586-791-6520 sales@burkardind.com

Electrocoat Services

Burkard Industries has worked to provide automotive and military approved electrocoat (also referred to as electrophoretic coat or e-coat) services for more than a decade. Today, our state-of-the-art system is recognized as one of the most capable in North America.Our e-coat line boasts a unique 14-stage pretreatment process consisting of both immersion and spray stages and also features an optional acid bath for laser cut and welded parts. We pride ourselves on providing excellent quality for all part configurations, big or small.

Electrocoat Process

Click the tabs below to learn about each step of Burkard Industries’ top-of-the-line e-coat system.

14 Stage Pretreat
Picture11As with all finishing operations, the most important step is pretreatment of the parts. Our 14-stage pretreat system includes spray and immersion stages to ensure that parts are properly prepared before they enter the electrocoat bath.
Immersion Acid Cleaning
Picture12Immersion Acid Cleaning, also known as pickling, removes oxidation residue from welding and brazing operations. This technique provides for a better quality finished product as oxidation residue cannot be completely removed by alkaline cleaners. Pickling also allows us to process laser cut parts which can cause issues for e-coating and powder coating. The acid cleaning stage can be bypassed for certain substrates, including aluminum or galvanized parts.
Bag Filtration
Picture13Each stage has pumps and bag filtration to ensure removal of all particulates from process solutions. This helps prevent contaminants from being deposited on parts.
Tanks with Cone-Shaped Bottoms

Picture14The three alkaline tanks and the zinc phosphate immersion tank have cone-shaped bottoms to collect sludge which is continuously pumped and filtered out in a closed loop return system. This minimizes the number of particulates in the tanks and, therefore, prevents the particulates from settling on parts.

Automatic Chemical Feed System
Picture15We automatically inject pretreat chemicals into the system tanks with pumps controlled by the central PLC based on total square footage processed and monitored pretreat parameters. This helps 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
Picture16Reverse Osmosis (RO) water is used to supply and make up the last seven stages of our electrocoat systems 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 eliminates problems associated with odd-shaped parts or parts with brackets. This process, also known as “burping”, eliminates air bubbles which can leave a void in the coating. Burping also allows for better drainage to prevent drip issues commonly caused by parts that hold fluid in pockets.
Automatic Voltage Control
Picture22The rectifier allows the central PLC to control 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 processed.
Final Rinses
Picture23Our cutting-edge system allows for six minutes of final rinse time after the application of the cathodic epoxy electrocoat. This process includes immersion and spray permeate rinses as well as a final immersion RO rinse which minimizes the drip marks commonly associated with e-coat.
Two-Zone Oven
Picture24The oven features two zones, each with independent burners. This provides for a dehydration process to occur prior to the standard e-coat curing. Dehydration allows for quick evaporation of pocketed liquids on complex parts, like brackets, or on horizontal surfaces prior to entering the cure cycle. This minimizes rejects commonly associated with electrocoating due to drips.
Filtered Oven Recirculation Air
Picture25The oven is equipped with filter banks which remove particulates from the air stream and provide for a smoother “Class A” finish.
Power and Free Conveyor
Picture26Our four-spur power and free conveyer has four load and unload stations. Part carriers remain stationary while loaded or unloaded at a station. The e-coat machine receives part recipe information with the use of an infrared smart-eye communication system.
Software Monitoring
Picture27

Our e-coat system uses the latest computer and controls technology to allow for the monitoring and alarming of key process parameters. This includes system alarms, process temperatures, as well as pretreat, e-coat bath, and operating-cost parameters.

Personnel receive system alarms to pagers and cell phones. We also provide historical tracking of key process parameters and recipe information from every load to meet ISO-9000 lot control requirements.

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