Company Announcement - Thermaspray takes surface coating technology to the next level as the first company in South Africa to introduce an array of coatings from Plasma Coatings in the USA, at world class standards.

Plasma Coatings combine the advantages of thermal spray (metal) coatings with polymer based top coatings to offer benefits of wear resistance, slip and traction. The metal base layer provides a hard durable wear resistant surface that protects components from wear due to mechanical or contact related forces. When a low coefficient of friction (low or zero traction) is required, polymer top coatings are applied to machinery components to reduce the traction and increase the release. A hydrophobic (water-resistant) and oleophobic (oil-resistant) non-stick surface is created to prevent sticking of materials such as food ingredients, adhesives or rubber which slip/slide over the components without adhering to it. For applications that require traction, a surface traction coating is available which eliminates slippage by combining the unique properties of surface traction and release.

Thermaspray Managing Director, Dr Jan Lourens, explains that this technology has not been supplied in South Africa before because up to now, the combination of thermal sprayed coatings and polymer coatings have not been available within one company. “We identified a distinct gap in the market for this type of coating which, by reinforcing the wear surfaces, achieving consistent performance through improved machine traction or allowing materials to slide (zero traction), deliver numerous times and cost saving benefits for end-users. This technology can extend component life up to 10 years and reduce costs by as much as 30%. A reduction in mean time between component replacement combined with savings such as cleaning materials as the easy-to-clean surfaces need less frequent cleaning, result in increased uptime and production."

“With Thermaspray’s long history as one of the best applicators of thermal spray coatings in South Africa, it made sound business sense to extend our capabilities,” continues Dr. Lourens. “Consequently, we bought in the ability to apply the polymers in partnership with Plasma Coatings USA, a Division of American Roller Company.” With Plants located in the USA (Wisconsin, Tennessee, Texas) as well as in China (Shanghai), Plasma Coatings has 45 years’ experience and know-how in plasma coating technology.”                                                                                   

Thermaspray which is a formal licensee of Plasma Coatings, has made a substantial investment in bringing the technology to South Africa. “We purchased new equipment including polymer spray systems and curing ovens and converted a current spray booth to meet all the necessary application standards for plasma coatings,” adds Dr. Lourens

The plasma or polymer spray system is a dual coating consisting of a base or matrix coating which is applied as a thermal spray coating followed by the application of a final layer of polymer coating on top. Thermal spray is the method of applying materials onto a prepared base material by heating particles in the stream of a heat source, creating a semi-molten state. Particles are then propelled by high velocity onto a prepared substrate where they adhere to the base surface via a mechanical bond.

The base coating is applied with one of four different types of thermally sprayed coating techniques or processes i.e. Combustion Wire Metallising, Electric Arc, Plasma and High Velocity Oxygen Fuel. Polymers, available typically in the .03 - .08 mm thickness range, are largely applied through dispersion or electrostatic systems with Fluorocarbons, Fluoropolymers, Silicones, Epoxies or Teflon® industrial coating. Plasma coating can be applied to aluminium, steel, stainless steel, tool steel, copper, ceramics, and synthetic materials.

The Plasma Coating range will benefit a wide range of diverse market sectors such as food processing, packaging, printing, tyre and rubber, paper & pulp as well as plastics industries. Environmentally friendly and FDA compliant, plasma coating can be safely used in the food processing industry to eliminate the sticking of food ingredients and prevent corrosion. In the packaging industry plasma coating reduces surface adhesion which speeds up product throughput in chutes, hoppers, etc. Plasma coating will save time and money for the plastics industry and tyre industries by facilitating the removal of materials from moulds and eliminating the need to reapply mould release sprays. The application of plasma coatings will protect boilers and digesters in the paper and pulp industry from abrasion, erosion, etc.

Dr. Lourens says that although the introduction of a new product into the market takes time, he is confident that plasma coatings will be widely accepted in the market due to the many cost and time saving benefits offered by this world class technology. “Industries who are currently having to follow the expensive route of replacing parts with new components from OEMs or who are repairing components with alternative and often inferior types of coatings i.e. polymers that do not have a Thermally Sprayed matrix (base) coating, stand to gain significant time and cost saving benefits from plasma coatings,” he concludes.

Thermaspray is an ISO 9001:208 Quality Management and Eskom Level 1 certified company that was established 17 years ago following the commercialisation of the Council for Scientific and Industrial Research’s (CSIR’s) Thermaspray and Repair Group. From its Olifantsfontein, Johannesburg headquarters, the company offers a full range of wear- and corrosion-resistant thermal spray coatings, Plasma Transferred Arc (PTA) cladding and a host of specialised allied services to OEM customers and end-users throughout South Africa. In addition to providing a comprehensive range of support coating finishing technologies including machining, grinding and burnishing in the bespoke finishing shop, Thermaspray also refurbishes industrial components damaged by friction, erosion, corrosion or cavitation.