Affordable Galvanizing Plant Manufacturer India, Africa, Kenya, Saudi Arabia, Sharjah, Kuwait, Dubai April 22, 2025 sazenviro Post in Uncategorized The galvanizing process is a vital step in ensuring long-term corrosion protection of steel products. As a leading Galvanizing Plant manufacturer in India, Africa, Kenya, Saudi Arabia, Sharjah, Kuwait, Dubai, our systems are engineered for high-throughput operations, consistent coating quality, and optimal energy and chemical usage. This article presents an in-depth overview of the galvanizing process, essential equipment, step-by-step operations, and key components used in a modern hot-dip galvanizing plant. Whether you are an infrastructure builder, utility fabricator, or industrial EPC company, investing in a technically sound galvanizing plant is essential for product durability and compliance with global coating standards such as ASTM A123, ISO 1461, IS 4759, and BS EN ISO 14713. Contact SAZ ENVIRO, a leading Galvanizing Plant manufacturer in India, Mumbai, Delhi, Pune, Kolkata, Hyderabad, Chennai, Bengaluru. What is a Galvanizing Plant?Contents1 What is a Galvanizing Plant?2 Step-by-Step Galvanizing Process Flow by Galvanizing Plant manufacturer in India, Africa, Saudi Arabia, Sharjah, Dubai2.1 1️⃣ Degreasing (Alkaline Cleaning)2.2 2️⃣ Rinsing (Water)2.3 3️⃣ Pickling (Acid Cleaning)2.4 4️⃣ Rinsing (Water)2.5 5️⃣ Fluxing (Zinc Ammonium Chloride)2.6 6️⃣ Drying (Preheat Chamber)2.7 7️⃣ Hot-Dip Galvanizing2.8 8️⃣ Cooling & Quenching2.9 9️⃣ Finishing3 Detailed Component List of a Galvanizing Plant by Galvanizing Plant manufacturer company in India4 Raw Materials Required for Galvanizing Process5 Key Technical Design Considerations5.1 Zinc Kettle Design5.2 Tank Construction5.3 Pollution Control6 Output and Efficiency Metrics of Galvanizing Plant by7 Compliance & Safety for Galvanizing Plant Setup8 Why Choose SAZ ENVIRO, A Trusted Galvanizing Plant manufacturer India9 Applications of Our Galvanizing Plants A galvanizing plant is a manufacturing facility that applies a protective zinc coating to steel or iron parts via hot-dip galvanizing. This process involves immersing cleaned metal components into a molten zinc bath at temperatures of around 450°C, forming a metallurgical bond between the steel and zinc. As a trusted Galvanizing Plant manufacturer company in India, Africa, Kenya, Saudi Arabia, Sharjah, Kuwait, Dubai, we offer turnkey solutions for small-scale to fully automated galvanizing lines with optimized material handling, pollution control, and thermal efficiency. Step-by-Step Galvanizing Process Flow by Galvanizing Plant manufacturer in India, Africa, Saudi Arabia, Sharjah, Dubai A modern galvanizing plant consists of the following process steps: 1️⃣ Degreasing (Alkaline Cleaning) Purpose: Removes oil, grease, dirt Solution: 5–10% caustic soda solution (NaOH) with surfactants Tank: Mild steel lined with chemical-resistant FRP Heating: Electric or steam coils (70–90°C) 2️⃣ Rinsing (Water) Removes caustic residue Requires continuous overflow system to maintain cleanliness 3️⃣ Pickling (Acid Cleaning) Removes rust and scale Solution: 10–15% hydrochloric acid (HCl) or sulfuric acid (H₂SO₄) Tank: Polypropylene (PP) or rubber-lined MS Optional: Inhibitors to reduce base metal attack 4️⃣ Rinsing (Water) Removes acid traces and prepares for flux 5️⃣ Fluxing (Zinc Ammonium Chloride) Prepares the surface for zinc adhesion Solution: 20–30% ZnCl₂ + NH₄Cl mix Heated to ~60°C Tank: Stainless steel or MS with PVC lining 6️⃣ Drying (Preheat Chamber) Removes moisture from flux film Chamber heated to ~100–120°C using hot air blowers 7️⃣ Hot-Dip Galvanizing Immersion into molten zinc bath at ~450°C Zinc purity: 98.5% minimum (ISO grade Zn SHG) Kettle: Special steel (EN S355J2+N or A516 Grade 60) with ceramic lining (optional) Heat source: Natural gas, diesel burner, or electric induction 8️⃣ Cooling & Quenching Water or air quenching depending on part thickness Purpose: Solidifies coating and reduces white rust 9️⃣ Finishing Ash removal, spangle smoothing, inspection Optional: Passivation dip (Cr³⁺ based) Detailed Component List of a Galvanizing Plant by Galvanizing Plant manufacturer company in India System Component Specification Degreasing MS Tank + FRP lining 5mm wall, 3mm FRP inner Pickling System PP or rubber-lined MS tanks Corrosion-proof, 10–15% HCl Flux Tank SS 316 or PVC-lined MS Steam heating coils included Rinse Tanks SS 304 or PP 2-stage rinse with overflow Dryer Unit Tunnel chamber with hot air blower 5 HP blower with temperature controller Zinc Kettle Custom fabricated steel pot 3m to 12m long, 1.5m–2m deep Burner Gas or diesel-fired Riello/Ecoflam, 500,000–2,000,000 kcal/hr Ash Skimmer Manual or pneumatic rake Removes dross and ash Dross Collection Sump or detachable tray Stainless steel pans Cooling Tank Galvanized or PP lined Continuous water circulation Fume Extraction Scrubber + Ducting PP blower, PVC duct, alkaline scrubber Control Panel PLC based system Temperature, burner, crane integration Handling System EOT Crane or Mono Rail Hoist 1–5 Ton capacity with motorized traverse Raw Materials Required for Galvanizing Process Material Purpose Caustic Soda (NaOH) Alkaline degreasing Hydrochloric Acid (HCl) Rust/scale removal Zinc Ammonium Chloride Flux solution Special High Grade Zinc (SHG) Molten bath material DM Water Final rinsing, flux makeup Cr³⁺ Passivation Chemical Optional topcoat treatment Key Technical Design Considerations Zinc Kettle Design Material: EN S355 J2 or ASTM A516 Gr. 60/70 Wall Thickness: 40–60 mm Life Expectancy: 5–8 years with proper maintenance Heating: Burner with pre-heated combustion air improves efficiency Tank Construction All chemical tanks designed with: Anti-vibration pads Overflows and sludge drain valves Maintenance walkways and access platforms Pollution Control Fume extraction systems with: PP wet scrubbers Mist eliminators PVC/FRP ducting pH neutralization unit for scrubber effluent Output and Efficiency Metrics of Galvanizing Plant by Parameter Value Daily Capacity 5 – 100 tons Zinc Consumption 55–65 kg per MT of galvanized product Energy Use 6–8 litres/hr (diesel) or 12–15 Nm³/hr (gas) Acid Consumption ~4–5 kg/MT Labor Requirement 6–10 persons per shift (manual plant) Compliance & Safety for Galvanizing Plant Setup Follows CPCB and SPCB pollution norms Designed as per OSHA safety guidelines Fume extractor interlocked with acid tanks Platform railings, PPE kits, acid-proof flooring Why Choose SAZ ENVIRO, A Trusted Galvanizing Plant manufacturer India As a trusted Galvanizing Plant manufacturer India, we offer: ✅ Turnkey solutions – from civil layout to final handover✅ Modular plants – scalable from 2 to 80 tons/day✅ International standard design – ISO, ASTM, BS compliant✅ Integrated fume scrubber and ETP solutions✅ Automation-ready controls (PLC + SCADA) We’ve delivered more than 50 plants across India, UAE, Kenya, South Africa, Saudi Arabia, and Indonesia, establishing ourselves as the most reliable Galvanizing plant manufacturing company India. 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