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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 stan |
|---|---|---|
| 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 |
Related Products — Complete Pretreatment Solution
Machines, chemicals and consumables selected from the real QLQ product range for this process. Every product page is live and ready to quote.
QLQ-ADPM Automatic Dry Type Polishing Machine
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QLQ-WTPCM Automatic Whirlpool Type Polishing +Separating Machine
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QLQ-WTPM Whirlpool Type Polishing Machine
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QLQ-VTPM Vibrating Type Polishing Machine
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Defects that start in pretreatment
| Symptom | Cause | Check |
|---|---|---|
| Patchy, dull first layer | Oil film survives degrease | Bath temperature, loading, concentration |
| Blister at edges | Oxide or smut under the deposit | Pickle time, rinse quality, air dry gap |
| Adhesion loss after baking | Passivation during transfer | Transfer time, activation dip strength |
| Water spots | Contaminated final rinse | Conductivity, DI resin condition |
FAQ
How do we know the degrease is working?
Water-break test: the surface should hold a continuous film for 30 seconds. If it breaks into islands, oil remains.
Can we skip electroclean for simple parts?
Only if the part is flat, clean and has no blind holes. Recessed geometry needs the current to reach it.
Why does the same bath work on Monday and fail on Friday?
Loading. Bath chemistry per litre changes with the surface area processed, not with the number of hours.