Coating solutions for ­refurbishments, repairs, and wear protection

In recent years, we have dedicated ourselves to designing and building coating technology that offers reliable and sustainable solutions for refurbishments, repairs, and wear protection. With 150 years of experience in the metals industry, our engineers have a fundamental understanding of all related processes and technical requirements for associated components.

This expertise extends to the development and design of bespoke coating solutions and proprietary coating equipment, combined in our lineup of TecGuard coatings. Each TecGuard solution is customized to meet the needs of different industrial processes, ensuring optimal performance and longevity. SMS coatings thus seamlessly combine sustainability and cost-effectiveness. We continually invest in research and development to stay ahead of technological advancements and industry trends, ensuring that our solutions are always at the cutting edge.

“Repairing parts instead of manufacturing new ones significantly reduces material waste and energy consumption. That’s why our coatings are inherently sustainable,” says Markus Mirz, Product Manager Coating at SMS group. “Additionally, we offer coatings that comply with environmental and local regulations, such as REACH in the European Union or OSHA in the US. These alternatives often provide a better service life compared to traditional coating processes, such as hard chroming, which involves toxic chemicals and is heavily regulated.” 

The sustainability of our coating solutions is further highlighted by their ability to significantly extend the service life of components. TecGuard-PRC coatings can triple or quadruple the service life of rolls in strip processing lines compared to hardened or chromed rolls, reducing machine downtimes. These rolls can be re-coated and repaired multiple times, lowering the demand for new materials and resources. This not only conserves raw materials, but also reduces the environmental impact associated with manufacturing new components. This helps our clients to achieve their environmental goals and regulatory compliance, all while maintaining high performance and reliability.

Markus Mirz gives an example: “One of our customers, a major steel manufacturer in South America, faced frequent downtimes due to wear on their deflector rolls in the pickling line scale breaker unit, heavily affecting the strip quality. After applying one of the TecGuard-PRC coatings, the customer reported an increase in service life of six months, reducing machine downtime by at least four shifts every year. This may seem insignificant, but small improvements across the whole pickling line add up.”

Another application is the repair of heavy machine parts such as rolling mill chocks or gearbox housings. The manufacturing process of such parts often requires casting and melting many tons of material, consuming significant energy and water. TecGuard-REP and BoreGuard coatings restore the bore geometry of worn-out chocks, ensuring perfect and smooth rolling for years. This process not only saves energy but also significantly reduces the carbon footprint of manufacturing. By opting for repair over replacement, companies can contribute to a circular economy, where resources are used more efficiently and waste is minimized.

Customers benefit greatly from our coatings through reduced total cost of ownership, improved part service lives, as well as better machine performance and overall equipment effectiveness. Extended service intervals increase machine availability, and the enhanced capability to withstand harsh operating conditions keeps the final product quality high for longer periods. CAPEX is transformed into OPEX, as machine parts last longer and investment intervals are extended. Our reliable coatings for wear protection reduce unexpected machine downtimes, making maintenance shutdowns more predictable and enhancing operational efficiency. This predictability is crucial for ensuring continuous production and meeting delivery deadlines, which are often critical in the competitive industrial landscape.

TecGuard coatings balance sustainability and cost-effectiveness, making them attractive for businesses aiming to consider both economic and ecological KPIs. Current supply chain crises underscore the importance of repair solutions and short lead times. While procuring new parts can take months or years, repair coatings and procedures are often completed in weeks. This agility in the supply chain is vital for maintaining operational continuity in today’s volatile market conditions. 

To keep to the tight schedules of planned machine shutdowns, we offer coating solutions and repairs in seven global service workshops, located in the US, South America, Europe, Asia Pacific, and China. In all major markets, these workshops offer a variety of coating processes, including high-velocity oxygen fuel spraying, atmospheric plasma spraying, and arc wire spraying, complemented by welding and electroplating facilities in certain markets. This global network of service workshops ensures that customers receive timely and efficient support, minimizing downtimes and enhancing productivity. By being strategically located near major industrial hubs, SMS group can provide rapid response times and localized expertise. Our ability to deliver solutions tailored to individual customer needs further underscores our commitment to providing exceptional service and support.

To ensure the continuous development and improvement of our coating technology, we established the Coating Competence Center, which aims to streamline all coating-related activities, securing the delivery of customized solutions that enhance plant availability and performance. The center connects knowledge gained from process technology, OEM equipment experts, material experts, and coating experts. The Coating Competence Center acts as a hub for research and development, driving innovations that meet the evolving needs of the industry. 

Innovations like the UniGuard coating, which significantly reduces wear on copper plates in continuous casting machines, highlight the growing role of coatings in reducing carbon footprints. By collaborating closely with clients, we develop solutions that reduce process costs and enhance the quality of final products, paving the way for future advancements in coating technologies that are beneficial in terms of both the environment and financial performance. This collaborative approach ensures that we remain at the cutting edge of coating technology, delivering solutions that are both innovative and practical. By staying attuned to market needs and regulatory changes, we proactively create solutions that address emerging challenges and opportunities in the industry.