ferro powder coatings presentation

Welcome to the world of * Ferro

* Ferro Industrial Products is a dynamic South African manufacturer and supplier of Vedoc Performance Surface Coatings for Industry, Masterbatch polymer additives to the Plastic Industry, Ceramic and Glaze Coatings for tile, tableware and sanitaryware manufacturers, thermosetting glass colours for decorating the glass and bottle Industries and Porcelain Enamel to a diverse marketplace.With Worldwide experience we offer specialized coatings benefiting thousands of end users with improved efficiencies, higher output and improved profits.\

Welcome to the world of * Ferro cont’d…

With our feet on the ground…………………..We aim for solid commercial success together with our customersWe will develop our resources with creative visionWe will lead by innovationWe will listen to our customers needsWe will provide quality products at affordable pricesWe will develop and empower our peopleThis will enable us to strengthen our position in the marketplace

1919…With a total investment of $1000 Harry D. Cushman incorporates Ferro Enamelling Company producing porcelain enamel frit in a plant at East 56th Street in Cleveland Ohio. Frit is a complex

ingredient in porcelain enamel.1920…Robert A. Weaver establishes Ferro Enamel & Supply Co. to market products manufactured by

Cushmans organization.1923…Weaver begins publishing the Enamelist, the first trade journal in the porcelain enamelling

industry.1926…To assist customers to do a complete enamelling job, Weaver designs and patents porcelain

enamel furnaces1932…A Ferro employee J.E,Hansen publishes Advanced Techniques of Porcelain Enamelling which

became accepted as the authority in the Industry.1946…Ferro initiates research into a revolutionary frit composition based on titanium dioxide and

amplifies Ferro leadership.1946…Ferro South Africa is established and the brand grows

1948…Ferro expands its colour division by developing inorganic pigments for ceramics and plastics in addition to porcelain enamel.

1969…Ferro answers the prayers of homemakers by developing a specialized porcelain enamel coating which continuously cleans household ovens.

Ferro continues with its Global network drive by expanding into most countries and into the 21st century where Ferro remains the leader in technology and supply

Ferro History

Business UnitsFerro Vedoc Powder

Performance Surface Coatings

OverviewWhy FerroWhat is powder coatingAutomotiveGeneral Metal FinishingArchitectural and IndustrialConsumer DurablesThe Vedoc RangeColour AccuracyConsultancy and TrainingProblem solvingCoverage ChartTerms

Performance Surface Coatings

Overview

Ferro Vedoc performance powder coating is one of the leading global providers of high quality, cost effective powder finishing materials for a wide range of general, industrial

and specialized applications. With more than 40 years experience supplying and supporting powder coatings to the Industry, our rich heritage brings a proud history of

business integrity, product consistency, customer care, innovation and generally environmentally friendly coatings.

Our expertise is enhanced by; our global network of business and technology professionals, state of the art integrated supply and manufacturing systems,

commitment to quality and safety standardsconsistent and unprecedented excellence in customer service

Ferro Vedoc Powder

Corrosion

Basically ‘solid paint’ Thermosetting or

thermoplastic Environmentally friendly Extremely efficient

Powder Coatings are

The Product and Partner of Choice

As the global technology leader in powder coatings innovation and quality, we manufacture the broadest range of products for the complete finishing

market.

We serve the full range of Automotive, architectural, consumer durables, general metal finishing and industrial goods markets, providing a choice of

powder coatings suitable for applications as diverse as anti graffiti surfaces in trains, ceiling tiles and shopping carts in supermarkets, auto and truck wheels

and exterior automobile trim, patio furniture and garden care equipment.

Why * Ferro Vedoc

PREPARATION OF

ALUMINIUM

Key Industry: Aluminium Finishing

Oct ‘04

Aluminium Finishing Company and Technology Overview



Oct ‘04

Examples of Aluminium Applications

Automotive

Cold FormingCoilAutomotive

Components

Aerospace GeneralIndustries

ArchitecturalAluminiumPackaging


Oct ‘04

Key Industry Aluminium Finishing



Oct ‘04

Architectural Aluminium

Extruded aluminium sheets and profilesfor outdoor and indoor application.

Spray - dip - cascade applications


Oct ‘04

Pre-treatment prior to paint


Oct ‘04

Pre-treatment Prior to Paint

Cleaners (acid, alkaline) Etching (acid, alkaline) Conversion (green, yellow chromate and chrome free)

For standard, short and long cycle, dip, spray and cascade application


Oct ‘04

Typical chromate pre-treatment cycles - Spray / Dip / Cascade

Short Cycle Standard Cycle Long CycleAlkali degrease

Rinse

Alkali etch

Rinse

Rinse

Acid etch

Rinse

Rinse

Chromate

Rinse

Alkali degrease

Rinse

Rinse

Acid etch

Rinse

Rinse

Chromate

Rinse

DI Rinse

Acid etch clean

Rinse

Rinse

Chromate

Rinse

DI RinseHot Air Drying

Hot Air DryingDI Rinse

Hot Air Drying


Oct ‘04

Chrome Pre-treatment Benefits

Traditional process. Suitable for use on several substrates. Large number of industry approvals. Easy to see pre-treatment layer (yellow). Coating thickness can be measured easily analytically. Easy to control. QUALICOAT and GSB approved process.


Oct ‘04

Non-Chrome Pre-treatment Benefits

Newly introduced to the market place. Improved worker safety. Reduced environmental impact. Reduced wastewater pre-treatment costs. Non-chrome pre-treatments available for all aluminium alloys. Satisfies current and future legislative demands. Off-line methods available for measuring coating thickness. Yellow colour pre-treatment is available (chemical reaction on the surface). QUALICOAT and GSB approved and pre-approved processes.


Oct ‘04

Qualicoat: GARDOBOND® X 4723 - Approval Nr. A-001

GARDOLENE® D 6899 - Approval Nr. A-011

GARDOBOND® X 4670 - (provisional A-023) GARDOBOND® X 4707 - (provisional A-024)

GSB: GARDOBOND® X 4707 – Approval Nr. 304A

GARDOBOND® X 4670 – Approval Nr. 304B

Product Approvals


Oct ‘04

Cleaners: Gardoclean® T 5374 Gardoclean® 501 Gardoclean® S 5201 Gardoclean VP 4857 Gardacid® 614 Alukleen 840/1

Line Card

Deoxidisers/Etchants: Gardacid® P 4326 Gardacid® P 5244 Gardacid® P 5244/1 Gardacid® P 4307 Gardacid® P 4307ES Gardacid® P 4345

Green Chromate Gardobond® K 701Yellow Chromate Gardobond® 723 Gardobond® C 4703Non- Chrome Gardobond® X 4723 / Gardolene® D 6899 Gardobond® X 4707 / Gardobond®

Additive H 7067 Gardobond® X 4670

Conversion Coatings:


Oct ‘04

Anodising


Oct ‘04

Anodising Cleaners (acid, alkaline) Long life etch additive Desmutting Anodising additives Electro-colouring (tin based) Sealing (cold, medium, hot)


Oct ‘04

Anodising Process

MechanicalPolishing

Brightening

Rinse Rinse Rinse

Rinse

AlkalineCleaner

AlkalineStripping Desmut Anodising Sealing

Rinse

Long Life Etch Additive

In-/OrganicDyeing

ElectrolyticColouring

Rinse

RinseRinse


Oct ‘04

Chemical Brightening Anodising

Rinsing after Anodising Natural Colour


Oct ‘04

The Chemetall Difference

Complete range of Chemicals. Approvals by Qualicoat and GSB. World-wide network of subsidiaries. ISO TS 16949:2002 certified facilities around the world. Sophisticated analytical laboratories and experienced personnel to provide high

level global support. Technology Centers of Excellence around the world support the business at both

a local and international level. Product and applications support available throughout the world. A different approach to the Aluminium Business


Oct ‘04

The Friendly Expertise Assistance in the engineering of new or modification of existing lines Evaluation of pre-treatment processes and selection of respective products Selection of the right pre-treatment processes Assistance in the start-up of lines, new or modified processes Training of personnel (in-house or in special training programs) Continuous servicing of the process during the entire period of application (on demand: defined service package) Optimisation of processes / process control Assistance in environmental, safety and quality issues Provision of laboratory capacity for analyses, test series, etc. Elaboration of customised problem solutions with reference to product, process, application techniques, etc. One stop shopping – Chemical management


Oct ‘04

Examples of Reference Accounts


Oct ‘04

Chemetall Support Around the World

A TYPICALFERRO

CUSTOMER

Ferro Powder coating is a dry form of paint containing most of the ingredients of a typical paint without the solvent.

They are universally recognized to be more application efficient than liquid coatings, and provide many benefits for the coater, end user and environment, including:

- Solvent free- no VOC emission - Applied by electrostatic application or by dip application in a fluidized bed

- Low fire hazard risk - Waste powder can be recycled providing >95% recovery

- Low cost of application due to ease of process resulting in one of the least expensive methods of coating available

- Economical one coat application - Increased durability of finishes on the final product

- Superior temperature, corrosion, wear and chemical resistance of the final product - Diverse product range to suit all applications

What is * Ferro powder coating and what are the advantages

The characteristics of Ferro powder also include:

- Superior corrosion resistance acting as a barrier to corrosive chemicals and moisture

- Superior chemical resistance of the finished film when in use - Superior Heat resistance when specifically developed for elevated

temperatures - Superior Abrasion resistance for applications such as office furniture

- Impact Resistance is a measure of the coatings toughness. Ferro powders are formulated to withstand high impacts on lawn mowers, automotive

components and children’s toys - Excellent Abrasion resistance and Mar resistance characteristics are

included in the formulations of the coatings.

What is * Ferro powder coating and what are the advantages cont’d…

Metal

Wood, Wood Substitutes, Ceramics, Glass, Plastics

Powder Coatings can be applied to

Advancing automotive design and component performance

Our world class products are engineered to meet the unique and rigorous performance requirements of global automotive manufacturers and tier

suppliers and enhance hundreds of car parts.Ferro has powder for all our customers needs from wheels, coil springs,

brake and suspension components, interior and exterior trim, oil filters, under hood components, and more.

Automotive

Our technical innovations in the automotive market have lead to many new practical applications. We have produced powder coatings with outstanding weatherability characteristics, developed unique materials with exceptional corrosion resistance for functional components such as high tensile steel springs and brakes, and married corrosion resistance with clarity for cost

effective, high quality aluminium wheel finishes.

We offer unique and consistent quality products and in partnership with our customers deliver cost savings coupled with performance characteristics

required by the automotive industry.

Custom coaters and metal fabricators depend on us for high quality products that meet the customers exacting appearance and performance requirements

adding value

Automotive cont’d…

Quality and value…when you need it

You can depend on our products to be consistent from batch to batch. Our selection of stock products are readily available in a vast array of colours,

appearances , performance characteristics and chemistries through our network of distribution depots throughout the country.

This means that our customers get what they need when they need it.

Our expertise in process optimization and application efficiency also allows us to help our customers reduce their applied costs and improve usage efficiencies

adding value through every step of the process.

Our customers can benefit directly from our work with Industry and Trade regulatory bodies, OEMs and various industry specifiers to develop products to

meet tomorrow in this fast growing industry.

General Metal Finishing

The Vedoc Hi-Q advanced polymer coating is designed as a superior exterior coating for architectural aluminum extrusions and panels, offering;

- additional external protection with added UV- ability to withstand the harsh extremes of the climate

- light fast colour range- warrantees, when applied by approved applicators

Architectural and Industrial Goods

Ferro is renowned for innovation in support of industrial applications and has pioneered low temperature curing, thin film applications and superb, durable

coatings. Whether for building and construction products, office and institutional furniture, industrial and agricultural machinery or electrical and

telecommunications equipment we set records for developing cost performing coatings for specific applications.

Architectural and Industrial Goods cont’d…

The * Ferro range of coating are fashioned to suit the changing trends in colour and performance in this sector. Our expertise and creativity is in serving the consumer. Our team of experts understands the economics, trends and performance needs of the changing consumers and delivers

powder coating technology tailored for all applications and uses as varied as household appliances, furnishings, healthcare, leisure, electronic equipment

and lawn mover parts.Ferro powders are increasingly demanded for products that require attractive fashionable finishes with the maximum durability for both interior and exterior

uses.Tough coatings…resistance to scratching…resistance to fading and wear…

lightfast

That’s Ferro powder

Consumer durables

Raw materials

Dry blending

Extrusion

Grinding Sieving

Application Wax

Production of powder coatings

VEP Epoxy Polyester

This range of powder exhibits excellent corrosion protection and chemical resistance when applied to properly pretreated metal substrates.It is suitable for application to iron, aluminium, zinc and magnesium castings as well as

sheet metal, aluminium and electrogalvanising for interior and certain limited exterior applications.

VP HI-Q Polyester… SABS 1578

This Superior UV resistant Vedoc range is formulated specifically for use in the architectural aluminium industry where strong resistance to exterior

exposure is required. This range carries a 15 year guarantee when applied to specification by a “Ferro Vedoc Approved Applicator”.

The *Ferro Vedoc Powder Range

VX Polyester

Vedoc VX polyester powders are suitable for exterior exposure. They are recommended where superior UV resistance is required and may be applied to suitably pretreated aluminium and mild steel. They are not recommended

for Aluminium extrusions for Architectural use.

VPU Polyurethane

Vedoc VPU powders is formulated as a superior polyurethane system for many external applications in the automotive industry.

The *Ferro Vedoc Powder Range cont’d…

VPC

Vedoc VPC powders possess high chemical resistance and are recommended for fusion……..like pipelines, valves and fittings.

VE

Vedoc Epoxy powders are manufactured for internal use only.


The Ferro Vedoc choice of finishes

- Smooth finish in Gloss, Semi Matt or Matt - Ferrotex textured finish used to hide substrate irregularities

- Vedoc Hammertone finish. - Vedoc Ferrograin provides a fine texture.

- Vedoc Clear powder is available where additional protection is required.

Also available

Vedoc Speckled, Wrinkled, Metallic and Fluorescent powders.


Application I

Application II - Corona Charging

Application III - Tribo Charging

Application IV

Powder Coating Formulations I

Average particle size 40 µm Average baking cycle 15 min

at 180°C Average film thickness 60

µm

Some Characteristics

Powder Coating Chemistries

Epoxy Hybrid (Epoxy/Polyester) Polyester (Polyester/TGIC) Polyurethane ‘Primid’ Acrylics

Powder Coating Statistics I

Powder Coating Statistics II

Powder Coatings Statistics III

Powder Coatings Statistics IV

Consumption in Tonnes Per Annum Growth in %

1996 1997 1998 1999 2000 2001Europe 222000 233000 247000 264000 280000 291000Growth 5 5,0 6,0 6,9 6,1 3,9Africa 22000 23000 23000 24000 25000 27000Growth 5 4,5 0,0 4,3 4,2 8,0North America 120000 132000 136000 140000 150000 155000Growth 10 10,0 3,0 2,9 7,1 3,3South America 20000 25000 29000 32000 35000 38000Growth 24 25,0 10 9 9 8Asia 118000 131000 149000 160000 180000 193000Growth 11 11,0 13,7 7,4 12,5 7,2World Total 502000 544000 584000 620000 670000 704000Growth 8,0 8,4 7,4 6,2 8,1 5,1

Worldwide Consumptionof Powder Coatings

0

50000

100000

150000

200000

250000

300000

cons

umpt

ion

in to

nnes

2000

Europe Africa North America South America Asia

Powder CoatingsConsumption/Regions 2000

Arch Metal Automotive Appliance Industrial Heavy Duty TotalEurope 40.000 16.000 35.000 170.600 2.400 264.000Africa/Mid East 5.500 2.400 4.000 8.600 3.500 24.000North America 4.000 18.000 30.000 75.000 13.000 140.000South America 3.000 3.500 11.500 11.000 3.000 32.000Asia 9.000 8.000 36.000 103.000 4.000 160.000World Total 61.500 47.900 116.500 368.200 25.900 620.000

Powder CoatingsConsumption/Applications 1999

Vedoc Colour accuracy

Every colour that is manufactured is sprayed, compared, analysed using “state of the art” technology, adjusted if necessary under the expert eyes of the colour specialists until a perfect match is achieved

Chose your colour from one of the following

Ferro Vedoc Colour chartFerro Vedoc Hi-Q colour chartRAL colour chartSABS colour chartNCS colour chart

Consultancy

Our technical consultants provide advice on all aspects of powder coating to ensure that maximum efficiency is achieved from the product.

Surface preparation..film thickness..oven temperatures..baking schedules..spraying facilities\\

……this is our business

Training…….People make the difference

* Ferro provides “on site” training from our technical consultants and certified training courses for spray operators at the * Ferro Training Centre at Brakpan.

ferro powder coatings presentation

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