Galvart 0723 Case Study : Mahindra & Mahindra
Client : Mahindra & Mahindra
Replacement of Thermal Spraying with GALVART-0723
Project : Galvanizing of tractor trailer base panels to meet stringent export corrosion protection requirements.
Background : For export-oriented tractor trailer base panels, the client was using conventional thermal spray galvanizing. While effective, the process presented multiple operational and environmental challenges that impacted productivity, safety, and overall project cost.
Challenges Faced :
The existing thermal spray process had several limitations:
Complex and highly operator-dependent application
Emission of toxic and hazardous fumes
Health and environmental safety risks
Time-consuming multi-step process
High operational and application costs
Material wastage during spraying
The client required a safer, more efficient, and cost-effective alternative without compromising corrosion performance.
Greenovoc Solution Overview
| Section | Details |
|---|---|
| Product Implemented | GALVART-0723 – Galvanizing Coating System |
| Product Description | High-performance, water-based galvanizing coating system engineered to replace conventional thermal spray processes while delivering equal or superior corrosion resistance. |
Coating Application Process
| Stage | Specification |
|---|---|
| Surface Preparation | Sand blasting to Sa 2½ standard |
| Coating System | Two coats of GALVART-0723 |
| Total Dry Film Thickness (DFT) | 80 microns |
| Application Advantage | Easy application, reduced dependency on highly skilled operators, improved workflow efficiency |
Benefits Achieved
Environmental & Safety Advantages
| Benefit Category | Details |
|---|---|
| Technology Type | Water-based green technology |
| Fume Emission | No toxic fumes |
| Applicator Safety | Safer working environment |
| Environmental Impact | Environment-friendly process |
Operational Improvements
| Improvement Area | Details |
|---|---|
| Packaging System | Single-pack system |
| Application | Easy and user-friendly |
| Material Usage | Zero material wastage |
| Skill Requirement | Reduced operator dependency |
Performance & Cost Benefits
| Benefit Area | Result |
|---|---|
| Cost Savings | 20% overall cost saving |
| Productivity | 200% improvement due to faster application |
| Corrosion Protection | Meets export standards |
| Performance | Superior to conventional thermal spraying |
Comparative Results Summary
| Parameter | Thermal Spray Process | GALVART-0723 |
|---|---|---|
| Application Speed | Slow | 200% Faster |
| Safety | Hazardous fumes | Safe & water-based |
| Cost | High | 20% Lower |
| Material Wastage | Significant | Zero |
| Export Compliance | Yes | Yes (Enhanced) |
Conclusion
By replacing thermal spraying with GALVART-0723, the client achieved higher productivity, lower cost, safer application, and superior corrosion performance, making it an ideal solution for export-oriented automotive components.