 | |
This is due to the relatively slow and predictable rate of atmospheric corrosion of zinc compared with steel, and the relative positions of zinc and iron in the electrochemical series. Zinc will corrode preferentially to give cathodic protection to iron when both are in contact in an aqueous medium, and any bare areas in a zinc coating on steel, caused by damage or operations such as cutting or drilling, are still protected by the surrounding zinc. Corrosion is a huge drain on the economy, estimated to cost at least four per cent of GDP in industrialised countries. The life and durability of steel is greatly improved when coated with zinc with no other material known to man able to provide such efficient and cost-effective protection for steel. One company leading the drive to harness the remarkable qualities of zinc for commercial use is Mazak.
As the largest consumer of the product in the UK, accounting for around 30 per cent of national consumption, Mazak has a strong history of pioneering new developments in zinc; its successful track record stretches back over 50 years and comprises generations of experience together with the application of unique technologies to maintain the company’s position at the leading edge of the industry. To support this commitment Mazak is an active member of the International Lead Zinc Research Organisation (ILZRO), a US based globally funded organisation that develops new and/or improved products and processes, which have fuelled Mazak’s technology improvements and brought it new markets and applications.
Mazak is currently the UK’s largest producer of zinc based diecasting alloys and pigments. The company’s Bloxwich site has been producing zinc alloys for over 50 years, continuing a tradition that has existed for over a century. In recent years there have been impressive developments in the field of zinc alloy coatings, providing greater atmospheric corrosion resistance than pure zinc. Process developments in continuous galvanising have also enabled a range of coatings to be produced with very closely controlled thickness and surface finish. Such advances have secured the commercial viability of zinc products for such applications. Equally important for the corrosion protection of steel products, pigments are especially useful for those complicated steel fabrications which cannot use zinc coated steel or be subsequently hot dip galvanised.
Another growth area is that of zinc castings, which is based on new alloys and new technology. Until the 1930s there were only two zinc casting alloys of any commercial significance: zinc-four per cent aluminium pressure die casting alloys with and without one per cent copper. Zinc casting now has a family of alloys. Mazak customers can choose the alloy and casting process most suited to their product. Zinc alloy castings are unique, particularly when produced by the pressure die casting process. They can be made to extremely close tolerances, with excellent surface finish, have a range of useful mechanical properties and can receive a wide range of applied finishes. As a result, zinc castings find a range of applications from automobiles to zip fastenings. Mazak supplies a global market with a diverse range of high purity alloys and exports more than 50 per cent of its UK production, mainly to Western Europe and the Far East. Export sales are assisted by a near global network of sales agents and representatives, which as well as providing good local customer relations, gets over language, cultural and time difference barriers.
Metal
Testing the Metal
Mazak Ltd is currently one of the world’s leading producers of zinc based alloys and pigments.
Mazak has maintained a leading position in the market, offering clients products of assured quality and high purity. The company is able to develop and tailor products for individual customer requirements.
Competition from plastics threatened the market for zinc castings in the 1970s, but the development of new alloys and dramatic improvements in process control enabled zinc castings to hold their own in many areas, particularly where strength and applied finishes are required. A further benefit of the process improvements was that castings could be made much thinner so that considerably less metal was used for a given product. This in turn meant weight saving, while at the same time quality and consistency improved and production costs were reduced. Mazak alloys are being used for the diecasting of high volume, high precision components in the automotive and white goods industries. While tailor made alloys are being used in the galvanizing of strip steel as well as the hot dip galvanizing of fabricated structures.
High Performance Products
Mazak’s range of high purity zinc oxides, dusts and phosphates provide its customers with a total package of high performance products. From pharmaceuticals to steel, the company maintains a position at the cutting edge of new developments, applying new technologies to develop a
leading range of non-toxic, anticorrosive pigments.
In recent times Mazak has opened a further production facility in Eastern Europe to meet increased demand. The Slovakian plant began operation in October 2003 and has enjoyed a successful first year of operation, trading well ahead of the company’s projections. The low tax rates and relatively cheap labour of Eastern Europe have proven to be a siren song for companies around the globe, but especially Western Europe, who are moving production facilities out of countries with higher wage costs to this eastern economic Shangri-la. As a result of this move Mazak is rapidly becoming the largest zinc consumer in Slovakia, which will probably be achieved in 2005.
Rail Connected
Both its facility in the UK and this newer location in Slovakia are accredited to ISO 9001 with the UK site also recognised with the environmental ISO 14001 standard. In addition, Mazak was the first company in this industry in the world to achieve BS 5750 (the forerunner of ISO 9001) in 1987. In both the UK and Slovakia Mazak is rail connected and this mode of transport is actively preferred for its incoming raw materials on cost and environmental grounds. This commitment has led to the company being recognised with environmental awards for the UK based on reduced road traffic.
In the UK Mazak’s market share continues to grow, further consolidating Mazak’s position. The company operates as part of the MFC Bancorp Group, a niche international financial services group with offices in Hong Kong, Shanghai, Vienna and Berlin.
The expansion of European economies and markets is providing Mazak with the potential for dynamic growth. The company is continuing to expand into new global markets and is committed to the continuing development of its production capabilities. Mazak continue to pioneer new developments in zinc, applying unique technologies, which are setting new standards in
product performance. VTR
|
