New technologies based on special polymers have been recently developed to prepare surface for cold forming in alternative to phosphate. This technology that is sludge free and can be applied at temperature of about 40 °C has huge advantages in terms of energy savings and water consumption as well as for maintenance.
The polymer coating can be applied on wire after pickling but take the maximum of its advantage when combined with a shot blasting device as the process is then completely environmental friendly. There is no rinsing and in consequence no waste water treatment water requested anymore. There are also no corrosive fumes to neutralize. The polymer bath is working at a much lower temperature than the phosphating reducing consistently the energy consumption.
The polymer coating can be applied to the coils in a classical immersion bath but can also be applied by aspersion allowing to reduce the polymer bath volume.