Yogender Singh, India, Asia-Pacific Correspondent08.19.24
E-coating has emerged as a popular coating technique in the automotive industry in recent years. Most of the automotive paint majors are paying increased attention to this innovative technique. Coatings World presents an overview of E-coating in India in this feature.
This process involves immersing the product in a water-based solution containing paint particles, followed by the application of an electrical current. The result is a uniform coating that provides exceptional corrosion resistance. The E-coating method, involving the immersion of metal parts in a water-based solution containing paint particles, facilitates a uniform coating on surfaces.
This innovative approach ensures excellent adhesion, even in hard-to-reach areas or complex geometries. The subsequent application of an electrical current drives the deposition of paint particles, providing outstanding corrosion resistance.
E-coat forms an undercoating film, whose thickness is only one-fifth of that of a human hair, to protect automobiles from rust. It serves the purpose of safeguarding the car body's surfaces, edges, and cavities from corrosion. Additionally, it effectively smooths out the roughness of pre-treated metal surfaces, creating an ideal foundation for the subsequent layers of paint to be applied.
With the expanded e-coat manufacturing facility in Mangalore, BASF will have the capability to manufacture the latest generation of e-coat products, such as CathoGuard 800 RE, that offers lower consumption, increased efficiency, and higher reactivity for electric vehicles.
“India's automotive market is booming with opportunities. With a mix of international and local car brands, and evolving consumer behaviors, India holds immense potential for BASF. I am incredibly proud of our strong growth in India and the region, thanks to our successful collaborations with customers and partners. But beyond the numbers, what makes me even more proud is our ability to leverage our innovations, passion for colors, and sustainability experience to serve the local market,” said Patrick Zhao, senior vice president, Global Automotive OEM Coatings, BASF at the time of inauguration of this facility in April.
The BASF site in Mangalore has been in operation since 1996, and it is now BASF’s largest production facility in South Asia. In 2022, the Coatings division expanded the Automotive Coatings Application Center, and has since been utilizing global resources to bring advanced expertise and methodologies to the market.
With robust anticipated demand of automotive in India in the short-, medium- and long-term, E-coating is expected to become more and more popular in coming years.
Speaking during Kansai Nerolac’s financial result presentation, Anuj Jain, managing director of the company, said, “Demand has been good in the automotive industry. In fact, automotive penetration in India is low, and generally in the last 10, 15, 20 years, we have seen that demand is cyclical. But as the country is progressing, the infrastructure is progressing, we believe that going forward, demand is not going to be that cyclical it is going to be stable. So that's good news for us because we have our largest market share in the automotive.”
“The process of painting the vehicle is universally considered to be the most complex, time-consuming and cost-intensive stage in the automotive manufacturing process. We (automotive paint producers) have been attempting to optimize the cost, time and performance through innovative practices. E-coating will go a long way in achieving these objectives,” a shop floor executive at India’s largest automotive paint producer Kansai Nerolac told CW on the condition of anonymity as he is not authorized to make a press statement.
Vikram Chauhan, CEO of Car Decor, a New Delhi-based automotive designer, told CW, “Advancements in e-coating technology and surface treatment would prove pivotal in enabling the transition to electric vehicles (EVs) in the country. EVs will also utilize more lightweight materials to extend the traveling range. This will have a significant impact on OEM coating processes, as the baking temperature of coatings needs to be reduced, due to the temperature sensitivity of the plastic substrates. This is already affecting the industry- both automotive producers and coating suppliers. OEMs are already utilizing multi-substrate car body construction to improve vehicle efficiency.”
Since E-coating takes place in an electrically charged chemical bath, the coating thickness and quality are meticulously consistent.
This leads to coatings as fine as 10 to 20 microns. It is compliant with global environmental standards, making it a sustainable choice. The process offers a more uniform and smoother finish compared to conventional methods. Also, it is one of the most economical and long-lasting options.
Overview of E-coating
E-coating, short for electrophoretic coating or cathodic dip coating, is an innovative method of applying a protective finish to various surfaces, primarily metal components.This process involves immersing the product in a water-based solution containing paint particles, followed by the application of an electrical current. The result is a uniform coating that provides exceptional corrosion resistance. The E-coating method, involving the immersion of metal parts in a water-based solution containing paint particles, facilitates a uniform coating on surfaces.
This innovative approach ensures excellent adhesion, even in hard-to-reach areas or complex geometries. The subsequent application of an electrical current drives the deposition of paint particles, providing outstanding corrosion resistance.
E-coat forms an undercoating film, whose thickness is only one-fifth of that of a human hair, to protect automobiles from rust. It serves the purpose of safeguarding the car body's surfaces, edges, and cavities from corrosion. Additionally, it effectively smooths out the roughness of pre-treated metal surfaces, creating an ideal foundation for the subsequent layers of paint to be applied.
Paint Majors investing in E-coating
Global coating major BASF India recently expanded its e-coat manufacturing facility at its Mangalore site. This strategic expansion is driven by the growing demand for e-coat solutions by local automotive OEM customers in India, as well as customers in the South Asian and ASEAN markets.With the expanded e-coat manufacturing facility in Mangalore, BASF will have the capability to manufacture the latest generation of e-coat products, such as CathoGuard 800 RE, that offers lower consumption, increased efficiency, and higher reactivity for electric vehicles.
“India's automotive market is booming with opportunities. With a mix of international and local car brands, and evolving consumer behaviors, India holds immense potential for BASF. I am incredibly proud of our strong growth in India and the region, thanks to our successful collaborations with customers and partners. But beyond the numbers, what makes me even more proud is our ability to leverage our innovations, passion for colors, and sustainability experience to serve the local market,” said Patrick Zhao, senior vice president, Global Automotive OEM Coatings, BASF at the time of inauguration of this facility in April.
The BASF site in Mangalore has been in operation since 1996, and it is now BASF’s largest production facility in South Asia. In 2022, the Coatings division expanded the Automotive Coatings Application Center, and has since been utilizing global resources to bring advanced expertise and methodologies to the market.
With robust anticipated demand of automotive in India in the short-, medium- and long-term, E-coating is expected to become more and more popular in coming years.
Speaking during Kansai Nerolac’s financial result presentation, Anuj Jain, managing director of the company, said, “Demand has been good in the automotive industry. In fact, automotive penetration in India is low, and generally in the last 10, 15, 20 years, we have seen that demand is cyclical. But as the country is progressing, the infrastructure is progressing, we believe that going forward, demand is not going to be that cyclical it is going to be stable. So that's good news for us because we have our largest market share in the automotive.”
“The process of painting the vehicle is universally considered to be the most complex, time-consuming and cost-intensive stage in the automotive manufacturing process. We (automotive paint producers) have been attempting to optimize the cost, time and performance through innovative practices. E-coating will go a long way in achieving these objectives,” a shop floor executive at India’s largest automotive paint producer Kansai Nerolac told CW on the condition of anonymity as he is not authorized to make a press statement.
Vikram Chauhan, CEO of Car Decor, a New Delhi-based automotive designer, told CW, “Advancements in e-coating technology and surface treatment would prove pivotal in enabling the transition to electric vehicles (EVs) in the country. EVs will also utilize more lightweight materials to extend the traveling range. This will have a significant impact on OEM coating processes, as the baking temperature of coatings needs to be reduced, due to the temperature sensitivity of the plastic substrates. This is already affecting the industry- both automotive producers and coating suppliers. OEMs are already utilizing multi-substrate car body construction to improve vehicle efficiency.”
Advantages of E-coating
E-coating offers several advantages over conventional painting methods in the automotive industry. It offers superior protection, ensuring components remain rust-free for long. Enhanced edge protection ensures that parts are safeguarded from all angles.Since E-coating takes place in an electrically charged chemical bath, the coating thickness and quality are meticulously consistent.
This leads to coatings as fine as 10 to 20 microns. It is compliant with global environmental standards, making it a sustainable choice. The process offers a more uniform and smoother finish compared to conventional methods. Also, it is one of the most economical and long-lasting options.
