7 Tank Phosphating Process for Powder Coating on Metal

7 Tank Phosphating Process for Powder Coating

7 Tank Process for Powder Coating on Metal is a seven steps process. These are steps which include Degrease, Rinse, Pickling, Rinse, Phosphating, Rinse, and Passivation. Sometimes we use Activator before Phosphating. We also know it as a Zinc Phosphating Process. Mahavir Chemicals provide a variety of M. Chem series of Pretreatment chemicals for 7 tank process for powder coating.

We offer the best quality M. Chem series of chemicals for 7 Tank Phosphating Pretreatment for Powder Coating. With our extensive experience in manufacturing, we have made a reputed name in the market. Our 7 Tank Phosphating Process Chemicals are safe and Biodegradable.

Our 7 Tank Process chemicals are ready to use for any Metal surface Pre-Treatment. Over and above that we provide a free consultation in setting up the 7 Tank Process Plant.

Steps for 7 Tank Phosphating Process for Powder Coating on Metal

Following are the steps that we have to follow for 7 Tank Process for Powder Coating on Metal

1) Degreasing in 7 Tank

First step in the 7 Tank Process for Powder Coating is to remove oil, grease, and soil from the metal surface. We provide M. Chem D.G. Series of both Alkaline and Acidic degreasers for the degreasing process of the 7 Tank Process. Alkaline degreasers are a blend of alkalies and Surfactants. Generally, it is used under Hot conditions. However, Acidic Degreasers are solvent-based liquids. They are acidic in nature. They remove rust and grease under cold conditions but are expensive as compared to alkaline degreasers.

Solution Strength: Dissolve 5-7 kg of M. Chem D.G. Series of degreaser in 100 litres of soft water.

Duration: 20-40 minutes

Temp.: Degreaser works generally in high temperatures of 75-80 c

2) Rinsing

After Degreasing, the next step is to rinse with water in the 2nd Tank of 7 Tank Process. Water wash is for removing the effect of degreasing from the metal surface. It prevents chemicals to go on further process. Make sure before going to the next step that it is rinsed properly.

3) Derusting in 7 Tank

Once the metal surface is cleaned with water, now move to De-rusting. Immerse the item in the 3rd Tank of 7 Tank Phosphating Process for Powder Coating filled with de-rusting chemicals solutions. For that use Acidic de-rusting and Pickling Chemicals to remove rust, scale and oxide layer etc. from all surface. M. Chem R.R. Series of chemicals provides best solution for de-rusting.

Solution Strength: Mix 25 liters of rust remover with 75 liters of soft water to make the solution of rust remover workable from Ambient temp to max 60 c.

Mix 10-12 liters of rust remover with 90 liters of soft water to make the solution of rust remover workable from 45 c to max 60 c.

Duration: 15- 20 minutes

Temp.: Ambient temp to max 60 C

4) Rinsing

Again, Rinse with water in the 4th Tank of 7 Tank Process of Powder Coating. 4th Tank of water wash removes the effect of de-rusting chemicals on metal surface. This stops the de-rusting chemicals to proceed further as they are acidic in nature. So, make sure before going to tank 5 that proper rinse of water has happened.

Maintain PH of water to 7 PH Scale.

5) Surface Activation in 7 Tank Process

Next step in 7 Tank Process for Powder Coating is Surface Activation. This step is optional. Surface activation chemicals activate the metal to get fine crystalline structure during phosphate coating. This will increase corrossion resistance and adhesion properties. Generally, crystalline structure less than 10 microns are preferable. Mahavir Chemicals offers M. Chem. S.M. Series for Activator. Acidic as well as new Alkaline Activator compound produce a compact crystal structure of phosphate coating.

Strength: PH and Alkalinity are to be maintained.

Duration: 20 minutes

Temp.: This works at Room Temperature.

6) Phosphating in 7 Tank Process

Phosphating Process is the most important process of 7 Tank Process for Powder Coating. In general, we call 7 Tank Process as Phosphating Process. For Phosphating to Metal, we prepare Zinc Phosphate Solution using M. Chem. L. P. Series of chemical for Phosphating. Zinc Phosphate solution makes the coating of sheet metal surface smooth and uniform. Zinc Phosphate Coating is grey in nature. M. Chem. L. P. Series of chemical for Phosphating gives the best result in 7 Tank Phosphating Process.

Strength: Fill the tank with 2/3 rd of its capacity with soft water. Add M. Chem L.P. Series of chemicals for bath solution of 1000 liters. Raise the bath temperature to minimum 50-60 C. Add toner crystals. Top up Tank with soft water and raise the temperature.

Duration: 5-20 minutes. Time may vary depending upon the temperature of bath and thickness of powder coating required.

Temp.: It works at 50-60 C.

7) Passivation in 7 Tank Process

Now, the last step in 7 Tank Process for Powder Coating is to Passivate the Metal. Passivation forms a chrome layer over the Zinc Phosphate. It increases the corrosion resistance protection of the metal parts. It seals the pores of sheet metal surface for obtaining maximum corrosion resistance over phosphate coating.

Strength: Fill the tank with 2/3rd of its capacity with soft water. Add M. Chem Passi. Series of chemicals for bath solution of 1000 liters. Raise the bath temperature. Top up Tank with soft water.

Duration: Time may vary depending upon the temperature of bath.

Temp.:75+/- 5 C. It works both in High and Low temperature.

Frequently Asked Question

Where can I get 7 Tank Phosphating Process Chemical?

We are the leading manufacturer of 7 tank process chemicals in Mumbai, India. With our expertise and trustworthiness, we emerged as a foremost supplier of pretreatment Chemicals. We offer wide range of best quality 7 Tank Process Chemicals.

What is Degreasing of Metals ?

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What is the best Degreasing Chemical ?

How is Degreasing Chemical applied ?

What are the different type of Degreasing Chemicals ?

What precaution should be taken while using Degreaser ?

Why do I need a Degreaser ?

The answer depends on the application. Dust, dirt, grease, and oxidation contamination can cause corrosion, slipping hazards, overheating, increase electrical resistance in contact areas, and many other issues. Degreasing may be required to prep for down-stream processes like painting or plating.

Cleaner Degreasers can clean oil, grease, oxides and handling contamination, from equipment and assemblies that include:

Metal and fiber optic cable splices
Motors and transformers
Programmable Logic Controllers (PLCs)
Pneumatic and hydraulic assemblies
Electronics and electrical equipment
Meters/measurement devices

Industrial strength degreasers are needed to remove grease, tar, asphalt, oil, and grime in these kinds of applications:

Clutches, armatures, generators, and compressors
Electrical motors and equipment
Bearings, chains, cables, pulleys and gear drives
Brakes, springs, and flywheels

What are the cleaning process to consider for Degreasing ?

Manual Degreasing Methods

It is common to clean grease and oil off of parts at a benchtop, work station, or in the field, which generally requires a manual cleaning method. Manual cleaning methods are more labor-intensive and less repeatable, so results may vary from operator to operator.

Aerosol – Aerosol packaging is a sealed system, which ensures fresh solvent every time. The spray pressure and pattern can add agitation, like a scrubbing action. A straw attachment is generally included to spray into tight areas.
Trigger spray – Spray bottles are common for water-based cleaners and isopropyl alcohol (IPA), but not for aggressive solvent cleaners.
Liquid immersion – The part can be immersed in a tray or bucket of solvent cleaner, and then wipes, swabs and brushes used to scrub off tough soils. Heating the solvent can improve the cleaning performance, but for safety sake, should only be done with nonflammable degreasers.
Presaturated wipes and swabs – For added convenience, wipes are available presaturated with a mild solvent like isopropyl alcohol.

Automated or Semi-Automated Degreasing Methods

For higher volume manufacturing, stamping or forming, or if minimal variability is required, like in critical applications like aerospace and medical, more automated cleaning methods are available.

Ultrasonic – Ultrasonic cleaning equipment use sound waves to break apart grease and lift it off the part. Ultrasonic equipment usually has the option of heating the cleaning material to increase cleaning performance. Cross contamination can be a concern, so change solvent regularly. Ultrasonic cleaning might be too rough on sensitive parts and materials.
Vapor degreaser – Vapor degreasing is the best cleaning process for the critical cleaning, like in aerospace and medical applications. Parts are submerged in a sump of boiling solvent or in a rinse sump with ultrasonics, and rinsed in solvent vapors. Specialized azeotropes or near-azeotropes solvents are required to avoid problems as the solvent is boiled and reconstituted over and over again.
Batch washer – Parts are either stationary in a rack or run on a conveyor, and the degreasing agent (usually water-based and highly caustic) is sprayed over the parts.

Does a degreaser need to be nonflammable?

Nonflammable degreasers are the safest options if they will be used near sparks, open flames, or hot surfaces. Techspray has several nonflammable degreasers available, including G3® Maintenance Cleaner, PWR-4™ Industrial Maintenance Cleaner, and Precision-V Maintenance Cleaner & Flux Remover.

The most common method of identifying the flammability rating of a degreaser is the GHS (Global Harmonized System) flammable pictogram (see diamond symbol above). Other standards, like NFPA (National Fire Protection Association) and HMIS (Hazardous Materials Identification System), provide a rating from 0 to 4, zero being the lowest flammability rating, or nonflammable.

Do I need to shut off power before cleaning electrical equipment?

Before you start spraying, shut down power to avoid the potential of sparks, electrical shorts or discharges, and other safety hazards. If disconnecting the power is not an option, look for degreasers with a dielectric strength above 30 kV (30,000 volts). Choosing a nonflammable cleaner would also add a layer of safety in case there is a spark.

Are there degreasers that are more toxic than others?

N-Propyl Bromide (nPB), Trichloroethylene (TCE) and Perchloroethylene (Perc) are highly toxic chemicals commonly used in degreasers to provide cleaning performance in a nonflammable formula. There are documented court cases where workers suffered major health effects when exposed to high levels of these chemicals. Workers reported headaches, dizziness, and even loss of full body control. There are also possible links to reproductive problems and cancer. All of this has caused maintenance facilities to reconsider their solvent choices, especially with manual cleaning when exposure tends to be higher.

While federal agencies have been slow in regulating nPB, CA OSHSB has a PEL of 5ppm and listed it as a developmental/reproductive toxicant under Prop 65. Pennsylvania has included it on its hazardous substance list. ACGIH has listed the TLV for nPB as 10 ppm, but there is a proposal to decrease it to 0.1 ppm. Comparable to TCE, PCE, and MeCl in toxicity, nPB has been determined by NTP as “reasonably anticipated to be a human carcinogen.” (source: NTP, “Report on Carcinogens, Thirteenth Edition: 1-Bromopropane”, http://ntp.niehs.nih.gov/ntp/roc/content/profiles/bromopropane.pdf.) Effective January 1, 2018, Ontario, Canada has implemented the ACGIH recommendations for nPB.

These risks have prompted maintenance facilities to rethink their solvent choices, especially with manual cleaning when exposure tends to be higher than the more automated cleaning processes. degreasing, by its very nature, is very hands-on, so close control of chemical exposure is generally very challenging. How many electricians do you see with a respirator? The best option is to avoid the most toxic solvents, even if they are legal and readily available.

The quickest and easiest method of identifying a potential concern is the GHS (Global Harmonized System) pictograms (see diamond symbol above). If you see the chronic toxicity pictogram (diamond containing person with exploding chest), that means the product contains something that can cause long-term effects. That doesn’t necessarily mean a carcinogen, but it should prompt you to look closely at the Safety Data Sheet (SDS). You may need to take extraordinary measures to reduce personal exposure, or if that is unrealistic for your application, avoid the product altogether. The acute toxicity pictogram (diamond containing skull and cross-bones) means the product can have a short-term health impact. Again, check the SDS carefully if you see this symbol

No degreaser contains toxic solvents like nPB, TCE, and Perc. While you still should pay attention to label warnings, SDS, and wear adequate personal protection equipment (PPE), the requirements will not be as over-the-top to stay within a safe range of exposure.

Are there environmental concerns with using degreasers?

Volatile organic compounds (VOCs), solvents that add to smog, or solvents with high global warming potential (GWP) have been a focus of a number of regulators. Some state (e.g. CARB or California Air Review Board), municipal, and even industry-specific regulations restrict the use of high VOC or high GWP materials.

To complicate things, VOC is defined and measured differently by various agencies. A degreaser might be considered low-VOC according to the standard EPA (Environmental Protection Agency) definition, but may be high according to CARB. If low-VOC is the goal, Techspray sells cleaners with minimal VOC under the Precision-V™ brand.

Phosphating 7 Tank Process for Powder Coating