AGCO/Fendt optimized its metal pretreatment process, significantly increases efficiency and sustainability through switching to a low-temperature surfactant in the dip degreasing process and introducing a liquid conditioning step in zinc phosphating.
Agricultural machinery manufacturer AGCO/Fendt, in collaboration with Henkel Adhesive Technologies, has optimized the pretreatment system at its Asbach-Bäumenheim plant. By using the low-temperature surfactant BONDERITE C-AD 20202 for immersion degreasing and introducing a liquid conditioning step in zinc phosphating, Fendt was able to significantly reduce energy and water consumption. The result: stable process quality at lower temperatures, noticeable savings, and reduced maintenance.
Degreasing and zinc phosphating are crucial for coating adhesion and corrosion protection. Degreasing removes contaminants, while zinc phosphating creates a protective, crystalline layer. Together, they enhance durability and service life.
Fendt focused on optimizing these processes as part of its sustainability strategy. The Asbach-Bäumenheim site, in collaboration with Henkel, launched a project to reduce energy and resource use in pretreatment, aiming for greater efficiency without compromising quality.
Fendt’s dip degreasing process initially operated at 55–65°C, resulting in high energy use and inefficiencies. To address this, Fendt collaborated with Henkel to introduce BONDERITE C-AD 20202, a surfactant for low-temperature operation. Tested with stubborn contaminants like ""white grease,"" the product proved effective at 40°C, improving cleaning performance without compromising quality. In May 2025, the system was converted to run at 40°C without active heating, saving an estimated 1,000 kWh per day while maintaining stable zinc phosphate coating and complete surface wetting.
Fendt optimized its zinc phosphating process by switching from a titanium-based powder conditioner to the liquid BONDERITE M-AC AL2000. The liquid conditioner evenly distributes throughout the bath, eliminating the need for stabilizing water and reducing maintenance. The process now operates at 40°C, cutting energy consumption by 15% and extending bath life fourfold. Water consumption decreased by over 90%, while the improved zinc phosphate layer enhanced corrosion resistance and paint adhesion. This shift enables precise dosing and reliable coating formation, supporting more resource-efficient production.
Fendt's shift to low-temperature dip degreasing and liquid conditioning at Asbach-Bäumenheim has led to significant reductions in water and energy use. The dip degreasing now saves around 1,000 kWh per day, while water consumption in the rinse stages before zinc phosphating is reduced by over 90%. Dominic Stettberger, Process Specialist, highlights that the goal of enhancing efficiency, product quality, and reducing the CO₂ footprint has been achieved with Henkel's expert support.
Fendt, founded in 1930 and part of AGCO since 1997, is a leading premium brand for agricultural machinery with over 10,000 employees and global production sites. Its product range includes tractors, harvesters, and smart farming solutions used worldwide.
At the Asbach-Bäumenheim site, key components are manufactured and prepared for painting. Strict pretreatment ensures reliable corrosion protection for machines operating in extreme climates. Fendt has partnered with Henkel for about 30 years to maintain high quality standards.
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