- 03 March 2008 -
PLATERS/PAINTERS Profile:
Master Metal Finishers
"Bridging the gap between mom-and-pop anodizers and those larger operations that serve the Boeings of the world direct." That is how Jeff Almeyda, president of Master Metal Finishers in Paterson, N.J., describes the niche market occupied by his firm—an operation specializing in proprietary aluminum anodizing processes and high-tech chromate conversion coatings. For him, it's all about being in a position to tackle specialized jobs often eschewed by finishers chasing the commodity side of the business.
"If an anodizer is going to survive and thrive, it's not going to be through the nickel-and-dime commercial jobs that are out there," Almeyda explained. "Rather, it will be through investing in specialized, high-technology processes in order to cater to the market that requires those services."
That pretty much explains Master Metal Finishers' winning formula to a tee. Take a thorough tour through the company’s 22,000-square-foot plant, and one can readily see this formula at work. Specializing in aluminum anodizing, hardcoating, and chemical film treatments, Master Metal Finishers employs what it calls a "synergistic combination of ultra-tight chemistry and performance parameters with a state-of-the-art computer anodizing system." (Translation: highly guarded proprietary processes.)
Without divulging too much, Almeyda explained how this combination of various chemistries and processes magically allows the use of significantly higher current densities than conventional anodizing systems. The end result, he says, is a harder, clearer film that can be deposited much more quickly than previously possible. Throw in some advanced computerized process controls, coupled with spectra-photometric color analysis for some real razzle-dazzle, and what you get is a consistently high finish quality and quicker turnaround—attributes any demanding customer would love.
"The basic overriding theme when I put this place together was to optimize every aspect of the operation from incoming RO/DI water, to the pretreatment, to the pulse rectifiers, to the triple-flow rinse systems and the chemistry," Almeyda said. In addition, the equipment allows operators to record every load that goes through the system. "Not only are the loads logged by the operators going through, but also by the actual computer system itself," he explained.
Another illustration of the technology at work: each rectifier's output is recorded in real time to a hard disc, showing operators the volts and amps (all time-stamped). The benefit: the company has traceability back across time. So, an operator can go back to that particular load and see the process parameters as if it were real time.
But perhaps the ultimate example of the perfect marriage of chemistry and processes is the quality of the finish itself. Dubbed "Mastercoat," Master Metal's signature finish touts wear resistance and aesthetic attributes that exceed some already demanding military specifications.
"In the old days, we used to brush the parts, black anodize them, and then put a clear black lacquer on them for brightness and also for a little more durability," said Kevin Almeyda, vice president. "But with our new process, we've been able to eliminate the lacquering stage entirely. We're basically providing our customers with a hard black coating ("hard" Type 2 or a "decorative" Type 3) with better corrosion and abrasion resistance, and a part that's consistent in appearance. For the customer it's also a finish with a tighter dimensional tolerance."
Clearly all these bells and whistles require not only intensive R&D but also significant capital investment. (Almeyda estimates that more than $1.5 million has been doled out thus far to spruce up the facility.) Many would see this as bucking the industry trend. "No new shops are going up these days," said a fabrication expert familiar with Master Metal's operation. "If someone is expanding, it's often a compromise based on existing facilities. And when there are new installations, most of the time they are OEMs," the source said.
From Jeff Almeyda's perspective, Master Metal Finishers is the only significant, new job-shop facility in the Northeast region in probably more than 20 years—at least by his count. "If anything, my research tells me guys are getting out of the business as opposed to investing millions into new technology."
One customer who can attest to the by-products of this investment is Middle Atlantic Products, a Fairfield, N.J.–based manufacturer of electronic audio equipment, power distribution paraphernalia, and the like. The custom finish that Master Metal provided was so durable that the client created a performance demonstration video showing how finished panels can stand up to abuse without any discernible evidence of finish compromise.
If you thought that was impressive, you would be even more wowed by the process required to strip a product incorporating this stubborn finish. "You can’t just strip it—you have to leave it in the deoxidizer for about 15 minutes to penetrate the pore structure before you get any access," Almeyda said. Another example of Mastercoat's tenacity: efforts by conventional CO2 lasers to engrave the surface of the hard anodize coat are only marginally effective; doped fiber lasers are required.
Satisfied clients are singing the praises. "We recently switched to the Mastercoat finish on all of our chassis, drawers, and panels," said Frank LoBrace, CPIM, director of purchasing, Middle Atlantic Products, Inc. "The brightness allowed us to eliminate an entire secondary operation, thereby improving throughput. The increased durability of the finish also helps us market a superior-quality message to our customers."
The same can be said for Holbrook, N.Y.–based B/E Aerospace, Inc., the world's largest manufacturer of air-handling and lighting systems for commercial and private aircraft. "Our clientele are very sensitive to quality in finishes and demand the very best," said Gary Hancock, vice president of operations. "Master Metal Finishers has been able to support us in our goal to always be the best in the industry."
(For more on this story, please see the March 2008 issue of Metal Finishing.)
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