Processes

Great added value through our solutions

Customized process engineering combined with precision electrolytes and additives – since the invention of stylus engraving, we have developed and manufactured innovative solutions for the gravure cylinder manufacturing industry.

The customer benefit is manifold: simple system-handling through built-in automation and high-quality chemicals and additives – produced and mixed in-house – that ensure highly successful results.

We understand customer requirements, processes and procedures. Our comprehensive overview contributes to a systematic, highly integrated product development phase in which we consider and coordinate all major machine and procedural aspects. This approach optimizes the processes that really count, leads to maximum cost-efficiency and increases the productivity and efficiency of our solutions.

Please click the image to open the interactive Galvanics Booklet.

Function

Electrolyte for dechroming
Based on sulfuric acid

-Cr

Helio^® DeChrome

Dechroming

Advantages

Low power and rectifier times
Copper protecting
Fast de-plating time
High concentrate

Long lifetime
Easy to handle
Wide window of operation

Process Time

~ 10 minutes

Process Parameter

Sulfuric Acid
Dechrome Concentrate
Process Temperature
Current
Voltage

~ 30 %
15 ml/l
22–35°C
±50–200 A (bipolar)
±15 Volt (bipolar)

Availability

Helio^® DeChrome Concentrate
Canister	5 Liter	Art.Nr. 104005
	10 Liter	Art.Nr. 104006
	20 Liter	Art.Nr. 104007

Helio^® DeChrome Salt
Bottle	1kg	Art.Nr. 117590

Analysis

Analysis Set DeChrome

Art.Nr. 01A.0.01.300

Function

Electrolyte for dechroming

-Cr

Helio^® DeChrome
CHEMICAL

Dechroming

Advantages

No rectifier
Copper protecting
Fast de-plating time

High concentrated
Salt

Process Time

2–5 minutes

Process Parameter

DeChrome Chemical
HCl 32 %

120–350 g/l
190–350 ml/l

Availability

Helio^® DeChrome Chemical
Barrel	25 kg	Art.Nr. 109504

Analysis

Analysis Set DeChrome

Art.Nr. 01A.0.01.300

Function

Alkaline electrolyte for electrolytic degreasing
Based on sodium and potassium hydroxide

DeGr

Helio^® Clean Classic

Degreasing

Advantages

Optimized for degreasing of gravure cylinders
Degreasing anodic and cathodic or in combination
For steel, copper and chrome plating
Degreasing of steel, copper and chrome cylinders in one electrolyte (tank)

Degreasing for Steel and Copper in one electrolyte
For Steel, Copper and Chrome plating
Available as salt to save shipping costs and as liquid concentrate for easy handling
Short process time
Long lifetime

Process Time

1–5 minutes

Process Parameter

Concentration
Concentration Salt
Density
Process Temperature
Current Density
Times and Polarity:
Steel 0 s cathodic
Copper 0–160s cathodic

150 g/l
100 g/l
~ 9°Bé
20–50°C
8 A/dm²
30–280 s anodic
10–160 s anodic

Availability

Helio^® Clean Classic Concentrate
Canister	30 kg	Art.Nr. 136209
IBC	1000 kg	Art.Nr. 136553

Helio^® Clean Classic Salt
Bag	22.5 kg	Art.Nr. 104003

Analysis

Analysis Set Degreasing	Art.Nr. 01A.0.01.601
Analysis Set Cu-Clean	Art.Nr. 01A.0.01.600

Function

Creates a layer to separate the engraved copper (ballard shell)
Based on albumin

DeGr

Helio^® Select Organic

Degreasing

Advantages

Saves shipping costs
High concentrated
Easy process handling

High reliable process
Smooth surface
Easy handling in waste water treatment

Process Time

Spray Time 15 sec
Reaction Time 20 sec

Process Parameter

Concentration
Process Temperature

3 g/l
20–30 °C

Availability

Helio^® Select Organic Salt
Bottle	1 kg	Art.Nr. 125453
	10×30 g	Art.Nr. 100438

Function

Creates a layer to separate the engraved copper (ballard shell)
Based on a silver complex

DeGr

Helio^® Select Silver

Degreasing

Advantages

High concentrated
Easy process handling
High reliable process

Smooth surface
Easy handling in waste water treatment
Visible layer

Process Time

Spray Time 10 sec
Reaction Time 20 sec

Process Parameter

Concentration
Process Temperature

1:19
20–30 °C

Availability

Helio^® Select Silver Concentrate
Canister	10 Liter	Art.Nr. 100434
	20 Liter	Art.Nr. 103994
Barrel	220 Liter	Art.Nr. 100436

Function

Alkaline electrolyte for electrolytic degreasing
Based on sodium and potassium hydroxide

DeGr

Helio^®Clean Copper Concentrate

Advantages

Optimized for degreasing of gravure cylinders
Degreasing anodic and cathodic or in combination
Degreasing Coppercylinders in one electrolyte
For Copper and Chrome plating

As liquid concentrate for a easy handling
Short process time
Long live time

Process Time

1 – 5 min

Process Parameter

Concentration
Concentration Salt
Density
Process Temperature
Current Density
Times and polarity

150 g/l
100 g/l
~ 9°Bé
20 – 50°C
8 A/dm2
Steel 0 s cathodic 30 – 280 s anodic
Copper 0 – 160 s cathodic 10 – 160 s anodic

Availability

Helio^®Clean Copper Concentrate
IBC	1250 kg	Art.Nr. 150117

Availability

Analysis Set Degreasing	Art.Nr. 01A.0.01.601
Analysis Set Cu-Clean	Art.Nr. 01A.0.01.600

Function

Coating of aluminum cylinders
Activates the aluminum to deposit with Helio^® PreCopper or Helio^® Chrome and Helio^® Zinc
For base cylinder or embossing

PreAl

Helio^® PreCoat Al

Aluminum coating

Advantages

Easy to handle
Reliable copper-aluminum bonding
Reliable chrome-aluminum bonding
Reliable zinc-aluminum bonding
Automatic process

Process Time

~ 15 minutes

Process Parameter

Helio^® Clean Al
Sulfuric/Nitric Acid
Helio^® PrCoat Al

55% DI-Water : 20% caustic souda : 25% HelioClean
1:1 with DI-Water
2:1 with DI-Water

Availability

Helio^® Clean Al
Canister	30 kg	Art.Nr. 145489

Helio^® PreCoat Al
Canister	25 Liter	Art.Nr. 145490

Function

Electrolyte for alkaline copper plating
Builds an adhesive layer of soft copper on steel
Phosphorus-copper complex

PreCu

Helio^® PreCopper

Pre-Copper Plating

Advantages

One component process
Easy to handle
Stabilizes pH value
High concentrate (less shipping costs)
Reliable steel to copper adhesion

Reliable copper to copper adhesion
Storable after alkaline plating
Wide window of operation
Cyanide free

Process Time

Up to 4 µm copper layer in 25 minutes

Process Parameter

Copper (as metal)
Helio^® PreCopper C
pH
Process Temperature
Current Density
Layer Thickness

4 g/l
20 % Vol
9
35–45°C
–2 A/dm²
4 µm

Availability

Helio^® PreCopper Concentrate
Canister	20 Liter (24.55 kg)	Art.Nr. 135739

Analysis

Analysis Set Alkaline Copper

Art.Nr. 01A.0.01.500

Function

Copper plating with insoluble anode
External chemical copper dissolving
Copper hardness 200–250 HV

+Cu

Helio^® CuMax

Copper Plating

Advantages

High speed copper plating
No nuggets in the anode basket
No anode basket maintenance
Low voltage plating (saving up to 30% energy costs)
100% copper dissolving

Increased plating quality
Higher process stability
Higher process control (analysis of additive)
High layer plating up to 3000 µm

Process Time

Up to 5 µm copper layer per minute

Process Parameter

Helio^® CuMax Basic Solution
Helio^® CuMax Dosing Solution
Helio^® CuMax Salt
Copper Sulphate
Sulphuric Acid
Chloride
Process Temperature
Current Density

1.2 ml/l
0.4 ml/l
100 g/l
220 g/l
65 g/l
75 ppm
35 °C
–35 A/dm²

Availability

Helio^® CuMax Basic Solution
Canister	20 Liter	Art.Nr. 139747

Helio^® CuMax Dosing Solution
Canister	20 Liter	Art.Nr. 138534

Helio^® CuMax Salt
Bag	25 kg	Art.Nr. 137497

Analysis

Analysis Set CuMax

Art.Nr. 01A.0.01.110

Function

Hardness additive for acid copper electrolytes
Based on thiourea
Copper hardness 190–220 HV

+Cu

Helio^® Copper Classic

Copper Plating

Advantages

Well known technology
Stable process
No copper annealing

Compatible to most common used additives
High concentrated (1:14)
Available as salt (saves shipping costs)

Process Time

Up to 3 µm copper layer per minute

Process Parameter

Helio^® Copper Classic
Dilution for dosing
Copper Sulphate
Sulphuric Acid
Process Temperature
Current Density

0.15 ml/l
1:14
220 g/l
60 g/l
30 °C
–25 A/dm²

Availability

Helio^® Copper Classic Concentrate
Canister	10 Liter	Art.Nr. 103992
	20 Liter	Art.Nr. 103993
Barrel	220 Liter	Art.Nr. 115406

Helio^® Copper Classic Salt
Bottle	500 gr	Art.Nr. 143604
	1kg	Art.Nr. 119999

Analysis

Analysis Set Cu Quick	Art.Nr. 01A.0.01.101
Analysis Set Cu Titration	Art.Nr. 01A.0.01.100

Function

Additive for acid copper electrolytes
Based on thiourea
Copper hardness 190–220 HV

+Cu

Helio^® Copper Rapid

Copper Plating

Advantages

Further developed technology
Based on well known system
High temperature resistant
Increased plating speed up to 4 µm per minute

Using all advantages of
Helio^® Copper Classic
High concentrated (1:17)
Available as salt (saves shipping costs)

Process Time

Up to 4 µm copper layer per minute

Process Parameter

Helio^® Copper Rapid
Dilution for dosing
Copper Sulphate
Sulphuric Acid
Process Temperature
Current Density

0.2 ml/l
1:17
220 g/l
65 g/l
40 °C
–30 A/dm²

Availability

Helio^® Copper Rapid Concentrate
Canister	20 Liter	Art.Nr. 143325

Helio^® Copper RE Agent
Canister	10 Liter	Art.Nr. 143326

Analysis

Analysis Set Cu Quick	Art.Nr. 01A.0.01.101
Analysis Set Cu Titration	Art.Nr. 01A.0.01.100

Function

Zinc plating with acid electrolyte
Direct structuring with DLS, Digilas and Cellaxy
For gravure and embossing applications

Zn

Helio^® Zinc

Zinc plating

Advantages

High plating speed
Easy process handling
Suitable for ballard shells or plating on size
Zinc as solvable anode material
No external peripheral equipment (carbonate freezing, zinc dissolving)

Low plating voltage
High corrosion resistance of the zinc layer
High quality zinc deposit
High current efficiency
High process stability
Plating up to 1000 µm

Process Time

Up to 3.5 µm zinc layer per minute

Process Parameter

Helio^® Zinc Basic Solution
Helio^® Zinc Dosing Solution
Zinc (ZnCl)
Boric Acid
Potassium Chloride
Process Temperature
Current Density

30 ml/l
2 ml/l
35 – 40 g/l
30 g/l
140 – 150 g/l
~ 50 °C
15 – 30 A/dm²

Availability

Helio^® Zinc Basic Solution
Canister	25 kg	Art.Nr. 145322

Helio^® Zinc Dosing Solution
Canister	25 kg	Art.Nr. 145321

Helio^® Zinc Wetting Agent
Canister	25 kg	Art.Nr. 145323

Analysis

Analysis Set Zn

Art.Nr. 01A.0.01.700

Function

Cleans the laser structured copper surface
Post treatment for Cellaxy or Digilas laser process
For gravure or embossing applications

Laser

Helio^® Laser FINISHER

Post treatment

Advantages

Cleans and activates the copper structure
Ensures chrome plating on all structures
Easy process handling

Process Time

~ 15 minutes

Process Parameter

Helio^® Laser Finisher
Phosphor Acid
Process Temperature
Current Density

~ 40 ml/l
1000 g/l
– 25 °C
– 30 A/dm²

Availability

Helio^® Laser Finisher
Canister	25 kg	Art.Nr. 139931

Analysis

Analysis Set Laser Finisher

Art.Nr. 01A.0.01.800

Function

Activates the lasered copper structure for chrome plating
For direct laser structuring of the copper with Digilas

Laser

Helio^® Laser ACTIVATOR

Post treatment

Advantages

Cleans and activates the copper structure
Ensures chrome plating on all structures
Simple spraying process
Capable of being integrated in degreasing tanks

Process Time

~ 5 minutes

Process Parameter

Helio^® Laser Activator
Sulfuric Acid

~ 40 g/l
10 % Vol

Availability

Helio^® Laser Activator
Bottle	5 kg	Art.Nr. 144066

Function

Elektrolyte for chrome plating
Based on chrome (VI) acid
Chrome hardness 850–1000 HV

+Cr

Helio^® Chrome Classic

Chrome Plating

Advantages

High ware ability during printing
Easy to handle
Stabile sulfuric acid content

Wide window of operation
Also available as concentrate (no dust)

Process Time

Up to 0.35 µm per minute

Process Parameter

Chromic Acid
Sulphuric Acid
Process Temperature
Current Density

260 g/l
2.5 g/l
55–60 °C
50–60 A/dm²

Availability

Helio^® Chrome Classic Salt
Barrel	25 kg	Art.Nr. 100400

Helio^® Chrome Classic Concentrate
Barrel	250 kg	Art.Nr. 142317

Analysis

Analysis Set Cr Quick	Art.Nr. 01A.0.01.200
Analysis Set CrO₃/Cr₂O₃	Art.Nr. 01A.0.01.201

Function

Catalyzed electrolyte for chrome plating
Based on chromic acid
Chrome hardness 1100–1500 HV

+Cr

Helio^® Chrome Rapid

Chrome Plating

Advantages

High current efficiency 25–30%
High deposition rates
High micro-cracking (300–600 cracks/cm)
Wide current density range
Wide current density range (40–120 A/dm²)

Good metal distribution
Smooth and bright deposition
Low service costs
Automatic dosing

Process Time

Up to 0.6 µm chrome layer per minute

Process Parameter

Chromic Acid
Sulphate
Catalyst
Density
Temperature
Current Density

240–340 g/l
2.6–3.8 g/l
100-180%
22–29°Bé
60 °C
40–120 A/dm²

Availability

Helio^® Chrome Rapid MakeUp Concentrate
IBC	600-1100 kg	Single-Wall
	1200 kg	Single-Wall

Helio^® Chrome Rapid for Dosing
Canister	25 kg
Barrel	250 kg
IBC	600 kg	Single-Wall and Poly
IBC	1200 kg	Single-Wall and Poly

Helio^® Chrome Rapid Catalyst
Canister	20 Liter	Art.Nr. 142452

Helio^® Chrome REOX3
Canister	5 kg	Art.Nr. 149972

Helio^® Chrome Wetting Agent FF
Canister	10 kg	Art.Nr. 142452149169

Analysis

Analysis Set Cr Quick	Art.Nr. 01A.0.01.200
Analysis Set CrO₃/Cr₂O₃	Art.Nr. 01A.0.01.201

Processes

Great added value through our solutions

Please click the image to open the interactive Galvanics Booklet.

Function

-Cr

Helio® DeChrome

Dechroming

Advantages

Process Time

Process Parameter

Availability

Analysis

Function

-Cr

Helio® DeChrome CHEMICAL

Dechroming

Advantages

Process Time

Process Parameter

Availability

Analysis

Function

DeGr

Helio® Clean Classic

Degreasing

Advantages

Process Time

Process Parameter

Availability

Analysis

Function

DeGr

Helio® Select Organic

Degreasing

Advantages

Process Time

Process Parameter

Availability

Function

DeGr

Helio® Select Silver

Degreasing

Advantages

Process Time

Process Parameter

Availability

Function

DeGr

Helio®Clean Copper Concentrate

Advantages

Process Time

Process Parameter

Availability

Availability

Function

PreAl

Helio® PreCoat Al

Aluminum coating

Advantages

Process Time

Process Parameter

Availability

Function

PreCu

Helio® PreCopper

Pre-Copper Plating

Advantages

Process Time

Process Parameter

Availability

Analysis

Function

+Cu

Helio® CuMax

Copper Plating

Advantages

Process Time

Process Parameter

Availability

Analysis

Helio^® DeChrome

Helio^® DeChrome
CHEMICAL

Helio^® Clean Classic

Helio^® Select Organic

Helio^® Select Silver

Helio^®Clean Copper Concentrate

Helio^® PreCoat Al

Helio^® PreCopper

Helio^® CuMax

Helio^® Copper Classic

Helio^® Copper Rapid

Helio^® Zinc

Helio^® Laser FINISHER

Helio^® Laser ACTIVATOR

Helio^® Chrome Classic

Helio^® Chrome Rapid