Bonderite E-CO DMC Ready for Data-Driven Industry 4.0 Applications

Henkel has introduced a new process control system addressing key challenges in metal pretreatment, as customers increasingly seek to implement data-driven Industry 4.0 solutions. Alongside the company's New Generation Conversion Coatings (NGC) for multi-metal substrates, the Bonderite E-CO digital multi-channel (DMC) control unit delivers maximum corrosion performance and sustainability at minimum process costs. Bonderite E-CO DMC is a process control system that allows users to operate complex metal pretreatment lines with up to fifteen or more stages. It features an intuitive touchscreen PLC interface and supports fully digitalized process control with flexible communication and remote access functionality. Maurizio Brancaleoni, Global Business Development Manager at Henkel's European Functional Coating Equipment Center in Funo di Argelato – Bologna, Italy, said: "Thanks to its adaptable open system architecture, our new digital multi-channel control system will integrate easily into our metal customers' existing conversion processes and automation concepts." "Combined with our New Generation Conversion Coatings, this system maximizes the benefits derived from Henkel's leadership in sustainable metal pretreatment technologies and process expertise." Bonderite E-CO DMC minimizes chemical consumption, water and energy usage, and waste. Additionally, it helps prevent manual handling and chemical exposure in metal pretreatment.

All equipment and process setup, adjustment, control and monitoring, bath preparation and replenishment can be effectively managed by the controller. The multi-channel system supports both single and multiple production lines in the same or adjacent buildings. It can control virtually unlimited numbers of process parameters and devices.

Furthermore, Bonderite E-CO DMC is equipped with internal memory that stores all parameter data and events to generate numerical, graphical and consumption reports and maintain a historical database. The controller's comprehensive connectivity easily links the system to other resources in local area networks and provides access to remote devices such as tablets and smartphones. It enables sending alerts with specific data to selected recipients via SMS or email and can be integrated into cloud-based data-driven solutions. Brancaleoni adds: "The system underscores Henkel's total solution approach and our commitment to supporting customers in implementing Industry 4.0." "Users can perform automatic parameter controls and even automate chemical dosing in tanks using a special function to correlate analyzed data with outputs – and all of this can be done without involving field personnel." The performance advantages of Bonderite E-CO DMC are available with any of Henkel's existing metal pretreatment processes, including conventional phosphating, while the technology combined with the company's New Generation Coatings demonstrates maximum sustainability. As zirconium-based alternatives for multi-surface metal conversion and corrosion protection, these New Generation Coatings (NGC) contain neither phosphates nor heavy metals, simplify water management and can reduce process steps, contact times, energy consumption and sludge. Leaving only a nano-thin, non-toxic coating layer on surfaces, Henkel helps customers optimize production costs, control and reliable quality. The European Functional Coating Equipment Center in Funo di Argelato (Bologna), Italy plays a significant role in the success of Henkel's innovative new metal pretreatment solutions through a dedicated series of Bonderite process control and automation systems. The center comprises a Development Department, a Storage and Service Laboratory. The Bonderite E-CO DMC system is available in Europe and North America and is part of a comprehensive group of application, control and support equipment for Bonderite metal pretreatment processes from Henkel.