Professional Zinc Alloy Surface Finishing Solutions
Rack underhåll
Rack maintenance
1. Process Flow Chart
2. Process Video
3. Process Details
1. Nitric Acid Removal Tank
Nitric acid tank or sulfuric acid tank, choose according to the effect of different products. Mainly remove the paint on the pendant and some residual plating impurities. Paint stripping alone cannot achieve thorough cleaning and needs to be combined with subsequent processes.
2. Three times Cleaning Tank
Remove residual liquid on the workpiece surface.
3. Electrolytic Removal Tank
Different from the sulfuric acid stripping function, it is specially used to remove residual electroplating impurities on the pendants, and the two are used in conjunction.
4. Three times Cleaning Tank
After electrolytic stripping, it needs to go through 3 water washes. It is recommended to add ultrasonic water washing (clear water is sufficient, with the temperature controlled at around 80℃), followed by another 3 water washes to ensure that impurities are completely removed.
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Workshop Planning Data
Rack maintenance — Data Zinc Alloy Finishing Managers Need
A dedicated rack maintenance cell strips, re-coats and repairs plating racks so contact points stay conductive — directly cutting rejects caused by burnt parts and skip plating.
120 m²Workshop Area
5 peopleTeam Size
45 kWInstalled Power
200-400 racks/monthDaily Output (10 h)
Quality Inspection & Control
| Check item | Method | Acceptance standard |
|---|---|---|
| Conductivity of tips | Milliohm meter | Contact resistance < 50 mΩ per tip |
| Coating thickness on rack | X-ray / visual | Stripped and re-masked racks fully coated |
| Spring tension | Force gauge | Grip force within 80-120% of new rack |
| Insulation integrity | Hi-pot / visual | No cracks, exposed copper on masked areas |
| Rack count control | Rack register log | 100% racks tracked with maintenance date |
| Reject reduction KPI | Line reject report | Rack-related rejects < 0.5% of output |
Workshop Layout & Floor Area
| Zone | Area |
|---|---|
| Strip & chemical area | 40 m² |
| Repair & welding bench | 30 m² |
| Re-masking / coating | 25 m² |
| Storage & rack racks | 15 m² |
| QA & office | 10 m² |
| Total workshop | 120 m² |
Manpower & Shift Plan
| Role | Headcount |
|---|---|
| Rack repair technicians | 3 |
| QC / inspector | 1 |
| Supervisor | 1 |
| Total (1 shift × 10 h) | 5 |
Power & Utility Demand
| Equipment | Demand |
|---|---|
| Strip tank heating | 15 kW |
| Welding / repair equipment | 8 kW |
| Exhaust | 6 kW |
| Air compressor | 7.5 kW |
| Lighting & auxiliary | 8.5 kW |
| Installed total | 45 kW |
| Typical running load | ≈ 32 kW |
Production Flow Chart
Collect Used RacksFrom plating line, register
Strip CoatingChemical strip of worn plating
Repair & ReweldFix tips, springs, frames
Re-mask / CoatInsulation repair, tip exposure
QC CheckResistance + visual test
Return to LineIssue to plating, log date
Daily Capacity — 10-Hour Operating Day
| Parameter | Value |
|---|---|
| Rack repair cycle | 2-4 h / rack |
| Racks per day | 10-20 |
| Racks per month | 200-400 |
| Rack service life | 6-18 months |
| Reject reduction | 30-60% of rack-related defects |
Output Value Estimate
| Parameter | Value |
|---|---|
| Repair cost per rack | USD 5-15 |
| Monthly saving (reject reduction) | USD 8,000-30,000 |
| Annual saving | USD 100,000-360,000 |
| ROI vs new racks | 3-8 × payback |
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