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Eliminating BSR Using Metal Coating Technologies

 

BSR. This acronym can stand for many different things (over 50, in fact, according to Google.)

 

But in the automotive sector, it can mean only one thing: buzz, squeak and rattle. And 99% of the people who deal with BSR in this industry really wish they didn’t have to.

 

We happen to be among the 1% that don’t mind ‒ because we have the tools and expertise to eliminate BSR for good. Here, I’ll introduce you to three of the coating technologies we use to help automotive manufacturers eliminate buzz, squeak and rattle from their vehicles.

 

But first ‒ what exactly is BSR?

 

What Does ‘BSR’ Mean in the Automotive Industry?

Buzz, squeak and rattle (BSR) is a catch-all term for a variety of fiction-induced noises that can be produced by a vehicle. It’s one of the biggest challenges facing automotive engineers today, and the number 1 cause of consumer complaints about new vehicles.

 

Generally, BSR is the unintended outcome of two component surfaces coming into contact with one another:

 

  • Squeak is caused by a stick-slip action when one part moves against another other.
  • Buzz is caused by the structure or component itself as it vibrates against another surface.
  • Rattle is caused by a collision between two components.

 

These noises might also be characterized by a consumer as squeals, creaks, clangs or bangs. At any rate, they’re the last thing any new vehicle owner wants to hear on their first long trip.

 

The automotive industry has long recognized the importance of vehicle noise when it comes to customer perception. Not only are speaks, buzzes and rattles annoying, they can have a hugely negative effect on how customers rate a vehicle’s quality and dependability. No one wants to save up for a brand-new car only to find that it starts rattling the second you take it down an unpaved road!

 

When you put it this way, I think you can see why 99% of the people who have this particular issue would much rather not. That’s why numerous articles, videos and blog posts have been made about BSR and how to solve it. In fact, in 2011, someone wrote an entire 296 book on this issue, covering such areas as background theory, testing, analysis and elimination with chapters from leading experts in the field!

 

Now, I might not have written the book on BSR, but I can tell you about three of the ways we can help you solve it here at Plastico.

 

3 Ways to Eliminate BSR Using Coatings

One of the go-to solutions for eliminating frictional noise is to apply a protective coating to at least one of the surfaces responsible.

 

Anti-BSR coatings save manufacturers a lot of time and trouble by avoiding the need to use secondary measures like felt spacers and lubricants post-production.  With the right application and the correct choice of coating, we can effectively eliminate BSR for the entire life of the vehicle.

 

Plastico Industries offers three coatings that are excellent in removing BSR: nylon, Plastisol and Polyarmor. Each product has its own unique properties and potential applications.

  1. Plastisol Coating offers colour, comfort, electrical insulation, texture, gripping power, and resistance to acids, alkalis and oils. Plastico Industries is an industry leader in Plastisol dip coating for the automotive industry.
  2. Polyarmor Coating offers a wide range of performance attributes including impact and corrosion resistance as well as UV protection. Plastico offers Polyarmor dip coating.
  3. Nylon Powder Coating offers resistance to corrosion, abrasion and chemicals, with natural lubricity and noise-dampening qualities. At Plastico, we offer nylon dip and nylon spray options.

Suffering from BSR? Let us show your components a little TLC and help you allieviate this headache once and for all! Our coating machines are designed to accommodate a myriad of parts. We’re set up to handle small, medium and large parts as well as small, medium and large volumes.

 

Call us at 1-888-664-9998  or contact us online to learn more about all our coating services

 

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Nylon Coating 101: Spilling the Beans on Nylons

Can your metal parts withstand the outdoor elements? What about harsh fluids or chemicals?

 

When the part specifications call for a tough exterior, nylon coating could be your answer.

…We know what you’re thinking. No, we don’t mean the nylons you wear on your legs — but rather the synthetic polymers used to produce durable powder coatings for all kinds of metal components.

 

But as you’ll see, we are talking about beans.

 

What are Nylon Coatings?

Nylon was a breakthrough in the area of the human-made polymers. Since it hit the commercial market back in the 1930’s, nylon has been well known for its applications in textiles — hence why stockings are so often called nylons.

 

But nylon is a highly versatile material with a whole world of applications beyond synthetic fabrics. Nylon can be melt-processed into all kinds of shapes or films, mixed with various additives, or processed into nylon powders and used to powder coat metals.

 

The most tried-and-true nylon powders are Nylon 11 and Nylon 12. These two materials are widely used to coat metal parts in just about every imaginable industry — automotive, textiles, medicine, sports and furniture, to name just a few.

 

Types of Nylon Coatings: Nylon 11 and Nylon 12  

At first glance, Nylon 11 and Nylon 12 look practically identical (at least in powder form.) But these unique coating materials have very different qualities.

 

The numerical labels — 11 and 12 — refer to the number of carbon atoms in the molecular building blocks of each material. These carbon atoms are what gives each type of nylon coating its respective qualities. To choose the right powder coat for your product, it’s important to know the difference between different nylon coatings.

 

Here’s what Nylon 11 and Nylon 12 have going on beneath the surface.

 

What is Nylon 11?

Nylon 11 is composed of high-strength macromolecules called polyamides. You don’t hear the term very often, but polyamides are all around us! Wool and silk are both polyamides, as are synthetic materials like Zytel and Kevlar.

 

Unlike other human-made polyamides, Nylon 11 is made from renewable raw materials — specifically, castor beans. This makes it a rare, bio-based engineering plastic derived almost entirely from biomass materials. How’s that for a low environmental impact?

 

Nylon 11 Applications

Chances are that you’ve come across this incredible material and not even known it.

 

In addition to powder coating, Nylon 11 is used to make shuttlecocks, brush bristles, filters, connectors, clips, racquet strings and even lingerie! Its unique qualities make it ideal for so many industries and applications.

 

As a powder coat, Nylon 11 is notable for its good elasticity, high elongation and high impact resistance. And that means what?

  • High elongation at break means the part can be bent or shaped with little to no breakage to the coating.
  • Elasticity means that if an outside force distorts the coating, the coating will revert back to its original shape once that force is removed.
  • Impact resistance is how tough the coating is. Nylon 11 is tough.

On top of all this, Nylon 11 has superior thermal resistance, meaning it performs well in super-hot environments like the engine of your car.

 

Nylon 11 can be applied using electrostatic spray or dip coating in a fluid bed.

 

What is Nylon 12

Nylon 12 is a durable nylon polymer that stands apart from Nylon 11 in several important ways.

 

To start, Nylon 12 is not made from beans, but rather from petroleum sources. It is stiffer and denser than Nylon 11, with a slightly lower melting point.

 

Most importantly, Nylon 12 is exceptionally strong, with strong resistance to cracking even in sub-zero temperatures. It also boasts superior resistance to UV rays. All in all, Nylon 12 performs better than Nylon 11 in extreme climates and temperatures.

 

Nylon 12 Applications

Nylon 12 is the go-to material for packing materials and films in the food production, pharmaceutical and medical industries. Automotive manufacturers also use Nylon 12 to prepare oil and gasoline-resistant parts since it resists chemicals and absorbs little to no moisture.

 

You’ll also find Nylon 12 as a bulking and opacifying agent in cosmetic and personal care products. We weren’t kidding when we called nylon versatile!

 

As a powder coat, Nylon 12 is excellent when it comes to protecting parts from the widest range of chemicals. It effectively resists hydraulic fluids, oil, fuels, grease, saltwater and solvents. It’s also a top performer in conditions where the temperature dips below freezing.

 

Ask the Nylon Coating Experts

Still have questions about nylon coatings? At Plastico Industries, we work with Nylon 11 and Nylon 12 daily. Send us your question and we’ll have an expert contact you as soon as we can.

 

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What Makes Nylon Coating Unique?

From a cost-per-part perspective, a nylon powder coating is typically costlier than traditional powder coatings. That hasn’t stopped nylon from becoming the material of choice for some of the most demanding metal coating applications, from crucial automotive parts to life-saving medical devices.

 

What makes nylon coatings stand out from traditional polyester coatings? To start, nylon delivers a standard of performance and durability that few materials can match. But it also sets itself apart as an environmentally-friendly choice that eases the burden of a manufacturer’s carbon emissions.

 

metal coating

 

Here’s what makes nylon powder a leading metal coating option:

 

1. Nylon Coating is Renewable, Recyclable and Environmentally-Friendly

Nylon powder coating is derived primarily from vegetable oil extracted from castor beans. These so-called ‘beans’ are the seeds of the Ricinus or castor oil plant, which can be grown and harvested with little to no carbon impact. With nylon powder coating, you can reassure your customers that the part is coated with an environmentally-safe, low-impact material.

 

2. Nylon Coating is Extremely Durable

It may come from a plant, but nylon powder coating is tough as nails. It goes on thin at .004 to .030 thousandths of an inch and hardens into a resilient coat. With impressive thermal, physical and mechanical properties, nylon coating dependably protects metal parts from chemicals, corrosion, abrasions, oil and fluids, and high impacts.

 

3. Nylon Coating Meets Autoclave Requirements

Few materials can withstand the rigours of the autoclave. Nylon powder coating meets the standards of autoclaving requirements, making it the coating of choice for many important medical industry applications.

 

4. Nylon Coating is Quiet

Noise isn't always the first thought when it comes to choosing a powder coating solution, but more and more manufacturers are turning an ear to the impact of noise on workplace health and safety. Nylon has excellent sound-dampening properties, reducing noise and helping to eliminate buzzing, squealing and rattling.

 

5. Nylon Coating is Surprisingly Affordable

It’s true: nylon powder coating usually costs more upfront than traditional powder coatings. However, its superior performance and durability make nylon the more cost-effective choice in the long run. Few other coatings can match its outstanding cost-to-performance ratio.

 

Nylon Powder Coating in Ontario

Specializing in Nylon 11 and Nylon 12, Plastico Industries is known as one of the premier nylon powder coaters in Ontario.

 

Our facility is equipped to provide a nylon coating with either an electrostatic spray or a fluidized bed dip. When we apply our nylon coating electrostatically, we spray the part with a dry powder that is fluidized with air and then cured. Fluidized bed coating is applied through a dip process in which the part is preheated and dipped into a dry powder that is fluidized with air and then cured.

 

If you are considering a durable coating that is also environmentally-friendly, contact Plastico today to learn how our nylon coatings will exceed your expectations!

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Plastico Industries is Proudly an ISO 9001:2015 Certified Industrial Metal Coater

As of September 6, 2018, Plastico Industries is officially recognized for conforming with the ISO 9001:2015 standard in our industrial metal coating services.

 

 

For Plastico Industries (and our parent company Latem Industries), ISO 9001:2015 certification means:

  • Plastico Industries’ top management demonstrates leadership and commitment to upholding a Quality Management System that meets ISO 9001:2015 standards.
  • Our Quality Management System comprehensively addresses risks, opportunities, changes and quality objectives.
  • We have plans and processes in place to meet our customers’ requirements for our services.
  • All our employees have the training and resources they need to support our Quality Management System.
  • The roles and responsibilities necessary to uphold this commitment have been assigned, communicated and understood.
  • We continuously monitor, measure, analyze, and evaluate our Quality Management System with an aim to improve wherever we can.

We’d like to take a moment to explain what it means to be an ISO 9001:2015 certified industrial metal coater and why it matters to us and our customers.

 

What ISO 9001:2015 Certification Means

ISO stands for the International Organization for Standardization. It is an independent, international organization that sets quality, safety and efficiency standards for products, services and systems.

 

Both the Standards Council of Canada (SCC) and the American National Standards Institute (ANSI) are membership bodies of the ISO.

 

The purpose of the ISO’s universal standards is to encourage manufacturers (and other organizations) to consistently meet customer expectations and regulatory requirements, and to enhance customer satisfaction by effectively applying a quality management system.

 

So, what does it mean to be ISO 9001:2015 certified?

 

In short, it means the organization has a proven commitment to providing quality and consistency to its customers.

 

To an industrial metal coater like Plastico, ISO 9001:2015 certification means delivering quality coatings that hit the deadline and meet or surpass our customer’s expectations every time.

 

To our customers, it demonstrates that our promises are backed up by a universally-recognized quality management process. We put lots of time and effort into ensuring our work meets the ISO standards from beginning to end.

 

How Plastico Earned ISO 9001:2015 Certification

Although the International Organization for Standardization develops these standards, the task of auditing organizations for compliance falls to independent certification bodies.

 

Plastico Industries passed an audit by The Registrar Company (TRC). TRC issued Plastico’s Certificate of Registration for ISO 9001:2015 on September 6, 2018. TRC is a trusted certification body accredited by the ANSI-ANQ National Accreditation Board (ANAB) for over twenty years.

 

ISO 9001:2008 vs. ISO 9001:2015

If you’re already familiar with the previous standards set in 2008, you’ll find few changes in the ISO’s current criteria. What has changed is:

  • New structure (expanding from 8 clauses to 10)
  • Renewed focus on top-level accountability, involving the highest levels of management in implementing and maintaining ISO standards
  • Emphasis on risk management throughout the organization, using the system as a preventative tool that encourages continuous improvements to process
  • More flexibility for organizations like Plastico to develop ISO documentation in a format that meets our needs as a industrial metal coater
  • Alignment with other key management system standards

Work with a Certified Metal Coater

Plastico Industries is proud to produce results that meet internationally-recognized quality standards. Start working with an ISO 9001:2015 certified industrial metal coater today.

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Choosing a Coating: Nylon Coating vs. Polyester Coating

Powder coatings protect metal parts from weather, corrosion, and whatever else you throw at it. Two of the most popular powder coating options are nylon and polyester coatings, each of which have broad applications in a variety of industries. These are a few of the main considerations when choosing between nylon coating vs. polyester plastic coating.

 

Nylon Coating Powder

 

Heat Resistance

An important difference between nylon coating and polyester coating is how each material reacts to heat. Nylon is a thermoplastic, while polyester is a thermosetting plastic. While the two sound similar, the distinction is important if the part to be coated will be exposed extreme temperatures.

 

Thermosetting plastics start out as separate polymer compounds. When subjected to sufficiently high temperatures, these polymers react to form a strong chemical bond. This bond is irreversible, and the plastic coating will remain solid even under extreme heat. In other words, poly coating is a one-way street: once it hardens, it is not possible to reform or recycle it.

 

Thermoplastics like nylon coating are different. Although thermoplastic compounds also melt under high heat, there is no chemical reaction involved, so the process is reversible. You can re-melt and re-form nylon coating as many times as you require! It is even possible to recycle nylon and thermoplastic coatings.

 

To borrow a metaphor, where thermoplastics are akin to butter, thermosetting plastics are more like bread. A baker can repeatedly melt and cool the same stick of butter, but they cannot break a loaf of bread back down into its ingredients!

 

For this reason, poly coatings are more heat-resistant than nylon coatings, but nylon coatings have advantages in other high-performance applications.

 

Durability

Depending on the application, both polyester and nylon plastic coatings can protect the surface of metal parts from abrasions. Polyester coatings tend be flexible, with impressive impact and chemical resistance. However, this is an area where nylon coating wins out overall.

 

Once applied to a part, nylon coating flows out to form a continuous, protective bond to the surface. This creates a powerful, resilient barrier against salt, UV rays, and all manner of wear-and-tear. Nylon coating remains durable even in thin applications, making it ideal for tight tolerances. Arkema’s ® Nylon 11 coating, one of our products of choice at Plastico, is specially designed to give metal parts a longer shelf life.

 

A secondary advantage of nylon coating is its low friction coefficient. This gives it an ability to cut noise and vibrations from the parts it covers, contributing to a safer work environment and helping to prolong the life of the machinery.

 

Sustainability

Manufacturers are increasingly becoming mindful of their impact on the environment. For those who are looking to incorporate more sustainable practices, nylon offers a renewable and eco-friendly powder coating solution.

 

Nylon coating is derived from castor beans, the product of a perennial plant called the Ricinus or castor oil plant. In addition to being recyclable, nylon coating carries almost no carbon footprint! Choosing nylon coating signals to customers that you care about your impact.

 

Nylon vs. Polyester Coating

Your choice of powder coating will depend on the part’s application and the performance you desire from the coating. Here at Plastico, we are confident in the superior performance of nylon coating, but we are happy to recommend powder coaters who specialize in poly coating as well.

 

Learn more about our powder coating services in Cambridge, Ontario.

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Which Industrial Coatings are Considered Food Grade in Ontario?

Industrial coatings considered food grade in Ontario

Nylon powder coatings are as diverse as the many industries that use them. One often-overlooked application is that of food production and processing. From the farm to the dinner table, powder coatings help to ensure our food is safe to consume.


Of course, not all coatings are suitable for this purpose. Food processing equipment and containers must meet certain standards to be considered food grade in Ontario.

 

Specialized food grade industrial coatings are often necessary for both the longevity of part and the safety of the food it touches. The right choice coating can make the equipment easier to clean and sanitize. However, it must also be non-toxic, non-absorbent, and free from defects (like cracks or crevices) that could harbour bacteria.

 

Which Industrial Coatings Are Considered Food Grade in Ontario?


In Canada, Health Canada and the Canadian Food Inspection Agency (CFIA) set policies and standards to ensure a safe food supply, including the safety of the equipment we use to process food and the materials we use to transport it. The American equivalent, the Food and Drug Administration (FDA), oversees this area in the United States.


The choice of food grade powder coating for a part will depend on the manufacturing process. Parts that will be placed in an oven will have to withstand high temperatures; parts that will be submerged in liquid must have a high resistance to corrosion. Non-stick coatings with a low friction coefficient are often sought in the food processing industry as well.


The type of food ingredient in question may also play a role in the decision. For example, certain materials are more susceptible to corrosion on exposure to acidic foods like pickles or tomatoes.


The number of industrial coatings considered food grade in Ontario is too numerous to list. Below are some of the most common categories of food grade powder coatings in use:

 

  • Polytetrafluoroethylene coating (PTFE): A thin, non-stick coating that stands up to high temperatures. It does not absorb liquid and has a low friction coefficient. Non-stick cookware and bakeware often use PTFE coating.

 

  • Fluorinated ethylene propylene (FEP): This food grade coating option is flexible and highly resistant to chemicals but lacks the high-temperature resistance of PTFE. Like PTFE, it is non-absorbent.

 

  • Antimicrobial coatings: A wide variety of food grade industrial coatings come with antimicrobial properties, which reduce the spread of bacteria and food-borne illnesses. Some contain an active ingredient that kills bacteria, while others resist them passively by preventing microbes from sticking to the surface of the part.

 

  • Rislan Nylon 11: This durable and versatile polymer coating boasts a low friction coefficient that makes it easy to clean. The main ingredient is Castor beans, which makes Nylon 11 100% renewable and environmentally friendly.


Here at Plastico, we’ve used Nylon 11 to coat everything from fryer baskets to pot handles to cutlery, food trays, and even seafood traps. While it doesn’t taste quite as good as it looks, it does qualify as food grade!

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Tim Keane
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November 26, 2019
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