“It doesn't matter which electric motor I buy, none will work. The paint layer comes off on every motorcycle”
Meindert Jan, who works in the fish processing industry, had to replace a properly functioning electric motor every six months because the paint was flaking off. Because paint chips between the fish is obviously not done in the food industry. Cleaning agents, salt water, industrial cold and weather influences damage the paint layer of an electric motor. This common problem was the starting signal for Kolmer Electric Motors to develop a coating that does stay in place. After four and a half years of research with many practical tests, an approved TNO test and food safety certificate, they launched the Kolmer Top Coating that extends the lifespan of an electric motor under extreme conditions by at least a factor of 4.
Where it all started: Jan & Meindert Jan
Jan Bakker, sales manager at Kolmer explains where it all started. 'Meindert Jan was not the first to encounter the problem of peeling paint or a rusty electric motor. On the contrary, the maritime sector, agricultural sector, chemical industry and cold stores also faced similar problems. Applying a layer of paint over it again and again was not the solution. The electric motor therefore overheats due to the increasingly smaller spaces between the cooling fins. At Kolmer we work customer-oriented. Exceeding customer demand is our goal. That's why we started working on this seriously.'
Coating that does not form a sealing layer but adheres to metal
A German laboratory was commissioned to develop a coating for electric motors that prevents peeling and rust under extreme conditions. In this way, the lifespan of a motor is extended, process uptime increases and maintenance costs are reduced. Jan Bakker explains: 'The special thing about this coating is that it does not form an extra protective layer, but penetrates straight through the paint and primer. It essentially adheres to the metal. This means that nothing can get under the paint and therefore it will not flake off.' Little can be said about the composition and effect of the coating in the context of confidentiality. However, many test results are public.
25 test locations
Jan: 'We first started testing at Meindert Jan in the fish processing industry. The electric motor for the conveyor belt is constantly exposed to moist fumes, hard jets from the high-pressure spray and cleaning agents. Previously, the production line was stopped every six months and a new electric motor was installed. That takes time and money, which is why Meindert Jan wanted to participate in a trial. That turned out well, the engine is still running.' Jan continues: 'We slowly gained confidence in our product. Many electric motors are also used under extreme conditions in the maritime sector. That gave me the idea of lowering two electric motors into the water of the Rotterdam harbour. One engine treated with our coating and the other untreated. After 9 months we took the engines out of the water and the difference was clearly visible. The untreated engine was affected by algae, seaweed, rust and deposits and on the treated engine only a little flash rust from the untreated ash. This flash rust could easily be polished away. Then we knew: with Kolmer Top Coating we can compete with the much more expensive stainless steel electric motors.
In total, coated and uncoated electric motors have been installed and monitored at 25 test locations. The engines came into contact with salt water, acid, lye, manure and freezing cold. All treated engines lasted 4 to 8 times longer.'
TNO and Food Safety Certificate
Jan: 'Of course we also received questions from customers whether the product is safe to use and safe for the food industry.' TNO investigated all safety risks and concluded that the product is harmless to humans and the environment. Moreover, the coating is not based on nanotechnology. 'Nothing against nanotechnology, but as long as the long-term effects are not known of what it does in the human body, for example, then it is preferably not used in my company,' says Martijn Stoffelsen (director of Kolmer). In addition, the coating has a guarantee certificate for safe use in food production. This certificate is issued by ISEGA Umweltanalytik GmbH. No coating particles end up in the food during the production processes.
C5 standard
Kolmer Top Coating does not yet fall under the C5 standard, because this standard assumes a certain layer thickness. Kolmer Top Coating, on the other hand, is a water-thin, transparent coating. In new construction, the standards in the replacement market must be met, which is more practice-oriented, and the Kolmer Top Coating may be used. Work is underway to get the Kolmer Top Coating approved for the C5 standard. Major parties, such as Damen Shipyards, Jan de Nul Group and Boscalis, are now testing this coating.
Sustainable and good for your wallet
In these current times there is a lot of scarcity. Scarcity of materials, but also minerals such as iron and copper are becoming increasingly scarce. 'If you can extend the lifespan of an electric motor, you save production energy and contribute to preserving the environment,' says Jan Bakker. 'We are open to challenges, after all exceeding customer demand is our motto. So if a reader with a specific problem wants to test the Kolmer Top Coating, we will be happy to help you with this.'
Speed Specials Service
Speed, specials and service are Kolmer's core values; fast delivery, modification of electric motors and 24/7 service when the engine is stopped. 'Applying and curing KTC, which can only be used on our own electric motors, does take 7 days to guarantee a wear-resistant smooth surface, but we do have the feeling that with Kolmer Top Coating we have been able to exceed the demand of our customers. ', concludes Jan Bakker.
Nederlands