With its state-of-the-art e-coating line and associated in-house laboratory for corrosion testing, Malben Engineering is driving continuous improvement, safety and corrosion protection for South Africa’s automotive original equipment manufacturers (OEMs).
Click to download and read pdf
The ‘closed loop’ conveyor system guarantees repeatability in key areas, from ensuring that no process is omitted to achieving contact time repeatability, which is fundamental to quality and optimising repeatable coverage.
“Because of its constant drive to improve, it is a privilege to work in the automotive industry. Safety is an important cornerstone, and corrosion protection is part of this. Our success is built around pre-empting customers’ requirements – and ensuring we are not a passenger in the process.
A genuine partnership is defined by taking the lead and adding real value and innovation in one’s service offering, rather than just following,” says Luca Smargiasso, Operations Director of Tier 1 automotive component supplier, Malben Engineering.
When it comes to e-coating and powder coating, critical corrosion protection processes, Malben’s standards are already significantly higher than those of its OEM customers. “Our state-of-the-art e-coating laboratory constantly analyses real-time data – and everything is managed via our design of experiments (DOE) methodology,” Smargiasso points out.
Investing in corrosion control
The coating of automotive components has evolved significantly since Malben launched in 1974. The company established an in-house plating plant in 1997 and, by 2001, had upgraded the facility to an alkaline, iron-zinc electroplating process. In 2005, Malben set up its e-coating and powder-coating lines.
“Over the last few years, we have enhanced our processes to improve our e-coating facility in line with our customers’ enhanced corrosion protection requirements. More and more vehicles are being exported to highly corrosive environments. For example, a vehicle going into the Northern Hemisphere is going to be operating in a very demanding, corrosive environment, given the weather and the salt spraying done on those roads in winter,” explains Smargiasso.
Mirriam Ratlhogo, Electromagnetic Field (EMF) Plant Manager at Malben, explains that e-coating, electro-plating and powder coating resist chipping, scratching and corrosion.
A step-change in corrosion testing
Malben has invested in extensive in-house testing processes to access real-time data rather than waiting on third-party information: “This gives us a lot more flexibility. It enables us to analyse process improvement in short time frames and implement these changes quickly, which is important in an evolving environment,” Smargiasso continues.
Although more complex testing, such as cyclic corrosion, is outsourced, Malben’s fully equipped e-coating laboratory can perform wet analysis, assess coating thickness and e-coat solids, and determine electromagnetic field process compliance with C2, C3, and 1P85 WSS standards. The salt spray chamber facilitates accelerated corrosion testing through continuous fogging. Manual tests include scratch and rub tests to ensure the paint is properly cured.
“Batch size sampling is essential due to the high volumes of components coated. During every nine-hour shift, tests are conducted five times. By working to its own higher specifications and standards, Malben has ‘room to move’ and quickly implement any adjustments required,” Ratlhogo explains.
Above and beyond
Malben recently engaged with another supplier to advise on process improvements required to achieve OEM standards, says Quality Director, Werner Kapp: “They wanted to understand what we were doing differently, as we had passed the corrosion test with flying colours.
“Furthermore, during one of our scheduled cyclic corrosion tests last October, we requested that a third-party laboratory continue testing for an additional five weeks, despite having met the stipulated nine-week cyclic corrosion test requirements. This demonstrates how Malben goes above and beyond to ensure corrosion protection excellence,” Kapp advises.
Technical precision
According to Ratlhogo, the conveyor system running from pre-treatment through to the curing ovens is also integral to the coating excellence achieved: “The ‘closed loop’ conveyor system guarantees repeatability in key areas: from ensuring that no process is omitted, to achieving contact time repeatability, which is fundamental to quality and to optimising repeatable coverage. The design of experiment-approved loading jigs also helps to maintain workflow and ergonomics,” she explains.
Head of Maintenance Quinten Ballot adds that attention to detail and careful monitoring set the company apart and give it a competitive edge: “On the e-coating side, everything is minutely monitored. What cannot be measured cannot be managed. Even the burner in the curing oven has been upgraded. Now AI-enabled, it constantly learns from its environment, adjusting to ambient/seasonal temperature variances to optimise heating patterns and gas usage, without compromising quality.
Thanks to ongoing investment not only in the e-coating facility and laboratory, but throughout the company, the lifting of the bar never stops!” Ballot concludes.
Despite a strong focus on supplying the automotive sector, Malben Engineering’s products are also used in various other industries, including mining and the construction sector.