PVD Coating System Case Study: Kitchen & bath fixture supplier achieves a significant ROI with optimized coatings applied in-house
PVD systems apply functional, durable, and decorative hard coatings that improve and add value to parts and products in many industries, including transportation and energy, medical devices, industrial tooling, home and luxury goods, consumer electronics, and sporting goods. This VaporTech case study explains Brasstech’s experience with PVD coating systems.
Brasstech (manufacturer of Newport Brass® and Ginger® brands kitchen and bath products) knows what it takes to differentiate from competitors. Operating successfully for more than 30 years, the plumbing fixtures leader first saw a need for higher-quality finishes in 1989 when it installed its first in-house physical vapor deposition (PVD) coating system.
By 2015, this equipment no longer met the company’s growing needs. Brasstech evaluated finishing options, which included powder coating, lacquering, e-coating, and electroplating. In the end, the company chose to continue and expand its successful PVD coating options and created a list of requirements for a new system:
A single system that can apply durable coatings to various
- part sizes and geometries in multiple colors.
- Easy-to-operate equipment with low maintenance
- requirements.
- Attentive customer support
- and strong process development capabilities.
- Low operation and maintenance costs, as well as efficient use of consumables.
- Minimal changes to the
- manufacturing floor.
Making the best decision in PVD coating machines
Brasstech was looking for a single system capable of applying durable coatings to various part sizes and geometries. The machine had to meet volume requirements and operate easily and efficiently. The company also needed an external resource for new finish development.
Brasstech evaluated available PVD coating systems and found only one that met all its requirements. The system Brasstech ultimately chose had to provide the required throughput and operational flexibility, a superior lower-temperature cathodic arc process, and coating development scientists to create and test new coatings. The system’s proprietary process could deposit durable, decorative, color-fast finishes on Brasstech products cost-effectively. Brasstech chose the VaporTech® VT-1500i™ system.
In addition to the machine’s capabilities, Brasstech felt confident working with VaporTech, a PVD equipment manufacturer with a solid history and installations worldwide. Brasstech appreciated the commitment to helping customers understand costs, determine ROI, and effectively incorporate PVD coating systems into its manufacturing process. Finally, as part of the equipment purchase, VaporTech provided expert services from initial installation and training to continuing service and support.
PVD Coating System Case Study: Higher throughput, higher yield
The VT-1500i system ran after only two weeks of process and maintenance training for manufacturing plant employees. “Installation went like clockwork,” Brasstech’s plant manager reported soon after, “The VT-1500i is so simple, we had five employees with no knowledge of PVD running the system right away.”
Since installing the VT-1500i system, Brasstech has incorporated the PVD finishing process into its brands. For example, the company converted one of its top products from plating to PVD for a harder, more durable finish. The VT-1500i system has also increased PVD throughput by 350% and boosted yields by 15%. The company has significantly increased its metallic color options while continuing to match legacy finishes. Most importantly, these coatings are more scratch-resistant, don’t discolor, and are easy to clean.
VT-1500i System
The VT-1500i machine may be an excellent fit for higher volume or quickly growing operations. This system provides approximately 70% of the throughput of our largest production coating system but in a very compact footprint when manufacturing space is limited. With the ability to coat parts up to 100 cm long and ten high-capacity racks, the VT-1500i system is a high-volume, price-competitive coating system for larger manufacturing operations.
VT-3000i™ System
The VT-3000i coating system is our highest-capacity machine, now available in a small footprint for easier integration and savings.
2min
Feb 5, 2020
