Pallumina thin-film process for automotive production recognized for sustainability contributions

More than 4 million vehicles are pretreated annually with Henkel’s portfolio of thin-film metal pretreatment processes. Henkel was recognized with an award from the Suppliers Partnership for the Environment for demonstrating outstanding innovation in an advanced manufacturing process leading to significant environmental and economic impact. The award recognizes the use of the (Pallumina) thin-film process on the 2021 Toyota Tacoma and Tundra.

Metal pretreatment is an essential part of vehicle production, as it enables paint adhesion to the vehicle body, while preventing corrosion. Henkel’s innovative thin-film process reduces the manufacturing steps of a conventional metal pretreatment process from seven down to just four. Key environmental advancements include the elimination of heavy metal phosphates, such as zinc phosphate, nickel phosphate and manganese phosphate, the reduction of up to a 90 percent in sludge generation and a significant reduction in water usage.

The process uses a metal-oxide conversion coating versus a zinc phosphate-based conversion coating, significantly decreasing sludge generation by reducing the need for metal etching and the use of fluoride additives. In turn, the need for regular tank clean outs is reduced and annual chemical clean outs are completely eliminated – reducing sludge disposal costs and labor costs.

“Today’s automotive OEMs are looking for solutions that enhance sustainability, while reducing costs, simplifying processes and delivering high performance,” said Cris Naida, Vice President Automotive OEM Americas, Henkel. “Henkel’s thin-film processes deliver on all of these – offering an exceptional solution for paint shop processes.”

The Pallumina thin-film process is effective across all major metals and can process up to 100 percent aluminum, further enabling the use of this lightweight metal. Use of aluminum is expected to double from approximately 13 percent on passenger cars and trucks today to 26 percent by 2040, according to the Center for Automotive Research. Aluminum plays an essential role in improving fuel economy standards of internal combustion engine vehicles and off-setting added weight of Battery Electric Vehicles.

The Suppliers Partnership for the Environment represents organizations from across the automotive value chain, including several of the world’s largest automakers and suppliers. The organization works toward a shared vision of an automotive industry with positive environmental impact.

Learn more about Henkel’s metal pretreatment solutions for the vehicle body-in-white here.