Batch Galvanising Lines

For over thirteen years, together with its partners INGENIA has not only been jointly planning and building safe and environment-friendly lines for hot dip galvanising shops, but also complete turnkey plants from the greenfield phase to the finished production hall. 

The realisation of individually designed zinc coating plants repeatedly proves to be an extremely complex assignment. This is because owing to the diversity of the respective needs of every individual client, for INGENIA comprehensive standardisation is out of the question. Instead, it is customised logistics that form the basis for the commercial success of customer galvanising lines.
 

Logistic Type BASIC

Logistic Type BASIC

The BASIC line incorporates INGENIA’s proven and CE-certificated, high-performance components. In this type of line, all processes are subject to independent worker completion and control.

 
The BASIC line type in overview:
 
  • Clear logistic sequences
  • All processes subject to independent worker completion and control
  • All components and machinery developed specially for the galvanising sector for an impressively long service life and a minimum maintenance requirement
  • Proven high-performance components
  • Limited Investment
Logistic Type SEMI

Logistic Type SEMI

This line incorporates partially automated processes and INGENIA’s proven and CE- certificated, high-performance components.

In this type of line, certain processes can be automated using a master computer, or be completed independently by a worker. However, loading and unloading, as well as lifting beam management are all carried out directly by the worker.
 

The SEMI line type in overview:

  • Part processes controlled and completed automatically using the master Computer
  • Loading and unloading carried out directly by the worker
  • All processes can also be completed manually
  • Safe automated process areas, as there are no overhead transports
  • Lifting beam management by the worker
  • All components and machinery developed specially for the galvanising sector for an impressively long service life and a minimum maintenance requirement
  • Proven high-performance components
  • Partly automatic
Logistic Type PROFESSIONAL

Logistic Type PROFESSIONAL

This line incorporates fully automated processes and INGENIA’s proven and CE- certificated, high-performance components. In this type of line, a master computer controls all processes and the intelligent logistic concept. 

This guarantees shorter lifting beam changing times and fewer personnel.

The Professional line type offers the highest safety level, as all the process areas are automated. 

The PROFESSIONAL line type in overview:

  • Intelligent logistics concept
  • Automated process guidance via a master computer
  • Advance process simulation
  • Safe automated process areas, as there are no overhead transports
  • Automated lifting beam management
  • Organised loading and unloading zones
  • Short lifting beam changing times
  • High throughput
  • Low personnel costs
  • All components and machinery developed specially for the galvanising sector for an impressively long service life and a minimum maintenance requirement
  • Proven high-performance components

 

Single Centrifuge (integrated)

Single Centrifuge (integrated)

Features:

  • Load weights of up to 100kg
  • Integrated protective hood
  • CE-certificated
  • Speed Monitoring
  • Oscillation monitoring
  • Radio remote control
     

INGENIA IZ centrifuges serve as a cost-efficient supplement in piece good lines. 

They can be retrofitted for use in all existing galvanising shops, or be integrated into the conceptual phase of new lines.

In addition, loading and unloading stations, quenching tanks and drier systems are all available. 


Advantages:

  • Suitable for use in virtually all piece good lines
  • Spinning directly above the zinc bath
  • Complete galvanising service for the customer (piece good + centrifugal zinc coating)
  • Safety through oscillation monitoring and speed control
  • Simple “plug & spin” handling
Pre-treatment technology

Pre-treatment technology

Modular products:

  • Waste air scrubbers
  • Tank manufacture
  • Floor coatings in areas subject to acid
  • Housings
  • Degreasing Systems
  • Flux preparation
  • Filling Station
  • Acid preparation
  • Acid tank farm
  • Tank heating
  • Piping
  • Accessories

Material pre-treatment plays a decisive role in galvanising quality. Therefore, the “degreasing”, “pickling”, “rinsing” and “fluxing” procedures follow sophisticated and strict recipes, which are pre-programmed in the automatic plant control system in a far-sighted, structured and individual manner. 

The gaseous emissions (hydrogen chloride – HCl) created in the encapsulated processing tanks are washed out of the atmosphere using special capture, extraction and high-tech waste air scrubbers. The HCl is then returned to the process tanks. As a result, the European directives with regard to exhaust air and flue gases are not only fulfilled, but also undercut.

The process tanks are made from polyethylene or polypropylene, whereby the choice of materials remains flexible. The tanks are encased in a steel corset.
 

Galvanising furnaces

Galvanising furnaces

Modular products:

  • Exhaust air flue
  • Pilling high-performance Boiler
  • Galvanising furnaces
  • Drier furnaces
  • Furnace housings
  • Heat recovery
  • Hot water Boiler
  • Dust filter
  • Control and temperature Regulation
  • Accessories

Furnace design is another area that demonstrates systematic efficiency and the use of the latest technology, which can be matched individually to any size of steel boiler. You can select between a flat flame or a high-velocity burner fitted with the most modern regulation and control technology available. Both variations are operable with gas, diesel or electricity.

  • Proven flat flame and high-velocity burners
  • The latest regulation and control technology
  • Insulation using high-quality ceramic fibres
  • Short installation times due to extensive prefabrication
  • Programmed temperature ramping function for boiler-protective heating
  • First class technical heating efficiency due to furnace chamber pressure Regulation
Drying furnaces

Drying furnaces

Modular products:

  • Transversely oriented tunnel driers
  • Longitudinally oriented tunnel driers
  • Underfloor driers with/without conveyor

In order to prevent zinc explosions and minimise ash formation, the steel parts subject to various flux agents are dried using circulatory air. This process takes place either in a tunnel drier with a conveyor, or in an underfloor drier with/without a conveyor. Irrespective of your choice of system, the drying furnace will be modified to match your requirements with regard to the location and material flow. 

Temperatures in the drying furnace generally range between 80-100°C although they can be as high as 140°C. The drying air is either heated directly or indirectly using a natural gas fired heating device and is then blown into the entirely sealed chamber via ventilators. An optimum airflow over the material to be dried is provided by the individual layout of the drying air piping.
Tunneltrockner mit Transporteinrichtung

  • Tunnel driers with conveyor
  • Underfloor drier with/without conveyor
  • Modifications to match the location and material flow in line with requirements
  • Optimum airflow over the material to be dried through the individual layout of the drying air piping
  • Durability of all the components through acid-resistant materials and coatings
Galvanising furnace flue gas capture and dedusting

Galvanising furnace flue gas capture and dedusting

Both gaseous (hydrogen chloride – HCl) and atomised (zinc chloride/ammonium chloride) emissions are formed during hot galvanising and may not exceed the respective current limits. Therefore, special capture, extractor and dedusting systems have to be installed. 

Our high-tech, exhaust air scrubbers are installed in the galvanising furnace housing with the appropriate openings for crane slings and the skimming process. The scrubbers quickly neutralise any harmful emissions and offer the major advantage of permitting the reopening of the housing only minutes after the immersion process.

Using this technology, your galvanising plant not only operates with outstanding energy efficiency, but also undercuts the European exhaust air and flue gas directives. In this way, we join with you to fulfilling our shared responsibilities to people and the environment.

Incidentally, the zinc dust extracted by the filters can be disposed of easily and returned to a recycling process. 

Turnkey plants

Turnkey plants

Modular products and part services:

  • Submission planning
  • Own developments & products
  • Detailed hall planning
  • Complete technical equipment
  • Material flow planning
  • Modular conveying technology
  • Installation & start-up
  • Furnace technology
  • Project planning
  • Service & maintenance
  • Simulations
  • Pre-treatment installations

In the case of turnkey plants, INGENIA undertakes the entire project management and complete interface coordination. For customers this means support during site and property analyses, approval procedures, cost supervision and joint realisation planning. The latter extends from the construction preparations and planning submissions, detailed planning, hall construction and plant technology, to the core logistics area and commissioning.

INGENIA is also subsequently close at hand with an extensive range of after-sales services.

The TURNKEY plant performance range at a glance:

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