Sol-Gel coatings
Hard-wearing, high-temperature sol-gel coatings for demanding industrial applications.
Sol-Gel Coating Technology
Sol-Gel coatings provide a hard, ceramic-like surface combining non-stick performance with excellent resistance to abrasion, scratching and elevated temperatures. They are particularly suited to demanding industrial components where conventional low-friction coatings may be vulnerable to mechanical wear or repeated cleaning.
The technology can provide an effective coating solution for components exposed to repeated production cycles, product build-up, packaging materials, adhesives, elevated operating temperatures and abrasive cleaning processes.
Unlike traditional fluoropolymer systems such as PTFE, PFA and FEP, selected Sol-Gel coating systems can also be formulated without intentionally added PFAS, providing manufacturers with an alternative where PFAS reduction forms part of their material, customer or procurement strategy.
The resulting surface combines useful release properties with significantly greater hardness and abrasion resistance than many conventional low-friction coatings.
Where surface hardness, abrasion resistance, elevated temperature capability and reduced reliance on PFAS are key priorities, Sol-Gel can provide a significant advantage.
Selected Sol-Gel systems can provide continuous service at temperatures of approximately 280–300°C, depending on the formulation, substrate and operating conditions. This makes it particularly useful for components subjected to repeated heating and cooling cycles or temperature spikes.
Performance Properties of Sol-Gel Coatings
Sol-Gel systems combine a hard, ceramic-like finish with useful release properties, making them particularly well suited to demanding industrial applications where wear, heat and repeated cleaning are key considerations.
Excellent hardness & scratch resistance
A hard, ceramic-like finish helps resist surface damage during demanding production use.
High abrasion resistance
Designed to withstand repeated contact, wear and abrasive operating environments.
Good to very good non-stick performance
Helps products, packaging materials and process residues release more cleanly from coated surfaces.
Reduced surface adhesion
Lower adhesion can help minimise sticking and unwanted material build-up during operation.
High-temperature capability
Selected systems are suited to applications involving elevated operating temperatures.
Resistance to repeated thermal cycling
Suitable for components exposed to repeated heating and cooling during production.
Reduced product & residue build-up
Improved release helps keep working surfaces cleaner during production.
Reduced cleaning requirements
Less sticking and contamination can help shorten cleaning and changeover routines.
Longer component service life
Greater resistance to wear and aggressive cleaning can help extend refurbishment intervals.
PFAS-free options available
Selected Sol-Gel systems can support customers seeking to reduce intentionally added PFAS.
Food-contact-compliant systems available
Suitable coating systems can be selected according to the application and relevant requirements.
Suitable for component refurbishment
Existing components can often be stripped, prepared and recoated instead of being replaced.
Sol-Gel Coating Applications
Sol-Gel coatings can support a wide range of demanding industrial components where release, wear resistance, heat tolerance and easier cleaning are important.
Heat Sealing
Heat seal bars and sealing plates operate through repeated heating and cooling cycles while being exposed to packaging films, adhesives and product contamination.
A suitable Sol-Gel coating can provide a hard release surface that helps reduce build-up while maintaining stability during demanding thermal cycles.
Weighing & Product Handling
Sticky, oily, seasoned or difficult products can adhere to trays, hoppers and discharge surfaces, interrupting product flow and reducing processing consistency.
Sol-Gel can help suitable contact surfaces remain cleaner and allow material to discharge more freely through the equipment.
Packaging Machinery
Packaging components can be exposed to repeated mechanical contact, packaging residue, adhesives and frequent cleaning throughout their service life.
Sol-Gel's combination of release performance and surface hardness makes it particularly useful where both sticking and mechanical wear need to be controlled.
High-Temperature Components
Selected Sol-Gel systems can be considered for components operating at elevated temperatures or experiencing repeated heating and cooling.
Certain systems can provide continuous service around 280–300°C, depending on the coating formulation, substrate and operating conditions.
Industries Best Suited to Sol-Gel Coatings
Sol-Gel coatings are particularly well suited to industries where components are exposed to heat, abrasion, repeated cleaning, product build-up or demanding production cycles.
Packaging
Ideal for heat seal bars, sealing plates, guide rails, forming components and other parts where release, temperature resistance and durability are important.
Explore Packaging Solutions →Food Processing
Suitable for hoppers, chutes, multihead weighing equipment and other components where product sticking, cleaning time and surface wear can affect production efficiency.
Explore Food & Beverage Solutions →General Manufacturing
A strong option for tooling, rollers, guides, fixtures and machine components exposed to repeated wear, friction and contamination.
Automotive
Can support production components and tooling where surface hardness, release performance, wear resistance and repeated thermal exposure are important.
Explore Automotive Solutions →Pharmaceutical & Medical Manufacturing
Relevant to suitable processing and handling components where clean release, surface durability and controlled material selection are key requirements.
Explore Pharmaceutical Solutions →Chemical & Process Engineering
Suitable for selected components operating in demanding process environments where heat, wear, build-up and cleaning cycles influence coating performance.
Explore Chemical Sector Solutions →Application-led coating selection: industry alone does not determine the correct coating. Marcote assesses the substrate, operating temperature, wear conditions, cleaning regime, product contact and required release performance before recommending a Sol-Gel system.
Could Sol-Gel Improve Your Application?
Send us your component details, operating conditions and performance requirements. Marcote can assess whether Sol-Gel is the right coating technology for your application and recommend a suitable system.
FAQs
Sol-Gel coatings are specialist surface coatings that form a hard, ceramic-like finish. Depending on the selected system, they can combine non-stick properties with high abrasion resistance, scratch resistance and elevated-temperature capability.
PFAS-free Sol-Gel options are available and can be formulated without intentionally added PFAS. The precise coating system should always be selected and documented according to the customer’s application and requirements.
In some applications, yes, but Sol-Gel is not a universal replacement for PTFE, PFA or FEP. Sol-Gel can offer advantages where hardness, abrasion resistance, temperature performance or PFAS reduction are priorities, while fluoropolymers may remain preferable where maximum release or exceptional chemical resistance is required.
Selected Sol-Gel systems can provide continuous service at approximately 280–300°C, depending on the formulation, substrate and operating conditions.
Food-contact-compliant systems are available. The appropriate system depends on the product being processed, operating temperature, cleaning regime and applicable regulatory requirements.
Typical applications include heat seal bars, sealing plates, multihead weighing equipment, guide rails, transfer components, idler rollers, folding and forming components, chutes, hoppers and other suitable product-contact surfaces.
Existing components can often be stripped, prepared and recoated, subject to their condition, substrate and suitability. This can provide a cost-effective alternative to purchasing replacement components.
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