Press
Minimal application for optimised engine cooling
Maximum robustness confirmed in independent tests
Wide range of applications in vehicle construction and the construction industry
With their design advantages, perforated sheets are indispensable in many applications, including in vehicle construction and the construction industry. To fulfil the highest requirements for durability and reliability, SCHÄFER Perforated Metal has developed PerfPRO: The innovative zinc-nickel coating combines reliable, extensively tested corrosion protection with the advantage of a higher air flow rate. This improves cooling capacity and thereby contributes to greater efficiency, for example in vehicle construction.
Perforated sheets coated with PerfPRO have a higher performance compared to standard coatings and offer comprehensive advantages in terms of service life, robustness, sustainability and even recycling. Added value is created in particular for construction machinery, commercial vehicles and agricultural machinery, where, in addition to corrosion protection, optimised air flow through the perforated sheets – primarily for engine cooling – is crucial.
Thanks to the special coating technology, it is possible to realise larger hole diameters by applying less material. The 50 per cent thinner coating compared to conventional processes improves the air flow rate by more than 20 per cent. This ensures improved cooling and therefore a longer service life and more efficient operation of the vehicles. An expert from an independent testing institute confirms: “Our tests confirm the uniform, metallic 3D coating of PerfPRO – free from edge alignment and defects. The thin layer structure increases the air permeability, which significantly improves the cooling capacity – for example in ventilation grilles of engines – compared to conventional coating processes.”
SCHÄFER Perforated Metal developed the new type of corrosion protection together with a partner company. The electrolytic coating is applied evenly after perforation of the steel sheets and thus also reliably covers the cut surfaces. Thanks to PerfPRO, completely new perspectives open up for perforated sheet applications under harsh conditions.
The effective corrosion protection and the resulting high durability are confirmed by independent test centres: PerfPRO passed the salt spray test for corrosion resistance in accordance with DIN EN ISO 9227 NSS:2023-03 for 1,008 hours – far exceeding the requirements of the standard. The adhesion test using thermal shock, based on DIN EN ISO 2819:2018-09, and the heat storage test were also successfully passed.
Independent testing institutes confirm the positive properties and associated benefits of a PerfPRO coating. Josef Andrek, Managing Director of the Institute for Electroplating and Surface Treatments Solingen (IGOS), explains: “While the standard for black passivated zinc-nickel surfaces in accordance with DIN EN ISO 19598:2017-04 only requires 720 hours without base material corrosion, PerfPRO clearly exceeded these requirements with 1,008 hours. The coating therefore fulfils the highest demands in terms of durability and corrosion resistance.”
PerfPRO was also successfully subjected to extensive thermal shock adhesion tests (based on DIN EN ISO 2819:2018-09) and a heat storage test. Here too, the innovative coating solution impressed across the board.
Users can choose from two versions: On the one hand, the zinc-nickel coatingPerfPRO and, on the other hand, the advanced version PerfPRO+ with additional powder coating. Both versions guarantee maximum air permeability and durable corrosion protection. PerfPRO+ also enables individual colour adjustments according to customer requirements – ideal for aesthetically sophisticated integration into design concepts. SCHÄFER Perforated Metal also ensures the highest quality standards with its own powder coating plant.
Sustainability was a clear focus during the development of PerfPRO. Thanks to the efficient use of materials, reduced coating thickness and recycling-friendly processes, the innovation makes an important contribution to environmental compatibility – an increasingly decisive argument for responsible companies.
With PerfPRO, SCHÄFER Perforated Metal is combining comprehensive expertise in punching and surface technology. This ensures precise coordination of all production steps – from the high-quality base material supplied by the in-house EMW Steel Service Centre to the final coating. Customers benefit from consistently high quality, short delivery times and customised solutions.
Equally impressive is the comprehensive selection of over 400 hole patterns in material thicknesses ranging from 0.75 to 3.0 millimetres. The hexagonal, round, square or slotted perforations offer individual advantages for each application in terms of air flow rate, stability and weight savings. The hexagonal honeycomb structure in particular enables an open surface of up to 80 per cent – a decisive factor for optimum cooling capacity in vehicle construction with high stability at the same time.
Perforated sheets are a proven, indispensable construction and design component with a wide range of functions in the automotive and commercial vehicle industry. They take a wide variety of forms. Well-known examples include protective and ventilation grilles on engines, perforated body parts to optimise the weight of off-road vehicles and construction machinery, loading areas for vans and tow trucks and engine hoods for tractors. Perforated sheets with the innovative PerfPRO coating are already being tested in practice by leading manufacturers.
Likewise, stationary applications also benefit from the advantages of the new type of corrosion protection: Perforated sheets with PerfPRO coating enable impressive solutions for façades, sound insulation walls, railings and many other applications on the outside of buildings.
With PerfPRO, SCHÄFER Perforated Metal is offering a corrosion protection that sets new standards in terms of quality and durability, while at the same time offering sustainable, versatile and robust solutions for demanding applications.
Innovative corrosion protection for perforated sheets: PerfPRO sets new standards.zip