HyProCoat 630: Advanced Sealer Solution for Zinc Finishing

As a pioneering company, occasionally, we bring products that no one is asking for to the market. Not because there’s no need, rather because no one else thinks it’s possible. HyProCoat 630 is one of those products, a sealer for passivated zinc and zinc-nickel finishes that can tolerate direct contact with and significant contamination from tri-chromium passivates.

With this technology, we’ve seen customers go from dumping and waste-treating a sealer once a month to less than once a year. While new products like this tend to have a higher upfront cost, the long-term cost savings for HyProCoat 630 can easily be seen. Just a few new makeups in a year of a product that might be half the cost of HyProCoat 630 demonstrates the savings on chemistry costs alone. Then considering lost production, labor cost for dumping and cleaning, and waste treatment costs, the advantage is clear.

Solving Technical Challenges in Industrial Applications

The only problem with introducing products that no one has ever seen is there is no shortage of new problems to be discovered and when things go wrong, the new product is the first thing to blame. In our first at-scale trial of HyProCoat 630 we hit our first unexpected problem. Our customer reported a thick foam blanket, staining on their parts, and a mess of precipitated product coming off on their filters.

This was obviously not what we wanted to hear in our first major trial, so we immediately began investigating potential causes. The presence of foam meant air was getting introduced somehow, but the question was where? The customer’s setup included a filtration system with intake well below solution level (some filtration setups have the intake far too close to the solution surface), so it wasn’t about the solution level and there were no leaks in the plumbing that we could find.

The customer was ready to kick us out thinking somehow the sealer was the problem because, “the old stuff didn’t do this”. Thanks to our team’s coolheaded charisma and faith in the product, we eventually found the culprit on the filter pump itself. A bad seal was pulling air into the pump and forcing it through the line building up a thick foam overtime. Once we replaced the seal, the product performed exactly as expected. Their previous bath life of 5-6 weeks became 5-6 months, minimum.

Unfortunately, our problems didn’t stop there. As is usually the case, we encountered one more challenge that we didn’t foresee when the product was in development: a wide range of products being dragged into the sealer. The third shop to trial the product was running three separate passivate processes using the same sealer tank for all three. This made things exceptionally complicated due to the wildly different nature of each process.

The customer was operating well for a few weeks with lots of praise for the product. Then suddenly they started seeing significant buildup on the sidewalls of the tank. Finally, the problem made its way onto the parts themselves, and something had to be done to save production.

We typically don’t recommend any pH adjustment or maintenance for HyProCoat 630. Its robustness towards pH swings usually means adjustment isn’t necessary. However, when a black passivate, blue passivate, and tri-chromium-based sealer are all going into the tank at once, we learned this wasn’t the case.

After some investigation and lab troubleshooting, we found that, for this particular line setup, there was an ideal pH range for long-term stability that we were falling out of as production went on. With a change in working pH and maintenance guidelines, they were operating smoothly again and as of today they’ve been making maintenance-only adds to the bath since 2024.

Driving Innovation in Finishing Chemistry

Since overcoming these initial challenges, HyProCoat 630 has established itself as the gold standard for reliability and sustainability in the finishing industry. Our journey proves that true innovation isn’t just about creating a product; it’s about the relentless pursuit of perfection in the face of the unknown.

At Pavco, we don’t just supply chemistry; we provide the deep-rooted technical expertise and industrial grit necessary to transform your production line. Our commitment to your success is unmatched. Whether you are facing persistent foaming issues, pH instability, or complex contamination across multiple processes, our team is equipped to engineer a solution tailored to your unique operational environment. Don’t let technical hurdles stall your production or inflate your costs.

Take the next step in optimizing your finishing process. Contact a Pavco technician today to discuss your specific challenges and discover how our advanced chemistry can drive efficiency and quality for your business.