Automatic Cu/Ni/Cr Gantry & Ni Barrel Plating Lines for Egyptian German Construction Co.

Project Overview

Egyptian German Company for Construction Industries, a prominent manufacturer supplying Egypt's fast-growing construction sector, partnered with our engineering team to build a fully automated electroplating workshop. The turnkey project delivered three automatic plating lines: one gantry-type Cu/Ni/Cr (copper–nickel–chrome) line and two barrel-type nickel (Ni) lines, engineered for high-volume, consistent metal finishing of construction hardware and fittings.

Customer Background

Operating in one of North Africa's most active construction markets, the customer required dependable, high-throughput plating capacity to protect and beautify metal components used across building and infrastructure applications. Manual and semi-automatic processes could no longer meet their rising quality and output targets, so they sought a professional partner capable of delivering complete, automated plating lines from a single source.

Project Snapshot

Solution Delivered

Our team engineered a complete automated plating solution tailored to the customer's product mix, plant layout and throughput goals. The scope covered process design, equipment manufacturing, on-site installation and full commissioning:

• Automatic gantry-type Cu/Ni/Cr plating line (1 line) — a programmable gantry system that transfers racks through pre-treatment, copper, nickel and chrome plating stages, producing a durable, decorative multi-layer finish with uniform thickness and excellent adhesion.
• Automatic barrel-type Ni plating line (2 lines) — high-efficiency barrel plating designed for large batches of small fasteners and fittings, ensuring consistent nickel coverage, reduced manual handling and stable output for mass production.

Key Features

• Fully automatic process control with PLC and intuitive touch-screen HMI for repeatable, high-quality results.
• Robust gantry transfer and barrel rotation systems built for continuous, heavy-duty operation.
• Optimized tank layout and rectifier configuration to precisely control coating thickness and reduce chemical consumption.
• Safe, ergonomic line design supporting efficient maintenance and straightforward operator training.
• Modular architecture that allows future capacity expansion without major rework.

Results & Value

With the three new lines in place, the customer achieved a major upgrade in both capacity and finish quality:

• Significantly higher daily output to support growing regional construction demand.
• Consistent, high-quality Cu/Ni/Cr and nickel coatings across large production batches.
• Reduced manual handling, lower labor costs and minimized process variation.
• A scalable, reliable platform ready for future product expansion.

Conclusion

This project reflects our ability to deliver complete, customized automatic plating lines for customers in emerging construction markets. From gantry Cu/Ni/Cr lines to barrel nickel lines, we provide end-to-end engineering that turns demanding surface-finishing challenges into reliable and profitable production. Contact us to discuss a tailored plating solution for your factory.