Galvatek is one of the leading suppliers of surface treatment plants globally. Our main market is the aviation industry and some 90 % of our sales is export sales mainly to Europe, China, SEA and Middle East. We have delivered over 600 plants over the past 40 years. We offer customer-tailored plant projects, from initial design to turnkey delivery and related support services. Galvatek belongs to the Belgium John Cockerill group and its surface treatment division which is one of the leading and growing actors in the global surface treatment market.
We are looking for an Automation engineer
We expect you to be positive and inspiring team player who enjoys interacting with clients and project team. To succeed in the job you need to have technical education, know-how of industrial PC and PLC control software and couple of years working experience in similar tasks. We also expect you to be ready to travel when necessary mostly in installation and start up / commissioning phases of the project.
Your English and Finnish language should be fluent, other languages are counted in as an advantage.
What we offer to you
We offer you an interesting job in a truly international company. We develop the high-end technology and always appreciate high quality. You will have a chance to use and develop all your skills. We expect you to be a professional from the start, but with our in-house and other training opportunities we ensure that you will be the best expert in this business also in the future.
We offer you a chance to travel internationally and to work with people from other cultures. Belonging to John Cockerill companies offers also good possibilities to advance within the frame of a big and truly global business environment.
Galvatek is a truly international company and majority of our sales has been export already for many decades.
About John Cockerill
For more than 200 years, John Cockerill has been providing answers to the needs of its times.
Today, John Cockerill catalyses opportunities by conceiving, modernizing and maintaining equipment in the fields of energy, defence, industry, environment and rail. With more than 6,000 collaborators, it achieves a turnover of 1.3 billion euros from its head office in Seraing (Belgium) and its numerous implantations Europe, the United States, Africa, Brazil, Russia, India, New Caledonia and China. www.johncockerill.com
Galvatek is now owned by Belgian company John Cockerill, formerly known as CMI Group. Galvatek was acquired by CMI Group/John Cockerill in February 2019. John Cockerill is an established engineering company with global activities in five continents, some 6000 employees and annual turnover of approximately €1.2 billion. Despite the owner’s name change, our customers can continue to identify and find us by the Galvatek name.
John Cockerill’s global industrial customer base and long experience in the project business in different environments and cultures are valuable assets for Galvatek too. Galvatek has been a part of bigger companies also in the past, but this time our owner is an internationally recognised and experienced industrial equipment and service provider with a lot to offer in terms of our future development and growth.
Galvatek’s business consists mainly of surface treatment plants for the aviation industry, where customer references, trust and financial strength are essential. John Cockerill therefore opens up new possibilities in this sector and strengthens our position in the global markets.
John Cockerill has introduced a strategy to develop the surface treatment industry globally and especially within the growing aviation industry. This is well in line with the efforts that Galvatek has made earlier on a smaller scale. John Cockerill now has three business units working towards this common strategy: Sleti in France, Tempro in China and Galvatek in Finland.
Joining forces with John Cockerill enables us to improve our service network for existing Galvatek customers, as well as to reach new customers in emerging markets. Galvatek welcomes the new ownership and company name and is excited to start working with our sister companies under the John Cockerill umbrella.
Best regards, Ulf Pråhl
Do you want to work in a responsible position, within a high technology company and in an international environment? We are looking for an experienced Sales Engineer to market and introduce our technology on a global level.
Galvatek is one of the leading suppliers of surface treatment plants globally. We have delivered over 600 plants over the past 40 years. We offer customer-tailored plant projects, from initial design to turnkey delivery and related support services.
Galvatek belongs to the Belgian CMI group and its surface treatment division which is one of the leading and growing actors in the global surface treatment market.
About CMI Group
For more than 200 years, CMI has been providing answers to the needs of its times.
Today, CMI catalyses opportunities by conceiving, modernizing and maintaining equipment in the fields of energy, defence, industry, environment and rail. With more than 6,000 collaborators, it achieves a turnover of 1.3 billion euros from its head office in Seraing (Belgium) and its numerous implantations Europe, the United States, Africa, Brazil, Russia, India, New Caledonia and China. www.cmigroupe.com
We are looking for a technical orientated Sales Engineer to our projects department in Lahti.
As Sales Engineer you will be a member in our sales team where you actively participate in marketing actions as well as offer preparation / pricing and quotation presentations to the customers. The quotation presentations to the customers includes both technical and commercial argumentation so you must be able to present these in the first stage and receive the customer reactions. Our main customers are in the global aviation industry worldwide having high expectations besides technology also on our personnel.
Sales Engineer will coordinate his work with business area managers and offering team. He will also personally make offers including pricing and factory planning. Besides personal contact calls, sales and marketing visits and other sales activities he will organise and run strategically important marketing activities e.g. symposiums and exhibitions.
The Employee undertakes to perform also other work duties indicated by the Employer within his directive powers. When needed you may also need to act as a project manager.
Our markets are global, and you are prepared to travel 60-70 days a year and keep in contact with existing and new potential customers. You will also need to collaborate with our sales partners and sister companies in the CMI Group both in France and China.
What we expect from you
We expect that you will have several years’ experience in investment project sales on international markets and that the project business is familiar to you. You also have some experience in project pricing and understand the content of a project budget.
We expect that you have an adequate technical education (MSc or BSc) and will be able to adapt the technical particularities of surface treatment equipment and Galvatek technology after a training period.
The training period will consist of actual hands on participation in sales processes as well as pricing methods and principles in Galvatek.
We expect you to have an entrepreneurial hands-on attitude, have strong communication skills and be experienced as team member. As over 90% of our business comes from international delivery projects you should be fluent in both English and Finnish, and any other language skills will be considered an advantage.
What we have to offer
We offer you an interesting job in an organisation that always appreciates high quality. You will have the chance to use and develop all your skills. You will be working mostly with clients from the aviation industry who expect extremely high quality and reliability.
As a part of an international growing group with activities in each continent we can also in the future offer you more interesting working opportunities within the CMI Group.
We offer you the chance to travel internationally and to work with people from other exiting cultures. Galvatek is a truly international company, and the majority of our products have been exported already for many decades.
RAPID EXPANSION AT ANODISING CENTRE SPECIALISING IN AUTOMOTIVE APPLICATIONS
BCW Treatments Ltd on Innovation Drive in Burnley is an aluminium anodising facility opened in early 2015 to provide a full service to companies using the subcontract machining services of BCW Manufacturing Group’s machine shops on the same industrial estate. Anodising is carried out in a Galvatek automated finishing line supplied by Turbex, which was deemed to be the best all-round package of three alternatives considered. Currently, an average of 2,600 square metres of product per week are finished across more than 240 part lines.
The Galvatek automated anodising line at BCW Treatments, Burnley.
Anodizing of automotive aluminium castings, sheets and extrusions
One of BCW’s automotive contracts involves the production of aluminium components mainly from A365 castings, 6060 extrusion, superplastic 5083, and 5754 sheet for a premium automotive customer in the UK specialising in manufacturing luxury sports cars and grand tourers. More recently, the subcontractor has received further business from another prestigious UK automotive customer that produces high performance 4×4’s and special operations vehicles. The work will start at the end of 2018 and entail the installation in an adjacent factory of a line for passivating components as a corrosion resistant pretreatment. Enquiries have also been received for finishing lightweight components for aircraft, such as cabin seating, and for electric cars, hybrids, amphibious vehicles and lorries. Consequently, by the end of the decade, the firm is destined to become a major force in component finishing in the north of England.
Dr Andrew Wilson, managing director of BCW Treatments explained, “Although more than a century old, modern anodising is an exacting discipline requiring extremely close control to achieve the highest quality and even more importantly the correct film properties.”Some manufacturers’ car parts are adhesively joined rather than welded and a nominal thickness of the anodic layer of between two and 10 microns is required, above which there is a risk of components pulling apart under stress. A tolerance band of four to six microns is achieved in the Galvatek line, so precise is the process.”
Two overhead transporters dip flight bars carrying aluminium components into 15 tanks sequentially. Up to five jobs can be processed simultaneously in the line.
Automation and ventilation play an important role
An enterprise resource planning (ERP) system drives the finishing process in Burnley, raising each manufacturing order and triggering the issue of material. The line’s control system learns which aluminium products are mounted on which universal or part-specific jig by scanning the manufacturing order. Once it knows the part number, the correct program is automatically selected. There are four load/unload stations at one end of the line, where components are loaded onto flight bars that progress to a buffer station from where they are picked up by one of two overhead transporters and dipped into 15 tanks sequentially. Up to five jobs can be processed simultaneously in the line.
Automatic dosing stations are provided for metered dosing of chemicals into several of the tanks, the quantity being worked out automatically according to the amount of surface area to be anodised on each flight bar. The working environment is clean and fume-free, as each tank is hermetically sealed and the lid is not opened until a transporter is directly above it. Positive pressure pulls the fumes through the handling system and extracts them to a scrubbing unit. After processing, flight bars are returned to four load/unload stations adjacent to the loading area and the test pieces are taken away for analysis, which includes pull and shear tests after adhesive has been applied. Following each successful test, the ERP system is advised that the components are ready to deliver to the customer.
The anodising line sequence
As a conveyor is not involved in transporting flight bars around the system, the anodising process starts in the centre of the line and progresses initially away from the load/unload stations. Alkaline degrease takes up to one hour in the first tank for the most soiled castings and the solution is rinsed off in town water in the next two tanks, the water being recycled between the second and third stage.
A fight bar being lowered by one of the transporters into a tank.
Tank 4 is a chemical etch using sodium hydroxide to remove pre-existing aluminium oxide from the surface of components. Immersion time is controlled to avoid unduly changing of the geometry of the components. It also precludes the need to plug holes, resulting in a cost saving and eliminating the risk of parts being returned by the customer if plugs are inadvertently left in at the time of delivery. An eco-rinse cycle in town water is performed in the next three tanks, again with recycling between the stages. The following process, which takes place at the far end of the line in tank 8, is the removal in a mix of nitric acid and hydrofluoric acid of alloying elements on the surface of components, especially of castings, that remain after chemical etching. Two further eco-rinse immersions in tanks 9 and 10 brings the pre-treatment to a close, by which time the components have travelled back past the centre tank towards the load/unload stations.
The actual anodising stage of the process is in tank 11, which contains sulphuric acid, and lasts between eight and 10 minutes, during which time a nominal 4 to 6 microns film thickness is deposited. An ecological feature of the equipment is continuous dosing of the acid, instead of recycling the fluid when the aluminium content reaches say 20 grams per litre. Avoidance of waste is made possible by employing a pump to recirculate the fluid through a retardation unit, where the aluminium is filtered out. A clean rinse in three successive tanks containing deionised water, which is produced locally within the line, ends with an ultra-clean rinse to ensure that conductivity is less than 200 microsiemens.
The last stage, prior to the flight bar being taken back to the unload station, is hydrothermal sealing at 96°C in a proprietary chemical blend. Reserved for high-end applications and involving 30-micron particulate filtration, the process seals microscopically small pores created on the surface of components as a result of dielectric breakdown during anodising.
Harri Salo has been appointed After Sales Engineer at Galvatek. In this position he serves as the primary contact for customers looking for spare parts for their surface treatment plants.
“I have been studying and working in spare part operations for decades, but this job has the broadest description so far. It feels good to have total responsibility for the entire spare parts process, from purchasing to delivery,” says Harri Salo.
Salo previously worked in spare parts and service operations at Kempower, Finnsonic and Kemppi. Kempower supplied electrical power sources to Galvatek, while Finnsonic fabricates ultrasonic washing lines and non-destructive testing devices, so Galvatek was already familiar to him. His latest job was at Kemppi Oy measuring and analysing power electronic components.
Salo graduated with a degree in Automation Engineering from Lahti University of Applied Sciences and later earned an MSc in applied electronics and electrical drives from Lappeenranta University of Technology.
He lives in Lahti with his wife and likes to spend his leisure time outdoors hiking, boating, motorcycling and staying at his summer cottage in the countryside.
Automated chemical cleaning line in action at N3 in Arnstadt, Germany.
10 years of operational experience and 20 years more life expectancy
N3 Engine Overhaul Services in Arnstadt, Germany, overhauls and repairs Rolls-Royce aircraft engines and their components. A joint venture of Lufthansa Technik AG and Rolls-Royce plc, N3 has been operating since 2007 and is one of the most modern maintenance operations in the world. N3 currently serves over 40 international airlines who appreciate the company’s quality, dependability and process orientation. Likewise, N3 relies on an automated cleaning line supplied by Galvatek to handle up to 250 engines per year.
N3 offers maintenance and repair services for Rolls-Royce engine types Trent 500 (Airbus A340), Trent 700 (Airbus A330), Trent 900 (Airbus A380) and Trent XWB (Airbus A350). For individual engine components, N3 also offers repair services for the Trent 800, Trent 1000 and RB211-535 series.
For the cleaning and subsequent conservation of various components and materials, N3 Engine Overhaul Services utilizes a wide range of advanced technological processes. The entrepiece of the chemical cleaning process is the cleaning facility, where component baskets are fed, computer-controlled, via a crane system into one of 27 cleaning tanks. Each tank has a capacity of over ten cubic meters and allows the processing of components with a diameter of up to 2 meters and weighing up to 500 kilograms. Depending on the application, the tanks are filled with different mediums and heated to temperatures of between 55 and 90 °C.
Three of the tanks have been additionally equipped with ultrasonic cleaning devices. Complemented by several flexible manual working stations, this enables the individually adapted cleaning of almost all components. Components susceptible to corrosion can also be vacuum packed after cleaning so they are ready for transport and storage.
Martin Spallek, Head of Component Repair, you have run a Galvatek chemical cleaning line for 10 years now. What kind of experiences have you had, and what kind of life expectancy you have for this facility?
“The reliable operations of our cleaning facilities are crucial for our business. After dismantling and prior to further processing, the engine components must be thoroughly cleaned and prepared for material testing and inspection. Any interruption at this point in the overhaul process causes delays in the turnaround time of the engines.
Overall, we have had positive experiences with the Galvatek chemical cleaning line. The period over the last ten years can be divided into three different phases. In the start-up phase of N3 Engine Overhaul Services, our focus was on starting up the operations of the cleaning line and on establishing fault-free working conditions. In the second phase, we maintained reliability with only a few unplanned interruptions in our daily business. In phase three, the current phase, we are focusing more on preventive maintenance to assure the availability of the cleaning line for the planned life expectancy of our facility, i.e. 20 more years.”
What is the role of the chemical cleaning line in your overall MRO process? What percentage of engine components can be run through the automated cleaning process?
“The cleaning line is N3´s single source for the automated cleaning of engine parts for the subsequent repair and NDT processes. Nearly 80 per cent of engine components pass through the automated cleaning line. A fast response from our assigned maintenance contractor helps us to keep availability at a high level in order to get all the parts cleaned in time.”
You have relatively big facilities for aero engine MRO and you also have ambitious growth plans. Is there enough capacity and reserve for your future needs?
“N3 Engine Overhaul Services initially started its operations in 2007. Today N3 serves more than 40 international airlines on behalf of Rolls-Royce. So far N3 has overhauled more than 800 engines in the Trent 500 (A340), Trent 700 (A330) and Trent 900 (A380) model ranges. With the new Trent XWB (A350 XWB) engine, output will increase from the current 100 engines per year to 150–200 engines per year in the coming years. This year it will already be 130 engines. The cleaning line is designed for a capacity of 250 engines per year, so it supports us growing our business.”
What are the benefits of the automated cleaning line compared to manual methods? How has the chemical cleaning line met your environmental and occupational safety needs?
“The benefits are obvious: With the automated cleaning line we are able to run 24/7 operations and guarantee a high output and fast processing time. The quality of the cleaning processes is sustainable high.
One of the main principles of N3 concerns the protection of the environment and the resultant obligation of supporting the well-being of our staff and the community. Environmental protection was considered when planning the company, and certification pursuant to ISO 14001 Environmental Management was established. Within the process of the continuous improvement of our operating procedures, the reduction or avoidance of negative effects on the environment plays a central role, in addition to an increase in quality and production efficiency.
The cleaning facility is equipped with a fully automated chemical water treatment system and a Candovent ventilation system in accordance with the current requirements for environmental protection. We are also able to save a lot of water with the cascaded water supply. But the main priority is on the health and safety of the workforce. Automated cleaning reduces contact between our operators and the chemicals to an absolute minimum. In addition, the chemical line prevents the release of chemical fumes and spillages.”
N3 Engine Overhaul Services
Plant: Chemical cleaning line Location: Germany Delivery: 2007 Designed capacity: 250 engines/year Engine types: Rolls-Royce Trent 500, 700, 900 and XWB Plant construction: 27 tanks + dryers + manual stations Process and production control: Automated (Galcont™ by Galvatek)
TSA to replace toxic substances in aluminium anodizing
The REACH Regulation of the European Chemicals Agency effectively bans the use of hexavalent chromium for surface treatment as of 2017. Exemptions may be granted only in exceptional cases, such as military aviation applications. Less toxic aluminium surface treatment processes have been developed to replace the use of chrome, such as TSA (Tartaric Sulphuric Acid) and PSA (Phosphoric Sulphuric Acid).
“The benefits of using chrome have been its excellent resilience, low friction and the anti-corrosive properties of chromic acid anodizing. The problem is that toxins are released when manufacturing and processing chromed components, so it is understandable why the EU wants to discontinue chromic acid anodizing,” says Galvatek Senior Adviser Arto Jämsén.
Galvatek offers TSA and PSA processes to replace chromic acid anodizing. These environmentally friendlier processes comply with the REACH Regulation, and they also reduce energy and wastewater costs and are significantly easier to use. Galvatek’s automated lines meet all the demands of NADCAP certification and OEM customers, for example in terms of the traceability of components.
New lines offer lower operating costs
“Replacing chromic acid anodizing with the TSA process can cut both power consumption and anodising time by half. The TSA process also requires less exhaust air, which creates significant savings in energy consumption,” says Jämsén.
Savings can also be generated by having to process lighter wastewater. Also, as corrosive toxins are not released into the indoor air, production facilities are not damaged and the work environment is safer.
“What is most important, of course, is that the treated component is at least as good as it would have been using the old chromic acid anodizing process. Furthermore, the processing of each component is documented in the Galcont system, making it easy to obtain NADCAP certification or to comply with the internal auditing of aircraft manufacturers,” Jämsén adds.
Galvatek has 36 years of experience in supplying aluminium surface treatment lines used in the production of aircraft components but also long history in building chemical cleaning lines for maintenance, repair and overhaul of aero engines. Galvatek systems can be found throughout the world on all continents, as the company has operated on a truly global scale for four decades.
“Our strengths include reliable turnkey deliveries with no unpleasant surprises in terms of schedules or costs. If a manufacturer already has a surface treatment line that complies with regulations, it is usually enough to modernise it. The old line can also be retained for other types of surface treatment, such as chromic acid treatment for military aviation applications.”
Patricomp introduces TSA to its existing surface treatment line
Patricomp in Halli, Central Finland, supplies components to the aviation industry, where its customers include Airbus, Embraer, Saab and the Finnish Air Force. Patricomp is the sole supplier of elevator tips for the Airbus 350, for example.
“We needed a new aluminium surface treatment line to comply with the REACH Regulation, as well as the demands of our customers. Airbus wants to switch to chrome-free components, and TSA is an Airbus-approved method. We were given very precise specifications by Airbus, according to which we introduced and use the process,” says Jari Vasenius, Sales Director at Patricomp.
Patricomp already had a surface treatment line delivered by Galvatek. It was originally installed in the late-1980s for manufacturing aviation components for the Saab 2000, for which Patria was a risk-sharing partner. The surface treatment line was modified in the 1990s when Patria began manufacturing components for the F-18 Hornet fighters of the Finnish Air Force.
“Today the same surface treatment line is used for CAA, TSA, cadmium, passivation, chroming and chemical milling process. While other companies are discontinuing the use of cadmium, we are actually investing in it to meet the demands of the military aviation sector,” says Production Manager Mirka Laakso.
Rapid modernisation project
Patricomp contacted Galvatek in spring 2012 and received a detailed offer in late 2012. The installations began in mid-September 2013, and the modernised line was inaugurated slightly ahead of schedule on 10 December. In the winter of 2013-2014 the line was tested, and Airbus approval was obtained in March 2014.
“The starting point was good, as the line already had free basins and we didn’t need to move walls. Galvatek’s experts calculated exactly what was required to comply with Airbus’s specifications in terms of electricity consumption, the surface area of the cathodes and fluid flows. In practice the modernisation meant resurfacing some of the basins, renewing electricity systems, increasing the number of sensors needed for documentation, and filtering the sulphuric acid and tartaric acid. Since the fluid is organic, it has to be filtered and purified using UV lights to prevent the formation of algae,” Laakso explains.
The modernisation work did not disrupt production at the Patricomp factory or the surface treatment line, which continued to operate at the normal pace of production throughout.
“The auditors from Airbus were very satisfied with the modernised line. The automated line and Galcont system document the processing of all individual components, as Airbus requires. This is a big difference compared to the old systems, in which components were floated in the basins manually. With such a line it would be very difficult or impossible to obtain approval,” says Jari Vasenius.
Galvatek was a safe choice
Both Laakso and Vasenius agree that they never had any uncertainties regarding the choice of supplier.
“The old line was built and modified by Galvatek, so it was quite natural to select Galvatek again to carry out the modernisation project. Selecting another supplier on the basis of cost alone would have involved a significant risk. We enjoyed excellent cooperation with Galvatek, and we were convinced by the expertise of the Galvatek team. We had no problems sticking to the budget or schedule,” Vasenius and Laakso admit.
Patricomp has annual net sales in excess of 5 million euros, 50 employees and 6000 square metres of production facilities. The factory is situated by the local airport in Halli together with Patria Aerostructures and Patria Aviation. Patricomp has Nadcap certification for NDT operations and heat treatment processes. Nadcap certification for surface treatment processes is expected in 2017. Patricomp has been part of the Spanish Aernnova Aerospace Corporation since June 2015.