We supply the Sugar Industry with coating protection solutions used to combat harsh wear and tear on equipment. This includes, but is not limited to: Sugar Cane Cutters, Hammers, Shredders. Sugar mill equipment is also subject to non-slip and non-stick coatings, as well as adhesion, hard-facing and protective coatings.
The above video shows you a Saint Gobain TufCote® Grade M, 6.3mm diameter being applied to a Sugar Cane Hammer. This is the best product for abrasion resistance and lays between 3 to 5mm thickness in a run.
The powder welding process utilises an Oxy-Acetylene flame which is ideal for the deposition of smooth, thin, well bonded layers onto a wide range of substrates, including cast iron. The hard-facing takes place at lower temperatures, which minimises oxidation and distortion of the workpiece and enables easy surfacing of edges.
The Oxy-Acetylene Flame Spraying process followed by subsequent fusing as a two-stage process, after spraying the coating is fused with an oxy-acetylene burner or for mass production by using induction heating or in a vacuum furnace allows the coating to be metallurgically bonded, extremely hard, corrosion resistant and resistant to impact and chipping. The powders used for spray and fuse hard-facing are typically compositions of Ni, Cr, Co, Bo, Fe, W and WC in varying blends.
The necessity for cutting/slashing and ploughing in the Sugar Industry means that the components used are subject to very abrasive and corrosive conditions, in their day to day use. Metal/thermal spray coatings and hard-facing can provide solutions for wear and corrosion resistance, as well as extending life and increasing performance of equipment in the Sugar Industry.
Components that can be coated include, but are not limited to:
- Cane knives.
- Sugar beet mill pump casing.
- Sugar beet bucket hooks.
- Sugar cane crusher roll bearing and journal.
- Sugar cane crusher rolls.
- Sugar cane shredder.
- Sugar cane cutter teeth.
The metal spray and hard-facing processes use various forms of equipment that employ wire, powder and cord to deliver the required solutions.
Every issue of abrasion does not involve the same solution and therefore requires a careful study of each individual or specific application according to:
- Type and size of the abrasive material.
- Abrasion rate, temperature, impact occurrence.
- Geometry, size and the weldability of the part.
TufCote® "rope like" hard-facing electrodes to improve abrasion and erosion resistance. It is brazed using an oxygen-acetylene torch and can be welded onto mild steel, low carbon steel, low alloyed steel, stainless steel, lamellar grey cast iron, spheroid cast iron. It can also be brazed on to certain alloys of manganese steel with precautions. TufCote® is weld-able on itself, making local repair or recycling of parts possible.