450 °C, 2.6 tonnes, 7 years – Facts about zinc kettle replacement at WIEGEL

Feuchtwangen – Replacing a zinc kettle is a technically demanding process and a key element of maintenance in hot-dip galvanizing. At WIEGEL, this step is carefully planned in advance – ensuring consistent quality, process stability, and long-term operational reliability.

How does the zinc return to the kettle?

After being pumped out, the zinc is reintroduced in so-called “jumbo” blocks.
One block weighs approximately 2.6 tonnes. Once the kettle has been refilled, the controlled heating phase begins.

This process requires experience and precision, as material properties, temperature control, and timing must be perfectly coordinated.

How long does it take to heat up the zinc bath?

It takes around five days until the first zinc becomes liquid again.
After approximately two additional days, the entire zinc bath is fully molten and the galvanizing process can restart.

Slow and even heating is essential to prevent material stress and to ensure a stable operating phase.

At what temperature does galvanizing take place?

The zinc bath is operated at approximately 450°C.
This temperature is kept as constant as possible throughout the entire service life of the kettle.

A stable bath temperature is a key factor for:

• uniform zinc coatings

• reproducible quality

• high process reliability

• efficient plant operation

How often is a zinc kettle replaced?

The service life of a zinc kettle depends on wear and tear. Key factors include:

• galvanized tonnage

• operating hours

• thermal load

On average, a kettle is replaced at WIEGEL approximately every seven years.

With around 30 galvanizing plants within the WIEGEL Group, this results in an average of about four kettle replacements per year. Each replacement is a carefully planned project requiring technical expertise and precise coordination.

Continuity through investment and planning

The regular replacement of zinc kettles is part of a long-term investment and maintenance strategy. The goal is to consistently ensure the highest quality in hot-dip galvanizing and to guarantee production reliability for customers and partners.

Haven’t seen the zinc kettle reel yet? You can find it here.

For further information about hot-dip galvanizing or our locations, the WIEGEL Group will be happy to assist you.