Polylloy Coatings Company Profile: Products, Industries, Partners and Proof

Polylloy Coatings Profile: Key Points

• Polylloy Coatings, Inc. is an R&D and manufacturing company in California's San Francisco Bay Area, at the heart of Silicon Valley, co-founded by Edita Rojasova and Surjit Gill.
• It makes the FlueGard, KilnGard, StackGard, CorrosionGard and WearGard families: 9 technologies across 5 categories of hybrid polymer-alloy-ceramic coatings for steel in severe service.
• Polylloy formulates, supplies, specifies and supervises; certified partners apply, through a network of 15 partners covering 22 countries.
• Industries served include cement, waste-to-energy, chemical processing, oil and gas, power and mining.
• Proof on record includes a Mexico kiln shell thickness study, long-running FlueGard baghouse inspections, French and Swiss cement plant case studies, a sulfuric acid immersion test and named power references; named customers are CEMEX, Holcim and Exxon.
• Quality documents are an ISO 9001:2015 registration (self-assessed certificate) and an independent third-party design and manufacturing verification by Fuller, Jones & Associates.

Polylloy Coatings, Inc. is a coating technology company in California's San Francisco Bay Area, at the heart of Silicon Valley, that makes FlueGard, KilnGard, StackGard, CorrosionGard and WearGard coatings for steel in severe service. Co-founded by Edita Rojasova and Surjit Gill, it formulates, supplies, specifies and supervises, while 15 certified partners apply.

Its coatings protect steel from corrosion, chemical attack, heat and abrasion, mainly in hot, corrosive flue gas service, with partners applying them under Polylloy's specification and supervision.

Polylloy Coatings at a Glance: Plant Challenges and How the Company Answers Them

Polylloy Coatings is summarized here in two parts: the company facts, then the plant problems its coatings are built for.

Company Facts

The core facts about Polylloy are set out below.

Challenge vs Solution Table

Each plant challenge below maps to a Polylloy product family or delivery practice.

Polylloy's primary benchmark is 316 stainless steel, not another coating brand. Protected carbon steel may offer a cost-effective alternative to stainless steel where the coating is suitable for the specified service conditions.

Who Makes FlueGard Coatings and the Other Polylloy Product Families

FlueGard coatings are made by Polylloy Coatings, Inc., which also makes four other product families.

Five Families, Nine Technologies

The five families are FlueGard® flue gas coatings, KilnGard®, StackGard®, CorrosionGard® and WearGard®, covering 9 technologies across 5 categories.

Polylloy describes its technology as an alloy-inorganic-organic (polymer-alloy-ceramic) hybrid approach, fundamentally different from conventional glass-filled epoxy, novolac and phenolic coatings; the exact chemistry varies by grade, as the table below shows. The wider range is described under Polylloy corrosion protection solutions.

Grades with Published Data Sheets

The grades below have published bulletins:

ESP means electrostatic precipitator and FGD means flue gas desulfurization. Final heat cured activation is completed during start-up using process heat; CorrosionGard-160S cures at ambient temperature. Choosing between these grades is covered in Polylloy coating grades by temperature and gas chemistry.

How Polylloy Coatings Delivers a Project with Certified Partners

Polylloy Coatings delivers projects through certified partners, keeping grade selection and specification in-house.

What Polylloy Does

Polylloy formulates, supplies, specifies, trains and supervises; certified partners carry out surface preparation and application. Its 2026 Company Profile sets out six delivery stages:

1. Site and data review: temperature, chemistry, condensation, particulate loading, substrate condition and shutdown constraints.
2. System recommendation.
3. Specification: surface preparation, environmental controls, film build and acceptance criteria.
4. Field execution: applicator training, supervision and hold points.
5. Inspection and closeout.
6. Maintenance support: condition monitoring, localized repairs and planned recoating recommendations.

The Partner Network in Brief

The network has 15 partners covering 22 countries across the Americas, Europe, the Middle East, Africa and Asia-Pacific. Names and territories are listed under Polylloy coating partners by market. How responsibilities split on site is explained in industrial coating contractors: who applies, who supervises.

Industries Polylloy Coatings Serves

Polylloy Coatings prioritizes cement and waste-to-energy, then chemical processing, oil and gas, power and mining. Its brochure also lists lime and battery recycling.

Industries Served and Typical Equipment

Typical equipment by industry, per the Company Profile:

• Cement and lime: kiln shells beneath refractory, baghouses, ducts, stacks and cyclones.
• Waste-to-energy and biomass: flue paths and air pollution control equipment.
• Power: FGD systems, ESPs, ducts and stacks.
• Petrochemical and chemical: vessels, tanks and process equipment.
• Mining, metals, smelting and battery recycling: abrasion, acidic condensation and hot particulate.

Equipment-level detail sits in the guides to cement plant corrosion protection and power plant corrosion protection.

Polylloy Coatings Proof on Record: Case Studies, Tests and Named Customers

Polylloy Coatings' proof comes from documented case studies, a laboratory test and named references. Results are project-specific.

Cement Plant Case Studies

On a Mexico kiln, an uncoated shell section lost more than 1.3 mm in 11 months; with KilnGard-600SCW, no measurable loss was recorded over a further 12 months. The same 20 to 26 m section was measured at 1 m intervals.

FlueGard was applied to coal mill baghouses at three cement plants in Mexico in 2004, 2007 and 2008. Inspections after about 20, 15 and 16 years reported no issues observed, excellent condition and excellent performance; only the 2008 unit is specifically FlueGard-225SQC.

At a French cement plant, FlueGard-225SQC on a fan housing, installed April 2024, has run about 24 months in hydrogen fluoride (HF), hydrogen chloride (HCl), sulfur oxides (SOx) and high-velocity dust service. At a Swiss cement plant, FlueGard-455CHT on about 75 m² of new duct, applied October 2024, showed no visible widespread delamination in inspected areas at about 17 months; heavy dust limited the inspection.

Laboratory Test and Power References

FlueGard-225SQC showed no observed deterioration after six months' immersion in 56% sulfuric acid at 60 °C. This is Polylloy's own report, reviewed by Edita Rojasova, not an independent test.

At Taipower Power Plant in Taiwan, a 12-month FGD field trial of FlueGard-225 coupons in the exit stack and absorber tower found no measurable loss of coating thickness. Pull-off adhesion exceeded 1,300 psi with failure in the dolly adhesive, and a 2 kV holiday test passed.

At the Woodland Biomass Power Plant near Sacramento, California (Xcel Energy), FlueGard-225 was trialed on one pulse-jet baghouse compartment in October 2003, after a previous high-temperature coating and a stainless lining had both been unsuccessful. After seven months the plant reported excellent condition and no corrosion, and requested the remaining compartments.

At PPL Brunner Island, Pennsylvania, StackGard-255SQW was applied to new FGD ducting in 2009; this is an application reference only.

Named Customers and Track Record

Polylloy names three customers, listed in the facts table above. One named-customer project is an Exxon Canada refractory-lined stack, where KilnGard-600SCW was applied beneath refractory on 18 prefabricated sections in 2026; that project is at application stage, with no in-service result yet.

The FlueGard-225 technology, formulated in 2000 with first field applications around 2002, has over 20 years of field performance.

Polylloy Coatings Quality System: ISO 9001:2015 and the FJ&A Verification

The Polylloy Coatings quality system rests on two documents, and each should be read for what it is.

What Each Document Is

The ISO 9001:2015 certificate of registration was issued through HIBO ISO Certifications, approved 14 July 2026 with expiry 13 July 2027. The certificate states that it is a self-assessed document.

Fuller, Jones & Associates (FJ&A) completed an independent third-party design and manufacturing verification, a document review of the ISO 9001:2015 scope dated 9 September 2026. By FJ&A's own statement it is not a product certification, laboratory test certificate or accreditation. How to weigh supplier quality claims in general is covered in how to choose an industrial coating supplier.

What Polylloy Coatings Does Not Publish, and When It is Not a Fit

Polylloy Coatings does not publish prices or universal performance claims, and some duties fall outside what its coatings are for.

Reviews, Prices and Universal Claims

This profile does not draw on testimonials or review ratings. Buyers can judge Polylloy on the documented case studies, the immersion test report and references discussed during a technical review, and project-specific performance detail comes from Polylloy's technical team.

Pricing depends on the operating environment, selected coating system, equipment condition, project size, and application requirements. No stainless steel cost multiple, saving or service-life advantage is published.

When Polylloy is Not the Right Fit

Polylloy is not the right fit for mild service where a conventional coating is adequate, or for sites that cannot blast to SSPC-SP10 near-white with a profile above 3 mils. Heat-cured grades need start-up heat that can be planned, and buyers needing a published price before a site review will not find one.

A coating does not replace refractory or restore lost wall thickness.

How to Engage Polylloy Coatings for a Severe-Service Project

To engage Polylloy Coatings, send the following:

• Equipment type and coated area.
• Operating conditions: normal, minimum and peak temperature, gas chemistry and abrasion.
• Location and outage timing.
• Photos and thickness readings, if available.

Polylloy selects the grade, writes the specification and names the partner for the country; the partner applies under Polylloy supervision. To book a Coating Performance Review, request a coating evaluation.

FAQs

Who Makes FlueGard Coatings?

FlueGard coatings are made by Polylloy Coatings, Inc., a coating technology company in California's San Francisco Bay Area, at the heart of Silicon Valley. The FlueGard family covers three grades for flue gas service: FlueGard-225SQC to 225 °C, FlueGard-425S to 425 °C with peaks to 500 °C, and FlueGard-455CHT to 455 °C (850 °F). Certified Polylloy partners apply them under Polylloy's specification and supervision.

Where is Polylloy Coatings Based?

Polylloy Coatings is based in California's San Francisco Bay Area, at the heart of Silicon Valley, where it develops and manufactures its coatings. Projects are delivered through a network of 15 certified partners covering 22 countries, with Polylloy's technical team writing the specification and supervising the application in every market.

Who Founded Polylloy Coatings?

Polylloy Coatings was co-founded by Edita Rojasova, its Co-founder and Chief Technology Officer, and Surjit Gill. Together they brought surface chemistry, materials science and industrial engineering experience to developing hybrid coatings that protect steel from corrosion, chemical attack, heat and abrasion, including in severe hot flue gas environments.

Does Polylloy Coatings Apply Its Own Coatings?

No: Polylloy Coatings formulates and supplies the coatings, reviews the site data, writes the specification, trains the applicators and supervises the work through inspection and closeout. Certified regional partners carry out surface preparation and application. That keeps application local to the plant while Polylloy stays responsible for grade selection and the specification.

Is Polylloy Coatings ISO 9001 Certified?

Polylloy Coatings holds an ISO 9001:2015 certificate of registration issued through HIBO ISO Certifications, approved in July 2026; the certificate states it is a self-assessed document. Separately, Fuller, Jones & Associates completed an independent third-party design and manufacturing verification in September 2026, a document review that is not a product certification.

Are There Polylloy Coatings Reviews?

This profile does not cite testimonials or review ratings. Buyers can assess Polylloy on documented evidence instead: case studies from cement and power plants, a six-month sulfuric acid immersion report, and named customers CEMEX, Holcim and Exxon. Polylloy's technical team supplies project-specific performance detail during an evaluation.

Which Companies Use Polylloy Coatings?

Polylloy names three customers: CEMEX, Holcim and Exxon. Its named power references include a 12-month FGD field trial at Taipower in Taiwan, a baghouse trial at the Woodland Biomass Power Plant in California (Xcel Energy), and StackGard-255SQW on new FGD ducting at PPL Brunner Island in Pennsylvania, an application reference.