GERMAN TECHNOLOGY PRODUCED IN SOUTH AFRICA
In the chemical industry, the key of a long lasting success is based on the following pillows:
With regards to the development of chemical product, never buy semifinished raw materials and mix same together, like most companies do. Instead, take the effort and develop new formulations and also invent new technologies for the processing. Key tech customers will explain in what way the performance of the products should be.
For the manufacture of any chemical product, a number of raw materials or semi finished chemicals are needed. It is FOCHEM’s strategy to, whenever possible, never use so-called “prepared products”, but to perform the refinement by yourself. This is an added responsibility, but ultimately it off. This is called “vertical diversification”.
Following this philosophy, Fochem had accomplished the following, to name a few:
Invention of a novel jet milling process. Such technology is in use for the Refinement and micro milling of crude graphite. The graphite particles are accelerated to a speed of up to 2 Mach, thus breaking up into nano particles.
Despite its high gravity, Fochem was the first company internationally in producing thin and stable graphite dispersions in water, that do not settle.
Another remarkable development is the a die-casting release agent, that is AMPHIPATIC, meaning HYDROPHILIC and HYDROPOBICС simultaneously without the use of a wax dispersion. This new generation product has remarkable properties, e.g. shorter spray cycles and always aluminium bright and shiny castings.
The global demand for ultra-fine, dry particles has grown significantly, driven by applications requiring enhanced surface coverage, such as coatings, and faster dissolution rates, as in pharmaceuticals. Traditional air jet milling achieves submicron fineness (0.2–5 microns) but is hindered by high costs and low yields. Fochem International’s proprietary jet mill technology revolutionizes this process, delivering particle sizes of 0.1–5 microns in large quantities without the need for costly compressors or steam generators. Unlike conventional systems using compressed air at 550 m/sec or steam at 1,200 m/sec, Fochem’s technology employs adjustable air velocities of 1100–1500 m/s, ensuring high kinetic energy and minimal mill wear. Particles grind against each other, reducing maintenance and enabling years of operation without upkeep. This confidential technology, not available for sale, supports Fochem’s production of high-quality micronized graphite for industries like automotive, aerospace, and electronics, served through its global distributor network in countries such as India, Brazil, and the USA.
In Fochem’s air jet milling process, pulverization occurs in a central chamber where particles are accelerated to near-sonic speeds by multiple air jets, without grinding media. The turbulent, toroidal chamber facilitates high-frequency particle collisions, progressively reducing particle size. Larger particles remain at the chamber’s exterior, while finer ones migrate to the center for discharge. Feed rate control ensures desired particle morphology and size distribution, with typical parameters including mill diameters of 0.05–1 meter, gas pressures of 8.3 Bar, and final particle sizes of 0.5–5 microns from starting sizes of 800 microns or less. This efficient, scalable process overcomes the limitations of traditional jet mills, which struggle with low yields and safety concerns from steam-based systems operating at 300–400°C, positioning Fochem as a leader in precision milling.
For coatings industry applications, Fochem International has developed an innovative bead wet mill technology to produce ultra-fine graphite dispersions. Unlike conventional bead mills, which use impact-based grinding with ceramic or metal beads, Fochem’s system employs high-pressure shear to gently defoliate graphite crystals. This preserves the crystalline structure, increases surface area, and transforms graphite from grey to bright silver, indicating the presence of graphenes. These qualities enhance lubricity, die coverage, and dispersion stability, critical for improving die life in forging and other applications. Fochem’s mills, significantly larger than commercial alternatives, produce thousands of tons of submicron dispersions, meeting industrial-scale demands for industries like automotive and aerospace.
Traditional bead mills suffer from small capacities, high friction, and contamination risks, damaging graphite’s structure. Fochem’s technology eliminates these issues, minimizing wear and impurities while delivering superior performance. Used by its sister company, Tribo-Chemie GmbH in Germany, this technology supports applications such as high-pressure die casting and forging. Fochem’s vertical diversification—from raw materials to finished products—ensures independence and customization, while its South African facility integrates advanced automation and quality control to deliver eco-friendly, high-performance solutions. With over 50 years of expertise and a global presence, Fochem’s innovative milling technologies set a new standard for precision and sustainability in industrial manufacturing.
For the past 40 years or so, so-called water-based release agents are in use for high pressure die-casting. Most of the products are based on colloidal aqueous wax dispersions, at times mixed with emulsified siloxanes. The manufacture of such products is fairly easy and follows standard types of procedures. These type of wax- based release agents have several disadvantage: The spray mists formed during the application cause severe built up on the dies and machines, and they also block spray nozzles.
Oil-based emulsions would not cause any such problems. Unfortunately the production of so-called hydrophobic emulsions that are also stable, has, with the prevailing emulsification technologies, not been possible, so far. FOCHEM INTERNATIONAL have devoted a lot of time and energy to this problem, and eventually a new technology was developed. For the first time ever, it is possible to produce hydrophobic, nano-fine oil emulsions that appear white with slightly bluish-pink, indicating that the light is scattered off the interphases between the components of the mixture. Emulsifiers cannot be used in the formulations, as they would render the product hydrophilic with negative effect on die release.
FOCHEM INTERNATIONAL is in the fortunate position to render any type of oil, that may be suitable as a die release agent, water soluble, and most importantly “hydrophobic”. Emulsions with a solids content of up 90 % can be produced. They can be mixed with water easily forming a perfectly stable emulsion.
Originally the high pressure die-casting plunger beads had been invented in the USA some 20 years ago. This achievement was very promising as they replaced the messy graphite oils. Apart from that, the shot sleeve, especially in the case of automatic dosing, was better protected against the erosion caused by the hot aluminium smelt. For the application of the plunger beads a so-called “beads dispenser” is needed.
The initial excitement of the global die-casting industry soon ended in disillusionment. The first beads dispensers could only handle beads not smaller than with 3 mm diameters, and the melting time of such large beads was way too long. A small pipe was needed that conveyed the beads into the shot sleeve. On larger machines this pipe heated up, and the beads started melting inside the small pipe, causing blockage. The initial beads dispensers were fairly unreliable, they either dispensed too much or no beads at all. Another draw- back were the white beads offered at the time, consisting merely of wax and nothing else. They were cheap and clean, but lubrication was non-existent. Eventually the die-casters around the world switched back to oil.
FOCHEM INTERNATIONAL realised the potential of the plunger beads lubrication and embarked on new developments. They had a vision to perfect the beads by making them smaller, perfectly round, uniform in size, and with a very much higher graphite content to improve lubrication. They also devoted a great effort in the development of a reliable dispenser. During that time a so-called shuttle was invented that moves the dosing pipe out of the heat zone during the application. In the beginning the beads on the market were produced by a so-called “dripping system”, yielding only large beads which are not perfectly round.
FOCHEM developed the first beads spray technology, which, depending on the nozzles and pressures used, can yield beads sizes between 0.2 and 3 mm, as required.
Today, FOCHEM INTERNATIONAL has the most advanced beads manufacturing facility in the world, south of Johannesburg. It operates fully automatic and produces more than 200 tons of beads per month, with graphite contents up to 30 %. The beads are exported to more than 20 countries. FOCHEM’s famous “3 D Beads Dispenser” is produced by its sister company TRIBO-CHEMIE in Germany.
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