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.
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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 |