Series production
Production-Ready Plasma: Process Control and Repeatability
The short answer
A plasma treatment is ready for series production when its settings are stored, its result is measured and its parameters are documented. Kalego Solutions, a manufacturer in Quebec City (Canada), validates every process on your parts before delivery, controls its equipment from your PLC (RS485, TCP-IP or Modbus) and delivers every project with a documented process file.
On your parts
Validation before delivery
RS485, TCP-IP, Modbus
Control from your PLC
20 programs
Stored trajectories (cell)
Process file
Delivered with every project
Three conditions for series production
Repeat
Settings become data: a trajectory stored and replayed without drift, a fixed curtain head across the full width. Operator-to-operator variation disappears.
Measure
Every batch is checked with calibrated test ink against a level set during validation. In seconds, with no instrument.
Document
Plasma parameters, characterization methods, validation results and operating procedures: the file that answers your customer audits.
What your PLC controls
| Equipment | Communication | What is set and stored |
|---|---|---|
| Compact plasma torch | RS485, TCP-IP | 1 to 3 nozzles, 700 to 1,100 W power, 30 to 60 L/min gas flow |
| Plasma curtain | Modbus TCP/IP, RTU | 60 to 500 mm width, 1 to 6 kW power; standalone touchscreen or OEM version |
| Turnkey cell | Internal memory, unlimited via PC | 20 programs of 200 points; linear, circular or rotary trajectories up to 300 mm/s; interlocked door, built-in extraction |
| DBD plasma reactor | Custom controllers | Size, gas and sample type defined for your process |
From sample to line, nothing ships unmeasured
Diagnosis
Your part, your goal, your line speed.
Within 48 business hours, free
Lab validation
Your samples treated in Quebec City, characterized, parameters documented.
Prototype tested on your parts
Every unit is tried on your parts before delivery: results carry over from commissioning.
Commissioning and support
Training for your technicians, then a maintenance and support program for the equipment’s whole service life.
Continuous process monitoring
- Recipes per part number
- [x]
- Process alarms
- [x]
- Parameter log and batch traceability
- [x]
- Measured batch-to-batch repeatability
- [x]
- Preventive maintenance
- [x]
Treatment stability: 24 h, 72 h, 7 days
| Material | After treatment | 24 h | 72 h | 7 days |
|---|---|---|---|---|
| [x] | [x] mN/m | [y] mN/m | [z] mN/m | [x] mN/m |
| [x] | [x] mN/m | [y] mN/m | [z] mN/m | [x] mN/m |
Three production cases
A [x] in the [y] sector
Material: [x]. Adhesion gain: [y]. Line speed: [z]. Stability over time: [x].
A [x] in the [y] sector
Material: [x]. Adhesion gain: [y]. Line speed: [z]. Stability over time: [x].
A [x] in the [y] sector
Material: [x]. Adhesion gain: [y]. Line speed: [z]. Stability over time: [x].
A technology validated outside our walls
Université Laval
Kalego’s DBD technology comes from its labs, where the company was founded in December 2019.
CHU de Québec
Research partner. The anti-fog technology was tested there for endoscopy.
NRC and Mitacs
Research and development partners. Mitacs gave Kalego an innovation award in 2024.
ACXYS Plasma Technologies
Kalego’s industrial and technology partner in atmospheric plasma.
Common questions about production
Can atmospheric plasma keep up with production rates?
Yes, if it is sized for them. A plasma curtain treats a full width in one pass with a fixed head: hundreds of parts per hour, all treated the same. For a precise zone, the torch mounts on your line or robot, with 1 to 3 nozzles.
How do I know in production that every part is treated?
With a test-ink check at the level set during validation: the ink spreads if the surface is above it and beads below it. The check frequency is defined with you.
What documents do we receive for our audits?
A process file: plasma parameters, characterization methods, validation results and operating procedures. For regulated markets such as medical or food, the level of documentation follows your sector’s requirements.
Who handles maintenance?
Kalego. Each custom reactor has its own maintenance and support program, and our team remains your direct contact, from commissioning to fine-tuning.
Can we see the process before committing?
Yes. Your parts are treated in our Quebec City lab, and some equipment can be rented for a trial on your line.
Where is the equipment made?
In Quebec City, Canada: designed, built and tested on site.
Does Kalego also make vacuum plasma equipment?
No. Kalego Solutions only makes atmospheric-pressure equipment, with no vacuum chamber and no pumping.
Kalego Solutions at a glance
Kalego Solutions designs and manufactures atmospheric plasma (DBD) surface treatment equipment in Quebec City, Canada. It integrates into production lines with no vacuum chamber and no chemical solvents. Spun out of Université Laval research, the company serves manufacturers in Canada and the United States.
- Headquarters and lab
- Quebec City (QC), Canada
- Technology
- Atmospheric-pressure DBD plasma, no vacuum
- Manufacturing
- Designed, built and tested in Quebec City
- Origin
- Université Laval, founded December 2019, incorporated 2022
- Partners
- Université Laval, CHU de Québec, NRC, Mitacs, ACXYS
- Markets served
- Canada and the United States
- Contact
- [email protected], reply within 48 business hours
As seen in
