From performance to process impact: the new questions in aluminium pre-treatment

The playing field in aluminium pre-treatment is shifting. Where the discussion long centred primarily on corrosion protection, paint adhesion and line performance, new considerations are now entering the picture. The use of recycled aluminium is increasing, the comparison between pre-anodising and chemical pre-treatment remains relevant, and at the same time energy consumption, wastewater, CO2 footprint and future regulation are weighing more heavily in technical decisions. What does this mean in practice? In a panel discussion, Xavier Michiels, director of Alulack, and Roland van Meer, Business Unit Manager at AD Chemicals, share their views on the questions currently occupying the market.

Recycled aluminium: technically feasible, process-critically more demanding

That recycled aluminium is being used increasingly is, according to both speakers, no temporary development. At the same time, this trend places different demands on pre-treatment. Roland van Meer: “Recycled aluminium can be powder coated perfectly well. The challenge lies primarily in the variation of the substrate and in how robustly your process is set up to handle it.”

At Alulack, that process setup has now taken concrete shape. Together with AD Chemicals, a pre-treatment system has been established that is tailored to processing recycled aluminium, in which Cleaner 602 plays an important role. Xavier Michiels: “When the uniformity of the material decreases, your process margins become smaller. You then need to be sharper on process control to maintain the same consistent quality.”

Practice thus shows that the question is not only whether recycled aluminium can be used, but above all how to organise your process so that quality remains reproducible. That is precisely where the market’s attention is increasingly shifting.

Roland van Meer and Xavier Michiels brainstorming about the future

Pre-anodising or chemical pre-treatment?

Another recurring question in the market is whether pre-anodising demonstrably outperforms regular chemical pre-treatment. To avoid basing that discussion on assumptions, Alulack and AD Chemicals objectively compared both routes in a benchmark, using the Qualicoat Seaside requirements as a technical reference framework.

Performance was assessed in areas including salt spray and filiform corrosion. According to Xavier Michiels, this produced a clear picture. “We did not want to conduct this comparison by gut feeling, but on test results. In our research, we saw no notable difference between the two systems.” Roland van Meer also sees an important lesson for the market in this. “Pre-anodising is technically applicable, but if a chemical pre-treatment system already demonstrably meets the specified requirements, including Qualicoat Seaside and 2000 hours AASS, you have to ask yourself whether a heavier process actually offers added value in practice.”

That question is precisely what makes the comparison relevant. Not only the technical outcome matters, but also the broader impact of a process. When performance is at least equivalent, energy use, CO2 impact and process complexity automatically become part of the consideration. In that respect, choosing pre-anodising is less obvious, as it is less favourable in terms of energy and CO2 impact without demonstrable technical added value.

New market question: not just does it work, but what does the process as a whole require?

According to Roland van Meer, that is precisely where the shift now becoming visible in the market lies. “The question is increasingly less about whether a system is technically compliant. Companies are also looking more explicitly at energy consumption, wastewater, CO2 footprint and the broader impact of their process choices.” For Alulack, this is no abstract theme. Energy consumption in the line has become a concrete point of attention. Xavier Michiels: “Today you look not only at what is technically possible, but also at what remains responsible and manageable in the longer term.”

One example is the etching process, which is configured at 20°C within the applicable Qualicoat guidelines. This highlights an important tension: high quality standards remain paramount, but are increasingly combined with the question of how processes can be made more efficient and future-proof. At the same time, Alulack and AD Chemicals are working on a next step: research into recycling of the etching process. This should provide insight into possibilities for using raw materials more efficiently, further reducing waste streams and lowering the environmental impact of the overall process. This shifts the focus from optimisation within the existing process to structurally smarter design of the process chain.

CO2 footprint: not yet a standard question, but clearly on the rise

The question of CO2 footprint is, according to both speakers, not yet asked explicitly on a daily basis, but the topic is clearly moving forward. Xavier Michiels: “We do receive questions about it occasionally, but not yet structurally. At the same time, you can see the topic coming, particularly from larger international parties.”

This aligns with broader developments in the chain, such as stricter transparency requirements and the rise of digital product passports. Roland van Meer expects measurability to carry more weight in the coming years. “CO2 footprint, raw material use and process impact will increasingly become part of technical and commercial assessment.”

This also changes the way pre-treatment is evaluated. No longer solely on test results, but increasingly on the combination of performance, consumption, emissions and future-proofing.

Wastewater and regulation are pressing more strongly on process choices

Legislation and regulation are also increasingly influencing considerations. In practice, wastewater often comes to the fore first. Almost every company in the sector must contend with stricter requirements around discharge, monitoring and environmental performance.

According to Xavier Michiels, this is now everyday reality. “Wastewater is an important topic. You notice that requirements are becoming stricter and that you have to actively configure your process accordingly.”

This makes themes such as filtration, reuse, closed systems and recycling more relevant than ever. Roland van Meer: “The sector will have to deal with this. You then need not only good chemistry, but also a broader vision on water flows, recycling and future compliance. Working fluoride-free is, in my view, also very much part of that development.”

Process knowledge becomes a differentiating factor once again

In a market where demands on reproducibility, sustainability and compliance are increasing, process knowledge is once again becoming a determining factor. Not only the chemistry, but above all mastery of the total process makes the difference. Xavier Michiels: “Bath control is essential for us. We want to know that the process is well set up and remains so.”

According to Roland van Meer, the theme of process knowledge touches on an important point for the entire sector. “It is not only about knowledge of the product, but above all about insight into the total process chain and the ability to make timely and targeted adjustments.”

That is precisely where the core of current market developments comes together. Aluminium pre-treatment is no longer evaluated solely on performance, but on the total impact of the process. And that is exactly where the conversation is shifting today.

Authors: Roland van Meer (AD Chemicals) and Xavier Michiels (Alulack)

From performance to process impact: the new questions in aluminium pre-treatment

Recycled aluminium: technically feasible, process-critically more demanding

Categories

Pre-anodising or chemical pre-treatment?

New market question: not just does it work, but what does the process as a whole require?

CO2 footprint: not yet a standard question, but clearly on the rise

Wastewater and regulation are pressing more strongly on process choices

Process knowledge becomes a differentiating factor once again

Newsletter

Metal Surface Treatment

AD International B.V.

+31 (0) 167 526 900

Visiting address

From performance to process impact: the new questions in aluminium pre-treatment

Recycled aluminium: technically feasible, process-critically more demanding

Categories

Pre-anodising or chemical pre-treatment?

New market question: not just does it work, but what does the process as a whole require?

CO2 footprint: not yet a standard question, but clearly on the rise

Wastewater and regulation are pressing more strongly on process choices

Process knowledge becomes a differentiating factor once again

Newsletter

Share this entry

Metal Surface Treatment

AD International B.V.

+31 (0) 167 526 900

Visiting address