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John Cockerill Surface Treatment

World-class surface treatment plants to any need – tailored for you.

Anaphoretic Coating Plants

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The design, manufacturing, supply and installation of industrial anaphoretic coating plants.

John Cockerill has been supplying automated anaphoretic coating plants (E-coat) mainly to the aviation industry for over 40 years. Our systems are used by the biggest manufacturers like Airbus. It is easy to fulfill the Nadcap, REACH and other strict aviation requirements with John Cockerill large, automated plants. We offer complete projects from planning and designing all the way to start-up and service during operations.

Degrease
Acid etch
Anaphoresis (E-Coat)
Curing

Typical anophoretic processes

Anophoretic is a process to create a protective 12–20 micrometer layer on the surface of aluminum alloy parts. The processed part itself acts as an anode. After the process, the part has electro-coated paint on the conductor substrate. Increasing the voltage in the process increases the thickness of the layer. Anaphoretic processes typically have faster cycle time and increased production capacity compared to other similar processes.

Chemical cleaning line with 3D transporter, which allows extremely flexible production process.
Chemical cleaning line with 3D transporter, which allows extremely flexible production process.

Typical products for anaphoretic coating

In the aviation industry, anaphoretic surface treatment plants are used for the chemical treatment of aluminum alloy aircraft parts and frame components. Anaphoretic aka E-coating stands very well against adhesion, bending, impacts, scratching, corrosion, humidity, heat, aging, seawater, fire, and UV. Anaphoretic surface treatment is used in the aviation industry as a REACH-compliant process, which doesn´t change the shape of the parts and is thus suitable for parts with complex shapes. The anaphoretic coating is also repairable afterward.

Typical anaphoretic plant

John Cockerill anaphoretic plants are typically fully automated turnkey deliveries that utilize our latest technologies in ventilation, multiple loading/unloading stations, and energy-efficient solutions. John Cockerill anaphoretic plants are always scaled and designed according to the needs of the customer and the maximum product dimensions in the treatment process. Tanks are typically 500–4000 liters in volume for relatively large aerostructures. Plants are manufactured in the EU and assembled on the client’s site.


Capacity

John Cockerill industrial anaphoretic plants have a very high capacity thanks to effective process automation. Process automation can save up to 70% in labour costs.

Process Ventilation

Process ventilation can reduce heating/cooling costs by up to 90% compared to traditional ventilation systems. Process ventilation uses up to 20 times less air than traditional plant ventilation systems.

Safety

Process ventilation and automation enhance occupational health and safety, as workers are less exposed to hazardous chemicals.

Manual Intervention

Despite accurate process automation there is sometimes a need to intervene the process manually. This can be made safely and easily in external sampling points.

Loading

Depending on the products the loading can be fully automated with automated transporters.

Dosing

Dosing of dangerous process chemicals is automated. Automated dosing keeps the quality consistent and allows dosing data to be saved in the database for further reporting.

Automated Transporter

Automated transporter moves batches from tank to tank controlled by a process automation system. The automated production control allows you to process different batches with different treatments at the same time. Automated systems optimize the capacity of the plant and eliminate human errors.

Process Tanks

Stainless steel or plastic tanks can stand decades of heavy use with the strongest chemicals. Tanks are covered with lids when not loading or unloading, thus preventing the evaporation of fumes. Our engineering know-how allows us to choose the correct materials, methods, and structures for each chemical process.

Process automation

Process automation keeps workers away from dangerous chemicals, keeps the quality consistent, helps reporting to meet aviation standards like NADCAP and enhances efficiency.

John Cockerill Surface Treatment anaphoretic plants have an extremely high level of automation. The automated systems cover both process control and production control by constantly monitoring and adjusting chemical processes while also controlling material handling. As a result, payroll expenses can be reduced by up to 70 percent compared to manually operated plants. Automated plants are also much safer than manually operated plants.

Energy efficiency and environmental friendliness

Every aspect of our plants has been optimized with energy efficiency and environmental friendliness in mind. For example, our closed-circuit evaporation plants produce minimal or no emissions in addition to being tailored to our customers’ needs.

John Cockerill’s meticulous design and production process lengthens the life of the plants even further and minimizes the lifetime running costs. We can guarantee a use-life of several decades for our drive motors and lifting motors, for example.

  • Lower electricity consumption
  • Minimal or no emissions
  • Optimized durability thanks to the best components and precision manufacturing