Alliance Green Services (Belgium)
Slag doesn't stick. Cleaning costs dropped 87,3%
The challenge
Alliance Green Services operates 10 CAT bulldozers at the slag processing site of Aperam in Genk. Metal slag adhered aggressively to the untreated chassis surfaces, making high-pressure cleaning with Gemex (a caustic acid cleaner) necessary every ten days.
After applying Interflon Film WB® as an anti-adhesion coating, the intensive cleaning frequency was reduced from once every ten days to occasional rinsing with water and reapplication of Interflon Film WB once every eight weeks. The caustic cleaning process was replaced by a simple water rinse.
The documented annual saving amounts to €35,672 based on a trial involving 4 treated bulldozers. If extended to all 10 bulldozers, this would represent an estimated annual saving of €89,180.
The approach
Interflon Film WB® was applied by spray gun to the bulldozer chassis prior to operational exposure. The coating forms a durable, chemically resistant anti-adhesion barrier on metal surfaces. The MicPol® particles bond chemically and mechanically to the metal surface, forming a durable protective film that denies slag a surface to grip. Contamination that does accumulate releases under low-pressure water rather than requiring chemical force.
Application conditions: surface temperature between 15°C and 40°C, dry time approximately 30 minutes, fully cured within 6 hours. Cleaning takes place on cooled equipment using normal mains-pressure water, no acids or specialist equipment required.
The product is rated to a maximum service temperature of 80°C. At Alliance Green Services, all cleaning is performed on cooled machinery, well within this limit.
Observed results over time
Interflon monitored performance across the full cycle before establishing the maintenance interval.
- Week 1: Results immediately apparent. Slag adhesion visibly reduced.
- Week 3: Slag dust released without mechanical assistance and could be rinsed off with a hose.
- Week 6: Full effectiveness maintained with water rinse alone.
- Week 8: Slag began to adhere more firmly, indicating the point at which recoating was required.
Surface treated with Interflon Film WB after 3 weeks: slag does not adhere and can be removed easily.
This established the 8-week maintenance cycle used as the basis for the savings calculation.
| Parameter | Before | After |
| Cleaning frequency | 1× per 10 days | Water rinse as needed + Film WB recoat 1× per 8 weeks |
| Cleaning method | Gemex caustic acid, high-pressure milling head | Water rinse on cooled equipment |
| Cleaning interval reduction | — | 82% |
| Annual cost saving | — | €35,672 (4 bulldozers) |
| Caustic chemical use | Significant | Eliminated |
Conditions and replicability
Interflon Film WB® retains its anti-adhesion properties up to a maximum service temperature of 80°C. The product is not intended for surfaces that remain above this temperature at the point of cleaning. At Alliance Green Services, all cleaning is performed on cooled equipment, which is consistent with normal operational practice in slag processing environments.
The 8-week recoating interval is based on observed performance at this site. Actual intervals will vary depending on slag volume, surface geometry, and operational intensity.
Conclusion
Alliance Green Services reduced its annual cleaning cost by €35,672 without changing its equipment or its operating process. A surface that does not allow contamination to bond does not require aggressive removal and the financial impact is proportional to how often that removal was previously needed.
An Interflon Technical Advisor can assess your cleaning costs, contamination type, and surface conditions and produce a projected saving before any commitment is made.
Technisch Adviseur: Christophe Chini
Author: Janneke van der Pol, MLT1
Frequently Asked Questions
Coating bulldozer chassis against metal slag reduced annual cleaning costs by €35,672 at Alliance Green Services (Genk, Belgium). The cleaning interval increased from every 10 days to every 8 weeks. Caustic acid cleaning was fully eliminated.
An anti-adhesion coating prevents slag from bonding to metal surfaces by forming a durable protective layer. This layer reduces adhesion, allowing contamination to be removed with a water rinse instead of chemicals or scraping.
An anti-adhesion coating remains effective in a slag processing environment for up to 6 weeks, with acceptable performance up to 8 weeks. After this period, slag adhesion increases and recoating is required.
An anti-adhesion coating is suitable for high-temperature environments up to 80°C after curing. It is typically applied where cleaning takes place on cooled equipment.
Anti-adhesion coatings benefit industries where contamination bonds to heavy equipment, including steel, mining, offshore and maritime. They reduce cleaning frequency and the need for aggressive cleaning methods.
