ZINC FLAKE COATING (Magni Coating)

Zinc flake coating is a non-electrolytic corrosion protection system made from microscopic flakes of zinc and aluminum suspended in an inorganic binder. It’s commonly used to protect steel and iron parts from rust—especially in automotive and heavy industrial applications.

What is it made of?

• Zinc Flakes – Provides sacrificial corrosion protection
• Aluminium Flakes – to improve protection barrier
• Binders – bonds the coating to the substrate

Magni Coatings is a brand name in the ecosystem of Zinc Flake Coatings developed by Magni Coatings System originating in America.

Magni® Coating is one of the world leading & most trusted Zinc Flake Coating brands with 500+ OEMs approval globally.

It holds the majority of Zinc Flake Market share in the world outlasting other reputed brands like Geomet, Dorken, Zintek.

Magni® is the world’s largest and most trusted zinc flake coating brand, backed by 500+ global OEM approvals — more than any other brand including Geomet® (by NOF, Japan), Delta® (by Dörken, Germany), or ZinTek® (by Atotech, Germany).

Originating from the USA, Magni has been the benchmark for corrosion protection in the most demanding industries for decades. Its multi-layer coating architecture delivers higher salt spray test (SST) hours, superior adhesion, and better friction coefficient control compared to competing brands.

For Indian automotive manufacturers supplying to global OEMs, Magni is often the specification of choice — not an alternative. At SAR Coatings, as an official licensed Magni applicator, we bring this world-leading technology directly to your components.

Magni zinc flake coating provides up to 1000+ hours of salt spray resistance (as per ISO 9227 / ASTM B117 standards), vastly outperforming conventional zinc electroplating which typically offers only 72–240 hours.

Even when compared to other zinc flake brands like Geomet® or Delta®, Magni’s advanced multi-layered base coat and topcoat system consistently achieves higher SST performance.

A standard Magni 565/560 system applied at SAR Coatings can protect critical automotive fasteners, chassis brackets, and structural components from corrosion for years of real-world service — making it the go-to choice for Tier 1 suppliers and OEMs like Maruti Suzuki, Toyota, Hyundai, and Volvo.

Absolutely yes — Magni® zinc flake coatings are 100% free from hexavalent chromium (Cr6+), lead, and other RoHS/ELV-restricted substances, making them fully compliant with global automotive and environmental regulations including EU ELV Directive, REACH, and BS EN ISO 10683.

This is a critical advantage over older-generation coatings and even some competing brands that may rely on hexavalent passivation steps. Additionally, Magni coatings are non-electrolytic, which completely eliminates the risk of hydrogen embrittlement — a major concern for high-tensile steel fasteners used in safety-critical applications.

At SAR Coatings, our Magni application process is environmentally responsible and fully audit-ready for your OEM compliance requirements.

SAR Coatings applies Magni® zinc flake coating across a wide range of component types and industries. Using both Dip-Spin and Spray application methods, we coat bolts, nuts, fasteners, brackets, chassis parts, suspension components, springs, and complex structural assemblies.

Industries we serve include Automotive (passenger vehicles, commercial vehicles, two-wheelers), Solar Energy (module mounting structures), Wind Energy (tower fasteners), Railways (coach and bogie hardware), and Infrastructure & Construction.

Whether you are a Tier 1 automotive supplier or an industrial manufacturer, SAR’s Magni-certified line is equipped to handle bulk volumes with zero compromise on quality backed by in-house salt spray testing and 100% inspection.

SAR Coatings is one of India’s official licensed Magni® applicators, which means we are directly certified and audited by Magni Coating Systems (USA)  not just a generic zinc flake applicator.

This is a critical distinction. While other coating companies in India may offer zinc flake services using brands like Geomet® or Delta®, SAR brings the advantage of the world’s No. 1 zinc flake brand, applied with strict process controls, dedicated infrastructure and OEM-backed quality systems trusted by Maruti Suzuki, Toyota, BMW, Volvo, Hyundai, Tata Motors, and Mahindra.

With zero warranty failures on record and 170+ satisfied customers, our track record speaks for itself. When your application demands the best, choose the applicator that applies the best SAR Coatings with Magni

Magni’s Official Licensed Applicator. Visit Website https://magnicoatings.com/global/applicators

The Coefficient of Friction (COF) is a mathematical ratio ($\mu = \frac{F_f}{F_n}$) that measures the resistance between two surfaces in contact. In the context of fasteners and automotive components, COF is the most critical factor in achieving a precise clamp load.

When a bolt is tightened, a significant portion of the torque applied is used simply to overcome friction. If the COF is inconsistent, you risk either under-tightening (leading to joint failure) or over-tightening (leading to bolt breakage). For OEMs, a stable and predictable COF ensures that every fastener performs exactly as engineered, regardless of the assembly environment.

While traditional coatings like Zinc plating often have high variance in friction levels, Magni coatings are engineered specifically for high-precision tensioning. Magni is the better choice for several reasons:

• Integrated Lubrication: Magni systems incorporate dry-film lubricants directly into the coating matrix. This eliminates the need for messy post-treatment oils or waxes that can rub off or contaminate the assembly line.

• Reduced Variance: Magni provides a highly controlled, narrow range of friction (typically between 0.10 and 0.16 depending on the spec). This consistency allows for automated high-speed assembly with zero “galling” or thread seizing.

• Global OEM Approval: Because Magni maintains its COF integrity even under extreme thermal cycling and corrosive environments, it is the global gold standard for brands like Ford, GM, and Chrysler.

• Repeatability: At SAR Coatings, our Magni application process ensures that the first part and the millionth part exhibit identical frictional characteristics, ensuring total reliability for your end-users.

Standard Zinc Plating typically offers 72 to 120 hours of protection before red rust appears. In contrast, our Magni and high-performance Zinc Flake coatings are engineered to withstand 1,000 to 2,000+ hours of Neutral Salt Spray (ASTM B117) testing. By using a thinner, more efficient layer than traditional galvanizing, we provide superior protection without compromising the dimensional tolerances of precision parts.