Manufacturing Technology

A new system for alkaline zinc-nickel plating, certified by TÜV Rheinland, has been launched by MKS Instruments. The new Atotech Compact Membrane Anode (CMA) closed-loop system for alkaline zinc-nickel plating enables virtually wastewater-free operations while minimising waste generation and reducing carbon footprint.

Atotech is a brand within the Materials Solutions Division of MKS, which develops process and manufacturing technologies for advanced surface modification, electrolysis, electrolytic plating and surface finishing.

The new closed-loop system functions as an all-encompassing solution, covering every aspect of the alkaline zinc-nickel plating process, including rinsing. It features a CMA, custom chemical additives, a vacuum evaporator, and a freezing unit, all of which contribute to significantly reduced environmental impact, enhanced product quality and a longer lifespan for the electroplating line.

Reducing cyanide sludge

The new technology also prevents the formation of organic breakdown products such as cyanide, thereby substantially reducing sludge formation. Its integrated freezing unit also plays a crucial role in purifying the electrolyte by eliminating accumulated carbonate, which ensures exceptional quality and improved performance throughout the plating process.

Additionally, the system’s evaporation method separates the zinc-nickel electrolyte from water, at which point these products are recycled back to the plating tank and rinsing stations. As a result, the necessary disposal and treatment of zinc-nickel wastewater is reduced by an impressive 90%.

Sabine Sengl, global product director CP, MSD at MKS, commented that the new Atotech CMA closed-loop system is a “game-changer” for the zinc-nickel plating industry, adding that rather than relying on current expensive and unsustainable wastewater treatment methods, the new system eliminates waste generation from the very beginning. “With its exceptional performance and environmental benefits, this system sets a new standard for sustainable zinc-nickel plating.”

Current efficiency and certification

The new Atotech CMA system enables a higher cathodic current efficiency of 20% to 30%, with rack plating reaching 65% and barrel plating achieving 80% cathodic current efficiency. Energy consumption associated with the compact membrane anode technology can be reduced by 32%, significantly improving the carbon footprint. In addition, the technology brings substantial savings through reductions in NaOH, chemical and metal consumption.

Independent and globally renowned testing service provider, TÜV Rheinland, has recognised the performance of the Atotech CMA closed-loop technology through its recent certification. This was obtained as part of the evaluation of electroplating lines from MKS customers, and quantifies the wastewater and rinse water reduction, as well as the reduced CO₂ footprint, and confirms the reliability and accuracy of the data collected on the new system by MKS.