Anderbolt Electroplaters was established in 1994 by Trevor Fox and has been proudly run as a family-owned business since then, priding itself on personalised service and lasting relationships with clients no matter the size of the job.

Based in Anderbolt, Boksburg, Anderbolt Electroplaters offers electroplating and component finishing to a range of different industries.

“In terms of the amount of finishes that we are able to offer, no other jobbing shop comes close to us,” says Darren Fox, Trevor’s son and the next generation, now Managing Director of Anderbolt Electroplaters. Fox joined his father’s business in 2001 and has been part of the growth trajectory it has experienced over the years since then.

Based in Anderbolt, Boksburg, Anderbolt Electroplaters offers electroplating and component finishing to a range of different industries

“We regard ourselves as the most comprehensive electroplating jobbing shop around,” continued Fox. “My dad is still very much involved in the business at 81-years-old. He plays golf a few times a week and does some odd jobs for us when needed but his industry experience and knowledge are priceless. He is still very well respected in the industry and there just aren’t that many people left in the industry these days with that kind of experience.”

“After initially starting a powder coating business next door to this business, Dad decided to branch out into electroplating with this business when the opportunity to purchase it came his way. It’s funny because neither of us were any good at chemistry at school – and that’s everything that electroplating is about – but Dad has made a success of this business and I am fortunate to benefit from it.”

“There are a lot of electroplating businesses around – but one of the key aspects that differentiates our business is that we are able to offer a number of different plating and finishing options. Other businesses may just offer one or two finishes that they have chosen, but we are basically a one-stop-shop if you will, as we offer 34 different kinds of finishes,” says Fox.

“In terms of the amount of finishes that we are able to offer, nobody comes close to us,” says Darren Fox, Managing Director of Anderbolt Electroplaters

“We have always tried to stay ahead of the game here and for example all of our rectifiers have been replaced with air-cooled rectifiers instead of oil or liquid cooled rectifiers. We have always just made the decision to spend the money and keep up to date with technology and processes. You need to put back into your business, if you not only want to grow it, but also if you want to stay ahead and be the best at what you do.”

The art of electroplating
The art of electroplating is an often-overlooked aspect of the metalworking industry. An unsung hero of preservation and finishing that we all just take for granted. It is an aspect of our industry that requires just as much precision as some of the components that are manufactured with machine tools and tight tolerances.

Electroplating has been part of manufacturing for more than a century and it remains critical to how components are protected, finished and made functional across a wide range of industries. The process may appear straightforward, but the precision and consistency it requires make it a technical discipline in its own right.

Anderbolt Electroplaters plate to SABS and DIN specifications and a number of our finished components are exported to Europe, the Middle East and Australia

In simple terms, electroplating uses an electrical current to deposit a thin layer of metal onto a component’s surface. The component acts as the cathode and it is immersed in a chemical bath containing dissolved metal salts. A metal anode of the same type is also placed in the solution. When current is applied, metal ions move through the electrolyte and form a coating on the component. The anode slowly dissolves, keeping the chemical balance in the bath stable.

Electroless nickel is common where wear and corrosion resistance are needed. Zinc is applied to steel components as a sacrificial coating to prevent rust. Copper offers excellent electrical conductivity and is used in electronics and as the primary layer for further plating. Chrome provides a hard and bright surface and continues to be widely used in automotive, sanitary ware and door hardware to name but a few. Precious metals such as gold and silver are applied where conductivity and oxidation resistance are critical, especially in connectors and electrical contacts.

Anderbolt Electroplaters generally services parts that are exposed to harsh environments like the mining, automotive, rail, pressings, pharmaceutical and machined component industries

There are a few methods of applying the coating, barrel plating is used for smaller parts that can be tumbled together during the various stages of the process. Rack plating suits larger or more delicate items that need to be held in place.

Anderbolt Electroplaters offers all of these methods in its arsenal of corrosion and surface finishing treatments.

Maintaining consistent results depends on controlling a range of variables – the chemical make-up of the bath, temperature, pH and the applied current. Even small changes can result in irregular coating thickness, pitting and poor corrosion protection. Many plating facilities now use some kind of automation on their lines and continuously monitor their filtration systems and conduct analytical testing to keep the process stable and repeatable.

Anderbolt Electroplaters also service decorative industries and finishes include for doorware and sanitary ware – where products can range from bath feet to flush valves, door handles and other decorative type finishes

A finished component

Environmental management has also become an important part of the industry. Traditional electrolytes once contained cyanide and hexavalent chromium, both of which pose significant environmental risks. Any reputable plating facility has already moved to trivalent chromium systems.

Compliance with global environmental standards has become as important as the technical quality of the coating itself. Anderbolt Electroplaters offers all trivalent passivations to local and international standards.

Despite advances in alternative surface technologies such as physical vapour deposition and spray coatings, electroplating remains a practical and cost-effective option. Its versatility, ability to coat complex shapes, and proven performance in demanding environments means that it is still a very relevant method of metal finishing in modern manufacturing.

“In this industry we speak about coating thickness and salt spray hours. Salt spray hours is a difficult term to define. I have heard guys say that 100 salt hours is about the equivalent of one year’s worth of corrosion protection. But then other guys will say something different. Essentially there is no direct conversion from salt spray hours to real world service life because real environments are a lot more complex.”

Aluminium Anodising. The anodising process produces a thick oxide layer on the surface of aluminium which is used to improve corrosion and wear resistance and can be done in a variety of colours

“We deal a lot with non-ferrous materials on the decorative side of the business – so brass, zinc die castings, aluminium and your stainless materials. On the industrial side of the business, it’s mainly your mild steels as well as the anodising of aluminium.”

“Anderbolt Electroplaters generally services components that are exposed to harsh environments like the mining, automotive, rail, pressings, pharmaceutical and machined component industries as well as doorware and sanitary ware – where products can range from bath feet to flush valves, door handles and other decorative type finishes – right through to the antique and restoration industries.”

Zinc flake coating machine
“We have recently installed an automated zinc flake coating machine. Zinc flake finishing is essentially an automotive specification type finish and one of its biggest advantages is the long and durable service life it gives finished components. Here we will be coating things like fasteners, brackets and some smaller components like springs. Our aim with installing this machine was mainly to target the automotive and mining industries. It is however not just limited to these, it can also be used in most other industries.” explains Fox.

Anderbolt Electroplaters services a wide range of industries and finishes can range from bath feet to flush valves, door handles and other decorative type finishes

Chrome plating (bright, satin and black chrome). Chrome plating is a process that involves applying a thin layer of chromium onto a surface, typically metal, to enhance its properties. The surface of chrome plating increases wear resistance, gives a bright, shiny, and smooth finish making it easier to clean and maintain

“We are approved applicators in South Africa for a German company called Dörken Coatings. Zinc flake coating is not actually an electroplating finish as there is no current involved in the process. The controlled process firstly goes through a degreasing line and then we send them through our shot blasting process whereby we eliminate any risk of hydrogen embrittlement. Following this, the components get dipped, spun and then baked before going through the necessary quality control checks.”

“Generally speaking, the zinc flake coating method involves two base coats and a top coat – with all the components getting baked in between – and this can give you in excess of 1 000 salt spray hours.”

“In this industry we speak about coating thickness and salt spray hours. Salt spray hours is a difficult term to define. I have heard guys say that 100 salt hours is about the equivalent of one year’s worth of corrosion protection. But then other guys will say something different. Essentially there is no direct conversion from salt spray hours to real world service life because real environments are a lot more complex.”

Anderbolt Electroplaters’ shot blasting machine

Anderbolt Electroplaters can accommodate one-offs and small runs

“To actively test salt spray hours (NSS), we can run salt spray testing on components in-house. This is an accelerated corrosion test that involves testing components and their coatings by exposing them to a fine mist of a salt solution. The components are placed in a salt spray chamber once coated and then continuously sprayed with a controlled salt mist, typically a 5% sodium chloride solution with the chamber kept at 35C. This replicates a harsh environment and is something we have done on all of our finishes. We are doing continual testing in this regard and we are also continuously analysing our tanks on a daily basis with our onsite laboratory,” continued Fox.

“As far as I am aware, we are the only electroplater in the country that runs a heat pump to heat our tanks. We have also invested in a solar powered system and have a 250kW system in place with panels on our roof. Additionally, we have added a generator for backup power if needed and we have made the strategic decision to keep a store of spares on site for issues that may come up like having spare rectifiers and filtration units available to minimise any down time.”

Anderbolt Electroplaters can cater to almost any component and industry with their extensive range of plating options

Zinc flake coating machine. “We have recently installed an automated zinc flake coating machine. Zinc flake finishing is essentially an automotive specification type finish and one of its biggest advantages is the long and durable service life it gives finished components. Here we will be coating things like fasteners, brackets and some smaller components like springs. Our aim with installing this machine was mainly to target the automotive and mining industries. It is however not just limited to these, it can also be used in most other industries.”

On galvanising – hot-dip or zinc plating?
“Hot-dip galvanising is a very different process to electroplating. What we do is called electro-galvanising – the material coating is still the same – zinc – except that what we do is a cold process. It’s done at room temperature versus dipping a component in molten zinc. The two different methods are also applicable for different types of finishes.”

“Our method of zinc plating though is more applicable to the type of components and industries that we service for example as it applies a thinner layer of zinc and will provide a smoother, more uniform finish versus a rougher, thicker finish you would get when hot-dip galvanising. Zinc plating is also more applicable to smaller more intricate components versus larger more industrial type components. Our finish will always be more pleasing to the eye.”

“We have a total of 94 tanks that include 32 different plating tanks. On the electro-galvanising or industrial side of the business we are able to plate a component 2.8m in length by 1.4m deep and 550mm wide. On the decorative side of the business, we can plate a component 1.8m in length by 700mm deep and 430mm wide.”

“The list of finishes we offer as I said is extensive and includes copper, antique copper, satin copper, nickel, antique nickel, satin nickel, chrome, satin chrome, black chrome, brass, antique brass, satin brass, silver, tin, electroless nickel, zinc, zinc nickel, zinc phosphate, zinc flake, Delta Tone / Delta Protekt, cold blackening and general anodising in different colours.”

“With hot-dip galvanising you are looking at a finished surface of about 60 microns whereas with our process of plating you are looking at a finished surface of about 8 up to 25 microns, depending on customer requirements. Think of it this way, if you are galvanising a nut and bolt at 40 or 60 microns you are never going to get a nut to fasten onto a bolt, unless it’s been cut to accommodate a much thicker coating.”

Bath and tank capacities
“We have a total of 94 tanks that include 32 different plating tanks. On the electro-galvanising or industrial side of the business we are able to plate a component 2.8m in length by 1.4m deep and 550mm wide. On the decorative side of the business, we can plate a component 1.8m in length by 700mm deep and 430mm wide.”

“The list of finishes we offer as I said is extensive and includes copper, antique copper, satin copper, nickel, antique nickel, satin nickel, chrome, satin chrome, black chrome, brass, antique brass, satin brass, silver, tin, electroless nickel, zinc, zinc nickel, zinc phosphate, zinc flake, Delta Tone / Delta Protekt, cold blackening and general anodising in different colours.”

“We deal a lot with non-ferrous materials on the decorative side of the business – so brass, zinc die castings, aluminium and your stainless materials. On the industrial side of the business, it’s mainly your mild steels as well as the anodising of aluminium.”

“We have been fortunate to work with a range of clients and industries over the years including your luxury safari lodges, artists and sculptors, general automotive and mining companies, aerospace, antique car restorers, interior designers, the scaffolding industry, the conveyor industry, the electrical industry, the rail industry, the sports industry – plating trophies for instance – there’s virtually no industry that we haven’t done work for directly or indirectly via suppliers and contractors. We once even gold plated a strip of aluminium for a sultan’s private plane.”

“We plate to SABS and DIN specifications and a number of our finished components are exported to Europe, the Middle East and Australia,” concluded Fox.

Anderbolt Electroplaters have 43 permanent staff and operate from a 2 100m2 factory.

For further details contact Anderbolt Electroplaters on Tel +27 (0)11 894 2046, Darren on 082 605 1265 or visit www.andele.co.za