Cataphoric Coating Technology
Our Cataphoretic Coating System
Zanardo S.p.A. has commissioned a brand new powder-coating system integrated with cataphoresis treatment for the world of electrical panels. This is the largest and most modern system currently available from any manufacturer of electrical panels.
The coating works by full immersion, ensuring the protective film penetrates into every narrow opening and hole in the product. The entire painting process is fully automatic and monitored by software on a 4.0 digital platform, integrated into the internal management system.
We are the first in the electrical panel sector to use a Japanese epoxy cataphoretic product from the automotive sector which guarantees mechanical seal, elasticity, long life, and can be painted over.
The Process
Material Loading System
- 3 stations Material loading stations
- 3,500 m Track length for loading material (11,483 ft)
- 125 Individual hangers on the conveyor system
- 250 kg Maximum weight per hanger (551 lbs)
- 3.5 m/min Working speed
- 8 m/min Material movement speed
Cataphoresis Treatment & Powder Coating
- 800 m²/hr Treatable surface area per hour
- 54 m Treatment tunnel length (177 ft)
- 110°C Drying oven temperature for 15 minutes
- 90 m³ Double cataphoresis immersion tank
- 4 pieces Max simultaneous coating (H.2200 x W.3500 x D.1000 mm)
- 165°C Cataphoresis polymerisation oven for 18 minutes
- 2 + 1 Automatic + manual powder-coating cabins
- 170°C Powder-coating polymerisation oven for 20 minutes
- 3 stations Material unloading stations
Advantages of the Process
Guaranteed Film Coverage
Full-immersion cataphoresis ensures the protective film penetrates every opening, hole, and narrow gap in the product.
Reduced Coating Thickness
Advanced application technology reduces applied coating thickness while maintaining superior protection.
Double Baking Process
Products undergo two separate baking stages for maximum adhesion and durability of the finish.
High Production Speed
800 square metres of surface treated per hour with fully automated 4.0 digital platform monitoring.
Guaranteed Pre-Treatment
Six pre-treatment stages with nanotechnology passivation ensure perfect sheet metal cleaning before coating.
Low Baking Temperatures
Efficient curing at 165-170°C reduces energy consumption compared to traditional coating methods.
Longer Product Lifespan
Japanese epoxy cataphoretic technology from the automotive sector guarantees mechanical seal, elasticity, and longevity.
Environmentally Friendly
Closed-circuit purification system with liquid cataphoresis paint containing just 1.5% solvent. Sharp reduction in coating waste.
Fully Automated
Entire process monitored by software on a 4.0 digital platform integrated into the internal management system.
Inside the Facility
C4 & C5X Durability Classifications
Cataphoresis combined with special powder coatings is available on request for products installed outdoors or in aggressive environments requiring C4 degree of durability. With these treatments, products are 100% comparable to galvanised sheet metal.
We are currently developing a treatment cycle with C5X classification, achieving 1,200 hours in salt mist testing — the highest standard for corrosion resistance in industrial enclosures.
