At Ples’s production facility in Hungary, traditional engineering meets modern coating chemistry. The challenge: to reliably and efficiently protect heavy components with extremely thick walls. The solution lies in a special KTL acrylate that combines corrosion protection and UV stability in a single step.
The Foundation: Heavy Metals and Metal Forming
About 100 kilometers northeast of Budapest lies a unique industrial niche. Here, the Ples company manufactures the legendary Trilex steel rims—originally a German-Swiss innovation known for its durability in the heavy-duty commercial vehicle sector. The manufacturing process begins with sheer force: steel blanks ranging from 7 to 30 mm in thickness are shaped using massive presses. Forces of up to 400 metric tons are applied in this process; these material thicknesses pose particular challenges not only for the mechanical processes but also for the subsequent surface treatment.
Pre-treatment: Cleanliness as the Foundation
Before the paint is applied, all components undergo intensive mechanical and chemical preparation. Blasting—which ensures the necessary surface roughness and removes scale—is followed by a modern 8-zone pretreatment process. Cleaning: An alkaline degreasing process reliably removes residues from the forming process and the machining equipment. Conversion coating: Zinc phosphating forms the chemical bond between the solid steel and the paint coating.
The Coating: KTL Acrylate as an Efficient Single-Coat System
While traditional KTL processes (usually epoxy resin-based) offer excellent corrosion protection, they are generally not UV-stable and require a topcoat. Ples takes a more efficient approach here. The system uses an acrylate KTL coating in the color RAL 3009 Oxide Red from FreiLacke. The key advantage of this system is that it functions as a single-coat system. The acrylate base provides high resistance to UV exposure, such as sunlight, while still delivering very good corrosion protection. The KTL acrylate was specifically tailored by FreiLacke to meet Ples’s application requirements and unique challenges. The focus was on achieving a balanced combination of corrosion protection, mechanical properties, UV resistance, and excellent color stability.
Process Parameters in Detail
- Coating time: 120–240 seconds
- Coating thickness: 30–40 μm—to ensure a closed, homogeneous surface even on solid and sandblasted components
- Rinsing concept: Two ultrafiltrate rinses with a cascade configuration ensure high material yield and an excellent overall surface finish
Conclusion
The Ples example impressively demonstrates that cost-effectiveness and high-end protection are not mutually exclusive. By eliminating the need for an additional topcoat, the company saves time, energy, and material costs without compromising the quality of the Trilex rims. A stable process that gives the “heavy metal” from Hungary the necessary shine and protection. (OM-10/26)
The Trilex rim is far more than just a component; it is a piece of industrial history. Originally developed by the Swiss company Georg Fischer AG (GF), it revolutionized the handling of heavy-duty vehicles at a time when flat tires were still a daily occurrence. Unlike the one-piece disc wheel rims widely used today, the Trilex system consists of a three-part rim ring. These segments are secured to the wheel hub by a special clamping system. This design was a masterpiece of engineering, as it offered tremendous stability combined with relatively simple installation. This allows a truck driver to change a tire without the need for heavy machinery—a feature that remains in use to this day, particularly in regions with limited infrastructure and in off-road applications.
Contact
Emil Frei GmbH & Co. KG
Am Bahnhof 6
78199 Bräunlingen-Döggingen (Germany)
Phone: +49 7707 151-0
Email: info@freilacke.de
www.freilacke.de
About FreiLacke
Since 1926, FreiLacke has been synonymous with innovative paints and coatings. Now in its third generation of family ownership, the company employs 600 people at its Döggingen, Black Forest, location, where it develops customized solutions for customers in the fields of bicycles, vehicle manufacturing, machinery and equipment manufacturing, contract coating, rail vehicles, wind power, functional furniture, warehouse technology, and construction and plumbing.