Professional Zinc Alloy Surface Finishing Solutions

Pretreatment

Barrel Polishing

Hand Polishing

Other Polishing

Wax Removal

Phosphating

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Workshop Planning Data

Pretreatment — Data Zinc Alloy Finishing Managers Need

The complete pre-treatment department combines polishing, dewaxing, degreasing, acid activation and phosphating so every zinc alloy part enters plating or painting with a chemically clean, activated surface.

450 m²Workshop Area

16 peopleTeam Size

150 kWInstalled Power

1-2M pcs/dayDaily Output (10 h)

Quality Inspection & Control

Check item	Method	Acceptance standard
Water-break test	Spray + visual	Continuous film ≥ 30 s on 100% sampled racks
Surface roughness	Ra tester	Ra ≤ 0.8 μm before plating; ≤ 0.4 μm bright
Activation quality	Copper flash test	Uniform flash, no skip plating
Phosphate coating weight	Weigh-difference	1.5-3.0 g/m² when phosphating applied
Cross-contamination	Bath titration logs	All baths within recipe control limits
Batch traceability	Work order scan	100% batch barcode traceable to QC records

Workshop Layout & Floor Area

Zone	Area
Polishing section	120 m²
Dewaxing & degreasing line	100 m²
Activation & phosphating line	100 m²
Rinse / DI / water treatment	60 m²
QA lab & chemical store	40 m²
Utility & lockers	30 m²
Total department	450 m²

Manpower & Shift Plan

Role	Headcount
Operators (all lines)	10
Chemical technicians	2
QC inspectors	2
Supervisor	1
Maintenance	1
Total (2 shifts × 10 h)	16

Power & Utility Demand

Equipment	Demand
Polishing equipment	45 kW
Dewax / degrease heating	38 kW
Phosphating heating + pumps	28 kW
Ultrasonic + rinse pumps	14 kW
Air compressor + exhaust	19 kW
Lighting & auxiliary	6 kW
Installed total	150 kW
Typical running load	≈ 118 kW

Production Flow Chart

PolishBarrel / hand / mass finishing

Dewax & DegreaseSolvent or hot alkaline

RinseMulti-stage counter-flow

ActivateAcid or pickle activation

Phosphatize (optional)Zinc phosphate for paint base

Final Rinse & DryDI rinse + hot-air dry, QC gate

Daily Capacity — 10-Hour Operating Day

Parameter	Value
Line cycle	40-70 min
Simultaneous batches	6-8 in process
Batches per 10 h day	16-22
Daily output	1,000,000-2,000,000 pcs
Monthly output (26 days)	26-52 million pcs

Output Value Estimate

Parameter	Value
Processing fee per piece	USD 0.003-0.008
Daily output value (10 h)	USD 3,000-7,000
Monthly output value	USD 78,000-180,000
Annual output value	USD 940,000-2,160,000