Alliance Green Services (Belgium)
Slag doesn't stick. Cleaning costs dropped 87.3%
Alliance Green Services operates 10 CAT bulldozers at the slag processing site of Aperam in Genk, Belgium. Metal slag adhered aggressively to the untreated chassis surfaces, making high-pressure cleaning with Gemex, an aggressive chemical 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 aggressive chemical cleaning process was replaced by a simple water rinse on cooled machine surfaces.
The documented annual saving amounts to €35,672 based on a test with 4 treated bulldozers. Annual cleaning costs for these 4 bulldozers dropped from approximately €40,861 to €5,189. If extended to all 10 bulldozers, this would represent a saving of €89,180 per year.
| Parameter | Before | After |
|---|---|---|
| Cleaning frequency | Once every 10 days | Occasional rinsing with water and reapplication of Interflon Film WB once every 8 weeks |
| Cleaning method | Aggressive chemical cleaner with high-pressure cleaning unit | Water rinse on a cooled surface |
| Reduction cleaning frequency | ~82% | |
| Annual cleaning costs | approx. €40,861 for 4 bulldozers | approx. €5,189 for 4 bulldozers |
| Annual saving | €35,672 for 4 bulldozers | |
| Use of aggressive chemicals | Significant | Eliminated |
The problem
In a steel slag processing environment, metal slag adheres aggressively to machine chassis surfaces, where it continues to build up and harden on untreated surfaces.
For Alliance Green Services, this meant that the chassis of the CAT bulldozers at the Aperam site had to be cleaned every ten days to remain operational.
The only effective removal method was Gemex, an aggressive chemical cleaner, applied under high pressure with a cleaning unit. Each cleaning cycle caused machine downtime, accelerated surface wear, consumed large quantities of aggressive chemicals and created safety and environmental risks. The process worked, but the cost and effort required to maintain it were substantial and recurring.
The approach
Interflon Film WB was applied to the bulldozer chassis with a spray gun before operational exposure. The coating forms a durable, chemically resistant anti-adhesion barrier on metal surfaces. MicPol® technology helps form a durable protective film on the metal surface that prevents slag from attaching. Any contamination that does build up can be removed by rinsing with water instead of using aggressive chemicals and high-pressure cleaning.
Application conditions: surface temperature between 15°C and 40°C, drying time approximately 30 minutes, fully cured within 6 hours. Cleaning is performed on cooled machines using ordinary tap water at normal pressure, without acids or specialised equipment.
The product functions up to a maximum operating temperature of 80°C. At Alliance Green Services, cleaning is performed on cooled machines, well within this limit.
Observed results over time
Interflon monitored performance over the full cycle before defining the maintenance interval.
- Week 1: noticeably good results. Slag adhesion was clearly reduced.
- Week 3: slag dust released without mechanical assistance and could be rinsed off with a hose.
- Week 6: full effectiveness maintained with only a water rinse.
- Week 8: slag began to adhere more strongly again, indicating that reapplication was required.
This established the 8-week maintenance cycle used as the basis for calculating the saving.
After only a few weeks, slag dust that previously adhered firmly to the chassis surface could be removed easily by hand.
After only a few weeks, slag dust that previously adhered firmly to the chassis surface could be removed easily by hand.
Conditions and reproducibility
Interflon Film WB retains its anti-adhesion properties up to a maximum operating temperature of 80°C. The product is not intended for surfaces that remain above this temperature during cleaning. At Alliance Green Services, all cleaning is performed on cooled machines, which matches normal practice in slag processing.
The 8-week recoating interval is based on observed performance at this location. Actual intervals may vary depending on slag volume, surface geometry and operational intensity.
Conclusion
Alliance Green Services reduced its annual cleaning costs by €35,672. Savings were achieved in cleaning labour and product consumption. A surface that prevents adhesion does not require aggressive cleaning, and the financial impact is directly linked to the frequency and duration of that cleaning.
An Interflon Technical Advisor can analyse your cleaning costs, type of contamination and surface conditions, and provide an advance estimate of potential savings.
Special thanks to: Alliance Green Services
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 denies slag a surface to grip, allowing contamination to be removed with a water rinse instead of chemicals or mechanical force.
At Alliance Green Services, the coating remained fully effective through week 6, with the recoating interval established at 8 weeks based on observed performance. Actual intervals will vary depending on slag volume and operational intensity.
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.
