ZVO Surface Days once again receive top marks

After three varied congress days and with 570 participants, a further increase compared to the previous year, the ZVO Surface Technology Days 2025 came to a successful close on 26 September at the Mercure Hotel MOA Berlin.

ZVO Board Member Jörg Püttbach opened the industry get-together for electroplating and surface technology on the evening of 24 September and then led through the entertaining programme, which featured two keynote speeches as well as several awards. In addition to the participants and a number of guests of honour, Püttbach welcomed the CDU member of parliament Vanessa Zobel MdB, who has been a member of the CDU since 2016 and is involved in local politics as a city councillor and deputy mayor. The trained banker is committed to more business and less bureaucracy so that we can move from talking to doing again, for affordable electricity and hard work that is finally rewarded again. She wants to make Germany future-proof as a business location - with pragmatism, speed and reliability. Consequently, Zobel was elected to the Committee on Economic Affairs and Energy in the new German Bundestag . In her speech, she emphasised the importance of energy policy and reducing bureaucracy - both of which are key challenges for the surface technology industry, which is dominated by SMEs. She took a clear look at the importance of competitiveness, security of supply and entrepreneurial relief for German industry.

In his subsequent speech on the state of the industry and the ZVO, Püttbach also addressed a number of questions to the CDU member of parliament. Because: " The ZVO serves to promote and further develop electroplating and surface technology in political and economic terms. Its representation of interests is aimed at comprehensive improvements to the framework conditions of its members," he explained, passing the baton on to Lukas Hanstein, who has been coordinating the political issues and necessary activities full-time as the new Head of Politics at the ZVO since 1 July 2025.

The subsequent keynote speech by researcher, business and transformation psychologist and trained actor Dr Carl Naughton focused on the adaptability quotient. We live in a world in which the only thing that remains the same is constant change. New technologies, economic disruption and social upheaval - if you don't adapt, you lose. Or, to paraphrase Darwin: "It is not the strongest who survive, but the most adaptable." However, this does not mean that we have to constantly reinvent ourselves. It's not about chasing every trend, but about reacting to change in a smart, conscious and flexible way. This is exactly where the "Adaptability Quotient (AQ)" comes into play. In his presentation, Dr Naughton vividly explained the AQ, why it is more important than IQ and why companies rely on adaptable employees. He showed ways to remain flexible without falling into chaos. Namely through the three stages of adaptation: recognising, understanding, acting. And through the three pillars of AQ: Situational Awareness, Neo Credos, Proactivity. He also explained how to avoid the most common thinking traps and how to capitalise on change. He actively involved the audience under the motto "acting instead of complaining", for example by having them solve tasks in several live experiments. The audience took away a new mindset for an uncertain world. They were given tools to deal with change with confidence, practical tips to increase resilience and flexibility, strategies to actively shape change and interactive exercises that have an immediate impact.

The welcome evening endedwithan informal get-together in the MOA atrium.

The lecture programme of the ZVO Annual Congress took place on the following two days.The almost 100 presentations focused on the topics of digitalisation and AI, bath and/or surface analysis, chemical metal deposition, sustainability, circularity and the tried-and-tested entrepreneur forum "Management meets surface". In addition, there were the regularly recurring thematic blocks, such as Young colleagues report, functional coatings, from process monitoring to product quality, future topics and new requirements for electroplating and surface technology.

Consultation hour on regulatory developments

The aim of the consultation hour organised by the Environmental and Chemicals Policy department was once again to inform member companies from the electroplating and surface technology sector about current developments in the field of environmental and chemicals policy at national and European level and to promote professional exchange.

The RUCP sees itself as the expert committee of the ZVO, which monitors and evaluates the multitude of regulatory requirements and develops well-founded positions for the industry. The consultation hour offered an open platform for queries, discussions and suggestions - with the clear aim of strengthening communication between the member companies and the association.

A key topic at this year's meeting was the current draft REACH restriction on chromium (VI) compounds. There was a great response to this topic, as numerous companies are directly affected in their day-to-day practice and through the authorisation process to date. The potential impact of the planned regulation on technical processes, investment decisions and competitiveness was the reason for a lively and intensive discussion.

One focus of criticism was the approach of the European Chemicals Agency (ECHA), which had set a so-called "early deadline" for the submission of comments in addition to the regular comment period. According to ECHA, contributions submitted before 18 September 2025 should already be considered at the meetings of the responsible committees (RAC, SEAC) in the autumn. This was criticised by the RUCP and other industry representatives, in particular the European umbrella organisation CETS, as a violation of the principle of equal treatment within the REACH Regulation. There is a risk that smaller companies or associations with fewer resources will be systematically penalised. The pressure to submit comments at an early stage could also lead to contributions not being prepared with the necessary care and depth.

In addition to this key topic, other issues were also discussed. These included the introduction and implementation of the new environmental performance indicators (BAT-AEPL) through the Seville Process, which will become an important benchmark for authorisations and official reviews.

The ongoing work of the "Sulphamic Acid Round Table", which was set up by industry representatives as a precautionary measure, was also reported on. The RUCP is actively involved here in order to enable a differentiated presentation of industrial practice and to develop sensible, realistic measures together with the authorities that do justice to both environmental protection and industrial applicability. This topic in particular showed how much the association's ability to make statements depends on information from the companies.

On the podium, Ilona Fey, Kerstin Zübert and Dr Georg Hünnekens - all committed contributors to the RUCP - were available as competent contacts for technical questions. They enriched the discussion with well-founded insights, professional depth and a direct link to practice. Their contributions once again emphasised how important the close interlinking of practical knowledge and association work is in order to be able to effectively represent interests.

The event impressively demonstrated how complex the regulatory environment in which the industry operates is - and at the same time how great the need for dialogue, information and strategic representation of interests is.

Therefore, an explicit appeal is made to all ZVO member companies: Get actively involved in the work of the Environmental and Chemicals Policy Department! Whether by attending meetings, contributing your expertise or supporting political processes - every commitment counts. Only together can we succeed in shaping the framework conditions for surface technology in Germany and Europe and influencing regulatory developments at an early stage.

Women in surface technology: challenges, opportunities and prospects

Female SurFaces, the women's network of the ZVO, once again hosted a dialogue-oriented session on the topic of women and surface technology with a focus on production. The three-part event kicked off with a presentation by Dr Elke Moosbach, who shed light on the development of women and the changes in the world of work, with a special focus on surface technology. A hundred years ago, women were still excluded from many areas of the economy, but today they are indispensable in many industries. And yet a great deal of potential remains untapped: While the shortage of skilled labour is growing, the proportion of women in technical and manufacturing professions remains low. The presentation highlighted the challenges, but also the strategic opportunities, for companies that see the shortage of skilled labour not as a problem, but as an opportunity and focus on the previously untapped potential of women.

This was followed by a dialogue between two industry leaders on the topic of women in production: Miriam Dürr as an employee and Claudia Wagner as an employer spoke openly about their experiences: What challenges do both sides have to face? What hurdles are there on both sides - from childcare and physical demands to dealing with chemicals? And what does it take to give more women not only access but also long-term prospects in production?

The subsequent panel discussion revisited the topic of (more) women in manufacturing jobs. Experts from business, science and practice analysed the current situation and discussed ways forward. The session was well attended throughout and the free chair at the panel was also well received by both female and male participants.

Results from research - Young colleagues report

The "Young Colleagues" lecture block at #OTBerlin25 once again offered a showcase of German universities and research institutes working in the field of surface technology. A total of eleven graduates and young employees were able to present their research work in three sessions.

Lea Breu, Bosch Manufacturing Solutions, spoke about the hydrogen permeation properties of anodised aluminium. She focussed on the relationship between the microstructure of the oxide layer and its permeability. This research is relevant for components in applications in the hydrogen economy.

Electrochemistry at the highest level was presented by Anna Lena Woeste, TU Ilmenau: The capacity of lithium-ion batteries can be increased by so-called "prelithiation" - in principle, a targeted initial charge before the cell is assembled. This application may become important for alternative anode materials such as silicon.

Marius Engler, TU Ilmenau and winner of this year's DGO Nasser Kanani Prize, researched electrochemical energy storage on a large scale. Iron flow batteries are storage systems that can support the energy transition in the future, but do not require critical or scarce materials. Engler was able to optimise the electrolyte and the deposition conditions using methods such as cyclic voltammetry and microgravimetry.

Jonas Rehbein, TU Ilmenau, opened the second session. His presentation focussed on decorative or functional chromium, chromium alloy or chromium replacement layers. The work aimed to improve the general understanding of chromium deposition from trivalent electrolytes and also to systematise it.

Mahmoud Elkady, HS Aalen, gave a presentation on functional chromium layers. A commercial trivalent hard chromium electrolyte was used to co-deposit hard material particles such as boron carbide, which improved both the microstructure and tribological properties of the chromium layer.

Nisha Poonia, TU Chemnitz, made a contribution to the electrodeposition of "stainless steel" (Fe-Cr-Ni alloys). She specialised in the co-deposition of silicon carbide particles in these alloys. Experiments on the influence of deposition parameters on the microstructure and tribological properties were planned, carried out, analysed and presented with impressive systematic clarity.

The lecture by Scott Dombrowe, HS Mittweida, also focussed on wear protection coatings. The topic was the deposition and characterisation of nickel-tungsten coatings. A special feature of these coatings is the high tungsten content and the associated high hardness after heat treatment.

At the beginning of the last session, Simon Kertzsch, HS Mittweida, gave an overview of plastic metallisation in all its facets. In particular, he discussed the metallisation of technical plastic materials such as PEEK and PEI using innovative approaches.

Gesina Kley-Steverding and Marc Edward-Piepenbrink, BIA Kunststoff- und Galvanotechnik, presented a process for recycling Cr(III) electrolyte rinsing water. The rinsing water is concentrated by reverse osmosis. The recyclate is then fed back into the electrolyte after activated carbon purification. Recirculation saves on chemical costs and only marginally affects the quality of the deposited layer.

Florian Pantleon, TU Ilmenau, presented his work on the electrochemical monitoring of pickling processes, which was honoured this year with the DGO Young Talent Award. Information about the progress of the pickling process and the condition of the pickling can be obtained by measuring transients directly on the component or by measuring noise on a test specimen. Pantleon has broken new ground in this area and has already developed a practical method.

Finally, Puya Sabeti, ZINQ, demonstrated the influencing factors of interface kinetics in hot-dip galvanising. It was impressive to see the depth and care with which the processes in this established method were investigated and how much the type and condition of the base material were taken into account when considering the result of the coating.

Functional layers

Trivalent hard chrome processes

As Oliver Daub, Dr Max Schlötter, emphasised in his introduction, previous efforts to replacehexavalent chromium processes with systems using trivalent chromium compounds for the production of hard chromium coatings have been associated with numerous difficulties. The coating from most available trivalent chromium electrolytes lacked some important properties such as uniformity, throwing power and corrosion resistance.

With new developments, significant progress has been made in properties that approach or in some aspects even surpass those of hexavalent hard chrome. The coating properties and the properties of the deposited layers from different electrolyte systems are compared.

With a new generation of electrolytes based on chromium(III) compounds, nearly crack-free trivalent chromium coatings can be deposited on simple or complex shaped substrates with exceptional throwing power. In terms of uniformity, the results also show that the ratio between maximum and minimum thickness of the chromium layer is significantly reduced. In addition, the process is less sensitive to pre-treatment. Even under extreme mechanical or thermal stress, excellent adhesion of the coating is observed. In addition, the corrosion resistance of the coated samples is improved compared to previous trivalent chromium coatings.

Hard chromium coatings from chromium(III) electrolytes

Andreas Waibel from the Fraunhofer Institute for Manufacturing Engineering and Automation IPA deals with the same topic as the previous speaker. The coatings made from classic chrome electrolytes have a number of favourable properties: high hardness, low coefficient of friction, anti-adhesive properties and high chemical and thermal resistance. This gives them exceptional performance, which contributes significantly to the efficiency and service life of technical components. To deposit such hard chrome layers, industrially applicable electrolytes still have to be based on chromium(VI) compounds, which are subject to strict regulations in the EU due to their environmentally harmful and unhealthy properties and are under constant pressure to be substituted.

In recent years, chromium(III)-based electrolyte systems have increasingly come into focus as a potential alternative. Despite intensive development activities, however, Andreas Waibel believes that these systems have not yet been able to keep up with the established chromium(VI) systems, both in terms of process and coating properties. The lecturer demonstrated this by comparing the properties of chromium(III) electrolytes and the coatings deposited from them with those of known chromium(VI) systems. He presented the results of current research work and gave an outlook on the necessary developments as well as the challenges for the intended future application of chromium(III) electrolytes for hard chrome deposition.

Experience with the introduction of and changeover to non-PFAS-containing wetting agents

Electroplating is not only under increasing regulatory pressure due to the use of hexavalent chromium compounds, but also because of lead and PFAS-containing wetting agents, as Anke Walter, Atotech Germany, emphasised. While proven alternatives such as trivalent decorative processes and the first functional hard chrome processes based on chromium(III) are already available, hard chrome plating with chromic acid (Cr(VI)) is still widely used. A key challenge is the control of chromium(VI) emissions, which has traditionally been achieved using PFAS-containing wetting agents for spray suppression. However, due to stricter environmental regulations in the EU and the USA, their use is severely restricted or already prohibited.

The speaker gave an overview of the status of developments in PFAS-free alternatives for spray mist prevention for decorative and functional chrome coatings. These products have been on the market for around three years and have been used successfully by numerous users. Anke Walter explained the differences and advantages of the new technologies and described the experience gained during their introduction and conversion in various areas of application.

Porous nickel layers as catalyst support layers for AEM electrolysis

Hydrogen is expected to play an important role on the path to decarbonising the energy and raw materials supply, including for energy storage in the event of surplus electricity or for use in the steel industry as a reducing agent. Proton exchange membranes (PEM), alkaline electrolysers and anion exchange membrane(AEM) electrolysis are used to produce hydrogen. The latter combines the advantages of the two aforementioned processes.

The development of a hierarchically structured anode is being investigated as part of the ZIM cooperation project NiProAEM; Christian Höß, TU Ilmenau, who is also involved in the project, presented it in his lecture. At TU Ilmenau, the deposition of a porous nickel layer is being investigated, which is then to be coated with a catalyst made from a nickel-iron alloy. The functionality of this catalyst carrier layer is to ensure the availability of the catalyst at the boundary layer to the membrane and to increase the electrochemically active surface area.

The investigations show that, in addition to the electrolyte composition, the current density and deposition time have a strong influence on the overall structure such as thickness, pore size and distribution for an optimal, porous deposition. It is interesting to note that the deposition time should not be too long, as in this case the porosity can decrease again. Cyclovoltametry and electrochemical impedance spectroscopy (EIS) were used to determine the electrochemically active surface. The researchers obtained the best layers at a current density of 0.8 A/cm2 and a deposition time of 180 seconds. As the recorded polarisation curves suggest, the layers are suitable for use in electrolysis with an anion exchange membrane (AEM).

Indium as a low-whisker alternative for the press-fit zone

In electronics, components are used for press-fitting into plastic to achieve electrical contacts. This requires coatings thatdo not form whiskers, which can cause electrical short circuits. Hans-Ullrich Eckert, Gerweck Oberflächentechnik, presented a coating for plugs using indium in tin layers that minimises whisker growth. The formation of whiskers is due to various reasons, such as internal stresses, the incorporation of organics into the layer, hydrogen incorporation or even temperature and humidity.

In the case of press-fit contacts, the main cause is pressure on the layers. Until recently, tin-lead was used as a solution, but this can no longer be used for regulatory reasons. An alternative to this is tin-silver coatings, for example, although these are subject to complex process conditions. Other options are tin-indium coatings or tin-bismuth coatings, although the latter does not allow the reprocessing of metal waste. This results in the preferred use of tin-indium coatings.

In order to qualify such a coating, it was necessary to develop the deposition process for use in the speaker's company. Thechallenge here was to test the coatingfor whisker formation, which is not easily possible as whiskers usually occur with a significant time delay. In order to obtain results quickly, the lecturer developed a suitable measuring system that provides results within a week. Another challenge was to carry out the reflow process, as the tin-indium alloy has a very low melting point of less than 120 °C.

Furthermore, the press-in and press-out forces had to be determined and optimised for the qualification. Although cold welding occurs with tin-indium, the forces are somewhat lower than with tin-lead. The process technology now allows the coating of components that fulfil all customer requirements.

Highly thermally conductive foils with diamond intercalation

Miriam Dürr, fem Forschungsinstitut, presented results from a ZIM project in which highly thermally conductive foils are produced by depositing metal with the inclusion of diamonds. Such films are used to dissipate heat in heat-sensitivedevices such as mobile computers or mobile phones. Copper is a suitable metal for this purpose due to its high thermal conductivity coefficient. To improve thermal conductivity, the aim is to increase heat conduction by integrating diamond into the layer. The classic process of galvanic deposition of copper on stainless steel rollers is suitable as a process technology; large parts of the copper foils for electronics are produced in this way.

In relation to the surface area that is relevant for heat transport, proportions of around 40 per cent diamond and 60 per cent copper are advantageous. The investigation into the area distribution was carried out using ion beam slope cutting technology, as this also allows the diamonds to be cut. This prevents the embedded diamonds from being mechanically removed from the coating during preparation.

Copper was deposited from an acidic electrolyte under standard conditions to produce the layers. It is important here to optimise the deposition to produce a layer that is as smooth as possible by modifying the introduction of diamond into the electrolyte and the resulting installation rate. The optimum size of the diamonds used is in the range of 6 to 12 millimetres for layer thicknesses of more than 100 millimetres. Analyses of the films produced show that an increase in the amount of intercalation leads to slightly better thermal conductivity of the films. Ideally, the diamonds should be in contact with each other, but without leading to the formation of pores.

Nickel dispersion layers for electrolysis applications

The nickel dispersion layers presented by Dr Nils Ulrich, Dr.-Ing. Max Schlötter, are intended for use in hydrogen technology, especially electrolysis. The development of hydrogen is particularly useful as a storage medium for sustainable electricity. For such electrolysis devices, it is important to keep the hydrogen overvoltage on the electrode surface as low as possible. Electroplated nickel and nickel dispersion layers are particularly suitable for electrolysis from alkaline electrolytes. Tin-nickel layers and tin-nickel-carbon layers can be consideredas corrosion protection layers . Particles as functional materials that ensure low hydrogen overvoltage are suitable for producing the dispersion layers. Similar goals are to be achieved with nickel alloys.

An electrolyte based on nickel sulphamate is used to produce the dispersion layers presented. This system achieves a good and uniform installation rate of the particles. The overvoltage can be noticeably reduced with suitable particles. It should be noted that the positive effect can only be observed for cathodes, while the layer without particles is more favourable for anodes. Load tests show that the electrodes exhibit constant overvoltage values over longer running times. The results are also confirmed in a test rig under real process conditions, particularly on the cathode side.

Chromium(VI)-free deposition process for deep black surfaces

Due to their deep black appearance, high absorption capacity and robust mechanical properties, black chromium coatings based on hexavalent chromium are used in a wide range of applications, both decorative and functional. However, a technically equivalent alternative that can dispense with the undesirable chromium(VI) compounds is still lacking.

As part of a project presented by Dr Heidi Willing, fem Forschungsinstitut, work has been carried out on an alternative galvanic process that can be used to produce coatings with comparable properties. This is possible, for example, on the basis of nanostructured, three-dimensional nickel-based surfaces.

The layer properties can be specifically influenced by varying the deposition electrolytes or parameters. Electrolytes based on nickel chloride, nickel sulphate and a combination of nickel sulphate and phosphate were used for this purpose. Among other things, the investigations show that the relevant colour values depend on the thickness of the deposited layers. Another option for producing the required black layers is the use of pulsed current. The focus here is on optimising the coating properties, especially with regard to colour, light absorption and mechanical properties.

Silver-graphite dispersion coatings - durable with exceptional tribological properties

Even with a graphite content of around 1% by weight, significant improvements in friction coefficients and electrical resistance can be achieved after loading compared to pure silver coatings. This finding is not new, as Dr Stefan Henne, Dr Max Schlötter, pointed out in his introduction. In order to fully utilise the potential of electromobility, the question currently arises as to whether this type of coating can also meet current and future requirements in terms of temperature stability and number of mating cycles. The requirements vary depending on the area of application. Connectors in the engine compartment are exposed to a temperature load of 180 °C, whereas temperatures of 150 °C are required in the charging socket area.

For the further development of the required coatings, measurement results are obtained with a newly developed test bench and new test concepts for tribological and electrical properties of contact coatings. In addition to friction coefficients, electrical resistances can be determined in situ. The number of mating cycles and the normal force can be varied in order to be able to simulate demanding requirements on contact surfaces. Work is also underway on a solution for the application of silver coatings at higher temperatures and exceptional tribological properties.

Galvanic platinum deposition on silicon-based semiconductor components

In microelectronics, metal-semiconductor compounds areused extensively in sensors and detectors, especially infrared detectors and cameras, primarily in the form of platinum-silicon semiconductor contacts.Currently, platinum coating on silicon-based semiconductor componentsis realised using sputtering techniques or platinum-containing printing pastes with subsequent heat treatment.

Mathias Fritz from TU Ilmenau is working on an approach to galvanic platinum deposition for such applications. Special attention is paid to the pre-treatment of the silicon for the subsequent platinum deposition by varying the current density, electrolyte composition and illumination of the substrate (light induced plating). The challenges include achieving a homogeneous platinum coating with low contact resistance and high adhesive strength.

Plasma electrolytic oxidation of steel

In his presentation, Dr Roy Morgenstern, TU Chemnitz, assessed the extent to which coatings produced by plasma electrolytic oxidation on steel with a compact coating interior and an open-porous surface can be used as adhesion promoters by combining several process steps.

In the first step, aluminium oxide-rich precipitation layers and PEO layers (PEO: plasma electrolytic oxidation) are produced at low DC voltage (< 100 V) or pulsed voltage with moderate amplitude (100 V to 200 V). The PEO layers produced in this way serve as a type of substrate passivation for a further PEO step in a silicate-phosphate electrolyte at pulsed voltage with increased amplitude (> 300 V). The substrate material used is a high-strength dual-phase steel with a bright or phosphatised surface that is relevant for lightweight structural engineering.

During the plasma-electrolytic oxidation, the electrical parameters and videos of the spark discharges are recorded over time. The coating is analysed at the macro level using optical microscopy, X-ray fluorescence analysis and X-ray diffraction, and at the micrometre scale using scanning electron microscopy and Raman microscopy.

The most suitable layer for substrate passivation due to its adhesive strength, homogeneity and layer thickness was produced in aluminate phosphate solution at 200 V voltage amplitude. During the second step of plasma-electrolytic oxidation in silicate-phosphate solution at 300 V, spark discharges and layer formation took place preferentially at locations with low layer thickness, so that in addition to layer areas with a high aluminium oxide content, areas containing silicon dioxide and iron phosphate increasingly developed during the process.

New requirements for electroplating and surface technology

The new ELV-R and its impact on surface technology

The European End-of-Life Vehicles Directive has regulated the use of lead, cadmium, chromium(VI) and mercury for almost 25 years and stipulates reutilisation and recycling quotas. However, according to Thomas Holzapfel, imds professional, there are numerous differences in implementation in the member states. It was also found that the use of recycled materials in new vehicles and the recovery of materials from end-of-life vehicles are inadequate. Another problem is that the term " end-of-life vehicle " is not really defined and therefore, for example, vehicles that are economically totalled in accidents are not recycled but sold abroad (outside Europe). And until now, the ELV only applied to vehicles in the M1 or N1 categories.

The new ELV Regulation addresses the problem areas identified by the EU and, when it comes into force, will apply directly in all member states. Vehicles in categories M2, M3, N2, N3 and O (buses/trucks/trailers) and L3e, L4e, L5e, L6e and L7e (two- and three-wheeled motorbikes and quads) will also be covered after five years. There will be new requirements for reusability, recyclability and recoverability. At least 25 per cent of the plastic content of a new vehicle must consist of recycled material (post-consumer), 25 per cent of which must be recycled plastic from end-of-life vehicles, with recycling already being taken into account during the design phase.

As car manufacturers now have to pay more attention to recyclability, there could be a shift in demand for the coating materials typically used to date. This will also indirectly affect the surface industry, particularly with regard to coatings on and made of plastics, the possible increased use of recyclates and possible changes in demand for metal coatings in terms of recyclability/reusability.

Chromium(VI)-free plastic pre-treatment

Companies in the field of galvanic coating of plastics are required by the European chemicals regulation REACH not to use hexavalent chromium compounds. This applies to both the production of the chromium layer and the pickling of the plastic, whereby suitable solutions are now available and have been introduced for the former.

On the other hand, the chromium trioxide-free pre-treatment of plastics has been the subject of development for years, both by process suppliers and by plastic electroplating companies themselves, as the representatives of SurTec International, Dr Sven Neudeck and Marvin Wagner from BIA Kunststoff- und Galvanotechnik, emphasised in their presentation. A large-scale process has already been tested in the BIA Group's newly constructed electroplating line in Solingen. However, significant disadvantages led to the decision to change the pre-treatment process.

In co-operation with SurTec and OKUNO Chemical Industries Co., Ltd. (Japan), a new process has now been established that works on the basis of permanganate in combination with silver and - under certain conditions - additionally with palladium, and enables reliable, adhesive and selective deposition.

Surface treatment and cleaning by electrolytic plasma polishing

When manufacturing an end product, many parts must fulfil certain characteristics, such as freedom from burrs, surface quality, dimensional accuracy or precision. Achieving these criteria with process reliability is essential, as it influences the quality of coating, welding and bonding processes, for example. The high surface quality is essential, for example, for the friction properties of a component or the cleanability and sterilisability in the subsequent area of application. The electrolytic plasma polishing of metallic parts presented by Matthias Kroll, plasotec GmbH, is ideal for the necessary surface treatment. The process can be used for all electrically conductive materials, i.e. primarily for metals. A low-concentration electrolyte with a salt content of around 5 per cent in water is used, with very high DC voltages of up to 320 V and current densities of less than 0.2 A/cm2.

As Kroll explained, the technology enables a significant improvement in surface quality and the removal of ultra-fine burrs. In addition, film and particulate contaminants are removed in an environmentally friendly manner in the same operation. As a rule, no upstream cleaning process is required for the process to be effective, which is a clear advantage when considering the economic viability of the entire process chain.

Electrolytic plasma polishingsignificantly improves the cleanability as well as the dripping and drying behaviour of components, thus reducing energy consumption. The use of an environmentally friendly electrolyte and the combination of several steps in the process chain in a single operation enables the economical and environmentally friendly surface treatment and cleaning of parts. Plasma-polished parts can generally be processed directly in the subsequent process. The speaker presented this using selected application examples from the fields of medical technology, precision mechanics and electronics production, among others.

PFAS-free systems for corrosion protection

The regulations surrounding a possible PFAS ban are driving the development of PFAS-free alternatives. Sabrina Hilbt presented Dörken Coatings' solutions, particularly for use on galvanic substrates. These include proven product solutions as well as a new, innovative PFAS-free silver top coat. A completely new PFAS-free generation of DELTA®-SEAL variants is also available. Using a number of successful customer projects as examples, she demonstrated the advantages of switching to PFAS-free solutions.

With PFAS-free product solutions, particular attention is paid to improving theCO2 footprint: PFAS-containing products such as topcoats with PTFE have a considerable impact on the environment due to their production and application. According to Hilbt, PFAS-free products make it possible to significantly improve theCO2 footprint and thus make an important contribution to a more sustainable future.

Research data management for the deposition of decorative chromium layers from chromium(III) electrolytes

An ontology for electroplated layers was developed and linked to the experimental data in a relational database for a research project on decorative chromium coatings from trivalent electrolytes, which was presented by Dr Christoph Baumer, TU Ilmenau. The data from electroplating practice, such as data on the raw material, electrolyte, coating process, pre- and post-treatment, plant, environment and, above all, the quality of the coating, were used for this purpose. The aim is to process and link this information in such a way that it is understandable for both humans and machines. This is made possible by knowledge graphs or ontologies, which create a semantic link between the expert knowledge of the electroplating specialists and the stored data. At the same time, they enable automatedstructuring and processing of the information.

With the help of simple queries, layer thicknesses, colour or gloss values can be linked to process parameters such as current density, electrolyte concentration, pH value or temperature. The determination of these complex process-structure-property relationships reveals previously unknown correlations and makes predictions and process optimisations possible. Based on the fundamental problems of data handling, the presentation showed possible solutions for data management in electroplating technology. These can be transferred to the industrial process, resulting in analogous advantages in terms of comprehensibility, transparency, linking and utilisation of the data.

Functionalisation of surfaces

The requirements for cathodic coatings, i.e. zinc coatings to protect steel substrates, have been increasing for several years. Dr Christine Rohr, SurTec International, had already taken a closer look at this topic in a presentation at the ZVO Surface Days 2025 and outlined a basic approach to modern coatings. In the meantime, the speaker has expanded on the approach taken at that time and developed a more in-depth consideration of the possibilities for influencing the fulfilment of multifunctional requirements for surfaces. Important of the numerous requirements include wear protection, mechanical loads, defined friction, protection against loosening, hot-dissolving behaviour, recoatability and, of course, the classic requirement for high corrosion resistance.

Studies were carried out, for example, to increase the adhesion of organic coatings using different phosphatings and to determine their behaviour on the adhesion of the coating. Significant differences were found in the application of bonded coatings with regard to the type of paint, the base material to be painted or the type of pre-treatment such as sandblasting.

When coating screws for vehicles, it was shown that the friction coefficients of passivated surfaces can exhibit high scattering and that relubrication can reduce this unfavourable effect. This ensures that uniform screw connections can be realised. Further requirements for fasteners are the provision of a screw lock to prevent unwanted loosening under operating load and of seals. For both cases, the speaker demonstrated possible solutions through partial coating with organic substances and the results that can be achieved.

Copper coating for heat exchangers made of cell wax structures

Mohammad Dodangi from Chemnitz University of Technology is working on a new method for producing complex hollow metal structures by metallising 3D-printed hollow structures with copper. These structures, based on triple periodic minimal surfaces (Schwarz-P), are particularly advantageous for use in heat transfer due to their significantly higher number of transfer units compared to conventional plate heat exchangers. According to the speaker, they offer superior thermal management, are more cost-effective than alternative methods such as metal casting or metal 3D printing and enable scalability for the production of structures in various sizes.

As part of the CORNET project WaxCelMet, a production chain that combines additive manufacturing, injection moulding and electroplating was developed and optimised for the production of hollow metal structures. By using low-viscosity waxes and polymer blends, the process enables either the removal of the substrate after electroplating to produce lightweight hollow structures or the retention of the substrate as a phase change material (PCM) for thermal energy storage.

The required electrodeposition process includes pre-treatment steps forpreparation and chemical copper deposition , and a suitable electroplating system was built to ensure uniform copper deposition on the complex geometry. The effectiveness of the process is assessed by optical microscopy and by evaluating the coverage and quality of both the chemically deposited and electroplated copper layers.

Regeneration of slip ring assemblies using galvanic processes

Currently, bronze slip ring assemblies in special formats for cranes and wind turbines are not overhauled in the event of repairs, but are instead newly manufactured. In order to minimisedowntimes and the associated high costs, such component groups should be regenerated efficiently and in an environmentally friendly manner. As part of a ZIM cooperation project, presented by Ivan Genov, TU Ilmenau, an environmentally friendly process for the electrochemical regeneration of bronze components with a tin content of ten per cent is being researched.

The aim is to develop a new type of electrolyte and a prototype for the continuous coating of worn slip ring bodies under optimised flow conditions and electrical field distribution. New complexing agents are being researched as an alternative to the established cyanide-based system. A commercial cyanide-based electrolyte is initially used as a reference point and to validate the deposition process. This allows thick bronze layers of several hundred micrometres to be produced on cylindrical bodies with the same alloy composition as in the base material and their characterisation.

The experiments showed that real-time monitoring of the electrolyte composition during the coating process is necessary, as the long deposition times lead to changes in the metal ion concentration. Square-wave voltammetry (SWV) was identified as an effective technique to solve this problem. The signal amplitude provides information about the actual coating composition obtained in the process. In addition, the cathodic peaks can be used to determine the concentration of metal ions in the electrolyte. The optimisation and validation of the SWV method enables the monitoring methodology for electrolytes to be adapted.

Challenges in the measurement of chromium(VI) in electroplating

As Dr Julius Gröne, Matthews International, emphasised, the determination of limit values is problematic in that it is often difficult to prove this. The planned restriction, which would allow companies to set clear limits, has not yet been implemented. This uncertainty means that companies are currently reluctant to invest in measures related to chromium(VI). A fixed limit would provide the necessary planning security and concretise the legal framework. In the case of chromium(VI), the SCOEL report (SCOEL: Scientific Committee on Occupational Exposure Limits) is used as a starting point for the toxicity of the substance. The limit value of 0.01 mg/m3 currently proposed by the ECHA cannot actually be measured. There are also challenges with regard to measurement accuracy, including repeatability, factors influencing measurement results and fluctuations due to external factors.

The presence of chromium(VI) on surfaces can be detected by relatively simple means (according to ISO 17075). Such chromium can be removed by washing withvitamin C (and/or ascorbic acid). Vaccination against pneumococci can be recommended as a preventive measure. Finally, it should be emphasised that washing hands before ingesting food is very helpful in protectingagainst chromium(VI) via the skin or mouth (Osha guideline). However, it is fundamentally important to set limit values that can also be managed in practice.

From process monitoring to product quality

Analysing process baths in real time

Online analytics for monitoring electroplating processes is now state of the art. It ensures an optimal composition of the electrolytes during the coating process. However, in order to make the best possible use of the potential of the process and measurement data obtained, it is necessary to link and analyse this flood of data in order to gain valuable insights into process stability and quality improvement - a topic that Dr Thomas Moritz from Hillebrand Chemicals is working on.

In the method he presented, data from various sources, such as online analytics, plant computers or ERP systems, is bundled via interfaces and brought together in a central database. This data includes analogue signals, such as temperature, pH value and electrolyte concentrations, as well as digital information, such as valve positions, pump statuses or rectifier data. Data is processed and visualised in an intuitive user interface that calculates real-time key figures such as the CpK value for process stability and monitors these using a traffic light system. Deviations are detected early by the System Health Service (SHS) team, which shortens response times and minimises quality losses.

In addition, the linking of system data, electrolyte data and customer-related information enables complete documentation of the production process. This enables batch-specific reports to be generated quickly in the event of queries and provides a new level of transparency and process reliability. The approach shows that the intelligent utilisation of the flood of data goes far beyond mere collection - towards data-driven decisions that can sustainably improve quality and efficiency.

AI-supported surface defect detection in series production

Automatic optical inspection systems (AOI) based on AI models (inspection models) offer an efficient and cost-effective solution for inspecting components for surface defects. However, the variety of component geometries and the detection of rare defects for which only a few sample parts are available pose a challenge, as Andreas Hofmann, Fraunhofer Institute for Physical Measurement Techniques IPM, emphasised in his introduction. Numerous representative defect patterns are required for the training of inspection models, which is often difficult or even impossible in practice, which is why AOI systems with AI support are hardly widespread in quality assurance to date.

In the speaker's experience, this challenge can be overcome by using a generative AI model in which the required image data of the defective parts is generated synthetically. This model is trained on the basis of just a few real defect images and learns to recognise the characteristics of the surface defects. The crucial step is to generate new, plausible images of defects. This expands the training data set, which in turn improves the recognition and classification accuracy.

The extended training dataset can be used for different coatings. This approach enables a high degree of flexibility and therefore successful use in different optical inspection systems for image data collection. Using various examples, such as the use of a tunnel inspection system and a free-fall system, the speaker demonstrated how application-oriented this combination of flexible inspection systems and generative AI is.

Process analytics on the way to AI-supported electrolyte management

Sustainability, occupational health and safety and cost pressure in the supply chain as well as rising energy and raw material prices are current key topics that are forcing a rethink towards automated electrolyte monitoring, which Daniel Schlak, Metrohm Germany, addressed. With the aim of increasing process efficiency, the automation of processes based on intelligent behaviour and machine learning will play a key role in the future.

Large amounts of data are already being produced through the use of modern measurement and control technology for automated media management, but utilising the data and combining it into an AI model is proving to be a challenge. Knowledge of the exact concentration over the life cycle of the electrolyte under consideration is essential for the creation of AI-based models. Both manual and automated analyses provide valuable results in this regard. In contrast to conventional laboratory methods, fully automated solutions such as online or atline systems allow continuous and close-meshed process monitoring with high data quality virtually in real time.

Automated analysis in combination with modern software solutions opens up a wide range of possibilities for automation and handling data volumes. Process data is continuously recorded, processed and transmitted to any process control system. In addition, process data can be retrieved from external sensors and customised programmes can be executed smoothly. Modular analysis systems play an important role here, combining all the analysis tools relevant to electroplating, such as titration, VA/CVS, XRF and Raman, as well as their possible combinations.

The right anode material - maximum performance

As Dr Cay-Uwe Pinnow, Helmut Fischer, emphasised, X-ray sources in ED-XRF measuring devices are often equipped with tungsten (W) as the anode material, as tungsten has excellent long-term chemical and thermal stability and also provides a very intense and universally applicable excitation spectrum due to its high atomic number (Z=74), which proves to be very advantageous for many applications in coating thickness measurement and analysis. In individual applications, however,the characteristic lines of tungstenlead to limitations, so that there are better alternatives for special applications. Alternative anode materials include elements such as molybdenum, chromium or rhodium.

Using the example of measuring nickel-phosphorus layers on copper, the combination of gold, nickel-phosphorus andcopper on printed circuit boards, zinc-aluminium on steel in automotive engineering or on steel as corrosion protection, as well as manganese phosphate as corrosion and abrasion protection and sliding material, the lecturer explainedthe advantages and limitations of the various anode materials in detail. For light elements in particular, such as those present in nickel phosphorus, chromium is better suited as an anode material for measuring the coatings than tungsten.

Correlation of dynamic contact angles and adhesion using a new test method

Simple contact angle measurement has long been an indispensable tool in the coating specialist's toolbox. According to Katharina Wulz, Krüss GmbH, it serves as a guideline for the formulation and evaluation of coating performance in terms of wettability, (re-)coatability, defect control, adhesion and more. While static contact angles are well known, dynamic contact angle measurements are less used. This is probably due to the fact that they are much more difficult and time-consuming, as a typical set of measurements (including repetitions) takes two hours or more.

A number of studies have demonstrated a strong correlation between dynamic contact angle measurements, particularly retraction angle data, and the adhesion of substrate coatings according to ISO 2409 (cross-cut adhesion/tape test). This correlation was tested on a variety of substrate types. A key aspect of this work is the use of a novel measurement technique, the so-called stood-up drop method, which quickly and reliably measures the retraction angle and reduces the typical measurement time to only a few seconds per sample (including replicates).

Digestion processes and microorganisms in wastewater

Wastewater treatment is an area of production that does not contribute directly to value creation. As long as processes run stably, limit values are adhered to and operating costs are low, this area is not the focus of attention. Unfortunately, in the experience of Alois Kinateder, GusChem, a variety of problems can occur. In addition to repeatedly exceeding limit values such as increased nitrite values, heavy metal values or COD concentrations, the process can ultimately fail due to technical faults, which makes intervention necessary.

In Kinateder's experience, microorganisms are the cause of a large number of faults in the wastewater sector. The biofilm leads to a reduction in flow rates, clogging and blocking of gravel filters and even the re-dissolution of heavy metals due to pH shifts. The lecturer demonstrated this with numerous practical examples. Various causes and remedial measures can be identified for these cases, whereby the focus is on permanently eliminating the cause of the fault.

Entrepreneur Forum - Management meets surface

Basis of assessment for the retention of extinguishing water

According to the Water Resources Act (WHG), soil and water bodies must be protected from contamination by extinguishing water that could be released from systems containing substances hazardous to water in the event of a fire. According to Christian Deyhle, Qubus GmbH, the operators of such plants are obliged to draw up a concept in order to prove that sufficiently dimensioned extinguishing water retention is available at the operating site. The current challenge for plant operatorsis the lack of a binding, nationally standardised assessment basis for extinguishing water retention. Despite this gap, authorities require plant operators to carry out the assessment of the necessary extinguishing water retention. This is currently carried out on the basis of existing sources of knowledge.

In the lecture, selected planning approaches were explained in more detail and practical examples of the technical realisation of extinguishing water retention systems were presented. The spatial conditions in the corresponding production sections, existing media with regard to water hazards or the available quantities of the individual media play a role here. The requirements are realised, for example, with fully automatic, semi-automatic or manual barriers.

Sustainability: from a topic of the future to an obligation

According to Jannik Lorenz, LoNa GmbH, the topic of sustainability is becoming increasingly important in corporate practice and is being reinforced by legal requirements. The introduction of the Corporate Sustainability Reporting Directive (CSRD) in the European Union marks a turning point.

This regulation leads to increased requirements for strategic planning and the management of sustainable measures. Companies are faced with the challenge of not only preparing for reporting, but also establishing sustainability as part of their business strategy. At the same time, this development opens up the opportunity to secure competitive advantages through targeted measures and to respond to the changing expectations of customers, employees and financial institutions.

In his presentation, Lorenz highlighted the growing relevance of sustainability in the corporate context, provided information on the specific requirements of CSRD and discussed the strategic implications for companies. He analysed how sustainability can be seen not only as an obligation, but also as an opportunity to operate successfully in the long term.

Online training for employees

In the experience of Dr Jan Picalek, FinishingX, online safety training for employees offers a solution to many of the problems facing the industry today. These include a lack of resources, cost pressure and increasing requirements for occupational health and safety. However, the speaker also pointed out that support with electronic aids, such as online training, cannot replace verbal instruction. However, it is a good way for small companies in particular to ensure that employees have the necessary expertise. Good safety standards, for example, not only prevent serious incidents such as fires or explosions. They also have a positive effect on motivation, absenteeism and staff turnover. In addition, the use of online seminars makes it possible to inform employees in their native language at a reasonable cost, thus ensuring the best possible understanding of an often difficult subject.

Standardisation in the field of surface technology for metals

In a joint presentation, Clemens Judersleben, Deutsches Institut für Normung e. V. and Dr Jens Riedel, iChem-AnalyticsGmbH, presentedthe process for creating standards, focusing on the planned standards for carbon coatings and ceramic hard coatings (NA 062-01-64 AA) and for chemical and electrochemical coatings (NA 062-01-76 AA) as a current example.

The NA 062-01-64 AA regulation defines carbon coatings as amorphous carbon coatings, including diamond-like carbon (DLC) and crystalline diamond coatings, whereby only hard material coatings produced using PVD and CVD processes are considered. In addition to existing specifications (DIN and ISO), for example on internal stresses or wettability of the coatings, the techniques for determining the hardness of the coatings will be considered in further work.

In the case of chemically and electrochemically deposited metal coatings, the development of hydrogen and the resulting embrittlement of substrate materials plays an important role, for which several regulations already exist (e.g. DIN 50940-2 or ISO 24251-2). The speakers emphasised the importance of intensive cooperation with industry experts. By taking on leadership roles in these committees, a clear steering influence can be exerted on future topics and priorities as well as the content of the standards.

Funding programmes for industrial innovations

Companies, especially small andmedium-sized enterprises (SMEs), are faced with the challengeof placing their innovation ideas in a targeted manner and promoting them efficiently. According to Dr Daniel Meyer, DGO, two proven funding programmes, Industrial Collective Research (IGF) and the Central Innovation Programme for SMEs (ZIM), offer tailor-made support for this.

The IGF enables pre-competitive research collaborations with scientific institutions, allowing companies to benefit from new technologies without having to make large investments of their own. The ZIM, on the other hand, promotes market-orientated research and development projects by individual companies or joint projects with partners. Both programmes strengthen the innovative power of industry, accelerate technology transfer and ensure the competitiveness ofGerman companies.

Opportunities and challenges of training and further education

For some time now, there has been an increasing shortage of qualified specialists in surface technology, both in the area of manual labour and at management level. The training centres - both technical colleges and companies - are called upon to motivate potential junior staff for training and provide them with the best possible support.

Dr Markus Richert and Frank Tischlinger from the Technical Vocational College (TBK) in Solingen presented the latest developments in this area. For example, intensive work is being done to develop and utilise modern teaching methods using digital systems for the surface coating profession. In addition, the framework conditions for trainees are being improved by offering distance or hybrid learning, which in some cases avoids or reduces the amount of travelling between the training company and the school.

According to the lecturers, considerable effort is required to impart the necessary basic and specialised knowledge so that the trainees can successfully complete their intermediate and final examinations. It is noticeable here that basic education in mainstream schools is increasingly showing deficiencies with regard to technology or that there are also language barriers. Further training to become a technician can now be organised much more flexibly in order to improve the financial situation of students due to loss of earnings during the two-year course.

Cover for bad debt insurance

The increasing number of insolvencies in Germany makes it clear how important it is now to deal with the issue of receivables protection, as Stefanie Wendisch, BüchnerBarella, emphasised in her presentation. Customers who were thought to be good are often worse than expected in terms of their true creditworthiness. In the automotive sector alone, credit insurers expect insolvencies in 30 per cent to 40 per cent of companies in Germany. As a result, there is a tendency to pre-screen TOP customers free of charge and with binding effect by inviting tenders on the market, which provides a good insight into whether the cover is actually worthwhile.

Uninsured losses are a burden on a company's liquidity. In addition to bad debt losses, insolvency proceedings can also be contested. In this case, the insolvency administrator has the right to contest incoming payments that were believed to be secure up to four years in the past. In her presentation, the lecturer went into details about portfolio analyses of TOP customers, special features of the cover modules and the correct way to deal with customers with regard to the issue of insolvency avoidance.

Value creation in the company

Although the end product in surface technology is a technically and visually functional coating from a global perspective, each company in the industry has developed its own individual strengths and serves an equally demanding market. According to Jörg Martin, Galvimax GmbH, product quality, service life, disposal costs, effectiveness and energy are only the most important factors for the resulting synergy effects of sustainable optimisation.

The task of cost optimisation as a supplier to large-scale industry with high demand is far less complicated than for smaller quantities with a broad parts portfolio. Large quantities, calculable capacity utilisation and costs make it possible to generate reliable key figures through coordinated optimisations, which allow the effectiveness of the measures to be transparently presented and monitored, while smaller order batches have to be evaluated from a completely different perspective. It therefore only makes sense to assess and evaluate optimisation measures over longer periods of time in order to determine the impact on added value.

Fire protection in electroplating plants through temperature monitoring

The risk of fire in an electroplating plant has remained high for years, as Jörg Buchgeister, atb Elektronische Steuerungen, noted at the beginning. In the past, electrical bath heaters were almost exclusively blamed as the cause of these fires. However, this is too short-sighted. The current contacts and the associated anode rails and other components are also often enough responsible for fires in electroplating systems. However, this can be greatly reduced by permanently measuring the temperature.

Using numerous examples from his practical experience, the lecturer explained the various options for preventing fire damage caused by heating systems in electroplating technology.

Employee brands in surface technology

The labour market is diverse and companies are faced with the challenge of finding suitable employees. Standardised recruiting processes no longer seem to do justice to this. Christina Geldmacher, ZINQ GmbH & Co KG, is therefore convinced that the recruiting process needs to change: A quick hire should no longer be the primary goal, but rather long-term prospects and development opportunities for the employee. According to her, the focus must be on the person and not exclusively on the position to be filled.

The speaker's company puts this into best practice by focussing on the employee with the employee brand Mach Dein ZINQ. This is about more than just work processes: Participation and career opportunities take centre stage. The prospects for applicants start with dual training and a permeability of the organisation right up to management level. The success is demonstrated by former trainees who are now in management positions. This benefits companies and applicants alike: Transparent development opportunities and individual appreciation ensure a sustainable work culture.

Securing company income by strengthening the employer brand

In his presentation, Axel Piepenstock, BüchnerBarella, showed how mandatory company income protection can not only motivate employees, but also strengthen the employer brand. This can certainly lead to a unique selling point for some time in competition with other companies in the neighbouring industrial area. The speaker explained in detail how talent can be attracted and retained in the long term.

Circularity in electroplating and surface technology

Sustainable sealing - suitable for the automotive industry?

Sustainability issues are playing an increasingly important role in a wide range of industries, be it the restrictions on the use of certain chemicals or the use of energy and resources, as Dr Michael Schem, MacDermid Enthone Industrial Solutions, emphasised.

Last year, a sealant was presented that consists of more than 60 per cent renewable raw materials. This includes the idea that raw materials are considered sustainable if they regenerate within their useful life. These approaches are also being applied to the field of coatings. One example of this is coatings based on natural raw materials. For example, plastics can be produced from starch.

For corrosion protection, bio-based substances are used in the sealants on zinc coatings. The requirements for the application are based on the function as corrosion protection, the appearance, the removability or the durability and shelf life. This makes it possible to produce sealants with more than 60 percent organic content with good behaviour in production and good performance properties.

Modular anodes for a sustainable future

The concept of circularity is becoming increasingly important in modern electroplating and surface technology. In his presentation, Christian Kurrle, Umicore Galvanotechnik, highlighted innovative processes, products and product designs that contribute to promoting sustainability in the industry. Anodes made up of modular segments that are tailored to production in order to ensure maximum capacity utilisation are ideal for this purpose. Users can utilise individual segments of an anode in different electrolytes and replace them when worn or mechanically damaged. This significantly extends the service life of the anode and at the same time reduces shipping costs thanks to the compact segments.

Another important aspect is the recovery of platinum and iridium. The establishment of a recycling process for these precious metals contributes to the sustainable use of resources and closes the material cycle.

Sustainable, energy-saving and resource-conserving transformation

Energy and resource-intensive industries and their value creation are currently facing major challenges and will continue to do so in the near future. Nico Bajorat, WHW Hillebrand, presented approaches for strategies, risks and opportunities to improve the situation through possible transformations and framework conditions. The focus of the tasks is on balancingCO2 emissions in accordance with the Greenhouse Gas Protocol in Scope 1, Scope 2 and 3 as well as sustainability reporting (CSRD) and the approach in accordance with the European Sustainability Reporting Standards (ESRS).

One specific measure is the use of electromechanical heat pumps using renewable energy, which, according to the speaker's experience, can achieve energy savings of up to 50 per cent. Other ways of saving energy include the optimisation of systems for generating process cooling, the use of highly efficient rectifiers, the reduction of heat requirements for pre-treatment or the expansion of photovoltaics for the use of self-generated electricity.

The aim is to draw up a comprehensive balance sheet for all manufacturing processes, products and resource flows and to determine the influence of the circular economy, energy-saving measures, the reduction of water consumption and waste as well as the use of renewable raw materials on the cost and climate balance. Scope 3 accounting in particular needs to be considered in detail, as it generates more than 50 per cent of greenhouse gas emissions for many companies.