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Machines & equipment for sale

Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating Line

Direct From Site Clearance

Direct Site Clearance Price [?]
£ 235,000 (+ VAT)
Clearance ends
12 March 2021 14:00 GMT while stocks last
Buyer's Premium [?]
5% BP will be added to your invoice
Part of a Direct Site Clearance
Alkaline Zinc Barrel and Rack Plating Line & Equipment at Bott Ltd
Condition
From a working environment, Seen working by RSW, Excellent Condition
Location
Bude, Cornwall, UK
Stock No
BOT500
Manufacturer
Process Plant and Equipment
Model
Fully Automatic Alkaline Zinc Barrel
Year of Manufacture
2000
Condition
From a working environment, Seen working by RSW, Excellent Condition
Work Envelope (WxDxH mm)
800//1440 x 1400 x 1000
Process Stages
32
Other Info
3/4 loads p/hr // 500kg SWL Transporter
Location
Bude, Cornwall, UK
External Dimensions (WxDxH mm)
4500 x 36,900 x 4500

Description

Process Plant and Equipment Alkaline Zinc Barrel & Rack Plating Line (Specification & Photos Set 1)

The following specification forms part of 

Alkaline Zinc Barrel and Rack Plating Facility comprising

The whole available for just £235,000 + VAT

To register an interest for the whole, or individual components, please contact Helen on +44 (0)1922 458000

Technical Specification

  • Plant Design: Straight Line Automatic Plant.
  • Process: Alkaline Zinc Electroplate
  • Base Metal of Components: Mild Steel
  • Components: Work Storage and Racking System Parts
  • Operation: Fully Automatic
  • Estimated Plant Output: 3 to 4 loads per hour 
  • Tank Section: 1400 mm wide x 1000 mm deep
  • Transporters: One 500kg SWL Transporter
  • Hoist/Traverse Motors: Variable speed with frequency invertor
  • Flight Bars: 4 off to accommodate plating racks.
  • Plating Racks - A quantity to be provided with plant.
  • Motorised Barrel Rigs - 7 off Progalvano Model 420.
  • Heating: Thermal Fluid with 6 Hour heat up time.
  • Cooling via: Chiller Unit/External Heat Exchanger
  • Electrical Supply: 415v 50hz 3ph with neutral

Approx. Plant Dimensions: (Including Ancillary Equipment)
Length: 36.9.0 Metres
Width: 4.50 Metres 
Height: 4.50 Metres

General Construction

The Automatic Plating Line is arranged in a straight line with the Load/Unload station at one end for efficiency of operation. The work is carried automatically through the line by an enclosed transporter complete with motorised raise lower and traverse.
At the load end of the line is a five position buffer section for on line storage of barrel rigs or flight bars dependant on what type of work is being processed. 

The work after loading travels over the post treatment section to the middle of the line where it then goes through the all-important section pre-treatment of two stage cleaning and activation before the electroplating stations (two barrel and one rack). 
On completion of electroplating the work is immediately rinsed and then carried over the pre-treatment section to the post treatment area where alternative passivation finishes can be carried out. This section runs back toward the unload station for maximum efficiency via two inline dryers, one for rack work and one for in barrel drying. 

At the unload station hopper chutes and roller track is provided to enable barrel work to be manually offloaded into tote pans for the option of centrifugal drying in two offline stainless steel Krom units.

The line is provided with a barrel or flight bar maintenance station at the opposite end to the load/unload station. 

Upgrade Potential

The existing electroplating stations (two barrel and one rack) are located at the far end of the line from the load station where there is already a potentially 3.5 metre long overrun section of transporter track which lends itself to installation of additional plating stations. There is also space allocated for installing a third in-line dryer (thermal fluid valved offtakes already in place) to service an increase in output if extra plating stations are fitted.

With the installation of the additional ampere hour controlled dosing systems required for Nickel metal, brightener, and leveller replenishment etc. the line could be converted to Zinc Nickel Alloy plating with its benefit of higher corrosion resistance as favoured by the automotive industry.

Transporter Equipment

1 Off Fully motorised 500kg SWL transporter system, to operate in two modes. 

Mode 1 Fully Automatic
Where all traverse and hoist movements automatically follow pre-set routes and process times. Either in fixed timeway or random control.

Mode 2 Semi-Automatic
Where all transporter movements are under the control of the operator via a pendant or joystick or keyboard control
The transporter has features as follows:

The traverse drive is by means of a variable speed motor and gear box under the control of a frequency inverter designed to give a smooth accelerating and decelerating speed ramp with traverse adjustable according to distances between stations.

The hoist mechanism is by means of a variable speed motor and gear box under the control of a frequency invertor designed to give a smooth accelerating and decelerating speed ramp with the ability to set different lift and lower rates.

The transporter is fitted with full safety interlocks, barrel rotation, anti-collision and pendant control for semi-automatic mode.

The transporter is fully enclosed to contain residual fume when work is raised from the tank.

Track Support Structure

The transporter runs on a gantry system manufactured in stainless steel RHS, supported on stanchions from the floor and lateral members to the external bodies of the tanks. The gantry system is 36.90 m long with track height of 2.06 m and centres of 2.15 m.

The full length of the operator side of the line is provided with a raised walkway manufactured in stainless steel with handrail, kick strips, grp decking and access steps at each end.

The self-supporting structure is in bolted sections lined and levelled without the need for special foundations.

Control System

The control system on the plant is fully automatic PLC based which will enable a variety of process routes to be run, with choices between rack or barrel plating and which passivation finish is required. All transporter movements are safety interlocked to comply with the applicable regulatory requirements. The PLC and control gear is located in the central control panel with a remote HMI at the load/unload station for convenient use by the operator.

The PLC and control software is currently being upgraded to a brand new 2020 version and a full technical specification along with operating instructions and wiring schematics will be available shortly.

Process Tanks

The line is constructed as modular free-standing tanks supporting all fittings and services. Each section is complete with stainless steel adjustable levelling feet. There are removable drip covers between each tank.

Process tanks are constructed according to the chemical process involved as indicated in the appropriate station description and generally as follows: 

  • 9mm thick rigid PVC, strengthened as necessary externally with encapsulated reinforcing bands. All welding is internal and external on all joints.
  • 9mm thick rigid polypropylene, strengthened as necessary externally with body bands. Tanks welded both internally and externally on all joints.
  • 9mm thick rigid PVC or polypropylene strengthened as necessary externally with body bands and reinforced with GRP. All welding is internal and external on all joints. All joints are complete with spark discharge test strips.
  • 304 or 316 stainless steel or titanium reinforced externally as necessary with body bands and tank top lip.
  • 6mm thick rigid polymer liners within mild steel coated tanks, strengthened externally as necessary with body bands. Tanks welded both internally and externally on all joints.

Electrolytic stations will be fitted with all necessary DC contact systems complete with interconnecting conductors and anode bars. Anode bars may be removable from the tanks.

All tank fittings and service components are secured with stainless steel hardware throughout wherever possible. **

Services

Water
Rinse tanks will be fitted with water inlets, manual control valves and weir or standpipe overflow outlets to drains. Adjacent rinse tanks will be connected in counterflow as indicated in the tank specification for water conservation as shown in the appropriate station description.
Drain valves will be fitted to those process tanks indicated in the attached specification sheets.
3 off drain pipework runs are fitted to the line. It will be approximately 1.1/2" diameter.

Compressed Air
1 off compressed air line with branches

Electrical
The equipment is complete with a box section ducting running the length of the line with flexible conduit connection to the components.

Heating and cooling

All heating, unless otherwise specifically stated, is PTFE (Teflon), 316 grade stainless steel, titanium electrical or heat exchange coil/plate immersion heaters, either vertically or base mounted within the process tanks, as indicated in the appropriate tank description.

All electrical heating systems will be complete with digital indicating solid state thermostatic controls, AC contactor, residual current circuit protection, magnetic overload protection and safety level protection devices.

Generally, where appropriate all heat exchange heating coils will be complete with sight glass, float trap strainer, check valve, temperature controller, isolating valves and bypass. (Final specification dependent upon choice of heating medial e.g. steam, high pressure hot water, thermal fluid).

All heating calculations are based on a 6 hour heat up period.

All heater controls will be wired back to a control cabinet sited at the operator end of the line which will be mounted all associated AC contactors, M.C.B'S, thermostatic controls and safety level protection controllers.

The cabinet provides a fully wired distribution system for electrical circuits within the cabinet and will require a single AC source run from the customer's adjacent isolator mounted within 3 metres of the cabinet.

Fume Extraction

Lip exhaust ducts are located between the appropriate process tanks.
Adjustable dampers are provided to restrict the individual flow and a spigot for connection of the factory manifold.

The equipment is complete with 9 off lip fume extraction ducts manufactured from polypropylene material extracting from the following processes:

  • Stage 14 Passivation
  • Stage 17 Soak Cleaner
  • Stage 18 Anodic Cleaner
  • Stage 21 Acid Dip 
  • Stage 27 Zinc Plate Barrel
  • Stage 28 Zinc Plate Barrel
  • Stage 29 Zinc Plate Rack
  • Stage 31 Dissolution Tank Zinc Plate Vat
  • Stage 32 Dissolution Tank Zinc Plate Barrel

The ducts are connected to a main manifold running the length of the plant through a horizontal fume scrubbing system, to a centrifugal fan, mounted on a support steel structure, with a discharge stack to atmosphere with termination in a high velocity discharge cone.
System sized for a second twin station barrel zinc plating tank.

Overview Features

  • 2 x Water input 1''
  • 3 x Drain 2"
  • 31m Track and catenary
  • 1 X Transporter Autoline Type
  • 1 x Emergency Stop Pull-cord
  • 4 x Flight Bars (Vat plating)
  • 1 x Control Cabinet

Stations Overview

Station 1 - Load/Unload

  • Tank construction: Stainless Steel
  • 1 x Twin hopper unloading chute (Removable for jig work)
  • 1 x Operator activated barrel rotation button
  • 1 x Roller track for component box removal
  • Barrel location cones 
  • Dimensions: 800 x 1400 x 1000 mm


Stations 2 - 6 Buffer Station

  • Tank construction: Stainless Steel
  • 10 x Barrel location cones
  • Dimensions: 4300 x 1400 x 1000 mm


Station 7 - Caltherm Hot Air Dry (In barrel)

  • Tank construction: Stainless Steel
  • This is a single barrel location system comprising the following:
  • 1 x Insulation 
  • 2 x Stainless steel lids
  • 4 x Pneumatically operated cylinders for lid operation
  • 2 x Barrel location cones 
  • 1x Barrel rotation contacts
  • 2 x Internal brush seals 
  • 2 x Directional air louvres
  • 1 x Centrifugal air circulation fan
  • 2 x Heat exchange batteries (thermal fluid) 
  • 1 x Drain facilities 
  • Temperature: 50°c
  • Dimensions: 990 x 1,400 x 1000 mm 


Station 8 - Caltherm Jig Vat Dryer (on rack)

  • Tank construction: Stainless Steel
  • 1 x Insulation 
  • 2 x Pneumatically operated cylinders for lid operation
  • 2 x Flight Bar location cones 
  • 2 x Directional air louvres
  • 1 x Centrifugal air circulation fan
  • 2 x Heat exchange batteries (thermal fluid)
  • 2 x Isolating Valves
  • 1 x Air Operated Control Valves 
  • 1 x Drain facilities 
  • Temperature: 50°c
  • Dimensions: 800 x 1,400 x 1000 mm 


Station 9 - Lacquer Dip (seal)

  • Tank construction: Polypropylene
  • 1 x Valved water inlet
  • 1 x Drain valve
  • 2 x Isolation valves
  • 1 x Air operated control valve
  • 1 x Thermal fluid coil
  • 2 x Level control
  • 2 x Temperature probe
  • 1 x Digital temperature controller
  • 2 x Location cones
  • 1 x Barrel rotation contact
  • Temperature: 35°c currently set to 20°c
  • Volume: 896 Litres
  • Dimensions: 800 x 1,400 x 1000 mm 


Station 10 - Rinse (D.I Water)

  • Tank construction: Polypropylene
  • 1 x Valved water inlet
  • 1 x Tank insulation
  • 1 x Inlet corner weir
  • 1 x Corner weir flow to drain
  • 1 x Drain valve
  • 1 x Valved air sparger
  • 2 x Isolating valves
  • 1 x Air operated control valve
  • 1 x Thermal fluid coil
  • 1 x Level control
  • 1 x Temperature probe
  • 1 x Digital temperature control
  • 2 x location cones
  • 1 x Barrel rotation contact
  • Temperature: 60°c currently set to 45°c
  • Volume: 896 Litres
  • Dimensions: 800 x 1,400 x 1000 mm 


Stations 11-13 Rinse

  • Tank construction: Polypropylene
  • 1 x Valved water inlet
  • 1 x Inlet corner weir
  • 1 x Corner weir overflow to drain
  • 1 x Drain valve
  • 1 x Valve air sparger
  • 2 x Location cones
  • 1 x Barrel rotation contact
  • Volume: 896 Litres
  • Dimensions: 800 x 1,400 x 1000 mm 


Station 14 - Yellow Passivate

  • Tank construction: Poly Vinyl Chloride
  • 1 x Valved water inlet
  • 1 x Drain valve
  • 1 x Valved air sparger
  • 2 x Isolating valves
  • 1 x Air operated control valve
  • 1 x Thermal fluid coil
  • 1 x Level control
  • 1 x Temperature probe
  • 1 x Digital temperature controller
  • 2 x Location cones
  • 1 x Barrel rotation contact
  • Temperature: 25°c currently set to 35°c
  • Volume: 896 Litres
  • Dimensions: 800 x 1,400 x 1000 mm 


Station 15 - Blue Passivate

  • Tank construction: Poly Vinyl Chloride
  • 1 x Valved water inlet
  • 1 x Drain valve
  • 1 x Valved air sparger
  • 2 x Isolating valves
  • 1 x Air operated control valve
  • 1 x Thermal fluid coil
  • 1 x Level control
  • 1 x Temperature probe
  • 1 x Digital temperature controller
  • 2 x Location cones
  • 1 x Barrel rotation contact
  • Temperature: 25°c
  • Volume: 896 Litres
  • Dimensions: 800 x 1,400 x 1000 mm


Station 16 - Nitric Dip

  • Tank construction: Poly Vinyl Chloride
  • 1 x Valved water inlet
  • 1 x Drain valve
  • 1 x Valved air sparger
  • 2 x Location cones
  • 1 x Barrel rotation contact
  • Volume: 896 Litres
  • Dimensions: 800 x 1,400 x 1000 mm


Station 17 - Soak Cleaner

  • Tank construction: Polypropylene
  • 1 x Tank Insulation
  • 1 x Valved water inlet
  • 1 x Drain valve
  • 1 x Lip fume extraction plenum chamber with control dampers
  • 1 x Thermal fluid coil
  • 2 x Isolating valves
  • 1 x Air operated control valve
  • 1 x Level control
  • 1 x Temperature probe
  • 1 x Digital temperature controller
  • 1 x Solution overflow weir
  • 1 x Coalescing type oil separator including:-
  • 1 x Undermounted collection tank
  • 1 x Circulating pump
  • 1 x Coalescing bed (vertical type)
  • 1 x Oil overflow
  • 1 x Aqueous overflow through a sparger located within the cleaner tank2 x Location cones
  • 1 x Barrel rotation contact
  • Temperature: 70°c currently set to 64°c
  • Volume: 1008 Litres
  • Dimensions: 900 x 1,400 x 1000 mm


Station 18 - Anodic Clean

  • Tank construction: Polypropylene
  • 1 x Tank Insulation
  • 1 x Valved water inlet
  • 1 x Drain valve
  • 1 x Lip fume extraction plenum chamber with control dampers
  • 1 x Recirculating pump and filter system (in tank Flo-king type)
  • 1 x Thermal fluid coil
  • 2 x Isolating valves
  • 1 x Air operated control valve
  • 1 x Level control
  • 1 x Temperature probe
  • 1 x Digital temperature controller
  • 2 x Anode bars
  • 1 x 12 volt 1000 amp Rectifier
  • 1 x set Bus bar connections
  • 2 x location cones
  • 1 x Barrel rotation contact
  • 2 x Stainless steel cathodes
  • Temperature: 70°c
  • Volume: 1120 Litres
  • Dimensions: 1,000 x 1,400 x 1000 mm


Stations 19-20 Rinse

  • Tank construction: Polypropylene
  • 1 x Valved water inlet
  • 1 x Inlet corner weir
  • 1 x Corner weir overflow to drain
  • 1 x Drain valve
  • 1 x Valve air sparger
  • 2 x Location cones
  • 1 x Barrel rotation contact
  • Volume: 896 Litres
  • Dimensions: 800 x 1,400 x 1000 mm 


Station 21 - Acid Dip

  • Tank construction: Polypropylene
  • 1 x Valved water inlet
  • 1 x Drain valve
  • 1 x Lip fume extraction plenum chamber with control dampers
  • 1 x Recirculating pump and filter system (in tank Flo-king type)
  • 2 x location cones
  • 1 x Barrel rotation contact
  • Volume: 896 Litres
  • Dimensions: 800 x 1,400 x 1000 mm


Stations 22-25 Rinse

  • Tank construction: Polypropylene
  • 1 x Valved water inlet
  • 1 x Inlet corner weir
  • 1 x Corner weir overflow to drain
  • 1 x Drain valve
  • 1 x Valve air sparger
  • 2 x Location cones
  • 1 x Barrel rotation contact
  • Volume: 896 Litres
  • Dimensions: 800 x 1,400 x 1000 mm 


Station 26 - Pre-dip

  • Tank construction: Polypropylene
  • 1 x Drain valve
  • 1 x Barrel rotation contact
  • Volume: 896 Litres
  • Dimensions: 800 x 1,400 x 1000 mm


Station 27/28 - Alkaline Zinc Barrel Electroplate

  • Tank construction: Polypropylene
  • 1 x Valved water inlet
  • 1 x Lip fume extraction plenum chamber with control dampers
  • 1 x Recirculating pump and filter system located in an external dissolution tank with balanced solution return (Tank sized from second barrel plating tank)
  • 1 x Solenoid operation water fed cooling oil
  • 4 x Anode bars
  • 1 x Tank divider (two cells) stray current baffle
  • 1 x Level control
  • 1 x Temperature probe
  • 1 x Digital temperature controller
  • 2 x Automatic chemical dosing pump
  • 2 x 16 volt 1000 amp Rectifier
  • 2 x set Bus bar connections
  • 4 x location cones
  • 2 x Barrel rotation contact
  • 4 x Stainless steel cathodes
  • Temperature: 25°c
  • Volume: 2352 Litres
  • Dimensions: 2,100 x 1,400 x 1000 mm


Station 29 - Alkaline Zinc Barrel Electroplate

  • Tank construction: Polypropylene
  • 1 x Valved water inlet
  • 1 x Lip fume extraction plenum chamber with control damper
  • 2 x Valved air spargers
  • 1 x Recirculating pump and filter system located in an external dissolution tank with balanced solution return 
  • 1 x Solenoid operation water fed cooling oil
  • 3 x Anode bars
  • 1 x Level control
  • 1 x Temperature probe
  • 1 x Digital temperature controller
  • 1 x Automatic chemical dosing pump
  • 1 x 8 volt 1000 amp Rectifier
  • 1 x set Bus bar connections
  • 2 x location cones
  • 2 x Barrel rotation contact
  • 3 x Stainless steel cathodes
  • Temperature: 25°c
  • Volume: 1612 Litres
  • Dimensions: 1,440 x 1,400 x 1000 mm


Station 30 - Barrel/Anode Maintenance

  • Tank construction: Polypropylene
  • 1 x Valved water inlet and flexible hose
  • 1 x Drain facility
  • Dimensions: 800 x 1,400 x 1000 mm


Zinc Dissolving Tanks

The use of a separate zinc dissolving tank is required when operating in production applications, to enable optimum control of zinc metal in the plating solution. The total volume of the dissolving tank system should be around 10 to 20% of the volume of the plating tank.

The system is designed to ensure the plating solution weirs from its tank into the dissolution unit, which is loaded with high purity zinc dome anodes contained in carbon steel mesh cages. The area of zinc under the solution is adjusted until the concentration remains stable, this quantity is typically ten times greater than daily usage.

Solution from the dissolution tank is then transferred by pump back to the plating tank via a filter.

As the rack and barrel plating solutions have different optimum zinc metal concentrations separate dissolution tanks are provided for each type of plating.

Tank 31 Offline Rack Plating Zinc Dissolution Tank serving online plating station 29 has nominal internal dimensions of 1000mm long x 800mm wide x 1000mm deep.

Tank 32 Offline Rack Plating Zinc Dissolution Tank serving online plating stations 27 & 29 has nominal internal dimensions of 2500mm long x 800mm wide x 1000mm deep.

Both tanks are constructed as freestanding steel outer tanks supporting polypropylene inner tanks which contain the process solution.

Both tanks are provisioned with fume extraction, heating, cooling, filtration, and pumped circulation systems to maintain the zinc solution in the optimum condition.

Support rails are provided for the zinc anode cages to hang from: at low level when the line is in operation and at high level in order to remove the anode cages from the solution when the line is not in use.

Rack

Station Number

Rack Zinc Electroplate

Time (min)

Temp

DC

1

Load

 

 

 

17

Soak Cleaner

5

64°C

 

18

Electro Cleaner

5

66°C

Yes

19

Cold Mains Water Rinse

   

20

Cold DI Water Rinse

   

21

Acid Dip 50% HCL

1

 

 

22

Cold Mains Water Rinse

   

23

Cold DI Water Rinse

 

 

 

26

Pre-Dip

   

27 or 28

Barrel Zinc Electroplate

20

25°C

Yes 

25

Cold Mains Water Rinse

 

 

 

24

Cold DI Water Rinse

 

 

 

16

Pre-Dip

 

 

 

15 or 14

Passivation

10

25°C

 

13 or 12

Cold DI Water Rinse

 

 

 

11

Cold DI Water Rinse

 

 

 

10

Hot DI Water Rinse

 

45°C

 

9

Seal

 

20°C

 

7

Hot Air Dry

10

50°C

 

1

Unload

   

 

Barrel

 Station Number

Barrel Zinc Electroplate 

Time (min)

Temp

DC

1

Load

 

 

 

17

Soak Cleaner

5

64°C

 

18

Electro Cleaner

5

66°C

Yes

19

Cold Mains Water Rinse

   

20

Cold DI Water Rinse

   

21

Acid Dip 50% HCL

1

 

 

22

Cold Mains Water Rinse

   

23

Cold DI Water Rinse

 

 

 

26

Pre-Dip

   

29

Rack Zinc Electroplate

20

25°C

Yes 

25

Cold Mains Water Rinse

 

 

 

24

Cold DI Water Rinse

 

 

 

16

Pre-Dip

 

 

 

15 or 14

Passivation

10

25°C

 

13 or 12

Cold DI Water Rinse

 

 

 

11

Cold DI Water Rinse

 

 

 

10

Hot DI Water Rinse

 

45°C

 

9

Seal

 

20°C

 

8

Hot Air Dry

10

50°C

 

1

Unload

   

pdf icon Print / Download Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating Line Datasheet

Additional files

Process Schedule

Photographs taken prior refurbishment. Our refurbishment service is not available on all machines.