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OVERVIEW

OSMANLI REKLAM® ANKARA FACTORY; FACTORY IN ANKARA OPERATES ACCORDING TO JIT (JUST IN TIME) PRODUCTION METHOD.

Factory in Ankara:
• Processes are followed with LCD displays.
• All the production lines are operated with CNC machines.
• 3D cut and carving technology.
• Capacity to produce pillars until 6 meters length and any diameter.
• Capacity to apply Thermoform printing until 500ˣ200 cm.

Osmanlı Reklam® factory in Ankara was built in 2011 by Osmanlı Reklam® and together with all the settled fields consists of three main departments – Light Metal Processing (Aluminium), Heavy Metal Processing and Furniture production. Our modern facility having advanced technology, has the capacity for simultaneous 3 material acceptance and 7 dispatch processes.

Osmanlı Reklam® factory in Ankara operates according to JIT (Just in Time) production method.

1. Dyeing Line
The most important work prior to the dyeing is the surface cleaning and corrosion. This process is generally performed with labour, but in Osmanlı Reklam® it is managed with chemicals. Thus, there is a rigid and perfect surface for painting. The adsorption rate of the painting is increased by applying Chromate Cover and, as a result, the stainless life of the product is extended.

The processes applied to the material to be painted:

• Degreasing (Purification of aluminum and steel from the oil and dust)
• Rinsing
• Etching (Nitric Acid) (corrosion of the surface to be painted)
• Rinsing
• Chromatizing (covering the material with chrome)
• Drying

a) Wet Painting Line
• Wet painting cabinets are equipped with Air Curtain technology: all the cabins have hot air ventilation at the top and water curtain at the bottom. Air pressurize the small pieces of the paint and they fall into the water circulating at the bottom. Thus, no dust can reach the material to be painted in appropriate temperature.
• Surface preparation line (4 cabins)
• Possibility to apply primers simultaneously at 2 lines
• Possibility to apply final coats simultaneously at 2 lines

b) Electrostatic Powder Painting Line
The painting is applied by the 4 axis ROBOT. Thus, the sensitive painting application at equal microns are enabled. The facility has the painting capacity of 1,5 meter/min. and can paint the material having the dimensions of 6.000 mm length, 1.500 mm height, 800 mm width at once and completely. Total daily electrostatic painting is 1 400 m2.

2. Light Metal Processing Line
3. Heavy Metal Processing Line
4. Quality Control and Dispatch Line
5. Assembly

DIPPING POOL

CHROMATIZING PROCESS

Chromatizing process for the first time was used in 1936 by E.J. Wilhelm who obtained patent for chromate coating on zinc by plunging zinc into sodium dichromate acidified with sulphuric acid for commercial purposes. Since the beginning, numerous processes have been developed with regard to the idea of a thin chromate coating on the working surface.

Chromatizing process is performed generally on zinc and cadmium coated steel, aluminium and sometimes on the other metals. In order to perform chromatizing process, the materials are plunged into static solution (dipping method).

FOR WHAT PURPOSE?

It is used as the top coat polish on the metal against corrosion. Thus the film layer prevent zinc from having white marked view when stored in a humid environment.

It is also used as bottom layer for painting. By this way adhesiveness of the paint on the part has increased.

USED TANKS

Tanks are made of stainless steel 316 type alloy while plastic lined tanks are made of (PVC or polyethylene or polypropylene), polyethylene, and polypropylene solid plastic material.

STAGES

  • DEGREASING

    Degreasing process is the first and the most important phase of the surface treatment process. There are lubricants used in order to stop reaction of air with the metal. Lubricants are generally composed of mineral oil, but animal oil also can be used. The role of these lubricants is to prevent metal from contacting oxygen in the air and, thus from rusting. But the same lubricants make the chromatizing process impossible. Besides, there should be no lubricant on the parts to be processed with paint or electrostatic powder paint: while drying at a temperature of 200 °C fat, remaining on the metal, expands and entering the pores – this can lead to yellowing of paint, colour differences and problems with gluing. Therefore after the metal is degreased completely, it is processed with chromate coating or phosphating.

    Materials dipped into degreasing pool are purified from the oil on their surfaces; water based oil and paints, scum and organic contaminants are removed in a pool containing oil solvent.

    Alkali oil degreasing chemicals are used in hot environment. The temperature between 60-95°C, and the period between 5-10 minutes is sufficient for 3-10% concentration degreasing. Acidic degreasing can function in a cold environment however its efficiency increases in a hot environment. These types of degreasing remove both the oil and the rust of the metal. The significant parameters that should be taken into consideration are temperature, time, total alkalinity, total acid, concentration and pressure. These parameters are monitored weekly in a laboratory environment and necessary arrangements are made to keep them at the desired range.

  • ETCHING

    The aim of etching cleaning is to eliminate the oxidised layer arisen from the contact with the air on the material. It provides to emerge the clean surfaces at the bottom by removing rust and oxide layers on aluminium by chemical means. The cleaning period of the surface with etching varies according to the rust level of the material and concentration of acid bath. Even if there is no rust on the product surface, it has to be kept in acid baths to be activated for chromatizing process.

  • CHROMATIZING

    Metal dissolves due to the effects of acid and causes release of hydrogen. The new-formed hydrogen cause to precipitation as colloidal chrome dichromate film by transforming Cr+6 (hexavalent chrome) into Cr+3 (Trivalent chrome) on the environment and by catching some of the metal chromate in return.

    The thin layer is relatively soft when it is just formed and can be stripped without being forced. In approximately 24 hours it is almost fixed and reaches 80-90% of its entire power. In a couple days it gains all of its power and reaches a level even that it endures cold forming works when necessary.

  • RINSING

    The aim of rinsing pool is to prevent the chemicals used in the previous pool from passing the next p When the rinsing pools are getting dirty, they are sent to the treatment plants and by this way healthy coating can be performed.

  • DRYING

OCCUPATIONAL SAFETY

  • PLANS

    Establishment of ISG and HSSE policy, the creation of ISG target, the creation of ISG risk analysis, emergency action plans, the creation of the annual training plan and strutting, the creation of the ISG process and procedure
  • APPLY

    ISG process to achieve their goals, procedures, OSH programs, the implementation of the annual work plan and training plan implementation
  • CHECK IT

    Internal audits, factory and field ISG controls, exercises, ISG environment measurements, YGG meeting, ISG shareholders' meetings
  • ACT

    Corrective and preventive actions, Revisions

Osmanlı Reklam manages OHS processes according to below pyramid to define the controls in OHS processes or to change current controls;

ISG Process Pyramids
HI QUALITY
LOW QUALITY