The advantages of zinc die-casting

Before we delve into the importance of design, it is essential to understand the benefits of zinc die-casting. This manufacturing process allows for components with complex geometries, small, high-precision details, and thin walls, offering a wide range of design possibilities. Using zamak as a casting material offers, among various positive properties, good mechanical strength, effective resistance to corrosion, and excellent thermal and electrical conductivity. The above advantages facilitate the designer’s work in the search for the most suitable material and production system for the product in the design phase, offering various construction possibilities provided by a single alloy.

The excellence of design

Design is undoubtedly a crucial factor in the success of any product, and in zinc die casting, it is no different. Functional design is all about balancing form and function, combining aesthetics and practicality to create a product that is attractive, functional, and efficiently buildable. In the case of zamak die-casting, the shapes of the product must be designed considering the possibility of being obtained from a mold and the ease of filling the mold with liquid metal. This aspect represents a fundamental factor for an efficient production process, as we have analyzed in the post: Surface defects in zinc die casting: flow marks, blistering and sink

Engineers and designers must also consider several crucial aspects to achieve design excellence.

Features

The functionality of a product is the fundamental element. It is essential to understand the component’s technical specifications and ensure that the design meets these requirements. Just as it is important to verify that the die-casting production process allows the creation of the shapes identified in the design phase, this involves careful assessment of mechanical stresses, tolerances, thermal and electrical properties, and interactions with other components in the system.

Aesthetics

In addition to functionality, aesthetics play a significant role in zinc alloy die-cast products. Well-designed products must be aesthetically pleasing and reflect the manufacturer’s identity. The design must take into account proportions, surfaces, finishes, and other aesthetic elements to ensure an attractive appearance. In fact, zinc alloys accept the application of a great variety of finishes, from various galvanic treatments to any type of coatings. The designer, therefore, has a vast range of solutions at his disposal to define the aspect of the product that is most suitable for the target market.

Feasibility

Zinc die casting offers a high level of flexibility in producing complex components; however, it is essential to consider production feasibility from the beginning of the design process. Designers must understand the capabilities and limitations of the zinc die-casting process and design the component to maximize manufacturing efficiency. For this purpose, close collaboration between designers and die casters is essential; the initial co-design activity is, in fact, one of the most critical elements for achieving the product’s productive and commercial success.

Choice of materials

Choosing the right material is crucial to successfully designing zinc alloy products. Zinc offers a unique combination of properties that can enhance product performance and life. Selecting specific zinc alloys for die casting and optimizing them for the needs of the product can significantly influence its success.

Conclusions

Achieving design excellence in zinc die casting requires carefully balancing design and function. A well-thought-out design not only fulfills the product’s functional requirements but also offers attractive aesthetics and efficient production. Investing time and energy in the design of zinc die-cast components can lead to outstanding results in terms of reliability and commercial success. With the proper attention to detail and collaboration with industry experts, it is possible to produce zinc die-cast components that meet both quality standards and aesthetic expectations.

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Characteristics of zamak

Zamak is an alloy composed of zinc, aluminum, magnesium and copper. According to the different percentages of these components the alloy has variable characteristics and can be used for the manufacturing of products for different market sectors. For an in-depth look at different types of zamak and their features, read the article ZAMAK molding in hot chamber die casting: chemical composition.

The characteristics of zamak that are particularly beneficial for the production of components for electronic products are:

Electromagnetic shielding

Zamak has good shielding properties with reference to Electromagnetic Interference (EMI). Therefore, it is especially suitable for the production of housings for electromagnetic cards because it is a product that requires a reduction of interferences

Heat dissipation

The properties of heat dissipation of zamak are similar, if not higher, to those of other materials. In this case, what makes zamak products competitive is the manufacturing cost of the product, the lifespan of the mold and the possibility to achieve products that do not need relevant secondary mechanical operations. For further information about this property of zamak, we suggest this case study: Zinc Heatsink Case Study: Loewe TV Heatsink.

Thin wall thickness and reduced dimensions

Zamak fluidity allows the achievement of a very thin wall thickness and of an extremely high level of detail in components of reduced dimensions. This is particularly important in the case of electronic products, which usually are characterized by very small dimensions and by a great number of details.

Stiffness and anti-vibration properties

These properties of zamak are especially relevant in case of electronic products employed in critical environments. In the industrial field, for example, electronic connections of some kinds of machine tools could be exposed to mechanical stress or vibration. It is evident that in cases like the one just described, zamak offers a protection and a vibration damping capacity that plastic could not offer.

To discover something more about chemical, physical and mechanical characteristics of zamak read the Zinc Association Engineering in Zinc, Today’s Answer, which contains very detailed information on these subjects.

Zamak components for electronic products: characteristics and competitive advantages

Let’s now analyze some zamak components for electronic products to examine their characteristics and competitive advantages.

Hard disk case

In this hard disk case we can observe how zamak properties contribute to the functionality of the product in several ways. Indeed, the case is anti-vibration and this allows the hard disk to work in stable conditions. Furthermore, as you can see in the picture, the product has both very small particulars and thin thickness. Specifically, directly during casting phase thanks to zamak it has been possible to realize the honeycomb grid that allows heat dissipation in the server through air circulation. With other materials the grid could have been achieved only through secondary operations, such as shearing, with unavoidable consequences in terms of timing and costs.

Housing for steering wheel lock

This housing hosts the electronic card of the steering wheel lock. In this case it is the properties of electromagnetic shielding and stiffness of zamak to make the product competitive compared with other similar products manufactured with other materials. As a matter of fact, the shielding allows the electronic card to function in optimal conditions without being subjected to the interference of near electromagnetic fields. Then, for this particular product, stiffness makes zamak especially competitive compared to plastic. Often when plastic housings are installed electronic cards tend to bend, whereas  the stiffness of zamak leads to a higher protection, thus extending its lifespan.

Device for checking, counting and separating banknotes

As far as this product is concerned, zamak has replaced stainless steel, thus cutting production costs and the need for mechanical operations and finishing. This has been made possible by the properties of zamak and especially by the capacity of the alloy to reach thin wall thickness and a high degree of detail. In this way the customer has obtained a product that does not need to be assembled, manufactured with molds with a long lifespan, which need little maintenance and with scrap rates close to zero.

Housing for corporate network connectors

The housing for corporate network connectors is illustrative of the properties of shielding, stiffness and resistance of zamak. For these kinds of products, shielding properties of zamak allow freedom to the electronic designer, who can mitigate the drawbacks linked to the electromagnetic waves without special precautions, but only through the choice of the most suitable material. Stiffness and resistance of the material make the use of the component suitable for particularly critical environments, such as production departments of a plant.

Conclusions

With this brief overview on zamak components for electronic products we have analyzed how some properties of zinc alloys allow the achievement of competitive and effective products. However, these are not the only components for the electronic industry that can be manufactured in zamak. For a more comprehensive overview visit our website www.bruschitech.com in the Services page.

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Industrialization of the product in zinc die casting

Industrializing a product means facing the entire design process taking into account the functional, qualitative and aesthetic specifications of the customer and of the construction technology, which in this case is the hot camber die casting of zinc alloys.

The industrialization of the product is therefore a complex process composed of various phases in which various departments intervene. Let’s analyze the delicate process that leads to mass production.

DFM

Already in the RFQ (Request For Quotation) phase, therefore still in the commercial phase, the project proposed by the customer is evaluated and analyzed in order to present an offer. Afterwards, once the sales process has been completed and the order from the customer has been received, the most substantial and vertical activities are undertaken. One of these activities is, for example, co-design: a phase in which the technical departments of the customer and of the supplier work together to optimize the product.

The study undertaken on the product, the co-design activity mentioned above, makes it possible to propose a series of activities aimed at increasing value and reducing costs, both as regards the product and the production process. The work carried out at co-design level culminates with the drafting of Design for Manufacturing, called in technical jargon DFM, a document that defines the most suitable shapes for the production process of the die cast and the tools that are necessary in the different phases of the process: mold, automations, frame for superficial treatments and others.

For a definition of DFM approved by the scientific community and for additional related information we recommend visiting the Society of Manufacturing Engineers website.

It is important to underline how the modifications suggested in this phase not only concern the aesthetic aspect or the functionality of the product, but also the resolution of problems emerged during the study phase: whether they are at product level, such as critical areas and deformation or too narrow tolerances, or at process level, for example it could be necessary to find alternative solutions for the configuration of the mold extractors.

For further information on DFM we suggest you to read the article Product design for die casting: how to speed up and optimize your DFM.

Kick-off

Once this initial phase has ended, it is time to bring together for a second time all the actors involved in the process with a meeting called kick off. The kick-off is the moment of the launch, typically it is a meeting called by the Project Manager in which all the departments involved in the realization of the project come together to discuss the production aspects. During the meeting, conducted by the Project Manager, the following areas intervene:

• Design: designers highlight the critical aspects of the product and the solutions identified at design level
• Quality: on the basis of the observations of the designers it identifies the elements on which it will have to focus its attention and the kind of analysis that it will be necessary to undertake to guarantee the respect of the requirements of the customer
• Production: it evaluates the technical aspects of the productive process and the relative criticalities, establishing machines, automations and processes necessary for the realization of the product
• Logistic: it manages the warehouse and its critical issues and the shipping of the goods to the customer
• Sales and marketing department: oversee communication with the customer at every stage of the project life, providing feedback on the progress of the processes

Kick-off is a very important moment because at the end of the meeting all the departments are ready to act together for the success of the project. At the end of the kick-off is therefore possible to start the construction of the tools necessary for production.

Sampling

During sampling phase the first samples, defined first off tool, are created. It is in this phase that the die casting mold and all the tools that will be necessary during mass production phase are tested.

All production departments contribute to the evaluation of the samples that are subsequently sent to the customer in order to obtain the approval.

Samples allow the verification of the compliance of the product to the requirements of the customer and the necessary analysis are undertaken by quality department and afterwards by the customer.

Samples, beside die casting process, can undergo different kinds of treatments. In some cases raw parts are sent to the customer, in other cases mechanical operations or superficial treatments are necessary.

In the case of superficially processed samples, external suppliers are involved. In this case it becomes necessary to carry out checks on the products arriving from suppliers and consequently on those delivered to the customer. In fact, it is important to monitor quality throughout the entire supply chain so as to guarantee to the customer products that are always compliant and that have passed strict controls.

Pre-Series

If sampling is aimed at the analysis of the quality and the dimensions of the samples the pre-series allows the verification, on a reduced scale, of the compliance to the established standards for the productive process.

In pre-series phase in fact the products are created with all the techniques and the processes that will be undertaken in phase of mass production allowing the verification of cycle time, of the production capacity of the plant and the respect of the parameters set in design phase.

Since the runs of the pre-series are limited and sometimes the product or the mold have to be subjected to modifications, in zinc alloys die casting it is advisable to carry out the pre-series, and the previous sampling, with prototypal molds. The prototypal molds do not have the lifespan of the molds for mass production but they are more suitable for the execution of modifications.

Importance of collaboration

We have seen how in the industrialization of the product expertise from different departments intervene at different levels and in different phases of the process. The operative bonds between the different departments become particularly evident in this phase and they are decisive in the functions of coordination, timing, management of the resources and project management.

Moreover, in industrialization phase the collaboration goes beyond the boundaries of the company and it involves customers and suppliers. In fact, the process of co-design can be undertaken only together with the customer and it is thanks to collaboration with the latter that it is possible to establish strategies aimed at reducing costs and at optimizing the product.

Also the collaboration with suppliers becomes fundamental because only through a careful monitoring of the entire production chain  it becomes possible to guarantee the quality of the products and to obtain the approval of the customer.

Conclusions

In this brief article we have described the phases that precede mass production of a component, then focusing on collaboration that is necessary for the success of any project, in particular in a delicate phase as the industrialization of a product.

In conclusion, we believe it is important to underline how, in this process, the Project Manager is a key figure that has to constantly monitor the processes and the contribution of every department verifying that, step by step, all the necessary operations are performed. It is only through the right collaboration that, in an articulate process composed by a number of steps, it becomes possible to achieve the goal in the best and efficient way.

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Zinc die casting for doors and windows

Variety of components made of zinc alloys for doors and windows

Generally, when it comes to zinc components for doors and windows frames one thinks immediately about galvanization, a process in which products realized with various kinds of metal are coated with a zinc layer to increase their superficial resistance.

However, it is possible to create a large number of components for doors and windows entirely made of zinc alloy.

Among these zinc alloy products some of them are more traditional and characterized by a long productive tradition in Zamak, such as corner transmission, case, external casing for panic exit handles, while some of them are more modern and linked with the recent developments of home automation, such as the keypad case for the remote opening of doors and windows or the covering plate for hotel door locks.

In this article, after briefly depicting the advantages that make zinc alloys a winning choice for the building industry, we will examine more in depth the productive process of some components for doors and windows. These products will be reviewed analyzing their productive process, their capability to undergo superficial or finishing treatments and the possibility of optimization in terms of design.

Competitive advantages of Zamak

Producing the previously mentioned components in zinc alloys results in a great advantage both for the final consumer and for the producer of windows and doors.

The use of zinc as raw material and the hot chamber die casting process allow the reduction of finishing operations and make it possible for the product to undergo a number of protective or aesthetical superficial treatments and for the production time to be reduced.

Differently from other materials, such as aluminum for example, that need different processing in different phases, Zamak allows the die caster to obtain, with a process that can be almost entirely automated, components ready for assembly. Moreover, thanks to the physical-chemical properties of Zamak, it is possible to reach final shapes with centesimal tolerances and to avoid the expensive mechanical operations that are required for the finishing of other metals.

Finally, a last competitive advantage of zinc alloys compared to other materials is the possibility to reach a minimum thickness of about 0.3 mm that, together with the capability to obtain complex geometrical shapes, allows a great design freedom.

To deepen your knowledge on superficial treatments for building industry components read the article Zinc Die Casting Finishes for Building Sector.

Requirements for zinc components for doors and windows frames

Zinc components for doors and windows frames can be characterized by a prevailing technical or aesthetical purpose but often it is necessary to comply with both these requirements. The products employed in this industry, indeed, are exposed not only to the final user sight but, in the majority of cases, also to external atmospheric agents. For this reason it is necessary to guarantee a superficial resistance able to remain unchanged over time. Indeed there are few pieces that stay hidden in the internal part of the frame and often also these components become visible when the frame is opened: therefore aesthetical quality is one of the main requirements for this industry.

However, we must not forget that components that at first sight seem to perform an exclusively aesthetical function, such as, for example, the cover plates of some locks or the external casing of handles, actually hold functional mechanisms and, with technological advancement, they have to comply with increasingly strict technical requirements

Let’s look at these components in detail, taking into consideration their productive process and the possibilities and the advantages that they offer in terms of design, and economic saving.

Components for traditional doors and windows frames

As previously mentioned some components in zinc alloys for doors and windows have a long die casting tradition. Already since the middle of the last century the technical advantages connected to the material and to the technologies of its processing did not go unnoticed. Below some brief case studies that depict the manufacturing process of these components.

Corner transmission

The corner transmission is a purely functional component: it is the mechanism that transmits the motion received by the rotation of the handle for the vasistas opening of frames. As already defined, the component becomes visible when the user opens the window and thus, even if it is often hidden, it is necessary for it to have a pleasing aesthetical appearance for the final user.

For this reason designers have to  design a product with functional characteristics and, in parallel, also an aesthetical value.

Thanks to versatility and to the characteristics of zinc it is possible to find, already at a design level, technical solutions for both the objectives. Even in the case of a functional component with an aesthetical quality, such as the corner transmission, die casting allows the achievement of a finished object with minimum thickness, narrow tolerances and aesthetic value such as to satisfy the final user.

Case

The case is a component of the opening and closing mechanisms of doors and windows. The piece has a technical function because it holds together and covers the linkage mechanism of transmission of the rotary motion in linear but, in addition to this function, as in the previous case, the case is distinguished by a noticeable aesthetic value because it is directly inserted in the living environment. Precisely for this aesthetic value the case undergoes superficial treatments aimed at increasing the superficial quality: this component, depending on the customer needs, can be coated or chromed.

Choosing Zamak for the production of the case is eventually profitable not only from a technical and aesthetical point of view, as already observed, but also from an economic perspective. In fact, zinc alloys allow the die caster to diminish the number of secondary operations because, thanks to their fluidity characteristics, they allow the realization of complex shapes. Thereby, thanks to Zamak, it is possible to obtain a number of details and micro details already during casting phase, without having to perform mechanical operations in other phases of the productive process.

For a further analysis of the characteristics of zinc we suggest you to visit the page from the International Zinc Association website.

Moreover, still concerning saving, the possibility of processes automation given by its technical characteristics makes Zamak competitive in comparison to other metals. In the specific case of the realization of this component it has been possible to automate the casting process up to the complete threading of the object without the contribution of personnel and therefore with a consistent saving on the cost of direct operators.

Case for panic exit handles

The case for panic exit handles is the housing of the mechanism that is connected to the central handle that allows the opening of the door. Every panic exit handle has two lateral cases that cover the opening mechanisms and they perform both a technical and aesthetical function.

Relatively to the aesthetical function, the use of zinc alloys makes it possible to perform a great variety of finishing aimed at obtaining functional or aesthetical objectives, such as, for example, the treatments to protect the component from weathering. This allows a great freedom of choice for product designers: in this way they can follow functional criterions without renouncing aesthetical factors.

Also relatively to technical aspects, the choice of zinc alloys provides actual advantages to the productive process. The possibility of producing components with thin walls thickness allows the die caster to create components employing less raw material in comparison to other metals, with a self-evident advantage in terms of costs for raw material and for energy necessary for the change of state.

In the specific case of the external case for panic exit handles various analysis, conducted with specific simulation software, made it possible to obtain an optimized product with a noticeable reduction of wall thickness starting from the previous design provided by the customer.

Zinc alloys for automated windows and doors

As defined, if for some zinc components for doors and windows frames die casting is a technology that has been used for a long time, for some others components, which are more innovative and modern, this kind of production is substantially a new field. Home automation and associated technologies are growing steadily and so is the smart locks market. If it is true that doors will still have hinges, locks and handles it is also true that it is necessary to reconsider these components to make them able to support automation and electronics. However, new functionalities require the design of new solutions: in fact, for example, the presence of circuits and electronic commands necessary implies an activity of redesign and redefinition of the components. Thanks to their fluidity and their chemical-physical characteristics Zinc alloys, manufactured with the die casting process, allow the creation of complex shapes and thin walls resulting therefore particularly suitable for the production of components for home automation. In particular, two components that can be produced with zinc alloys appear with an increasing frequency on the market, so much that they have become common used. These components are the keypad case for remote opening of windows and doors and the cover plate for electronic locks.

Plate for electronic locks

The first of these zinc alloys for windows and doors components is the covering plate of electronic locks. The plate, considering its covering function, has to primary meet aesthetical requirements. However, in parallel, it also has an housing function for the electronic components that allow the opening of the locks: for this reason, as in other previously mentioned cases, besides the aesthetical value also technical aspects have to be considered.

The die cast, after the casting process, is separated from the injection channel, then it is thermal deburred and threaded. Afterwards it is prepared for the superficial treatment with polishing process and it is galvanized to obtain the finishing of satin or polished chroming and gliding. These treatments increase not only the aesthetic value of the product but also its superficial resistance and, as a consequence, its lifetime. Zinc alloys, also in this case, allow the producer to obtain, through optimized and automated processes, products with an excellent superficial quality at competitive prices in comparison to those for the same product realized with other metals.

Keypad case for the remote opening of windows and doors

A second zinc component for doors and windows frames that is increasingly common is the keypad that allows the opening of doors and gates by code. Also in this case the requirements are both technical and aesthetical: the piece, exposed to the weather conditions, has to resists salt spray tests, to keep an excellent aesthetical quality over time and to host, protecting them, the internal electronic components. Zinc, characterized by dimensional stability and resistance to the different weather and climatic conditions, proves to be an optimal choice. Finally, the capability to take complex shapes and to achieve an high level of detail and precision allows the customer to design the component with freedom in such a way that he or she can obtain the most satisfying product.

Conclusion

The employment of zinc alloys through hot chamber die casting process, in comparison to other alloys or technologies, often results in an economic advantage for the producer of components for doors and windows frames. In fact Zamak allows the reduction of secondary operations and the automation of a consistent part of the processes: with a great saving in terms of time and costs. Moreover, the design freedom, the possibilities offered by optimization and the great variety of superficial treatments that it is possible to perform on zinc components for windows and doors frames allow the achievement, without waste of time and material, of products that are compliant with the requirements defined by the customer and that are ready for the final user.

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Competitive advantages of lamps and lights in zinc alloys

The lighting market demands specific requirements that Zamak components are perfectly able to meet. Let’s explore some of them:

Employment of zinc alloys with led spotlights and CFLs

In 2005, with 2005/32/EC directive, European Union introduced the gradual substitution of incandescent bulbs and halogen spotlights with products with lower energy impact: such as led spotlights and compact fluorescent lamps (CFLs).

This directive completely changed the situation of the lighting market, allowing producers and designers to adopt new technologies and to expand the range of possibilities: both in the choice of materials and in the design of the products.

One of the consequences of the employment of these new lighting technologies is that zinc alloys have become competitive in comparison to other metals.

In fact, in the past high temperatures reached by lighting systems imposed the realization of articulated heat dispersion systems, which actually limited the employment of Zamak. Now, with the new regulations, it has become possible to employ Zamak for the creation of lamps and lights with innovative shapes and qualities.

Sustainability of the productive process

CFLs and led spotlights allow a saving on the cost of electricity bill because to produce light they employ less energy than other technologies: this means more saving for the final user and more environmental sustainability globally.

Also Zamak, even if in a different way, allows an important energy saving: thus proving to be a winning choice. Melting and manufacturing zinc alloys in fact requires less energy than that required for the treatment of other metals or metal alloys.

In addition, always on the subject of sustainability, at the end of their life cycle zinc products are 100% recyclable.

The productive process of zinc alloys components is less energy consuming compared to others and, together with the lesser energetic expenditure of the lighting system and the recyclability of the products, allows the producer that choses to use these products to make really informed choices. The advantages deriving from the choice of Zamak for components of lamps and lights do not affect only the producer of lighting components but also the final consumer and the environment. The producer will save on the creation of the components, the final consumer will have more choice and saving opportunities, and all of this while respecting the planet and its resources.

Life span of molds

The melting temperature of Zamak, lower than the one of other metals or metal alloys, means a further advantage for the producer of lighting components. In fact with a lower melting temperature of the metal also the wear and corrosion of the mold will be lower.

This means an important advantage in terms of life span of the mold and of decrease in the number of maintenance and repair works necessary to mass production.

Thanks to the choice of Zamak and to the hot chamber die casting process, with which the metal alloys are manufactured, the producer of lighting components will be able to produce large volumes of products over long periods of time in view of an initial investment for the mold that will not incur additional expenses in the medium and long term.

Possibility to create complex shapes with an high degree of detail

Lamps, lights and spotlights are design objects and their shapes are often articulate and complex. Zinc alloys, thanks to their fluidity, allow the creation of the shape desired by the customer directly during the die casting process without the necessity of further mechanical operations.

Over the possibility to create every kind of shape, the fluidity of zinc alloys makes it possible to obtain, already during the die casting process, all those elements that are necessary to the functionality of the product such as treads, holes, plugs and wings for the potential heat dispersion.

Moreover, zinc alloys allow the creation of components with extremely thin walls: this way the employment of raw material is reduced. In the case of lighting products the advantage is not only economic but also functional: lamps and lights with finest shapes can be hang more easily and can be better integrated into the furnishing environment.

Aesthetical factor: superficial treatments

Lastly, also regarding superficial treatments Zamak die casts prove themselves to be competitive compared to products made with other kinds of metals.

Zinc alloy die casts allow low cost mass processing, for example vibration and thermal deburring, with a noticeable advantage regarding also delivery times. In addition, the surface of zinc alloy die casts is ideal for receiving different kinds of treatments such as chroming, gilding, liquid or powder painting. This way products can take on the exterior appearance required by the customer.

In an industry like the lighting one this characteristic of great adaptability is very important because it allows the products to integrate harmoniously with different styles and furnishing environments, allowing a wider catalog and helping designers to wholly express their creativity.

Lighting components: case studies

After analyzing some of the reasons why Zamak components are competitive and particularly indicated for the lighting industry we will now examine some products underlining their characteristics and peculiarities.

Body for recessed spotlights

This component, with simple and elegant lines, hosts and frames the spotlight that is to be recessed into the wall. The frame of the spotlight can be round or squared but it can also assume more complex shapes in order to satisfy the design needs of the producer. Furthermore, the variety of superficial treatments, chroming, gliding, liquid or powder painting, as previously mentioned, allows great versatility to the product that can be inserted in different kinds of furnishing environment.

Table lamp: led support

In this case the customer desired a polished product, able to reflect light, characterized by simple and clean lines. Zamak made it possible to obtain, with an extremely limited number of processing, components with the thin walls required by the design of the object and with the smooth and defect-free surface perfect for chroming.

Adjustable spotlight for shops

This adjustable spotlight is intended for the lighting of shop windows: where it is necessary to direct light in specific directions. The product consists in two components: the mobile case and the external frame. The frame is the support for the case that, as anticipated, can be regulated to direct the light beam.

For the product in the photography the painting chosen by the customer is a white painting, in this way, in fact, the frame merges with the wall of the shop window without visually interfering with the exposition of the products it lights up.

Ring for cable spotlights

Cable spotlights are ideal for all the environments in which it is necessary to illuminate a room in all its length. The lighting system in fact allows the installation on parallel tracks of the desired number of spotlights and makes it possible to orientate them accordingly to the needs.

This ring for cable spotlight is a product designed for a minimalistic and elegant lighting. Its surface is chromed and it appears smooth, polished, bright and without any slightest defect.

Furthermore, the product is representative of the capability of Zamak to reach extremely thin wall thickness. In fact the die cast has been obtained, directly during casting phase, with all the elements that assure its closure and functionality. In addition, the reduction of wall thickness, with the weight diminution that it implies, results optimal for a cable lighting system.

Case for cable spotlights

This product is a design item with a particular shape that integrates a heat dispersion system. Also in this case it has been the productive freedom allowed by Zamak to allow the realization of all the details required by the customer in a single component.

In the picture it can be noticed how the surface of zinc alloys die casts allows an optimal result of gliding: also this products stands out for its brightness and for the quality of its surface.

Conclusions

Lighting components made of zinc alloys, whether they are lamps, lights or spotlights, are therefore products able to stand out and to be advantageous from many points of view. From the point of view of creativity and design they allow great design freedom making it possible to create, with a mass production process, products with unique and particular shapes.

Furthermore, Zamak die casts, thanks to the great number of superficial treatments they can undergo, are particularly indicated as components for furnishing products because they are able to integrate with different styles and environments.

Finally, economic and environmental advantages are not to be underestimate: to choose Zamak as raw material and die casting as productive process allows energetic saving and the employment of recyclable and sustainable materials.

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The necessary premise to obtain Zamak components for household appliances able to become an added value for the entire object is the creation of a relationship of understanding and trust between the die caster and the producer of appliances. In fact, only through the mutual exchange of expertise and knowledge it is possible to achieve optimal results, able to meet not only the customer’s requirements, but also the expectations of the final consumer.If you want to learn more about saving opportunities connected with the choice of the right die casting supplier we suggest you to read the post How the right die casting supplier can help your company’s VAVE. 

Advantages of Zamak components for household appliances

In the first part of this article we are analyzing the main advantages that result from the choice of zinc alloys for household appliances components with an eye to the needs of the household appliances producer and to the expectations of the final consumer. Thereafter we will present some brief case studies able to illustrate the processes and the strategic choices that have been adopted in order to obtain optimized products.

The advantages on the side of the household appliances producer that will be considered are:

• Co-design
• Functional beauty
• Design freedom
• Freedom of superficial treatments
• Finishing and assembly
• Cost reduction

  From the final consumer side we will consider the value added by zinc component in a household appliance in these regards:

• Appearance, quality, resistance
• Cleaning
• Recyclability
  

  Advantages from the producer’s point of view

  There are many advantages on the producer side, for some of them we will offer a more complete analysis while for others we will just discuss some details, providing indications on where to find articles that address these subjects more in detail.

Co-design

As anticipated, it is only through a relationship of understanding and trust that it is possible to question established methods and procedures in order to define new ones able to lead to an optimization of processes and products. To establish such a relationship it is necessary to choose a supplier of Zamak components for household appliances with the competences, the experience and the knowledge necessary to undertake, together with the customer, the co-design process. In fact the right supplier will be able to work on the design of the component suggesting optimization strategies for molds and filling flows, shapes and walls able to lead to the creation of unique and exclusive products.

To discover some of the co-design strategies that it is possible to implement to reduce weight, and as a consequence costs, of household appliances we suggest to read Weight reduction for white goods industry.

Functional beauty

The co-design process shall be led by the principle of functional beauty, which is the removal of unnecessary details aimed at improving the aesthetical qualities of the functional parts.

The achievement of functional beauty is synonym of true collaboration between designers and manufacturers, in fact it implies a joint and targeted action that allows the obtainment of results able to satisfy both sides.

To achieve functional beauty, thanks to the synergy achieved during the co-design phase, it is necessary to put at the core of the process the coexistence of functional and aesthetical elements without forgetting that, to obtain really valid results, it is necessary to consider options compliant with the die casting productive process.

In the article Functional beauty: the case of Nespresso KitchenAid Artisan 5KES0503  it is possible to find a more detailed definition of functional beauty and its exemplification through a case study.

Design freedom

Functional beauty and co-design are tools that help the producer of household appliances to obtain products able to meet his or her requirements. However, both the hot chamber die casting technology and the choice of zinc alloys allow a great design freedom. In fact through the die casting process it is possible to obtain complex and articulate shapes with very thin walls that allow the creation of unique components and customized details and shapes.

Freedom of superficial treatments

The surface of zinc alloys die casts is particularly suitable for superficial treatments and finishing. In fact components can undergo various kinds of treatments in order to achieve an external appearance that is appealing and customized according to the requests of the customer. These treatments are, for example, chrome plating, powder coating and liquid painting. Moreover, the advantage given by this kind of treatments is not only aesthetical but it results also in an augmented superficial resistance of the products, and, for extension, of their life time.

Finishing and assembly

Thanks to the introduction of automation, anthropomorphic robots and ad hoc realized machineries it is possible to automate a great number of secondary operations, such as assembly and finishing, and of quality control. The possibility to undertake these operations with a reduced contribution of personnel allows the customer to obtain ready-to-use components at a competitive price and with a reduced cycle time. Moreover, the development of automations and ad hoc machineries allows quality and compliance controls to be done quickly and in exemption from the risk of human error with a noticeable decrease of returns due to not compliance.

Costs reduction

Beyond the saving opportunities allowed by automation and accuracy in designing the mold and the filling flows, it is important to underline also the cost effectiveness resulting from the choice of zinc as raw material for the creation of die casts.

In fact zinc alloys are different from other metals or metallic alloys for their competitiveness in costs and production times. Zinc alloys do not require high temperatures to melt and, as a consequence, also the cooling times result reduced. These factors, in their turn, mean a cycle time that is short if compared to the one of other metals and in an increase of the productive capacity of the plant.

Zinc can be competitive also in comparison to plastic materials: for example, to obtain the stiffness and resistance of zinc, plastics have to be reinforced with glass fiber or with special polymers with a resulting increase of the costs for the material.

Advantages from the customer’s point of view

Customer experience is what the customer feels when approaching to a product. In defining the quality of this relationship there are a number of variables connected to the actual situation, but also to consumption and market trends. Specifically, for the relationship between the user and the appliance some important factors are: the performance of the product, its usefulness, appearance, texture, resistance, the global perception of the object and its alignment, or misalignment, to consumption trends.

Let’s now analyze some relevant factors, able to influence the customer experience for a home appliance and to determine the perception of value and quality of the object.

Appearance, quality, resistance

Zamak components for household appliances are able to convey good visual and tactile sensations. From a visual point of view an element made of zinc, which is coated or chromed, distinguishes itself from the rest of the body of the appliance resulting in a prominent and valuable element. Also from a tactile point of view a metal functional element gives feelings of greater reliability and resistance in comparison to the same component made of plastic. In this way it is possible to obtain a differential advantage given by the visual and tactile feelings of the user that result in a perception of value.

Cleaning

On the customer side an important aspect when choosing an appliance is the easiness of cleaning. To clean chromed zinc is easier than to clean other surfaces: the metal has an hard and smooth surface that lends itself well to be polished and on which it is easy to find, and to remove, stains and rings. The added value determined by an appliance that is easy to clean is not only aesthetical because, in this case, also cleaning variables intervenes, which are particularly important if the object is intended for the treatment of food.

Recyclability

In the last few years, consumers gained an always greater awareness in matter of environmental sustainability and recycle. The search for easily disposable products and with little environmental footprint has been able to modify markets that were solid and it caused changes in sales and supply chains. Household appliances, characterized by a quite long life time are an excellent source of recyclable materials. Zinc is a valuable material that offers the possibility to be recycled repeatedly and that allows C2C productive practice, namely the kind of production that from the beginning establishes the re-employment of the used materials. Therefore, for the consumer, choosing household appliances with zinc components proves to be a guarantee of recyclability and eco-friendly practices.

To know more about the advantages connected to recyclability in the production of Zamak components for household appliances we suggest you to read White goods: improving sales through sustainable choices.

Case studies

The household appliances with Zamak components can be large or small and intended for professional or domestic use.

Below we present three case studies, the first one is about a small coffee machine intended for the consumer market, the second one is about a professional coffee machine and the third one is about a component for white goods such as the hinge for washing machines.

Appliance for domestic use: coffee machine

Among the zinc alloy components for household appliances we would like to focus on a component of the coffee machine: the cup support, a functional component with a primary aesthetic quality.

The optimization of this product started with a PDCA study that made it possible to consider and to analyze all the phases of the process and to undertake the actions necessary to optimize it.

Thanks to the study it has been possible to identify the appropriate parameters for the regulation of the fusion and for the filling of the mold and the time intervals necessary to optimally complete the productive process. Thanks to the results of the analyses conducted during the simulation phase it has been possible to estimate the changes in the superficial quality and the cycle time variations depending on the temperatures of the mold.

Moreover, thanks to the results of the study, it has been possible to focus the attention on the most value adding actions to the entire productive process: this way it has been decided to make the production more effective with the introduction of an automation dedicated to the processing of the components.

In particular the automation concerned the superficial treatment of the cup support, a component that, due to its particular shape, could not undergo processing of the internal surface before chroming phase. For this reason it has been identified a mold filling that allowed the reduction to zero of the faults in the not workable part. Furthermore, already during the die casting phase, a superficial roughness such as to allow a good result of the subsequent chroming treatment was obtained.

To deepen this subject we suggest you to read the article Zinc Die Casting for small appliances: components for coffee machines and to watch the video Die casting for household appliances: coffee machines 

It is possible to gather more information on the future development of the coffee machines market reading the article Using zinc in die casting for smart coffee makers.

Appliance for professional use: coffee machine

Professional appliances have to meet the expectations of the workers that use them daily and of the consumers of the service made possible by the appliance.

The professional coffee machine we are discussing in this case study is an example of the above mentioned situation: the appliance has to be considered efficient by the professional but it also has to give the same impression to the less expert eye of the customers.

A challenge, in manufacturing components for this product, has been to realize a chromed wall with the name of the appliances brand imprinted on the surface.

The obtainment of a writing in relief directly during die casting does not allow the component to undergo the polishing operations that components to be chromed usually undergo. For this reason it has been implemented a strategy aimed at obtaining a surface suitable to be chromed right after die casting. Studies conducted with special simulation software allowed the right injection and outlet points to be found and to be moved to the internal wall of the component in order not to affect the surface quality. Moreover, filling flows have been optimized to obtain a surface without air inclusions and porosity and the vacuum valve allowed a further reduction of these faults bringing the scrap rate close to zero.

Only zinc could have allowed this result: with other materials such a thin relief and a superficial quality such as to guarantee an excellent result of the galvanic treatment without previous preparations could have not been obtained.

On International Zinc Association website it is possible to read a data sheet of this product with a brief description of the optimization process  undertaken for its components.

White goods: washing machine

The hinges for the washing machine porthole are a functional component that can be produced in zinc. An interesting aspect, related to the realization of this product, is the necessity to assemble plastic bushings on the die cast. To optimize this productive process  it has been found the solution to design an automation able to perform the necessary semi-automatic assembly operations. Thanks to the system controlled remotely by PLC it is possible to place the hinges in different positions according to the version to be assembled. The introduction of this automation allowed the reduction of the cycle time and of the manual contribution of the operator with a consequent cost reduction. Moreover, automation has allowed precise outputs to be obtained, compliant with high qualitative standards.

For more information and to watch the machine for the semi-automatic assembly in action watch the video Bruschi – Die casting for household appliances: hinge for washing machines.

These are just some of the components for household appliances that it is possible to produce in Zamak, in fact, as mentioned above, the great versatility of the material allow a wide range of solutions to be created.

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The case study concerns a component produced for the building industry and the related mold, which was built 10 years ago. Over the years the mold began to cause problems due to its wear condition: it was therefore necessary to study and examine mold design and to introduce significant changes, in order to reduce casting defects that emerged on the component.

In accordance with the lesson learned approach, Bruschi engineers have analyzed production performances of the component and defined new parameters on the basis of the knowledge they assimilated through the years. Furthermore, cutting edge technology, such as simulation software, has allowed Bruschi design department to foresee material reactions and to make accurate changes to mold design, in order to reduce casting defects. In this way, they have figured out new solutions with the aim of achieving a component that could meet the requested quality standards.

Elements that influence superficial quality of the diecast

Superficial quality of a component produced with die casting technology can, indeed, be determined by multiple factors, such as mold thermoregulation and temperature of the material injected in the cavity, but it mainly depends on the filling method of the feeder. The design of an appropriate feeder, which allows a symmetrical filling of the cavities, is therefore a fundamental requirement to avoid superficial defects on the product. On the contrary, an asymmetric or divergent feeder can cause air entrapment in the die cast, as well as areas with evident cold laps caused by irregular filling.

Case study

This case study is about a component that is part of a hinge for a door. After several years of component production with the first mold, the latter was worn out and it caused superficial defects on the product, such as cold laps, lack of material and porosity. Bruschi engineers have conducted an analysis of the parameters and of the geometry of the mold, after that they have identified the leading cause of the defects: the incorrect filling of the cavities. In order to solve this problem they have thus decided to design and build a new mold. With a view to reduce casting defects the design department has therefore modified mold design, more specifically feeder design.

Phase 1 – Simulation

The first phase of mold design project concerned simulation of the filling of the cavities with thermofluidodynamic simulation software Magmasoft, which allows foreseeing to a good approximation the behavior of the material during filling phase. With Magmasoft it is indeed possible to examine different parameters, such as temperature of the metal in every stage of the filling, air pressure in the cavity, material speed and presence of areas with air entrapments. For further information on simulation, here are some previous posts:

• Simulation for HPDC: surface aesthetical quality in automotive
• Simulation for HPDC: shrinkage porosity case study
• Simulation for HPDC: die maintenance and optimization of set up

Simulation has highlighted three main problems:

• Asymmetrical filling
• Divergent feeder
• Lack of homogeneity in the material temperature

To best define the corrective actions to implement engineers had to carefully observe product’s shape: the component has, indeed, a thicker upper section and a thinner lower section. The product’s geometry has thus requested a specific care during the design of the feeder because, in order to achieve a symmetrical and regular filling, it was necessary to add further elements that could facilitate the dynamic behavior of the filling fluid.

Phase 2 – Upper section design

Simulation phase has revealed that the filling of the upper section was asymmetrical and therefore caused air entrapment in the die cast, with consequent air bubbles presence on the component’s surface. The cause of the asymmetrical filling was ascribed to the different speeds at which the material started to fill the cavity. As a matter of fact, the fluid entered from the injection point with a high kinetic energy and continued its way by following the cavity geometry, which drove the material to fill specific areas that were thus quickly and more filled, reaching instead only at a later stage those areas that were not in the direction of the main flow.

The first problem to solve was therefore related to the asymmetrical entrance of the material in the gate: in order to symmetrize material entry in the cavity, designers have added a damper at the end of the main feeder. With the new configuration the flow, before dividing, fills the damper while losing kinetic energy and continues its way towards the cavity at a constant speed.

The second problem, still concerning the upper section of the die cast, was related to the divergence of the feeder in specific sections, thus causing the appearance of turbulences. Consequently, engineers have designed a convergent feeder, which has helped to better channel the material and to facilitate the filling of the cavity, thus reducing boundary layer separation.

Phase 3 – Lower section design

The lower section of the product is visibly different from the upper section. Indeed, it is a thinner part that, with the first mold, was filled by material at low temperatures thus causing the presence of cold laps and lack of material. By observing the component’s shape, it was indeed clear that a uniform filling was difficult to obtain, particularly in the lower section: the material filled in the first place the whole upper section, which is characterized by an important dimension, while it reached only at a later stage the lower section. Consequently, the material started to fill the lower section at a too cold temperature, such as not to guarantee an appropriate level of superficial quality.

With the aim of solving this problem, Bruschi team has designed a devoted feeding system through the addition of two auxiliary runners. The runners have been added to the lower section of the component in order to achieve a regular filling, by maintaining a stable material temperature in the entire die cast. The two auxiliary runners, as well as the main feeder, have been designed in order to obtain a symmetrical flow: to achieve this result engineers have added two further dampers to the auxiliary runners.

In addition to that, considering the particular shape of the product, in order to further facilitate the filling in the whole cavity, engineers have designed a partially tangential in-gate capable of channel the material in critical areas. The lower section presents, indeed, some inserts that, without this type of gate, could potentially obstruct the material flow, thus impacting on filling uniformity. This kind of solution therefore determines a better material distribution, by facilitating its entrance in the cavities and the reaching of the most critical areas.

Achievements

After having modified mold design engineers have conducted the simulation of the filling of the cavities with the software Magmasoft and have obtained excellent results: the previously observed critical issues have indeed remarkably decreased. Specifically, through the design of a new feeder, designers have achieved a higher filling uniformity, which has consequently determined the reduction of casting defects on the component’s surface.

This case study therefore confirms the importance of knowing how to draw on previous experiences for the resolution of new problems, by combining know how and technology in order to achieve increasingly outstanding results. Mold design and Magmasoft have allowed designers to test various solutions before proceeding with the actual production of the component, thus obtaining relevant benefits in terms of quality, time and costs.

To get updates on trends and innovations in the Zinc Die Casting industry, you are welcome to subscribe to our blog.

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1. DESIGN FREEDOM

Zinc, more precisely zinc alloys (ZAMAK), is a material that allows the production of components having nearly any type of shape. Thanks to zinc it is possible to obtain very thin surfaces that could not be achieved with other materials, such as aluminum. This results in a wider freedom in the design of a component, with consequent uniqueness and distinctiveness of the produced piece. Zinc thus represents an exceptional metal for the manufacturing of components which result complex from a shape perspective.

The following table contains zinc and aluminum values of minimum wall thickness: 

By choosing zinc for the production of small appliances it is possible to achieve several advantages related to the quality of the components, as zinc alloys present stable shrinking and high resistance. For example, compared to plastic materials, zinc presents a better typical precision and a superior yield and tensile strength (Table 1): these features result in a higher design freedom, not to mention remarkable qualities of the final product.

Table 1 – Typical Precision, Yield Strenght and Tensile Strenght values for zinc and plastic materials

2. HIGH END AESTHETICAL TREATMENTS

Several superficial treatments can be applied on zinc alloys. Specifically, it is possible to enhance aesthetical characteristics of the components through treatments which transform the product and improve its finish. The main aesthetical treatments realizable on zinc are:

• Galvanic treatments: polished chrome finish, satin chrome finish, different colors finish
• Liquid Painting
• Powder coating
• Special treatments to avoid material wear

Furthermore, specific treatments that take advantage of the physical properties of the alloy can be realized on zinc components. Among the mentioned treatments, powder coating is a brilliant example of an aesthetical treatment achievable through powder electro-deposition and cooking at high temperatures (around 200°C). This type of coating permits to obtain a better texture to the touch compared to painting. Realizing this treatment on a zinc component lends to it a significant added value.
Materials treatments generally follow the trends of the reference sector. A limitless variety of solutions that can be applied to zinc can help to fulfil this variable requirement.

3. SUPPLIER’S SUPPORT

A customer that relies on a qualified zinc supplier can discover in its vertical experience the ability of working on design too and to recommend to its customers innovative layouts and special finishes. This service, known as co-design, is the collaboration between client and die casting supplier, which aims to realize a product with specific functions and mechanical features that is at the same time compliant with manufacturing processes. Co-design can help designers to deeply understand zinc properties and to fully take advantage of their supplier’s know-how.
Zinc is a versatile material that allows experimenting with shapes and designs, thus permitting the conception and creation of unique and original pieces. As zinc die casting represents a very vertical market, its suppliers have a deep and vertical knowledge of the subject and can support customers in the production of distinctive pieces. The adaptability of zinc alloys proves especially helpful as far as small appliances are concerned: whereas other products are more standardized and creative design is limited, small appliances turn out to be a suitable product to test zinc versatility. As they are composed of several components, it is possible to imagine a wide variety of solutions with the use of zinc alloys, thus implementing the appearance, the performance and the distinctiveness of a product.

4. CUSTOMER EXPERIENCE

A further aspect that has to be taken into consideration when selecting a material is the customer experience. The relationship between end user and product consists of several variables, such as performance and usefulness, but also visual appearance, texture and durability. Zinc components convey excellent perceptions in terms of visual impact and touch feeling. A product made of zinc is more likely to be perceived as clean, resistant and of top quality.
As regards these features, it is essential to consider that the consumer has access to the use of small appliances through handles and buttons. If the body of the product is made of plastic, the handle or the button should be made of zinc, in order to offer the user a different experience in the use of the product. These details enhance the customer experience and make the difference in the customer’s choice of a product.

5. CLEANING OF COMPONENTS

From the end user’s point of view the ease of cleaning of a product is an aspect that influences the purchasing choice. For example cleaning chromed zinc components is easier compared to other surfaces, because they present a hard, solid and smooth surface. A product with these characteristics simplifies the cleaning process, making it quicker and more efficient: this results in a benefit for the consumer. Not only chromed zinc components are easy to clean, but they also convey a perception of neatness and brightness that impacts on the consumer’s eye. These qualities make zinc components stand out compared to other surfaces.

6. ZINC RECYCLABILITY

Virtuous companies are increasingly looking for sustainability. To support a sustainable development it is advisable to use recyclable materials, one of which is zinc. Zinc alloys can be re-melted and re-used several times without detriment to their properties. Normally the use of re-melted zinc alloys is limited to roughly 50% and this enables to completely exhaust production scrap. Today the implementation of this recycling system allows recycling a great number of zinc die casting scraps. Zinc thus represents a material with very low toxicity, not energy intensive to produce and recyclable. These properties make zinc an “environmentally friendly” material. 

7. REDUCED LEAD TIME

Lead time is the period of time that a company needs to fulfill a customer’s request in terms of supply. Logically, a short period translates into quicker results and a more satisfied client. In order to achieve this condition, zinc represents an efficient material thanks to its reduced cycle time. As a matter of fact, lead time is a concept related to cycle time: the period of time required to complete the manufacturing of a product, including every single process that leads to the finished product. Considering the cycle time of a product it is therefore possible to assume its related lead time. By choosing zinc instead of other materials, such as aluminum and plastic, lead time will be shortened, resulting in a more efficient and quicker service.
As mentioned above, cycle times related to zinc alloys die casting are lower compared to cycle times of aluminum alloys and plastic materials. In the first case, aluminum is molded at significantly higher temperatures, therefore the cycle time is superior due to cooling range. As far as plastic is concerned, it has superior filling times.
Below a table indicating values of cycle times of zinc alloys, aluminum alloys and plastic materials.

Table 2 – Typical production speeds and Broad production speed range for zinc, aluminum and plastic materials 

CASE STUDY N.1

Bruschi produces several components for coffee machines. In this specific case a client has contacted Bruschi to realize a cup holder tray for a coffee machine. The tray has been entirely realized in zinc and completely chromed. The entire surface of the component is considered aesthetical surface because the exterior is visible to the user’s eye and the interior becomes visible when the consumer removes the plastic cover and has access to the internal part of the tray to clean it.

The chrome process is composed of preliminary phases for the piece preparation. Particularly, the component has to be cleaned and polished through the use of rollers, tapes and scraping material. It is necessary to clean the internal part of the component too. For this reason Bruschi has conceived some alterations to the technological process that have allowed the achievement of an equivalent result.

Bruschi managed to solve the problem and produced a cup holder tray made of ZAMAK, externally and internally chromed.

CASE STUDY N.2

In this second case a client has requested to Bruschi the production of chromed handles for coffee machines. The complexity of realizing this component lied in its layout, in productivity and in the superficial quality. The handle was a particularly critical component because the standard mold cavities layout did not allow achieving the performance and costs level demanded by the client. Thanks to the experience and the expertise of Bruschi’s designers, Bruschi has conceived an alternative method to supply the mold. Designers have thus created a new mold that was compliant with the criteria demanded. Thanks to the new layout costs and performance levels have reduced.

In conclusion, the use of zinc for the production of coffee machines components generates remarkable advantages. By preferring the employ of zinc it is possible to design and create a functional and aesthetical product, able to combine design freedom and high-end aesthetical treatments, together with a proper balance between costs and production levels.

To get updates on trends and innovations in the Zinc Die Casting industry, you are welcome to subscribe to our blog.

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As the Journal of Industrial Engineering International reports, customers are more and more calling for environment-friendly products and this demand puts pressure on the whole supply chain, because it involves manufacturers, suppliers, retailers and customers. The latter are asking for a greener supply chain that promotes environmental protection and, at the same time, are also developing a well-defined purchasing behavior, which avoids unsustainable products and services. Businesses are therefore studying new methods in order to reach green supply chain management (GSCM), the integration of environmental issues and supply chain that results in reducing manufacturers’ impact on environment while enhancing an organization’s performance.

White goods recycling system

As far as white goods are concerned, emphasis is placed on their recycling cycle: manufacturers must therefore focus on materials. According to AHAM, the Association of Home Appliance Manufacturers, household appliances are increasingly being recycled: they are overtaken only by automotive industry as a source of recycled materials. The growing interest towards recycling has allowed to achieve significant results in the household appliances industry, also thanks to the United States Environmental Protection Agency, specifically with the Responsible Appliance Disposal (RAD) program, which in 2017 has recycled almost 70 million pounds of ferrous metals, 4 million pounds of nonferrous metals, 17 pounds of plastic and 3 million pounds of glass. As data highlight, consumers are increasingly aware of the importance of recycling and are more and more adopting a responsible and sustainable purchasing behavior: white goods industry is therefore continuously renovating and appliances’ manufacturers must face new challenges that environmental consciousness generates, developing products with recyclable materials through sustainable processes.

Metals recycling

White goods are characterized by a long life cycle, normally 10 to 18 years, and when they are no more usable they provide a consistent amount of recycled materials, specifically metals. As stated by The Global Metal Waste and Recycling Market report, the most recycled metals are iron, steel, aluminum, copper, lead and zinc; in addition to that, the report indicates the leading recycling industries, which are building, automotive, shipbuilding and consumer appliances. Metals are among the main materials that undergo a recycling process: they are perfectly suitable for recycling, indeed metals are valuable, can be easily transported thanks to their density and, furthermore, they present properties that allow them to be recycled repeatedly. In the U.S. metal recyclers manage thereabouts 120 million tons of recycled metal every year, with the metal recycling industry having registered nearly $27 billion in 2018.

Zinc recyclability

White goods are complex machines composed of several elements and different materials, among which zinc represents an intelligent and recyclable choice. As a matter of fact, zinc has exceptional metallurgical and chemical properties that remain unchanged also after recycling process, making zinc a suitable material for a wide range of modern products, such as white goods and small appliances.

To calculate zinc recycling rates experts rely on two main methods: the End of Life (EoL) recycling rate and the Recycled Content. Usually EoL is preferred because it measures the quantity of available zinc recovered at the end of product life and recycled, whereas the Recycled Content approach considers the amount of recycled material in a given product. Recent analyses report that around 45% of zinc at the end of life is estimated to be recovered and recycled; in developed regions, such as Europe and North America, this percentage reaches 50%.

Typical Recycling Rate Indices

What is more, zinc not only is itself recyclable, but also contains numerous substances that are recyclable: this quality certifies zinc as Cradle-to-Cradle (C2C), a concept inspired by nature that promotes circular economy. According to this approach a product is designed already considering future reuse and, at the end of its life, it is seen as a new source instead of waste: materials and elements that compose the product are thus recovered and again inserted into the processing cycle.

Zinc benefits in white goods manufacturing

Taking into consideration customers’ request for quality products manufactured with sustainable practices, zinc constitutes an ideal material for white goods components. Indeed, zinc presents high recycling rates and excellent aesthetical quality, combining two of the most demanded characteristics by end-users. Highlighting zinc properties can therefore be an efficient promoting strategy, thus meeting customers’ expectations, providing environmental-friendly solutions and improving selling rates.

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