Processes
More services, less thinking
The decision to implement our services over time is the result of our passion and pursuit of perfection.
A product handled entirely by us is checked after every step and cared for down to the smallest detail.
The complexity of our work requires extra attention.
For an optimal result, every treatment and every process must be carried out at maximum efficiency.
Taking charge of all the steps and developing a production cycle that allows us to process each item to the best of our ability was the best choice we could make to present ourselves to our customers as the only ones responsible for their products.
By doing so, we give customers the peace of mind they need by bypassing the effort of having multiple suppliers to achieve the end result.
Our services are applied on:
Brass
Iron
Zamak
Stainless steel
Aluminium
Washing
Ultra-pure water and more. A good wash is better!
Washing is a process that removes any oily residue, polishing paste, mechanical processing and emulsion substances from materials such as brass, zamak, iron, aluminium and stainless steel without altering their colouring.
For this purpose, we have equipped ourselves with a solvent degreasing plant with ultrasound that can thoroughly wash any item.
It consists of four tanks, three of which are connected to a closed-loop and vacuum system with a two-stage activated carbon machine that self-regenerates to achieve zero emissions into the atmosphere.
The fourth steam tank is fed by an automatic vacuum distillate and keeps the product perfectly clean at all times.
In 2023, we purchased a new final washing machine, which, thanks to the production of ultra-pure water, allows previously galvanised products to be washed as thoroughly as possible, by means of a mechanical action mediated by high-powered pumps.
Thanks to the nozzles inside the pumping structure, it is possible to remove any residue due to the galvanic treatment.
The plant is equipped with two main elements: a part that represents its heart, used for the production of ultrapure water and a part delegated to the mechanical replacement of surface water.
In this plant, we are able to wash articles that must be prepared before PVD treatment even more thoroughly.
Metal cleaning
Well begun is half done. Our journey towards customer satisfaction begins.
The preparation of articles is the first fundamental step in order to provide you with an excellent product, at the highest quality level.
It is important, before proceeding with treatment, to prepare the surface that is to be worked in the electroplating and painting processes in the best possible way.
Inside are:
– Five robotic islands.
– A flattening machine to carry out grinding on flat workpieces.
– Five operator-controlled machines for polishing.
– Five operator-controlled machines performing grinding and satin-finishing of all kinds.
– Eight-headed jerk rotary tables for polishing large batches.
1. Grinding
Grinding is a process that consists of removing all impurities from the treated surface with the aim of making it uniform, homogenous and smooth.
It is carried out on brass, zamak, iron, aluminium and stainless steel parts in their raw state.
To achieve this, we have equipped ourselves with a robotic island that deals entirely with grinding.
This new-generation island has the ability to machine any item, thanks to its versatility through the design and implementation of a gripper and special holders.
2. Polishing
Polishing is a stage that is carried out after the buffing stage to remove the emery work and make the surface as homogenous as possible and free of imperfections, so that the item can then be processed with transparent paint, gold plating, chrome plating and any mirror finish.
To achieve this, we have equipped ourselves with three robotic islands.
3. Satin Finishing
Satin finishing in electroplating is a surface operation that gives the object a scratched appearance.
We are equipped with a highly efficient robotic satin-finishing island with which we make any item either raw or already galvanised to give that scratched effect.
4. Coating on Copper
Coating on copper is performed on any die-cast material that has porosity or cobwebs due to die-casting and on which excellent quality is desired.
Initially copper plating is carried out at a thickness (with acid copper) ranging from 50 to 100 microns and then we move on to coating, which is a process carried out by hand by the operator that levels the surface of the object eliminating all defects and imperfections.
Electroplating
A process that will leave you galvanised!
Galvanic treatments on brass, zamak, iron, aluminium and stainless steel provide the possibility to carry out customised finishes based on the need and taste of the customer requesting the order, regardless of what their sector is.
The reasons why a professional decides to electroplate his product fall into two macro-categories:
– Aesthetic-decorative, as galvanic treatments improve the appearance of the product by giving it a shiny, satin, matt or semi-matt surface.
– Functional, i.e. corrosion protection as the addition of a metal layer can protect the product from phenomena such as oxidation and benefit its surface properties such as hardness or wear resistance making it more durable.
Our two electroplating lines are the heart of production.
Line one has eighty positions, fully enclosed, with six carriages for maximum flexibility managed by PLC.
Having plant flexibility as a priority, albeit at the expense of large production runs, allows us to carry out a > number of galvanic finishes, with no thickness limits, to satisfy + specific requests.
This is a huge advantage because we are always able to track every frame and every bar inserted into the plant, keeping the cycle and processing times monitored.
Each of our tanks in the line has a filtering pump for better quality and consistency.
One of its most important features is that it is a completely closed plant with suction from above to prevent the spread of any pollutants and an efficient chemical-physical purification system, which is also closed-loop.
Thanks to this line we are able to process your metals such as brass, zamak, iron, aluminium and stainless steel and perform processes such as alkaline copper, acid copper plating, polished nickel, hexavalent and trivalent chromium plating, black trivalent chromium plating, 24 carat gold, 18 carat gold and other opaque finishes in various colours.
Line two is equipped with fifty-one positions, completely enclosed, managed by PLC so that the product path inside the plant can always be traced and the entire processing cycle can be printed and certified.
It is totally made of stainless steel with moplen tanks with an extremely advanced top suction system. Again, we are able to work on metals such as brass, zamak, iron, aluminium and stainless steel by doing treatments such as polished nickel activation, Wood’s nickel, matt pearl nickel, hexavalent and trivalent chromium plating, 18 carat gold and 24 carat gold.
Painting
An extra caress for added protection.
Varnishing is a process that combines galvanic coating with the application of a layer of varnish or other protective material on the metal surface to make it anti-fingerprint and protect it from corrosive and atmospheric agents.
We have two painting plants, one semi-automatic and one fully automatic, both pressurised, equipped with a pre-washing, blowing and drying oven section.
In this way, we perform one-component and two-component transparent protective coatings with automatic mixing in gloss, semi-matt and matt variants.
The first painting plant is semi-automatic: before being painted, the article is washed, blown and dried in order to be free of dust and other materials that could compromise its processing.
It then continues on its way to the drying and cooling stage and is finally ready to enter the water curtain coating booth, where the operator begins processing.
The manual work allows millimetric precision, reaching every corner of the product even with small batches.
Once the operator’s painting work is finished, we come to the ‘flash-off’ phase, where the paint has time to relax before being baked in the oven for a few hours.
After cooling, the operator removes the pieces from the frame and subjects them, one by one, to rigorous quality control, after which they are ready to be packed and shipped directly to the customer.
The same process is also carried out in the automatic coating plant with a cup that can reach up to 80,000 revolutions.
This is complementary to the manual one and is able to guarantee absolute continuity and consistency in the process.
Also in this case, the product can be transparently painted with matt, semi-matt and pigmented finishes.
