Case Study
Inconsistent Adhesion on Aluminum Substrates
Through a powder supplier introduction, Freedom Coatings connected with Circle-Prosco to solve persistent adhesion issues on aluminum substrates. Circle-Prosco identified Steelcote™ 1750, a zirconium cleaner-coater, as the right fit for Freedom Coatings’ single-stage recirculating batch system — a solution that would handle all substrates in one chemistry, eliminate phosphate sludge, and support the company’s commitment to environmental stewardship. Circle-Prosco managed the full transition and stayed hands-on through startup and ongoing optimization.
Industry
Custom Powder Coating
Product
Steelcote™ Pretreatment
Location
Spartanburg, South Carolina
Problem
Freedom Coatings operated a batch pretreatment system using traditional iron phosphate chemistry in a recirculating hand wand setup. While reliable on steel, the process produced inconsistent adhesion on aluminum. And aluminum was showing up on more and more customer RFQs. Iron phosphate relies on a reactive iron surface and struggles with aluminum’s native oxide layer. The chemistry also produced sludge and scale in a recirculating tank that was difficult to access and required HAZMAT disposal for cleanouts. Freedom Coatings was effectively limited to steel-preferred work and passing on aluminum opportunities.
Action
Circle-Prosco recommended Steelcote™ 1750, a zirconium cleaner-coater designed to clean and coat in a single stage, fitting directly into Freedom Coatings’ existing recirculating system. The transition included full disposal of the iron phosphate solution, thorough removal of residual phosphate scale and sludge, and charging and optimization of the system with the new zirconium chemistry. After startup, Circle-Prosco continued monitoring soil-load over the following months to confirm the product was handling Freedom Coatings’ varied mix of incoming parts and substrates.
Result
Dramatically improved adhesion across aluminum, steel, and galvanized substrates. Freedom Coatings’ blast vendor reported needing two to three times longer to remove powder — confirming the adhesion gain. Eliminated phosphate sludge and scale, removing the need for HAZMAT cleanouts. Achieved consistent coating results regardless of operator technique, thanks to zirconium oxide’s self-limiting deposition. Freed production time previously spent on system maintenance and reworks. And it enabled Freedom Coatings to confidently take on aluminum work, including high-profile projects like the Thomas and Vivian A. Wong Honor Tower at Unity Park in Greenville, SC — a tribute to police, firefighters, and first responders, powder coated across concrete, steel, and aluminum.