAT
MACHINE
E-COAT
SYSTEM
ELECTROCOATING & THE KOCH SYSTEM ADVANTAGES
George Koch Sons, LLC specializes in turnkey electrocoating systems that include surface preparation, electrodeposition, curing, waste treatment, material
handling and all auxiliary systems.
We offer exceptional design and engineering, exceptionally low life-cycle costs,
and more than 40 years of success in adapting electrocoating technology to suit
the individual needs of customers.
Today, and 20 years from now, KOCH’s team of electrocoat specialists stand with
you to assure that your process, your people, and your production runs smoothly
and predictably.
LEADERSHIP IN ELECTROCOATING
George Koch Sons has long been committed to creating and improving the
techniques and technologies that are integral to World Class electrocoating.
ECOAT ADVANTAGES
Precise Control - High Repeatability
Properly engineered systems offer
precise control over film thickness,
highest film integrity and an
unblemished appearance. The process
offers extremely high repeatability of
results, and is a practical alternative
for metal parts of virtually all sizes and
shapes, gages and grades.
Superior Material Utilization
Through use of closed loop
rinsing, ultrafiltration and
the basic process itself,
electrocoating allows virtually
100% material utilization.
Environmentally Friendly & Safe
Many electrocoat paint formulas
are now available which are free
of heavy metals; many are also
near-zero in VOCs and HAPs. And
because the paint is 80-90% water,
the risk of fire - “the ultimate”
environmental disaster - is vastly
reduced.
Energy Efficient
Electrocoating may not require a dryoff oven, thus exhaust air and make-up
needs are minimized
Koch Headquarters
George Koch Sons, LLC
10 S. Eleventh Avenue
Evansville, IN 47712
888-873-5624
http://www.kochllc.com
Koch EUROPE
George Koch Sons Europe, Ltd.
Tame House, Fradley Park
Lichfield, WS13 8RZ
United Kingdom
Phone: 0044 (0) 1543 444001
Koch Mexico
George Koch Sons dé México S. R.L. dé C.V.
Av. Campanario 99 Int A-11
Col. El Campanario
76146 Queretaro, Mexico
Phone: 01152-442-245-2323
Sales Department
Sam Woehler
Vice President, Sales
Office: (812) 465-9822
Cell: (812) 483-3843
slw@kochllc.com
Rick Cannon
Specialty Products Sales Manager
Office: (812) 465-9716
Cell: (812) 455-9335
rac@kochllc.com
Ron Cudzilo
Regional Sales Manager
Central & Western USA
10512 N. Forest
Kansas City, MO 64155-1951
Office/Fax: (816) 734-8876
Cell: (812) 454-1232
rcc@kochllc.com
Don Miller
Regional Sales Manager
Southeastern USA
Office: (812) 465-9871
Cell: (812) 480-6328
dem@kochllc.com
Dan Hostetler
Thermal Acoustical Sales Manager
Office: (812) 465-9771
Fax: (812) 465-9814
Cell: (812) 483-3182
ddh@kochllc.com
Todd Turnock
Acoustical Distributor Sales Manager
Office: 812-465-9815
Cell: 812-204-3923
tturnock@kochllc.com
Mexico Sales
Antonio Gallegos
General Manager, Koch de Mexico
Office: 01152-442-245-2323
Cell: 01152-1-442-359-4129
agn@kochllc.com
coating systems • thermal solutions • acoustical solutions • environmental conservation • material handling
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