Innovations in Sustainable Decorative Plating: Insights from the Surface Coating Expo 2025

The Surface Coating Expo 2025 highlighted advancements in sustainable decorative plating, focusing on chrome-free and PAS-free processes. Key topics included health risks associated with traditional chrome plating, regulatory updates, and innovative techniques for plating on plastics. The conference emphasized the importance of environmentally friendly alternatives and showcased successful implementations in the industry.

The Surface Coating Expo 2025 brought together industry leaders to discuss the future of decorative plating, particularly focusing on sustainable practices. This blog post summarizes the key points discussed during the conference, including regulatory updates, health risks associated with traditional plating methods, and innovative chrome-free and PAS-free processes.

The conference commenced with a warm welcome to all attendees, setting the stage for an in-depth discussion on sustainable products related to decorative plating and plating on plastics. The agenda included updates on regulations, insights into decorative plating techniques, and a summary of the industry's outlook.

Health Risks of Traditional Chrome Plating

One of the primary concerns addressed was the health risks associated with traditional chrome plating. Exposure to hexavalent chromium, commonly used in plating processes, poses significant health hazards, including:

• Lung cancer
• Damage to the nose and throat
• Respiratory system issues

Due to these risks, the European Union has set a sunset date for the use of chromic acid, with expectations for a complete phase-out by 2028. This regulatory shift is crucial for protecting workers and the environment.

The Challenge of Forever Chemicals

Another critical topic was the discussion of polyfluoroalkyl substances (PFAS), often referred to as "forever chemicals." These man-made chemicals do not naturally degrade and accumulate in the environment, leading to serious health concerns, including liver disease. The United States has already discontinued products containing PFAS, and other countries are following suit. As a responsible partner in the industry, the speaker's company has also removed PFAS-containing products from their portfolio.

Innovations in Plating on Plastics

Chrome-Free Processes

The conference highlighted advancements in plating on plastics, which traditionally present challenges due to their non-conductive nature. The new chrome-free process involves:

1. Surface Conductivity: The first step is to make the plastic surface conductive without using chrome.
2. Multi-Layer Plating: Following this, a multi-layer plating process is applied, typically involving copper, nickel, and chrome for aesthetic appeal and performance.

This innovative approach not only eliminates the use of harmful chrome but also reduces energy consumption, as the new process operates at a lower temperature (35°C) compared to traditional methods (65-75°C).

Adhesion Testing

Adhesion is critical in plating processes, especially for plastics. The new chrome-free process achieves a peel strength of 15 to 20 Newtons per cm, meeting industry standards. Two primary methods for testing adhesion were discussed:

• Thermal Cycle Testing: This stringent test, based on VW standards, showed no blistering or delamination in the samples tested.
• PE Strength Testing: This method further validated the effectiveness of the new process.

The speaker shared that over 300,000 parts have been successfully plated using this new method, with positive results across various materials, including PP and PA.

Trichrome Plating: A Sustainable Alternative

The conference also introduced trichrome plating as a viable alternative to hexavalent chrome plating. Trichrome offers a variety of finishes, including:

• Bright finishes (Trichrome Plus, Trichrome Ice)
• Dark finishes (Trichrome Smoke, Trichrome Shadow, Trichrome Titan, Phantom Graphite)

These finishes are part of a multi-layer nickel system that meets all industry requirements for corrosion performance and adhesion. The trichrome process is already in production and has received approval from multiple OEMs.

Enhancing NSS Life

To further improve the durability of trichrome finishes, the company has developed two post-treatment processes:

• Tricil 300: Designed for bright finishes to enhance neutral salt spray (NSS) life.
• Tricil 500: Applicable for both bright and dark finishes, also enhancing NSS life.

Conclusion and Future Outlook

The Surface Coating Expo 2025 underscored the industry's shift towards sustainable practices in decorative plating. With the impending phase-out of hexavalent chrome and the introduction of chrome-free and PAS-free processes, the future looks promising for environmentally friendly alternatives. The speaker encouraged attendees to adopt these innovative processes to contribute to a healthier environment.

As the industry evolves, it is essential to stay informed and adapt to these changes. For more information, attendees were invited to visit the company's stall at the expo.

In summary, the conference highlighted the importance of sustainability in decorative plating, showcasing advancements that not only meet industry standards but also prioritize health and environmental safety

Revolutionizing the Plating Industry: The Eden System at Surface Coating Expo 2025

The Eden system, presented at the Surface Coating Expo 2025, addresses significant challenges in the plating industry, including waste generation and productivity loss. This innovative electrodialysis technology enhances bath life, reduces costs, and maintains high-quality plating, making it a game-changer for industries like automotive and hydrogen applications.

At the recent Surface Coating Expo 2025, a significant focus was placed on the challenges faced by the plating industry. The presentation highlighted the innovative Eden system, which stands for Electrodialysis for Electrolytic processes. This technology aims to tackle the pressing issues of waste generation and productivity loss associated with traditional electrolytic plating methods.

Challenges in the Plating Industry

The plating industry has long struggled with several challenges:

1. Waste Generation: Regular dumping of plating baths leads to substantial waste, which is both environmentally and economically detrimental.
2. Downtime: The need to frequently replace baths results in significant downtime, adversely affecting productivity.
3. Quality Degradation: As baths age, the quality of the plating diminishes, leading to lower corrosion resistance and increased internal stress in the plated materials.

Overview of the Eden System

The Eden system offers a solution to these challenges by utilizing electrodialysis technology. This system is designed to:

• Maintain consistent nickel concentration in the plating bath.
• Reduce waste generation significantly.
• Extend the life of the plating bath, potentially allowing for continuous operation if managed correctly.

Key Components of the Eden System

The Eden system can be likened to a human body:

• Bath Module: Acts as the brain, controlling the overall process.
• Working Module: Functions as the heart, driving the plating process.
• Membrane Module: Serves as the kidney, filtering out byproducts and maintaining bath quality.

Benefits of the Eden System

Enhanced Productivity

The Eden system allows for:

• Higher plating rates and loading ratios, which are crucial for automated production lines.
• Consistent quality throughout the bath life, ensuring high corrosion resistance and minimal internal stress.

Cost Savings

The Eden system presents significant cost benefits:

• Waste Volume Reduction: 35% less waste generated compared to traditional systems.
• Hypophosphite Reduction: 75% less hypophosphite produced, which is a common byproduct.
• Nickel Savings: Up to 65% less nickel waste, preserving this valuable resource.
• Overall Cost Reduction: A total savings of approximately 20% in the cost of ownership.

Comparison with Traditional Systems

When comparing the Eden system to traditional and feed-and-bleed systems:

• The feed-and-bleed system incurs 21% higher costs than traditional systems.
• The Eden system can save up to 74% in operational costs compared to traditional methods.

Proven Technology in the Industry

The Eden system has been in industrial use for over a decade, demonstrating its reliability and effectiveness. It has been particularly well-received in the automotive industry, with 22 units currently operational—18 in Europe and 4 in Japan. Notably, 11 of these systems are utilized within the automotive sector, while one is dedicated to hydrogen applications, reflecting the growing demand for efficient plating solutions in high-volume production environments.

Conclusion

The Eden system represents a significant advancement in the plating industry, addressing long-standing challenges related to waste, productivity, and quality. Its proven technology and cost-saving benefits make it an essential tool for industries aiming to enhance their plating processes. As the demand for high-quality plating continues to grow, the Eden system is poised to play a crucial role in shaping the future of the industry. The anticipation for its adoption in regions like India further underscores its potential impact.

Revolutionizing Surface Treatment: Sustainable Cleaners and Descalers for the Industry

Mr. Sumeet Saxena from MKS Autotech India discusses the importance of sustainable cleaning methods in the surface treatment industry. He emphasizes that cleaning is foundational for successful coatings and introduces innovative products like UniPrep and AC that operate at room temperature, extend bath life, and reduce environmental impact. The presentation highlights the shift from conventional to sustainable practices, showcasing case studies that demonstrate significant improvements in safety

In the surface finishing industry, cleaning is not merely the first step; it is the foundation for achieving successful coatings. Mr. Sumeet Saxena, Product Marketing Manager at MKS Autotech India, emphasizes the critical role of modern cleaners and descalers in enhancing surface treatment processes. This blog post delves into the insights shared during his presentation at the Surface Coating Expo 2025, focusing on sustainable cleaning methods that can transform cleaning from a cost center into a profit center.

The Importance of Cleaning in Surface Treatment

Cleaning is essential for ensuring that the surface beneath any coating is free from contaminants. A world-class coating applied to a dirty surface can lead to severe consequences, including:

• Increased rejection rates
• Rework and waste of resources
• Loss of trust in quality and consistency

These issues highlight the need for a robust cleaning process that not only performs well but also aligns with sustainable practices.

Conventional vs. Sustainable Cleaning Processes

Limitations of Conventional Cleaners

Conventional degreasers may effectively clean surfaces, but they come with significant drawbacks:

• High Energy Consumption: Operated at elevated temperatures, leading to a substantial carbon footprint.
• Restricted Substances: Many conventional cleaners rely on substances that are increasingly restricted in modern markets.
• Short Bath Life: The efficiency of conventional cleaners diminishes over time, resulting in frequent bath makeups and inconsistencies in cleaning results.

The Case for Sustainable Cleaners

MKS Auto Tech advocates for a shift towards sustainable cleaning solutions that operate at room temperature and offer longer bath life. This transition not only reduces energy consumption but also minimizes environmental impact. The two key pillars of this sustainable approach are:

• Long Life: Sustainable cleaners can last significantly longer than conventional options.
• Low Temperature: Operating at room temperature reduces energy costs and carbon emissions.

Introducing Uni Prep: A Smart Cleaning Solution

MKS Autotech has developed a product called UniPrep, which exemplifies the sustainable approach to cleaning. Key features include:

• Room Temperature Operation: Eliminates the need for high energy consumption.
• Natural Degradation: The formulation degrades oil naturally over time, maintaining bath stability.
• Extended Bath Life: Users have reported bath life extending up to six times compared to conventional cleaners.

Uni Prep is not just a cleaner; it represents a smart and sustainable approach to degreasing that can significantly enhance productivity and reduce costs.

Addressing Descaling Needs with AC

In addition to cleaning, the surface treatment industry often faces challenges related to scaling, particularly from welding and heat marks. MKS Autotech offers AC, a descaler designed to tackle these issues effectively. Key benefits include:

• Reduction of Mechanical Hazards: Unlike mechanical methods that can cause injuries and noise pollution, AC provides a safer alternative.
• Environmentally Friendly: AC avoids the use of strong acids that are hazardous to both health and the environment.

Implementation Process

The Uni Prep and AC products can be integrated into a seven-stage cleaning process:

1. Apply UniPrep (degreaser)
2. Rinse
3. Apply AC (descaler)
4. Rinse
5. Follow with interlocks

This systematic approach ensures thorough cleaning and descaling, resulting in a stable and reliable surface treatment process.

Case Studies: Real-World Applications

North American Study

In a North American facility, workers faced safety issues due to mechanical cleaning methods. After implementing Uni Prep and AC, the facility reported a significant reduction in near-miss incidents and improved overall safety.

European Agriculture Manufacturer

A European agriculture manufacturer struggled with scaling issues that were previously addressed using hydrochloric acid. After switching to Uni Prep and AC, they experienced remarkable improvements in cleaning efficiency and safety, leading to successful long-term adoption of these products.

Conclusion

The transition from conventional cleaning methods to sustainable solutions like Uni Prep and AC is not just beneficial but necessary for the surface treatment industry. By adopting these innovative products, companies can achieve:

• Increased productivity
• Cost savings through reduced chemical and energy consumption
• Extended bath life and improved cleaning results

MKS Auto Tech is committed to providing ready-made solutions that enhance the sustainability and reliability of surface treatment processes. As the industry evolves, embracing these advancements will be crucial for maintaining competitiveness and environmental responsibility.

Thank you for your attention, and I welcome any questions regarding these innovative solutions