Client Background
A major hot-dip galvanising facility partnered with London Electronics to improve process consistency and reduce costly rework during zinc coating operations.
The customer required a reliable timing system capable of providing clear visual indication of dip cycle status across the production floor.
The Challenge
In galvanising, immersion time is critical to coating quality.
Over-dipping can damage components and increase zinc usage, whilst under-dipping can lead to poor coating adhesion and reprocessing.
The customer needed a system that would:
- Provide accurate dip timing
- Display countdown information clearly across the plant
- Offer simple visual operator guidance
- Support different timing presets for various products
- Operate reliably in a harsh industrial environment
The Solution
London Electronics supplied a custom timing and visual indication system based around the versatile INT4 Digital Panel Meter.
The INT4 was programmed to control each dip cycle whilst driving:
- A large wall-mounted LED countdown timer
- Multi-colour Andon stack lights
- Relay outputs for alarms and process control
Operators can easily select different preset timings depending on the product being processed.
The visual indication system provides clear operational status:
- Green – Ready
- Amber – Dip cycle active
- Red – Remove product
Key features included:
- High-visibility LED timer display
- Viewing distances up to 30 metres
- Multiple programmable timing presets
- Relay-based automation
- Rugged industrial design
- Simple operator control
The Results
The system delivered immediate improvements in process consistency and operational efficiency.
Benefits included:
- Improved coating quality
- Reduced scrap and rework
- Lower zinc consumption
- Easier operator training
- Faster product changeovers
- Clear visibility across the plant
Conclusion
By combining the flexibility of the INT4 Digital Panel Meter with high-visibility displays and simple operator controls, London Electronics delivered a dependable process timing solution tailored to the demanding galvanising environment.
The result is improved consistency, reduced waste and reliable long-term operation.
Need a Custom Timing or Control System?
Contact London Electronics to discuss industrial timing systems, process displays and custom INT4-based control solutions for your application.