Energy transition in galvanizing: success story in Brazil

FIB Belgium presented and successfully implemented its latest technology during a recent project for the Brazilian company Morlan, a leading wire manufacturer in the fencing industry.

Morlan had been operating its galvanizing line with a gas-only heating system, which carried significant risks in case of supply disruptions. As Industrial Director José Roberto explains: “Our heating system for the zinc bath was LPG gas. A few years ago, we faced a very serious issue, which was the truck drivers' strike. If we were to run out of LPG, the zinc bath would harden. That would have destroyed the furnace and all the ceramic components.”

Dual energy solution for safety and flexibility

To solve this critical issue, Morlan partnered with FIB Belgium to implement a dual energy system, combining the original gas heating system with electric immersion heating elements. Marcus Nicolosi, FIB Group representative, describes the innovation: “This setup allows modulation of gas energy usage alongside electric energy. In case of any variation or shortage in either energy source, you won't run the risk of zinc solidification, which would be a catastrophe in a galvanizing line.”

Beyond ensuring safety, the system also delivers economic savings and supports Morlan’s shift towards greener operations: “It guides the company towards more environmentally friendly operations, avoiding greenhouse gas emissions.”

A perfect match for Morlan’s needs

For Morlan, the results exceeded expectations: “The solution presented by FIB was perfect for us, even better than we expected. We had a line with 12 gas immersion burner heaters: they were repositioned and grouped to allow the insertion of 10 electric heating elements, interspersed with those gas burners,” says José Roberto. “We were confident we would get a result like what we are seeing today, because they are highly capable and very committed to the customer.”

FIB also highlights the strong collaboration with Morlan. “They understand the value of this kind of solution and fully support us in implementing it. They are very open to receiving the innovations we are always seeking,” comments Nicolosi.

Looking to the future

The successful project has strengthened trust between the two companies. José Roberto concludes: “A thank you from Morlan for their capability and their dedication to solving our problems. Let’s see if we can do this on another line in the future.”

With this achievement, FIB Belgium once again demonstrates its ability to deliver innovative galvanizing solutions that increase safety, efficiency, and sustainability in the global wire industry. Contact FIB Belgium today to discuss tailored solutions for your galvanizing lines and discover how innovation can transform your production.