Financial Evaluation of Advanced Gear Coatings

In recent years there has been an active shift from conventional Hard Chromium plating to advanced protective coatings in the European plating industry. These coatings present suitable properties in order to be applied on gears improving their performance and complying with environmental standards. This study evaluates the financial feasibility of two emerging coating technologies utilizing SiC150 and Graphene through a detailed cost and cash flow analysis.

Firstly, unit costs were calculated for all stages of the coating process, including material, energy, equipment, labour, and overhead costs. For a standard gear, per-gear costs were determined for both SiC150 and Graphene coatings. When scaling up to batch production and considering the base gear costs, the analysis resulted in total production costs in which Graphene showed a slight cost advantage. Based on industrial-scale projections conducted at a later stage, the scalability and cost efficiency of both coatings were confirmed.

Finally, a cash flow analysis over ten years was calculated, incorporating expected sales growth, operating expenses, and an industrially relevant gross margin. Based on the analysis a positive cumulative cash flow is achieved from the early years, demonstrating strong long-term economic potential.

Hard Chromium plating remains lower in unit cost, however, the MOZART advanced coatings deliver non-financial benefits, such as enhanced wear resistance, extended service life, and reduced environmental and health risks. Between the two coating alternatives, Graphene coatings provide a small cost advantage.

This analysis targets to evaluate the adoption of SiC150 and Graphene coatings in industrial gear manufacturing supporting informed decision-making for manufacturers who need sustainable and high-performance coating solutions.

Funded by the European Union under the GA no 101058450. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or RIA. Neither the European Union nor the granting authority can be held responsible for them.