Strategy to optimize the galvanising process for products in small batches in a galvanising plant

Abstract

This study was performed to optimize the zinc usage, through zinc pickup, for products to be galvanized in small batches or one-off. A strategy was also developed to that end. Five factors influencing the galvanising process, namely surface profile, immersion time, extraction rate, zinc temperature and chemical composition of steel were investigated through the Taguchi’s design of experiment approach. It was found that, for a good process capability, immersion time should be kept to a minimum. The best surface preparation method for reactive steels is by grinding and the optimum galvanising temperature for the latter is 445oC. A protocol for handling variations has been devised for the galvanization of small batches of products. Though many researches are being performed to improve the zinc coating, many galvanising factories face these issues. The results are expected to help all the developing galvanising companies which receive products to be galvanized in small batches.