GLS Tanks International GmbH, an Austrian specialist in the manufacture of enameled steel tanks, silos, and containers, has upgraded a process step crucial to the quality of the final product: sheet metal surface preparation prior to enameling. At the core of the new solution is an EMC brushing line equipped with boeck roughing blocks, capable of delivering clean, uniform surfaces ready for a defect-free enameling process.

Over 35 Years of Know-How in Industrial Enameling

Headquartered in Heidenreichstein, Lower Austria, GLS Tanks International GmbH has been a benchmark for over three decades in the design, manufacturing, and assembly of enameled steel tanks for industrial, municipal, and agricultural applications: from drinking water and wastewater, to biogas and fermentation storage, up to tanks for oil, bulk materials, and liquid manure. With an export share exceeding 97%, the company operates across nearly every continent and serves as a go-to supplier for major international food and beverage groups.

The key strength of the GLS Tanks construction system lies in combining industrial prefabrication of sheet metal panels, streamlined logistics, and rapid on-site assembly: individual panels are packed compactly, transported in containers, and assembled on-site into a 100% leak-tight tank.

Why Surface Preparation Is a Key Factor

The exceptional durability of GLS tanks stems from the enameling process: enamel powder is electrostatically applied to the panels, after which the coated sheets are brought to high temperatures in a furnace. Here, the powder melts and bonds chemically and physically to the metal surface, forming a glassy, extremely resilient protective layer. The result merges the advantages of two materials: steel provides mechanical strength, stability, and flexibility, while glass delivers permanent corrosion protection and creates a hygienic, bacteria-free surface.

For this bond to endure for decades, panel surfaces must enter the furnace perfectly clean, uniform, and free of contaminants. Any trace of dirt, residue, or surface irregularity can compromise enamel adhesion and cause defects that only become visible after firing—at which point the component requires costly rework.

The Challenge: An End-of-Life Laser Cutting Processing Machine

Raw sheets at GLS Tanks are cut to size on laser systems. During cutting, micro-spatter can settle onto the metal surface; if not removed before enameling, these particles become potential trigger points for defects. However, the machine previously used for this stage had reached its technological limits and could no longer meet the quality standards demanded by the process today.

This prompted the decision to invest in a new EMC solution dedicated not to traditional edge deburring, but to full-surface processing of the panel. The objective: obtain uniformly brushed sheets completely free of residual particles, creating optimal conditions for the subsequent enameling process.

The EMC Solution: DIABLO 1650 CC with boeck Tooling

To address this challenge, GLS Tanks chose EMC's DIABLO 1650 CC, a machine engineered for double-sided processing in a single pass. Unlike the previous setup based on deburring discs, the DIABLO 1650 CC integrates two processing stations equipped with a total of 380 boeck deburring blocks that simultaneously treat both sides of the sheet.

A standout feature of the machine’s brushing concept is that the abrasive belt covers the entire surface of the panel, removing contaminants along the edges as well—a detail that proved decisive for final quality during testing.

Following the deburring stage, the panels travel on a roller conveyor toward a washing system where they are cleaned with a water-alcohol solution. Only then are the sheets rolled to the required tank diameter and sent on to powder coating and furnace firing.

Technical Details That Make the Difference

Dual deburring station: 380 blocks process both sides of the sheet in a single pass, ensuring high throughput and consistent quality.

Silicon carbide abrasive: Exceptionally hard, sharp grains deliver high stock removal while preserving a very fine finish. The hardness and friability of silicon carbide mean that as grains wear down, fresh cutting edges continually form, ensuring consistent performance over time and extended tool life.

Automatic compressed-air cleaning: Every ten seconds, nozzles clear away dirt accumulated in the tools, sustaining stable performance.
Doubled suction capacity compared to the previous machine, creating a cleaner working environment. Quick-change tooling system that provided an immediate, measurable performance boost from day one.

Tangible Results from the First Months of Operation

Data collected by GLS Tanks during the initial months of operating the new line demonstrates clear gains:

Rework rate cut nearly in half: With the old machine, approximately 10% of parts required a second enameling cycle due to insufficiently cleaned sheets or surface imperfections. With the DIABLO 1650 CC, this figure dropped to 6%—a decisive process improvement translating directly into savings in labor hours, powder consumption, and furnace capacity.

High throughput: Roughly 5,500 sheets were processed in the first month of operation alone, an output volume that would have been unattainable with the previous setup.

Controlled tool wear: Over that same period, wear amounted to just 3 millimeters, confirming the efficiency of combining the EMC machine with boeck tooling.

Tailored production capacity: For 2.5 mm thin sheets requiring a throughput of roughly 30 parts per hour to feed the enameling furnace, the new line fully met operational requirements.

The Value of Application Expertise

A factor repeatedly highlighted by GLS Tanks is the value of the application expertise accompanying the technological investment. Dialing in the correct process parameters—feed rate, block feed pressure, and belt speed—is critical to achieving optimal results: excessive belt speed, for instance, can strip abrasive grains prematurely from the backing, while improper feed settings cause unnecessary tool wear.

Through this precise calibration phase, EMC's application engineering enabled GLS Tanks to unlock the maximum performance of the new line immediately—striking an ideal balance between throughput, quality, and tool life, with further optimization potential still to be explored in the coming months.