Significantly Reducing loss of added value
The aim of every production is to maximise the quality of products while minimising waste. Nevertheless, if a component is classified as out of order, a short-term and sustainable solution is required to prevent a potential loss of added value.
Expensive parts that, despite careful manufacturing, develop micro-cracks do not need to be scrapped. Impregnation is a state-of-the-art method by which defective parts are processed and returned to production with their quality requirements restored. The cost of impregnating a part amounts to only a fraction of what the component caused leading up to the complaint. As a result, impregnation contributes significantly to streamlining and cost reduction in production, helping to eliminate the risk of further complaints in post-production.
Antrok offers the impregnation of metals and plastics of all types using our special vacuum impregnation process. With our modern impregnation plant, we treat your components with high-quality synthetic resin and seal micro-cracks and small specks to ensure the required component quality.
Antrok specialises in impregnation for the automotive industry. We guarantee maximum flexibility. To ensure the just-in-time manufacturing of your components, we work around the clock in 3 different shifts with a capacity of 0.8m3 per rack. In doing so, we adapt to your needs in a flexible way. We remain in constant contact with our partners on the customer side, implement your requirements and even make daily output announcements.
RELIABLE SEALING OF YOUR
- Individually tailored process solutions
- Collection service using own fleet of vehicles
- Inspection of incoming goods by trained personnel
- Part-tracing via DMC code
- Impregnation of metals and plastics
- Quality inspection by means of UV light after impregnation (100% test upon customer request)
- Registration, Documentation and shipping
High-Quality materials and efficient plant Components
The key element during impregnation is the casting resin used. By using the high-quality Maldaner IM3000 in the machining of your components, we benefit from the unparalleled quality of the market leader. The IM3000 is subject to strict quality checks and is the licensed casting resin for all well-known national and international automobile manufacturers.
Your casting parts are impregnated in fully automated systems individually adapted to our requirements by Antrok Automatisierung – or Antrok Automation. The expansion of a standard system with a second manipulator and polymerisation tank makes it possible to adapt the throughput capacities flexibly and economically to the quantity.
High-quality impregnation resin
When choosing our impregnation resin, we insist on the highest levels of quality:
|Density (20°):||1,04 g/ml|
|Viscosity (20°) of the Frikmar cup no. 3:||27s|
|Vapour pressure:||< 15 Pa|
|Temperature resistance (hardened):||-110°C to +200°C|
1 - Preparation
2 - Mounting the racks
3 - Loading
4 - Vacuum / Resin basin
5 - Centrifuge
6 - Sinks
7 - Polymerisation
8 - Cooling and repacking
9 - Quality control
QUALITY ASSURANCE AT EVERY STEP
Antrok is certified in accordance with DIN ISO 9001:2015. This means that its QMS, which is used throughout the compony, has proven itself as functional and consistent. Our guaranteeing of quality is based on four important components.
All processes in the receipt of goods, production and shipping of goods are clearly defined with regard to material flow. Materials are transported internally via set parking spaces following the warehouse management principle of first in, first out. Lean systems ensure that the unmachined and finished parts cover the shortest possible distances.
Water quality plays a crucial role in impregnation. All system parameters, such as pH value, temperature, water quality and resin content, are checked and thoroughly documented at every shift change. The demineralised water needed to prevent mineral residues in our impregnation process is produced in our own reverse osmosis plant and is continuously monitored by machines.
VISUAL INSPECTION AND QUALIFICATION
After each cycle, the impregnated components are inspected visually under cold light for any resin residues. By evaluating key performance indicators, we can monitor the degree of fulfilment in terms of quality and productivity. In order to continuously improve, our employees working in these areas receive regular technical and quality training.
By applying the principles of total productive maintenance (TPM), a number of maintenance and inspection measures can be determined so as to guarantee the continuous availability of production. The causes of failure can be prevented by changing wear parts in a timely manner and on the basis of their condition and by on-site employees maintaining and repairing the plants. All measures are documented in a maintenance database.