Glass Vacuum Coating

8/10/2019 Glass Vacuum Coating

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HE COMPANYKolzer was

founded in 1950and was one of the

pioneers in early vacu-um technology. The ini-tial activities of the com-pany were dedicated tothe assembly of machin-

ery, followed closely byresearch and the settingup of an operative struc-ture near Milan for theconstruction and produc-tion of machinery forvacuum treatment.

The company is nowin its second generationof ownership, with thetwo DEsposito broth-ers: Antonio andDavide, with Antonio in charge of

new projects and marketing andDavide as head of production. Bothsons, however, have considerableexperience in the activities of thecompany, having started to workthere with their father when they wereabout 16 years old, starting fromworkshop activities.

Kolzers staff is made up of spe-cialized technicians, all with theirown solid and extensive experience.The company also holds an Englishcourse for its personnel twice a

week, for all levels of personnel.

Growth and expansion

Kolzer has annual growth of 20per cent each year even if the prices

of its machines remain almost thesame. Expansion also means num-bers and area. At present the compa-ny occupies an area of about 3,000square meters, but by 2009 the ideais to move to an area of about 5,000square meters.

PRODUCTIONAND MARKET SECTORSThe two sectors that the company

has always concentrated on are plas-ma treatment in general and deposi-tion for metallic-style finishings.And, therefore, classical metallizationin vacuum and the application of anultra-thin layer of metal combinedwith a variety of colours for decora-tive purposes for everyday objects, aswell as for optical purposes.

Deposition treatment was first

used as a technology in the 1900s for

reflective purposes. The fist metal-lization applications were used onaircraft carriers that had to continu-

ously metallize the reflectors thathelped the planes to land on the ship.In fact, each ship has its own metal-lization unit.

Kolzer was the first company toimport to Europe paints for plasticmaterials from the United States, tobe combined with (and after) metal-lization treatment with higher metal-lization resistance or with morecolour-ed effects.

In the 1970s, Kolzer had almost500 employees, because at that time

the market for vacuum applicationsunderwent a considerable boom. Infact Kolzer manufactured plants forfreeze-drying, refrigerator-fillers,neon-fillers, up to the ophthalmicsector, as well as its normalmachines for a variety of vacuumprocesses. In these applications, lowvacuum is used for filling process-es, while high-vacuum enables amore complex effect on the structur-al and molecular level.

These changes in the applications

of vacuum all took place end of the60s, beginning of the 70s. In fact, dur-ing that period, the applications ofvacuum began to evolve importantlyat industrial level. The first sputteringplants were set up in 1974 calledhot cathode - and was a bobbin thatwas immerged and grown in galvani-ca material, to which a radio frequen-cy was attached to the extremities ofthe bobbin, pulverized and sputteringtherefore took place.

Kolzer started to re-utilize sputter-

ing about 10-12 years ago on an indus-trial scale, where applications rangefrom refrigeration to satellites, and isnow in the world of micro-processors.Therefore, all machinery is highly pro-tected and there are no (0 per cent)emissions from the plants.

The machinery manufactured bythe company ranges from smallplants up to the largest with 100inches in diameter and 150 inches indepth the largest in Europe.However, the most sold product for

Kolzer is its machine with a diameter

VACUUM INTERNATIONAL 2/2007 - 33w w w . v a c u u m t e c h . e u

Activities at Kolzer started in 1952

A vintageimage


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of 36 inches, with 400 installed

worldwide in various different sec-tors: from aerospace (as in 1972-73for Augusta) which is still up andrunning. In fact, Kolzer also gained anew contract with this company now called Augusta Westland forwhom it supplied a vacuum cadmi-um plating plant to its factory inFrosinone, near Rome, where it pro-duces helicopters. These plants carryout a coating of six microns toobtain anti-corrosive layers.

The company has also supplied a

plant to Geox - shoe manufacturer, toenable to obtain the famous hydropho-bic membrane that allows air but doesnot allow water in our shoes.

Kolzer has also carried out studieson wood for the American Forestry

Institute, for anti-fire, oil and water

repellence. Other classical applica-tions are those for photovoltaics, andsolar thermal.

Also in this sector, Kolzer iscarrying out studies on a new processfor installations in China withBeghelli. Kolzer is already present inChina with Altay Scientific whichmanufactures educational instrumentsthere. Kolzer has also collaboratedwith other companies in the realiza-tion of a range of guns and revolversfor personal safety, as well as machin-

ery installed and used in research cen-tres where the use of vacuum technol-ogy is continuously being studied.This is mainly because of the totallack of contamination from gas in avacuum environment. Just one of the

most important treatments to beobtained in a vacuum environment isthat applied to water. The latter can

become a detergent without the needof any additive.

Sputtering enables any kind ofmetal to be applied to any kind ofsubstrate (also with decorative prop-erties) with perfect optical qualitiesand electrical conductivity. All withrespect to the environment and com-pletely repeatable and low cost too.This makes vacuum the ideal tech-nology thanks to its high flexibility.

In fact, other than the process,there is also the level of vacuum to

be considered. And, therefore, forcold plasma, for example, we arespeaking about low pressure, whichranges from 10-2, 10 -3, millibar, usu-ally classified as a pre-vacuumenvironment. All depositions, onthe other hand, are applied in a10-3, 10-6 millibar environment,classed as high-vacuum. The nextstep is ultra-high vacuum: from 10-6,10-10 millibar, not used in industrialapplications, and only used inresearch and aerospace, but all with

the same machine.

Market sectors

With 98 per cent of matter in theuniverse formed of plasma, it has enor-mous potential in industrial applica-

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Kolzers first industrial vacuum deposition plant

Working procedures


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structured coatings, with manufactur-

ing processes that are ecological, sim-ple and at the same time economical.

Kolzer nominates itself as pro-moter of production systems forindustry in order to carry out theautomation and feasibility of innova-tive processes, perfectly repeatablewithout end, obtaining superior lev-els of quality. Economical processeswhich consume very little; very up todate since the environmental impactis almost non existent having no pro-duction waste.

PLASMA TECHNOLOGYThe nature of a plasma varies a lot

according to the type of gas, or to themixture of different gases, pressure ofgas/gases, form of volume which con-fines the plasma itself, the type ofelectric field which supports andmaintains the plasma. The plasma ofparticular gases, among which oxy-gen is always present, allows oxida-tion to develop at a low temperaturewhen it comes into contact with the

tions. Plasma treated surfaces increasethe processability of the same surface,while sterilizing it at the same time,

eliminating all contaminants. Plasmacan also substitute all cleaningprocesses where water is used.

Kolzers market sector at present isfirst of all sputtering (in stronggrowth), followed by metallization ofplastic surfaces for decorative appli-cations, optical and automotive, andthen plasma, used for industrial wash-ing and sterilization.

There are many industrial sectorsthat are moving away from the use ofdangerous substances, especially in

the case of domestic appliances,where the RohS norms are in force,which restrict of the use of certainhazardous substances in electrical andelectronic equipment.

SPUTTERINGSputtering technology represents

a real alternative to definitively sub-stitute chrome electroplating coatingonto metal and plastic which is con-sidered to be a strong pollutant anddangerous for health. As well as

being the cleanest technology amongthe coating techniques, sputteringgives a combination of advantageslike no other since it is a method ofproduction which is economicallyefficient generating the thinnest andmost uniform coating possible.Secondly, it is a dry process at lowtemperature and thirdly it forms anindestructible bond between film andsubstrate, since it binds them togeth-er at a molecular level.

In addition to having characteris-

tics of hardness and resistance toabrasion, innovative colours can beobtained for decorative motifsapplied to the surfaces of high qualityconsumer goods. It offers great versa-tility compared to other coatings,since being a cold transfer, it can beused for the deposition of conductingor non conducting material on anytype of substrate, including metals,ceramics and plastic materials whichare temperature sensitive.

Glass, because it is a hard, smooth

and brilliant material, it is the per-fect substrate. In fact, there is noneed for a coating base to prepare the

surface for the sputtering process.

The process

Coating using sputtering is one ofthe most flexible methods to physical-ly deposit vapour "PVD" (PhysicalVapour Deposition).

The coating material is insertedinto the vacuum chamber as acathode under the form of a metalplate. After the chamber has beenemptied, the process gas is intro-duced (argon is usually used as it has

a high atomic weight). A high volt-age is applied and the gas is intro-duced. The positive argon ions gothrough an acceleration process onthe negative cathode and then expelthe atoms of the metal plate (evapo-rating material), which then fall ontothe substrates already in the chamberand condense them. The impact ofthe atoms on the evaporating materi-al produces sputtering as a result ofthe acceleration given by the suc-ceeded particle.

Unlike many other vacuum depo-sition techniques, there is no fusionof material, therefore all the metalsand alloys can be deposited withhigh efficiency and high control.

Different cathodes made of differ-ent materials can be inserted in avacuum coating system to producemultiple layer systems. It is also pos-sible to modify the combination ofthe single layers by varying the com-bination of the reactive gases.

NANOTECHNOLOGYKolzer is also involved in researchand development activity with univer-sities and international research cen-tres to apply the solutions which willbe tomorrows achievements.

Solutions which are already presenttoday in the industrial world: nano-technology. Surface engineering,regarding atoms, has always beenKolzers starting point for the produc-tion of innovative coatings. The objec-tive is to develop functional nano-


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surfaces to be treated.That is, the forma-

tion of functionalgroups on thesurfaces them-selves whichpermit optimalconditions for

total cleaning tobe obtained.

Plasma cleaning

The aim of the plas-ma plants manufactured

by Kolzer is to clean surfaces (of anynature, shape and size) and to modifythe chemical and electrostatic charac-teristics of the surface of products.Plasma is a dry, clean process whichtakes place at room temperature anddoes not use cleaning agents (nowaste material) and: removes organic pollutants or

residual layers; increases surface tension and

therefore surface wettability, byreducing the point of contact of liq-uids at optimal values;

forms a surface which is able toreact actively with the contactpolymers (varnishes, adhesives,inks, etc).By changing the nature of the

process gas and their mixtures differ-ent surface characteristics can beobtained. The plants designed andproduced by Kolzer are suitable forvacuum treatments of objects whose

purpose is to obtain chemical modifi-

cation of the surface in preparation totreatments such as varnishing, gluing,connection, coating and decoration.

The goods to be treat-ed are inserted into theprocess chamber inspecific loading sys-tems (frames, trays,baskets or sifters) andare unloaded at the endof the treatment cycle.

Plasma deposition

The growth of thinfilms on a surface canbe carried out effec-

tively through chemi-cal reaction in the vapour phase(Chemical Vapour Deposition, CVD)of composites containing the ele-ment to be deposited. Varying theprocess parameters, the precursorsand the shape of the reactor, thePECVD technique allows numerousmaterials to be deposited. PECVD:Continuous research carried out byKolzers technicians and constantcollaboration with clients and themost important science laboratories

both national as well as foreign havemade it possible to set up specificprocesses dedicated to the most var-ied application fields: surface hard-ness, low friction coefficient, anti-corrosion in acid and alkaline envi-ronments scratchproof, non stick,anti-printing and biocompatibilitycharacteristics.

SYSTEM ENGINEERING AT KOLZERKolzer vacuum plants consist in

their main part of:

vacuum chamber; vacuum pumping group; process chamber with cathodes

which introduce the necessaryenergy to generate plasma;

feeding system and control of gasflow;

electric feeding system and plasmacontrol;

PLC, PC and management andcontrol software which guaranteethat the results obtained can bereproduced;

auto-diagnosis safety systems.

The process area in plasma con-sists of cathodes which generate anelectric discharge which supports the

plasma. The cathodes are essentiallystainless steel, aluminium or titaniumplates onto which an electric feed-ing is applied (a radiofrequency,microwave or direct current). Thestainless steel treatment chambercontains all the parts that operate inthe real process: cathodes, gas feed-ers, piece holders. The chamber isinternally lined with a teflon mat-tress. A hinged door provides com-plete access to the chamber. The elec-trodes adhere to the chamber walls.

All the other groups making up theplant are connected to the vacuumchamber: pumping group, vacuuminstruments, gas and electric feeders.The vacuum chamber has a spy win-dow to check the plasma. In the test-ing phase, the vacuum chamber iscontrolled with a helium mass spec-trometer to guarantee perfect holdand tightness.

THE PLANTSKolzers plant engineering tech-

nology stands out because it adapts itsconcepts to individual client require-ments. In addition, Kolzer offersqualified engineering for complexproduction systems. The range ofsupplies includes plant families, fromthe Mini compact plant for researchcompanies and laboratories, to biggerand more complex systems and spe-cial plants for in-line processes andlarge sized articles.

DGK horizontal range

The DGK

is the classic work sys-tem, with the most complete range ofprocess chambers in order of size: DGK24 diameter 610 millimetres; DGK36 diameter 1,000 mm; DGK48 diameter 1,200 millime-

tres; DGK60 diameter 1,600 mm; DGK72 diameter 1,800 mm; DGK100 diameter 2,500 mm.

The DGK comes with two load-ing systems with carriage to faci-litate loading and unloading.

Moreover, the sizes of the plants list-

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ed can be personalized in accordanceto production needs.

MK vertical range

The MK is the most modern andinnovative work system: the materialto be treated is loaded directly into thetwo doors of the system, for a faster

work cycle.This plant range is made up of:

MK48 diameter 1,250 millimetres; MK60 diameter 1,600 millimetres; MK72 diameter 1,800 millimetres.

All plants have automatic processcontrol, temperature detection, pres-sure and gas flow regulation, as wellas different substrate supports, includ-ing patented rapid loading systems.

Supplied on request: cold/hotwater feeding, cleaning plants, radia-tion plants and instruments for quali-

ty control, for example: Kalo-Tester,Rockwell-Tester, microscope withimage elaboration.

RESEARCH AND DEVELOPMENTKolzers staff of researchers, tech-

nicians, engineers and a world net-work of commercial support andassistance, form a total quality pro-ject in which more than 900 clientsall over the world, who use the Kolzersystems, participate actively and prof-itably. The combination of factors,

key to the success of the total quali-ty project, has guided the companysince its first steps.

ASSISTANCE AND POST-SALESPost-sales assistance for Kolzer

begins when the machine is sold, withinstallation and training of the person-nel who will be using the machine.Assistance is available non-stop online. To be able to guarantee this, eachand every component of the machineshas its own historical certificate -

where it comes from, the code num-ber. In fact, Kolzer guarantees thecomponents of its machines for aperiod of two years, while the entiremachine is guaranteed for 12 years!

Moreover, Kolzer also has its ownsoftware in Windows format, whichwas installed on one of its machinesfor the first time in 2005.

Kolzer has recently sold its second

plant to Bennett Mirror in NewZealand, a demonstration of how eventhe different time zones do not have an

effect on the assistance and collabora-tion with Kolzer.

Outsourcing is also an importantpart of Kolzers activities. Thesecompanies are mostly located in theUnited States, where the componentscome from, and because the UnitedStates is ahead of Europe as faras vacuum technology is concerned.Automation comes from Japanand generators from Germany. Then,of course, it is the Italian ability toput together these parts to make a

good machine.

Kolzer

Via Francia, 420093 Cologno Monzese - Milano - ItalyTel: +39 02 2543193Fax: +39 02 27305586E-mail: [email protected] - www.kolzer.it

EMERGINGENTREPRENEURS

In March this year, Kolzer waslisted among the 30 emerging

entrepreneurs in Italy for their

international propensity andstock market listing. The list was

made up by one of Italys most

important newspapers Corriere Della Sera - with the

collaboration of experts fromten different sectors.

The resulting list was made upof 109 companies, from whichthe best 30 were voted.

DGK48 Sputtering Plant

Glass Vacuum Coating

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