Rising energy costs are a key issue that poses challenges for many industries. Surface treatment plants are particularly affected, as these processes are often energy-intensive. This article looks at how engineered cover balls can help save energy and increase the efficiency of surface treatment plants.

Challenges posed by rising energy costs

Energy costs are a significant factor in production. The volatility of energy prices and the general trend towards rising costs force companies to look for solutions to reduce their operating costs and maintain their competitiveness.

Efficiency in surface treatment

Surface treatment processes are often automated to ensure fast and efficient production. However, a significant portion of energy costs go unused when baths and tanks are left uncovered. This leads to increased energy consumption, evaporation and other problems such as corrosion and additional maintenance requirements.

Technical Cover Balls: An Innovative Solution

What are technical cover balls?

Technical cover balls are specially designed balls that are placed on the surface of liquids in baths and tanks. These balls arrange themselves and cover the liquid surface by over 91%.

material properties and durability

The balls are made of materials such as HDPE (high-density polyethylene), PP (polypropylene) and PVDF (polyvinylidene fluoride), which can withstand extreme conditions including high temperatures, different pH levels and high pressure.

Functionality and application

Simply placing the balls on the liquid surface creates an insulating layer. This flexible cover does not affect the function of the automated machines, as the balls are flexibly pushed aside when the parts are immersed and lifted out.

Advantages of technical cover balls

Energy savings through insulation

The insulating effect of the balls leads to a significant reduction in energy consumption. Up to 75% of energy can be saved, especially in heated tanks and baths.

reducing evaporation

A layer of cover balls prevents the liquids from evaporating. This not only saves material but also reduces the release of dangerous gases and mists into the environment.

minimizing corrosion

By reducing evaporation and protecting the liquids from external influences, corrosion is also minimized. This extends the service life of the systems and reduces maintenance costs.

Improved health and safety conditions

Engineered cover balls contribute to workplace safety by reducing the risk of splashes and exposure to hazardous fumes, resulting in a safer work environment and reducing the need for high-performance exhaust systems.

Practical Application and Experiences

Practical examples

An outstanding example of the successful use of technical cover balls is the company trio-Eloxal GmbH & Co. KG, a company in the field of surface finishing of aluminum. Trio-Eloxal needed a cover for its sealing bath in the anodizing plant that had to withstand high temperatures of 96° to 100° in order to ensure smooth and safe operation.

Problem

The company trio-Eloxal GmbH & Co. KG required a cover for its sealing bath in the anodizing plant that had to withstand high temperatures of 96° to 100° in order to ensure smooth and safe operation.

Solution

Our engineered balls offered the perfect solution for this challenging task. After careful analysis, we recommended the use of 50 mm HDPE balls, which are known for their temperature resistance and excellent insulating properties.

Advantages:

• Temperature resistance: The 50 mm HDPE balls are specially designed to remain intact even at extremely high temperatures. This makes them ideal for use in the trio-Eloxal compaction bath.
• Insulation: The balls completely cover the liquid in the anodizing tank, prevent boiling water from escaping and reduce steam to a minimum, making the working environment safer and increasing the efficiency of the compaction process.

Results

The implementation of our HDPE balls enabled trio-Eloxal to overcome the challenges of high temperatures in the compaction bath. The balls proved to be an effective cover, significantly improving both insulation and safety during operation.

customer testimonial

Tim Schauenburg, Managing Director at trio-Eloxal, was extremely satisfied with the results:

"We have been using the plastic balls from Euro-Matic GmbH since 2016 and, thanks to their good quality, they are in constant use. The following pictures show the insulating balls in use with boiling water in the surface finishing of aluminum and they completely meet our expectations."

ROI and profitability

Cost-benefit analysis

A detailed cost-benefit analysis shows that the acquisition costs for technical cover balls are quickly offset by the saved energy costs and the reduced maintenance costs.

comparison to other solutions

Compared to other solutions, technical cover balls offer a simple but effective method for reducing energy costs. Their flexible application makes them particularly attractive for automated production processes.

market overview and future prospects

Development of the market for technical cover balls

The market for engineered cover balls is growing steadily as more and more companies recognize and utilize the benefits of this technology.

Technological advances

As technology advances, engineered cover balls are becoming more durable and effective. New materials and production methods are contributing to this development.

Future challenges and opportunities

In the future, it will be important to further optimize the technology and expand the possible applications. This offers numerous opportunities for innovations and improvements.

Conclusion

The “Cover for sealing bath” project at trio-Eloxal GmbH & Co. KG demonstrates the high performance and reliability of our technical balls. This solution offers an effective and long-lasting way to meet the special requirements of aluminum surface finishing and thus contributes to the optimization and safety of production processes. The successful implementation underlines the quality and versatility of our products in industrial use.

FAQ's

What are technical cover spheres? Technical cover spheres are specially designed spheres that are placed on the surface of liquids in baths and tanks to reduce evaporation and save energy.

What materials are used for technical cover spheres? The spheres are made of materials such as HDPE, PP and PVDF, which can withstand extreme conditions.

How do technical cover spheres contribute to energy savings? The spheres form an insulating layer on the liquid surface, thereby significantly reducing energy consumption, especially in heated tanks and baths.

Are technical cover spheres safe for the environment? Yes, by reducing evaporation and preventing the release of hazardous gases, technical cover spheres contribute to environmental friendliness.

How long do technical cover balls last? The durability of the balls depends on the material used and the operating conditions, but they are generally very durable and offer a long-term solution.

Which industries benefit most from technical cover balls? Industries with energy-intensive surface treatment processes, such as the chemical industry, metal processing and electroplating, particularly benefit from the advantages of technical cover balls.