Manufacturing Process - How We Make Our Nickel Micro Screens
MANUFACTURING AND QUALITY
Step 1 — Raw Material Selection
Manufacturing Process Overview
How We Manufacture Our Nickel Screens
Our screens are produced by electroforming — a process in which nickel is deposited, atom by atom, from a liquid bath onto a precisely machined mandrel. The slot pattern forms around resist elements on the mandrel surface, producing slots with a smooth conical internal profile. Once the nickel has been deposited to the required thickness, the screen is separated from the mandrel and hard chrome plated.
This process — electroforming followed by chrome plating — is the method used worldwide for manufacturing high-performance nickel screens for sugar centrifugals. It is chosen because it produces slot geometry that cannot be replicated by cutting, punching, or weaving: a precise conical taper, smooth internal walls, and consistent width from top to bottom of each slot.
Our entire production process — from incoming material to final dispatch — is monitored by an ERP-integrated quality management system that tracks parameters in real time and flags deviations before they affect the finished product.
Production process in brief:
- 99% pure virgin S-grade nickel; no scrap received and inspected on arrival
- Electroforming bath parameters set and monitored — temperature, current density, pH, and nickel concentration controlled throughout deposition
- Nickel deposited to specified thickness, forming screen body and slot pattern simultaneously
- Screen separated from mandrel and inspected for slot width and dimensional accuracy
- Hard chrome plating applied at 12–18 microns
- Final inspection against 20+ parameters before dispatch
Step 3 — Electroforming
This is the heart of our process. The prepared mandrel is immersed in our electroforming bath — a controlled solution of nickel sulphamate — and an electrical current causes nickel ions to deposit, atom by atom, over the mandrel surface. The slots form naturally around precisely positioned resist patterns. This process produces slots with a smooth, conical internal profile that cannot be replicated by punching or cutting.
Our electroforming bath parameters — temperature, current density, pH, and nickel concentration — are monitored continuously by our ERP system and adjusted in real time to maintain the specified deposition rate and internal stress level.
Materials used
Materials and Input Standards
Nickel:
We use 99.99% pure virgin S-grade nickel; no scrap in our electroforming bath. S-nickel is the highest purity grade available for industrial electroforming and is specified because:
- Higher purity produces a more uniform grain structure in the deposited nickel
- Lower impurity content reduces internal stress in the finished screen
- More consistent material properties mean more predictable performance across batches
Lower-grade nickel introduces variability in grain structure and stress that can lead to premature screen failure, slot enlargement, or deformation under centrifugal load.
We do not use lower-grade material to reduce cost.
Chrome:
Hard chrome is applied by electroplating from a chromic acid bath. The chrome layer provides the screen’s wear resistance — it is significantly harder than nickel and protects the slot geometry from the abrasive action of massecuite during centrifugal operation.
- Chrome plating thickness: 12–18 microns
- Industry standard for comparison: 8–12 microns
- Applied uniformly across the screen surface including slot walls
- Mirror-smooth finish — protects sugar crystals from surface damage during separation
The additional 4–6 microns of chrome thickness compared to industry standard translates directly into longer service life under the same operating conditions.
Quality Assurance
Inspection and Process Control
Quality in our manufacturing process is maintained through process control during production, not only through inspection at the end. Our ERP system monitors electroforming bath parameters continuously and any deviation from specification triggers a corrective action before the affected screens proceed to the next stage.
Every finished screen is then inspected individually against the following parameters before it is approved for dispatch:
Dimensional checks:
- Overall screen height — verified against specification
- Screen diameter — top and bottom measured
- Cone angle — checked against mandrel specification
- Wall thickness — measured at multiple points
Slot checks:
- Slot width — measured at minimum five points across the screen surface
- Open area — calculated and verified against specification
- Slot wall finish — inspected for burrs, rough edges, or irregularities
- Conical profile confirmation — non-blinding geometry verified
Surface and plating checks:
- Chrome plating thickness — measured and recorded
- Surface finish — mirror-smooth, no voids, no pitting, no areas of exposed nickel
- Visual inspection for cracks, warping, or deformation
Structural checks:
- Overall dimensional conformance to purchase order specification
- Screen integrity — no cracks, splits, or deformation
Screens that pass all checks are logged in our ERP system and released for dispatch.
Screens that fail at any check are rejected and do not proceed to packing. There are no exceptions to this process for any order size or customer.
Testing and Standards
Testing Procedures
- Slot width measurement:
Slot width is measured using calibrated gauges at a minimum of five locations across the screen surface — not only at a single central point. This ensures that slot consistency is confirmed across the full working area of the screen, not just at one location. - Chrome plating thickness:
Plating thickness is measured using an eddy current or magnetic induction thickness gauge, calibrated to traceable standards. Results are recorded against each batch. - Dimensional verification:
All dimensional checks are carried out using calibrated measuring instruments. Measurement records are maintained in our ERP system and are available to customers on request. - Certifications:
We hold an Import Export Code (IEC) for export operations. Quality certificates detailing inspection results for a specific batch are available on request for all orders. Customers requiring specific documentation for import clearance or internal procurement systems should advise us at the time of order.
Quality Commitment
Our Commitment to Consistent Quality
A nickel screen that passes inspection today needs to perform consistently for the duration of your crushing season — which may be 120 days of continuous operation processing thousands of tonnes of massecuite. That places a real and specific demand on manufacturing quality that goes beyond meeting a dimensional specification at the point of dispatch.
We manufacture to the same standard on every order. The same nickel purity, the same chrome specification, the same inspection process — whether the order is for two screens or two hundred. Customers who have used our screens for multiple seasons can expect the same performance from the next order as they received from the first.
If a screen we supply does not perform as expected, we want to know about it. We take product performance feedback seriously and investigate any reported issue. Our technical team is available to discuss screen specification, performance data, or any concern about product quality directly.
Step 5 — Hard Chrome Plating
The electroformed nickel screen is then hard chrome plated to a thickness of 14–16 microns. Chrome is significantly harder than nickel, and this outer layer provides the screen’s wear resistance and surface finish. Our chrome plating bath is maintained to produce a mirror-smooth, uniformly thick layer that adds hardness without altering slot dimensions.
14–16 microns is above the industry standard of 12–14 microns. The additional chrome thickness extends screen life measurably — particularly in mills processing high-purity, abrasive massecuites.
Step 6 — Final Quality Inspection : 20+ Parameters
Every finished screen is inspected against a 20+ parameter checklist before it is approved for dispatch. This includes:
- Slot width — measured at multiple points across the screen surface
- Open area percentage — verified against specification
- Chrome plating thickness — verified by thickness measurement
- Surface finish — mirror-smooth, no burrs, no chrome voids
- Overall dimensions — height, diameter, cone angle
- Conical perforation geometry — non-blinding profile confirmed
- Structural integrity — no cracks, warping, or deformation
- Screens that pass all parameters are stamped, logged in our ERP system, and prepared for dispatch.
- Screens that fail at any parameter are rejected — no exceptions.
Step 7 — Packing and Dispatch
15+ Years
of nickel screen manufacturing expertise
20+ Parameters
checked on every screen before dispatch
14–16 Microns
chrome plating — above the industry standard of 12–14
Location Advantage
Located Where It Matters Most
Plot No. G-93, MIDC Area, Ahilyanagar (Ahmednagar), Maharashtra 414111 — our location is not incidental. Ahmednagar district sits at the centre of Maharashtra’s sugar industry, with major mills in Kolhapur, Solapur, Nanded, Pune, and Chhatrapati Sambhajinagar all within practical delivery reach.
For Indian sugar mills, this means shorter lead times, lower freight costs, and a supplier who understands the local crushing calendar — and can move fast when you need an urgent replacement before the season begins.
For international buyers, our MIDC address is well-served by freight logistics to Nhava Sheva (JNPT), India’s busiest container port, enabling reliable shipping timelines to ports across Asia and Africa.
Our Commitment
Reliable & Consistent Quality
Every screen we make meets the same specification. No batch-to-batch variation. No compromise when demand is high.
Technical Support
Our team understands centrifugal operations. We help you choose the right screen for your machine and massecuite grade — and we're available after the sale.
Competitive Lead Times
We plan production to match the Indian crushing calendar. Pre-season orders are prioritised. Emergency requirements are handled with urgency.