New automated zinc electroplating line in Postojna

Postojna, 15 May 2025. LIV Systems runs a fully automated zinc electroplating and passivation line, built in 2020 and 2021 to replace a line from 1980 that no longer had enough capacity. Before, part of the plating had to be sent out, with extra transport and longer lead times. Now all zinc plating is done in house.

The line has run under a temporary operating permit since 2023. Update 2026: the full operating permit has been granted.

“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 Damjan Švigelj, then CEO. “We must keep all our key processes under our roof to serve our customers reliably and competitively.”

The line covers 2,000 m² and runs 24/7. Buffers keep it running during operator breaks. Robots with vision cameras for quality inspection and automatic loading and unloading are under review. In its current set-up the line plates and passivates nearly 10 million parts a year across our main product groups, which leaves room for growth.

“We identified several internal optimisations that reduced material waste, improved product quality, and brought measurable economic benefits,” notes technical director Silvo Požar.

What the line changes

• Capacity: higher volumes for growing European demand.
• Lead time: no waiting for an outside plater.
• Energy: 1.41 MWp of solar on our roof since 2023, heat recovery and a modernised wastewater treatment plant.
• Environmental protection: the plant stands on the Karst, so the line has certified floor protection. All environmental and health and safety checks were passed.

How zinc plating and passivation work

In electroplating, an electric current deposits a thin, even layer of zinc on the steel part, 10 to 15 µm on our standard castor parts. The zinc corrodes instead of the steel.

Passivation then forms a conversion layer on the zinc that slows the zinc itself from corroding. Our passivation is Cr6+-free and blue as standard; other colours on request.

We check the result in our own salt spray chamber to ISO 9227. Our standard zinc plating reaches up to 240 hours. More on the surface treatments page.

What it means for customers

Shorter lead times, plating capacity for growth, and a price that can compete with Far Eastern imports in price-sensitive segments, with a longer-lasting product made in Europe.

“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.