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PROCESSING

Our company manufactures zinc alloy die cast components and it processes plastic materials through mould injection, the most commonly used technology in processing plastic materials. We offer equipment and moulding products, and we can provide any necessary mechanical processing and surface finishings.

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ZAMAK MOULDING

Santoni is a leading manufacturer of zinc alloy die cast components. Our equipment includes small to medium-sized Agrati, Frech and Colosio hot chamber machines for the production of components weighing from 1 mg to 3 kgs. Zamak die casting ensures we can provide solid net shaped components and parts with consistently high quality. This can always be achieved at a reasonable price, both in small and large scale production.

Zamak offers a higher impact and wear resistance than other alloys or plastics used for producing components: it is as hard as cast iron or brass. Corrosion resistance is further strengthened with a galvanic finishing process, including zinc coating, chromium plating, nickel plating, and satin finishing.

The high level of accuracy ensured by Zamak die cast components allows easier processes, including painting, satin finish, polishing and chromium plating, and even silver or gold plating.

Zamak typical ductility and its high strength provide great flexibility during the design stage of small pieces and details.
Zinc alloys offer tighter tolerances and better finishings than other alloys used in component die casting, such as aluminium and magnesium.

With Zamak die casting, we can produce pieces weighing from a few milligrams to some kilos.

Die cast Zamak components are cheaper than pieces made of other alloys.

The processing of zinc alloy Zamak doesn’t release any air or environment pollutants. This alloy has a very low melting point at just 410/420°C, ensuring significant energy savings.

Zamak alloys are easy to use, offer fast cycles and low melting temperatures. That’s why they are often preferred to other alloys, i.e. in the production of automotive components, furnishing components and accessories, household appliance components and handles, taps and fittings and bathroom furniture, shower hinges, whirlpool bath grips, valves and pneumatic products, hardware, interior furniture and lighting, door handles, ornaments and artistic products, mechanical components, religious items and fancy goods, jewellery, clothing small details and fashion accessories.

Zamak alloys were developed in 1929 by New Jersey Zinc Company. The name ZAMAK refers to the German initial letters of the elements contained in this alloy: Z (Zink – zinc), A (Aluminium – aluminium), MA (Magnesium – magnesium), K (Kupfer – copper). At the time, the highly pure zinc needed for this alloy was not available in Europe; that’s why Morris Ashby was allowed to produce the alloy with local zinc obtained through electrolytic refining.

The characteristics of today’s Zamak are the result of almost 100 years of studies and international researches by many organizations aimed at identifying the most suited composition for each application. Zamak 15 is a high quality zinc alloy offering many benefits: it provides high tensile strength, and it offers high impact and corrosion resistance.

Zamak ingots are melted at a temperature of about 420°C in a furnace located next to the press; then, the Zamak alloy is injected into a mould. Zamak alloy high flowability and low melting point enable the production of pieces with very low tolerance limits and a variety of complex shapes.

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PLASTIC MOULDING

Thermoplastic material injection moulding is the most commonly used technology in plastic material processing. Our moulding department uses Negri Bossi injection presses equipped with dryers to dehumidify materials. We can produce pieces in any shape, size and weight, and we offer co-moulding to integrate steel, brass, bronze and aluminium inserts. In our moulding processes we use the following materials: PS, ABS, PC, PA, POM, PMMA, PC-ABS, PP, PE – they can be fibreglass reinforced. Santoni can mould for you also self-extinguishing, antistatic, UV resistant, non-toxic polymers with food contact certification. With plastic material moulding we manufacture a wide range of products mainly used in electric, HVAC, mechanic, textile, automotive, hobbies and lighting applications.

The plastic material to be processed is the key component. After going through a drying or dehumidification pre-treatment, it is sucked in the injection cylinder by a feeding system.

A screw inside the cylinder rotates and shifts run by hydraulic pistons, thereby creating the friction needed to melt the material together with the heat generated by electric resistances in the injection cylinder.

When the material reaches the required viscosity, it is injected in the mould (injection or filling stage) at a given speed through hot runners, and it fills the negative mould cavity. When the cavity is full, the maintenance stage starts – when the temperature drops the part begins hardening till it gets cold.

ripresa e trattamenti superficiali

REMACHINING AND SURFACE FINISHINGS

When the equipment is ready and the pieces are moulded, they are sent to our workshop – or to third party operations – where they go through any mechanical processing or finishing required by the customer.

The Zamak die cast or thermoplastic moulded pieces can be re-machined to obtain holes, threads, bores…; they can also be barrel finished and sand blasted, or cleaned, brushed and mirror finished. These machining processes will remove any moulding flashes, and obtain a finished piece.

Pieces can go through painting and galvanic treatments, including chromium plating, nickel plating, copper plating, and satin finishing, to achieve a better surface finishing.

Finally, the piece is packed according to the customer’s requirements.