The MAR ZINC PRO ES 97 process is a new, maximum performance plating system that is a true advancement in the science of chloride zinc plating. This new process offers super bright, lustrous, ductile, fine-grained deposits without burning, staining or whiting out, over the entire plating range. The unique, technologically advanced formulation is designed to provide uniform deposit distribution similar to that of alkaline baths. This formulation is designed to take advantage of separate make-up components for rack and barrel since these two processing techniques require distinct additive for maximum performance.

The MAR ZINC PRO ES 97 process requires little control and is very tolerant to a high concentration of dissolved iron, bath impurities and general abuse. This, in turn, substantially reduces rejects, down time and maintenance. In addition, the MAR ZINC PRO ES 97 process contains a built in ductilizing agent making it ideal for plating heavy thicknesses. Plated deposits remain ductile so there is less chance of chipping, flaking or cracking. This process provides the most uniform deposit available with excellent, unsurpassed throwing power similar to alkaline baths.

The MAR ZINC PRO ES 97 process provides a truly receptive plated surface that will accept trivalent chromate films more readily than competitive processes. The MAR ZINC PRO ES 97 process will allow the trivalent chromate film perform to its maximum capability regarding salt spray protection.

WARRANTY AND DISCLAIMER:This information is based on our experience and is, to the best of our knowledge, true and accurate. MAR-Tech Holdings Inc. gives no warranty, expressed or implied and the products are sold upon condition that the purchasers will make their own tests to determine the quality and suitability of the product. Any information or suggestions are given without warranty of any kind and the purchasers are solely responsible for any loss arising from the use of such information.

The MAR ZINC PRO ES 97 process is extremely versatile to bath composition. A variety of ratios of metal to chloride can be easily used with this process. Its low foaming formulation allows for bright, trouble-free plating even at elevated bath temperatures without loss of performance. All this adds up to the MAR ZINC PRO ES 97 process providing the most plating performance while being the most economical chloride zinc plating process available.

The MAR ZINC PRO ES 97 process has an extremely wide current density plating range, allowing for non-burned deposits utilizing high current densities.

Operating Parameters

Range: Rack: Barrel:
Zinc Metal 15 - 50 g/l 43 g/l 29 g/l
Zinc Chloride 30 - 120 g/l 90 g/l 60 g/l
Boric Acid 15 - 40 g/l 25 g/l 25 g/l
Potassium Chloride 160 - 280 g/l 180 g/l 220 g/l
Total Chloride 92 - 196 g/l 133 g/l 136 g/l
MAR ZINC PRO ES 97 MUR 3 - 5 % BV 4 % by BV.
MAR ZINC PRO ES 97 MUB 3 - 5 % BV 4 % by BV.
pH 5.2 - 6.2 5.6 5.6
Temperature 65 - 120° F
(18 - 48° C)
80° F
(27° C)
80° F
(27° C)
Agitation Mild Air or
Barrel Rotation
Mild Air Mild Air or
Barrel Rotation
Cathode Current Density 0.5 - 75 asf 3 - 75 asf 0.5 - 30 asf
Anode Current Density 15 - 35 asf 15 - 35 asf 15 - 35 asf
Anodes 99.99 pure zinc 99.99 pure zinc 99.99 pure zinc
Filtration Continuous
15 micron
At least 1 turnover/hour At least 1 turnover/hour
Voltage 2 - 15 volts 2 - 6 volts 6 - 15 volts

Note: Use only untreated, high purity grade Potassium Chloride. Remember Zinc Chloride powder is 52% Chloride and 48% Zinc Metal. Potassium Chloride is 47.6 Chloride. Zinc Chloride is approximately 50% Zinc Metal and 50% Chloride.

  1. Make sure tank is clean and free from contamination.
  2. Fill tank to approximately 75% of final volume with water
  3. Add Zinc Chloride and dissolve.
  4. Add Potassium Chloride and dissolve.
    Note: Heating may be required at this point since the dissolution of salts is endothermic.
  5. Add the required amounts of MAR ZINC PRO ES 97 C and MAR ZINC PRO ES 97 BR.
  6. Adjust pH to the proper operating parameter. Hydrochloric acid is used to adjust the pH down and Ammonium hydroxide to adjust pH up.
  7. Filter for approximately 6 hours to remove any impurities
  8. Small addition of peroxide may be necessary if potassium salts contain iron.


Iron builds up in the solution during operation and can produce white staining (low iron contamination) to blue to black stained (higher iron contamination) deposits after chromating and increase deposit stress. This is due to the acidic pH of the bath and drag in of dissolved iron from the pre-treatment cycle and the parts themselves.

The MAR ZINC PRO ES 97 process has excellent tolerance to dissolved iron and does not require frequent treatment. However, the level of iron in the solution eventually reaches the point where it must be removed to prevent the co-deposition of iron. The suggested treatment is to add 0.05% by volume hydrogen peroxide at the end of the plating day. In some cases 1 – 1.5 grams per 1000 litres of plating solution of potassium permanganate pre dissolved in water can also be effectively used. If added during production, good filtration is of necessity in that roughness may occur from precipitated solids unless filtered.


The presence of heavy metals is apparent in the low current density areas in the form of dull to black deposits and or skip plating in more severe contamination conditions. Low current density dummy plating is recommended or if contamination is very severe, zinc dust treatment can be utilized.

Zinc dust should be mixed in water slurry at 120 g/l and then adding 0.1% of this solution to the zinc bath. It should be added with agitation and then allowed to settle after 15 minutes of mixing. This typically should be done in a treatment tank and not in the plating tank. Filtration is necessary after treatment to prevent re-dissolution of the contamination.


Organic contamination detracts from deposit brilliance and leveling, reduces chromating ability and causes brittle, burned deposits. With low levels of contamination, the solution can be circulated through a carbon packed filter, however, in a more severe case, batch carbon treatment may be required.

Pretreatment is important with any zinc process. Good pre-plate cleaning and pickling are necessary to produce high quality deposits. The effectiveness of the pre-plate cycle is not always apparent simply by observing the plated finish.

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