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At Broxap, we are committed to protecting and improving the environment. Whether that’s through transformational outdoor projects we deliver across the UK, or here in North Staffordshire, where we are based.
The manufacturing industry faces many challenges in improving sustainability. It is a testament to our environmental commitment as a business that we’ve tackled these issues head-on to help drive positive change across the sector.
Among the many actions we’ve taken is an investment of around £1.2 million in a new automated powder-coating system. This innovation has revolutionised our production processes and reduced our environmental impact.
Pretreatment technology
The Eurotherm powder coating system delivers benefits for our clients, our workforce, and the broader environment.
It features a highly innovative pretreatment stage that enables precise powder coating while remaining highly energy efficient. The system has increased capacity at our 125,000 sq ft manufacturing facility and delivers on Broxap’s high standards for a durable, long-lasting, and superior product finish.
The ‘power and free’ system, designed by Eurotherm, allows manual loading of products before they travel through the powder-coating processing zones on an automatic overhead bi-rail conveyor.
This flexible design allows the system to handle Broxap’s wide and varied range of product shapes and sizes. It can process components up to 5,500mm long x 1,050mm wide x 2,900mm high, with weights of up to 550kg, at a conveyor speed of 1m/minute.
The first stage involves a pretreatment and washing tunnel, which incorporates the Pronortec system. This is a unique nanotechnological conversion process that uses the chemistry of organic phosphorus compounds, yielding a system free of heavy metals.
The nanocoating produced by the Pronortec process is highly hydrophobic, providing excellent adhesion and exceptional corrosion resistance.
A reverse osmosis system purifies rinse water, cutting water consumption by up to 50% compared to conventional zinc phosphate pretreatment. It produces no wastewater and eliminates toxic sludge.
The technology is energy-saving too, using half the gas and electricity of a typical zinc phosphate system. This efficiency is partly due to the design of the drying and curing ovens. They feature the latest burner technology and are built to retain optimal heat levels for longer while reducing heat loss.
After pretreatment, products enter a manual powder-coating booth, designed for easy cleaning to support efficient colour changes, before entering the final drying and cooling phase.
Project Transform
The Eurotherm automated powder coating system, supplied by PFS Paint Finishing Systems, is part of Project Transform, a £3 million programme to accelerate Broxap’s journey towards net zero goals.
Project Transform also includes:
- A fibre laser cutting machine.
- New press brakes with automatic tool-changing.
- Briquetting technology and waste wood heaters.
- A state-of-the-art five-axis CNC machining centre.
Together, these smart technologies and innovative systems increase efficiency, reduce energy consumption, and support green energy generation.
These optimised methods also extend the lifespan of our products, improve durability, and allow for remanufacturing and recycling, helping to save raw materials.
These practices are becoming more critical to sustainable manufacturing in the UK, and we’re very proud to put ourselves at the forefront of change.