Manufacturer LIV Systems Launches Sustainable Electric Zinc Galvanisation Line to Boost Production
[Slovenia, 15 May 2025] – LIV Systems d.o.o., Europe’s leading manufacturer of castor wheels for waste containers, proudly announces the successful installation of a fully automated electro-zinc galvanisation and passivation line. This marks a major leap in the company’s long-term industrialisation strategy, increasing production capacity, reducing lead times, and decreasing dependence on external suppliers—all while delivering on sustainability.
The new line replaces a 40-year-old unit that was no longer fit for purpose. Previously, LIV Systems did not have enough in-house capacity and had to outsource galvanisation, incurring additional logistics costs and longer turnaround times. Now, the process is not only in-house but exceeds expectations in precision and efficiency. “We have seen the disruptions to global supply chains caused during the 2020–2022 pandemic, and recent political tensions have only reinforced the need to operate independently,” said CEO Damjan Švigelj. “We must keep all our key processes under our roof to serve our customers reliably and competitively. We need full control—and now we have it.”
The new line covers 2,000 m², operates 24/7, and includes buffer functions that allow uninterrupted production—even during operator breaks. Integrating robotics with vision cameras and AI for quality inspection and automated loading and unloading is already under review.
With its current setup, the line can apply galvanisation and passivation treatment to nearly 10 million pieces per year across LIV Systems’ main product groups. This future-proof capacity allows room for sustained growth.
Production is running under a temporary approval licence, with all tests and certifications successfully completed. “We identified several internal optimisations that reduced material waste, improved product quality, and brought measurable economic benefits,” notes production manager Silvio Pazar. “It’s proof that environmental protection, sustainability, and profitability can go hand in hand.”
Key Benefits of the New Line:
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Increased Production Capacity: Enabling higher volumes to meet growing European demand.
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Reduced Lead Times: Faster throughput ensures quicker delivery to clients.
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Sustainability Advancements: The line is powered by a 10,000 m² rooftop solar plant (installed in 2023), includes smart energy win-back systems, and is supported by a modernised wastewater treatment plant.
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Environmental Compliance: The site is built on Slovenia’s sensitive Karst region and includes certified floor protection. All infrastructure and operations have passed rigorous environmental and health safety checks.
How Zinc Plating and Passivation Work — And Why It Matters
If you're specifying or purchasing metal castors and wheels, surface protection is critical. At LIV Systems, we've perfected the twin processes of electrozincing and passivation over decades — ensuring your components stay protected, even in harsh environments.
🔩 Electrozincing
This is an electrochemical process where a fine, even layer of zinc is applied to the metal surface using an electric current. It acts as a protective shield, preventing corrosion and extending the lifespan of your components.
🔒 Passivation
After zinc coating, parts are treated in a chemical bath to form an additional protective layer. This improves resistance to rust, enhances surface appearance (silver, yellow, or black), and further increases durability.
🧪 Real-World Testing
We use a salt spray cabin in-house to simulate years of exposure to weather and road salt in just a few days. This guarantees that our finishes perform not just in theory — but in the real world.
Together, these processes give you:
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Longer product life
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Fewer service interruptions
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Lower maintenance and replacement costs
This surface protection expertise is fully integrated into our production line — giving customers unmatched quality, consistency, and reliability.
Conclusion: Local Control, Global Competitiveness
This investment allows LIV Systems to scale its operations without compromising on quality or environmental responsibility. Even in price-sensitive segments, the company can now compete directly with Far Eastern manufacturers—offering a more durable and sustainable product, manufactured locally and responsibly.
“This is part of our long-term strategy to deliver high-quality products with short lead times, even in the face of global uncertainty,” said Švigelj. “Our customers know they can rely on us—and we’re doubling down on that trust by reinforcing our commitment to excellence, sustainability, and control over our own production.”