Client: Australian commercial refrigeration service provider
Industry: HVACR (Heating, Ventilation, Air Conditioning & Refrigeration)
Challenge: Severe galvanic corrosion on evaporator coils in cold storage units
Solution: Xi'an BaiQi Metal custom aluminum-zinc-indium sacrificial anode kits
Result: 3x+ extended evaporator lifespan, 80%+ reduction in maintenance costs
Case Details
1. Client Background & Pain Point
Our client, a leading Australian refrigeration service company, was facing a recurring, costly issue across their commercial cold storage and supermarket HVAC systems: evaporator coil corrosion and leakage.
In the humid, condensate-rich environment of cold rooms, the copper evaporator tubes and steel end plates form a galvanic cell, leading to accelerated corrosion. This caused frequent coil perforation, refrigerant leaks, unplanned system shutdowns, and expensive emergency repairs—costing the client tens of thousands of dollars annually in labor, parts, and lost business.
They needed a reliable, long-term solution to protect their evaporators without complex retrofitting.
2. Our Custom Solution
After a detailed technical consultation, we designed and manufactured a custom aluminum-zinc-indium sacrificial anode kit tailored to their evaporator specifications:
- Anode Core: High-purity Al-Zn-In alloy discs (50mm diameter, 25mm thickness) with a 6mm fully drilled through-hole for secure M6 screw mounting, optimized for low galvanic potential and maximum corrosion protection.
- Accessory Optimization: We worked with the client to refine the mounting design, switching from a single pre-bent strap to two separate 7-shaped brass mounting straps for easier installation and better adaptability to different evaporator configurations.
- Complete Kit: Each set includes 1 anode, 2x 1mm² PVC-insulated copper cables, 2 mounting straps, M4 screws, 4.8mm rivets, and all necessary hardware for a one-stop installation.
3. Implementation & Results
The client installed the anode kits in 12 high-corrosion cold storage units across 3 supermarket locations. After 12 months of continuous operation, the results were transformative:
✅ Zero Coil Leaks: No new corrosion-related perforations or refrigerant leaks were reported in the protected units.
✅ Significant Cost Savings: Annual evaporator maintenance and repair costs dropped by over 80%, with an estimated 3-5 year extension of coil service life.
✅ Easy Installation: The optimized 7-shaped strap design reduced on-site installation time by 30% compared to traditional fixed straps.
✅ Minimal Maintenance: The anodes only require a simple visual inspection every 6-12 months, with no ongoing operational costs.
4. Key Takeaways
Sacrificial anode cathodic protection is the most cost-effective, proven solution for preventing galvanic corrosion in HVACR evaporator systems. Our custom kits deliver:
- Proven Corrosion Protection: Al-Zn-In alloy anodes sacrifice themselves to protect copper/steel coils, stopping corrosion at the source.
- Customizable Design: Tailored to any evaporator size, configuration, and installation requirement.
- Low Total Cost of Ownership: One-time installation with minimal maintenance, delivering long-term savings for years.
5. Get Your Custom Anode Solution
At Xi'an BaiQi Metal, we specialize in manufacturing high-quality sacrificial anodes and complete corrosion protection kits for the global HVACR, marine, and industrial sectors. Whether you need standard or custom-designed solutions, our engineering team can deliver products that meet your exact specifications.
Contact us today to discuss your corrosion protection needs and get a free technical consultation and quote.
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