In both glass manufacturing and paper processing, production equipment operates under extremely demanding conditions. Components such as moulds, rollers, chutes and dryer drums are constantly exposed to abrasion, thermal stress and chemically aggressive environments. Over time, these factors lead to surface degradation, product defects and unplanned downtime.
To address these challenges, thermal spray coating technologies based on chromium oxide (Cr₂O₃) have become a preferred solution. Applied through plasma spray processes, these ceramic coatings provide a highly resistant surface layer that enhances durability while maintaining the surface quality required for consistent production output.
Why Chromium Oxide Coatings Deliver Superior Performance
Chromium oxide coatings are characterised by their exceptional hardness and chemical stability. Their ceramic structure allows them to resist abrasive wear caused by materials such as silica particles in glass production or fibrous suspensions in paper processing.
At the same time, these coatings offer excellent resistance to oxidation and chemical attack, making them suitable for environments involving steam, high humidity and alkaline substances. Unlike metallic coatings, chromium oxide maintains a stable surface finish over time, reducing the risk of defects such as sticking, scoring or tearing during production.
The dense microstructure achieved through plasma spray application ensures strong adhesion to the substrate and minimal porosity, creating an effective barrier against both mechanical and environmental stress.
Integration with Plasma Spray Technology
At TSS, chromium oxide coatings are applied using advanced plasma spray systems capable of generating extremely high temperatures. This allows the material to be deposited in a controlled manner, forming uniform coatings even on complex geometries.
The process is carefully managed to ensure optimal coating thickness, surface roughness and adhesion. Following deposition, components undergo precision finishing operations, including grinding and polishing, to achieve the exact specifications required for each application.
The key stages of the process include:
- surface preparation to ensure optimal adhesion
- controlled plasma spray deposition for uniform coating structure
- post-coating finishing to achieve precise surface roughness and tolerances
- final quality checks to validate performance and durability
This integrated approach ensures that coatings not only protect the component but also support production quality.
Applications in Glass and Paper Manufacturing
Chromium oxide coatings are widely used across both industries to protect critical components and improve operational efficiency. In glass manufacturing, they are applied to moulds, plungers and distribution systems, where resistance to heat and abrasion is essential. In the paper industry, they are used on rollers, calender rolls and drying systems, where surface integrity directly affects product quality.
By maintaining a stable and wear-resistant surface, these coatings help reduce defects, extend production runs and minimise interruptions caused by component wear.
Operational Benefits and Long-Term Value
For plant managers and industrial operators, the adoption of chromium oxide coatings translates into measurable improvements in performance and cost efficiency. Longer component life, reduced maintenance frequency and improved product quality all contribute to a more stable and predictable production process.
In an industrial context where downtime and inefficiencies directly impact profitability, investing in advanced thermal spray coating solutions provides a clear competitive advantage. Chromium oxide coatings, supported by the expertise and process control of TSS, offer a reliable way to protect critical equipment and optimise production performance over time.