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Gilbeyco JWE Rack and Barrel Phosphating Line

Stock Code: PAL003Model: Rack and Barrel PhosphatingNew or Used: Used (Second Hand)Work Envelope (WxDxH mm): 1200 x 2057 x 1200Process Stages: 9 wet stagesOther Info: Upgraded in 2008External Dimensions (WxDxH): 17500 x 3000 x 4200

The Marketplace for Surface Technology.New and Used Process Equipment & Machinery.

Riley Industries LtdA subsidiary of Barry Riley & Sons Ltd. Directors: R T Barry Riley, M P A Riley, Secretary: J C Riley

Registered in England no. 1965748

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Gilbeyco JWE Rack and Barrel Phosphating LineGilbey - Jaquet Weston Engineering, Manganese and Zinc Phosphate Rack and Barrel Plant Pall's IndustryExcellence

Pall Europe Ltd have always been participants in virtually every aerospace/defense and industrial program thatrequires reliable fluid clarification. Pall has taken a leadership role in the design and development of products andspecifications to resolve complex system contamination control problems throughout all major requirements of theengineering and aerospace sectors.

Producing filter housing systems in both carbon steel and stainless steel for the: Aerospace, Automotive,Environmental, Hydraulic and Lubrication, Mining, Mobile Equipment OEM, Offshore, Primary Metals, Pulp andPaper industries

Now having secured a new facility for the production of the industrial carbon steel components, this site has gearedup their production facilities to meet the demands of the stainless steel products and as such no longer require thesewell maintained and specified phosphating and paint facilities for the aerospace sectors.

This plant was originally built by Gilbeyco ltd, but more recently re-engineered by Jaquet Weston Engineering in2008 to include; New transporter, Barrel rotating facility and uprated Lanemark gas fired tube burners.

In most operations where the corrosion resistance of finished workpieces must be especially high, conversioncoatings are applied using zinc or manganese phosphate . This approach is widely used in the automotive industryand in certain sectors of the appliance and electronics industries. Similarly, phosphating is often specified by thearmed services, especially for equipment that may be exposed to severe environments. Moreover, many operationsusing electro-coating or powder coatings, particularly when a one-coat finish will be exposed to the weather, pretreatworkpieces with a phosphate solution.

Phosphating is a process which changes a metallic surface to a non-metallic surface by chemical conversion of themetal. The phosphate coating therefore forms an integral part of the surface, the translucent crystals appearing blackto dark grey in colour. Suitable for ferrous metals it is an economic and speedy process, affording excellent corrosionresistance, wear resistance, adhesion and lubricity properties.

Manganese phosphate coatings have a more stable structure than Zinc phosphate; especially under high pressureand high temperature. In addition to corrosion resistance and lubricity the surface also acts as a binder for lubricantsand rust preventive waxes, along with its load bearing properties which make it ideal for bearing and slidingapplications.

Manganese phosphating also provides a surface that can hold much higher volumes of top coats (exceeding thecapacity of Zinc phosphates) and also improves the adhesive bonding properties of plain carbon steels.

Immersion phosphating process

In this immersion process, zinc, manganese and other alkali metal phosphating systems do not greatly differ fromone other. The individual basic steps, that are normally carried out are ;

1. Cleaning stage ; Temperature (°C): 55-95 Time (min) : 5-10




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Gilbeyco JWE Rack and Barrel Phosphating Line 2. Water rinse ; Temperature (°C): 15-30 Time (min) : 0.5-1.5

3. Activation ; Temperature (°C): 20-40 Time (min) : 0.5-1.5

4. Phosphating ; Temperature (°C): 40-60 Time (min) : 3-10

5. Water rinse ; Temperature (°C): 15-30 Time (min) : 0.5-1.5

6. Post-rinse ; Temperature (°C): 20-40 Time (min) : 0.5-1.5

Cleaning is usually based on an alkaline or strongly alkaline solution in the concentration range 1-5%, and pH 10-13.The cleaners used contain large amounts of silicate and sodium hydroxide. The surfactants used often include thestrongly-foaming anionic types, usually mixed with non-ionic types.

Phosphating PlantThe plant consists of an 11 station line, which includes 9 x wet process tanks, a drip/holdingstation and rotary indexing load station.

Current tank/process lineup:

Tank 1, Rinse Tank

Tank 2, (not currently used)

Tank 3, Acid activation (Gardacid P4441)

Tank 4, Rinse

Tank 5, Soak cleaning (Gardoclean 390)

Tank 6, Bond agent (Gardobond Z 3480)

Tank 7, Rinse

Tank 8, Passivation (Gardolene D 6900)

Tank 9, (not currently used)

Associated and ancillary equipment

Control panel

The process control panel governs and monitors the process sequence through an E100 MMI operator interface.The interface allows the operator to select and modify the parameters within individual programmes to tailor thesystem to their individual needs.




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Gilbeyco JWE Rack and Barrel Phosphating LineThe panel also monitors both the solution levels and auto topup and the process heating through Eagle 2048controllers. Both the flue gas temperature and solution temperature are monitored allowing the system to be finetuned to balance the heat load against the variable output gas burners.

Process tanks

The process tanks are predominantly stainless steel insulated interchangeable tanks with GRP outer cladding, fittedwith immersed tube gas fired Lanemark TX20N 60kW burners. The burner flue gas system has a single fan poweredexhaust system allowing just a single flue exit from the building.

Automatic transporter

The transporter is a PLC governed lifting and moving device that can hold up to five separate automatedprogrammes within its memory. The transporter has a lift capacity of 500kg and can also be manually driven throughits movements with the attached pendant control.

The automatic transporter has a safety light beam guard running the whole length of the plant which will instantlydisarm the entire system in the event of any person or object coming into the travelling path of the transporter.

2 x barreling rigs

Stainless steel carrying rig with a 24 volt 3 phase AC motor gearbox, a stainless steel gear train and shafting drivingtwo polypropylene end gears 600mm in diameter with stainless steel backing plates 1400mm apart supported on two40mm thick polypropylene side arms with a center tie bar,

There are four work rails to support various types of components, the components are held in position with polycones and clamped in position between the rails.

The barrels are powered by tank mounted low voltage 24 Volt 3 phase contacts and will also rotate whilst beingcarried on the transporter.

3 x rack flight bars

The flight bars allow either the products to be directly suspended from its cross rails or surroting other fixtures andjigs.

Moving rack product fixture.

The system is equipped with an innovative product holding fixture, the fixture consists of twin moving beams that arepivoted at the center. Across the beam, racks can be added to hold a variety of products of differing sizes andmixes. When the fixture is loaded the racks lie flat and when lifted the racks tilt upwards.

The purpose of this is to permit any air to escape from blind holes and closed bores preventing air locks. Upon thefixture entering the tank the rack lowers and tilts the other way to expel the air.

Indexing rotary load station




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Gilbeyco JWE Rack and Barrel Phosphating Line

A manually operated indexing load station allows a fixture to be safely loaded and unloaded independently of theautomatic cycle of the transporter, protecting the operator from any possible robotic movements and the danger ofentrapment.

PVC fume extraction system

A multi legged PVC fume extraction system with tank mounted lip extraction ducts, coupled to a matching PVCchemically inert fan and exhaust stack. The system provides the removal of fumes and odours arising from the tankskeeping the surrounding clean and safe for the operator.

Solution air agitation

The air agitation system keeps the solids which form the chemistry within the tanks in suspension and evenlydistributed throughout the tank.

Auto solution makeup

The active tanks are fitted with Watson Marlow 520D intelligent peristaltic pumps which automatically doses thecorrect amount of replenishing chemicals when filling or maintaining the solution levels.

View Gilbeyco JWE Rack and Barrel Phosphating Line on our web site athttp://www.rileysurfaceworld.co.uk/machines/26496.htm

PHOTOGRAPHS TAKEN PRIOR TO REFURBISHMENT.




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