Fully Automatic Plating Plants are used in the metal finishing industry to carry components held commonly in Racks or Barrel, mechanically through a number of treatment cycle Tanks, by means of PLC operated transport wagons.

The advantages of “KCPL” Automatic plants are direct savings in labour cost, Better process application & production control, Improved solution maintenance and quality control, Lower floor space, Possibility of larger and deeper Tanks with larger and heavier rack sizes. Better control of dragout, Lesser danger of solution contamination, Efficient fume extraction and ventilation, High quality ETP process and so on…….all leading to a high rate of economy in production costing.

KCPL plating and metal finishing plant includes manufacturing of complete Plant such as Process Tanks & Ancillaries, Flight Bars, Material Handling Systems, PLC Automation, Centralised Control Panel, Fume Exhaust System, Heating System, Cooling System, Effluent Treatment Plant, Service line connection, etc. * Installation * Commissioning * Maintenance * After Sales Service backup. We can undertake complete responsibility for all peripheral aspects of an automatic plant as featured above including training of operated personnel. We have our own specialist staff for installing the plant and equipment so as to enable smooth, dependable and successful commissioning with our responsibility.

Water Demineralisation is a process of removing mineral salt from the water. Only those substances which ionise in water can be removed by this process before it can be used for any Industrial Applications.It contains two resin columns.

CATION EXCHANGER COLUMN :

Strong Acidic Resins to replace the metallic cations with hydrogen ions. When no more hydrogen ions is available for exchange, it must be regenerated with HCl.
ANION EXCHANGER COLUMN : 
Strong Basic Resins to remove anions of both strong and weak acids and producing water which is sensibly free from dissolved solids. Regenerated by passing Caustic soda.
RAW WATER QUALITY :

The raw water should preferably be municipal tap water at ambient temperature, free from colour suspended matter, turbidity, free chlorine, heavy metals, oil, etc. Boring, Well, River bed and turbid water will demand analysis and vigorous pre-filtration before passing through the "DM. Plant”
TWO-BED SYSTEMS (K SERIES) : 
Our two-bed demineralisers are used where water containing as little as 5 ppm of dissolved solids or conductivity less than 25 µs/cm is required. Choose from a range of models to suit exact needs available in PVC, FRP, LDPE & MS Rubber lined columns, charged with resins, multi-valve controls, conductivity cell.

Special Barrelling Units are made to meet production requirement. The unit on left side is for a hoist lifting mechanism having plating & rinsing tank attachments, while on right is two Barrels plating set up with fittings for doubling output. Any type of tailor made Barrel can be designed and fabricated. from 5 kg to 80 kg capacity.

For bulk plating of the small articles and samplings the barrels plating has been considered the most economical method because of low labour cost and elimination of racking and rack maintenance.

A complete range of manual and automatic plating barrels as small as 5” x 3.5” A/F to as large as 48” x 18” A/F and also custom built.

PORTABLE PLATING BARRELS : Miniature Barrels

This fully immersed polypropylene / perspex barrel is suitable for 0.5 to 2 Kg. plating range. The barrel is powered by geared motor, 12 volts D.C. (with power drive) or A.C. geared motor. The tank of PP/PVC / Perspex fitted with Bus-Bars & Danglers. Optional : Heater, Air Agitation, Cathode Movement, Filter, Rectifier etc.

This basically involves a tub or 'U' shaped duly rubberlined barrel to hold polishing media (chips), either dry or water with chemical compounds. The unit is mounted on a sturdy frame. Powered by eccentric motor of 3 hp, 440V spring mounted to impart maximum vibration in output; supplied with or without rectangular outer cover body & noise-free lid.

Connectors made of Brass are available in single way and double ways. The dia of connectors will be ½", 3/4" & 1" or higher sizes. Also available clamps for strip conductors; cable and bus bar connections.

Heavy Duty Buckets are available in capacity: 10, 15 & 25 litres, with or w/o perforation for dipping and rinsing operations. Also available tailor-made PP/PVC baskets with or w/o perforation.

These fabricated Baskets and Trays are suitable for alkaline cleaning and acid dips. Made out of Stainless Steel/M.S./Titanium wire mesh or perforated sheets, in sizes from 6” x 5”ht. onwards, with fixed or collapsible handle. Rectangular trays are also available from 10” x 6” x 2” ht onwards with fixed handle, for multiple purpose utilities.

Today we have several options to select the material of construction in plating Tanks for solving corrosion problems. They are durable and cost effective. Plain double welded tailor-made self-supporting tanks of any shape & dimension and volume as desired can be adopted for Storage, Electroplating, Electropolishing, Anodising, Phosphating, Pickling and other Process requirements. Fabricated from Rigid Polyvinyl Chloride (PVC), Perspex, Polypropylene, Linear Polyethylene, Polyglass (PP), CPVC, PVDF,Stainless Steel 304/316, Mild Steel etc. supplied with rim, reinforcement and legs. All the tanks externally coated with acid & alkali resistant epoxy paint or FRP in Isotholic, Bisphenol or Vinylplasters Resins.

The plain fabricated tanks can be supplied with "drop-in" liners internally to suit the individual process application. Lining such as Semi-hard Rubber, Lead (loose, patch bonding or full bonding), Antimonial/Lead. Tin/Lead lining, Stainless Steel, Rigid P.V.C /Polyglass (P.P.) / PVDF Flexible (PVC) / CPVC, Fiberglass-reinforced Plastics (FRP) Spray Galvanising, etc. are in general for various corrosion resistance applications.

Heavy duty buffing machines from 0.25 to 7.5 H.P. are available in two or four ball bearings. Construction of the machines are made sturdy and robust to offer vibration free performance. All Bench Polishers are equipped with reversely, threaded tapered spindles to take buffing mops.

These are small application oriented filter units, especially designed for precious metal plating operations. Table top model with plate type filter stack, portable, mostly with magnetic drive, sealless, PP Chemical Pump powered by 1 or 3 phase motor.

Cartridge type filtration units comprising of seal type PP chemical pump or sealless magnetic drive powered by AC motor of PVC, PP or CPVC non metallic corrosion proof maintenance free filter chamber (also in S.S.) with cartridge type filter elements and standard fittings. Available in a wide range from miniature to Industrial models :

(Bag, Carbon or Cartridge individually or in combination) : This is an on-line filtering device with or w/o pump set for flow upto 5000 lit/hr. upto 10 micron with replaceable filter bags, activated carbon or filtering cartridge. Must for contaminated plating solution or water containing excessive dissolved solids, thereby enhancing efficiency of filter / DM water plant.

This custom fabricated special equipment is for multi-purpose utilities like Hot Water Curing System or Evaporation of Drag out, Process baths, Rinses to reduce Waste Water Volume. The concentrate is returned to the process or pumped out for disposal. Single or double chambered in MS, SS, (also in PVC or PP) with sources of gas, steam and electric heat, controllers and safety fittings. Additional fittings like transfer pump, combination of auto-fill and clean out systems, steam or hot water steam atomizing chamber, etc.

For steam heating and hot water or cool solution, normally Titanium Coils are used. Also used are Stainless Steel, Tantalum & Zirconium. Built to customer's specific requirement such seamless coils are fabricated to the shape & size and tested.

Titanium Jigs, Fixtures specially for PCB Plating, Anodizing and other industrial usages are fabricated as per Technicalities. Fasteners like Bolts, Nuts Washers, Screws, Rivets, Hooks etc are purely tailor made as per BSW, BSP, Metric, UNC, UNF, NPT & BSPT specifications.

Komal Chemiequip manufactures Titanium Anode Baskets for Acid Copper Plating, Nickel Plating / Forming, comprising of pure titanium sheet and expanded metal with suitable reinforcement and sturdy hooks for load and current carrying capacity. Sizes varying from 4.5” to 12” width, 1” to 2” thickness and 6” to 48” height, in vertical shape. Other shapes like Horizontal, Round, Bend, and special baskets for Printing Rollers in 'U' shape are also available Dipping Baskets from expanded mesh or perforated sheet.

ANODES Are commonly available in form of Plates, Flats, Oval, Dog Bone, Rounds, Nuggets, Balls, Pallets, Crowns or Coins, for plating like:

Nickel: 
Nickel squares, plates, flats and 'P', 'R' & 'S' Rounds, Coins or Pellets.

Chrome: 
7% Antimonial/Lead or 7% or 10% tin / lead alloy anodes in plates, corrugated flats, rods (round) or Bonded on MS core.
Cadmium: 
Cadmium plates or flats or rods (round or oval) or sphere balls or nuggets.
Copper: 
For Acid Copper Bath : Phosphorised Copper Anodes and for Cyanide Copper Bath : Cast/Rolled Electrolytic Copper Anodes in plates, flats, rods(round, oval or dog bone) or round balls/ nuggets.
Zinc: 
Zinc Anodes as per the shapes of copper anodes. For acid zinc plating special high grade zinc slabs (99.995%) to be used.
Tin: 
For alkaline & acid tin baths, Tin Anodes in shapes like Copper Anodes, or 90% Tin / Lead alloy are also available. 
Solder: 
Solder Anodes of 60:40% or 63:37% (tin lead) like that of Copper Anodes.
Silver: 
Silver Anodes of 99. 99% can be supplied in shapes & sizes.
Gold: 
Carbon Anode/S.S. Anode of 316 qualities / Graphite Anode or Pt.Ti. Mesh.

Anodising: 
CP Lead Cathodes as per requirement.
Cleaning: 
S.S. Cathodes/Anodes as per requirement.

The state of art, solid state, thyristorised, high precision, ripple free, constant current and constant voltage, air cooled, compact Rectifier units are single phase input, high quality, maintenance free, with CVCC modes, coarse and finer Potentiometer controls for both voltage and amperage, ripple less than 1% on full load, digital meters with overload protection and short circuit proof, easy operation.