Development and construction of plants for electrolytic surface pretreatment and finishing of strip, wire and profiles/tubes.
STAKU Anlagenbau GmbH
Lich (Hesse)New on Amplifa
About STAKU Anlagenbau
STAKU Anlagenbau GmbH, based in Lich (Hesse), develops and manufactures complete production plants for the pretreatment and finishing of semi-finished metal products made from strip, wire, profiles and tubes. The company was founded in 1974 as STAKU Stahl- und Kunststofftechnik GmbH in Gießen and has focused on electrolytic process engineering since 1985. Under the e-systems product brand, STAKU offers patented processes such as e-clean (electrolytic cleaning and pickling), e-phos (zinc-calcium phosphate coating, patent EP 1 574 601), e-molyphos (phosphating with lubricant release for stainless steel and titanium), e-copp (electrolytic copper plating) and e-bead (cyanide-free bronze deposition on steel wire). The portfolio is complemented by ultrasonic inline cleaning plants (Ultraclean), strip brush machines, hot-dip plants and filter systems for wastewater and exhaust air purification. Processes are developed in the in-house laboratory and tested in pilot plants; assembly of plants up to 30 m in length takes place in the company's own assembly hall. Customers include companies from the strip, wire, welding wire, profile/tube, screw and cold heading industries, the steel industry, bulk metal forming and medical technology; plants are exported worldwide.
- Site
- Lich
- Processes
- Electrolytic cleaning (e-clean), Electrolytic phosphating (e-phos, zinc-calcium phosphate coating), Electrolytic phosphating with lubricant release (e-molyphos), Electrolytic copper plating (e-copp), Electrolytic galvanizing, Electrolytic polishing, Electrolytic tire cord production (e-bead, bronze deposition without cyanides), Ultrasonic inline cleaning (Ultraclean)
- Materials
- Steel, Stainless steel, Titanium, Copper, Copper alloys, Bronze, Aluminium, Nickel
- Certificates
- Specialist operation pursuant to WHG §19, monitored by TÜV, Specialist operation pursuant to WHG §19 (monitored by TÜV Hessen)
- Founded
- 1974
- Industries
- Strip industry, Wire industry, Welding wire industry, Profile/tube industry, Steel industry, Screw/cold heading industry
- 01
Process development in the in-house laboratory (including pilot plants)
- 02
Engineering of the plants
- 03
Manufacture of components in affiliated workshops
- 04
Assembly and pre-acceptance in the assembly hall (up to 30 m plant length)
- 05
Worldwide sales, export and commissioning
Locations
Lich
DEHeadquarters with office, production halls, assembly hall and laboratory
- Materials
- Steel, stainless steel, titanium, copper, aluminium, non-ferrous metals
- Ultrasonic inline cleaning plant Ultraclean
- Digital ultrasonic generators (80–3000 W, 25 kHz–1 MHz)
- Strip brush machine (130–250 mm strip width)
- Electrolytic inline degreasing plant e-clean
- Electrolytic inline pickling plant e-clean
- Electrolytic strip treatment plant e-clean
- Electrolytic inline phosphating plant e-phos
- Strip tinning plant
- Oil separator, automatic band filter, electrolytic copper separator
- Plate phase separator, paper disc band filter, floating skimmer
- Assembly hall 700 m², ceiling height 7.5 m
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Electrolytic cleaning (e-clean)Surface | – | – | – | – | Steel, Stainless steel, Copper, Copper alloys, Aluminium, Nickel, Chromium/nickel alloys, Non-ferrous metals |
| Electrolytic phosphating (e-phos, zinc-calcium phosphate coating)Surface | – | – | – | – | Steel, Stainless steel, Titanium, Wire, Strip |
| Electrolytic phosphating with lubricant release (e-molyphos)Surface | – | – | – | – | Stainless steel, Titanium |
| Electrolytic copper plating (e-copp)Surface | – | – | – | – | Steel, Steel wire |
| Electrolytic galvanizingSurface | – | – | – | – | Steel, Strip |
| Electrolytic polishingSurface | – | – | – | – | Stainless steel |
| Electrolytic tire cord production (e-bead, bronze deposition without cyanides)Surface | – | – | – | – | Steel wire |
| Ultrasonic inline cleaning (Ultraclean)Surface | – | – | – | – | Chromium/nickel alloys, Non-ferrous metals, Wire, Strip |
| Strip brushing (mechanical strip cleaning, abrasive/washing brushes)Surface | – | 130-250 mm | – | – | Copper strip, Nickel strip, Aluminium strip |
| Strip galvanizing plants (hot-dip finishing with HCl spray pickling/flux bath)Surface | – | – | – | – | Steel strip |
| Strip tinning plants (hot-dip finishing with brush degreasing/flux bath)Surface | – | – | – | – | Non-ferrous metal strip |
| Electrolytic inline pickling for bar stockSurface | – | – | – | – | Bar stock (sintered, graphite-contaminated), Copper, Zinc, Tin |
| Electrolytic inline degreasing for bar stock (central conductor process)Surface | Degree of cleanliness < 10 mg/m² | 2,500-13,500 mm | – | – | Copper, Copper alloys |
| Pickling (immersion pickling process, sulphuric acid)Surface | – | – | – | – | Steel, Wire, Strip, Tubes |
| Electrolytic surface treatment / pretreatment of body panels (Galfan pretreatment)Surface | – | 1,600 mm | – | – | Steel sheet (body panel) |
| Wastewater treatmentEngineering | – | – | – | – | – |
| Exhaust air purificationEngineering | – | – | – | – | – |
| Process water treatmentEngineering | – | – | – | – | – |
| Plant engineering (development and construction of complete production plants for strip, wire,Engineering | – | Plants up to 30 m total length | – | – | Steel, Plastic |
17 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Ultrasonic inline cleaning plant | STAKU Ultraclean | – | Wires and strips, treatment times approx. 1 second | – | Lich |
| Digital ultrasonic generator | STAKU Openframe, Standalone, DIN rail generator, 19" housing, module generator | – | Power 80 W to 3000 W; frequencies 25, 30, 40, 50, 75, 250, 500 kHz, 1 MHz; mains connection 230/240 | – | Lich |
| Ultrasonic transducer | STAKU Immersion transducer, plate oscillator, rod oscillator | – | Power 80 W to 3000 W; frequencies 25, 30, 40, 50, 75, 250, 500 kHz, 1 MHz | – | Lich |
| Strip brush machine | STAKU | – | Strip width 130-250 mm, strip thickness 0.1-0.5 mm, abrasive or washing brushes | – | Lich |
| Electrolytic inline degreasing plant | STAKU e-clean | – | Bar stock up to 63 mm Ø, bar length 2,500-13,500 mm, cleaning line 4 m, total plant length approx. | – | Lich |
| Electrolytic inline pickling plant | STAKU e-clean | – | Bar stock up to 63 mm Ø, current densities up to 250 A/dm², treatment time 1-3 seconds | – | Lich |
| Electrolytic strip treatment plant | STAKU e-clean | – | Strip width 1,600 mm | 1995 | Lich |
| Electrolytic inline phosphating plant | STAKU e-phos | – | Treatment times 6 seconds (instead of the previous 20 minutes) | 1998 | Lich |
| Strip tinning plant | STAKU | – | Non-ferrous metal strips, combined plant with brush degreasing including flux bath with filtration | 1996 | Lich |
| Assembly hall | – | 1 | 700 m² floor area, ceiling height 7.5 m; assembly of wire/strip treatment plants up to 30 m total | 2014 | Lich |
| Oil separator | STAKU | – | Continuous electrolyte treatment (oil separation) | – | Lich |
| Automatic band filter | STAKU | – | Continuous filtration of the degreasing bath | – | Lich |
| Electrolytic copper separator | STAKU | – | Treatment of the pickling acid, removal of dissolved metals | – | Lich |
| Plate phase separator | STAKU | – | Separation of the oil phase (bath maintenance) | – | Lich |
| Paper disc band filter | STAKU | – | Solids filtration (bath maintenance) | – | Lich |
| Floating skimmer | STAKU | – | Degreasing baths | – | Lich |
| Compact unit with reserve tank | STAKU | – | Built-in heating and control system (bath maintenance) | – | Lich |
Additional services
Reference customers
Quality and Certification
STAKU is certified as a specialist operation pursuant to WHG §19 with external monitoring by TÜV Hessen, which is required for the construction and erection of HBV plants and for handling substances hazardous to water. In the in-house laboratory with pilot plants, processes are continuously improved and new processes are developed.
| Evidence | Lich |
|---|---|
| Specialist operation pursuant to WHG §19 (monitored by TÜV Hessen) |
History
- 1974
Foundation of STAKU Stahl- und Kunststofftechnik GmbH by Ing.(grad.) Kurt Gerhard in Gießen.
- 1976
Move to own rooms and halls (approx. 3,000 m²) at Bahnhofstraße 33–35, Lich; pickling plants for wire, strip and tubes are exported worldwide.
- 1982
Certification as a specialist operation pursuant to WHG §19 with external monitoring by TÜV Hessen.
- 1985
Shift of focus from chemical to electrolytic process engineering.
- 1992
Dipl.-Ing. Jörg Gerhard joins the company after studying process engineering (RWTH Aachen); research on new pretreatment and coating processes in the laboratory.
- 1995
ThyssenKrupp Stahl AG orders an electrolytic surface treatment plant (e-clean) for body panels with 1,600 mm strip width for Galfan pretreatment.
- 1996
Complete strip tinning plant for the NA-Konzern (Hamburg) based on e-clean technology.
- 1997
Jörg Gerhard takes over the company and founds STAKU Anlagenbau GmbH in Lich for the development and worldwide sale of the galvanizing plants.
- 1998
Commissioning of the first electrolytic inline phosphating plants for cold heading wires; treatment time reduced from 20 minutes to 6 seconds.
- 2004
On the occasion of the 30th anniversary, patent application for the e-phos process (zinc-calcium phosphate coating).
- 2007
Development of the e-copp process for continuous electrolytic copper plating of steel surfaces.
- 2010
Granting of patent EP 1 574 601 for e-phos; presentation of the e-systems product range at Wire & Tube in Düsseldorf.
- 2014
Inauguration of a new assembly hall (700 m², 7.5 m ceiling height) and an open-plan office (approx. 430 m², 15 workstations); plants up to 30 m total length can be assembled and pre-accepted.
- 2015
Further development of the e-phos process into e-molyphos: electrolytic phosphating with lubricant release for stainless steel and titanium.