Automated Immersion Systems Guide | PROCECO

01 / THE FUNDAMENTALS

What are automated immersion systems?

One integrated line. Multiple process stages. Controlled results.

Automated immersion systems transfer parts through a sequence of cleaning, rinsing, chemical treatment, and drying stations. Recipes define the processing conditions and handling sequence for each workpiece.

Built around your process

Also known as automated dip tanks, surface treatment lines, and multi-stage immersion systems, these lines combine configurable tanks with automated handling and process controls.

02 / INSIDE THE LINE

From contaminated part to prepared surface

Pre-cleaning & degreasing

Remove oils, machining fluids, grease, and production contaminants. Ultrasonics, agitation, or spray assistance can support contaminant removal.
Rinsing

Remove residual chemistry before the next tank. Multiple rinse stages help limit chemical carryover and preserve bath conditions.
Surface Preparation

Use application-specific etching, pickling, activation, or descaling to prepare your substrate for subsequent treatment.
Chemical Surface Treatment

Anodizing, phosphating, conversion coating, plating, penetrant application or passivation changes the surface according to your corrosion, adhesion, or wear requirements.
Final rinse and drying

Remove remaining chemistry and dry your parts for inspection, assembly, coating, or shipment.

process-tanks

Process tanks

Separate cleaning, rinsing, and treatment baths preserve the sequence your workpiece requires. Tank count follows process complexity.

automated-transfer-hoists

Transfer hoists

Programmed handling controls dwell time and transfer speed, keeping exposure consistent across production batches.

ultrasonic-cleaning

Ultrasonic cleaning

Cavitation helps dislodge fine contaminants from precision surfaces and complex features where direct spray access is limited.

Rotating parts basket in cleaning tank

Agitation and rotation

Workpiece or solution movement improves chemical contact by reducing stagnant boundary layers.

filtration

Filtration

Removing contaminants from circulating solution supports bath cleanliness and extends useful bath life.

Industrial water recovery loop

Water recovery

Rinse-water recycling and drag-out control reduce fresh-water demand and chemical carryover when designed for your process.

Select chemistry around your substrate and finish

Material compatibility and the applicable process specification determine the treatment sequence.

chemical-cleaning

Chemical cleaning

Removes oils, particulates, manufacturing residues, and corrosion byproducts.

acid-etching

Acid etching

Prepares a chemically active surface for subsequent finishing.

anodizing

Anodizing

Supports corrosion resistance, wear resistance, and durability on suitable aluminum components.

phosphating

Phosphating

Supports corrosion protection and paint adhesion.

passivation

Passivation

Removes free iron from stainless steel to support corrosion resistance.

Conversion coating treatment icon

Conversion coatings

Form protective surface layers for corrosion protection and coating adhesion.

fpi-immersion-systems

Fluorescent Penetrant Inspection

Ideal for revealing flaws, cracks and signs of fatigue, and for exposing metal grain structure. Learn More about our FPI systems

NDT-Fluorescent-penetrant-inspection-in-automotive-1

Fluorescent Penetrant Inspection Immersion Systems (FPI)

Each liquid penetrant and FPI system is custom-designed to meet the customer's specifications, parts, and production output criteria.

Learn more about our FPI systems

Immersion and spray: application considerations
Consideration	Automated Immersion	Spray Cleaning
Complex geometries	Fluid contact with accessible internal features.	Depends on spray access and orientation.
Surface treatment	Suited to many bath-based chemical processes.	Suited to compatible spray processes.
Production throughput	Scalable with handling and tank capacity.	Scalable with conveyor or batch design.
Delicate parts	Evaluate agitation and chemistry.	Evaluate pressure and workholding.
Investment	Multiple tanks and automated handling add capital requirements.	Configuration and process complexity drive equipment cost.

Start with process validation
Confirm the cleaning method against your actual workpieces and acceptance criteria before selecting equipment

Repeatability

Control processing time, temperature, chemistry, and transfer conditions.

Cleaning Performance

Combine immersion with suitable ultrasonics or agitation for challenging features.

Production Flow

Coordinate transfers and reduce manual handling bottlenecks.

Quality Control

Support consistent processing across batches and shifts.

Traceability

Capture process conditions, batch history, and quality records.

Resource Efficiency

Reduce avoidable water and chemical losses through appropriate system design.

Capital & facility needs

Account for automation, floor space, utilities, ventilation, and wastewater treatment. Learn more

Chemistry & process engineering

Plan bath monitoring, filtration, material compatibility, and maintenance access. Learn more

Capital & facility needs

Capital & facility needs

Capital & facility needs

Account for automation, floor space, utilities, ventilation, and wastewater treatment. Learn more

Chemistry & process engineering

Chemistry & process engineering

Chemistry & process engineering

Plan bath monitoring, filtration, material compatibility, and maintenance access. Learn more

Aerospace OEM and MRO

Engine components, pre-inspection cleaning, chemical treatment, and overhaul processes.

Automotive & Tier Suppliers

Gears, transmission components, powertrain parts, and ring-and-pinion assemblies.

Precision Manufacturing

Complex machined parts with internal passages, threaded features, and demanding cleanliness requirements.

Heavy Equipment

Rebuilding, maintenance, forged components, and industrial assemblies.

08 / SELECTION & ROI

Define the process before the equipment

Set your expected process outcomes

Define the expected process outcomes, acceptance criteria, and contamination or surface condition requirements (i.e., cleaning, etching, plating, penetrant inspection) to establish clear validation standards.
Evaluate geometry

Identify blind holes, cavities, internal channels, and sensitive surfaces that affect fluid contact and drainage.
Map process stages

Define cleaning, rinsing, surface treatment, and drying requirements before sizing tanks or selecting handling equipment.
Set throughput goals

Specify parts per hour, shift patterns, and anticipated growth to balance dwell times with transfer capacity.
Define automation

Determine handling, robotics, and MES or ERP connectivity requirements based on your production environment.
Calculate ownership cost

Include water, chemistry, energy, maintenance, labor, and downtime alongside equipment and installation costs.

OUR PARTNERS

Surface-treatment-in-the-general-manufacturing-industry

Maximize line performance while lowering operating costs

Standardize work holding. Consistent fixturing supports repeatable contact, handling, and drainage.

Reduce drag-out. Limit solution retained on workpieces to reduce carryover and chemistry loss.

Evaluate counterflow rinsing. Multi-stage rinsing can reduce water demand while maintaining rinse quality.

Plan for expansion. Allow space and process capacity for additional stages as requirements evolve.

Monitor bath conditions. Record process data to support quality review and troubleshooting.

09 / WHAT`S NEXT

More connected. More traceable. More efficient.

Industry 4.0 connectivity, remote diagnostics, sensor-based maintenance, and digital batch records can extend your visibility into production. Advanced ultrasonic configurations and water-recovery systems should be evaluated against your component types, chemistry, and resource targets, rather than specified as universal requirements.

Connected production

Real-time monitoring, remote diagnostics, and production-system integration.

Condition monitoring

Sensor data to support maintenance planning and early issue detection.

Ultrasonics

Frequency selection matched to the workpiece and cleaning objective.

Sustainability engineering

Water reuse, energy efficiency, and chemical conservation.

PROCECO Surface Treatment Systems integrate automated cleaning with processes such as acid etch, anodizing, and phosphating. Define your workpiece and process requirements before choosing your configuration.