Alliance Green Services (Genk, Belgium)
Steel slag processing: €35,672 annual saving through anti-adhesion coating
The challenge
Alliance Green Services operates 4 CAT bulldozers on the Aperam slag processing site in Genk, Belgium. In a steel slag processing environment, metal slag accumulates aggressively on machine chassis, bonding to unprotected surfaces and hardening in place.
For Alliance Green Services, this meant chassis required cleaning every ten days to remain operational. The only effective removal method was Gemex caustic acid applied under high pressure with a milling head. Each cleaning cycle caused machine downtime, accelerated surface wear, consumed significant quantities of aggressive chemicals, and created safety and environmental risks.
The process worked, but the cost and operational burden of maintaining it were substantial and recurring.
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.
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 | — | 94% |
| 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.
