Case Studies

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Corrosion in the Sugar Industry

Baramati Agro Sugar Factory

Before After

Problem

Molasses tanks were heavily corroded. Shot blasting — the standard surface-prep method — was essential but prohibited on-site for safety reasons. Rust and dirt still had to be removed and cleaned before painting to address both corrosion and paint bonding.

Solution

Shot blasting was avoided by using SGNC, which achieved two goals simultaneously — rust removal/prevention and surface preparation for painting. RFGPL also developed a custom primer with an appropriate heat-transfer ratio so surplus heat from the molasses would dissipate quickly, and a suitable PU top coat offering UV resistance and reflectivity.

Impact

Dramatic cost reduction per maintenance cycle with multi-year corrosion-free performance.

Rs. 170/sq.m Shot blasting cost

Rs. 35/sq.m SGNC cost

4+ years Corrosion-free service

RCF Chembur — Quantified Proof of Performance

Rashtriya Chemicals & Fertilizers, Chembur

Problem

Industrial tanks, cranes and pipelines required durable anti-corrosion protection with measurable cost savings and field-friendly application.

Solution

SGNC was applied as a nano-modified anti-corrosive system requiring no special equipment, converting surface rust directly into coating.

Impact

Measurable performance gains across drying time, gloss, scratch resistance and lifecycle cost.

< 1 hour Surface drying

>90% Surface gloss

Rs. 89/sq.m Cost savings

Rs. 89 lacs 100,000 sq.m savings

Eastern Railway — Longevity Proof

Eastern Railway, Bengal

Problem

Corrosion-prone track section subject to heavy foot traffic, discharge and garbage. Normal rail paint does not last even one year.

Solution

SGNC applied on 25.12.2008 on rails and fittings in encroachment-prone locations.

Impact

By 2012–2013 (4+ years later), SGNC-coated rail sections still showed intact paint while uncoated areas were badly corroded. Confirmed by official letter dated 11 July 2013 by Mr. Arup Kumar Dey, SSE/P-Way/BGA, Eastern Railway.

25 Dec 2008 Applied

4+ years later Verified intact

< 1 year Normal paint life

Thermo-Cool Solar Reflective Coating

CASA TVS, Vijayawada

Before Coating 56.9°C

Outside surface

46.7°C

Inside shade

After Two Coats 44.7°C

Outside surface

35.5°C

Inside shade

Problem

Metal roof surfaces reaching extreme temperatures, driving high indoor heat load.

Solution

Two coats of Thermo-Cool solar reflective coating applied to blue metal roof.

Impact

Significant reduction in exterior and interior shade temperatures.

Corrosion in the Sugar Industry

Problem

Solution

Impact

RCF Chembur — Quantified Proof of Performance

Problem

Solution

Impact

Eastern Railway — Longevity Proof

Problem

Solution

Impact

Thermo-Cool Solar Reflective Coating

Problem

Solution

Impact

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