586-791-6520 sales@burkardind.com

Custom E-Coat Services

Burkard Industries’ goal to provide the highest quality electrocoating service in the industry came to fruition with the June 2003 launch of our Best-In-Class Electrocoat (E-coat) system. Today, the system is recognized as one of the most capable E-Coat systems in North America.  The special features of Burkard Industries’ electrocoating line will provide a “Class A” finish for customers that demand the highest standards in quality. Burkard Industries’ E-coat line boasts a unique fourteen stage pretreatment system that consists of both immersion and spray stages.  We have an optional acid bath for laser cut and welded parts.  We provide excellent quality for all part configurations from eight foot vehicle hoods to the complex masking of gas filler tubes.

Burkard’s State of the Art E-Coat Process

Click the tabs below to learn about each step of Burkard’s custom e-coat process.

14 Stage Pretreat

Picture11As with all finishing operations the most important step is pretreatment of the parts. The fourteen stage pretreat system includes spray and immersion stages to ensure that parts are properly prepared prior to entering the electrocoat bath.

Immersion Acid Cleaning

Picture12Acid Cleaning, or pickling, removes oxidation left from welding and brazing operations which cannot be removed by the alkaline cleaners providing for a better quality finished part.  This also allows us to process laser cut parts which are often a problem for both e-coating and powder coating.  The acid cleaning stage can be bypassed for certain substrates including aluminum or galvanized parts.

Bag Filtration

Picture13Pumps and bag filtration are on all stages to ensure particulates are removed from all process solutions preventing contaminants from being deposited on parts.

Cone Bottom Tanks

Picture14The three alkaline tanks and the zinc phosphate immersion tank have cone shaped bottoms.  Sludge settles in this area and is continuously pumped and filtered out in a closed loop return system which minimizes the amount of particulates that are in the tank and can settle on parts.

Automatic Chemical Feed System

Picture15Pretreat chemicals are automatically injected into the system tanks with pumps that are controlled by the central PLC based on total square footage processed and monitored pretreat parameters.  This will maintain much tighter controls on the critical characteristics of the pretreat baths.   Quality Control personnel also perform chemical titrations each shift to ensure process integrity.

 

Reverse Osmosis Water

Picture16RO water is used to supply and make up the last seven stages of the system to ensure that chemical tanks and rinse tanks are of the highest quality.

 

Burping and Tilting

Picture20Picture19The line is designed to tilt parts in tanks which can eliminate problems with  odd shaped parts or parts  with brackets.  By burping these parts,  air bubbles which leave a void in the coating are eliminated. Parts that hold fluids in pockets can also be tilted above the tanks to create better drainage in order to prevent drip issues.

 

Automatic Voltage Control

Picture22The rectifier is set up so that the PLC controls the voltage applied based on the square footage of the parts in the e-coat tank.  This results in a consistent film build regardless of the size of the load being processed.

Final Rinses

Picture23The system provides six total minutes of final rinse time after the application of the cathodic epoxy electrocoat.  This includes immersion and spray permeate rinses followed by a final immersion RO rinse. This will minimize the drip marks commonly associated with e-coat.

Two Zone Oven

Picture24Each zone has independent burners to provide for a dehydration process prior to the standard e-coat curing.   The dehydration zone allows for quick evaporation of pocked liquids on complex parts (i.e. brackets) or horizontal surfaces prior to entering the cure cycle.  This minimizes rejects commonly associated with electrocoating due to drips.

Filtered Oven Recirculation Air

Picture25The ovens are equipped with filter banks, which remove particulates from the oven air stream providing for a smoother Class A finish.

Power and Free Conveyor

Picture26The system has a four spur power and free conveyor with fourteen load/unload stations.  Part carriers remain stationary while being loaded or unloaded at a station and part recipe information is communicated to the e-coat machine with the use of an infrared smart eye communication system.

Software Monitoring

Picture27The latest computer and controls technology provide monitoring and alarming of key process parameters. This includes process temperatures, pretreat parameters, e-coat bath parameters, operating  cost parameters, and system alarms.

System alarms are sent to appropriate personnel through pagers or cell phones.  Historical tracking of key process parameters and recipe information from every load is also available to ensure ISO-9000 lot control requirements are being met.

Contact Us!

Coating Compliance

Burkard Industries is ready for your order with an unrivaled list of compliance approvals. From the Big Three in Metro Detroit to Tesla in California on the West Coast and countless other companies world-wide. We range from Automotive to Industrial to Commercial and any other industry that wants the best quality E-Coating, Powder Coating or CARC application. 

SpecificationE-CoatThickness
MS-PB-45-1E-Coat15-20 microns
MS-PB-45-2E-Coat20 microns (.8 mils)
MS-PB-60-2E-Coat20 microns (.8 mils)
MS-PE-16-2Black Powder Coat.002 Min
MS-PE-16-2Black Powder Coat.002 Min
MS-PE-16-2Black Powder Coat.002 Min
MS-PE-16-2Wheel White Powder Coat.002 Min
MS-PE-16-2Black Powder Coat.002 Min
MS-PB-59-1Gray Powder Coat.002 Min
SpecificationCoating(s) - DescriptionThickness
49-00023-101, -102 or -103
Zinc Phos/E-Coat Prime
.7 - 1.0 mils
49-00023-201
Zinc Phos/E-Coat Prime
.7 - 1.0 mils
49-00077-000
Military 53030 or 53022 primer
1.0-1.5 mils dry
49-00077-001
Military 53084 prime
0.75-1.25 mils
DBL 7391-04
Cathodic e-coat
per part dwg
SpecificationCoating(s) - DescriptionThickness
ESA-M64J19-B1/B4Black Cathodic E-coat20-25 microns
ESA-M2P15-A
ESB-M70J1-ABlack Powder Coat.001 in min
ESB-M70J5-ABlack Powder Coat
ESE-M2P171-A1/A2Black Powder Coat
ESF-M70J1-ABlack Powder Coat.001 in min
ESF-M70J4-ABlack Powder Coat.003 in min
ESN-M2P86-ABlack Powder Coat
WA05 PB 195ABlack Powder Coat
WSA-M2P170-A1Black Powder Coat
WSB-M64J28-A1/A4Black E-coat20 microns nom.
WSK-M2P149
WSK-M2P153-A1 thru -A6Any (as specified)as req'd to meet perf requirements
WSK-M3P1-Czinc phosphate
WSS-M2P177-B1, -B2
WSS M2P177-C1, -C2, -C3E-Coatspecified on print
WSS-M2P180-CBlack Powder Coat
WSS-M2P185-Apaint performance
WSS-M2P190-Apaint performance"E-coat 20 min
Powder 50 min"
WSS-M21P41-A2cathodic e-coat
WSS-M64J39-A1/A5 System IEdge Protection Cathodic E-coat
WSS-M64J40-A1/A4Epoxy E-Coat over Zn Phos20-25 microns
WSS-M70J5BBlack Powder Coat
SpecificationCoating(s) - DescriptionThickness
GMW14664 Type BPowder coat2-4 mils
GMW14669 Type Aexterior
GMW14669 Type Binterior
GMW14671, Type AE-Coat16-22 microns
GMW14671, Type BE-Coat23-35 microns
GMW14671, Type DPowder>/= 40 microns
GMW14671, Type EType A-D w/specified thicknessas specified
GMW14671, Type Fas specified on dwgas specified
GMW14671, Type GSpray Paint>/= 40 microns
GMW14671, Type He-coat20-40 microns
GMW14872
GM9984120Electrodeposition Primer- Cathodic E-Coat for Small Parts15 or 20 microns
GM9984050Black Powder Coat.038-.075
GM9984050Black Powder Coat.038-.075
GM9984050Black Powder Coat.038-.075
GM9984050Black Powder Coat.038-.075
GM9984275Black Powder Coat1.54-4.0 mils
GM9984275Black Powder Coat1.54-4.0 mils
GM9984275Black Powder Coat1.54-4.0 mils
GM9985586Gray Powder Coat
GM197M WA05 PB 195ABlack Powder Coat
GM197M WA05 PB 195ANeutral Medium Powder Coat
GM/Fisher Guide 3515-2Silver Horn Powder Coat
GM/CPC FBMS 1-43Black Powder Coat
GM4350M-AxxxPerformance spec for EC or Powder
SpecificationCoating(s) - DescriptionThickness
HES D2021 Class 1, Grade 4Black E-coat>20 microns
HES D-22399 Class IIPowder Coat
5100Z-TRO-6001E-Coat"inner 15 min
outer 20 min"
SpecificationCoating(s) - DescriptionThickness
TMS-9009 Class I
Decorative exterior parts
Powder
"20 microns Grade 17 or 19
25 microns Grade 20"
TMS-9009 Class IPDecorative exterior parts supplied primed only w/subsequent topcoat.
E-Coat or Powder
15 microns
TMS-9009 Class IINon-Decorative exterior parts that will be topcoated or if not topcoated, will not be subject to UV.
E-Coat or Powder
15 microns
TMS-9009 Class IIADecorative exterior parts that will be topcoated or if not topcoated, will not be subject to UV.
Powder (or E-Coat if post assembly topcoated)
15 microns
TMS-9009 Class IIINon-Decorative interior parts.
E-Coat or Powder
38 microns min
TMS-9009 Class IIIADecorative interior parts that will be subject to UV.
Powder (or E-Coat if topcoated)
38 microns min
TMS-9009 Class IVClass II for frame/chassis parts25 microns
TMS-9009 Class VEngine & engine parts25 microns
TMS-9009 Class VICasting sealer13 microns
CEMS G-5, Part V, Grade-56Cathodic E-coat primer20-24
SpecificationCoating(s) - DescriptionThickness
NES M5083 CEDE-Coat20 microns
NES M5083 CED-EE-Coat/Edge Protection20 microns
NES M5083 CED-TE-Coat/Edge Protection, Thick30 microns
NES M5083 ET-2DPowder Coating20 microns
SpecificationCoating(s) - DescriptionThickness
R026-198-39Black Powder Coat
CMT0030Black E-Coat.6-1.0 mils
CMT0030Black Powder Coat 1.5-3 mils
CMT0030Gray Powder Coat1.5-3 mils
CMT0030Black Powder Coat 1.5-3 mils
CS0031 Type 1Black Powder Coat 1.5-3 mils
CS0031 Type 1Gray Powder Coat1.5-3 mils
CS0031 Type 2Black E-Coat.6-1.0 mils
CMT0048Black Powder Coat
CMT0048Silver Powder Coat
CMT0048Black Powder Coat
CMT0048Red Powder Coat
SpecificationCoating(s) - DescriptionThickness
TSH2354GE-Coat20 microns
01206-00050-AMed build TSH2354G e-coat w/TSH3600 zinc phos
w/enclosure 20-33 microns outside (>15 on inner surfaces)
01206-00344High build TSH2354G e-coat25-45 microns
SpecificationCoating(s) - DescriptionThickness
VW 13750 Ofl-X630 KTLE-Coat (w/zinc phos)15-35 microns
(>/= 12 in cavities)
VW 13750 Ofl-X634 KTLE-Coat (w/zinc phos) w/paint topcoat35-60 microns
(>/= 20 in cavities)
CompanySpecificationCoating(s) - DescriptionThickness
Azure DynamicsSPC00218E-Coat
American AxleMS-4005 Type IIIE-Coat
American AxleMS-4005 Type IVE-Coat
American AxleMS-4005 Rev. EE-Coat
BendixBW-329-P Code ABlack E-Coat
BorgWarner01ES00002E-Coat
Brose562161E-Coat
Caterpillar1E1950HBlack Powder Coat
Caterpillar1E1951AYellow Powder Coat
Caterpillar1E1951AYellow Powder Coat
Caterpillar1E1951DGray Powder Coat
Caterpillar1E1952 HBlack Powder Coat
Caterpillar1E1952JBlack Powder Coat
CNHMAT0101QGray Powder Coat
CNHMAT0101QGray Powder Coat
CNHMAT0101QYellow Powder Coat
CNHMAT0101QRed Powder Coat
CNHMAT0101QBlack Powder Coat
CNHMAT0101QTan Powder Coat
CNHMAT0103Black Powder Coat
Cummins21073 Rev.4Lead Free Black E-Coat
DensoCaterpillar RadiatorBlack Powder Coat
Hendrickson Truck34568-003 Rev.GE-Coat
IsuzuISC-B51-001E-Coat
JCI
(Johnson Controls)
MEPW-PLUS-SP-04-07-05-EE-Coat or
Powder Coat
Key Safety Systems (KSS)E50266 Rev.06E-Coat
Kenworth (PACCAR)RO26-198-6Black Powder Coat
Kenworth (PACCAR)R026-198-39Black Powder Coat
TeslaTM-0023F-P-EC Table 1E-Coat
TeslaTM-0023F-P-EC Table 2E-Coat
TeslaTM-0023F-P-EC Table 3E-Coat
TeslaTM-0023F-P-EC Table 4E-Coat
TRWMS00019Lead Free Black E-Coat
TRWPS00005Trivalent Zinc Plating
VolvoSTD 121-0006Zinc Black Plating
Western Star Trucks4102-3404E-Coat