Malcolm Enamellers is a Made in the Midlands Silver Member Our company
Based in the West Midlands, Malcolm specialise in the application of surface coatings including electrocoat, powdercoat and heat-resistant finishes, as well as having the ability to treat laser cut edges as part of all of our processes.
At the forefront of outwork metal finishing for over 60 years, we have an unrivalled reputation for flexibility, fast turnarounds, quality, innovation and competitive prices.
Running 24-hour shifts, we can:
tailor our processes to suit your requirements, giving you the reassurance that your products are in safe hands.Supplying the automotive, commercial, industrial and agricultural sectors, we have experience processing all types of components, from small pressing to large castings and heavy fabrications up to 500Kg.
Services
If you produce a metal item, anything from a small pressing to a large casting or fabrication and require it to be painted, any colour. With the assurance that the finish will resist the rigours of corrosion and wear and tear, you need electropainting, powdercoating or both from Malcolm.
With the ability to treat laser cut edges prior to painting on all of our processes, we have become a "one stop shop" for your coating requirements.
Electropainting (e-coat)
Widely used throughout the automotive industry as a primer, this coating provides excellent corrosion resistance (typically in excess of 1000 hours salt spray to ASTM B117) and is an ideal base for overcoating with both powder coating and wet spray.
Normally available inside 24 hours.
Powder coating
Powder coating is a durable and tough finish designed usually as a cosmetic finish, on top of either electropainting or phosphate, and is supplied in a range of colours.
Normally available inside 24 hours, or 48 hours with e-coat.
Electropainting
Electropainting (E-Coating, electrocoating) is a painting method, which uses an electrical current to deposit paint on conductive materials.
The electrocoat system applies a DC charge to a metal part immersed in a bath of oppositely charged paint particles. The paint particles are attracted to the metal part and paint is deposited on the component, forming an even, continuous film over the entire surface, until the coating reaches the desired thickness. At that thickness, the film insulates the part, where attraction stops and the process is complete. Depending on the polarity of the charge, electrocoating is classified as either anodic or cathodic. Electrocoat is also known as an electrophoretic, cathodic or cationic coating.
E-coating was developed originally for the automotive industry because it is economical and provides superior coverage, adhesion, and corrosion resistance. It coats aluminum, zinc, brass, steel, any material that conducts electricity. Usually applied on top of suitably pretreated surface prepared by aqueous degreasing to remove light oils, greases etc then a conversion coating of usually zinc phosphate to provide a suitable key for the electropaint to adhere to and provide corrosion protection.
Typical parts coated using this process are pressings, stampings, forgings, castings, spinnings provided for a wide range of applications including automotive, agricultural, industrial, household, electrical.
Electrocoat applied using the correct conditions, has excellent corrosion resistance qualities; typically 1000 salt spray (automotive) and is extremely durable. Subsequent coatings of powder coat or wet spray will enhance cosmetic, corrosion and Ultra – violet resistance.
Powder coating
Powder coating is one of the most advanced coating processes available provides the ultimate finish durability and longevity. Powder coating is a method of applying a decorative and protective finish to a wide range of materials and products. The powder coating process involves electrostatically charged resin & pigments that are sprayed onto an electrically grounded surface. The substrate is then heated in an oven and cured while the powder is baked on. The result
Colour selection is virtually unlimited with high and low gloss finishes available. Texture selections range from smooth surfaces to a wrinkled or matte finish, and rough textures designed for hiding surface imperfections.
Our Powder coating process is environmentally safe. There are virtually no VOC's (Volatile Organic Compound) released during the application and curing of the powder.
Wet spray
This is another process, usually a cosmetic colour finish which is applied either onto phosphate or e-coat, or it may be specialised such as textured or heat resistant.
Facilities
We have just commissioned our latest state of the art EP (electropainting) plant, which is the largest outwork EP plant in the UK. This gives us the ability to coat over 3 metres in length and up to 500Kg, as well as being able to treat laser cut edges, which is typically required for large fabrications.
This is in addition to our two existing EP lines, which also have the capability of treating laser cut edges as well as processing over one million components per week.
This gives us unrivalled flexibility, being able to offer both spray and immersion pre-treatment technology, which can be matched to each component we process, depending on whether it has complex internal recesses or flat surfaces.
Our Powdercoating and wet spray application areas in addition to the EP, really makes us a "One stop shop" providing flexibility, coupled with quick and efficient turnaround.
Production Control
Traceability of product is fundamentally important through any process. With tight schedules and just in time working by our customers, it is vital that once the work is with us, they can access its progress and know when it is ready to collect.
Orpheus, is a production control solution developed by Malcolms, using bar code technology, allowing total order tracking and traceability from quotation through to invoicing.
Order Tracking
Once the parts are on site, our customers can access their product details through the Internet, via our web site and view where they are in our production process, using its unique reference code. This enables our customers to optimise their own production and logistical routes, in order to be efficient with their own customer.
Logistics & Transport
We have our own fleet of vehicles with the facility to deliver and collect throughout the UK.
Use of trailer swaps at Malcolms and our customer sites allows for quick, easy and convenient turnaround of goods and vehicles. Our fully weather proof loading dock system makes sure that your goods stay completely undercover and safe from the elements, ensuring product quality.
Transport fleet owned and operated by Malcolm
(5 Artics, 2X16 tons, 2X7 tons, 14 trailers).
Trailer exchange facilities.
Covered loading and unloading facilities.
Product traceability throughout processes using Orpheus production control software.
Quality & Testing
As part of our commitment to high standards, we have adopted activities for continuous improvement to reduce waste, increase efficiency and create a better working environment.
We are accredited to BS EN ISO 9001:2000 by the B.S.I., coupled with our integrated Orpheus bar coding management system, this gives us total control and traceability of product.
We have our own in-house testing facilities, which allows us to constantly monitor our processes in accordance with all of the major OEM specifications.
The automated monitoring systems on all of our plants are key to maintaining process and product stability.
All staff are, or have been enrolled on training programmes with nationally recognised awards, delivered in partnership with City of Wolverhampton College. As a result, our workforce are constantly developing and improving their own skills to their own and the company's benefit
