Characteristics of Picklex®
Picklex® - Eliminate acid, media
blasting, Phosphate, Chromate, Chemical Sealer & Rust Inhibitor
from Metal Pre-treatment Process
US EPA Tested/Verified :
Picklex® - Eliminate EPA & OSHA problems by an Unique Metal Surface
Preparation & Pre-treatment
Process for steel & aluminum
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Picklex® Product and Process Summary
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Picklex® is environmentally safe, non-toxic, non-hazardous, non-flammable, water-soluble and ready to use product (does not fall under any EPA, OSHA or DOT regulation).
Picklex® is used for metal surface preparation/pre-treatment (for both steel including stainless steel, aluminum, galvanized steel etc.), replacing all conventional hazardous/toxic surface prep/pre-treatment chemicals presently used for preparing metal surface before finishing, such as Acid, Phosphate, Chromate, chemical sealer, rust inhibitor etc. Picklex® Process produces much better quality final finishing with no waste disposal (does not even need any waste treatment or rinse water treatment). Also, this process removes light surface rust, weld scale and laser scale, eliminating media blasting or acid etching/pickling.
Note: This process eliminates all hazardous/toxic wastes from the metal surface preparation & pre-treatment process before finishing, which EPA (Environmental Protection Agency) has been trying to reduce for a long period of time.
Picklex® performs metal surface preparation and pre-treatment at the same time (cleans and coats at the same time) before finishing. Picklex® has no waste disposal (final rinse water also has no waste disposal) and no expensive waste treatment is necessary. The surface preparation & pre-treatment process (Picklex® Process) is a maximum four step process, where cold rolled steel and aluminum (including stainless steel and galvanized steel) can be used at the same time (conventional process uses two separate processes). Picklex® in one application, does multiple jobs at the same time, e.g., removes light surface rust, laser & weld scales, cleans & conditions the metal surface and converts 100% of the micro-rust/oxidation on the surface to a conductive, metallurgical protective coating (a composite conversion coating with negligible thickness), ready for any type of finishing. This process provides a zero rust and a contamination free steel and aluminum surface for excellent bonding and high salt spray hours (ASTM B117).
Picklex® has a large metal surface area coverage, which along with no disposal, etc. makes the process very cost effective.
No heavy metal in the final rinse water: Picklex® does not etch while removing surface rust, laser/weld scale etc., and therefore no heavy metal goes in the Picklex® bath or the final rinse water. The rinse water can also be continuously disposed to the drain. No chemical sealer is needed.
Note: Same product grade of Picklex® can be used for cold rolled steel including stainless steel, aluminum and galvanized steel in the same bath.
De-scaling hot rolled steel or heat treated metal: One-step de-scaling/de-rusting can be performed by Picklex®. There will be no sludge, waste disposal or waste treatment from this process.
Picklex® has high coverage and along with the other savings from eliminating steps, such as removing white rust, flash rust, weld/laser scales etc., this process is very cost effective and produces high quality results.
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Advantages of Picklex® Process over Conventional Process
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Eliminates all hazardous & toxic chemicals, such as acid, phosphate, chromate, chemical sealer etc.
- Uses less steps and space
- One short process for both ferrous and non-ferrous metals (such as, cold rolled steel, aluminum, galvanized steel etc.)
- No waste disposal and no waste treatment
- No heavy metal in rinse water
- No regular monitoring or concentration adjustment
- No sludge
- Picklex® bath does not get contaminated by rust/scale particles
- The finishing quality remains almost the same all the time
- No EPA or OSHA regulation
- Very cost effective - Cuts down lot of labor, time and maintenance costs
- Very less operator involvement, reducing operator errors
- Quick return on new set up (due to less equipment and set up costs)
- Reduces overall process time, labor and running costs
- Convenient, safe, ready to use and very simple process (dipping or spraying process)
- Eliminates flash rust or any oxidation problem
- Provides a rust/contamination free surface for better adhesion
- No cleaning of tanks needed
- Continuous process with almost no down time
- Easy clean up with water
- Cleaner & healthier working conditions
- Reduces quality rejections to almost zero (such as, bonding failures etc.)
- Provides very long term indoor rust protection (in terms of several
years) without finishing (for in between transit or storage time before
final assembly and finishing)
Industrial applications: For surface preparation and
pre-treatment of ferrous & nonferrous metal (including stainless
steel & galvanized steel) before Welding, Priming, Liquid painting,
Powder coating, Galvanizing, E-coating, Chrome plating etc.
De-scaling/de-rusting of hot rolled steel and heat treated metal.
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Picklex® - Zero Waste Disposal from Metal Surface Preparation & Pre-treatment Process for steel & aluminum
PICKLEX ® does not lose the strength or concentration while in use and therefore there is no waste. Also, it maintains the pH level automatically, and no monitoring of pH is needed. If PICKLEX® is kept in a fairly clean condition by proper filtering, it is a continuous process with Zero Waste Disposal. (just filling up the used chemicals)
NOTE : If the metal parts are in a good condition after de-greasing and rinse (that is, if the steel parts has very less visible surface rust or in case of aluminum), there may not be any need of a filtering system for the PICKLEX® tank
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Eliminate Flash Rust Problem
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Eliminate Flash Rust problem from Metal Finishing Process
In traditional way of cleaning and pre-treatment of metal, different hazardous and toxic chemicals are used. After the cleaning is complete, because of in between rinsing with water, the rust starts forming immediately (flash rust). Even if a rust inhibitor or phosphate coating is applied on the metal surface after rinsing, a thin film of micro-rust has already formed on the surface, which stays underneath and will grow later on, making the life of the finish top coat shorter. In case of PICKLEX®, the metal parts are cleaned and coated at the same time and does not allow any rust or oxidation to form on the surface.
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Pickling/De-Scaling/Conditioning/Coating After Heat Treatment of Metal
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Picklex® - One Step Metal De-scaling/Pickling/Coating Process
Heat treated metal can be dipped in PICKLEX®, where de-scaling, pickling, conditioning of metal are performed in one step and the metal surface is provided with a conductive, metallurgical protective coating at the same time. The metal surface is now ready for welding, liquid painting, powder coating, e-coating, electroplating etc. (also the protective coating will provide a very long term rust protection during storage under covered area without any top coating or during shipping under covered area). No Hydrogen embrittlement is caused by this process. This process replaces the present acid pickling process through phosphate treatment and has no Waste Disposal, no Waste treatment and no Sludge.
Please look at the article in "Fastener Technology International Magazine" about electroplating heat treated fasteners after one-step de-scaling/pickling/coating by PICKLEX® without using any other chemical.
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Hot Rolled Sheet Metal
after Picklex® Treatment
(Left Side)
| | Original condition of the Hot Rolled Sheet Metal
with Mill Scale and Surface Rust
(Right Side)
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Storing and Shipping of Metal
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Picklex® - Very Long Term Rust Protection during Metal Storage & Shipping
PICKLEX® coated metal can be stored for a long period of time without painting, if kept under covered area. There is no product in the market which will store metal without rusting for such a long period of time, with the metal surface already prepared for subsequent operation. For shipping with just PICKLEX® coating, cover with Plastic or ship in a closed compartment to prevent contact with large amounts of water.
Note: A piece of rebar (shown in the picture) was coated with PICKLEX® only (without any top coating), and was kept inside the warehouse since March 1994. As of now, no visible rust has formed on the surface.
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