Metal pre-treatment: process control system tackles key challenges

Henkel has introduced a new process control system that addresses key challenges in metal pre-treatment as customers are increasingly seeking to implement data-driven Industry 4.0 solutions. 

In combination with the company’s New Generation Conversion coatings (NGC) for multi-metal substrates, the BONDERITE E-CO digital multi-channel (DMC) controller enables maximum corrosion performance and sustainability at minimised overall process costs.

Bonderite E-CO DMC is a process control system that allows users to run complex metal pre-treatment lines with up to fifteen or more stages. It features an intuitive touch screen PLC interface and supports fully digitalised process control with flexible communication and remote access functionality.

Thanks to its adaptive open system architecture, the new digital multi-channel control system easily integrates in to customers’ existing conversion processes and automation concepts.  

Together with New Generation Conversion coatings, it maximises the benefits derived from Henkel’s sustainable metal pre-treatment technologies and process expertise.

Bonderite E-CO DMC minimises chemical usage, water and power consumption as well as waste. 

In addition, it helps to avoid manual work and chemical exposure in metal pre-treatment. All equipment and process setup, adjustment, control and monitoring can effectively be managed by the controller, including bath preparation and refill. 

The multi-channel system supports both single and multiple production lines in one and the same or neighbouring buildings. It can control a virtually unlimited number of process parameters and devices.

Furthermore, Bonderite E-CO DMC is equipped with an internal memory that stores all parameter data and events for creating numerical, graphic and consumption reports as well as maintaining a historical database. 

The controller’s comprehensive connectivity easily links the system to other resources in local area networks and provides access for remote devices, such as tablets and smartphones. It enables alerts with discrete data to be sent to selected recipients by SMS or email and can be integrated in cloud-based data-driven solutions.

The system underscores Henkel’s total solutions approach and commitment to supporting customers as they implement Industry 4.0. 

Users can run automatic parameter checks and even automate the dosage of chemicals in the tanks by using a special function to correlate analysed data with outputs – all without involving any personnel on site.

While the performance benefits of Bonderite E-CO DMC can be tapped into with any of Henkel’s existing metal pre-treatment process, including conventional phosphating, the technology unfolds its maximum sustainability in combination with the company’s New Generation Coatings. 

As zirconium-based alternatives for multi-substrate metal conversion and corrosion protection, these NGC contain neither phosphates nor heavy metals, simplify water management and can reduce process steps, contact times, energy consumption and sludge.

Leaving only a nano-thin, non-toxic coating layer on substrates, Henkel helps customers to optimise the cost, control and reliable quality of production.

The Bonderite E-CO DMC system is available throughout Europe and North America, and belongs to a complete range of application, control and support equipment for Bonderite metal pre-treatment processes from Henkel.