ipcm® n. 57 - May/June 2019 by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

® In this issue :

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

INTERNATIONAL PAINT&COATING MAGAZINE

INDUSTRIAL CLEANING TECHNOLOGIES

ISSN 2280-6083

ipcm digital on

www.myipcm.com 2019

10th Year - Bimonthly N° 57 - MAY/JUNE

A new generation coarse texture powder coating

For more information on Interpon Anodic Powder Coatings, visit www.interpon.it

Power - Quality - Control

Gema Europe Srl Via Goldoni, 29 | 20090 Trezzano s/N | Italy T +39 02 48 400 486 | F +39 02 48 400 874

www.gemapowdercoating.com

‘Thru-Process’ Temperature Profiling in Industrial Ovens

A Look at the Near Future

INNOVATIONS: PRESENT&FUTURE

ANALYSIS

CONTENTS MAY/JUNE

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

86 05 10 18

FOCUS ON TECHNOLOGY he Advantages of Robotics 4.0 for the Flame T Hardening of Maserati Car Bumpers

EDITOR’S LETTER BRAND-NEW HIGHLIGHT OF THE MONTH

IST and Water Energy’s Winning Strategy Presented at the European Coatings Show 2019

21 28

BRAND-NEW SUCCESS STORIES

Blasting with Stainless Steel - High Durability, Lower Wear, More Control

32 40

SUSTAINABILITY FOCUS ON TECHNOLOGY

Future-Proof Powder Coating with the Right Recipe for Sustainability and Growth

49 50 54

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

INNOVATIONS: PRESENT&FUTURE Direct-to-Metal: Straight on Metal, Straight to the Future

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

BRAND-NEW

How to Coat 700 Alloy Wheels per Hour with One Plant: Mapsa’s Solution

FOCUS ON TECHNOLOGY

114

Lecitrailer: International Companies Uniting to Create Europe’s Largest Semi-Trailer Cataphoresis Plant

HIGHLIGHT OF THE MONTH

Inspiration & Innovation: Are You Curious Enough?

FOCUS ON TECHNOLOGY

Pieffeci Torino: The Smart Way for Painting

104 FOCUS ON TECHNOLOGY

BRAND-NEW

FOCUS ON TECHNOLOGY

PSP, One of the Italian Pioneers of Contracting Paint Stripping, Counts on the New FASTRIP Spray Technology to Treat Automotive Components

120 INNOVATIONS: PRESENT FUTURE &

Material Savings Thanks to Correct Corrosion Protection

130 SUCCESS STORIES

C-Line: The Most Flexible Powder Coating Solution for Wheels

INNOVATIVE PRE-TREATMENT SOLUTIONS Pre-treatment is changing. You need solutions that meet the real demands of the industry: efficiency, savings, and most of all, safety. You need solutions that are reliable and adaptable to your operations – not someone else’s. That’s why you need Quaker Chemical. Our new heavy metal free solutions can be tailored to your particular requirements to ensure not only excellent corrosion protection but also reliable adhesion to subsequent paint coatings. Because at the heart of the metal surface treatment industry, you’ll find us.

It’s what’s inside that counts.®

Come and visit us at: GIFA Dusseldorf Stand G59, Hall 11

CONTENTS MAY/JUNE

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

FOCUS ON TECHNOLOGY

140

I nvesting in Technology and Quality: Omar’s Strategy

INNOVATIONS: PRESENT&FUTURE Wörwag and SMP Automotive Count on the Cleancert IBC + Impeller

186 132

ICT - CASE STUDY

198

inked Cleaning and Mass Finishing Solution L for Brake Components: Continuous Processing of Parts that Must be Glued Together

FOCUS ON TECHNOLOGY

A Coating System Tailored to Customer Needs for the Treatment of Urban Hygiene Vehicles

158 STANDARD

124

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

& LEGISLATION

144 INNOVATIONS: PRESENT FUTURE 148 INNOVATIONS: PRESENT FUTURE

178 ICT - TECHNOLOGY OVERVIEW

Clariant Forecasts Colour Formulations Synergizing with New Mobility Trends in Automotive Styling Shades Trendbook &

Pollutant Emission Control in Industrial Coating Processes &

Manual Coating with Extra Power

152 SUSTAINABILITY

olutions for Surface Finishes on Additively S Manufactured Metal Parts

S.M.A.R.T.: UCIF’s Annual Conference

160 TRADE FAIRS CONFERENCES 162 ZOOM ON EVENTS 170 ICT - INDUSTRY NEWS 172 ICT - CASE STUDY

138 HIGHLIGHT OF THE MONTH

ICT - CASE STUDY

A New Cleaning Tunnel for Tramec’s High Added Value Production

Innovative Developments for Ultra-Fine Cleaning and Activation - New Cleaning Solutions for Altered Requirements

182 ICT - CASE STUDY

An Automated and Eco-Friendly Cleaning Cycle for High Quality Oil Hydraulic Components

190 ICT - TECHNOLOGY OVERVIEW

Becoming Greener and Greener: Reusing Instead of Disposing!

194 ICT - TECHNOLOGY OVERVIEW

Deburring and Cleaning PPS Plastic Parts in a Single Process - CO2 Snow Jet Technology for Innovative Lighting Technology Components

204 ICT -ZOOM ON EVENTS

Visionaries have no rivals.

Look into these eyes. Can you see it? Trace the purple paint with your ﬁnger. Can you feel it? It’s the motivation to discover superior solutions for the challenges of tomorrow in our everchanging world. It’s the passion exuding from our global network of employees. It’s the

conﬁdence that we can deliver true value for your coating formulations. Now, look into these eyes. Join us in shaping the world of coatings. www.coating-additives.com

relevant information about the safety and quality of

your products updated and at hand

A NEW FOCUS ON INNOVATION www.adaptacolor.com

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

Alessia Venturi Editor-in-chief Direttore Responsabile

Digital transformation has been accomplished.

e have proof of this every day, when visiting companies for our articles: there is no longer any management that does not choose the Industry 4.0 route. From single coating booths to whole plants, digitisation and automation have found application in all European business models. Industry 4.0 generated 13 billion of investments in one year (2017) In Italy alone1, far beyond the already optimistic forecasts of the Italian government that launched the related investment incentives. The purchase of machinery, hi-tech equipment, robots, artificial intelligence devices, and digital solutions to optimise production has gone hand in hand with the development of clusters of firms that combine their skills to develop applications, software, tutorials, and online training courses offered through special buying platforms, actual digital market places for the manufacturing industry. Once again, the automotive sector has acted as a driving force: long since dominated by robotics in all production phases, it is now turning digital solutions into maintenance assistants, artificial inspectors of coating anomalies, and simulators used to define specific process parameters for each product to be processed. On May 17, during the last Open House of Dürr AG, the world market leader in the production of car coating systems, we have seen the future – above all, the first Automated Guided Vehicles (AVG) for the transport of bodies and materials from one station to another, an innovation stemming from the tendency to design painting plants no longer as a production line but rather as a series of modular workstations. Custom coating application on bodies with no overspray and no need for masks was even more surprising, although it is already going to be outdated by the pro version of this technology, which is currently being tested and will soon offer the possibility of coating logos and lettering in a similar way to digital printing. What you have in your hands is one of the most beautiful and content-rich issues that we have produced in these first ten years of business at EOS Mktg&Communication, the publisher of ipcm®. I would call it a record issue, in terms of both content quality and advertising spaces. There was no better way to celebrate our first attainment than by doing our job (although the actual party is coming soon). We founded our company on the desire to work, on professionalism, on the enthusiasm and the will to offer a completely new product in terms of form, content, multichannel and international distribution, and visibility – not a clone, but something new and fresh able to reflect the world industry’s two main focusses: internationalisation and digitisation. In this issue, including a content-rich special report on coating technologies for the automotive and transport sectors, we tell the innovation stories of several prominent companies from various countries, united by the passion, professionalism, and know-how of those who have contributed to achieving such innovations. We tell about the coating sector. Because communicating is the most beautiful journey. 1 From an article by Luca Orlando, Il Sole 24 Ore, May 14, 2019

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

Opening photo: Coating remains a crucial sector in the production of manufactured goods and it can improve its efficiency also thanks to flexible hanging systems.

ANALYSIS

A Look at the Near Future Adriano Antonelli Tecno Supply - Ibix Srl, Santa Maria in Fabriago (Ravenna) – Italy

adriano.antonelli@tecnosupply.com

e are still in an uncertain

created. An agreement on the terms and

relationship between China and the United

situation, in which many factors

conditions for the UK leaving the EU has

States. The recent summit did not result in

can influence the stability of a

never been reached. The Parliament is

a clear trade agreement and the markets

market that has recovered only recently

divided and the Brussels leaders seem to

fear dramatic backward steps, despite

and, at least in the Euro area, not completely

have lost patience. A “Hard Brexit” could

some signs of easing of tensions. Customs

homogeneously. One of these is Brexit.

heavily influence trade relations between

duties raised by the US administration,

Despite the upcoming deadlines, the

the EU and UK countries. Italy is a net

on the other hand, have not brought

English situation still appears complex and

exporter, an important trading partner

benefits to the American economy, as the

unclear: there seems to be no way out. The

that could be heavily affected by the

balance of trade reduced against forecasts.

impression is that the post-referendum

consequences of the Brexit deal. We could

Tensions and uncertainties inevitably cause

choices have not been strategically managed

say, “Fog in Channel; continent cut off.”

a reduction in trade and a slowdown in

and that a smooth withdrawal plan was not

Other uncertainties concern the confused

economy.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

Italy’s economy is suffering the

ANALYSIS

Within this little reassuring

slowdown of the

context, as the

European and

second European

global one and its

manufacturing

situation is also

power, Italy must

uncertain. The few

find new outlets

improvements of

for its products

the last few years

in order to reach

seem to have

markets that, on

given way to a the current year’s growth is expected to be stagnant

the other hand,

new recession and

are inexorably

Figure 1: The hook-releasing heads must have reduced dimensions to prevent corrosion from starting and spreading over the entire coating.

or even negative.

advancing and Coating remains a crucial sector in

the production of manufactured goods and it must

at a standstill. A slight recovery in domestic

be efficient in order not to burden with additional

consumption and export is keeping the weak

costs products with a significant added value. In this

Italian economy afloat, but it is not enough to

framework, the best hanging systems are flexible

boost growth. Such slowdown, in any case, is

and non-dedicated frames, which avoid occupying

involving the whole of Europe, so much so that

a frame with only one component and enable to

even the German economy is not growing as

distribute their cost among different range products

expected.

(ref. Opening photo). The hook-releasing heads

As for industrial production, in particular

must have reduced dimensions to prevent corrosion

in the automotive sector, which has

from starting and spreading over the entire coating

always driven the manufacturing industry,

(Fig. 1). The frames’ limited weight is another

further signs of precariousness and

important factor for reducing cleaning costs and for

The last crucial aspect is hanging density:

abandonment of diesel

while preventing the

vehicles will damage the Italian

workpieces from

economy, which was a pioneer

shadowing each other,

for this type of engine at the

it is possible to hang

expense of the electric one,

as many components

a technology for which it is

as possible per square

clearly lagging behind the

metre and thus

Asian giants. A plus point are

significantly reduce

the interest rates that remain

costs (Fig. 3). This can

low in the United States and

sometimes require an

negative in the European

off-line pre-hanging

Union. The European Central

operation.

Bank is ready to stimulate

Some products available

the economy, if necessary. However, the problem is that this huge liquidity unfortunately fails to reach the real economy.

Simple Principle

easy handling (Fig. 2).

uncertainty can be found, the perhaps premature

Industrial Wastewater Treatment

developing.

Private and public investments are virtually

especially in Italy. For example,

Your Leaders in Zero Liquid Discharge

in stock and ready for use 2 1

Figure 2: The frames’ limited weight is another important factor for reducing cleaning costs and for easy handling.

from the HangOn range, a brand distributed by Ibix Srl

Effective Result

Leading companies rely on vacuum distillation systems for the sustainable treatment of industrial wastewater. Do you want to benefit from a zero liquid discharge production with VACUDEST aswell?

division Tecno Supply, are functional to this goal.

www.h2o-de.com

3 1

Figure 3: Hanging density is essential to significantly reduce costs.

The HQL bar is produced completely

A more solid version of this bar is the

The frame is economical and flexible,

automatically in order to reduce its cost

HQC type: it houses hooks 1.5 mm in

since it allows skipping levels. The hooks

to that of a disposable item, if desired.

diameter, but only on one side. It is

have a pitch of 50/75/100 mm.

There are two hooks with a diameter

possible to insert the bar coupling into a

Another flexible and economical system

of 1 mm on the bar, so as to make it

central hook with a diameter of 10 mm.

that can be used for small parts and

possible to hang the parts symmetrically

The R 58 bar-holder guarantees stability

profiles is the HQS frame, featuring

(Fig. 4). For example, the HQL 800X33

and the possibility of removing the bar

metal slats for hanging individual parts

bar features 46 hooks within a length of

easily also thanks to the BHG 20 cap.

and profiles (Fig. 5). The hook with a diameter of 4 or 5 mm

the universal system HCF. In this way,

guarantees an overall frame resistance

the system becomes modular and it is possible to insert the bars based on the

800 mm. The bar can be integrated into

up to 100 kg. The HQS frame has been recently launched on the market along

length of the product. The HQL G6 cap

with various types of hooks, thanks to

also guarantees a perfect electrostatic

which each customer can create the

field.

most suitable configuration for their specific use. The shaft length can reach 2400 mm; the sheet thickness is 1.0 mm and its height is 18 mm. It is possible to choose different configurations: sheets on one side only (i.e. sheared), zigzagshaped, or bent from 0 to 180°. In addition to the HangOn standard range, manufactured in an automatic and standardised way, it is possible

to build ad hoc frames, hooks, and systems based on customer needs. 4 1

The construction of piece-carrying

Figure 4: The HQL bar allows inserting a double hook so that the workpieces can be hung symmetrically.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

5 1

Figure 5: Hanging small components.

trolleys also makes it possible to manage industrial surface treatment processes more efficiently.

BRAND-NEW

Condoroil Stainless: Anode Cell Products for E-Coat Paint Systems ÂŠ Condoroil Chemical Srl

ondoroil Stainless offers electrodialysis cells for e-coating. The cells are

made of ion-exchange polymeric

temperature, number of seconds under voltage, maximum voltage, ripple of the rectifier and, more importantly, a value for Volts

membranes, characterised by

multiplied by seconds. For instance,

low deformability, low electrical

the instrument can be used once

resistance and long life.

every shift on products of similar

According to the need of the e-coat

size and shape, making it possible

tank, the cell can be flat, C-shaped

to verify that the parameters, and

semi-open or tubular.

therefore the film thickness, are still the same.

The most used model is the tubular

-P ROCESS DATALOGGER: This

one, which is manufactured in different diameters by welding the

instrument has up to 10 sensors

flat membrane on a mechanical

that check and monitor the electrical

support.

parameters. According to the

The range is completed by a series

position of the piece during the

of optional devices that allow to use

and manage the cells in the best way.

Figure 1: PROCESS MONITOR is among the instruments provided by Condoroil in order to control and monitor the cells.

In addition to the traditional assembly accessories (i.e. splash

coating process and the position of each sensor, it can also show on graphs the film formation process and thus report any possible problem. From the resulting graphs

guards, plug-in electrical connections,Â safe guard, protective nets, regulatory flowmeters, manifolds, etc.), Condoroil offers instruments to control and monitor the cells: - PROCESS MONITOR: This instrument monitors that the parameters have not changed. This is important tank (Figs. 1 and 2). When used regularly, it allows to reduce the number of film thickness measurements required. Its display shows the minimum and maximum

ÂŠ Condoroil Chemical Srl

to form the film in the e-coat

2 1

Figure 2: Process monitor checks that the parameters have not changed in the e-coat tank.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

BRAND-NEW

3 1

Figure 3: This graph shows the coating film formation process detected by the process datalogger instrument.

of each sensor it is possible to monitor

Condoroil Stainless can also supply a complete anolyte

the coating process inside the tank,

recirculation plant and, always linked to e-coat field,

pointing to any weaker or slower

filtration and ultrafiltration plants.

section in the tank, showing electrical problems with one or more anodes

For further information:

and the ripple from the rectifier (Fig. 3).

www.condoroil.com

to be installed together with the new cells, shows the useful life left of the membrane so as to allow the user to set up replacement operations in time (Fig. 4).

- TOTALIZER: This simple instrument,

Another service offered by Condoroil Stainless is the analysis of the membrane of the cell. In particular, Condoroil Stainless can analyse the removed membrane to check the potential presence of contaminants and/or the electric resistance of the polymer – a useful data to know if the replacement has been carried out at the right time.

4 1

Figure 4: Totalizer indicates the useful life left of the membrane.

BRAND-NEW

Economic Shot Blasting of Castings he surface treatment of castings has a decisive influence on the quality of the final products. At the fair GIFA which takes place in Düsseldorf from

25th - 29th June 2019 AGTOS will present a steel mill tumble belt shot blast machine in hall 16, booth A39 (Fig. 1). This type of machine is used for removal of sand and finishing the surfaces of casted mass products (Fig. 2). Special features bring decisive advantages to the operator. The brackets of the steel mill tumble belt are designed to be particularly wear-resistant. The change intervals extend significantly. The ventilation of the blasting chamber has

2 1

been designed in a special manner which ensures that the workpieces leave it dust-free immediately after blasting. In

Figure 2: The blast machine by AGTOS is used for removal of sand and finishing the surfaces of casted mass products.

this way, the cycle time can be short ened. A longer air outlet is avoided after the blasting process. In addition, the system has comparatively small gaps in the blasting chamber. This prevents jamming of the workpieces and ensures their quality. In addition, the plants will be equipped with the strong and easy-to-maintain AGTOS high-performance turbines. Even the reliable filter technology is a popular advantage due to the maintenance-friendly design. The exhibition team likes to show the details at the exhibit.

Process flow The workpieces are fed to the blasting system by means of a feeding device. A steel caterpillar belt forms a hollow and mixes it. After the machine is closed, the blasting process starts. Highperformance turbines installed in the upper part of the blasting room throw the blasting abrasive onto the parts. This way they are removed from the molding sand and blasted. By changing the belt movement in the forward run the workpieces move back from the blasting chamber into grid boxes, or on a discharge belt. After the blasting process, a coating or the dispatch of the workpieces follows.

Figure 1: The steel mill tumble belt shot blast machine by AGTOS will be showed during the next GIFA fair.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

For further information: www.agtos.de

Many surfaces, your goods, our colors

Industrial&Automotive

BRAND-NEW

Growing Filter Portfolio for Explosion-Endangered Areas

rotecting people is one of the core objectives of Freudenberg

Filtration Technologies innovative solutions. This applies equally to particulate

Whether filter mats, pocket or cassette filters, filter cartridges or filter plates, all provide almost the same level of performance as standard Viledon® products. This includes

matter and harmful gases

high dust holding capacity with

in road traffic, in offices and

low pressure drop, long service

production buildings, or even

life and maximum operational

in preventing explosions.

reliability combined with low

The standard in this area

operating costs.

is the ATEX (ATmosphères

One specific example are the

EXplosibles) product directive

ATEX-certified patented edrizzi

of the European Union. Its

paint mist separators. Used in

aim is to protect human

paint booths, they are capable

life in potentially explosive

of the dry separation of up to

environments. Freudenberg

25 kilograms of overspray per

offers a wide range of regularly

filter. In addition to the large

inspected filter models, to

range of regularly inspected

minimize risks and maximize

ATEX air filters, Freudenberg

safety in hazardous areas of

Filtration Technologies also

this kind. This range has been

offers individual advice on ATEX

further expanded recently. The ATEX directive stipulates that all air filters used in potentially explosive

topics.

Figure 1: For maximum safety, every conductive filter element is individually tested for conductivity.

for ambient room air or in production plants – must have

guarantees this performance

precisely defined electrostatic

by means of comprehensive

properties. All Viledon®

individual filter testing.

filters bearing the “Ex” mark,

The certified ATEX product

meet these requirements.

range from Viledon®

Their compliance with the

combines the highest safety

conductivity specifications is

requirements with proven

confirmed by the DEKRA test

filtration performance and

mark, which applies not just

efficiency (Fig. 2).

environments – whether

to the filter medium but to the entire filter (Fig. 1). Freudenberg Filtration Technologies reliably

Figure 2: Viledon® air filters for explosion-endangered areas.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

2 1

For further information: www.freudenberg-filter.com

BRAND-NEW

Updated “Special Effects” by Europolveri

uropolveri developed this new “Special

reference masters, being the final appearance in

Effects” folder to supply an updated

terms of colour, surface finishing and gloss level

instrument to its customers, giving them

depending on different factors, such as curing

the chance to take decisions easily and quickly.

and application conditions, size and the thickness

The collection shows 67 examples of metallic,

of the piece.

bonded, transparent and dotted products

The “Special Effects” folder is divided into two

characterized by a wide variety of gloss level

major categories: polyester powders for outdoor

and structure.

applications and epoxy polyester powders for

Thanks to their impressive uniqueness, these

interior purposes.

products are among the most popular coatings

A detailed legend is also provided to identify all

within Europolveri range, and are available

products specifications.

in stock. Though, they represent only a small part of the variety of articles formulated and

For further information:

produced following customer requests.

www.europolveri.it

comes from the necessity to show not only the different colours, but also the particular type of finishing and /or surface that assure the customer to perceive the mixture of these two effects. Because of this all the samples in the folder are powder -coated aluminium panels. However, it must be specified that the colours in this folder should not be considered as

The collection “Special Effects” shows 67 examples of metallic, bonded, transparent and dotted products characterized by a wide variety of gloss level and structure.

The need for this collection

BRAND-NEW

ÂŠ Gardco

Introducing the New Feedback Data Loggers for Temperature and Relative Humidity Measurement

Figure 1: DL-RHTA (left) and DL-RHTX (ASTM F2170 Compliant - Right) DataLoggers.

he Feedback DataLogger and

The Feedback DataLogger requires the Tramex

Features

App by Gardco have been

Feedback Data Logger App and a compatible iOS or

- Bluetooth BLE enabled for use with mobile

designed and developed for

Android mobile device.

devices

professionals who depend on accurate, ÂŠ Gardco

- Up to 100,000 data point entries

reliable readings using the very best, state of the art technology (Fig. 1).

- Instant set up and start modes - Precise Ambient Relative Humidity and

The Feedback DataLogger and

Temperature logging (In-situ RH logging for

App log up to 100,000 data point

DL-RHTX models only)

entries for relative humidity,

- Intuitive and instructive App interface

temperature, dew point and grains

- Adjustable Interactive chart, spreadsheet,

per pound, transmitted wirelessly

report and easy-export functions

via Bluetooth BLE technology to

- Connectivity up to 165ft (50 meters) for highly

your mobile device.

accessible data downloads

On the App it is possible to visualize

2 1

live readings, thermal conditions and psychrometric charts as well as creating and exporting spreadsheets, charts and reports (Fig. 2).

- Used to perform ASTM F2170 (DL-RHTX only) - Item Nos. TH-851101, TH-851112, TH-851121.

Figure 2: On the App it is possible to visualize live readings, thermal conditions and psychrometric charts as well as creating and exporting spreadsheets, charts and reports.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

For further information: www.gardco.com

Â®

Opening photo: IST and Water Energy’ stand at the European Coatings Show.

HIGHLIGHT OF THE MONTH

IST and Water Energy’s Winning Strategy Presented at the European Coatings Show 2019 From an interview with Massimiliano Mingacci (IST) and Tommaso Ponara (Water Energy)

demineralisation, and IST-Italia Sistemi

technological innovations in terms of plant

reducing CO2 emissions, energy consumption,

and waste produced. Water Energy,

Tecnologici SpA, established in 1987 and

engineering, products, and regulations. These

established in 2006 and operating in the

specialising in the design and production

n the last few decades, the industrial

changes particularly reflect in the need to limit

sectors of industrial and coating process

coating sector has undergone a

the environmental impact of companies by

water treatment, osmosis, filtration, and

profound transformation through several

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

of distillers for solvents and cleaning solutions, have chosen to create a partnership precisely in order to keep up with these changes. We have talked about this with Tommaso Ponara, the owner of Water Energy Srl (San Pietro in Casale, Bologna, Italy), and Massimiliano Mingacci, one of the partners of IST-Italia Sistemi Tecnologici SpA (Modena, Italy), during the international event European Coatings Show, where the two companies had a common stand. ipcm®: How did the collaboration between IST and Water Energy start? “It started a few years ago, when IST realised that a sudden transition from solvent-based coatings to more sustainable, water-based solutions was occurring among both users and manufacturers,” says Massimiliano Mingacci. “IST mainly operates in the graphic arts sector and, for some years now, in the industrial coating one, for which it produces cleaning systems for drums and containers dirty with both solvent and water-based paints. We looked for a flexible and close partner, in terms of both location and vision, which could help us offer a complete technology package to our customers. We found it in Water Energy (Fig. 1), a company specialising in the production of process coating water treatment, sludge treatment, osmosis, and chemical-physical systems. “Thanks to this synergy, IST is now able to offer a complete solution for any need: when a firm needs to eliminate paint residues from drums and containers, as well as treating and purifying the waste water produced by this cleaning operation, we integrate our systems with Water Energy’s technology. Recently, the graphics sector also saw an increase in the use of water-based products at the expense of solvent-based ones: this shows that our solutions will be able to also serve new markets in the future.” “This collaboration with IST proved to be a winning choice for Water Energy, too,” states Tommaso Ponara. “For years, we have offered our plant solutions to specific market niches in the coating sector: now, our target also includes the producers and formulators of paints, inks, and pigments, thus expanding our customer base worldwide.” ipcm®: What technological innovations are you presenting at the ECS? “We have just launched two new plants for cleaning bins and drums containing both water-based and solvent-based coatings (Fig. 2). Whether a company wants to reuse them

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

Coatings Show as a showcase to officialise our collaboration. Having found good success during the 2017 edition, this year we have chosen to participate again with a common stand (ref. Opening photo). This represents our willingness to show once again the solidity of the partnership between IST and Water Energy, two companies that share the scientific and technological know-how to meet any customer need despite maintaining their own identity,” explain Tommaso Ponara and Massimiliano Mingacci. “Participating in the European Coatings Show, the world’s leading trade fair in the field of raw materials for paints and coatings, is an extremely important occasion for us to get in touch with both the producers of raw materials, pigments, and resins and the coating

formulators. Indeed, they both need to clean and dispose of any waste

Figure 1: Water Energy owner Tommaso Ponara (left) and IST Sales Manager Massimiliano Mingacci (right).

produced by their chemical activities,

from drum maintenance and to store other paint products or dispose of

disposal to process water purification and recycling.”

and reclaim them, they must be perfectly clean. Therefore, after cleaning, in the case

ipcm®: Are you pleased with this

of solvents, the treatment is performed

partnership?

with our wide range of distillers. In the case

“Good synergy has been created

of water cleaning, the water is treated and

right from the start to achieve our

purified using a Water Energy system, that

common goals. We have already

provides a turnkey solution, also including

had several positive experiences

the chemicals necessary for treatment,”

together, from the design of simple

says Mingacci.

solutions to the development of

“Water Energy, on the other hand, is

more complex systems,” states

presenting a fully automated water treatment

Mingacci. “Moreover, we have had

system, able to independently adapt to

the opportunity to present our

different types and concentrations of

joint solutions not only in European

pollutants,” states Ponara.

trade fairs, but also in more distant markets such as China, America, and

ipcm®: What prompted you to

2 1

Thailand.”

participate in the European Coatings Show? “Pleased with the results obtained in the last few years, we have chosen the European

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

Figure 2: At the European Coatings Show, IST presented a new fully automated plant for cleaning bins and drums containing water-based and solvent-based paints.

Ponara, on his part, concludes the interview with the proverb “Unity is strength”.

ST Powder Coatings S.p.A. Via E. Segrè, 46 36075 Montecchio Maggiore ITALY Tel.: +39 0444 165400 info@stpowdercoatings.com

ST Powder Coatings España S.L. C/Batalla de Brunete, 11 28946 Fuenlabrada - Madrid ESPAÑA Tel. +34 916 977 292 espana@stpowdercoatings.com

ST Powder Coatings Portugal L.d.a. Rua R.B. Rodrigues, 210 4475-132 Maia - Porto PORTUGAL Tel. +351 220 944 229 portugal@stpowdercoatings.com

Barten S.r.o.

Porfesték Kft.

Ružová 307, Louky 763 02 Zlin CZECH REPUBLIC Tel. +420 573 332 198 barten@barten.cz

Szurdokpart u. 70 3200 Gyöngyös HUNGARY Tel.: +36 37 505 050 hungary@stpowdercoatings.com

www.stpowdercoatings.com Subscribe to our Newsletter

I N T R O D U C I N G

T H E

N E W

THERMO-SE TTING POWDER C OATINGS F OR A RC HI TEC T URA L C OATINGS INDUSTRY

GSB International Non-bonded corona application 32 colors range ideal for panels and aluminium profiles

BRAND-NEW

Successful Trade Fair Presentation of KAP Surface Technologies in Hannover

he company of KAP Surface

surface technology at the booth of KAP

company from unsolved succession

Technologies presented itself

Surface Technologies - such as the SolGel

arrangements and want to continue

from April 1st to 5th 2019 at the

direct passivation process, which KAP ST

to operate successfully in the market.

world’s largest and most important

uses to improve the service life of

The perspectives offered by KAP are

industry fair - the Hannover Messe

e-mobility technologies.

convincing - in 2017/2018, five owners

(Germany), which once again attracted

KAP is a fast-growing medium-sized

entrusted their company with KAP and

more than 200,000 visitors with around

industrial group with currently around

even became shareholders of KAP

6,000 exhibitors this year.

EUR 420 million in sales and around 3,000

themselves.

For the second time, the newly

employees worldwide at 29 locations.

The Hannover Messe can definitely

created industrial group is under one

As a medium-sized industrial group,

be considered a complete success.

roof with its three strong brands -

KAP focuses exclusively on medium-sized

In a relaxed atmosphere a variety

Galvanotechnische Oberflächen GmbH,

companies and is a reliable partner for

of interesting discussions with

Metallveredlung Döbeln GmbH and

entrepreneurs. Long-term thinking is

current existing customers, as well

Heiche Oberflächentechnik.

combined with modern management

as with potential new customers was

The company builds on the many years

approaches and excellent access to

conducted.

of experience of the management team:

finance and global markets. This makes

Nicolai A. J. Baum, Dr. Ing. Hartmut Sauer

KAP interesting for owners and families

For further information:

and Daniel Klein.

who want to save their medium-sized

www.kap.de

KAP Surface Technologies is committed its 10 locations in Germany, Poland, Hungary and the USA, is optimally positioned for the future. State-of-the-art plant technology and excellently trained

to a long-term growth strategy and, with

employees ensure continuous price and quality leadership in electroplating. With coatings such as zinc, zinc-nickel, copper-nickel-chromium, e-coat and powder coating, as well as anodising and passivating, almost all relevant coatings in the field of corrosion protection are covered. Many business partners and many interested parties gathered information on the latest technologies in the area of

The KAP Surface Technologies’s booth at Hannover Messe in Hanover, Germany.

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

BRAND-NEW

Shown for the First Time at GIFA: Compact Continuous Feed Shot Blast Machine for Small, Delicate Castings

t the GIFA 2019 exhibition

With this new machine concept Walther

in a spiral motion. This ensures that all work

Walther Trowal introduces

Trowal meets the demands of customers in

piece surface areas are equally exposed to the

the compact troughed belt

the foundry industry, who want to integrate

blast media stream.

continuous shot blast system

their blast cleaning operations seamlessly

Meik Seidler, Sales Manager at

THM 300/1 to the public. This

into already existing manufacturing lines.

Walther Trowal, recognizes a significant

machine was especially developed

The troughed belt work piece transport

trend towards continuous shot blasting:

for processing high volumes of small,

system Walther Trowal is utilizing for its

“The THM continuous feed machines with

delicate work pieces. The new design

continuous shot blast machines is gently

their unique troughed belt work piece

combines the small footprint of

moving the work pieces through the machine

transport system are more and more

batch machines with the advantages

displacing the conventional batch

of continuous feed operation and,

Figure 1: The compact troughed belt continuous shot blast system THM 300/1 combines the small footprint of batch machines with the advantages of continuous feed operation.

thus, helps streamline and speed up the blast cleaning processes for small castings (Fig. 1). Walther Trowal developed the THM 300/1 specifically for small, delicate or thin-walled cast work pieces like, for example, aluminium or zinc die-castings with diagonal

tumble belt machines. Our customers integrate the THM systems into linked manufacturing processes allowing them to significantly simplify the work piece handling. The work pieces are continuously fed into the machine at preset cycle times determined by the actual production volume. Intermediate transport operations from one process stage

mm (about 0.8 to 6.0”). Work pieces

to the next, as well as intermediate

can range from components for toys

storage, are completely eliminated.”

(model cars and trains), furniture

For the new blast system Walther

parts, components for the computer

Trowal is using the newly developed

industry and even small automotive

WTY turbines with curved throwing

parts.

blades. Compared to conventional

For the first time a shot blast

blast turbines they generate a

machine for processing small work

substantially higher throwing speed.

pieces is available with the footprint

This increases the impact energy of the

of a batch tumble belt machine that

blast media on the work pieces, which

permits, however, continuous feed

in turn helps reduce the processing

operation (Fig. 2). Compared to the

times.

smallest THM machines supplied

A communication processor

to date by Walther Trowal, the

allows integrating the shot blasting

dimensions of between 20 and 150

THM 300/1 design is considerably more compact: It requires an area of 1

existing production lines.

controls. Explosion protected dust collectors ensure safe operation

only 1,4 × 2,7 m (5 x 9 feet) and can, therefore, be easily integrated into

operation into higher-level process

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

in line with prevailing explosion prevention standards.

BRAND-NEW Troughed belt continuous shot blast machines guarantee gentle work piece transport The THM troughed belt continuous shot blast © Walther Trowal

machines from Walther Trowal are equally usable for mass produced bulk parts as well as for delicate individual components with complex shapes. Because of their simplified work piece handling and superior shot blast results they are more and more displacing conventional batch tumble belt machines. The THM continuous shot blast machines are

3 1

especially advantageous for processing delicate work pieces: The parts in the trough are not colliding with each other from relatively high dropping heights but are passing through the

machine with a gentle rolling movement (Fig. 3).

Figure 3: The troughed belt principle: The work pieces are gently rolling over the transport rods equipped with a polyurethane lining. They do not collide but are passing through the machine by gently touching each other.

The transport rods are covered with a polyurethane lining, which further protects the work pieces from getting damaged or nicked. Since there is a technological trend towards more delicate components, which must be blast cleaned, the gentle work piece transport through the shot blast machine is especially important. The Walther Trowal troughed belt transport system makes sure that the work pieces are passing through the machine without getting damaged. For somewhat larger work pieces with complex shape the troughed belt machine concept also produces better blast cleaning results than spinner hanger shot blast machines: While passing through the trough the work pieces are continuously rotating. This ensures that the blast media is reaching all work piece surface areas, and always from the same distance. The result: All-around highly homogeneous 2 1

Figure 2: The troughed belt blast machine THM 300/1 is ideal for continuous feed blast cleaning of small work pieces. To demonstrate the work piece variety this machine can handle, for the photo different components were placed on the troughed belt.

shot blasting results. Walther Trowal will be present at GIFA 2019 in Düsseldorf, Germany (June 25 – 29, 2019) on Hall 15, booth D 15. For further information: www.walther-trowal.de

Opening photo: All Phoenix TM thermocouples are manufactured to the highest quality standards and conform to the ANSI MC96.1 special limits specification.

INNOVATIONS: PRESENT&FUTURE

‘Thru-Process’ Temperature Profiling in Industrial Ovens Carola Konitzer PhoenixTM GmbH - Bad Oeynhausen, Germany

carola.konitzer@phoenixtm.de

ccurate oven temperature profiles are essential to guarantee

What is temperature recording?

high-quality coated products and their reproducible production.

All industrial ovens are equipped with sensors that report the

With the PhoenixTM ‘thru-process’ measuring systems of the

recorded environmental temperatures back to the oven controller.

TS04 series, the product temperature profile data in coating processes

Often several of these sensors are present, at least one in each

can be easily and effectively monitored (Fig. 1). The system consists of

oven zone. But how can you tell what really happens on and in

a data logger, a heat protection barrier and the ThermalView Finishing

the product? One possibility is to pass long trailing thermocouples

Software. The following describes the operation and structure of the

through the oven. This is not only cumbersome and time consuming,

system.

but also has the consequence that the oven can’t be fully loaded,

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

Figure 1: With the PhoenixTM ‘thru-process’ measuring systems of the TS04 series, the product temperature profile data in coating processes can be easily and effectively monitored.

and so the production is disturbed. On top

The TS04 finishing system has been

thermocouples at all relevant points (the

of that, the partially loaded oven behaves

developed as a complete solution

different options are discussed in more

differently than under production conditions,

for monitoring product temperature

detail below). The profile data obtained

and the long thermocouples are prone to

profiles, especially in coating processes.

is stored inside the data logger. This is

electrical and magnetic influences. This

The flexible system is easy to use and

protected by the thermal barrier from the

makes the evaluation and assessment of

records the temperature data of the

temperatures prevailing in the oven. After

the collected data even more difficult. In

product during the oven run. The system

the end of the process, the data logger is

turn, IR temperature sensors only display

is located directly at the product, e.g. in

removed and read out. The ThermalView

surface temperatures at specific points, need

the automotive industry, a car body can

Finishing Software converts the raw data

line of sight of the product, and cannot give

be prepared so that it can be introduced

into meaningful process data.

any indication of what happens inside the

at any time in the painting line. In

This information can be used to make

product.

preparation, the body is equipped with

quick and informed decisions about how

End-to-end solutions – from body shop to coating and final assembly. www.eisenmann.com

2 1

Figure 2: The new model PTM1-200-LT data logger with a maximum operating temperature of 80 °C is available in either 6, 10, or 20-channel versions.

to solve thermal cure problems. The

Software

compared and analyzed with archive

measurement results are available

The ThermalView-Finishing Software

profiles. A full report can be created

as a complete temperature profile

was developed especially for the coating

either in print or PDF format for easy

at a glance. This can be used, for

industry and is an easy-to-use complete

communication of profile results.

example, for process or product

package. The entire oven process is

These are just a few of the many

optimization, customer audits,

illustrated by detailed graphical data. For

features that can be used to analyze

reduction of operating costs, saving

example, the burner and fan positions

the process in detail.

of resources and much more. In

can be entered so that problem areas

addition, with the optional 2-way

can be quickly identified. The cure

Datalogger

wireless telemetry communication

window can be stored and, as the exact

The new model PTM1-200-LT data

upgrade, there is the ability to

temperature data is displayed as a

logger with a maximum operating

receive the collected data in real

curve for all mounted thermocouples, it

temperature of 80 °C is available in

time. This eliminates the waiting

can be recognized at a glance whether

either 6, 10, or 20-channel versions

time and the oven manager can

all measuring points are within the

(Fig. 2). They work in a temperature

intervene directly in the ongoing

specifications. Also profile comparisons

range from -100 °C to + 500 °C.

process and effects are analyzed

are possible. Changes to the oven

The accuracy is +/- 0.3 °C, and

immediately.

settings, or at the product can be

resolution of 0.1 °C. The datalogger

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

memory size is 3.8 million data points. In addition to the optional radio telemetry, there is also the option of data transmission via Bluetooth. This means that the test set-up can now be started and checked easily by a smartphone or tablet directly at the oven, during production. The calibration certificate and the calibration data are stored in the logger and can be transferred to the ThermalView software by just a click of a button. You have all the necessary information at a glance for quality audits at any time. A proof of specification is directly visible and comprehensible.

Thermal Barrier The TS04 thermal barriers with heat sink are made of high heat-resistant stainless steel, robust closures and 100% silicone-free insulation material. The microporous insulation and the built-in phase change heat sink provide enormous heat protection in a compact size. Designed for typical cure temperatures of

SIMPLIFY COATING.

Your information and management platform for simplified coating 4.0.

140 °C - 220° C and cure times of approx. 30 minutes, the thermal barrier TS04-60 measures 60 mm in height, 180 mm in width and 420 mm in length. The barrier provides thermal protection at 200 °C of 0.8 hours.

Thermocouples For temperatures up to 300 °C, probes are available for various mounting methods. This makes sensors with magnets ideal for ferrous workpieces. For other materials, sensors are available with clamps or with open tip, for gluing on (ref. Opening photo). All sensor cables are equipped with double PTFE insulation and additional steel mesh, and are available in various cable lengths. For special applications, other mounting options or materials, such as high temperature glass fiber cable insulation, can be used.

Conclusion Temperature logging in industrial ovens has been applied for many years. The benefit of such procedure is process control and resulting product coating quality. In addition improved oven efficiency and optimized operating costs are possible. All this is directly related to the correct setting of the ovens. The aim of every oven measurement is to bring the energy and the quality of the products into balance so that both are optimized. This is precisely what the PhoenixTM ‘thru-process’ temperature monitoring systems provide.

wagner-group.com

SUCCESS STORIES

Blasting with Stainless Steel - High Durability, Lower Wear, More Control

hat if your company can’t find

powder coating support,” remembers Jo

Coatings is an exception among them

a supplier that can meet your

Tilkin. “From our own experience, we knew

because they specialized in coating pieces

powder coating needs? The

exactly what metal processing companies

of large dimensions (Fig. 2). “Last summer

Tilkin family provided a solution in 1998 by

needed but we had to first familiarize

we purchased a new curing oven which is

jumping into the unknown world of powder

ourselves with the powder coating process.

able to handle work pieces up to 18 x 3.6

coating specialization. Today, after 20 years

At the beginning what we lacked in

x 3.6 m (60 x 12 x 12 ft). It is the largest in

of consistent growth, this Belgian company

knowledge, we made up for with courage

the Benelux countries. If a structure won’t © Ekkow Photography

services the Benelux countries with the largest curing oven. Purchasing the oven was the result

fit in our oven, then it won’t fit on the transport vehicle. Our customers are

of implementing a

now able to fabricate

philosophy of being

their structures in

able to measure each

one step and have

process step in a detailed

them completely

manner, in order to be

powder coated,

able to achieve constant

which is an enormous

improvement.

advantage. The new

This philosophy is

oven has opened up

what led Tilkin Powder

other opportunities

Coatings to switch to

in new markets,

VULKAN INOX’s stainless

including neighbouring

steel grit blast media,

countries.”

GRITTAL® (Fig. 1). With this decision, the desired surface quality is consistently achieved, dust disposal is

Figure 1: Tilkin Powder Coatings has selected VULKAN INOX’s stainless steel grit blast media, GRITTAL® in order to improve its blasting process.

significantly reduced and cost efficiency is increased.

With Courage and Passion Powder coating specialist Tilkin began

Quality Through Process Monitoring An additional strength of Tilkin Powder

and passion. Our name stands for quality,

Coatings can be found in their complete

and this is something we work hard for

process monitoring and traceability of all

every day.”

production steps. “Industry 4.0 has been in use here for 10 years,” comments Jo Tilkin.

construction and currently has 30

Largest Curing Oven in the Benelux Countries

employees. Michel Tilkin and his children,

In the early years, the biggest challenge

only possible to retrace production quality

Jo and Rosy, have experienced continuous

was to convince customers about the

if you are able to measure everything and

development since their beginning. “In the

advantages of powder coating. Today, the

therefore guarantee quality for yourself and

1990s, there were very few companies in

process is established and the demand

for the customer. This is very important to

the Tongeren region of Belgium that were

for it has grown tremendously, so has the

us, since the quality of powder coating is

able to provide blasting, metalizing and

number of powder coaters. Tilkin Powder

often displayed years after being applied.”

its business activity in metal building

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

“Our own ERP System has time and again driven us to achieve greater perfection. It is

With this approach, Tilkin Powder Coatings became the first European company to receive the EN 1090-1 certificate. “At the

SUCCESS STORIES

end of the production cycle I know exactly what happened and can take action. More than 10 years of calculations and development stand behind our process, from which our customers benefit. Today, they can receive quotes and submit orders online in just a few steps.”

30 Times Less Blast Media Use In the course of surface preparation, the blasting results would be checked continuously. As a result, the aluminium oxide blast media in use was determined to be a weak point. Jo Tilkin points out that, “Blasting prior to coating is a decisive step

2 1

in our surface preparation. The correct RA values and the cleanliness of the surface guarantee bonding of the ensuing powder

Figure 2: Tilkin Powder Coatings specializes in the powder coating of large dimensions pieces.

coating, metalizing or galvanizing (Fig. 3). However, we continuously experienced fluctuations in the blasting results although according to our monitoring, all process parameters, such as blast pressure, distance and angle to the object, were constant.” The cause of the fluctuations was the very quickly during blasting and thereby rapidly lost its grain size. These changes to the blast media were consequently transferred to the blasted surface, resulting in the required roughness no longer being achieved. Even within one production charge of blast media deviations can occur. Jo Tilkin adds, “That is not acceptable if one demands top quality. In addition, the aluminium oxide usage was very high and there were always delivery issues.” In the search for a blast media change, Jo Tilkin came in contact with Bert Gysen from Magistor, the representative of VULKAN INOX blast media in Belgium. Bert introduced Jo to GRITTAL®, an angular and very hard stainless-steel grit blast media, manufactured from high quality raw materials and alloys. Bert saw GRITTAL® as being the solution to Jo’s requirements. That is because GRITTAL® is extremely durable and the breakdown of the individual grains, compared to mineral grit blast media, takes place very slowly.

Competence in Shot Blast Technology We offer new and second-hand wheel blast machines including conveyor and filter systems. Our range of products and services include: • Wear and Spare Parts • Repair and (remote) maintenance • Services … for wheel blast machines of other makes as well.

, us at GIFA Please seerf, June 25-29, Düsseldo nd A39 hall 16, sta

AGTOS

Gesellschaft für technische Oberflächensysteme mbH Gutenbergstraße 14 D-48282 Emsdetten Tel. +49(0)2572 96026-0 info@agtos.de

www.agtos.com

195-01/19-4c-GB

brittle-hard aluminium oxide blast media that fractured

SUCCESS STORIES

very stable and the blasting result,

Quality Differences are a Thing of the Past

in regards to roughness and surface

The initial results have been

area output, are safely reached.

extremely positive for Jo Tilkin, who

As a result, the work mix remains

In addition, GRITTAL ’s 30 times

says, “Quality differences are now

greater durability reduces the dust

completely in the past because

development when blasting and the

GRITTAL® doesn’t break down

residual dust on the blasted surface.

very fast. GRITTAL®’s absolute

Visibility and blasting conditions

homogeneous and stable work mix

for the blast room operator are

allows us to control the process

vastly improved and the blast media

better and at the same time use

waste shrinks to approx. 3% of the

less blast media. In addition, we are

previous amount. These were good

able to reduce the blast pressure,

arguments for the owner, who

which reduces compressed air costs.

was listening intently. The switch

We also have less dust, and dust

to GRITTAL® began last August in a

is the last thing we want to have in

new blast room, which has the same

the powder coating booth! It is also

dimensions as the curing oven.

something we want to prevent in the

blasting process as it blast system. Now our blast room operator has much better visibility while

accelerates wear on the

blasting the work pieces, and less post-blast dust to blow off (Fig. 4). A

4 1

Figure 4: The blast room operator has much better visibility while blasting the work pieces, and less post-blast dust to blow off.

company may have the best machines, however,

our production process as good and

it is the employees that

as efficiently as possible, without

work on the product that

contamination and with perfect

make the difference.

controls. The great thing about our

Because of that, it is very

relationship with VULKAN is that they

important that we can

supported us during the optimization

make their work more

process, are always available for

pleasant by using a new

consultation and cooperate with us to

blast media.”

carry out the necessary adjustments

Execute Each Step as Efficiently as Possible

3 1

Figure 3: The correct RA values and the cleanliness of the surface guarantee bonding of the ensuing powder coating, metalizing or galvanizing.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

in order to reach our goal. The initial investment cost is high, but our cost per square meter will drop significantly.

In order to have concrete

I am already convinced of that, as

numbers regarding cost

well as of the better quality. You can

improvements, Jo Tilkin

compare this to switching from a

will wait for one year.

bicycle to a Formula 1 race car!”.

Jo declares, “It is important for us to

For further information:

execute each step in

www.tilkin.be and www.vulkan-inox.de

SUSTAINABILITY

Hel en

HMG er, ld

, DSM ets M

lenius, Tekn Ca o ik

Fred er

John Fa

Five on Five Interview: Sustainability According to the Industry Players - Part III

a, Tikkurila kul ar

elcome to the third and final part of our first Five on Five interview. Earlier this year, we asked 15 questions to five senior figures of five leading companies from within the surface treatment industry. We split the answers into three sets of five and with each article we delved deeper into how the industry is embracing Sustainability and facing its challenges, what it represents business-wise and how companies are measuring up to competitors. In case you missed the first two articles you can read them online at www.myipcm.com: - Part I can be found by selecting issue n. 55 of ipcm® (January/February 2019) and scrolling onto page 38; - Part II can be found by selecting issue n. 56 of ipcm® (March/April 2019) and scrolling onto page 28.

Joel Sv

Elis aM

5 ON 5

Our aim was to give our readers some unique, thought-provoking and hopefully inspiring content to go hand-in-hand with our newly launched sustainable section. The Five on Five format allows for a broad overview of the actual picture of sustainability within the industry, which thankfully shows that each and every player has this as a genuine priority throughout their organisations. Lastly, we would like to thank once again all the below who took time out of their busy schedules to work with ipcm® on this series: the time spent answering our questions alone shows how serious these companies are about sustainability.

Joel Svendsen - Belzona President Helen Mets - President of DSM Resins & Functional Materials John Falder - HMG Paints Managing Director Fredrik Calenius - TEKNOS Chief Procurement Officer Elisa Markula - Tikkurila CEO & Minna Avellan - Director, Communications and Investor Relations of Tikkurila

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

n, Belzona dse en

SUSTAINABILITY doing this is by developing and marketing products under our Brighter Living Solutions brand – so-called because they are demonstrably better than mainstream solutions in terms of their environmental (e.g. CO2 emissions, resource extraction, waste) and/or social impact (e.g. working conditions and health and safety). Brighter Living Solutions currently account for 62% of DSM’s product portfolio. DSM is striving to be a leader in product stewardship. Our focus is to consume fewer resources overall; replace scarce, toxic or polluting raw materials; extend product lifetimes and enable retrieval and recovery of organic waste streams – all while growing and improving our innovative product portfolio and business performance. Specifically, DSM has identified three key platforms where we can drive sustainable growth: climate change and energy, resources and the circular economy, and nutrition and health.

Can you describe your 11 sustainability program? Joel Svendsen, Belzona – We started working on steel, but of course steel isn’t the only material that suffers from degradation. Over the years we have gone after various different materials, so we can extend their lifespan. In trying to do this, we’ve also strived to not include nasty chemicals or have a high level of toxicity. So, Belzona has tried really hard in using materials that are as environmentally safe as possible. And safe for people as well. These things tend to go hand-in-hand. If you can, use ingredients that have low toxicity or low volatility. Helen Mets, DSM – Our sustainability strategy revolves around people, the planet and profit - and they not only apply to how we view the external world – so the products we develop and the relationships we form across the value chain - but also to how DSM conducts its own operations. We believe that combating climate change is a responsibility and a business opportunity, so we are very active in improving our own carbon footprint and advocating for climate action. We plan to realize 30% of our own carbon footprint reductions. One way the company is

John Falder, HMG – The HMG sustainability program is a way of being at HMG. From your first day you can see how we try to act. HMG Paints is committed to making continuous improvement in the management of its environmental, economic and social impact. We work with our partners to promote environmental care, increase understanding of environmental issues and disseminate good practice.

Fredrik Calenius, TEKNOS – We have defined four focus areas in our CSR program: sustainable solutions & services, responsible operations & supply chain, people development, and future generations. –– Sustainable solutions & services: We invest in and develop solutions and services which are better whether it is for environmental, quality, health, safety or human aspects. This goes beyond just environmental-friendly products; it can be e.g. a service educating our clients. –– Responsible operations and supply chain: We work as a responsible company within our entire value chain, from procurement of raw materials to the manufacturing and delivery of the products to our customers on time, safely and with the respect for the environment. –– People development: We strive to foster a culture based on our company values Creativeness, Persistence and Fairness. People are our biggest asset. We are committed to develop our employees’ competences and skills, attracting the best talents, and creating an environment in which ideas and initiatives flourish. –– Future generations: Continuity describes and affects all our actions. We want to make choices, which bear to all the generations to come. We want to build a company, which the next generation will be proud to lead and be part of in the future.

5 ON 5

A N ZI

3 NI

ROBUSTO-AFFIDABILE FACILE DA USARE

G AR

La MIGLIORE tecnologia per il TUO rivestimento AN

NESSUNA CALIBRAZIONE

Made in Germany

a division of

Via La Viola, 2 - 48022 S. Maria in Fabriago (RA) Tel. +39 0545 994589 - Fax +39 0545 994567 www.tecnosupply.com - info@tecnosupply.com

Ganci - Attrezzatura - Mascheratura - Spessimetri - Pulisci Catena

SUSTAINABILITY Romolo Tavani © Adobe

5 ON 5

Minna Avellan, Tikkurila – Our sustainability program is called “A Colorful Tomorrow”. It provides Tikkurila with a framework for responsible and sustainable business development, and takes environmental, financial and social aspects into account. In 2017, in line with our strategy, we defined, together with key business personnel, sustainability customer promises. These promises guide our sustainability initiatives and support the business development from the sustainability point-of-view: –– We drive our portfolio towards maximized performance with minimum environmental impact –– We improve and protect air quality with our products and professional services –– We drive at better resource efficiency with quality, safety and durability on top of our minds

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

–– We are a responsible and active partner in our communities –– Based on these promises, we are in the process of defining new sustainability targets and agenda.

s there a project that didn’t 12 Iwork out? Joel Svendsen, Belzona – Quite a long time ago, perhaps the 1990s, we put a lot of effort into water-based systems. It was one way of reducing the cost, without incorporating any hazardous solvents into the product. We were able to make these systems work, but we were unable to achieve the same level of performance as the two-coat systems that we already had. So, in the end, the performance

dictated our path. It was the right thing for customers. It was better to have a more expensive solution that lasted longer. From a sustainability standpoint, even if it’s a more expensive solution, if it allows you extend the lifespan and performance of that structure or equipment, it’s worth it. Helen Mets, DSM – Rather than a project per se that didn’t work out, in terms of obstacles, DSM finds itself in a challenging position where it needs to pull the market along. The value of sustainability and sustainable products is not fully understood. Sustainability itself is not the only benefit. Product performance, appropriate price point and even materials that are easier to work with, are high priorities for both industrial customers and consumers alike.

SUSTAINABILITY John Falder, HMG – One of the key areas that we struggled with is plastic. Plastic waste is difficult to deal with, so HMG favours metal packaging wherever possible which can be recycled. As we know there is a worldwide push on plastic usage currently and HMG is fully supportive of this. Fredrik Calenius, TEKNOS – We are still in the very early stages of implementing our sustainability policies so it’s a little bit early to answer this, however so far everything is going smoothly.

UHS platform technologies VOC-compliant coating

Minna Avellan, Tikkurila – Of course, there has been demanding projects during the years – in product development, finding new raw materials, in the development of production processes etc. We have strict quality requirements and if those are not met, we might discontinue a project.

o employees actively participate in these 13 Dprograms or activities? Joel Svendsen, Belzona – I do think it’s important to get our staff involved in these programs and activities as well. I will say, it is much easier these days. In decades past, there was a certain negativity towards environmental initiatives. For example, I remember a lot of people saying “If it’s not a nasty chemical, it’s not going to work well. Give me the really nasty, dangerous stuff - that’s the good stuff!” Crazy to think that people would have had this approach to sustainability. So, certainly it’s good to see people move away from this standpoint. Helen Mets, DSM – Sustainability is part of our DNA and we have a shared mission and regard ourselves as a “purpose to life” company, so our employees are actively engaged in all aspects of our sustainability activities – from energy saving initiatives to research & development. Our extensive scientific community – or who we refer to as our Bright Science team - are dedicated to creating innovative, sustainable solutions in the fields of nutrition and health, climate and energy, and resources and the circular economy. John Falder, HMG – Yes, employees from all levels of the business actively engage in programs and activities. Especially those activities which have an impact on our

UHS-Systems The conversion from solvent-based to water-borne coating systems is often linked with high investment costs. The new ultra-high-solid platform technologies from FreiLacke can significantly reduce solvent consumption, even without system conversions. FreiLacke is now using its new ultra-high-solid systems (or UHS for short) which entirely meet the demands for a reduction in the VOC content in paints and coatings. With a solids content of up to 80 percent by weight, they have a VOC value of less than 350 g/l. www.freilacke.com

SUSTAINABILITY

5 ON 5

local community and those that have an impact on the day-to-day running of HMG. This has been reflected in the two BCF Coatings Care Awards that HMG has won. Fundamentally, it’s also key that employees are sustainable away from HMG, being good neighbours and providing a positive impact on society. Fredrik Calenius, TEKNOS – During 2018 and late 2017 Teknos conducted internal stakeholder interviews and workshops to define key priority areas and materiality for its sustainability work. The process started with an initial stakeholder interview, which was held in autumn 2017 by a third-party organization and was followed up by the establishment of a CSR team and ongoing workshops and interviews with key stakeholders inside the organization. Stockr @ shut terstock

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

The CSR team represents different functions and units of Teknos including R&D, QEHS, Procurement, Sales, Marketing, Product safety and HR to ensure that the voices of internal and external stakeholders are taken into account. In spring 2018, Teknos involved over 130 people in face-to-face workshops from different business functions and countries across the organization to define the most crucial topics, opportunities and risks in terms of sustainability. The future will show, but we surely hope and anticipate that our employees will continue to participate actively. Minna Avellan, Tikkurila – Depending on the country, employees can participate in various sustainability-related campaigns and projects, for instance community involvement projects and safety campaigns. Moreover, we

have been inviting people to contribute in the development of the company’s sustainability agenda. This is an important topic and we will definitely put more efforts to engaging employees.

hat is the role of third-party 14 Wcertifications in sustainability

within the paints and coatings industry?

Joel Svendsen, Belzona – Their biggest role is in the realm of energy efficiency. Most importantly, they’re helpful because there is a temptation to make poor decisions when they aren’t in place. They ensure people look at the long-term goals and aims, rather than short-term, easy-to-achieve “success”.

SUSTAINABILITY Helen Mets, DSM – Third-party certifications play a very important role for their ability to instil confidence and trust in consumers. They raise the bar in consumer choice – so much so, that they function like a demand driver, particularly for more sustainable, safer and high performing products. John Falder, HMG – The BCF Coatings Care program has been important. Even though Coatings Care is a voluntary programme, it’s a great basis for good management practices. It offers HMG and other participating companies the opportunity to pursue a common, effective management approach for their health, safety and environmental programmes and advises best practices on how to achieve high standards by self-assessment and by measurement of improved performance.

Fredrik Calenius, TEKNOS – Sometimes it can be hard for customers to understand or even believe a company’s sustainability claims. Third-party certifications are a good way to demonstrate to different stakeholder that the company lives up to its sustainability claims and also to help customers to choose the most sustainable option, i.e. to increase trust in the company and to help customers make the right choices. In my opinion, the coating industry makes no exception in this. As the interest and knowledge from the customer’s side for these certifications grows, they can also prove to be a competitive advantage, and help the whole industry to develop towards a more sustainable direction. Thus, I believe that certifications have a big and increasing role for both customers and coating companies.

Minna Avellan, Tikkurila – The third-party verifications reflect proven and standardized quality, durability and safety of our operations and products. Because we want to continuously improve our performance and promote the sustainability aspects of our operations, different kind of third-party certifications are a trustworthy proof that we are progressing and meeting the international standards. The majority of Tikkurila’s sites are certified according to the ISO 9001 quality management system standard, the ISO 14001 environmental management system standard, or the OHSAS 18001 health and safety management system standard. The certificates confirm the compliance of our management, processes and practices with the international quality, environmental, occupational health and safety standards,

VULKAN INOX GmbH S t ain les s S t eel Ab r as i ve s

Less consumption and waste No dust and rust Significant cost saving

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5 ON 5

SUSTAINABILITY

5 ON 5

and ensure that those are developed systematically. Within our portfolio, we have more than 300 eco-labelled products. The ecolabels include the Nordic Swan Ecolabel, EU Ecolabel, M1 classification measuring low emissions and allergy label.

ow do you see the future of 15 Hsustainability? Joel Svendsen, Belzona – I think something we have to accept about the near-future of sustainability is that for some areas, there are no alternatives to petroleum products. For operating airplanes and ships, vessels that need to carry a great deal of energy, we’ll see petroleum for a long time. However, as battery technology improves, we’re going to see more and more things moving away from petroleum power. Cars are leading this shift. I think we’re going to be increasingly shifting to electric cars, which means our power plants must be bigger. Previously, it was thought the size of power plants, or our electrical distribution networks didn’t need to increase. People thought that we could continue to improve energy efficiency in lieu of our energy infrastructure. But it’s much more efficient to produce power in a plant, rather than in an electric car. And of course, by using electric power you open a whole load of other energy sources such as wind power, geothermal etc. – areas, which we are already working in and providing repair and protection solutions. We predict that there will be more work for us in electrical

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

distribution, battery manufacturing and mining materials for the batteries. Helen Mets, DSM – Becoming more circular and reducing carbon footprint are the most pressing challenges for industry to solve. We have to think big and bold and develop a future where every product has a value proposition which supports its sustainability credentials traceably through the supply chain, as well as performance - and at an affordable cost. DSM believes there will be opportunities created by dynamic shifts driven by positive changes in consumer behaviour and rapidly emerging

technologies. We will become even more focused, extending our innovative spirit into new industries and applications, challenging boundaries and exceeding expectations about what sustainability can deliver. We will also continue to lead the charge through advocacy to truly shape a sustainable future. John Falder, HMG – The next steps for HMG are keeping sustainability on our agenda with continuous improvement

across the business and extending this to our upstream and downstream partners. Sustainability has played an important role in the previous 88 years of HMG Paints and we believe it will play an equally important role in the next 88 years. Fredrik Calenius, TEKNOS – Sustainability will be more and more important in a company’s success. In the future we believe that the focus will be on developing new business models and solving the social and environmental problems. This is the way we will build our business. Elisa Markula, Tikkurila – Our purpose is to offer “surfaces that make a difference” and that includes sustainability as a part of our DNA. Especially Millennials want to work in companies that have a purpose and when we embed sustainability as part of our core, we believe that we will not only attract new talents but also engage our current employees to serve our purpose. We will continue the work in all operations and © Belzona functions in our company as everybody has a clear role to execute sustainable actions in their work, and we want to make that work more visible through clear measurements and KPI’s. We will require more sustainable actions also from our suppliers to keep developing truly sustainable products and services and increase our communication towards stakeholders, especially for our customers. We want to be seen as the most responsible and sustainable employer and player in our market areas.

ÂŠ Nordson Deutschland GmbH

Opening photo: Over the long term, the considerably enhanced coating quality will be accompanied by major material savings. For the H.P. Kaysser plant, the target savings were estimated to be about 30%. Actual signs of significantly reduced powder consumption are already apparent and its exact extent will be closely monitored and documented.

FOCUS ON TECHNOLOGY

Future-Proof Powder Coating with the Right Recipe for Sustainability and Growth Corinna Hellwig Nordson Deutschland GmbH â&#x20AC;&#x201C; Erkrath, Germany

ics.eu@nordson.com

.P. Kaysser is growing and planning

H.P. Kaysser GmbH + Co. KG in Nellmersbach,

finishing facilities, H.P. Kaysser invested in

for the future. Their new powder

Germany is one of the leading companies

a new powder coating system, using dense

coating plant provides the flexibility to

in the area of sheet metal machining and

phase technology with state-of-the-art

economically coat small and large workpieces in

processing. In order to raise the technical

application engineering from Nordson.

series production or batch size one.

and performance capabilities of their surface

With more than 70 years of experience

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

providing development and strategy

efforts in this area for some time when, in

system soon made it clear that this

support to customers from practically

the spring of 2015, he asked his son Timm

project would require significant

every business sector, today H.P. Kaysser

to be responsible for the planning and

investment and the construction of two

offers intelligent, economical solutions

construction of a new coating system. “We

brand new production halls.

that range from engineering services

were looking for the right combination of

For the planning and configuration of

and the full sheet metal processing chain

the highest quality coating, in an optimal

the coating technology, Kaysser drew

right through to logistics. With some

process,” recalls Timm Kaysser. “Firstly,

on the extensive experience of

30,000 m² of facilities, the company’s

we needed the best ingredients for the

CS Oberflächentechnik, a company that

fully automated operations fabricate and

identification and coding of workpieces

had already participated in the creation

process products made of steel, cast iron,

throughout the transport, pre-treatment,

of several major powder coating lines.

stainless steel and non-ferrous metals

masking and coating operations. But we

The first new production hall was

– as individual units or in small, medium

also needed an intelligent control system

completed at the end of 2018

or large batch sizes. Customers take

to link everything together.”

in the first phase of the project.

advantage of their high quality, low prices

A second construction phase slated for

and rapid lead time, with the company

completion by the end of 2020 is still

experiencing steady growth. H.P. Kaysser have always excelled in surface finishing and even in their early history they focused on alternatives to liquid coating systems. When H.P. Kaysser installed their first powder coating plant in 1969, this new technology had only just been launched on the market, and their plant was one of the first and biggest in Germany. The vintage system was still fully functional and in daily service until recently, working alongside a second unit, installed in 1989 to automatically process larger workpieces. Over the past 30 years, coating

underway. With 2,800 m² of floorspace,

Over the past 30 years, coating operations and associated processes such as colour change and system cleaning have achieved such a high level of automation that modern powder coating lines are essentially when it comes to meeting the demands of “smart factory”: maximum flexibility for the economical production of even small and extremely small series right down to batch size 1.”

operations and associated processes

the first hall houses a powder coating line that handles components up to 2.5 x 1.0 x 1.5 m in size and 350 kg per carrier, in series and with eight scheduled colour changes per day. Workpieces first pass through a pre-treatment area comprising of up to six zones and incorporating numerous buffer and sorting storage options for maximum flexibility on their way to the heart of the powder coating plant: a state-ofthe-art coating booth from Nordson, designed for both maximum colour change speed and extreme cleanliness.

such as colour change and system

Based on a ColorMax3 booth, a variant

cleaning have achieved such a high level

Accordingly, the plant specifications stated

was adapted to the existing space

of automation that modern powder

the following requirements:

constraints, which is why the

coating lines are essentially when it

– Secure investment in long-term, future-

2.6-meter-long foreshortened booth

comes to meeting the demands of

proof technology

with a lower roof as installed at

“smart factory”: maximum flexibility for

– Extremely high flexibility in production

H.P. Kaysser is designated as a

the economical production of even small

– Minimized environmental impact and

ColorMaxE (“Engineered”).

and extremely small series right down to “batch size 1”.

Sustaining growth, enhancing flexibility The modernization and improvement of powder coating capabilities to meet

maximized sustainability – Creation of capacity to coat all in-house

The high-strength, exceptionally smooth surfaces of the booth components

production in the company’s own coating

ensure minimal powder-in-process at

system, irrespective of the size and

all times and perfect illumination in the

weight of the components

booth, facilitating easy visual quality

– Creation of additional capacity to cover subcontract work as a job coater.

inspections. During operation, the intelligent airflow management system provides regular

current and future requirements were nothing new to Thomas Kaysser, CEO of

The size of the components to be

compressed air pulses to convey

H.P. Kaysser and son of the company’s

coated and the resulting dimensional

excess powder to the central channel

founder. He had already been focusing

requirements for the powder coating

extraction system, which effortlessly

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

Figure 1: Booth, powder guns and powder feed centre form an integrated colour change system that enable eight extensively automated, extremely rapid and contamination-free colour changes. Nordson HDLV pumps are virtually maintenance-free, which means they also enhance quality, flexibility and production benefits over the long term.

transports it back to the powder feed

All manually cleaned powder system

centre. Following the same principle, the system cleans itself during each colour change – almost fully automatically. Inside the booth, the powder is applied by eight Nordson Encore HD automatic powder guns, which are designed both for coating with dense phase technology and for use in highly automated production and cleaning systems. The Nordson ColorMax Booth, Encore ®

HD Powder Guns and Spectrum® HD Powder Feed Center form an integrated colour change system that enable eight extensively automated, extremely rapid and contamination-free colour changes (Fig. 1).

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

The first new production hall was completed at the end of 2018 in the first phase of the project. A second construction phase slated for completion by the end of 2020 is still underway. With 2,800 m² of floorspace, the first hall houses a powder coating line that handles components up to 2.5 x 1.0 x 1.5 m in size and 350 kg per carrier, in series and with eight scheduled colour changes per day.”

components are easily accessible, thereby also helping to keep colour changes short. To ensure that the required colour is always available at exactly the right time, a Nordson Spectrum HD powder feed centre supplies virgin/recycled powder. Due to the high transfer efficiency of the Nordson application equipment, only very little overspray is generated. This overspray is drawn to the twin cyclone where the still usable powder is collected in the surge hopper and pumped back to the powder feed centre via a HDLV transfer pump.

sieve before it passes through to the main hopper where it is mixed with virgin powder-ready to be used again. For economical reasons as well as cleanliness, the planning of the H.P. Kaysser coating system emphasized

D17 2028/C ECC 1

salt spray tests

PV-1210

Years

VDA 621-415

1963 2018

Klimawechseltests

CETP 00.00-L-467

lar

fre

edo

ST 423-0014 DIN EN ISO 9227

Feuchtelagerung

constant climate tests

STD 1027, 14

VDA 621-415

Kesternichtests

KKT

Konstantklimatests

ASTM B-117

VCS 1027, 1449

Umweltsimulation

Normalklima

This reclaimed powder is then sieved by an ultra-sonic

SAE J2334

Due to the high transfer efficiency of the Nordson application equipment, only very little overspray is generated. This overspray is drawn to the twin cyclone where the still usable powder is collected in the surge hopper and pumped back to the powder feed centre via a HDLV transfer pump. This reclaim powder is then sieved by an ultra-sonic sieve before it passes through to the main hopper where it is mixed with virgin powder-ready to be used again.”

Salznebelprüfung

environmental simulation

FOCUS ON TECHNOLOGY

humidity storage

CORROSION TESTING EQUPMENT

Wet chemical quality testing

the importance of efficient powder recovery. Only a

Depending on the test specifications, the

minimal percentage of unusable powder fines end up in

process

the final filter, making this a highly efficient application

Condensation Water [K], Ambient Air [B],

system.

Intuitive operation The powder coating system is controlled by a PowderPilot

systems

Salt

Spray

[S],

Hot Air [W], Pollution Gas [G] and controlled Relative Humidity [F] can be combined individually or as combinations (cyclic

HD control system from Nordson. An icon-based touch

tests)

screen user interface provides the operator with relevant

conditions

information about the status of individual system modules

- 20°C (lower temperatures on request) and

as well as step-by-step instructions when – during a colour change, for example – operator intervention is required. For the most part language-independent, the control system makes operation very intuitive and largely eliminates operator error and training needs. For individual workpieces and for workpieces with highly complex geometries that cannot be coated in the powder coating booth system, a manual coating booth was installed (Fig. 2). The manual glass booth supplied by the system integrator Rippert Anlagentechnik GmbH & Co. KG was equipped with a Nordson Color-on-demand® System, which was supplied by iOS Industrieofen-Service GmbH together with their powder management system. This system is

over

variants.

Testing

phases of irrigation (Volvo STD 423 and Ford CETP 00.00-L-467) are possible. The units are intuitive to use, optional as a practical manual or comfortable automatic solution. Gebr. Liebisch GmbH & Co. KG Eisenstraße 34 33649 Bielefeld | Germany Tel: +49 521 94647 -0 Fax: +49 521 94647 -90 sales@liebisch.com www.liebisch.de

designed for ten colours and up to 15 colour changes per day.

Made in Germany since 1963

quality. While coating thicknesses with the old coating system line generally varied between 150 and 200 µ, the use of the new system was able to lower the coating thickness by approx. 80 µ down to 120 µ. A high level of process control, due to Nordson’s Dense-Phase Technology, will allow the customer to achieve further powder savings and higher quality as he can precisely control his powder application in further optimizations. Welcome side effect: Over the long term, the considerably enhanced coating consistency will be accompanied by major material savings. For the H.P. Kaysser plant, the target savings were estimated to be around 30%. Actual signs of significantly reduced powder consumption are already apparent and its exact extent will be closely monitored and documented (ref. Opening photo).

2 1

Another value testifies to the

Figure 2: For individual workpieces and for workpieces with highly complex geometries a manual coating booth was installed.

exceptionally economical and sustainable operation of the system: although the automatic booth’s

Minimizing environmental impact and maximizing energy efficiency

Nordson “Going Green Package”,

96% cyclone efficiency requirement

whereby devices operate in combination

represented an ambitious target, it was

with an intelligent control system,

achieved already during the start-up

Investment in a new production plant is

to continuously adapt to the actual

phase.

inextricably linked with the expectation

energy requirements of the moment.

With their choice of efficient dense

of decades-long utilization.

For example, when the light barriers

phase technology, highly automated

“Decision-makers of my generation

detect significant gaps in the supply

components, an integrated plant control

can no longer focus almost exclusively

of products to the booth, all powder

system with barcode identification of

on technical and commercial aspects.

guns are switched to standby, and

carriers and, not least, a 50% increase

Today, we also give environmental,

the booth airflow is reduced to the

in production capacity, the “Surface

sustainability and energy-related

minimum required extraction rate,

Finishing” business at H.P. Kaysser is

questions the same priority, right from

using a frequency inverter to reduce the

perfectly prepared for continued long-

the start,” says Timm Kaysser.

electrical power required.

term growth.

Having opted for a fully solvent-free,

Timm Kaysser’s interim assessment is

eco-friendly powder coating system

Initial results: it was worth it!

with sophisticated cleaning and

After 30 months of planning and

together with our industrial partners

conveying systems that essentially

construction, the project’s first phase

and tradesmen we’ve put something

eliminate powder waste, he has no

comprising the new production hall with

together here that works really well.”

doubt whatsoever that he’s on the

the powder coating line inside started

And with a grin, he adds: “The best

right path to long-term sustainability.

up for the first time in November 2018 –

ingredients and not too many cooks – all

Moreover, the new automatic coating

with impressive results from day one.

of whom agree on the recipe: As in so

line is configured for exceptional

What strikes the eye immediately is the

many other cases, this was the key to

energy-saving operation due to the

tremendous improvement in surface

success here.”

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

positive. “By all appearances, I’d say that

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international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

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HIGHLIGHT OF THE MONTH

FOCUS ON TECHNOLOGY

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INNOVATIONS: PRESENT&FUTURE

104

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INNOVATIONS: PRESENT&FUTURE

Inspiration & Innovation: Are You Curious Enough?

Pieffeci Torino: The Smart Way for Painting

The Advantages of Robotics 4.0 for the Flame Hardening of Maserati Car Bumpers

Direct-to-Metal: Straight on Metal, Straight to the Future

How to Coat 700 Alloy Wheels per Hour with One Plant: Mapsa’s Solution

PSP, One of the Italian Pioneers of Contracting Paint Stripping, Counts on the New FASTRIP Spray Technology to Treat Automotive Components

Material Savings Thanks to Correct Corrosion Protection

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Product Customization: Dürr Enables Fully Automated Painting of Cars in Two Colors for the First Time

he more customized, the better

car body has been painted in the basic

No masking tape required

– this motto governs more and

colour, which has then dried and cooled,

Dürr’s new process, known as

more purchasing decisions. When

masking tape must be applied by hand

EcoPaintJet, is much more efficient, as

it comes to the colour of cars, the trend

– except for the areas due to be painted

it dispenses altogether with the need

toward customization is also on the rise.

in a different colour. Then the car body

for masking the car body. This is thanks

Buyers of small cars, in particular, are

goes back to the painting line, where

to a totally new applicator. Fixed to a

increasingly ordering contrasting and

the second colour is applied. After more

robot arm, it moves over the target area and applies paint with

for the roof, to stand out from

razor sharp lines. The

accent colours, for example the crowd. For the automotive

paint lands exactly on

industry, two-tone painting

the intended areas

means considerably more

and nowhere else –

cost and effort. Not only

not even the tiniest

does it require more time

amounts. As a result,

and energy, it also creates

the rest of the car

a lot of wastage. Thanks

body no longer has

to a pioneering innovation

to be masked. It only

offered by Dürr, this is now

takes a cycle time of

changing. With its EcoPaintJet

120 seconds to apply

system, the world market

a contrasting colour

leader in automotive painting

to a car body roof. By

technology presents an

comparison: when

automated application solution that ensures an unprecedented level of precision in applying sharp paint lines. The EcoPaintJet

using masking tape,

the time required to

Figure 1: The applicator of the EcoPaintJet does not generate any overspray at all, so that it dispenses altogether with the need for masking the car body.

also offers important benefits

put on and remove the masking tape alone is about 50 minutes.

in the painting of electric cars.

cooling and drying, the tape must be

Electric cars seem flatter

When only one type of paint is applied,

removed, once again by hand. This is

EcoPaintJet helps electric car

the efficiency of modern automotive

not only associated with high labour

manufacturers to fulfill an important

paint shops is unrivaled. Thanks to their

costs, but the energy consumption for

customer requirement. Some e-cars are

highly automated processes, large plants

the curing of paint increases by at least

built slightly higher than conventional

paint 300,000 car bodies per year while

25 % compared to single-color painting.

models, since the battery is installed in

maintaining a consistently high level of

In addition, 6 to 15 square meters of

the floor assembly, under the passenger

quality. However, adding a contrasting or

masking tape must be disposed of per

compartment. Many buyers, however,

accent colour, for example on the roof or

car body. Moreover, the painting line is

would like their cars to look low-slung

as a design strip, means a considerable

blocked by the second paint application,

and sporty. To get this effect, a dark

amount of extra work: Once the entire

which wastes valuable time.

contrasting colour is used to paint a strip

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

BRAND-NEW

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

between the roof and side wall as well as

has around 50 hardly visible holes with

It also determines how the applicator must turn

on the rocker panel, which makes the car

a diameter of approx. one tenth of a

plus the speed required to apply exactly the

look flatter. The EcoPaintJet is perfectly

millimeter (Fig. 2). They are used to apply

right amount of paint.

suited to this purpose, as it applies the

paint to the car body surface in parallel jets

strip precisely without compromising the

from a distance of 30 millimeters.

existing finish.

The EcoPaintJet is currently being tested at several carmakers’ sites. In the meantime, Dürr

The applicator is the centerpiece of the

is already working on a further development

perfectly designed EcoPaintJet system. This

of the technology, which can also paint more

The EcoPaintJet achieves its high level of

also includes the EcoRPL 133i painting

complex geometries. This enhanced version,

precision because the applicator does

robot, which moves the applicator without

known as EcoPaintJet Pro, enables each hole

not generate any overspray at all (Fig. 1).

any vibration. A measuring system,

in the nozzle plate to be opened and closed

Overspray refers to fine droplets of paint,

equipped with sensors, provides maximum

individually. This offers even more possibilities

which are produced by other atomizers,

precision. It takes a 3D measurement of

for product customization. In the future, the

and land outside the target area. The

the area to be painted and sends the data

automatic application of lettering and logos

EcoPaintJet has an intricately machined

to the control software. This continuously

should also be possible – similar to a digital

nozzle plate, measuring only a few square

calculates along which path the applicator

printer.

centimeters, which prevents the formation

must be moved over the surface to achieve

of overspray. The nozzle plate, which forms

an optimum paint finish – this is called

For further information:

the underside of the rectangular applicator,

“automatic path generation”.

www.durr.com

No more overspray

2 1

Figure 2: Around 50 hardly visible holes on the nozzle plate are used to apply paint to the car body surface in parallel jets from a distance of 30 millimeters.

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

BRAND-NEW

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Mankiewicz Relies on Coating Hardeners from the Ultra Line of Covestro

or its Alexit® coating systems,

meet the requirements of customers

hardeners; only the specification range

the Hamburg-based coatings

and authorities in the future.” The

of the residual monomer content was

manufacturer Mankiewicz Gebr.

improved standard is important for the

reduced,” says Dr. Markus Mechtel,

& Co. KG uses hardeners from Covestro,

entire value chain of the coatings and

expert for automotive coatings at

which are setting new standards in

adhesives industry.

Covestro. The reduction of the residual

occupational safety. The Bayhydur ultra ®

monomer content was made possible

and contain less than 0.1 percent by

Seamless application in coating formulations

weight of residual monomers.

For Mankiewicz, it is particularly

Dr. Felix Niefind, laboratory manager

“Improved, application-oriented

important that the coatings based

at Mankiewicz, confirms: “We were able

occupational safety is a quality attribute

on the Covestro ultra line are not

to fully replace the Covestro hardeners

that enhances our portfolio,” says Dr.

subjected to expensive and tedious

previously used in our formulations

Heinz-Wilhelm Wilde, head of research

technical testing at customers from

with the ultra products.”

and development in the automotive

the automotive industry and other

coatings division at Mankiewicz. “Thanks

industrial sectors.

For further information:

to the new ultra line from Covestro,

“The quality of the ultra products is

www.covestro.com

we are also already well prepared to

at the same high level as previous

and www.mankiewicz.com

products used are part of the ultra line

by continuous process improvements at Covestro.

Mankiewicz Gebr. & Co. KG uses hardeners from the Ultra Line of Covestro to meet the needs of its customers from the automotive industry.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

G R

Opening photo: With a production of 7,000 trailers and semi-trailers per year, Lecitrailer is among the leading European producers.

FOCUS ON TECHNOLOGY

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Lecitrailer: International Companies Uniting to Create Europe’s Largest Semi-Trailer Cataphoresis Plant Alessia Venturi ipcm®

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

he entrance to the new factory that

The environment that houses the new

As is often the case, Lecitrailer’s plant is

houses Lecitrailer’s impressive semi-

cataphoresis and coating line is completely

the result of the collaboration of various

trailers and bodywork components

new, starting from its look: it is a 10,000 m2-

leading companies in their respective

cataphoresis line (ref. Opening photo) is

wide modern, well-lit, and spacious factory,

sectors. GEINSA (Bilbao, Basque

located at the end of an area that connects the

occupied only in part by the finishing plant

Country) acted as the prime-contractor,

bodies production and welding department

despite its huge size – a capacity of 5,000 kg per

designed the whole line, and supplied

with the finishing one. To the left, there is a line

the pre-treatment system, the ovens,

built in 1996 by GEINSA, in which it is possible

the cataphoresis plant, a pre-oven, the

to manually apply both a coat of zinc-rich

cross-linking oven, the finishing booth,

primer and finishing enamel on semi-trailers;

and the top coat curing oven; GEINSA

it features a convection drying oven for both paint layers. To the right, there is the new shot blasting, cataphoresis, and liquid finishing line (Fig. 1), processing all Lecitrailer’s semi-trailers requiring only a cataphoresis treatment and all components that also require the application of a top coat (two-component high-solid enamel); this occurs in a new coating booth

This is the largest cataphoresis plant in Europe in terms of tank capacity. In future, it will also handle contracting coating operations, one of the objectives that the Lecitrailer aims at achieving with this investment.”

also equipped the entire pre-treatment and cataphoresis line with systems for water demineralisation and waste water purification and it developed the 4.0-oriented management software as well as all its integrations with the control software systems of individual machines. SILVI (Lesmo, Italy) provided the cataphoresis tank and the ultrafiltration

equipped with pneumatic personnel lifting load bar, a chain conveyor with from FUTURA’s

system. FUTURA Convogliatori Aerei

a dedicated curing oven. This is the largest

7000 Series, ten 17 m long pre-treatment

(Robecco Pavese, Italy) was chosen by

cataphoresis plant in Europe in terms of

and cataphoresis tanks with a volume of

GEINSA as the technological partner for

tank capacity. In future, it will also handle

210 m3 each, ability to treat workpieces with

the part handling aspects, since it is one

contracting coating operations, one of the

a maximum size of 14 x 2.6 x 2.8 m, and

of the few European plant-engineering

objectives that the Spanish company aims at

maximum electrodeposition coating capacity

firms in this field currently capable of

achieving with this investment.

equal to 150 m2 of surface.

building a conveyor with such a large

platforms with x, y, and z-axis movement and

Figure 1: An overview of the new cataphoresis and coating plant that Lecitrailer commissioned to GEINSA (Erandio - Bilbao, Basque Country).

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

2 1

3 1

Figure 2: FUTURA Convogliatori Aerei (Robecco Pavese) designed the power&free overhead conveyor with storage buffers and a capacity of 5,000 kg. This photo shows the unloading area with the load bars’ storage buffer.

Figure 3: COGEIM’s automatic shot blasting machine with 24 turbines.

size and capacity (Fig. 2). Finally, COGEIM

Lecitrailer’s production; we are the fourth

even own a factory about 100 km away

(Casorezzo, Italy) supplied the shot blasting

manufacturer in France with a share

from Zaragoza that produces insulated

system (Fig. 3): it was chosen directly

of 8.36% and the fifth manufacturer in

panels for refrigerated vehicles.

by Lecitrailer by virtue of a long-term

Portugal and Italy. We also distribute

“Lecitrailer’ strength is its vehicles’

collaboration.

our products, i.e. high added value, fully

customisation degree. That is why both

customised vehicles, in Bulgaria, Holland,

the chassis production and body shop

Denmark, Belgium, and Russia,” says

areas are equipped with a production

Lecitrailer Marketing and Communication

line for standard vehicles and another

Lecitrailer is among the largest European

Manager Sebastián Esteban Bueno. “At the

one for customised vehicles,” states

manufacturers of trailers and semi-trailers.

Zaragoza plant, we perform sheet metal

Esteban Bueno. “We support the

It is a family capital business established in

processing, laser cutting, welding, assembly,

carriers during the whole service life

1990. With a factory covering 260,000 m2 in

and finishing operations on trailers, semi-

of their vehicles. No other producer

Zaragoza (Aragon, Spain - Fig. 4) and 850

trailers, body kits (Fig. 5), tippers, and other

offers a similar customer service, which

employees among the headquarters and

components. We also build bodies for

we provide through our after-sales

the after-sales service centres of Zaragoza,

motor vehicles from 5,000 kg upwards. We

assistance centres. Our customers rely

Lecitrailer: at least 30 years of success

Madrid, Barcelona, Valencia, Seville, and Lyon, Lecitrailer has been the Spanish market leader in the production of trailers and semi-trailers for almost twenty years.

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

“We are the major company among the leading manufacturers in terms of product range and customised solutions. We have a production of 7,000 vehicles a year and we work to order. In 2018, we had a market share of over 22% in Spain. Export accounts for 54% of

Figure 4: A bird’s eye view of the Zaragoza factory with the new plant devoted to the cataphoresis and coating line.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

4 1

FOCUS ON TECHNOLOGY

floor. The machine is followed by a blow-

on them to repair both Lecitrailer and any other brand’s vehicles in the shortest time – which they can because they are fully equipped, they have virtually all the parts of a vehicle in their warehouses, and they are open from 6 am to 10 pm.”

A flexible, highly productive plant Although all Lecitrailer products, i.e. chassis, body kits, and tippers, are subjected to cataphoresis, not all parts have to be shot blasted. Chassis and components coming from the sheet metal machining and welding area can enter the new coating department through two different paths. The parts to be shot blasted are loaded into the automatic machine through a floor roller conveyor. The COGEIM shot blasting system has a capacity of 5,000 kg, it is equipped with 24 turbines, and it can treat parts that are both hung or moved on the

As is often the case, Lecitrailer’s plant is the result of the collaboration of various leading companies in their respective sectors. GEINSA acted as the prime-contractor, designed the whole line; SILVI provided the cataphoresis tank and the ultrafiltration system; FUTURA Convogliatori Aerei was chosen by GEINSA as the technological partner for the part handling aspects; finally, COGEIM supplied the shot blasting system.”

off station and a tilter (Fig. 6) that rotates the workpieces by 360° in order to remove almost all abrasive residues. The piece-carrying skid then reaches a lifting platform, which transfers it to the bridge crane that handles the flying bars along the pre-treatment and cataphoresis tanks. All other products, including the ones that the company coats as a contractor, are hung onto the FUTURA power&free overhead equipped with different storage buffers; this is done by means of an elevator with a 5,000 kg capacity located in the loading station (Fig. 7). “The parts are hung to the flying bars and then to the FUTURA load bars, which directly proceed towards the pre-treatment and cataphoresis line without going through the tilter or the lifting platform,” explains GEINSA

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Figure 5: A coated tipper and body kit ready to be unloaded from the line.

load bars and flying bars back to the loading station (i.e. before the tanks), ready to pick up the next workpiece from the lifting platform after the tilting phase.” “The first bridge crane works in the first six pre-treatment tanks (Fig. 9). When it reaches the sixth tank, it places the flying bar on four hydraulic pins that transfer it to the second bridge crane, which completes the treatment with the tank #7, the cataphoresis tank, and the ultrafiltrate cleaning tanks.

5 1

Meanwhile, the first bridge crane returns to its starting position to pick up a new flying bar and begin the cycle again,” says along the remaining tanks, places the

Lecitrailer Chief Operating Officer Carlos

“The ten line tanks (Fig. 8), i.e. seven pre-

components in the tank #8 (cataphoresis)

Martín Lafuente.

treatment, one cataphoresis, and two

where the electrodeposition process

“The pre-treatment process includes seven

ultrafiltrate cleaning tanks, are linked to

takes place, and finally reaches the end of

stages as follows,” explains Jon Franco

two bridge cranes. The first bridge crane

the tank area to deposit the parts and the

Labrador from GEINSA, “alkaline spray

picks up the flying bar and advances up

flying bar on the main FUTURA conveyor,

degreasing in a tank equipped with an oil

to the tank #6, where the second bridge

located before the oven. In the case of

separator and a magnetic filter to eliminate

crane takes over; it moves forward

chassis, the conveyor sends the empty

any dust and abrasive residues from the

Technical Manager Jon Franco Labrador.

6 1

Figure 6: The tilter that turns the workpieces by 360° to drain abrasive residues.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

Tutti i colori in pochi minuti

www.salcomix.com www.akzonobel.com

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Salcomix è il marchio di AkzoNobel per un sistema di prodotti vernicianti industriali dal design modulare, che può essere utilizzato per fornire vernici per una grande varietà di applicazioni per l‘industria leggera, in modo rapido e flessibile. Questo è possibile grazie a un sistema di miscelazione che offre una superiore precisione del colore con la massima diversità di prodotto.

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

conductivity <10 µS. Some tanks are fed with osmotic water from the first step and others with water from the second step, in order to guarantee the proper conductivity level for each process phase. Moreover, the line employs a reverse-cascade system and draining units, exploiting the water with a lower conductivity value to reduce that of the tanks with lower quality,” explains Jon Franco. Thanks to a telemetry system and continuous data collection by its software package, the whole plant is monitored and controlled from one management room (Fig. 11) located next to the pre-treatment and cataphoresis line. This collects all data about temperature, conductivity, pH value, pre-treatment pumps pressure, ovens

7 1

temperature, booths conditions, and coating parameters, as well as data © Lecitrailer

Figure 7: The imposing FUTURA elevator with a 5,000 kg capacity. This photo shows the load bar (grey) and the flying bar (green) that handle the parts along the treatment line.

from the demineralised water production and ultrafiltration systems. “The PLCs of the individual machines in the line send their data to the management room, so that the

workpieces; alkaline immersion degreasing at 40-45 °C; two rinses, Figure 8: A view from below of the pre-treatment and cataphoresis line composed of ten tanks.

one using water with conductivity <900 µS and the second using water with conductivity <90 µS,

8 1

so that the parts enter the © ipcm ®

subsequent conversion tank in optimal conditions for treatment; nanotechnology conversion with Chemetall’s Oxsilan product, which deposits a zirconium layer with a thickness between 10 and 12 nanometres; and two rinses, the last of which is performed using water with conductivity <30 µS, so that the workpieces enter the cataphoresis tank in perfect conditions for coating.” The system is equipped with a two-step osmosis system (Fig. 10) developed by GEINSA. “Lecitrailer uses well water with a very high conductivity value, higher than 3000 µS. In the first step, osmosis lowers such value to 60-70 µS; the second brings it under 10 µS. The system can generate 12,000 l/h of water with conductivity <60 µS and 7,000 l/h of water with

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

Figure 9: A flying bar attached to the bridge crane #1 in the tank #5 (conversion): behind it, the hydraulic pins of the tank #6 can be seen, where the transfer to the bridge crane #2 takes place.

9 1

FOCUS ON TECHNOLOGY

10 1

operators can control the entire plant from a single location, without having to monitor each PLC. During loading, a 24-digit barcode is associated with each workpiece; besides transferring all process information to the different stations of the coating system so that they work according to the matching program, this also collects all the process and treatment parameters required for traceability.” In the tank #8, i.e. the cataphoresis one (Fig. 12), the flying bars are separated from the bridge crane to ensure that the voltage is not transmitted to the factory structure and they are swung to eliminate the air bubbles generated during immersion. Only in this way can the deposition of the cataphoresis coating be uniform on the entire workpiece surface. The cataphoresis tank was designed to treat a maximum surface area of 150 m2, although the average surface of

With a factory covering 260,000 m2 in Zaragoza and 850 employees among the headquarters and the after-sales service centres of Zaragoza, Madrid, Barcelona, Valencia, Seville, and Lyon, Lecitrailer has been the Spanish market leader in the production of trailers and semi-trailers for almost twenty years.”

Figure 10: The osmotic and demineralised water production system supplied by GEINSA.

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

iron and aluminium, and therefore we chose to use a multi-metal pre-treatment technology with Chemetall’s Oxsilan product. This is a great advantage with a view to the future development of our contracting service. Indeed, our main raw materials are carbon steel and galvanised steel (also from coils), but flexibility is the real strength of this new coating plant. The cataphoresis treatment preceded by a nanotechnology conversion stage, moreover, guarantees greater paint adhesion. It is a technology with a low

11 1

environmental impact and it represents

Figure 11: The plant management room.

a chassis ranges between 70 and 75 m2. “The thickness to be applied is very high: it ranges between 40 and 50 microns, i.e. greater than the thicknesses normally applied to car bodies,” says Jon Franco Labrador, “because the impact of gravel on semi-trailers is much more severe than on a car. The tank is therefore equipped with a 1,200 amp rectifier to evenly apply such thicknesses over a surface up to 150 m2. Lecitrailer, e.g. semi-trailer tippers, reach this size. Furthermore, let us not forget that one of our objectives is offering a coating contracting service by making

Indeed, a few body parts coated by 12 1

Figure 12: A detail of the cataphoresis tank designed by SILVI (Lesmo).

full use of the potential of such a large

Figure 13: The final stretch of the pre-treatment line before pre-heating, where the workpieces are transferred from the bridge crane #2 to the FUTURA overhead conveyor.

cataphoresis line, which is unique for its size at the European level.” “The tank is equipped with 52 cataphoresis cells, it is 17 metres long and over 4 metres deep, and it has a capacity of 210 m3,” adds Carlos Martín from Lecitrailer. “We use BASF’s Catoguard water-based epoxy product. The immersion in the tank lasts up to 3 minutes and the coating thickness varies depending on the applied voltage and the workpiece dwell time. After cataphoresis, the parts are pre-heated minutes (Fig. 13). We coat both galvanised steel and stainless steel as well as both

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

13 1

at 90 °C and then cured at 190 °C for 45

FOCUS ON TECHNOLOGY

14 1

Figure 14: A bird’s eye view of the curing ovens and the coating booth installed by GEINSA.

the best corrosion protection system for our products. These have also improved in terms of aesthetics: unlike the silvery tone of galvanised steel, the grey cataphoresis layer enables us to customise all products with the RAL colour required by each order – which is going to last over time, as we give a 10-year anti-perforation warranty. Finally, although we conventionally apply a two-layer system including cataphoresis + polyurethane finish, we can guarantee even greater protection upon request with a three-layer coating that includes cataphoresis + epoxy or zinc-rich base coat + polyurethane finish.” “We have favoured flexibility over productivity, even though the coating capacity of this plant is much higher than our needs: the production takt time is 28-30 minutes, whereas the coating one is 15 minutes, i.e. about double,” says Martín. “Our objective is to increase the coating quality of Lecitrailer’s whole production, by offering better performances to our customers, while at the same time starting to offer a contracting service ourselves.

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All other products, including the ones that the company coats as a contractor, are hung onto the FUTURA power&free overhead equipped with different storage buffers; this is done by means of an elevator with a 5,000 kg capacity located in the loading station.”

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Performance by design

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

The old manual coating line supplied by

months after starting this line, I can safely say

GEINSA is still in use for the application

that we are very pleased with it. The differences

of the top coat on vehicles greater than 5

in terms of coating can be perceived in the

tonnes, but that aside this line covers 99%

long term and through quality tests, rather

of our production.”

than in terms of aesthetics: our products have

After the curing of the cataphoresis layer,

improved their quality and resistance degree,”

the workpieces may take a different route

adds Martín.

depending on their matching finishing

“This system gave us the treatment flexibility

station: the chassis proceeds towards

and quality degree we needed. Lecitrailer can

the manual coating line, whereas the

currently offer different finishing solutions,

customer parts, tippers, and body kits go

always with cataphoresis as the starting point.

towards the coating booth installed by

With the AkzoNobel conventional system

GEINSA on the new line (Fig. 14).

including cataphoresis + solvent-based 2K

“We chose a simple manual application

polyurethane enamel and the nanotechnology

booth with pneumatic guns (Fig. 15)

pre-treatment process, we can already

and Graco mixers,” says Labrador.

achieve a salt spray resistance equal to

“The shape of Lecitrailer’s workpieces presents many Faraday cages: that is why electrostatic application was ruled out. We have also installed pneumatic lifting platforms with a three-axis movement

15 1

Figure 15: The interior of the GEINSA spray paint booth with mobile coating platforms on its bottom.

over 1,200-1,300 hours, also thanks to the high cataphoresis thicknesses we manage to deposit, which are among the highest available on the market. With the addition of an epoxy or zinc-based primer, we can reach

(x, y, and z) to guarantee

even higher resistance

coating ergonomics to our

levels. In future, we

operators.”

intend to replace the

Lecitrailer has favoured flexibility over productivity, even though the coating capacity of this plant is much higher than its needs: the production takt time is 28-30 minutes, whereas the coating one is 15 minutes, i.e. about double.”

The reasons for the investment “As a leading manufacturer, a cutting-

solvent-based enamel with a water-based product.” “This line was not installed only to meet the coating needs of

the technology Lecitrailer

Lecitrailer,” says Carlos

was lacking to compete

edge finishing plant was

Martín, “but also to

with other producers,”

help other companies

states Carlos Martín

coat quality large-sized

(Fig. 16). “In 1996, we

products, since it is the

installed a conventional

largest cataphoresis

manual primer + enamel

line in Europe in

coating system, but the

terms of capacity. Our

finishing needs of our

collaboration with GEINSA,

market have soon evolved

which we chose as the

to the point of requiring

prime-contractor for such

a guarantee of at least

an important project for

10 years of corrosion

our future, started in 1995

resistance. A cataphoresis

with the installation of the

plant was the only possible

manual primer + enamel

solution.” “Before making this investment, we performed many tests; now, about four

16 1

Figure 16: From left to right Jon Franco Labrador, Carlos Martín Lafuente and Sebastián Esteban Bueno.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

finishing line. We will continue to count on GEINSA even in the future.”

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Opening photo: Merck has developed Shape the Future initiative in order to help the automotive industry master the new technological challenges.

HIGHLIGHT OF THE MONTH

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Inspiration & Innovation: Are You Curious Enough? Stefano Corrado and Laura Zanini Merck Spa, Milan – Italy

stefano.corrado@merckgroup.com - laura.zanini@merckgroup.com

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N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

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to reality.

From decorative printing to

Skyscrapers are well-known landmarks

high-quality coatings, Merck’s

in many countries and these surfaces

effect pigments have been

structures especially require serious

helping make the world

long-lasting protection. Durazane® is

a more colourful — and

the solution for optimal protection of

functional — place for more

a multitude of surfaces. It offers many

than half a century.

benefits, including strong and

Take for example that

LEDs create new lighting effects.

long-lasting protection against

distinctive convertible driving

past: these pigments create

corrosion and scratches, while also offering easy-to-clean properties and strong thermal resistance.

Driving Innovation

Figure 1: Durazane® is the solution by Merck for optimal protection of a multitude of surfaces. It creates a barrier, that offers scratch protection, high-temperature resistance, water and dirt repellency and corrosion prevention.

eye-catching automotive coatings. Durable coatings help vehicles stay looking their best even after years on the road.

Cars of the future are expected to be smart and efficient, which poses

interested in electric mobility solutions,

And how about that striking building

numerous challenges for the automotive

which lead to a decrease in traditional

façade downtown? Builders set

industry: Customers want their cars to

combustion engines. It also demonstrates

trends with effect pigments in

drive autonomously, which is already being

the automotive industry’s need for additional

architectural coating applications that

tested intensively, but further innovations

innovations in this particular area

make buildings both more attractive

are required for serial production. Within

(ref. Opening photo). To help the

and resistant to the elements.

the next ten years, more than 50% of the

automotive industry master these challenges,

Used in food, ceramics, plastics, and

world’s population will be digital natives.

Merck has developed Shape the Future

even furniture, these high-quality

This forces the automotive industry to

initiative that includes four fields of action:

pigments make a big difference in

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

the look and feel of many products.

stable depth of colour, the

drought-defying flora & the radiant

Unmistakable packaging and

harmonious transitions and the

horizon. Meoxal® Victoria Red

labelling make for appealing product

highly reflective gleam that makes

captivates with its intense colour

design, plus can curb counterfeiting

this pigment ideal for dark hues,

& extraordinary brilliance. Its high

and boost security.

giving them an enviable elegance

opacity fires up red tones in particular

For countless everyday items, effect

and lightness. Xirallic NXT effect

and gives them an immense radiance

pigments add a bit of colour to the

pigments are the result of further

and intensity. This red combines

world.

development of the fabulous

flowing transitions with consistently

Merck’s experts have the specialist

Xirallic® product features with

colour-intense surfaces and clearly

knowledge and the broad range of

a close look at market needs.

accentuated degrees of brightness to

products to create fascinating special

Powerful colours, sparkling

create an exciting interplay – thrilling

effects for effect pigment

and harmonious at the same time. The

50 years of experience in

individual particles,

applications. With over developing new generations

which are based on

of effect pigments, they

aluminium platelets,

help manufacturers lend a

create an elegant

contemporary and high-

sparkle with seductive

quality appearance to many

intensity, radiating

of their products.

warmth and purity,

Recently introduced effect

metallic appearance.

pigments to discover:

Optics results are the

- Xirallic® NXT Amur Black:

enormous brilliance with outstanding colour

Bluish black with a metallic shade and strong hiding

saturation, elegant

power. Balanced 3-coat

sparkle effects of individual particles

black stylings possible.

and luminous

Subtle elegance,

metal effect.

intense darkness,

It gives the

mystic sparkle,

warmth of

unique texture.

elegance

Just as moonlight

and fulfills

is reflected by the ocean’s waves and bathes everything in a silvery light, Xirallic® NXT Amur Black

Figure 2: Bluetiful is one of cross-linking effect topics developed by Merck.

especially high demands for outdoor applications such as automotive coatings and other high-end paint

lends a lively metallic sheen to

applications.

all kinds of surfaces, which don’t

elegance and unmistakable purity.

become fragmented by sharply

Merck’s pigment designers have

contoured edges of light as they

developed a masterpiece in

would with metal pigments. In

brilliance and intensity. Specially

brilliant light, the hue seems to

developed for automotive

Empowering surfaces to add that something special to surfaces

consist of millions of sparkling

coatings, Xirallic® NXT effect

No matter what we’re doing or where

dots and to blur the boundaries

pigments provide exceptional

we are – we interact with, see, sense, or

between solid and liquid. It is the

sparkle and flop behaviour as well

contact surfaces every minute of the day.

as superior performance.

Surfaces are everywhere. Merck’s mission

complex and novel combination of the black shimmer of the

- Meoxal® Victoria Red, The Great

is to empower customers to create

surface, the endless motion of the

Victoria Desert: Breathtaking

surfaces that do what they need them to

Living Sparkle®, the chromatically

beauty composed of red earth,

do – and look exactly the way everyone

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

expects them to look. Some examples: precious possessions can be protected so that they still looks wonderful after years; engines can be helped to operate in their optimal range for high efficiency. Durazane® is the solution for optimal protection of a multitude of surfaces. Available in both organic and inorganic forms, after curing react with the surface creating a barrier, that offers scratch protection, high-temperature resistance, water and dirt repellency and corrosion prevention (Fig. 1). Designed for solvent-based system, surfaces can be spray coated, deep coated or applied by microfiber cloth. They are very requested in valued markets, which require extreme protection, e.g. automotive industry, architectural building, aeronautical and nautical industries, flooring, production plants, etc. Achieving the perfect surface can be a tricky balancing act. Fluorosurfactants are important to reduce coating defects… but are they safe? When it comes to Tivida FL®, the answer is yes. Merck has

Surface Engineering

TRIntegral Real, Virtual, Predictive

created a range of surfactants that deliver all-round reassurance. In fact, all of Merck’s fluorosurfactants are non-toxic and non-bioaccumulative. Coatings with high-performance Tivida® FL additives, make it easy to achieve perfect surfaces. Sometimes a tiny spark caused by static electricity can bring consequences. There’s a simple but effective way to stop static electricity from discharging: make material surfaces antistatic and conductive with Iriotec® 7000 pigments. Simplifying identification for the possible need of durable markings on products, maybe priority on brand protection: Razor-sharp markings that last an eternity, but are totally safe is absolutely possible with special laser-sensitive Iriotec® 8000 pigments. More possibilities and advantages can be offered by changing the way you mark products and materials. Discover why lasers are becoming the new normal when it comes to marking.

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Curiosity is fostering us to find new way of improvement. For example, in the field of inspiration tools, a bunch of inspiration tools focusing either on different market areas (mobility, consumer electronics, etc.) or on cross-linking effect topics (Bluetiful Fig. 2, Red through Life, Achromatic, etc.). In the field of the Digital Color Card App: the coating world at a glance, always with you on both your Android or Apple devices. Are you curious enough?

Legazpi 6 48950 ERANDIO - BILBAO BASQUE COUNTRY (EU) Tel +34 944 676 091 www.geinsa.com

Opening photo: Pieffeci has managed the axle coating line of the Driveline plant in Turin of FPT-Industrial since 2001.

FOCUS ON TECHNOLOGY

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Pieffeci Torino: The Smart Way for Painting Alessia Venturi ipcm®

he digitisation of a factory with an

among humans is certainly not less

outsourced industrial, and especially coating

Industry 4.0-oriented approach

important in this process: the interaction

processes for large industrial groups. In the

starts with the precise definition

and exchange of knowledge and skills

2017-2018 biennium, it started a digitisation

of objectives and ends with the perfect

among plant and machine suppliers is key

program with its “Plant Supervisor”

calibration of communication protocols

to creating a fully functioning and efficient

project. This was aimed at creating an

among machines, without which “Industry

interconnected system.

interconnected system that guarantees

4.0” would remain only a theoretical

This is what happened in the Turin

quality, monitors and guarantees product

concept. At the same time, communication

installation of Pieffeci, a company handling

traceability, continuously monitors

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

working conditions and process parameters, digitises

installed new Graco ProMix PD2K mixing

reporting activities, digitises and

machines (Fig. 1), linked to

automates previously manual

Gaiotto Automation robots

operations, favours operators

integrated in the primer

access to work instructions by

and enamel application

projecting them on special Smart

booths.”

TVs in real time, and balances

Precisely optimal

the instantaneous production

communication between

load by optimally distributing

Graco’s and Gaiotto’s

the material flows among the

engineers allowed to

unloading descenders and thus

develop an accurate and

improving the entire production

functional communication

process’ efficiency.

protocol between the PLCs

Pieffeci achieved all these

of the various machines

objectives with the installation

and the MES production

of tags on the line’s load bars

management software

to guarantee the unambiguous

package, in order to

identification of workpieces

guarantee full product

and their product and process

traceability, monitor

characteristics; the integration

consumption, carry out

of eleven RFID readers to track

predictive maintenance

products and detect all process

plans, and digitise many

parameters in the key stations of

operations.

the coating plant; the installation

“The new Graco mixers

of sensors and actuators

are connected to the

throughout the production

LAN via special gateways:

plant; the implementation of

in this way, they are

an MES management software

interconnected with the

package, interconnected with

factory management

the factory IT systems and the PLCs of operating machines; and the integration of remotely controllable machines for

software system and

remotely controlled.

Figure 1: Pieffeci installed new Graco ProMix PD2K mixing machines.

They receive incoming processing data (paint flow rate) directly from the PLCs

remote assistance, in order to improve coating and control all application

interconnected with the MES software

and process parameters.

package and they send consumption

“The investment for the revamping of the

data to the PLCs (and then to the MES)

coating plant that we manage at the premises FPT-Industrial in Turin was aimed at two main goals: on the one hand, the digitisation of production and the optimisation of the two-component paints’ mixing operation to improve our coating quality degree; on the other hand, the rationalisation of paint consumption and application trough the reduction of the touch-up operations required,” states Pieffeci-Turin production manager Mario Rizzolio. “Specifically, Pieffeci

Pieffeci-Turin, a company handling outsourced industrial, and especially coating processes for large industrial groups, started a digitisation program with its “Plant Supervisor” project in the 2017-2018 biennium.”

at the end of the cycle. The central MES communicates with machine PLCs via an OPC server, whereas the Gaiotto PLC connects the robots with the mixers, thus becoming the single collector of data coming from and to the mixers themselves,” says Pieffeci project manager Renato Piazzolla. “The Gaiotto PLC has two communication protocols, i.e. Profinet and Profibus. The mixing machines and the RFID readers are connected on the

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Profinet side, whereas the

gather a considerable amount of data and store

robots and the process sensors

them on a server that can be interrogated both

are connected on the Profibus

at the end of the process through reports and

side. The Gaiotto PLC gathers all

in real time,” states Mario Rizzolio.

information and sends it to the

About Pieffeci-Turin

the workstations equipped with

ipcm® readers will probably remember this

barcode guns, the printers, the

company for our previous article about its

operator input devices, and the

industrial coating activities in the Bonfiglioli

Smart TVs.”

plant in Forlì1: since the 1990s, by operating

“As a part of this 4.0-oriented

through specific procurement contracts,

investment, we have wired a

Pieffeci Spa has dealt with the performance of

series of sensors that monitor

industrial coating processes at the premises

the pre-treatment parameters,

of its customers. It handles production,

the coating parameters of

technological management, and plant

the robots, the actual paint

maintenance activities; through its Equipment

consumption, the catalysis rates,

Engineering service, it also designs new

the conditions of the paints

systems for its customers, supervising their

in use and in preparation, the

supply, installation, and start-up. Pieffeci has

environmental conditions of the

managed the axle coating line of the Driveline

coating booths, the AHU (Air

plant in Turin of FPT-Industrial since 2001; in

Handling Unit), flash-off unit,

this factory, besides axles, FPT also produces

and oven temperatures, and

engines and gearboxes intended both for

the overall lead times. The tags

2 1

on the load bars manage up to 120 variables of the set process

Figure 2: Axle bridges at the entrance to the pre-treatment tunnel.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

parameters; during coating, they

Optimal communication between Graco’s and Gaiotto’s engineers allowed to develop a precise and functional communication protocol between the PLCs of the various machines and the MES production management software package, in order to guarantee full product traceability, monitor consumption, carry out predictive maintenance plans, and digitise many operations.”

MES. This, in turn, interfaces with

3 1

Figure 3: The robotic blow-off station.

1 ipcm®_International Paint&Coating Magazine no. 45, Vol. VIII, 2017, pages 16-26 “High automation and continuous monitoring via PLC for the efficient outsourcing of coating operations”

FATI

FOCUS ON TECHNOLOGY

srl

CATENE PER TRASPORTATORI CUSCINETTI A SFERA

CATENE AD ALTE PRESTAZIONI HIGH PERFORMANCE CHAINS LEISTUNGSFÄHIGE KETTEN

NOVITÀ NEW NEUHEIT

HPCOAT

Particolare dei cuscinetti con HPCOAT Detail of bearing with HPCOAT Ausschnitt der Lager mit HPCOAT 4 1

internal applications of the CNH industrial group (the whole range of IVECO commercial vehicles and of

con | with | mit HPCOAT

agricultural and earth moving machines of the others CNH industrial brands: New Holland Agriculture, CASE IH, and CASE Construction) and for other major manufacturers (ref. Opening photo). “Pieffeci’s activity is tightly linked to FPT’s production coating phase starts immediately after the end of the assembly process on the FPT production lines: the already-mounted products are loaded onto an overhead conveyor that is directly linked to the painting system. Our production speed must be adjusted and synchronised to that planned by our customer, which has a variable workflow in terms of parts and speed depending on orders, with an average of several hundreds parts per day, mainly produced in two shifts. Pieffeci’s production service ends with the delivery to the warehouse of coated, retouched, and ready-for-shipment products: in other words, we

process,” explains Mario Rizzolio. “Technically, the

Aspetto dopo 200 ore in nebbia salina Surface after 200 hours of salt spray test senza | without | ohne Aussehen nach 200 Stunden in Salzsprühtest HPCOAT

Coefficiente Resistenza alla d’attrito corrosione Friction factor Corrosion protection Reibwert Korrosionsfestigkeit Costi di Durata alle alte manutenzione temperature Maintenance costs Life-time at high Wartungskosten temperatures Corrosione Beständigkeit gegen Corrosion hohen Temperaturen Korrosion Autolubrifcazione Abrasione alle Self lubrification alte temperature Selbstschmierung Wear at high Produttività temperatures Productivity Abrieb bei hohen Produktivität Temperaturen

LESS

Figure 4: A detail of the numerous blind holes present on the parts painted by Pieffeci.

FATI srl Via C. Porta, 14 | 23861 Cesana B.za (LC) | Italy t. +39 031 655688 | f. +39 031 656772 info@fatisrl.com | www.fatisrl.com

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

5 1

Figure 5: Masking instructions displayed on a Smart TV.

take charge of raw workpieces and we return coated parts to our customer, which takes care of shipping logistics. The coating standard is defined by the customers’ specifications. Quality control is carried out by two operators.”

The finishing of axle bridges: a perfectly designed process The 4.0-oriented investment started from the production lines connected Pieffeci Turin Paintshop. After the loading stations there is a small storage buffer followed by the reception and coding “zero” station.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

“We equipped each piece-holding bar with

The tags on the load bars manage up to 120 variables of the set process parameters; during coating, they gather a considerable amount of data and store them on a server that can be interrogated both at the end of the process through reports and in real time.”

an RFID tag that uniquely identifies it. During coding, we match the FPT identification tag (containing all product data, such as GAN, serial number, design, client, date and time of progress, and FPT approval state) with the related coating program. From that moment, the match between the bar number and the carried workpiece is unique,” explains Renato Piazzolla. “Thanks to the MES software system, a first quality gate enables us to detect eventual anomalies: after a gun reads the barcode,

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

the MES displays a check-list on a dedicated monitor, based on which the operator can identify any native defect of the workpiece. We can thus immediately identify right, at the beginning of the production process, any non-conformities such that the workpiece does not have the necessary requirements for a correct application of paint (blocking non-conformity). “The component database is shared by Pieffeci and FPT and it is continuously updated. We carry out a weekly update of our coating programs matched with FPT designs,” states Mario Rizzolio. “Currently, we have 70 coating programs to handle 12 macro-families composed of the about 4000 products that make up FPT’s production range and that can even only differ in the position of a sensor. Our team constantly updates the database following the addition of new product variants and matches them with the part-specific coating programs; or, if needed, a new program is defined.” The plant’s takt time from coding to unloading is 56 seconds. Pre-treatment (Fig. 2) occurs on an Imel plant with Henkel products. The cycle includes six stages: alkaline degreasing, rinsing with mains water, rinsing with demineralised water, phospho-degreasing with light iron salts, rinsing with demineralised water, and further rinsing with demineralised water. The next stage is a blow-off operation performed in a fixed station at the end of the pre-treatment tunnel and in two robotised stations (Fig. 3), one on each side, which act on specific deposit spots following pre-set programs. “Before this 4.0-oriented investment, we generated a single FIFO queue of coating programs during the coding phase,” says Renato Piazzolla. “Now, after our RFID readers read the tags placed on the load bars, the various machines of the line, such as for example the blow-off robots, collect the data related to each program

6 1

immediately before execution. This is a big

Figure 6: The pump for the manual sealing of axle bridges, necessary to prevent oxidation.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

advantage because, if the plant technologist

FOCUS ON TECHNOLOGY

Each workstation has a different FIFO queue. The plant is composed of seven different chains – slow, very slow, and fast. With the old management system, a FIFO queue was created during coding and the parts were transferred from one chain to another with the risk of not following the FIFO order and thus generating gaps. The current management system, on the other hand, detects any gaps on the chain; moreover, the creation of a FIFO queue for each workstation has eliminated a problem that made the company lose valuable production time.” decides to make a last-minute program change for any reason, there are no consequences on the overall coating cycle.” Subsequently, the parts enter the drying oven at 60 °C for 30 minutes to eliminate any residual moisture or water deposited in blind holes (Fig. 4). At the exit of the oven, there is a cooling station where an AHU lowers the temperature of the workpiece to make it immediately processable. This is followed by a masking phase with bags and thermoformed films that protect the hubs and studs of axle bridges. Whenever the RFID reader detects a tag, the MES projects part-related work instructions on the Smart TV in real time, until the next reading (Fig. 5); this applies to both masking and sealing instructions. “In this area, we manually seal specific areas of the rear axles intended for Stralis trucks, in order to prevent oxidation on some boxed surfaces (Fig. 6),” explains Mario Rizzolio. “After coating, on the other hand, we automatically perform conventional sealing operations on all the areas of the light axle range requiring it.” At this point, the bridges reach the actual coating area. Pieffeci applies a two-component watersoluble polyurethane system supplied by Sherwin Williams, consisting of a black primer and an Iveco Colour grey enamel. The coating area therefore

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

7 1

Figure 7: Robotic application of the black primer.

consists of a primer application booth, a

read, the management PLC stores the

two on each side. After the enamel

flash-off station, an enamel application

working conditions of the carried part

application, the parts are subjected to a

booth, a second flash-off station, and a

and sends the data to the following RFID

further 15-minute flash-off phase before

curing oven.

reader. Here, we also create a second

entering the curing oven with a lead time

“With a two-year project carried out between

FIFO queue. Another RFID reader is

of 45 minutes and an air temperature

2014 and 2015, we disposed of the old

placed before the enamel application

curve that reaches 100 °C.

coating system and implemented new

booth, which works exactly like the

“Each workstation has a different FIFO

booths and an automatic pre-treatment,

one preceding the primer booth and

queue. Our plant is composed of seven

blow-off, and drying system supplied by Imel

generates another FIFO queue.”

different chains – slow, very slow, and

and equipped with Gaiotto robots. Before

The primer application booth (Fig. 7)

fast. With the old management system,

the primer booth, an RFID reader checks

is equipped with four robots applying

we created a FIFO queue during coding

the tag of the incoming bar and selects

two coating layers per side. The parts

and the parts were transferred from

the matching coating program,” explains

undergo a 50-minute flash-off phase

one chain to another with the risk

Renato Piazzolla. “The RFID antenna can

at room temperature before entering

of not following the FIFO order and

detect in real time any change made by the

the enamel application booth (Fig. 8),

thus generating gaps. The current

technologist to the painting program during

identical to the primer one and also

management system, on the other hand,

the reception phase. Every time the tag is

equipped with four painting robots,

detects any gaps on the chain; moreover,

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

In the sea of the Big Data

imel 4.0 technology, to be always one step ahead

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SPECIAL ON AUTOMOTIVE & TRANSPORTATION

with the creation of a FIFO queue for

day,” states Andrea Scipioni from AS

independent pistons for higher

each workstation, we have eliminated

Verniciatura, the Graco distributor

delivered pressure stability, therefore,

a problem that made us lose valuable

that participated in the project

less retouching operations,” adds

production time,” states Rizzolio.

and supplied Pieffeci with the new

Graco finishing sales manager Marco

systems. “The company relied on

Caporello. “The mixing that takes place

us and invested in the new ProMix

in the final segment of the circuit, about

PD2K mixers. They are radically new

80 cm from the gun, halves the use of

“Previously, we used Graco Promix

products, so much so that Pieffeci

cleaning solvent and reduces waste

2KS mixers with volumetric counters.

was the first company in Italy to install

and spent products to be disposed of.”

Sometimes, with particularly high

these Graco machines. It carried out

“Based on specifications, Pieffeci must

temperatures inside the plant, these

a pilot project with the installation

apply a total thickness of 70-80 microns

blocked the automatic flow rate control

of one mixer in October 2017; after

on its workpieces,” says Scipioni, “with

system due to “false alarms” resulting in

fine-tuning and the assessment of its

spraying programs that require flow

frequent maintenance operations and

reliability degree, it replaced all the

rates from 50 to 350 cc depending

downtimes,” says Piazzolla.

mixers in the line within one year.”

on the treated parts’ surfaces. ProMix

“Indeed, coatings tend to leave deposits

“These machines guarantee great

PD2K systems work well even with

within the volumetric counters during the

coating accuracy thanks to two

very low flow rates because they

Graco’s ProMix PD2K mixing machines

8 1

Figure 8: Robotic application of the Iveco grey enamel.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

POWDER COATING SOLUTIONS

COLORFUL. FUNCTIONAL. CUSTOMIZED. More than 300 RAL shades available from stock. 9 1

Figure 9: The mixer control panel.

can perform optimised mixing programs in terms of consumption and overspray.” Pieffeci installed a mixing machine for each robot, which guarantee as follows: - Increased dosage and flow rate delivery precision, since the machines are more stable as they are controlled in a closed loop, with a significant increase in finishing quality; - Reduced use of solvent for cleaning the feeding circuit, since the products’ mixing only occurs in the final part of the circuit; - Reduced maintenance in terms of both frequency and duration. - Interconnection with the MES management software system that allows remotely controlling the mixers’ functions, thus gathering paint consumption and alarm data in a precise, accurate, and constant way (Fig. 9).

EcoPolifix Srl − Socio unico Via del Lavoro, 14-16, 31039 Riese Pio X (TV), Italy T: +39 (0) 424/848555 | F: +39 (0) 424/540505 E: info@ecopolifix.it Member of HELIOS. Part of KANSAI PAINT.

www.ecopolifix.it www.helios-powdercoatings.com

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Figure 10: From left to right, Alessia Venturi from ipcm, Marco Caporello and Miranda Houbrechts from Graco, Andrea Scipioni from AS Verniciatura, and Renato Piazzolla and Mario Rizzolio from Pieffeci.

Final production stages Three different descenders take care of

10 1

applies the sealant through a highly precise point-to-point operation through two

the unloading phases depending on the

innovative dispensers developed by Pieffeci

type of processed axle bridges.

(Fig. 11).”

They put the parts in specific containers and transfer them to the final

Digital Factory goal: achieved

touch-up phase, a manual operation

Thanks to its “Plant Supervisor” project and its

that is significantly less needed since

investments in automation and in the ProMix

Pieffeci installed the new Graco mixing

PD2K mixers, Pieffeci is now able to:

machines. Finally, masks and barcode

- Constantly monitor all works in progress in

tags are removed from the workpieces,

the various sections of the plant;

which are approved and delivered to the

- Track the position of specific workpieces on

customer in a specific area of its logistics

the system;

department.

- Digitise the daily plant start-up operation,

“In 2016, we developed and

eliminating the need for paper compliance

implemented another important

documents to be filled out by the maintainer;

automation project for the application

- Assign the urgency status to specific

of a sealant on all axles’ areas with

workpieces;

difficult-to-coat edges or gaps,” says

- Receive immediate notifications about

Mario Rizzolio (Fig. 10). “We employed

system anomalies;

very innovative technological solutions,

- Digitise all reports on production, quality,

including a laser-scanner vision system

11 1

controlling the two new Comau robots. The system identifies the axles’ shapes and position through a scan and it

Figure 11: Robotic sealing after retouching.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

and defects; - Precisely assess and ensure repeatability of the coating quality degree. The objective 4.0 has been achieved.

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HMG Paints Launch Revolutionary CV Top Coat Acrythane 4G

MG Paints Ltd, the UK’s largest Independent paint manufacturer, has announced the launch of a revolutionary, one visit application, commercial vehicle top coat.

Acrythane 4G is a high gloss, high solids acrylic polyurethane coating developed to meet and exceed the stringent requirements of the commercial vehicle market (Fig. 1). Ideal for OEM, repairers and builders within a demanding marketplace, Acrythane 4G has an optimised balance of early hardness, fast cure and long pot life. Its ultra-fast air-dry properties create process and energy savings for users. Developed to provide outstanding gloss, final appearance and properties over traditional systems. “I have been using HMG products for many years now, the 4G product is without doubt the best gloss I have seen from a Commercial Transport coating” said Kenny Wells of

Wells Coachworks.

durability over a range of HMG primers, Acrythane 4G offers enhanced

2 1

Figure 2: Utilising HMG’s innovative UNIT LITE tinting system Acrythane 4G is available in a wide variety of colours including RAL, BS and Commercial Vehicle standards.

With its revolutionary “one visit application,” Acrythane 4G does not require the end-user to observe the usual intermediate flash-off time. This allows the end-user to save not only time but also energy and materials. Feedback from early users included comments such as “4G is a fantastic product! From its application to its flow out, resulting in an outstanding gloss finish. We just love it.” Brendan Whelan, Enniscorthy Autobody Ltd. Johnie Lee of South Derry Commercial Spraying commented “I am very happy with HMG’s 4G top coat, the thinner options allow me to control the speed in colder and warming weather. This is very important to me as one person painting a large area needs full control of the speed of application.” Acrythane 4G is both VOC and REACH compliant and available as both a coloured top coat and clear coat. Utilising HMG’s innovative UNIT LITE tinting system Acrythane 4G is available in a wide variety of colours including RAL, BS and Commercial Vehicle standards (Fig. 2). 4G can be applied by conventional gravity and HVLP spray guns, giving coverage of 9.3 square metres per litre until 50 microns film thickness. Surface preparation is as simple as a solvent wipe or shot blasting.

Figure 1: Acrythane 4G has been developed to meet and exceed the stringent requirements of the commercial vehicle market.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

For further information: www.hmgpaint.com

BRAND-NEW

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

its acquisition of automotive coatings

PPG: WE PROTECT AND BEAUTIFY THE WORLD™ 1

manufacturer Hemmelrath. Financial

PPG works every day to develop and

PG announced that it has completed

PPG Completes Acquisition of Automotive Coatings Manufacturer Hemmelrath terms were not disclosed.

deliver the paints, coatings and materials

Headquartered in Klingenberg, Germany,

that its customers have trusted for more

Hemmelrath is a manufacturer of coatings for

than 135 years. Through dedication and

automotive original equipment manufacturers

creativity, PPG solves the customers’

(OEMs). With more than 450 employees, the

biggest challenges, collaborating closely

company operates manufacturing facilities

to find the right path forward. With

in Klingenberg and Erlenbach, Germany; Jilin,

headquarters in Pittsburgh, the company

in construction, consumer products,

China; Duncan, South Carolina, United States;

operates and innovates in more than

industrial and transportation markets and

and Indaiatuba, Brazil. Hemmelrath supplies

70 countries and reported net sales of

aftermarkets.

automotive plants worldwide, and more than

$15.4 billion in 2018. It serves customers For further information:

7 million vehicles are coated with its products each year.

1 We protect and beautify the world is a PPG trademark.

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The Hemmelrath’s production site in Erlenbach, Germany.

www.ppg.com

Opening photo: The trident logo has always recalled a refined style combined with pure lines, two peculiar elements of Italian design.

FOCUS ON TECHNOLOGY

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

The Advantages of Robotics 4.0 for the Flame Hardening of Maserati Car Bumpers Monica Fumagalli ipcm®

stimates in the field of robotics are only partly reassuring: in its

ranked fifth in Europe and tenth on a global level in 2018, with

preliminary World Robotics Report, the International Federation

190 robotic systems installed for every 10,000 employees.

of Robotics (IFR) wrote that 384,000 robotic devices were sold

Eastern countries lead the ranking: South Korea is firmly in first

worldwide in 2018, i.e. one percentage point more than the previous

place since 2010, with 710 robotic systems for every 10,000

year1. According to the findings of the international association, Italy

employees. The automotive industry is the main beneficiary of the Industry

1 https://www.ifr.org

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

4.0-oriented developments in this sector: from welding

FOCUS ON TECHNOLOGY

Manager Daniele Balzano,

and assembly to coating and sealing, every stage of a car manufacturing process involves the use of increasingly cuttingedge and high-performance robots. In the Mirafiori plant (Turin, Italy), the bumpers of the Maserati Levante car model are

The Mirafiori plant (Turin, Italy), where the bumpers of the Maserati Levante car model are coated, has replaced its robotic devices with two new generation robots built by CMA Robotics (Pradamano, Udine, Italy) for the flame hardening of plastic components. This has guaranteed several strategic advantages for its coating process.”

“is devoted to the flame hardening of all plastic components built in polypropylene and intended for the sportiest Maserati cars. Attention to detail is evident even in the choice

coated.

of materials and moulding

It has replaced its robotic

technologies: this is the only

Maserati: attention to detail and unique design

FCA plant that coats plastic components both

by CMA Robotics (Pradamano, Udine, Italy) for the flame hardening of plastic components.

The trident logo has always recalled a

versatility and high impact resistance, as well

This has guaranteed several strategic

refined style combined with pure lines,

as polyurethane, which enhances the vehicles’

advantages for its coating process (Fig. 1),

two peculiar elements of Italian design

lines better than polypropylene.”

including greater compliance of painted

(ref. Opening photo). However, it is the

surfaces to quality standards, significant

care with which every detail is designed and

operational savings in terms of process and

built that makes every Maserati car unique

Flame hardening: a crucial phase for the coating of plastics

consumption, and greater operator safety

(Fig. 2).

Flame hardening is a crucial phase in

thanks to an innovative access system that

“The recently updated plant,” explains

the plastic coating process, because it

was tailor-made for this factory.

Mirafiori-Maserati Bumper Shop Production

enables plastic polymers to increase the

in polypropylene and in ABS, characterised by

devices with two new generation robots built

Figure 1: The two robots for flame hardening plastic bumpers built by CMA Robotics (Pradamano, Udine).

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

CMA flame hardening robots: main features The two 6-axis robots installed belong to the GR6150 HW series of CMA Robotics. “This is the top model of CMA,” says CMA Robotics Sales Director Marco Zanor while describing the selected devices. “It has a load capacity of 15 kg and it is designed to possibly ingrate pumps and colour change units, which are then managed by the robot control module in order to guarantee speed, waste reduction, and high quality. Its work area allows handling large parts and it can be increased by using ground or overhead transfer carts (Fig. 5 and Table 1). The robot can be equipped with multiple guns or rotating bells and perfectly integrated with any air and paint flow regulation device, by

2 1

using extremely sophisticated software that

Figure 2: The Mirafiori plant in Turin paints bumpers for all versions of the Levante car from Maserati range.

is also easy to use and equipped with all the diagnostic tools required by the Industry 4.0 parameters (Figs. 6 and 7).”

surface tension of the substrate and

This was the first time that CMA

therefore the adhesion of the paint

participated in an FCA call for tenders:

An innovative offline system for PC program generation

layer applied later (Fig. 3). “This is the

it was an important success for them.

“Currently, the robots work on two shifts,” says

first station of our coating process

At the same time, it gave us the

Balzano, “and they have a production capacity

for plastic components (Fig. 4),” says

opportunity not only to add a new

of one skid per minute, with a flame hardening

Balzano. The workpieces come here

supplier to the list of those already

time of approximately 50 seconds; the plant

after undergoing an alkaline-acid

known to our factories, but also to

however could potentially process 400 skids

pre-treatment operation, performed

deepen the knowledge of a

per shift. Each frame can accommodate 1

to remove any oil, dust, and particle

new robotic technology.”

to 4 parts, depending on the type and shape of the component (Fig. 8).

residues left on the surface, and a drying phase.

Thanks to the monitoring

The flame hardening plant consists

of the workpieces

of a booth equipped with the two robots designed and installed by CMA Robotics, the company that won the tender issued by the FCA purchasing department for the updating of this system. “We included CMA among the ©

candidates,” states Mirafiori-Maserati

cs oti ob AR CM

FCA Engineering Paint specialist Ilario Crosio, “because we had appreciated a robotic system we had

3 1

seen in operation within a coating line in Modena: the application was different, but the installed technology was the same.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

Figure 3: The three-dimensional layout of the flame hardening station.

through the 3D scanner,

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

the system selects the most suitable flame hardening program based on the type and number of components on the skid. The robots can store 99 programs each, with several secondary options: therefore, the variables for the creation of programs are numerous.” “The offline system,” adds Zanor, “allows developing and verifying the programs executed by the robots. The system detects the threedimensional conformation of workpieces, on which some flame hardening spots determine the trajectories to be followed by the robot (Fig. 9). The program also

4 1

enables to manage all the flame hardening parameters

Figure 4: Bumpers subjected to flame hardening.

the required results. The software package uses the same interface of the robot control unit and it includes an

of the guns, in order to obtain

Applied robotics 4.0 The robot management system is linked to a

online guide with suggestions for various

series of Industry 4.0-oriented digital checks

features. After saving, a program is sent to the

that allow real-time detection of information

robot to be elaborated as a flame hardening

on the two robotic devices, from methane

program; similarly, the programs executed on

gas consumption to executive parameters

the robot can be elaborated by the software

such as voltage, flame temperature, and

package for possible modifications.”

other process variables. Such real-time

“The benefits of this system, “states Balzano,

monitoring also enables the generation of

“include the possibility of programming

alarms in case of failure.

without interrupting production, the

“Another important feature of this

process simulation option, the ease of

4.0-oriented system is the fact that, if

programming (which is actually performed

the robot detects a process defect, the

by our staff), and the use of the same

management system records the anomaly

interface for the scanning system and the

and prevents the execution of subsequent

robot control unit. Since this technology

operations: this saves material, time, and

enables the robot to recognise the parts

labour also involved in operations that do

on the skids, the device only processes

not directly concern the flame hardening

the material actually present on the frame,

process. The faulty parts are therefore

which reduces methane gas costs, VOC emissions, and the amount of CO2 in the booth, as well as increasing productivity thanks to the reduction of cycle times.”

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

5 1

Figure 5: The work area of the robots’ mechanical arms.

immediately eliminated from the production flow, without being treated and discarded at the end of the process as was the case previously.”

FOCUS ON TECHNOLOGY

Table 1: Technical data of the GR6150 HW robot produced by CMA Robotics.

METAL METALFINISHING FINISHINGLINES LINES

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

6 1

Figure 6: A detail of the wrist in function.

The two 6-axis robots installed belong to the GR6150 HW series of CMA Robotics. This is the top model of CMA. It has a load capacity of 15 kg and it is designed to possibly ingrate pumps and colour change units, which are then managed by the robot control module in order to guarantee speed, waste reduction, and high quality. Its work area allows handling large parts and it can be increased by using ground or overhead transfer carts.” Safety comes first

a team of highly specialised

“There are also important benefits in

engineers, able to independently deal with the offline programming

FCA has long invested in training

terms of safety,” says Balzano. “First of all, the robots’ design guarantees that the

of all bumper processing phases,

gun supply cables and connections are

including flame hardening and

completely integrated inside the arm and

coating (Fig. 10). “Our staff has

no longer exposed. This eliminates the risk

the necessary skills to resolve

of critical issues that could jeopardise the

any critical issue that may arise

flame hardening process and increases

during processing and prevent

the safety degree of the booth. A further

future failures with a predictive approach,” states Mirafiori-FCA

7 1

precaution for the health of the operators is the innovative system using nominal

Product Process Specialist and

tokens that correspond to the role of

Coating Technologist Andrea

each employee, placed at the entrance

Russi. “CMA’s robot technology

to all workstations: this allows performing

was also based on these premises.”

different operations based on the type Figure 7: End view of the wrist and gun support coupling.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

of token inserted, thus further improving

One partner for your automated paint applications Preprogrammed centralized controls Easy integration Modular build User friendly interface (HMI)

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SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Figure 8: Each skid can house 1 to 4 components depending on the type and size of the workpieces: for instance, only one bumper and its strip or, alternatively, 4 smaller size mouldings can be arranged.

the safety of our operators. Last

8 1

but not least, we should mention the two robots’ dual anti-collision system: the first device allows stopping production in the event of a collision with the components on the frame; the second one is based on a dynamic software system that constantly checks whether pre-set areas may interfere one with each other and stops the robot before this happens.”

Conclusions After the flame hardening operations, the components reach the coating plant, where the primer, base coat, and final clear coat are applied. The cycle ends in the cross-linking ovens of the coating system (Fig. 11 and 12).

Figure 9: The result of a 3D scanning on screen.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

9 1

FOCUS ON TECHNOLOGY In Process Temperature Monitoring

Comprehensive • Up to 20 thermocouples • Wireless setup and download via Android App • 2-way Telemetry • Bluetooth • 3.8 million data points • Calibration data embedded

Easy!

10 1

• Graphical Analysis for quick data evaluation and reporting.

Figure 10: The staff of Maserati-Mirafiori with Alessia Venturi from ipcm®: from left to right, FCA Engineering Paint Luciano Paradiso, Product Process Specialist and Bumper-shop line Technologist Andrea Russi, FCA Engineering Paint Ilario Crosio and Mirafiori-Maserati Bumper-shop Production Manager Daniele Balzano.

Accurate • IP67 Data Logger • Reliable Thermocouples • Thermal Barrier in Stainless Steel or Aluminium • Waterproof version for E-Coat Dryers

11 1

Figure 11: Bumper coating.

2 Hall 1 425 Booth

PhoenixTM GmbH Tel +49 5731 30028 0 www.PhoenixTM.de info@phoenixtm.de

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

The integration of the two CMA robots has led to an improvement in final coating quality degree through better wettability of substrates and greater adhesion of paint. It is worth mentioning that, since the installation of the two robots in August 2018, FCA has achieved a technical effectiveness value close to 100%, as no faults have occurred yet. The technical characteristics of this advanced technology combined with specific IT functions has given unprecedented peace of mind: this is another benefit of Industry 4.0 for the automotive sector.” achieved a technical effectiveness

is that 2019 shows a steady growth

robots in our flame hardening

value close to 100%, as no faults

in sales also thanks to the decisive

process has led to an improvement

have occurred yet. The technical

push of the automotive industry,

in our final coating quality degree

characteristics of this advanced

with Maserati remaining one of the

through better wettability of

technology combined with

flagships of its high-end segment.

substrates and greater adhesion

specific IT functions have given us

of paint layers, states Balzano.

unprecedented peace of mind:

Finally, it is worth mentioning that,

this is another benefit of Industry

since the installation of the two

4.0 for the automotive sector.”

robots in August 2018, we have

Our hope for the robotics sector

“The integration of the two CMA

12 1

Figure 12: One of the three-layer coating systems applied on the Maserati bumpers is blue.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

Opening photo: The aesthetics of finishes plays an increasingly fundamental and strategic role in the agricultural and earthmoving machinery sector.

INNOVATIONS: PRESENT&FUTURE

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Direct-to-Metal: Straight on Metal, Straight to the Future Davide Terzoli, FRANCHI&KIM Spa, Castenedolo, Brescia – Italy

marketing@franchi-kim.it

he global industry has always

the guiding goal of its business, from

Franchi&Kim invests huge human and

strived to increase production

the sales and logistics departments

financial resources to keep pace with

quality and efficiency through

to the production workshop and

the evolution of raw materials, in order

innovations and technological

the R&D lab. The great challenge

to improve and perfect its coating

improvements. Every sector tries to

of the last decades has been the

products.

achieve the same performance with

transition from solvent-based to

The world of water-based paints is

less time and costs in order to provide

water-soluble coatings – a major

constantly evolving to better meet the

customers with better and more

technological change for paint

needs of users: the market currently

competitive products. Franchi&Kim has

manufacturers and an innovative

requires stable, reliable, simple to use,

always focussed on customer service as

challenge for applicators. Each year,

and high performance products. The

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

The global industry has always strived to increase production quality and efficiency through innovations and technological improvements. Every sector tries to achieve the same performance with less time and costs in order to provide customers with better and more competitive products. â&#x20AC;? water-soluble resins is always lower. The last

serious cleaning and preparation issues,

problem presented by water-soluble paints is the

which result in paint adhesion problems also

everlasting compatibility, or bond, between dry

considering the polarity differences between

films and water; for structures exposed to the

water and metal working oils (Fig. 1).

elements, this generates serious risks of blistering

For applicators, the challenge is primarily

or early corrosion (Fig. 2).

technological, i.e. improving the preparation

Franchi&Kim has developed a range of high

of substrates before painting. For coating

performance water coatings for industries and

manufacturers, the main challenge is to

professionals, based on the best results obtained

find specific additives to improve surface

by its research and development division.

wettability and compatibility. Hardening or

Many of the above-mentioned problems have

drying times are another very delicate issue

been reduced or even eliminated thanks to the

for water-based paints: water evaporation

companyâ&#x20AC;&#x2122;s field experience. This firm firmly believes

is much slower and more complicated in

in the evolution guaranteed by direct contact

uncontrolled environments compared with

with customers and their needs and, therefore,

that of solvents and the reactivity of

pursued over time through the recommendations

ÂŠ Franchi&Kim

metal surfaces to be coated always present

Figure 1: The metal surfaces to be coated always present serious cleaning and preparation issues, which result in paint adhesion problems.

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

of technical and sales employees. Both its one and two-component systems achieve excellent anti-corrosion, mechanical, and chemical performance levels. As for application, they are much appreciated for their ease of use and resistance. Very long pot life, high verticality, and excellent distension are the main features of new generation water-soluble paints (Fig. 3). Among water-based products, Direct-to-Metal (DTM) or “one-coat” products represent a niche of ever-growing importance; these coatings, in fact, enable to replace primers and top coats with a single coat of paint. Franchi&Kim offers both one-component alkyd or polyurethane and two-component acrylic solutions. The latter, in particular, are the core of a new coating philosophy that combines high performance with great ease of use. Indeed, twocomponent acrylic DTM products simplify coating by allowing to use only one paint and one catalyst instead of a traditional epoxy primer and a polyurethane finish with their respective catalysts. This is a considerable advantage in automatic systems with limited tanks for painting products: by simplifying the coating cycle, it is possible to allocate more space for a higher number of colours. Using only one coating brings benefits also in terms of equipment cleaning, since epoxy, polyurethane, and acrylic products have different requirements for pipe cleaning solvents. This reduction in materials and products also eliminates many problems and errors that may arise when different catalysis percentages must be adopted if different catalysts are used, which can generate confusion and mix-ups among products; the reorganisation and stocking operations are also considerably

2 1

easier to manage.

The use of a single product speeds up the paint application phases. In many cases, by taking advantage of the verticality of the Franchi&Kim formulations, it is possible to obtain the required thicknesses (70 to 100 µm) with just one coat or to apply two coats with a wet-on-wet process, without any downtime for repainting. This also applies to any oven process, which does not require a first stage for the primer and a second one for the top coat.”

100

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

Figure 2: For structures exposed to the elements, the everlasting compatibility, or bond, between dry films and water generates serious risks of blistering or early corrosion.

3 1

Figure 3: Very long pot life, high verticality, and excellent distension are the main features of new generation water-soluble paints.

INNOVATIONS: PRESENT&FUTURE

It is well known that aesthetics is crucial in most productive sectors, such as for instance in the construction of agricultural and earthmoving machinery or of some industrial plants, e.g. numerical control or woodworking machines.”

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Figure 4: The use of a single product speeds up the paint application phases.

Franchi&Kim’s new DTM coatings have very long pot life times of up to 90-120 minutes, thus enabling to set the cleaning process and any system alarms with very high parameters and ensuring excellent continuity of use, without the waste due to unnecessary plant cleaning operations. The use of a single product speeds up the paint application phases (Fig. 4). In many cases, by taking advantage of the verticality of the Franchi&Kim formulations, it is possible to obtain the required thicknesses (70 to 100 µm) with just one coat or to apply two coats with a wet-on-wet process, without any downtime for repainting. This also applies to any oven process, which does not require a first stage for the primer and a second one for the top coat. Franchi&Kim’s two-component acrylic DTM products have a high cross-linking reactivity and they are fully hardened with a quick dwell time of 40 minutes at 55-60 °C. Once out of the oven, the workpieces can be packaged and stored immediately.

info@waterenergy.it

www.waternergy.it

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

UV resistance characteristics, resulting in excellent gloss retention and durability. Thanks to the addition of anti-corrosion pigments, all paints as also classified as C3H or C4M products according to the EN 12944 standard. Last but not least, these coatings feature great elasticity, which results in higher impact resistance and better adhesion to substrates subject to significant thermal expansion. Franchi&Kim takes particular care in the selection of its resins, in order to guarantee that a wide range of surfaces can be coated with its acrylic DTM paints, e.g. steel, zinc, aluminium, and plastics: all these can be accurately protected by the elastic and uniform film of this

5 1

range of paints. The AQUAMIX colour system

Figure 5: Franchi&Kim’s Direct-to-Metal product range guarantees perfect distension even with high thicknesses, thanks to the coatings’ excellent substrate wettability and expansion capacity.

can be used for all these coatings, made with high coverage and outdoor resistance pigments and in a wide range of colours and shades: RAL, RAL DESIGN, NCS, COLORADOMIX 935,

The Direct-to-Metal coating range of

agricultural and earthmoving machinery

COLORADO BOX 2.0, and MUNSELL. They all

Franchi&Kim includes a wide spectrum

or of some industrial plants, e.g. numerical

allow using the Play&Color portable colour

of gloss values: 10 gloss with AQUACRIL

control or woodworking machines (ref.

detection system.

OPACO DTM Serie 2122, 40 gloss with

Opening photo and Fig. 6). The use of high

AQUACRIL SATIN DTM Serie 2115, 60 gloss

quality acrylic resins gives Franchi&Kim’s

Direct-to-Metal: a brilliant solution with a bright

with AQUACRIL SEMILUCIDO DTM Serie

formulations excellent weathering and

future.

Serie 1399 (containing no anti-corrosion pigments). This allows meeting the needs of every applicator, ensuring perfect film distension even with high thicknesses thanks to the coatings’ excellent substrate wettability and expansion capacity (Fig. 5).

2017, and 90 gloss with AQUACRIL LUCIDO

In fact, it is well known that aesthetics is crucial in most productive sectors, such as for instance in the construction of

Franchi&Kim takes particular care in the selection of its resins, in order to guarantee that a wide range of surfaces can be coated with its acrylic DTM paints, e.g. steel, zinc, aluminium, and plastics.”

102

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

6 1

Figure 6: Nowadays, high quality aesthetic results are required even for some industrial plants, such as numerical control or woodworking machines.

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Opening photo: Mapsa, a part of the Corporación Mondragón, the eighth Spanish business group, provides all major OEMs with its alloy wheels: PSA Group, Opel, Seat, Volkswagen-Audi Group, Kia, and Ford.

FOCUS ON TECHNOLOGY

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

How to Coat 700 Alloy Wheels per Hour with One Plant: Mapsa’s Solution Alessia Venturi ipcm®

ith a speed of 7.99 m/min., it

with innovative solutions to solve the typical

These are just some of the features of

is among the fastest coating

and unique problems of wheel coating

the turnkey plant designed and built

lines in use in the alloy wheel

processes, now intensified by the industry’s

by Olpidürr (Milan, Italy), the world

industry and one of the largest in the

strict specifications, such as wheel shape,

competence centre for alloy wheels of the

world in terms of productivity. It was

paint thicknesses, presence of surface

German group Dürr, and installed by the

designed with an Industry 4.0-oriented

areas not to be coated, oven temperature

Spanish cooperative Mapsa (Pamplona,

approach for full traceability of wheels,

control profiles, temperature at the exit

Spain) in 2018. With a productivity of almost

each of which is matched with its actual

from coolers, and soft wheel grip during

700 alloy wheels per hour – 685, to be

process parameters. It is also equipped

transfer among synchronised circuits.

precise – this is an imposing plant, built

104

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

cooperatives of Navarre. Its strong customer

in the framework of the expansion of the already existing paintshop. “Conceiving an optimal layout with the space and material flow constraints imposed by Mapsa was the first challenge faced already in the offer phase,” says Flavio Bodini, the Sales Manager for the wheel sector at Olpidürr. The line is arranged on three levels, with five synchronised conveyors; a robotised loading station and a continuous flow unloading station sending the parts to the inspection and final check lines; two identical powder primer application

With a speed of 7.99 m/min., it is among the fastest coating lines in use in the alloy wheel industry and one of the largest in the world in terms of productivity. It was designed with an Industry 4.0-oriented approach for full traceability of wheels and equipped with innovative solutions to solve the typical and unique problems of wheel coating processes.”

orientation and focus on the research and development of new design and finishing solutions for alloy wheels have made Mapsa an important supplier for all major OEMs: PSA Group, Opel, Seat, Volkswagen-Audi Group, Kia, and Ford (ref. Opening photo). “Mapsa manufactures alloy wheels for some of the leading OEMs” says Investments & Engineering Manager Jesús Rodríguez Bueno. “Our fully integrated cycle starts with melting, low pressure moulding, and fully automated X-ray control and ends with machining, thermal

booths; two booths applying liquid base

treatments, and coating. Design, quality, and

coats and clear coats and overlooking an

flexibility are the characteristics that set us

air-conditioned clean room; ovens and

apart from our competitors. We work in close

Ecopure TAR recovery afterburner with a

Mapsa: corporate leadership for customer satisfaction and safety

capacity of 25,000 Nm3/h, i.e. the largest

Wheels guarantee a vehicle’s safety: they

our wheels in 25 European countries, as well as

in Dürr’s range, to purify the air exiting the

ensure stability, road holding, and braking

India, United States, Russia, and South Africa.

liquid coating booths, the flash-off units,

effectiveness. At the same time, they are also

We only produce OEM rims between 15 and 20

and the cross-linking oven; auxiliary

an important aesthetic element, able to define

inches. We have two coating lines in addition

systems and devices including

and enhance the design of a car. Established in

to the new Olpidürr one: one applies acrylic

chemical-physical water treatment,

Orkoien, a town on the outskirts of the famous

products and also treats diamond wheels

demineralised water production, and

Pamplona, in the Spanish region of Navarre, in

and the other performs conventional coating

coating sludge separation units.

1957, in 1991 Mapsa turned into a cooperative

operations. We decided to install a third coating

This line was designed in compliance

and became part of the Corporación

line, particularly such a large line, because we

with the principles of Industry 4.0, i.e.

Mondragón, the eighth Spanish business group,

wanted to increase the productivity and painting

with a supervision system that, in addition

thus becoming one of the main industrial

capacity of this factory, Mapsa’s only one.”

coolers for each process phase; a Dürr

collaboration with our customers also to develop suitable finishing solutions. We supply

to managing and © ipcm ®

controlling all machines, allows full traceability

Line features “The whole line is

of each wheel, which is

automated. The loading

identified by a

station is equipped with

Datamatrix code reader

a robot that picks up

during loading so as to

the wheels from a roller

uniquely match it with

conveyor and arranges

its process parameters

them, three at a time,

when passing through

on the load bars of

the individual sections of

the one-rail overhead

the system.

conveyor (Fig. 1) going

Currently, the plant is

through the whole

in the ramp up phase,

pre-treatment section

ready to handle the

– the only overhead

increasing production

conveyor out of the

volumes of Mapsa, one

five linked to this line,”

of the leading companies in the European automotive sector.

Figure 1: The robotic loading station.

explains Mapsa Project Manager Oleksandr Kudinov.

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

105

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

which also includes a drying and degassing oven and a forced cooling tunnel, another 6-axis robot with a gripper grasping the wheels by their rims picks up three parts at a time from the load bars and deposits them on a stabilised inverted one-rail conveyor. This is equipped with piece-holders, or spindles, with a contact area with the wheels’ bearing surfaces and centring cones and a retractable mask in a polymeric material, which avoids indentations in the coupling areas inside the hub and prevents paint adhesion. The floor conveyor is linked to the powder coating station, where the primer is applied in four different colours: white, black, dark grey, and light grey (Fig. 3). At the entrance of each

2 1

powder booth, the operators cover the wheel areas that must not be painted with suitable

Figure 2: The spray pre-treatment tunnel.

masks in an air-conditioned room. In order to ensure maximum quality, after “If required by customer specifications, we

being transferred to the first floor conveyor,

designed to avoid balance differences

can increase the parts’ corrosion resistance

the wheels always move within closed and

between full and empty bars; they are

by activating a stage with zirconium salts,”

ventilated areas with filtered and conditioned

suitable for wheels with significant

adds Mapsa

differences in diameter and height and

Coating Director

to prevent any contact with the exposed

Raul Velasco.

areas of the wheels.”

“We guarantee a

Pre-treatment occurs through a

minimum corrosion

Chemetall 12-stage process that

resistance value

includes a surface conversion step with

of 1,000 hours in

the well-known SAM product, specifically

the salt spray test

developed for the alloy wheel industry

and 240 hours in

by Chemetall itself (Fig. 2).

the CASS Test. We

The cycle is composed as follows:

have an internal

three degreasing stages, two rinses

laboratory that

with mains water, a deoxidation stage,

performs any

a rinse with demineralised water, a

quality test required

conversion stage with the SAM polymer

by the alloy wheel

to increase the corrosion resistance of

industry: cyclic

parts, and two rinses with recirculated

corrosion tests,

demineralised water first and then with

solvent, acid, and

fresh demineralised water. Specific

gravel resistance

analysis tools continuously monitor

tests, coating

the active baths, so that the control

adhesion tests, water immersion tests (one

air. “We installed two identical GEMA booths

system automatically doses the various

of the most important ones to check the

for applying the powder primer (Fig. 4),” says

chemical products. Conductivity is

quality of finishes), and acetone immersion

Kudinov. “This unusual choice for the sector

measured at the exit of this line section,

tests (to verify the proper polymerisation of

of alloy wheels has enabled us to significantly

since it is an indicator of the final

coatings).”

increase our productivity by taking advantage

cleanliness degree of wheels.

At the end of the pre-treatment circuit,

of the quick colour change system.

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N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

“The new plant’s load bars have been

3 1

Figure 3: The robotic transfer from the overhead conveyor of the pre-treatment circuit to the floor conveyor of the powder application circuit.

FOCUS ON TECHNOLOGY

The booths are multicolor, that means that

After the powder application station,

cell with a necessarily limited size. Finally,

each booth can apply any colour. The booths

the wheels are deposited on the metal

all this must be made while avoiding the

work in parallel: while one is applying a colour

spindles (with a simplified centring

obstacles in the area consisting of the

on the wheels, the other one is changing

device) of the stabilised inverted one-rail

devices that must necessarily be installed

the colour whitout the need to stop the

conveyor linked to the curing oven and

near the robot’s work area,” explains Flavio

production. This also improves flexibility.”

cooler circuit, through another automatic

Bodini from Olpidürr. “In these case, it was

“The powder coatings are applied with a

transfer by a 6-axis robot with a grip that

essential to perform simulations during

feeding technology using dense phase pumps

picks up three rims at a time. “Among

planning, thus defining the best layout and

AP01.1 and a last generation Opticenter

the many technical challenges of this

moving obstacles so that the fastest axes

powder management unit with separate

project, one in particular required the

can always be used and critical points are

management modules for each gun (Fig. 5),”

attention of Olpidürr’s engineers: the

avoided in the pre-set trajectories.”

states Esteban Reboiras, Managing Director

wheels’ transfer from the powder booth

“As for the powder curing oven, Mapsa’s

at System Pulver, the sole distributor of GEMA

conveyor to the curing oven and cooler

specifications were also extremely

in Spain. “Moreover, thanks to the excellent

one. Indeed, the involved robot also has

challenging in terms of temperature

collaboration we started with Dürr, our booth

to perform an intermediate stop-over

consistency and maximum temperature

air purification system also treats the air from

in the hub and bearing surface cleaning

allowed. Therefore, the oven features

the machines removing powder residues

station. Moreover, the two conveyors with

separate and independent temperature

from the spindles, the conveyor, and all wheel

a speed of 8 m/min. and a cycle time of

rise and maintenance areas, in order

areas on which no deposits are allowed.

15 s must be synchronised while moving

to minimise any differences in the

This has enabled Mapsa to avoid installing any

a mass (grip and wheels) of almost 200 kg

temperature profiles of the various

additional filtration systems.”

with a 2 m footprint inside a robotised

wheel surfaces with extremely different

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SPECIAL ON AUTOMOTIVE & TRANSPORTATION

IR station and send the

thicknesses and, at the same time, ensure

application of the liquid

compliance with the dwell time required

base coat and clear coat,

wheels to the liquid

by paint suppliers. Thanks to the conveyor

as requested by paint

coating station at the

routing, however, the footprint remains

suppliers to achieve

required constant

extremely compact,” explains Olpidürr

better finishing quality.

temperature.

Project Manager Alessandra Sapla.

“Always coating at the

The area including the

After the forced cooling station, another

same temperature and

liquid base coat + clear

robot automatically transfers the wheels

preventing sudden

coat system application

on the spindles of the stabilised inverted

changes is very

station and the cross-

conveyor of the liquid coating application

important for quality

linking oven is crossed

and drying circuit. The first section of this

purposes,” states

by the fifth and last

circuit consists of a quality inspection

Sapla. “Therefore, even

floor one-rail conveyor,

booth and an oven with IR lamps to heat

though the system is

equipped with aluminium

the wheels’ mounting faces before the

fully air-conditioned and

spindles (Fig. 7). The

consequently the booths

two spray booths for BC

operate with constant temperature and humidity (differentiated between winter and summer to reduce

and CC are configured

5 1

integrating EcoBell +

Figure 5: Gema’s Opticenter powder management unit.

energy consumption),

EcoGun technology complete with an automatic servo axis system. “Mapsa tries

to apply its base coats and clear coats mainly

fast medium wave IR lamps featuring a power

employing the electrostatic bells (Fig. 8), while

regulation system and mounted on specific

using the guns only for the touch-up operations

frames. This also ensures that the wheels

needed to reach an adequate coverage

constantly reach the optimal temperature

degree,” says Alessandra Sapla. “This minimises

for paint distension (Fig. 6).” In order to save

the use of paint, thanks to the high transfer

energy, if conditions permit, it is possible to

efficiency of the bells that reduces overspray

set the cooling section so as to turn off the

and production costs.”

we chose to include a chamber equipped with

4 1

Figure 4: Powder primer application.

Mapsa installed two identical GEMA booths for applying the powder primer: an unusual choice for the sector of alloy wheels which has enabled the company to significantly increase our productivity by taking advantage of the quick colour change system.”

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N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

6 1

Figure 6: A sample check of the wheel temperature after passing into the IR pre-heating chamber.

FOCUS ON TECHNOLOGY

equipped with an air conditioning unit featuring heating and cooling batteries, a droplet separator, and preliminary filtration and finishing stages. A CO2 flame detection and extinguishing system protects the

booths, the recirculation pipes, and the air treatment recirculation units. Verind (Milan, Italy), belonging to the international group Dürr as its world competence centre for application technologies in the wheel sector, integrated the coating booths with automatic equipment and eco-technologies specifically developed for high-end wheel coating © ipcm ®

processes by combining advanced solutions 7 1

Figure 7: The robotic transfer from the powder application circuit to the liquid application one.

used in the automotive industry and adapted to the high line speed of the Mapsa plant. The project was developed with flexibility and modularity criteria, installing the innovative Dürr EcoBell2 electrostatic

while maintaining a very limited footprint.

technology for the application of liquid coatings

The aeraulic system includes recirculation

and achieving a very high automation degree

units in order to guarantee consistent

in compliance with the Industry 4.0 principles.

thermo-hygrometric conditions in the

The Dürr EcoBell2 electrostatic technology with

The application of liquid coatings (one-

booths and reduce the airflow to be sent

titanium bells guarantees as follows:

component solvent-based products) occurs

to the afterburner for the abatement of

- high surface finishing performance for the

in two opposite booths, separated by an

VOCs, while increasing their concentration

air-conditioned clean room that allows

to reduce this machine’s consumption.

- high transfer efficiency and high reliability;

observing the painting process and adjusting

The system includes a downstream heat

- extensive control of the spray cone thanks to

the different parameters as needed with

recovery unit to produce hot water for

total process control ergonomics. “From this

heating the pre-treatment baths and for

clean room, it is possible to fully monitor both

air conditioning (Fig. 9). Each booth is

Advanced solutions for the application of liquid base coats and clear coats

application of base coats and clear coats;

the separate adjustment of the two flows; - closed-loop control of turbine rotations and high voltage control.

the application process and the state of the the need for the operator to physically move,” explains Alessandra Sapla from Olpidürr. “The operations to be performed in the paint management unit are limited to loading and cleaning: this increases operator safety by exposing them as little as possible to an

Figure 8: The base coat and clear coat are applied with EcoBell2 Dürr electrostatic technology.

adjacent coating management unit without

environment with the presence of solvents, although adequately ventilated.” The solution adopted for the liquid application booths is the Dürr Vertijet side water-veil technology including a wet abatement unit and a Venturi scrubber, which minimises overspray with an exclusively fluid dynamic process and with no need for abatement nozzles or filters in the extraction tower,

8 1

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

109

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

“The coating process of

and overspray,” adds

aluminium wheels is very

Verind Commissioning

complex due to the 3D

Engineer Ivan De

shape of these products.

Angelis. Verind also

That is why we integrated

designed and supplied

automatic colour change

the booths’ waste

systems, the servo axis

water treatment and

technology for the EcoBell2

demineralised

bells, and Dürr automatic

water production

guns conveniently

system.

arranged and activated

Demineralisation occurs

with an automatic cycle

with an ion exchange

(Fig. 10),” says Alessandro

resin system (Fig. 12)

Soba, Sales Manager at

allowing removing all

Verind. “An electronic

salts dissolved in water.

supervision system including PLCs and PCs with a graphic interface for line operators enables

It is fed with recirculated

9 1

water from the cleaning processes.

Figure 9: One of the technical levels of Mapsa’s painting installation.

The plant consists of

to monitor and record all

an activated carbon energy saving and efficiency reasons.”

column for the elimination of organic matter

related data. The base coat and clear

“The automatic system developed by Verind

and a duplex system (i.e. while the first unit

coat paint mix room unit is equipped

to recover the products generated by colour

is operating the second remains in stand-by

with Dürr pumps with a continuous paint

change cycles, which are collected in a tank

mode) to handle a 24/7 production flow.

recirculation system; each pumping

placed in the coating management unit through

The plant operation and the resin

group has a paint level and pressure

specific fluid circuits, is a true innovation for

regeneration process are managed

control (Fig. 11).

Mapsa. This reduces contamination of the

automatically through a control panel and

Variable speed agitators have been

water veils in the booths and therefore both

by appropriately sized valves in acid-proof

installed, driven by electric motors for

the use of waste water purification products

material.

application process phases and their

10 1

11 1

Figure 10: Automatic control panel of paint application parameters of EcoBell and EcoGun.

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N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

Figure 11: Paint mix room box with paint pumping unit for BC and CC complete with Dürr pumps and controls.

FOCUS ON TECHNOLOGY

physical plant is composed of an acidification station dosing an acid and a metal salt, a neutralisation station dosing lime milk, and a flocculation station dosing polyelectrolyte. This mixture is then separated in the subsequent lamellar decanter. Such separation leads to the formation of two flows: water, free of any dissolved substances, and sludge, collecting all the removed impurities. After filtration with sand and coal, water can be discharged; the sludge collected from the bottom of the decanter is sent to a thickening and dehydration section with a plate filter press.

Accessory systems Mapsa’s line also includes an innovative cleaning system for the wheels’ hub interiors and bearing surfaces after the powder primer application. 12 1

Figure 12: Duplex automatic demineralization system.

“Developed by Olpidürr and currently patent-pending, this machine is set according to the coating program matched with each wheel, which includes specific cleaning requirements for its hub and mounting face, depending on the car manufacturer’s specifications,” explains Alessandra Sapla. The patent-pending cleaning system for the powder line

Regeneration water (acid and alkaline eluates), together with process

conveyor’s spindles is also extremely high performing, as it was designed

water, is then treated in a chemical-physical plant for the abatement

to completely solve the cleaning issues of powder application circuits’

of metals (aluminium), fluorides, COD, and other salts. The chemical-

spindles and conveyors.

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Attention to maintenance

alarm, displaying, and process parameter and machinery status

The line must produce quality

setting functions, the supervision

wheels (Fig. 13): that is why

system includes a wheel tracking

the machines must be able

software system that enables

to be inspected and both the

each wheel in the plant to be

replacement of consumables and

identifiable on the control PC

wear parts and the scheduled

workstations’ screens and the

maintenance operations in

operator panels equipped with

general must be carried out

this feature.

easily and safely. This line has

All wheel types, together with

been designed keeping these

their geometrical characteristics

needs in mind. For instance, all air

and matching cycles, are stored in

13 1

conditioning machines and the oven heating and forced cooler

the supervision system and they can be retrieved and matched

Figure 13: A finished wheel.

ventilation units are installed on a

with the batches to be produced during the day through a panel in

platform with easy-access spaces

the loading area. In this way, the supervision

and paths for machinery maintenance.

system communicates the required process

Attention to safety The plant was designed and built while constantly checking compliance with safety regulations and criteria. For example, the whole route along which the load bars can be carrying wheels is protected with wire nets and all access doors to robotised plant sections are equipped with electric locks. It if is necessary to see a station in function, as

Mapsa’s line includes an innovative cleaning system developed by Olpidürr for the wheels’ hub interiors and bearing surfaces after the powder primer application and a vibrator supplied by Rösler to clean the Teflon masking caps used on wheels.”

parameters to the line machines, the pick up and deposit coordinates to the robots, and the information needed to implement the program corresponding to the wheel’s type and cycle to the PLCs. If a Datamatrix code is present on the wheel, the process and coating data are also matched with the individual wheel and transferred to Mapsa’s mass memory units.

Conclusions

tunnel, operating procedures

“The line’s commissioning

have been defined to allow observation only to specialised

in the case of the pre-treatment

ended about a month ago,” says Jesús Rodríguez Bueno

personnel. Another example is

(Fig. 14).

the liquid coating application

“We are now implementing

station: due to the presence

the ramp up phase, and

of solvents, concentration

especially optimising the

detection tools have been

coating thicknesses. It is

installed in suitable positions to

early to disseminate any

guarantee the intervention of

savings and efficiency data,

the supervision system in any

but one look is enough to

situation of potential danger.

perceive that Olpidürr has designed a solid, advanced,

The supervision system The supervision system is

and well-conceived line. 14 1

an impressive productivity

based on Siemens 1500 Series PLCs and the Wonderware System Platform software package. In addition to all the

112

Above all, this plant gives us

Figure 14: From left to right: Raul Velasco from Mapsa, Esteban Reboiras from System Pulver, Juan Mari Ormart from Mapsa, Alessandra Sapla from Olpidürr, Oleksandr Kudinov and Jesús Rodríguez Bueno from Mapsa, Ivan De Angelis from Verind, and Alessia Venturi from ipcm.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

level and it will be able to meet our needs for many years to come.”

Oops...

FASTRIP FASTRIP, for the easy, effective and rapid paint stripping of metals.

ALIT Technologies, the chemical paint stripping specialist. Products, machines, processes and consultancy.

www.alit-tech.com San Bonifacio â&#x20AC;&#x201C; Verona - ITALY

FOCUS ON TECHNOLOGY

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

PSP, One of the Italian Pioneers of Contracting Paint Stripping, Counts on the New FASTRIP Spray Technology to Treat Automotive Components © ipcm ®

Monica Fumagalli ipcm®

n the field of surface treatments, the automotive industry is certainly among the sectors demanding the highest coating performance and compliance

with the most stringent requirements. One of the most overlooked aspects in this framework is the paint stripping of car components that need to be recovered and reworked. The number of these parts is higher than one might think and the complexity of this operation is determined by the different materials used (aluminium, zamak, galvanised sheet metal, steel, etc.) and the number of recovery attempts made on defective parts, which are uneconomical to eliminate from the coaters’ production process (ref. Opening photo). PSP Sverniciature Sas (Bornasco, Pavia, Italy) specialises in the maintenance of frames, hooks, and piecehanging accessories intended for coating lines and in the recovery of coated parts that present any defects. During its history, it has implemented all development stages of the various stripping technologies. “PSP was among the first companies to start a paint stripping contracting business at the end of the 1980s,” says Massimiliano Prederi, the owner of this firm together with his wife Elena. “The development of this field contributed to regulate both the paint stripping of coating hooks and the recovery of defective parts, which used to be performed with operations that did not respect health and the environment. “PSP started by using the cryogenic technology to paint strip frames and hooks. Then, we implemented the thermal technology with a pyrolytic oven for the Opening photo: Car components such as windscreen wipers and roof rails are among the most complex products to paint strip.

114

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

PSP Sverniciature Sas specialises in the maintenance of frames, hooks, and piecehanging accessories intended for coating lines and in the recovery of coated parts that present any defects. During its history, it has implemented all development stages of the various stripping technologies. PSP was among the first companies to start a paint stripping contracting business at the end of the 1980s.”

FOCUS ON TECHNOLOGY

Figure 1: The FASTRIP paint stripping plant installed by Alit Technologies at the premises of PSP Sverniciature Sas.

coatings from defective products. In

“We chose to add this new treatment to the ones

system installed in our factory and supplied

the pyrolytic oven, the workpieces

already performed,” states Prederi, “with the aim

by Alit Technologies (San Bonifacio, Verona,

are introduced into the chamber for

of offering, in addition to the paint stripping of

Italy), we can now treat any type of material

pyrolysis (flameless combustion) at

coating frames and accessories, a process suitable

(Fig. 1).” The machine developed by Alit, a

a maximum temperature of 450 °C,

for all the materials that are difficult to handle with

firm specialising in chemical paint stripping

so as not to permanently deform the

the cryogenic and thermal technologies, such as

solutions for metals, is based on the spray

metal elements treated.”

application technology, an innovation for

Chemical stripping is a process that

the paint stripping sector presented on the

has existed for many years, although

pages of this magazine on the occasion of

harmful paint strippers to the

the launch of the FASTRIP range1. PSP is the

environment were used in the past.

first company in Italy to use it for large-scale

The research and development of new

products.

products has led many companies in

The state of the art of paint stripping

recovery of iron workpieces. With the last

the sector to develop acid or alkalinebased paint strippers with increasingly better performance in terms of safety

PSP’s growth followed the evolution of paint

and environmental impact. That

stripping technologies, with all their pros

is why, in order to differentiate its

and cons. “Cryogenic paint stripping is a low

process range and offer a complete

environmental impact technique,” explains

service to its customers, PSP has

Prederi. “It is very effective for removing

recently implemented a new chemical

thick layers of paint deposited on coating

paint stripping technology developed

hooks, but it is less suitable for removing

by Alit.

1 I. Paolomelo, Innovative Paint Stripping Systems: Alit’s New Products Presented at PaintExpo 2018, in ipcm® International Paint&Coating Magazine no. 51 (May-June 2018), pages 104-105.

Figure 2: The entrance to one the two chambers of the spray paint stripping plant.

2 1

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

115

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

FASTRIP’s requirements “The FASTRIP paint stripping plant installed in the factory of PSP is a modular system with one tank,” says Alit Technologies owner Loris Rossi (Fig. 2). “The parts are loaded into a basket that subsequently enters the first tank, where they are treated at a temperature of 120 °C (Fig. 3). During the spraying of the paint stripping product, the basket rotates by 360° for the whole cycle, which ends with a suction phase. After checking that all workpieces have been properly stripped, the basket is removed from the stripping tank and is placed in a second, identical tank containing water at 70 °C to rinse the components. In this way, after verifying that they have been stripped in compliance

3 1

with specifications, the parts can be Figure 3: The inside of the chamber, with its basket rotation system.

for example the aluminium workpieces

galvanised frames are recovered

constituting automotive components

before being sandblasted in a

and design products like handles and

two-chamber shot blasting machine

lamps.” Indeed, chemical paint stripping is

supplied by OMSG (Villa Cortese,

particularly suitable for treating metal alloys

Milan, Italy) and specifically tailored

that reach their melting point at 300 °C, such

to PSP’s needs. The oven installed by

as aluminium.

Ciroldi (Villa Ganaceto, Modena, Italy)

PSP’s paint stripping processes: different operations for a complete service

paint strips frames and recovers iron parts. Alit Technologies’ FASTRIP paint stripping plant, finally, is used to recover products in any type

Each paint stripping plant installed by

of metal, especially aluminium

this Italian company performs a different

and similar alloys, with defective

operation: in the cryogenic system,

coatings.

116

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

The machine developed by Alit, a firm specialising in chemical paint stripping solutions for metals, is based on the spray application technology, an innovation for the paint stripping sector presented on the pages of this magazine on the occasion of the launch of the FASTRIP range. PSP is the first company in Italy to use it for large-scale products.”

immediately packaged and prepared

4 1

Figure 4: The vertical arrangement of bars facilitates the paint stripping operations.

FOCUS ON TECHNOLOGY

for delivery.” The system’s modular

The machining residues, composed of the

structure allows replacing only the saturated bath while using the second tank for cleaning and rinsing, so that it is not necessary to completely replace the stripping solution. However, Alit did not only design and supply a mere paint stripping plant. “Besides meeting the customer’s paint stripping requirements,” adds Rossi, “our staff identified other critical issues related to this process. That is why we tried to provide PSP with a complete system integrated with all useful devices to make its operation cost effective and eco-friendly. In addition to the new stripping technology, our engineers designed and installed a diathermic oil heater, a scrubber for fume abatement, and a sludge treatment unit.”

PSP chose to add this new treatment to the ones already performed with the aim of offering, in addition to the paint stripping of coating frames and accessories, a process suitable for all the materials that are difficult to handle with the cryogenic and thermal technologies, such as for example the aluminium workpieces constituting automotive components and design products like handles and lamps.”

paint stripper and the waste produced by the coating removal process, are gathered in a decanter to be dehydrated and then filtered with a filter-press specifically developed to recover the paint stripper, which is separated from sludge and recirculated into the machine with some fresh product. The solid residue is disposed of as special waste.

The advantages of the new spray technology “Thanks to the technology installed,” says Prederi, “for our chemical paint stripping process we can use products with a low environmental impact, which are activated at 120 °C (i.e. almost the double of the temperature required by immersion processes, occurring at 50 or 60 °C) but

Aluminium Wheel Painting

Excellence in surface finishing For the painting of aluminum wheels, Dürr delivers powerful technologies along the whole process, starting with wheel surface cleaning and chemical conversion for effective corrosion protection, painting and curing, to the purification of air exhaust. Dürr offers their own application technology with specially patented features that fit best with the requirements of quality-oriented aluminum wheel surface painting. www.durr.com

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

have very high flash points

jeopardise the stripping

and are not toxic. As a

process due to their contact

further benefit, they also

with the workpieces’ surfaces.

allow performing a “soft

Secondly, thanks to the

stripping” operation, i.e. a

vertical arrangement of

delicate stripping process

the bars, these do not lean

that does not change the

against each other as they

molecular structure of the

would do with a horizontal

workpiece or the chemistry

arrangement, thus favouring

of metal, which can thus

the removal of paint. In order

maintain its peculiar

to facilitate the parts’ exit

resistance characteristics.”

from the stripping chamber,

“The system,” Rossi explains,

we have equipped our plant

“can perform a quicker paint

with side platforms where

stripping cycle compared stripping processes requiring an immersion in the tank, because it

they can be easily gathered.

5 1

with conventional chemical

We have created a special

Figure 5: From left to right: PSP Sverniciature Sas owner Massimiliano Prederi, Elena Leonelli, and Loris Rossi, the owner of Alit Technologies (San Bonifacio, Verona).

combines the benefits of of high temperatures: a cycle lasts

(max. 2000x1400 mm) that can host 136 bars. Alit Technologies’ team

is currently developing a project to

mechanical action with the effects

rack for long workpieces

increase this spray paint stripping

about 20 minutes per removed

plant’s maximum capacity up to a

paint layer, on average. Moreover,

workpiece size of 2500x1400 mm.”

the components are arranged within the basket (Fig. 4). This has

Simplified stripping of automotive components

two advantages. First of all, by

In the field of automotive

avoiding bulk processing, there is

components, the recovery of

no need for spacers, which could

several workpieces poses an issue.

vertically and in fixed positions

CMY

In particular, PSP treats numerous batches of windscreen wipers and roof rails. “The spray stripping results

Thanks to FASTRIP system, the diversity of materials and the recovery attempts performed by the applicator are no longer an issue: the defective coating removal speed and the ability to perform a multi-metal treatment have solved these problems and even streamlined the process, revolutionising the way in which paint stripping has always been conceived.”

118

on these products are optimal,” states Prederi (Fig. 5). “The chemical product used only removes the upper surface layer without damaging or altering the galvanised one (Fig. 6). Thanks to our FASTRIP system, the diversity of materials and the recovery attempts performed by the applicator are no longer an issue: the defective coating removal speed and the ability to perform a multi-metal treatment have solved 6 1

Figure 6: The spray stripping results on the products treated by PSP.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

these problems and even streamlined our process, revolutionising the way in which we have always conceived paint stripping.”

Opening photo: The minimum material thickness of 2 mm determined for the buckling load case was validated in different 3-point bending tests.

INNOVATIONS: PRESENT&FUTURE

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Material Savings Thanks to Correct Corrosion Protection Christian Lenzmann Dörken MKS-Systeme GmbH & Co. KG – Herdecke, Germany

clenzmann@doerken.de

uspension parts in cars play a major role: Brakes, springs, wheels

The chassis in the car represents the connection between the body

and many other components form a complex composite. It is

and the road surface. This means that it transfers energy between

precisely here that a reduction in weight through lightweight

the vehicle and the road. It also enables the steering and braking of

construction can take effect and ultimately reduce the vehicle’s fuel

the vehicle. Technically sophisticated and safety-relevant systems

consumption. But only with the right corrosion protection.

are therefore essential. The chassis as a whole and the steering

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INNOVATIONS: PRESENT&FUTURE

elements in particular are exposed to

A curing process cross-links the

extreme stresses: Potholes, cracks or

coating layer to form a homogeneous,

unevenness on the roads strain the

cohesive film. The procedure is

parts and therefore require high quality.

particularly well-suited to complex

In order to avoid these problems, a car

structures and large batches, also

needs different types of steering: control

penetrating hollow spaces. However,

and trailing arms as well as twist beams.

cathodic dip painting only offers

Depending on the vehicle category, the

passive corrosion protection, with

components are made of steel or even

the result that rust and the risk of

aluminium. These components require

disbonding arise where the coating is

a minimum of buckling strength, which

damaged down to the substrate.

is usually given by the design geometry and material thickness.

Coating options against corrosion

Proven corrosion protection: Zinc flake This problem can be solved by combining a zinc or zinc flake basecoat from the

KTL – cathodic dip coating is particularly well-suited to complex structures and large batches, also penetrating hollow spaces. However, cathodic dip painting only offers passive corrosion protection, with the result that rust and the risk of disbonding arise where the coating is damaged down to the substrate. This problem can be solved by combining a zinc or zinc flake basecoat from the Dörken MKS portfolio with either a Dörken MKS top coat or a cathodic dip coating.”

However, in order to maintain the

Dörken MKS portfolio with either a

movable requirements on the

Dörken MKS top coat or a cathodic dip

component and the material thickness,

coating. This achieves high-performance

the components must be protected

cathodic corrosion protection. Especially

against corrosion. This can be caused

the coating systems made of zinc flakes

by water, cold and heat and particle

are recommended for suspension arms,

friction such as salts or dirt. A frequently

as they are applied in very thin layers

used surface protection is the KTL

(8–20 µm). Hollow spaces and weld

coating. KTL – cathodic dip coating – is

nuts also present no challenge. The thin

an electrochemical coating process

coating leads to excellent and long-lasting

in which the component is coated

corrosion protection and thus to long

via direct current in a tank filled with

functionality of the component.

aqueous, electrically conductive dip

Another advantage: The zinc flake

Simulation tests for sheet thickness reduction

coating. The deposited layer thickness is

systems are also suitable for high-tensile

The daily work and development of

typically between 10–40 µm.

steel, as no hydrogen is produced in the

long-lasting corrosion protection

coating process and the risk of

technologies drove Dörken MKS to the

hydrogen-induced stress corrosion

question of how high the theoretical

cracking is thus avoided. The low

weight reduction of components can be

cross-linking temperatures of 220 °C also

through wall thickness reduction. The

prevent material damage to the steel due

ACS (Automotive Center Südwestfalen)

to excessive heat stress. The coordinated

was therefore commissioned to

top coat ensures a high active cathodic

investigate this on a simplified example

protective effect – even after stone

of a chassis control arm. These are

impact. This means that in the event

usually oversized with a wall thickness

of damage to the coating, the ignoble

of 2.6 mm – i.e. they are produced from

zinc in the basecoat sacrifices itself on

the outset with a risk premium that

contact with water and oxygen in favour

already includes damage caused by

of the more noble steel base material.

potential corrosion. The results of the

In addition, zinc flake systems meet the

study are impressive: Theoretically, up

requirements of the manufacturer’s

to 30% of the mass can be reduced.

own driving tests and thus meet the

How was this figure determined? Using

increasing quality requirements of the

the Leonard Euler buckling test.

OEM’s.

In the first step, the finite element

Suspension parts in cars play a major role: Brakes, springs, wheels and many other components form a complex composite. It is precisely here that a reduction in weight through lightweight construction can take effect and ultimately reduce the vehicle’s fuel consumption. But only with the right corrosion protection.”

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

121

method was used to determine how the simplified model (in the form of a steel U-profile) behaves with the current sheet thickness of 2.6 mm under buckling load (Fig. 1). This means that the U-profile is compressed in its

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

longitudinal direction in the simulative model construction until it buckles. The U-profile buckled at a force of 49.2 kN. The OEMs’ specifications – depending on the vehicle model – are only approx. 35 kN. The over-sizing was already evident here. For this reason, the second step was to investigate up to what plate thickness the U-profile can be reduced under a given buckling load of at least 35 kN without neglecting the required buckling strength. The simulation showed that the sheet thickness of the U-profile could be reduced to approx. 2 mm – with full compliance with the required buckling strength. This means that the mass can be minimised by up to 30%.

The daily work and development of long-lasting corrosion protection technologies drove Dörken MKS to the question of how high the theoretical weight reduction of components can be through wall thickness reduction. The ACS (Automotive Center Südwestfalen) was therefore commissioned to investigate this on a simplified example of a chassis control arm.”

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Figure 1: The simplified model of a suspension arm: U-profile with a material thickness of 2.6 mm.

Compliance with mechanical properties Within the scope of the study, the influence of corrosion on the mechanical properties was also investigated with the aid of a 3-point bending test (based on DIN EN ISO 14125, ref. Opening photo). The bending test showed hardly

The results of the study are impressive: Theoretically, up to 30% of the mass can be reduced. How was this figure determined? Using the Leonard Euler buckling test.”

any deviations between the test specimen with safety pad and the 2 mm thick U-profile. If it were not for the risk of corrosion.

a phosphate and subsequent

First, the minimum bending stiffness

cathodic dip coating surface. The

of the profile was calculated.

test specimens were then subjected

The reference sheet thickness was

to a stone impact (in accordance

the 2 mm thick profile, which yielded

with EN ISO 20567) in the buckling

a bending stiffness of 3.1 kN/mm.

area and three corrosion stresses

Then the profiles were coated:

were applied: the salt spray test

the 2 mm thick U-profile with a

(in accordance with DIN EN ISO

high-performance zinc flake basecoat

9227), the accelerated corrosion

and top coat from Dörken MKS,

test II (ACT II) and the VDA test (in

the 2.6 mm thick U-profile with

accordance with VDA 233-102).

INNOVATIONS: PRESENT&FUTURE

Zinc flake coating: Low wall thicknesses with the same component performance The results were clear: The 2 mm wall thickness test specimen coated with the zinc flake system performed without red rust infestation in all three corrosion tests. 1,000 hours in the salt spray test and six cycles each in the climate change tests were achieved. At the same time – both loaded and unloaded – a bending stiffness between 3.2 and 3.4 kN/mm was achieved in the 3-point bending test. By way of comparison: The 2.6 mm thick U-profile showed recognisable red rust infestation at the same times and an unloaded bending stiffness of approx. 4 kN/mm and values between 3.8 and 3.9 kN/mm after loading.

Within the scope of the study, the influence of corrosion on the mechanical properties was also investigated with the aid of a 3-point bending test (based on DIN EN ISO 14125). The bending test showed hardly any deviations between the test specimen with safety pad and the 2 mm thick U-profile. If it were not for the risk of corrosion.”

Weight saving due to effective coating system The ACS study commissioned by Dörken MKS shows: The additional 0.6 mm, which is planned in practice as a safety component, can be saved with the aid of effective corrosion protection. It became clear that this could also reduce the buckling strength. An effective corrosion protection thus fulfils both the different corrosion properties and the mechanical properties and can lead to an overall saving of around 30%. More than promising for the future of lightweight construction!

COATING METAL PARTS?

Coating systems and application technology from one supplier Your expert for automatic coating machines for coating metal parts, plastic parts, glass and many more will be happy to advise you!

www.sprimag.com

Opening photo: Omar powder coats automotive components such as trailers, semi-trailers, tow hooks, suspension systems, and chassis.

FOCUS ON TECHNOLOGY

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Investing in Technology and Quality: Omar’s Strategy Ilaria Paolomelo ipcm®

n a sector in which German giants

companies to establish and compete in the

special and niche trailers, swap bodies

are achieving excellent sales results

heavy vehicle market.

and city trailers.

according to the statistics of the Italian

For this automotive&transportation special

Since when it was established in 1963,

Association of the Automotive Industry

issue, ipcm® has had the opportunity to visit

Omar has focussed on continuous

(ANFIA), modernising their production

Omar Rimorchi Srl, an Italian company that

investment in resources and technologies

plants and investing in cutting-edge

has produced trailers, semi-trailers, and

and on customer satisfaction. In line with

technologies and equipment seem to

equipment for industrial vehicles for about fifty

its mission, this company, based in the

be the only solutions available to Italian

years. This firm’s core business also includes

Marche region and with 80 employees,

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N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

having been very pleased with the quality

to a new location and renewing its production

results achieved and the collaboration

cycle by automating its surface finishing process.

established, we relied again on this company

“Having a large surface area where we could

based in Villa Cortese (MI, Italy),” says Tonucci.

store our products was one of the main reasons

“About two years ago, Omar installed a

that led Omar to move in the new plant located

continuous flow tunnel shot blasting machine

in Schieppe di Terre Roveresche (PU), covering

with a horizontal roller conveyor designed

over 80,000 m . This transfer was also the starting

specifically for cleaning metal structures that

point for renewing our production department,”

must be subjected to a subsequent coating

states company founder and owner Marco

process. The LAUCO 3015-16 system is

Tonucci. “For this, Omar relied on two important

composed of a loading roller conveyor, a

Italian partners: OMSG Officine Meccaniche

central tunnel with a shot blasting chamber

San Giorgio, specialising in the production of

equipped with 16 turbines, and an unloading

shot blasting and sandblasting machines, and

roller conveyor”, explains Giorgio Pozzi from

Eurotherm, which supplies coating systems.”

OMSG. “After the carpentry and assembly

The shot blasting process: a prerequisite for achieving the highest quality degree

1999-2019

hi-tech

has recently taken two important steps: moving

conveyors

operations, the metal sheets undergo mechanical pre-treatment through our shot blasting plant. The components to be treated are arranged on the loading roller conveyor (Fig. 2), they go through the tunnel where

in order to obtain perfect surface cleaning before

the shot blasting process takes place thanks

coating. “Having already worked in the past with

to the 16 turbines located strategically to

a shot blasting machine designed by OMSG and

cover their large surfaces, and they leave the

Omar installed a new shot blasting plant (Fig. 1)

CM AUTOMAZIONE srl 1

Figure 1: The LAUCO 3015-16 shot blasting system supplied by OMSG.

Via Monte Bianco 20 20833 Giussano (MB) - IT p. +39.0362.314075 f. +39.0362.861222 info@cmautomazione.it

www.cmautomazione.it

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

plant by means of the unloading roller. This is equipped with brushing and blowing systems for removing any metal abrasive residues and with a hopper for recovering them (Fig. 3).” “One of the main features of the LAUCO system is the possibility to adjust the component’s forward speed to obtain the required finishing degree in one quick passage,” adds Giorgio Pozzi from OMSG (Fig. 4). “Finally, another peculiarity of the plant installed at Omar’s premises is that the loading and unloading rollers are on the floor. This translates into an advantage in terms of both space and operator safety, since the current legislation requires the use of laser scanner sensors as a safety protection.”

The coating plant and cycle Omar powder coats trailers, semi-trailers, tow hooks, suspension systems, and chassis (ref. Opening photo). After shot blasting, these are directly coated without the need for any additional chemical pre-treatment. “Since we treat a maximum of 6 load bars per day, we chose to install a static system with a powder coating booth and a curing oven. Inside the large coating booth, the operator hangs the workpieces to be painted on the load bars, which are moved by an automatic conveyor controlled by a touch screen PLC (Fig. 5). Here, a powder primer from the AkzoNobel dry-on-dry system

2 1

is applied. The components are then taken to the curing

Since when it was established in 1963, Omar has focussed on continuous investment in resources and technologies and on customer satisfaction. In line with its mission, this company has recently taken two important steps: moving to a new location and renewing its production cycle by automating its surface finishing process.”

126

Figure 2: Components to be treated arranged on the loading roller conveyor.

oven where they undergo a pre-polymerisation process at a temperature of 160 °C. After this first phase, the parts

3 1

Figure 3: The filtering system of the shot blasting machine.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

Efficient © ipcm ®

FOCUS ON TECHNOLOGY

and reliable solutions for surface coating since 1988.

4 1

Figure 4: Alessia Venturi from ipcm and Omar Rimorchi Srl owner Marco Tonucci.

go back to the coating booth for the application of the second coat of the dry-on-dry anti-corrosion powder system. The surface treatment ends in the oven, where the

electrostatic systems for liquid painting

components are cured at a temperature of 200 °C (Fig. 6),” explains Tonucci. “After coating, the parts are moved onto a mask for the assembly of all the components required to complete our products, such as braking, electric, and

electrostatic systems and spraying booths for powder coating

pneumatic systems and accessories like suspensions and axles. Finally, we assemble the coated components to the bodywork. All these assembly processes are performed in different stations, each with a dedicated work team.”

pneumatic systems for high-, medium-, and low-pressure painting

Future projects “The installation of these new shot blasting and coating

IR and UV drying systems

plants is only the first step of our plant renewal plan. The next phase will be the integration of a radio-controlled robot to automate the hanging of the workpieces to the load bars, thus eliminating the use of a bridge crane.

robot and reciprocators

Thanks to this system, which is still in the design phase,

CM SPRAY s.r.l. www.cmspray.it

eosmarketing.it

About two years ago, Omar installed a continuous flow tunnel shot blasting machine with a horizontal roller conveyor designed specifically by OMSG for cleaning metal structures that must be subjected to a subsequent coating process.”

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

we will also eliminate the

results achieved. We have

blowing phase after shot

improved the quality of our

blasting, because the robot

products, because the powder

will tilt the parts, thus

coated products guarantee

automatically removing any

better aesthetic quality

abrasive and scale residues.”

while meeting the surface protection specifications of

Cheaper, faster, and more efficient: the benefits of Omar’s choices

our target market. We mainly focus on the Italian market, but 20% of our production is exported abroad. By choosing to use powder

need for more space to store our products to modernise our plants and reorganise our production department.

5 1

“We took advantage of our

Figure 5: A detail of a component powder coated by Omar.

to powder coating. We are pleased with the investments

Omar powder coats trailers, semi-trailers, tow hooks, suspension systems, and chassis. After shot blasting, these are directly coated without the need for any additional chemical pre-treatment.”

made and the excellent

6 1

Figure 6: Eurotherm’s coating plant consists of two modules: a powder coating booth and a static curing oven.

128

costs. Finally, we have helped improve our employees’ manual shot blasting process

another also brought a the transition from liquid

our production time and

lives, both by replacing the

Moving from one site to further challenge for us:

coatings, we have also halved

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

with an automatic one and by eliminating the solvent emissions of the liquid paints we used in the past,” states Tonucci.

SUCCESS STORIES

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

he powder coating of wheels for the automotive industry

C-Line: The Most Flexible Powder Coating Solution for Wheels transfer efficiency and even layer thicknesses. During the coating process, the 3D axis system

places high demands

on manufacturers. Increasing

moves all powder guns through

customisation, different wheel sizes,

the booth simultaneously with

superlative surface quality and a wide

the wheel (Fig. 2). The guns are

variety of colours are just some of

arranged opposite each other in

these. The flexible and extendable

order to make the best possible

C-Line coating unit from WAGNER

use of the “moving powder cloud”.

is the ideal, compact solution for

This means that, even at high

high-quality, highly automated wheel

throughput speeds of up to

coating (Fig. 1). It was developed

7 m/min, a wide and stable

especially for coating wheels in the

powder cloud is produced that

automotive industry. Key design

yields outstanding coating results

criteria included the smallest possible

for wheels between 13” and 24”

footprint to allow easy integration into

in diameter. At the same time,

existing production systems.

The compact construction of the means that it occupies just one third as much space as well-known systems

Figure 1: C-Line unit in the WAGNER Technology Center in Markdorf (Germany), with PXS powder centre.

be programmed and controlled to suit the wheel type and positioned fully automatically. © WAGNER

C-Line, with its 2-meter booth length,

each individual powder gun can

currently available on the market. To achieve maximum coating quality, the C-Line from WAGNER uses cutting-edge control technology. It is self-explanatory and offers the user a superb level of user-friendliness and control. The parameters are input entirely visually, with the guns being assigned their position via a visual “teach-in” method. Complex parametrisation processes are dispensed with, and no programming skills are needed. In view of the present shortage of skilled workers, this represents a major bonus when it comes to staff deployment. 2 1

The modern application technology also performs impressively on complex wheel geometries, with superlative

130

Figure 2: The modern application technology performs impressively on complex wheel geometries, with superlative transfer efficiency and even layer thicknesses.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

SUCCESS STORIES

ÂŠ WAGNER

PAINTING ROBOTS & SYSTEM INTEGRATOR We are able to provide the full range of articulated and cartesian robots for every painting need! LeBot MV A5-A6: 5 and 6 axis articulated robot with self-learning, point to point and 3D offline programming, also available in chariot, carriage and carousel configuration with 3D Lesta shape acquisition system. Figure 3: Exemplary integration of the C-Line into a powder coating system: In this case, in combination with the PXS powder centre.

The extremely small booth is cleaned from the outside through a large opening. In combination with the contact-free spindle seal on the conveyor inlet, the booth

LeBot C5: 5 axis cartesian robot with 3D Lesta shape acquisition system.

design with the stepped floor and suction from one side, colour changes can be carried out in less than 15 minutes on the entire system. The optionally available automatic gun blow-off mechanism, which moves the guns from the outside along the blowing nozzles, also accelerates the colour change process. The coating booth, which is around two-thirds smaller than other systems, features a filter, cyclone and pipe systems with compact dimensions. This not only saves space, but it also typically reduces energy consumption by 50% compared to conventional coating systems, resulting in a further improvement in the ROI.

LeBot IA6: articulated 6-axis industrial robots with jointed-arm kinematics for all point-to-point and continuous-path tasks, controlled by our LeCRob K-Manager software. LeBot IA6 robots can work with 3D Lesta shape acquisition system.

The new C-Line is available in a modular single or multi-booth arrangement and can also be prepared for the integration of coating robots. The extendable configuration also allows combinations of multiple booths to be arranged in series to cover conveyor speeds of up to 12 m/min. For a quick set-up, the booth components are supplied in a small number of pre-assembled modules. This shortens the assembly time and keeps investment costs low (Fig. 3). The C-Line from WAGNER is the most flexible powder

WWW.LESTA.IT

coating system for wheels on the market and offers users a superlative degree of automation, simple operation, space-saving positioning and the best coating quality at low investment costs. For further information: www.wagner-group.com

LESTA S.r.l. Via D. Chiesa, 42 - 20020 Dairago (MI) - Italy +39 0331.430817 +39 0331.1581053 info@lesta.it

Opening photo: Officine Pilla specialises in the setting up of satellite vehicles, compactors, and industrial vehicles for urban hygiene.

FOCUS ON TECHNOLOGY

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

A Coating System Tailored to Customer Needs for the Treatment of Urban Hygiene Vehicles Barbara Pennati ipcm®

“O

fficine Pilla has its roots in the past,” says Nicola Pilla,

production units in Montelongo and in Santa Croce di Magliano,

who manages this Italian family business together with

in the province of Campobasso. “At the beginning, our activity

his brother Antonello: the company was established by

was strictly artisanal, as our father took care of setting up tippers

their father Arturo among the lush hills of the Molise region, with

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N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

for industrial vehicles,” he explains. “My brother and I joined the

FOCUS ON TECHNOLOGY

distributor of paint products and equipment that provides it with Salcomix coatings, an AkzoNobel brand that guarantees a high paint customisation degree thanks to its colour system.

Glossy and highly resistant finishes The production flow of Officine Pilla starts with raw materials, especially iron, aluminium, or steel, processed in the plant of Montelongo (Campobasso). Here, sheet metal cutting and bending as well as assembly operations take place. The assembled products (Fig. 2) are then transported to the plant of Santa Croce 1

di Magliano, where the degreasing, sheet

Figure 1: An example of the tipper vehicles produced by Officine Pilla.

company in the 1980s, at a time when the relationships with customers were changing and the tipper sector alone did not guarantee a future of growth. We therefore needed to change and make a qualitative leap that allowed us to establish ourselves

metal sealing, coating, and final setting up processes are carried out.

Officine Pilla is specialized in the setting up of satellite vehicles, compactors, and industrial vehicles. In 2004, the company chose to devote itself in particular to mini-compactors, because they enable them to be more competitive especially in terms of production and delivery times. Currently, Officine Pilla produces around 200 small and medium-sized vehicles a year.”

throughout the Italian territory.” © ipcm ®

“Starting from the experience acquired in the repair of urban hygiene vehicles, an activity that we had been implementing over the years, in 1989 we designed and built our first municipal waste collection vehicle. In 1991, we officially became Officine Pilla, specialising in the setting up of satellite vehicles, compactors, and industrial vehicles (ref. Opening photo). In 2004, we chose to devote ourselves in particular to mini-compactors, because they enable us to be more competitive especially in terms of production and delivery times. Currently, we produce around 200 small and medium-sized vehicles a year (Fig. 1).” Officine Pilla’s products are distributed in a widespread way in Italy and partly also abroad. The company has two production sites in Molise and about twenty employees. For the coating of its vehicles, Officine Pilla always relies on Colormax, a multi-brand

2 1

Figure 2: An assembled product, ready to be degreased and coated.

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

133

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

A highly flexible colour system Colormax is the sole supplier of the Salcomix paints and the equipment used by Officine Pilla, including the 12 m x 5 m booth (Fig. 3). “We deal with coating products and equipment for all fields, from the building to the industrial sector. We use our know-how and skills acquired in fifty years of activity to identify the best solutions for our customers based on their production needs,” states Colormax owner Matteo Picciotti (Fig. 4). “Our collaboration with Officine

3 1

Pilla has been going on for © ipcm ®

Figure 3: A tipper ready to be coated in the booth.

decades now. Together with them, we have developed the most suited coating system not only to their production needs but also to their climate, as very

“The assembled products

low temperatures are reached

undergo a chemical degreasing

in winter in this area, making the

phase followed by the

painting process really difficult.”

application of a two-component epoxy base-coat and two layers of a two-component polyurethane top-coat,” says Nicola Pilla. “Finishes are very important to us. Most

4 1

thicknesses (170 to 200 microns) and glossy colours. In addition,

specifications require high

we must guarantee excellent abrasion resistance and durability. That is why it is crucial for us to rely on a technological partner like Colormax, which has always been able to support us and advise us on the most suitable equipment and products for our needs.”

Figure 5: The coating of small workpieces occurs with Graco AirMix guns and pumps.

134

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N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

Figure 4: From left to right: Nicola Pilla from Officine Pilla and Matteo Picciotti from Colormax.

Colormax supplies Officine Pilla with three types of white and a grey shade, mainly used for counter-frames. However, Colormax has also happened to be required particular types of orange or green, which they have custom-produced for Officine Pilla. This is the advantage of the Salcomix system: it allows to create tailor-made products based on customer requests while ensuring excellent quality performance and result repeatability.”

kwanchaift©fotolia

FOCUS ON TECHNOLOGY

For over thirty years Novaresine has been creating highly innovative products to meet the needs of the alkyd and polyester resin market. Continuous investments in research and technology allow us to offer a cutting-edge brand for various sectors, with a wide range of products to cover the specific needs of the clientele.

“As for the coatings, the Salcomix system enables us to create custom-made products. We supply Officine Pilla with three types of white and a grey shade, mainly used for counter-frames,” says Picciotti. “However, we have also happened to be required particular types of orange or green, which we have custom-produced for Officine Pilla. This is the advantage of the Salcomix system: it allows us to create tailor-made products based on customer requests while ensuring excellent quality performance and result repeatability.” The latest innovation implemented by Officine Pilla in terms of coating was the adoption of electrostatic guns. “Whereas for coating small parts we use Graco airmix guns and pumps (Fig. 5), at the beginning of the year we also implemented Graco Pro Xp electrostatic guns with Triton pumps (Figs. 6 and 7) to paint large workpieces,” explains Nicola Pilla. “This project was also developed in collaboration with Colormax, which supplied us with the whole equipment. The electrostatic system has enabled us to increase our application speed and improve coverage. Moreover, although it has been adopted for a relatively short time, we have already observed a 30% product saving.”

All-round collaboration “Colormax has been our only supplier for our entire coating process for many years now,” says Nicola Pilla. “The relationship that has been created now goes beyond a mere working relation. Not only did they support and advise us in the choice of our coating technologies, but they even stayed close to us in times

TO BE A TEAM

TO BE CLOSE TO THE CLIENT

of difficulty, such as during the 2002 earthquake that

TO BE FOR THE ENVIRONMENT

TO BE NOVARESINE

www.novaresine.com

eosmarketing.it

caused the collapse of our paint shop.”

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Colormax

(25%), bodywork (25%), and wood and marine sectors (10%). Colormax collaborates with several international brands. For over thirty years, it has been a dealer of the brand Graco, for which it acts as a service and warranty centre for the building, anti-corrosion, and finishing sectors. It has also collaborated with AkzoNobel for the distribution of the International, Salcomix, Sikkens and Herbol brands for five years now.

Colormax was established as a small local paint manufacturer in Altino (Chieti, Italy) in 1969. Over the years, it has specialised in the supply of a complete range of coating equipment and products. The firm is now managed by Matteo Picciotti and Andrea Buccella and it has thirtythree employees and six distribution offices with showrooms in Atessa, Altino, Chieti, Moscufo, L’Aquila and

Giulianova – the sixth site will soon open in Mosciano Sant’Angelo – that guarantee a widespread presence in the Abruzzo, Molise, Marche, Campania, and Lazio regions. Colormax provides its customers with consultancy services and products for the treatment and coating of any type of substrate intended for any use. Its core business are products and equipment for the construction field (40%), followed by the industrial

6 1

Figures 6 and 7: Graco Pro Xp electrostatic guns and Triton pumps, supplied by Colormax.

7 1

“The products used so far have

“In the past, it happened that our

timely response in case of need,” states

proved to be of excellent quality,

customers bought technologies and

Matteo Picciotti.

including the Salcomix coatings,

products from different suppliers. This

“For the future, in collaboration with

which we have been using for over

made our intervention difficult, in case

Colormax, we are developing the best

ten years,” adds Pilla. “Colormax’s

of problems. That is why we decided

solution for the installation of a mechanical

after-sales service has always been

to offer a complete service by taking

pre-treatment plant to guarantee an even

consistent and very attentive: their

care of the whole coating process,

higher quality level to our customers.

engineers have always intervened

from consulting and design to the

Finally, we will invest in a photovoltaic

promptly in case of problems,

supply and maintenance of coating

system to reduce our environmental

enabling us to resume production as

equipment and products. This allows

impact and increase cost efficiency,” says

quickly as possible.”

us to guarantee an effective and

Nicola Pilla.

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Opening photo: Clariant, a focused and innovative specialty chemical company, links past and future in the 2021-2023 Automotive Styling Shades Trendbook.

HIGHLIGHT OF THE MONTH

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Clariant Forecasts Colour Formulations Synergizing with New Mobility Trends in Automotive Styling Shades Trendbook Stefanie Nehlsen Clariant International Ltd – Pratteln, Switzerland

138

stefanie.nehlsen@clariant.com

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HIGHLIGHT OF THE MONTH

technology, how to create a colour travel

lariant, a focused and innovative specialty chemical company, links past and future in the

2021-2023 Automotive Styling Shades Trendbook. The new guide predicts subdued alongside lively colour surprises to match the unprecedented changes impacting mobility in the coming decade. Launched at the European Coatings Show, the latest edition of Clariant’s popular colour inspiration and support resource also takes a bold step in terms of convenience and content to capture the imagination of its strong audience of followers within the automotive paint

Launched at the European Coatings Show, the latest edition of Clariant’s popular colour inspiration and support resource also takes a bold step in terms of convenience and content to capture the imagination of its strong audience of followers within the automotive paint and coatings industry, and designers and trend analysts at OEMs.”

effect which works on white, or how to simulate a fluorescence effect under a UV-absorbing clear coat. Clariant’s future colour selections play with this high-speed movement towards a more urban and digital tomorrow. Energetic fresh colours leap off the page while other consumers will seek comfort in more understated hues. As an added extra, 2021-2023 Automotive Styling Shades Trendbook recognizes the industry’s most widely-used red pigment - Pigment Red 254 – and the return of red shades since the turn of the millenium. The in-depth feature coincides with

and coatings industry,

Clariant’s pioneering

and designers and trend

launch of a more

analysts at OEMs.

environmentally-

Content-wise, viewers

compatible version

explore a historical journey

of the pigment

of how and why colour

based on the

in cars has changed over

renewably-sourced

more than a century,

material bio-succinic

before traveling into

acid.

the future to discover

Samples coated with

the influence of shifting

original paint in all

mobility trends on colour

the colour shades

preferences for 2021-2023

complete the new

(ref. Opening photo).

Trendbook (Fig. 1).

Bernhard Stengel-Rutkowski,

“Clariant’s colour

Marketing Manager

Senior Global Technical 1

at Clariant, explains: “Recalling the car colours of the past reveals

Figure 1: Clariant forecasts colour formulations synergizing with new mobility trends in 2021-2023 Automotive Styling Shades Trendbook.

know-how is highly appreciated by paint suppliers to the automotive industry, as well as designers

technology leaps, long-term trends and correlations

even totally new ways of driving on and

and trend scouts of industries which

that help us to make more plausible

above the ground, are likely to have an

you wouldn’t relate to cars at all,” says

predictions about the future. Never

important effect on colour in cars.”

John Dunne, Head of Business Unit

before, however, did these predictions

Challenging traditional formulation

Pigments at Clariant. “As one of the few

have to take into account such a

knowledge and taking advantage of

pigment producers spearheading trend

staggering degree of disruption.

synergies between new effect pigments

colour forecasting for this industry, our

Business models that have been

and Clariant’s organic pigments, the

interpretations of how the changing

valid for more than a century

trend shades for the coming years are

world and emerging technologies will

must cope with an unprecedented

not only nice and colourful but tackle

influence consumer colour preferences

plethora of changes. Electrification

on-going obstacles in coatings

in the next decade has become a

and digitalization, urbanization,

formulation, too. For example, how to

solid base of inspiration and business

autonomous driving, car sharing,

make dark cars detectable by LIDAR

decisions for our customers.”

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Opening photo: Perfect results: Bumpers in the coating line at SMP.

INNOVATIONS: PRESENT&FUTURE

SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Wörwag and SMP Automotive Count on the Cleancert IBC + Impeller Melanie Ievolo SCHÜTZ GmbH & Co. KGaA, Selters – Germany

melanie.ievolo@schuetz.net

ndustrial packaging occupies a key role in supply chains. In highly

industry are applied in layers that are only a tenth of a millimetre

demanding industries, packaging is used to store and transport

thick. It is crucial to avoid any kind of contamination with surfactant

high-value products, and hence makes a crucial contribution to

substances, such as silicone oils and fats. These products frequently

maintaining quality. This applies in particular to modern automotive

lead to wetting defects in the coating which impair both the

coatings: the sensitive coatings used in today’s high-tech automotive

appearance and the perfection and can also severely compromise

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INNOVATIONS: PRESENT&FUTURE

the coating’s protective function. This leads

Impeller and an S56x4 bung. Thanks to the

supplier’s central warehouse, particularly

to follow-on processes which generate

integrated Impeller, the container can remain

in comparison to the steel containers

considerable additional costs. Maximum risk

closed throughout the entire supply chain

previously often used for these purposes.

minimisation from the very start is absolutely

from filling to emptying. At the same time, the

Up to four IBCs can be stacked on top

essential.

contents can be easily and effectively stirred.

of each other – instead of only two steel

An especially critical issue is that viscous

Conventional stirrers are no longer required

containers, meaning that the Cleancert

coatings require stirring before they can

and the risk of contamination is significantly

models also ensure that the available space

be used. However, even the immersion

reduced. The system is available for all 1,000

is used more efficiently (Fig. 2).

of a stirrer carries the potential risk of

and 1,250 litre Ecobulk types with DN 150 and

The downtime of empty containers is also

is opened or closed and any form of contact with other equipment can cause contamination. With these potential risks along the supply chain, it is reassuring

significantly reduced to a maximum

contamination. Every time the packaging

of seven days thanks to collection by the Schütz Ticket Service. Empty steel containers remained in the plant for up to one month, which occasionally

to know that packaging manufacturers,

caused bottlenecks in the company’s

fillers and consumers can work together

warehouse.

to prevent this happening. Together, these efficiency in the day-to-day handling of

Lower speed – gentle stirring process

coatings.

During processing in the air-conditioned

stakeholders can significantly increase

paint mixing room, clear coats, primers

Teamwork for gleaming coating results

and base coats are continuously stirred to ensure a homogeneous

Schütz has been supplying Karl Wörwag

consistency. In order to determine

Lack- und Farbenfabrik with IBCs

the advantages of the Cleancert IBC

since 2003. The coating manufacturer,

+ Impeller closed packaging system

headquartered in Stuttgart-Zuffenhausen,

in practice, SMP conducted a series

develops and produces high-quality paints

of tests, each lasting several weeks.

for a wide range of industrial applications:

The disposable stirrer is connected to

from vehicle interiors and exteriors to car

the screw cap of the IBC and is fitted

bodies, commercial vehicles, household appliances and the furniture industry. The business relationship with the packaging manufacturer from Selters in Westerwald has grown steadily over

at the Schütz factory. A conventional

drive system can be connected

Figure 1: Clean business: In-house storage of the Cleancert IBCs at Wörwag.

without requiring major modifications or conversions (Fig. 3). In the SMP test series a model by the agitator manufacturer Planetroll was used.

the years. Schütz also works closely with Samvardhana Motherson Peguform (SMP

DN 225 filling openings. “These advantages

If required, as part of its services, Schütz

Automotive), a major customer of Wörwag.

absolutely convinced us, and that is why we

will arrange contact with this cooperation

The specialist for plastic-based components

use Schütz’s Cleancert IBC for clear coatings

partner. Planetroll is very familiar with

supplies major automobile manufacturers

and primers as these products are particularly

the system, and the company’s portfolio

in Europe, China, Mexico, Brazil and the USA

sensitive to surface defects”, says Benno

includes complete drive solutions with

with ready-coated bumpers and other car

Beuter, application engineer at Wörwag.

all the necessary components such as

body parts.

The coatings specialist orders empty IBCs

transverses, couplings and steel shafts.

Wörwag and SMP were seeking a solution

which are delivered and stored in-house as a

The drive is placed above the screw cap

to minimise the risk of contamination during

further safety and hygiene measure (Fig. 1).

and fixed to the steel grid with a frame.

filling and subsequent processing of clear

At Wörwag’s customer SMP the filled

The drive shaft is inserted into the hollow

coatings and primers. Schütz had the ideal

containers are also delivered to a covered

shaft of the Impeller and fits in the hub;

packaging: an IBC from the Cleancert line

area and stored under roof. The Cleancert

the rotation of the shaft is passed on to the

configured to support the process with an

IBCs score yet again at the automotive

Impeller inside the container.

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SPECIAL ON AUTOMOTIVE & TRANSPORTATION

Figure 2: Efficiently stacked: The filled IBCs ensure that space is ideally used in SMP’s central warehouse.

revealed business management advantages: SMP was able to dramatically reduce the amount of work spent on corrections (ref. Opening photo and Fig. 4). This special cooperation showed how important it is to involve all companies along the supply chain.

Prevention during the production of Cleancert products Cleancert offers the highest level of technical cleanliness and safety for 2 1

product and process; all components that come into contact with the filling product are free from silicone. the paint in directly. This eliminates

The initial idea for the development

Impeller’s bucket agitator change

the need for a previously required

of this product was the certification

their position depending on the

preparatory step at an additional

of all production sites according to

centrifugal force.

station. The company uses the S56x4

the industry standard FSSC 22000,

The speed can be individually

bung to take samples for viscosity

combined with the implementation

adjusted to the filling level.

measurement and / or to add setting

of numerous specifications within the

The result of the comparative test:

or correction agents, if necessary,

framework of the HACCP and FMEA

with external steel stirrers, 140 to

during the stirring process.

standards. These apply to buildings,

200 revolutions per minute were

“The use of the Impeller as a

plants and the entire production

required for homogenisation. This

disposable system completely rules

high speed led to increased micro-

out the risk of contamination due

foam formation due to air intake

to residual product adhering to

into the product. When stirring with

the stirrer. This greatly increases

the Schütz Impeller, however, 80

process reliability”, explains

to 110 revolutions were sufficient.

Manfred Guttmann, head of the

The lower speed ensured gentle

paint shop at SMP. “This eliminates

stirring processes with optimum

the complex and time-consuming

results. Anton Krojer, the SMP

cleaning process for the agitator,

application engineer in charge of the

as well as other risks. Employees

test series, is highly satisfied with

no longer have to handle solvent-

the positive test results: “Thanks

based cleaning agents which greatly

to the efficient stirring processes,

improves work safety.” The multiple-

we no longer need preparatory

week test phase in the production

homogenisation measures prior to

of components for bumpers using

a container change.” Since the IBC

Cleancert IBCs and Impellers

including the Impeller and traverse

impressively confirmed all theoretical

drive can be transported flexibly and

aspects of the optimisation and

The three movable blades of the

considerably less time is required for homogenisation, it was possible to connect the container directly to the production line after the drive had been installed and feed

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Figure 3: The IBC with the Impeller and agitator drive is directly connected to the production line with a 2” Camlock.

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INNOVATIONS: PRESENT&FUTURE

4 1

Figure 4: Positive effect of the IBC + Impeller packaging system: fewer corrections required during the final inspection.

environment. One aspect is detailed hygiene regulations. For example, employees must change their gloves and clean the workplace before starting production. There are also measures to prevent contamination or dust, as well as glass and blade management procedures. Maintenance regulations and checks on the machines, systematic pest control throughout the entire factory premises, requirements for the controlled use of all working materials, especially greases and lubricants, and a secure goods receipt complete the package.

Seamless traceability Schütz manufactures the Cleancert packaging just-in-time on the basis of specific customer orders: the IBC inner bottles are transferred to the final assembly stage and installed immediately after the blowing process. Each production step and each component can be clearly assigned to the corresponding packaging. Identification via a barcode system enables complete traceability, right down to the batch and process level. On request, Schütz can also assign individual identification numbers for articles or packaging materials. Finished Cleancert IBCs are loaded indoors and shipped directly without intermediate storage. Pre-produced components such as screw caps, outlet valves or bung plugs are also hygienically packed in small quantities and stored separately. If dispatch is to take place at a later date, the containers are stored in special closed rooms. Optional plastic covers offer additional protection. Combined, all of these precautions make a considerable contribution to maintaining the quality of the subsequent filling product.

Opening photo: Rotary concentrator + RTO system.

INNOVATIONS: PRESENT&FUTURE

Pollutant Emission Control in Industrial Coating Processes Ruggero Baldi Airprotech Srl – Magenta, Italy

r.baldi@airprotech.eu

here are various types of harmful

volatile compounds VOC, solvents,

and pulmonary levels; volatile organic

substances that can be released

chemical additives, and others,

substances can have even more serious

into the environment by coating

depending on the specific type of

consequences, with high incidence on

and surface protection processes – solid

process. Solid-state substances like

cardiovascular diseases and tumours.

substances and particles such as paint

particles and dust can cause significant

The main objective of the ventilation and

powders, crystallised substances, gaseous

and short-term damage at the bronchial

pollution abatement systems intended for

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INNOVATIONS: PRESENT&FUTURE

Control of emissions and abatement of pollutants

organic compounds VOC or volatile inorganic

plants is guaranteeing the work areas’ healthiness, in order for both permanent

The selection and installation of an

solutions are also available in which different

and occasional employees operating near

adequate ventilation and exhaust system

technologies are used one after another to

these machines to find adequate working

for fumes and gaseous effluents produced

cope with all possible cases and collect all

conditions in terms of safety and health, in

by coating and surface protection processes

pollutants, even with different natures. The

compliance with the regulations in force on

represent the first intervention phase.

design of pollutant abatement plants should

the permitted concentration limits.

The second but equally important phase

take into account both technical and cost

industrial coating and surface protection

compounds VIC. In specific cases, integrated

requirements, including investment and © Airprotech Srl

Environmental ventilation and fume extraction Ventilation and fume extraction systems

operating costs.

Powder coating plants

are generally composed of a series

In the case of powder coating plants, the

of aspiration hoods that collect the

ventilation system’s task is sucking in as

fumes and substances generated by

much excess paint (i.e. not deposited on

industrial processes and convey them

the products) as possible. The first stage

outside the work environment, in order

usually performed by this type of plant is

to ensure adequate ventilation of the

a pre-filtration process with disposable

different areas. The purpose is to suck

filter panels. The characteristics of

such volatile particles or substances and

the system, such as material and

prevent them from spreading inside the

permeability, are selected according to

plant, with harmful consequences on

the type and concentration of powder in

operators and surrounding equipment.

the fumes.

The choice of the type and size of a

In applications where the excess paint

suction and ventilation system, first of

sucked by the ventilation system is

all, calls for the identification of all areas

dry, the final filtration unit is generally

where pollutants and dust are generated and emitted, as well as for the analysis of pollutants and their concentration. Then, the extractor hoods or modules’

composed of a cartridge fabric filter or

filter sleeves. In some cases, the fabric

Figure 1: A Venturi scrubber-type wet filtration plant.

type and size are selected to guarantee

filter is combined with cyclone systems for pre-separation. Both cartridge filters and filter sleeves are often integrated

the aspiration of substances without

is the integration of an emission control

with an automatic filter cleaning unit that

affecting or interfering with production

unit, including an adequate system for

extends their service life.

processes. Finally, the complex system

the abatement of the polluted substances

If the ventilation system must handle a

of channels and pipes that transfer

conveyed out of the work area. As already

sticky powder due to the type of paint

the particles or pollutants outside the

mentioned, there exist reference regulations

used, fabric filters cannot be used, since

work environment is designed. Various

that establish the pollutant emission limits

the fine powder would irreversibly stick to

parameters such as the static pressure

allowed. Such limits are set according to the

the surface of the filtering elements thus

at the suction points, the speed of the

specific processes and pollutants involved.

making them useless in a short time. Wet

gases inside the channels, and the

Several technical and plant engineering

filtration systems such as Venturi scrubbers

pressure losses generated on the way

solutions have been designed for the

are installed for these applications (Fig. 1).

to the gases’ final release point are

different needs of various production

Venturi scrubbers-type wet filtration

taken into consideration. Moreover,

and coating processes, all with the goal

systems are used to remove solid particles

partitioning systems and valves are often

of minimising the amount of pollutants

from gases through interaction with water.

installed on the channels, in order to

that are released into the atmosphere

The type and size of the system depend

allow independent adjustment of the

through the chimney. The technical

on the characteristics of the powder and

volumes sucked by each channel and

solutions differ according to the specific

particles to be treated, i.e. their quantity,

thus balance the system by ensuring

pollutants to be treated, i.e. solid particles

concentration, granulometry, density,

adequate suction at each point.

or gaseous substances such as volatile

composition, and wettability.

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145

Figure 2: Active carbon system.

than the initial one. The high concentration flow leaving the rotor is fed by the combustion unit, sized for a limited flow rate where solvents are completely removed. In the case of pollutant concentrations higher than 1000 mg/Nm3, it is possible to install a regenerative thermal oxidiser (RTO) that can reach the optimal condition of auto-thermal operation. This guarantees minimum consumption of the support gas, exclusively

2 1

used for the start-up and heating processes (Fig. 3). RTOs are specifically designed to eliminate pollutants from process gases through high temperature thermal oxidation. The chemical

Liquid coating plants

energy contained in these pollutants is transformed into thermal

With liquid coating plants, the aspiration system must remove

energy to favour the combustion itself. It is therefore possible

the greatest possible amount of vapours and gaseous

to recover up to 96% of the heat produced by the VOC and

substances generated within the machine. Also with this type

support fuel combustion reaction, thus significantly reducing plant

of plant, disposable filter panels can be used for pre-filtration in

management costs.

order to collect any solid particles and dust in the fumes. Typical pollutants generated by liquid coating processes are volatile

Aluminium anodising plants

organic compounds VOC and, in general, solvents contained

Anodising plants for aluminium products are composed of tanks

in the paints, which require adsorption, pre-concentration, or

containing different chemical products that perform the surface

thermal oxidation abatement systems.

finishing process combined with the presence of colours and the

In the case of flows with a low concentration of pollutants (less

electrostatic action.

than 300 mg/Nm ), the simplest and most commonly used

In this special process, vapours and fumes are released in the

solution is the adsorption of pollutants through “disposable”

environment full of volatile inorganic compounds VIC, which must

activated carbons (Fig. 2). These plants require the use of

be sucked in and treated with cleaning towers and, possibly,

different types of activated carbon as adsorbents for the

chemical reagents. Cleaning towers are used for the removal of

removal of pollutants. Removal occurs through adsorption

volatile organic (VOC) and inorganic compounds VIC, which are

phenomena based on the surface interactions between

soluble in water or in aqueous solutions with suitable chemical

contaminants and the surface of activated carbons. The gaseous

reagents that make one or more components of a gas mixture

effluents pass through the activated carbon bed and pollutants

change from the gas to the liquid phase. The size of the plant and

are adsorbed on the surface of the material, thus saturating

the type of chemical reagent depend on the chemical composition,

the activated carbon bed itself; the clean gas is then released

concentration, and solubility of the pollutants to be eliminated.

into the atmosphere. The carbons are progressively charged periodically. When the concentration of pollutants is up to 1000 mg/ Nm3, the most suitable solution involves the installation of a

with volatile organic substances and they must be replaced

rotary concentrator with zeolite elements combined with a regenerative thermal oxidiser (RTO, ref. Opening photo). The air to be treated in the rotary concentrator, containing a medium-low concentration of volatile organic compounds VOC, is purified in the concentrator consisting of a zeolite rotor and expelled into the atmosphere; downstream of the concentrator, VOC are concentrated into an air flow up to 20 times lower

Figure 3: A regenerative thermal oxidiser (RTO).

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INNOVATIONS: PRESENT&FUTURE

Manual Coating with Extra Power Mario Ferro Gema Europe Srl, Trezzano sul Naviglio, Milan – Italy

m.ferro@gema.eu.com

ema brings high performance to manual powder coating: The PowerBoost function of the new OptiFlex Pro series delivers 110 kV high voltage

and 110 µA charging current at the touch of a button. With this full increase in power, any coating, even with the most difficult powders, can be applied quickly and safely. Coating large areas manually takes time and effort. This fatigues the coaters and lowers the coating quality. Gema’s solution to this problem is PowerBoost. Directly at the new OptiSelect Pro manual gun, 110 kV high voltage and 110 microampere additional charging energy can be activated via a button (ref. Opening photo). The result is maximum area performance and greatly improved productivity, even with the most difficult powders. The maximum charging power of 110 kV over the entire working range optimally charges the powder particles in every situation and regardless of the type of powder. Gema has made no compromises on safety. The OptiSelect Pro manual gun was designed, tested and certified by Gema as usual for maximum operational safety. This also applies to all accessories of the new line.

PowerBoost - the interaction of the latest technologies PowerBoost is the integrated interaction of coating gun, control and flat spray nozzle. The components newly developed by Gema and designed for PowerBoost result in a high total area performance with clever fan expansion of the powder cloud. This works like a broad brushstroke and enables fast work with perfect layer build-up. The high coating performance, the precise control with the proven DVC and PCC functions and the

Opening photo: The new OptiSelect Pro manual gun features the innovative PowerBoost: Directly at the new manual gun, 110 kV high voltage and 110 microampere additional charging energy can be activated via a button.

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INNOVATIONS: PRESENT&FUTURE

modern nozzle range make the ideal solution for every application. From large surfaces

the new OptiFlex generation

to difficult geometries, from standard powders to sophisticated metallic powders - with OptiFlex Pro every coater produces first-class results in a short time (Fig. 1). All OptiFlex Pro manual units are equipped with the latest OptiStar 4.0 controls as standard and are compatible with the Gema E-App. Coaters and production managers can check productivity and maintenance data and

Figure 2: The new manual gun OptiSelect Pro with PowerBoost nozzle is a reference in comfort and performance.

access configuration and system information via a smartphone. The user manual, the Gema website and the contact details of the

2 1

local Gema contact are also accessible via the Gema E-App.

OptiSelect Pro - even more balanced and comfortable The concept and material selection for the new OptiSelect Pro have been fundamentally revised for the PowerBoost high-performance technology. The activation of the PowerBoost directly at the gun enables the coater to use the extra power anytime and anywhere. Despite the integrated © Gema

power pack for generating up to 110 kV high voltage, the manual gun is light and balanced and at the same time robust and durable. And off course with ATEX and PTB tests it complies with the highest possible safety standards (Fig. 2). The manual gun also makes colour changes easy for the coater. The integrated cleaning function

Figure 1: PowerBoost is the result of networking modern controls, a powerful coating gun and an efficient flat spray nozzle.

Coating large areas manually takes time and effort. This fatigues the coaters and lowers the coating quality. Gema’s solution to this problem is PowerBoost. Directly at the new OptiSelect Pro manual gun, 110 kV high voltage and 110 microampere additional charging energy can be activated via a button.” international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

149

meet the highest demands for constant and reproducible powder ejections (Fig. 3).

Highest industrial suitability The new generation OptiFlex Pro convinces with greatly improved coating performance, maximum safety and state-of-the-art control technology. The high standard is also reflected in the high-quality “Clean Look” design. Clever detail solutions such as the off-center column for more space for placing the powder carton and better manoeuvrability contribute to convenient handling (Fig. 4). With OptiFlex Pro Gema launches a series of devices which is prepared for every case of manual powder coating. This is confirmed by the first customers who, after only a short

3 1

period of use, certify that the OptiFlex Pro is

Figure 3: With only one wear part, the OptiFlow injector is extremely maintenance-friendly and efficient.

highly suitable for industrial use. Thanks to PowerBoost, it is now even more powerful.

cleans the entire powder path from the

The new OptiFlow injector measurably improves transfer efficiency and takes proven injector technology to a new level. Some OptiFlex Pro models are available with the OptiSpray application pump to meet the highest demands for constant and reproducible powder ejections.”

injector to the nozzle tip at the touch of a button. An optional PowerClean function is available for even stronger cleaning. The outer housing of the control unit is now coated with non-stick material. which additionally reduces the cleaning effort.

This prevents the adhesion of powder,

Proven injector technology reinvented The OptiFlow injector is used as standard on Gema manual devices. The new version of the proven technology has only one wear part. After replacing this one-piece nozzle, the injector is as good as new again. The new OptiFlow injector measurably improves transfer efficiency and takes proven injector technology to a new level. Some OptiFlex Pro models are available with the OptiSpray application pump to

Figure 4: Sophisticated and powerful: All OptiFlex Pro units are designed from A - Z for industrial suitability.

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Aluminium closures

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for

Outdoor • Anti-skid coating • Copper imitation • PE coating • PUR/PA cycle • PVdF cycle • Wood effect • Wrinkled coating

Innovative coil coatings Worldwide market presence High performance paints and inks Salchi Metalcoat Srl Viale dell’Industria 3/A-3/B - 20875 Burago di Molgora (MB) ITALY Ph. +39 039 6251824 Fax +39 039 6251829 E mail: info@salchirh.it - www.salchimetalcoat.com

ÂŠ Perstorp

SUSTAINABILITY

Alkyds offer a number of performance benefits that make them an attractive option for coating formulators, particularly for wood applications.

Exploring the Opportunities for the Alkyd Resin Market to Create a Sustainable Future for the European Coatings Industry

ith increasing regulatory focus

plant sources, alkyd resins are a

option for coating formulators, particularly

and consumers demanding

logical choice for sustainable coatings

for wood applications. This is because

products that are more

compared to other petrochemical based

the drying time is long enough to let the

sustainable and eco-friendly, the coatings

resin systems. Following a period of

penetration into the wood substrate take

industry needs to evolve and, as such,

decline, the alkyd coatings market has

place. Low VOC, solvent-borne systems

there is a search for technologies that

stabilized in recent years and is currently

are widely available as are water-based

meet these requirements without

enjoying a period of modest growth.

systems whose performance is constantly

compromising cost or performance.

As a thoroughly tested technology,

improving, with the added benefit of

Containing more than 50% of natural

alkyds offer a number of performance

superior environmental credentials.

oils and carboxylic acids from renewable

benefits that make them an attractive

There is also a recognition, particularly

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SUSTAINABILITY

amongst professional painters, that alkyd-based paints

developments steps in the surfactantsâ&#x20AC;&#x2122; world. Unfortunately,

offer performance advantages that other systems cannot

these water-based paints didnâ&#x20AC;&#x2122;t achieve the expected success

match, namely with regards to ease of application and the

as the high volumes of surfactants used in the manufacturing

possibility to apply several coats in a short period of time.

process caused both cost and formulation issues. The products

Here, we explore the opportunities, and challenges, facing

were around 30% more expensive than their petro-sourced

the alkyd resin market in supporting a more sustainable

counterparts and the bio-sourced raw materials had an

future of the European coatings industry, and look at the

undesirable yellowing effect on the paint. The drying was also ÂŠ Perstorp

market from the perspective of three very different, but forward-thinking organizations.

considered too slow and quite quickly these new water-based products lost favour with consumers,

A short history of alkyd resins

producers and distributors. Clearly, maintaining the

Alkyd resins have long been

critical performance

recognized for their green

attributes is key to success

credentials based on the natural fatty

in the search for a more

acids and polyol content that makes

sustainable solution.

up the majority of the resin. As early a reputation for their high quality,

Crunch time for cobalt?

glossy application performance

There is another key

thanks to their low molecular weight.

factor at play in the alkyd

The oxidative drying also provided

resin market. In the face

good hardness development and

of regulatory reform, the

corrosion resistance properties.

challenge of replacing cobalt

In the 1950s, the emergence of

for the global coatings

emulsion polymerization technology

industry remains. Cobalt

driven by acrylic and vinylic polymers,

has been under scrutiny for

made it possible to make water-based

several years. The European

products that were easier to clean

Chemicals Agency (ECHA)

and more economic to produce as a

has listed five cobalt salts

result of lower crude oil prices. These

as substances of Very High

new water-based paints captured the

Concern and the Cobalt

majority of the architectural coatings

Reach Consortium have

market.

self-classified 12 cobalt

In recent years the focus has been

compounds as toxic to

on the development of durable

reproduction, class 2.

as the 1930s, alkyds had gained

and sustainable coatings, looking for solutions that would support the transition from fossil to

Alkyd resins have long been recognized for their green credentials based on the natural fatty acids and polyol content that makes up the majority of the resin.

Labelling and harmonization reports from the Dutch authorities are long overdue

bio-based products with equivalent

and the industry regards

performance. Alkyd resins

it as inevitable that, in the

have traditionally been solvent based but regulatory

future, cobalt containing products will require some level of

requirements to reduce VOC emissions have been a key

hazard labelling.

driver in the development of water-based alternatives. The

The entire current system for alkyd paints was set up and

first bio-sourced alkyd polymers and water-based paints

perfected around cobalt as the primary drier and any

were launched in 2011, made possible thanks to critical

replacement drier must not undermine the performance

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153

SUSTAINABILITY functional properties of the coating, be

continue to develop ever-more effective

their popularity.

environmentally sustainable and ultimately,

alternatives to cobalt compounds in

However, the search for a cobalt substitute

cost-effective.

solvent and waterborne alkyds.

is not an easy one. There is no such thing

Catexel is not a typical supplier to the

While posing a troublesome challenge

as a ‘simple drop-in’ cobalt-free solution.

coatings industry but has developed

for manufacturers, the regulatory threat

The type and ratios of both primary and

an iron-bispidon catalyst as a cobalt

jeopardizing cobalt’s long-term viability

secondary driers need to be explored -

alternative for alkyd systems after

can be perceived as an opportunity

ensuring effective through dry in

recognizing that the stain bleaching

for the makers of paints to consider

the absence of cobalt. Any viable

mechanism for one of its catalysts

innovative technologies. Early adopters

alternative must be applicable in all

was chemically similar to the alkyd

of cobalt free solutions can cement their

alkyd-based (solvent-based, water-based

curing mechanism. This revelation was

brand’s reputation as conscientious and

and high solids) coating segments, and in

commercialized by the OM Group and

sustainable.

all geographies. It must be fully compatible

brought to market as Borchi Oxy Coat.

Replacing cobalt is a logical step to

with other materials used in paints,

Since then Catexel has commercialized

deliver a complete, sustainable coating

maintain the aesthetic, protective and

manganese based drying systems and

solution but a fully optimized system

advantages of alkyd systems that is key to

Cost is always an important factor for any coating but it’s even more sensitive for decorative paints.

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SUSTAINABILITY can only be achieved by resin manufacturers, integrated coating companies and other additive suppliers working together. Collaboration is not always an easy process but it is much more likely to achieve real change.

Overcoming barriers to adoption Cost is always an important factor for any coating but itâ&#x20AC;&#x2122;s even more sensitive for decorative paints. Fluctuations in the price of raw materials have a key role to play here and one in particular, cobalt is currently undergoing a significant shift. The relative price between cobalt and cobalt free driers has always been significant however, shifts in the cobalt market are closing that gap. As cobalt is increasingly required to produce lithium-ion batteries for mobile phones and electric vehicles, the availability of the metal is decreasing. This is driving up prices and the coatings industry, as a relatively minor user, will bear the brunt. As such, the increasing cost of cobalt could act as a potential driver for the faster adoption of sustainable alternatives. The challenge for the alkyd resin market is to produce a solution that offers the same performance attributes with lower VOC levels at the same, or lower, price with proven sustainability credentials.

Sustainable without compromising performance While bio-based product penetration has progressed well in many industries such as cosmetics and detergents, in the paint industry, green chemistry has so far remained below 5 to 10%. This low adoption rate can be explained by two key factors; technical performance and cost. From a technical perspective many coatings based on water-based alkyds have struggled to achieve the required performance attributes such as gloss, adhesion and resistance to corrosion. There is also a need for further development of bio-based di-acids as those currently available on the market have a number of performance limitations. An alkyd could be up to 100% bio-based and performing. The basic components that make up an alkyd are fatty acids, di-acids and the polyol. All three can potentially be extracted from natural non-fossil resources. An example is the polyol Voxtarâ&#x201E;˘ M100 provided by Perstorp AB, that is 100% Bio-based and produced with a heavily reduced carbon footprint.

Voxtar M100 is a “drop in product” which is produced

SUSTAINABILITY

acrylic polymer, while still enabling high

in a mass balance concept

gloss formulations

that is certified by a third

and open time.

party. Resin producers

With outstanding

purchase this molecule and,

wood and steel

together with any given

protection properties,

di-acid or fatty acid, compose

alkyds are the

an alkyd with specific given

sustainable coatings

properties.

choice of the future.

Improvements in bio-sourced

There is a huge

polymers, delivered by

growth potential

the market leader in

for the waterborne

eco-friendly resin maker

solutions and

Ecoat and commercialized

Perstorp’s sustainable

under the bio-based brand

polyols help reduce

name Secoiaä, have been

carbon footprint even

made possible by selecting

further.

the most appropriate build the 98% bio-polymer

Collaborate to innovate

backbone and by optimizing

A coating is a complex

the production process. The

combination of

choice of the raw material

components and

is key as it determines the

their applications,

overall drying mechanism

hence performance

and final performance.

requirements, vary

For example, the fatty acid

widely. To develop

used determines the level

resin formulations

of yellowing and hardness

that meet the

development. Early hardness

performance and

is related to the molecular

environmental

weight of the resin and

requirements

therefore to the diacid

required by the

and/or the polyol used.

coatings market

bio-based raw materials to

Bio-based pentaerythritol (Voxtar™ M100 from Perstorp) is therefore an

To develop resin formulations that meet the performance and environmental requirements required by the coatings market without compromise, collaboration across the entire supply chain is crucial.

without compromise, collaboration across the entire supply chain is crucial.

excellent building block as

There are many

it enables to get 4 primary

These bio-based water-borne coatings

hydroxyl groups with a 3D structure.

are cost competitive and offer a

individual players bringing new ideas in

The Perstorp’s mission is to support the

number of benefits including lower VOC

their particular field, but collaboration

coatings industry in becoming more

emission, improved personal safety,

can deliver far more than individual

sustainable with bio-sourced polymers

low odor, soap-and-water clean-up,

companies alone and is much more likely

that reduce the carbon footprint of

easier disposal and lower yellowing.

to achieve the permanent, economically

paints and ultimately, produce a higher

They also dry quickly enough to behave

viable, sustainable change the industry

quality product for the end user.

like solvent-based alkyd or water-based

needs.

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ESTAL Congress 2019 in Istanbul – Adding value to Aluminium ESTAL ESTAL is the European federation of national associations who represent the leading architectural aluminium finishers in Europe. Our association also includes major industry suppliers with a precious expertise in aluminium finishing. In the building industry aluminium and its alloys are frequently specified for applications where durability and low maintenance are desirable. Who should attend? The ESTAL Congress focuses on solutions for technical, economic and ecological issues regarding the production and use of surface treated aluminium. It is the ideal event for decision makers of the aluminium finishing industry who are interested in innovations and in exchanging views with colleagues and speakers. It is an excellent opportunity for industry suppliers to promote their products on the Turkish market and develop relationships with current customers. Presentations’ program This year’s Congress motto is “Adding Value to Aluminium” and inspiring speakers will present a variety of perspectives from politics, business and university research. For all events, the official language will be English. Key topics will include among others: – Surface finishing of secondary aluminium – The global trade system and its implications for the European aluminium industry – Impact of European legislation on aluminium finishing – Pre-anodizing process for vertical coating lines – Cast aluminium alloys for anodizing applications – Advanced experimental approaches to better understand the corrosion of metals. – Colouring of anodized surfaces Congress venue The congress will be held at the Swissôtel the Bosphorus Istanbul from 18 to 21 September 2019:

Preview the preliminary presentations’ programme on our website www. estalcongress2019.org. If you would like to be considered for a presentation, please submit an abstract of your presentation to ESTAL at secretariat@estal.org Sponsorship Opportunities and Exhibition If you wish to enhance the visibility and exposure of your company and attract new business, a range of sponsoring opportunities are available to you. Get in touch to find out the sponsoring opportunities available in Istanbul: www.estalcongress2019.org

www.swissotel.com/hotels/istanbul

Organised by ESTAL and AYID the Turkish Aluminium Surface Treatment Association

Sponsored by:

Book now your seat at the ESTAL Congress in Istanbul: www.estalcongress2019.org

STANDARD & LEGISLATION - UCIF Informs

S.M.A.R.T.: UCIF’s Annual Conference Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

info@ucif.net

CIF never misses the chance to

treatments. An overview will be offered of

evolving according to their philosophy and

inform its members by organising

R&D activities, application technologies,

corporate research. Many of these firms will

events that not only deal with

solutions, and processes aimed at improving

also be accompanied by customers that will

the great technological growth that

the yield of a material or component; several

present the actual benefits obtained with the

surface treatment-related processes have

issues will be then discussed separately.

adopted solutions, explaining in detail their

experienced in the last few years, but

The conference will be simple yet complete,

application technologies and industrial uses.

also enable the field’s operators to get in

starting from its title: “Finishing becomes

The decision to give the reporting companies

touch, get to know each other, and share

SMART”, where SMART is the acronym of

the opportunity to host their clients as

experiences. Already several months

Surface, Manufacturing, Advanced, Research,

co-speakers was made by UCIF’s Board of

ago, UCIF, the Italian Surface Treatment

and Technology.

Directors to offer an even more concrete

Equipment Manufacturers’ Association,

contribution in terms of both theoretical and

started organising a conference that will take

The speakers will be the representatives

technical information to the attendees.

place on November 6, 2019 at the premises

of a dozen member companies of our

of Fondazione Cariplo in Milan. The aim

association, who immediately booked

The conference will not focus on a single

will be presenting these innovations to the

their slots to speak to the audience and

area or sector. We will talk about coating

entire industrial world interested in surface

explain how the finishing industry is

technologies for the automotive industry (from chassis to brake pads), modern paints and their components, robotic cleaning and washing systems, environmental sustainability,

AR C

FA C

market data and trends not

ES E

TR EN

M AN E

S M A R T

only for the finishing industry but also for its related sectors, as well as several international opportunities.

AD VA N

RF AC

impact. We will also present

emissions, and environmental

“La Finitura diventa SMART”

UCIF strongly believe in this event aimed at presenting the technological level reached by surface treatments and offering an occasion to network and get to know international companies and their key individuals. UCIF is

UNIONE COSTRUTTORI IMPIANTI DI FINITURA

very proud of this conference and it has already opened registrations.

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2 - 4 SEPTEMBER 2019 EGYPT INTERNATIONAL EXHIBITION CENTER

www.thebig5constructegypt.com

EVERYTHING INFRASTRUCTURE & CONSTRUCTION. BUILDING THE NEW EGYPT. MEP SERVICES

CONSTRUCTION TOOLS & BUILDING MATERIALS

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INFRASTRUCTURE SYSTEMS AND SERVICES

BOOK YOUR STAND TODAY, SPACES LIMITED FORE MORE INFORMATION PLEASE CONTACT: Menna Lotfy, Project Manager +2 010 606 55 999 (Egypt) email: mennalotfy@dmgevents.com

Kenny Hajj, Sales Manager +971 (0) 56 4047856 email: kennyhajj@dmgevents.com

ORANISED BY:

TRADE FAIRS & CONFERENCES

INTERNATIONAL PAINT&COATING MAGAZINE

: MEDIA PARTNERSHIP - ipcm

JUNE 2019 aee automotive engineering expo plast-ex subcon itm poland automechanika middle east the big5 africa construction expo astana mining & metallurgy heat treatment & industrial furnace SIAE Salon International de l’Aéronautique et de l’Espace yapi fastener fair mexico biobased coatings europe intermold plastexpo metec

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Nuremberg, Germany June 4-5, 2019 Toronto, Canada June 4-6, 2019 Poznan, Poland June 4-7, 2019 Poznan, Poland June 4-7, 2019 Dubai, UAE June 10-12, 2019 Cape Town, South Africa June 11-13, 2019 Astana, Kazakhstan June 12-13, 2019 Guangzhou, Cina June 13-15, 2019 Paris, France June 17-23, 2019 Istanbul, Turkey June 18-22, 2019 Napoles, Mexico June 19-20, 2019 Düsseldorf, Germany June 19-20, 2019 Nagoya, Japan June 19-22, 2019 Casablanca, Marocco June 25-28, 2019 Düsseldorf, Germany June 25-29, 2019

www.automotive-engineering-expo.com

http://admtoronto.com/plastex

www.itm-polska.pl

www.automechanikadubai.com

www.africanconstructionexpo.com

www.amm.kz

www.heattreatmentexpo.com/

www.siae.fr

www.yapifuari.com.tr

www.fastenerfair.com/mexico/english/fastener-fair-mexico/

www.wplgroup.com/aci/event/biobased-coatings-europe/

www.intermold.jp

www.plast-expo.ma

www.metec-estad2019.com

速

TRADE FAIRS & CONFERENCES

INTERNATIONAL PAINT&COATING MAGAZINE

: MEDIA PARTNERSHIP - ipcm

速

newcast Gifa chemspec coatings expo vietnam surcar

D端sseldorf, Germany June 25-29, 2019 D端sseldorf, Germany June 25-29, 2019 Basel, Switzerland June 26-27, 2019 Ho Chi Minh, Vietnam June 26-28, 2019 Cannes, France June 27-28, 2019

www.newcast.com

www.gifa.com/

www.chemspeceurope.com

www.coatings-vietnam.com

http://cannes.surcarcongress.com/

JULY 2019 svtm 2019 automotive engineering show aluminium china

Lille, France July 3-4, 2019 Chennai, India July 4-6, 2019 Shangai, China July 10-12, 2019

www.svtm.eu

www.aes-show.com

www.aluminiumchina.com/en/

SEPTEMBER 2019 the big5 construct egypt asia pacific coatings show the big5 construct nigeria schweissen

Cairo, Egypt

www.thebig5constructegypt.com

September 2-4, 2019 Bangkok, Thailand September 4-6, 2019 Lagos, Nigeria September 9-11, 2019 Linz, Austria September 10-12, 2019

www.coatings-group.com/apcs/bangkok

www.thebig5constructnigeria.com

www.schweissen.at

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he European Coatings Show set new records once again this year, underscoring its position as the

European Coatings Show 2019: World’s Leading Trade Show for the Coatings Industry Larger and More International Than Ever leading show for the international coatings industry: about 30,500 trade visitors1 (2017: 30,198) from 124 countries (2017: 120) seized the opportunity offered by this year’s event to learn about innovations in paint, coating and sealing compound manufacture from 1,156 exhibitors from 46 countries (2017: 40). The exhibition area, extending to eight halls this year, turned the Exhibition Centre Nuremberg into the central platform for coatings experts from around the world to share ideas and experiences. In addition to the trade show, the overlapping European Coatings Show Conference also proved a drawcard with an even more international presence: about 800 participants came from 54 countries to listen to the presentations by leading scientists and development experts. Exhibitors and trade visitors travelled

Larger and more international than ever 2019 European Coatings Show took place from 19 to 21 March in the Exhibition Centre Nuremberg (Germany).

last time. Visitors at this year’s show

of paint and coatings manufacture. They

Even larger international contingent among both exhibitors and visitors

had more space this year, with eight halls

The 2019 European Coatings Show was

Turkey, which were among the top ten

in total. In six of them, including Hall 9

thus larger, more varied, and even more

in visitor statistics, and also many other

as a new addition, exhibitors displayed

international than previous events in the

countries in the Asian, North and South

raw materials used in paints, printing

series. Most of the exhibitors came from

American, African and Australian markets.

inks and adhesives, while two more

Germany, followed by China, Italy, the

halls were devoted to laboratory and

Netherlands, USA and India. Products

production technology, and also testing

and services from exhibitors based in

and measurement devices.

the Czech Republic and China were

European Coatings Show illustrated the sector’s power of innovation

exhibited at the pavilions from both of

The attractions of the trade show

these countries. The proportion of both

included the ever-popular product

international exhibitors and international

presentations – three stages hosting

trade visitors was even higher than

open exhibitor presentations, in which the

to Nuremberg from six continents to discuss every aspect of the process chain

1 The visitor, exhibitor and floor space figures for this trade fair event are calculated and certified in accordance with the uniform definitions published by FKM – German Society for Voluntary Control of Fair and Exhibition Statistics.

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represented 124 countries, including the likes of Italy, the Netherlands, the UK and

ZOOM ON EVENTS

exhibitors each had 15 minutes to give a brief talk about the development and performance of new products. The power of innovation of the sector was also illustrated at the show by a number of research institutes, universities, and many young companies. In addition to a pavilion for young and innovative companies from Germany, the new Start-up Area was very much the place for newcomers, with nine international exhibitors taking part in the

Industry visitors with top experience in the procurement process The first survey results confirm the key role the visitors play in their companies’

European Coatings Show for the first time.

procurement decisions: nine out of ten are involved in the decision-making process when it comes to procurements, an even higher

from all around the world. With about 800

The most popular presentation series

figure than last time.

delegates from 54 countries taking part, its

included “Water-borne Coatings”,

international attendance was even greater

“Dispersing Technology”, “Microbial

Conference focuses on eco-friendliness and functionality

than on the previous occasion.

Protection” and “Science today – coatings

Participants learned about the latest

tomorrow”. Eco-friendliness and

The European Coatings Show Conference

research results and trends in coating

functionality are thus topics which the

once again brought together leading

development in 144 presentations

industry continues to consider particularly

R&D experts and prominent scientists

grouped into 24 sessions.

confirmed by the interactive survey of participants during the Conference. The use of titanium dioxide, something that has been the subject of intense discussion, was a new item on the agenda. The European Coatings Award for the best Conference submission went to Professor Markus Antonietti, director colloid chemistry at the Max Planck Institute of Colloids and Interfaces. In his keynote presentation, he discussed a new procedure for obtaining monomers, polymers and solvents from biomass waste. The next European Coatings Show takes place in the Exhibition Centre Nuremberg from 23 to 25 March 2021. For further information: www.european-coatings-show.com

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PaintExpo 2020 – Trends and Impetus for Coating Technology

aintExpo will once again transform

The industry sector’s global players will be

in-house painting operations or coating

the Karlsruhe Exhibition Centre

on hand, as will its innovative small and

job-shops are involved. Painting and

(Germany) into an international

mid-sized companies. A complete range

coating requirements which have to be

marketplace for innovations, applications,

of solutions targeted at optimising coating

fulfilled for the production of industrial

future technologies and trends covering all

processes and making them fit for the

products, as well as consumer

aspects of industrial coating technologies

future will await trade fair visitors.

goods, are becoming more and more

from the 21st through the 24th of April, 2020.

demanding around the world. On As a key technology, industrial coating

the one hand, painting quality has

400 companies had booked booth floor

has a decisive influence on a company’s

to be further improved and justice

space for the 8th world’s leading trade fair.

value creation chain – whether

Already at the end of March 2019, roughly

8th World’s Leading Trade Fair for Industrial Coating Technologies will take place in Karlsruhe (Germany) from 21 to 24 April 2020.

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efficiency, for the painting and coating of components made of metals, plastics, wood, wooden materials, glass, material combinations and more. This begins with parts pre-treatment and includes everything from systems and application technology, conveyor systems and drying, right on up to quality assurance and packaging of the coated products. Where painting systems are concerned, attention will be focused on new and further developed solutions for all types of coating processes including ultra-high-solid systems, chrome replacement coatings, gel coats and systems which provide coated surfaces with special functional and/or decorative properties, improve corrosion protection and contribute to reduced consumption of materials and energy. Responses to

demand for individualised products

well in advance of the event – makes it

challenges resulting from the trend towards

which, at the same time, are subject

clear that suppliers of industrial coating

individualisation right on down to batch

to tremendous cost pressure. On the

technologies see the world’s leading

size 1 will be offered by exhibitors with

other hand, stricter environmental

trade fair as an indispensable event.

system and optimisation concepts which

regulations have to be complied with

And thus it’s already plainly apparent

are consistently laid out for flexibility, quality

and resources need to be used more

that we’ll present the world’s most

and efficiency.

efficiently. Beyond this, lightweight

up-to-date and comprehensive

Simulation and automation of the coating

design with multi-material substrates,

offerings for industrial coating

process are further current issues which

as well as new production processes

technology to the visitors, as well as

will be in focus at the upcoming PaintExpo.

such as additive manufacturing with

solutions for their individual tasks”,

In particular in the field of

rough, porous surfaces are resulting in

reports Jürgen Haußmann, managing

job-shop coating, Industry 4.0 is also

new challenges for painting and coating

director of event promoters

gaining relevance, i.e. digital integration

technologies. And on top of it all, coating

FairFair GmbH.

of the coating process into production.

service providers and in-house coating

Solutions by means of which this can be

automation and digitalisation as well.

All Technologies, Materials and Industry Sectors

Attention will be focused on all of these

PaintExpo’s exhibition programme

coating technologies.

issues at the upcoming PaintExpo, which

covers all industrial coating technologies

“Complete and fully representative

will be held at the Karlsruhe Exhibition

throughout the entire process sequence

state-of-the-art offerings make it possible

Centre from 21 through 24 April 2020

from powder coating, as well as liquid

for job-shop coaters and visitors from

with offerings more comprehensive

and UV painting, right on up to coil and

companies with in-house painting

than anywhere else around the globe.

in-mould coatings. Exhibiting companies

operations from all industry sectors to

Roughly 400 companies, including all

will present innovations, technologies,

quickly find technically and economically

of the industry sector’s market and

processes and services for designing,

ideal solutions for their tasks”, says Jürgen

technology leaders, had already made

running and optimising processes

Haußmann with confidence.

firm bookings for their booth floor space

in order to meet the great demands

at the end of March. “Strong demand

placed upon quality and flexibility,

For further information:

for exhibition floor space at PaintExpo –

as well as material, energy and cost

www.paintexpo.com

departments are dealing with trends like

implemented will also be exhibited at the world’s leading trade fair for industrial

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CWE IMEX 2019: The Asia-Pacific’s Largest B2B Exhibition for Metal Working, Fabricating, Welding & Finishing Industry utting & Welding is the core of modern

The 9th edition of CWE IMEX EXPO 2019, is

CWE IMEX series of international events

technology and has witnessed a

being hosted by ITEI - The Indian subsidiary of

have played a major role in showcasing

remarkable evolution today, following

ITE Group PLC (UK) - from 20th-22nd September

the strength of the Indian cutting, welding,

the utmost precedence that machines

2019 at Bombay Exhibition Centre, Mumbai,

laser and allied industry by attracting

have garnered in our lives. There is a rapid

India. It is supported by reputed industry

global attention to these technological

development in this industry and new

associations including ‘Rajkot Engineering

advancements. CWE IMEX event has

methods are being discovered and added

Association’, ‘Society of Manufacturers of

established itself as a “Business Festival of

day by day. The future of welding holds even

Electric Vehicles’, ‘Welding Dealers & Mfrs.

the Cutting, Welding & Laser Industry” and

greater promise as methods are devised for

Association Delhi’ and the ‘World Metal Forum’.

joining dissimilar and non-metallic materials, and for creating products of innovative shapes and designs. Asia-Pacific is the largest market

and fabricating industry in the country. CWE IMEX 2019 is planned with other specialized co-located exhibitions to

for welding and cutting equipment.

serve as a Complete Business Carnival

China and India hold the key for

for manufacturing and fabricating

future market trends in welding and

Industries, like:

cutting equipment market owing

- HTF - for Advanced Hand Tools,

to high industrial growth rate, high

Power Tools and Fasteners

growth rate in the construction sector

- UMEX – for Economical Pre-Owned

and high growth rate of automotive

Machinery in the industry

industry in these regions. In India,

- WOM – for Metal Production,

welding contributes significantly to the GDP in several ways, such as welding intensive industries, auxiliary products, complementary goods,

Processing and Metal Working Industry The 9 edition of CWE IMEX EXPO 2019 will take place from 20th-22nd September 2019 at Bombay Exhibition Centre, Mumbai, India. th

- TECHINDIA - for Engineering and Manufacturing (Pumps, Valves, Compressors and more).

employment, and user industries. Keeping in mind the growth of welding

It is an internationally renowned series of

The said Biggest Business Carnival will

industry there is an urgent need for a

exhibitions focusing on cutting and welding

have largest gathering of trade visitors

Unified Business Platform which can connect

technology, robotics, welding automation,

from various segments of manufacturing

the welding Industry of India with the global

welding consumables, laser technology,

and fabricating industry like steel, metal

welding industry. It is this scenario that

materials testing, non-destructive testing,

forming and metal working, sheet working,

CWE IMEX 2019 has become the ideal

machine tools and allied industries. It is

OEMs, automotive, sub-contracting and

business platform to help the Indian

the only comprehensive business platform

fabricating, rail coach factories, boilers,

manufacturing industry and fabricators for

serving the cutting, welding and laser industry

heavy engineering, EPC, shipbuilding and

technology & knowledge transfer, identifying

and over the years, this leading business

more.

alternate suppliers of machinery and spares,

event has become the perfect platform for

new source of investments, face to face

showcasing the entire spectrum of products

For further information:

interaction with industry players, identifying

and services relating to the cutting, welding,

http://cweonline.in and

new market opportunities etc.

laser and allied industries.

http://imexonline.com

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Supplemento a IPCM n° 57 - May/June 2019

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TECNOFIRMA S.p.A. - Viale Elvezia, 35 - 20900 Monza (MB) Italy - Phone +39 039 236 01 - Fax +39 039 324 283 - www.tecnofirma.com - tecnofirma@tecnofirma.com - Company Certified ISO 9001 since 1992

ICT - INDUSTRY NEWS

Parts Cleaning Without Compromises

s an essential prerequisite for

“Organic contamination can be removed

use two different systems. If this happens,

high quality and functional

very effectively with an organic cleaner

it entails the purchasing of two cleaning

safety, industrially manufactured

(hydrocarbons, modified alcohols,

systems with traditional plant and process

components must be thoroughly cleaned

chlorinated solvents). Inorganic residues

technology.

in the manufacturing process in order

can be removed with a water-based

A unique feature of HEMO GmbH is the

to remove processing media and other

inorganic cleaner”, explains Dieter Göller,

hybrid cleaning system which allows the

contaminants such as abrasives, chips, etc.

HEMO Managing Director.

combined use of aqueous solvents and

HEMO GmbH, based in Ötisheim, Baden-

It is a well-known saying: “like

detergents in a vacuum system (Fig. 2).

Württemberg (Fig. 1), is a technology

dissolves like”. While certain inorganic

Depending on the requirements, only one

leader in this field. Specialized in

contaminants such as dried emulsion

of the two products can be used in the

industrial cleaning with solvents and

residues or fingerprints cannot be

same system at a time or, if necessary,

hybrid processes with solvents and

completely removed using a solvent,

they can be used also in combination in

aqueous media, the company focuses on

organic residues can only be reliably

order to achieve the best possible result.

uncompromising quality and individual

cleaned with an aqueous system, if the

HEMO systems clean any type of

customer service.

number of cleaning stages and/or bath

component, material and size, starting

Industrial parts cleaning is dominated by

preparation are properly managed.

from small precision components to large

wet cleaning processes, which include

items or 30-meter long stainless steel

Key strength: hybrid cleaning

The contaminants to be removed usually

Therefore, having to choose a

automotive industry and its suppliers,

consist of both organic substances – like

cleaning system often means finding

companies in the aerospace, medical,

oils and greases - as well as inorganic

a compromise. In particular, if the

precision machining and electronics

residues such as salts, abrasives or

result achieved does not meet the

industries rely on the quality of these

emulsions.

specifications, the only alternative is to

cleaning experts.

aqueous and solvent-based cleaning.

Figure 1: The headquarters of Hemo GmbH.

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tube bundles (Fig. 3). In addition to the

ICT - INDUSTRY NEWS

Figure 2: A unique feature of HEMO GmbH is the hybrid cleaning system which allows the combined use of solvents and aqueous cleaners in a vacuum system.

HEMO belongs equally to the Müller and Hösel families. In addition to Dieter Göller, two other managing directors, including a member of the Hösel family, are running the company. Both original locations were retained after the merger. In addition, a new company headquarters was built in Ötisheim in 2017. With a total of 130 employees, the company generates a constantly growing annual turnover of over 30 million euros. “Our success is based not only on the high cleaning quality offered by our systems, but above all on our good advice and customer service”, explains Dieter Göller. “We recommend which plant and process technology © Hemo GmbH

is best to use in order to meet individual cleaning needs and

2 1

we offer practical cleaning tests to help customers make a more informed decision”. HEMO will maintain its consulting and quality strategy in the coming years. “We want to focus on expanding our services, and not so much on further sales growth. For the future, the main task of the company is to keep

Strong together

our level high and satisfy our customers”.

“HEMO GmbH was founded in 2017 by the merger of the two family-owned companies Hösel GmbH and EMO

For further information:

Oberflächentechnik GmbH”, explains Dieter Göller. “Both had

https://hemo-gmbh.de/

cooperated closely since the end of the a competence network that now includes five other industrial parts cleaning specialists: the German companies LPW

1990s and founded the Surface Alliance,

Reinigungssysteme GmbH and Bertoma GmbH, Mecanolav Ridel S.A.S. in France, NGCT Cleansys PvT. in India and Washtech S.A. in Mexico. HEMO GmbH is partner of these companies”. The six members of the Surface Alliance are all medium-sized companies, that operate together worldwide and offer the complete program for critical cleaning by complementing each other optimally. Long-time experience, proven technologies and a wide-ranging service and sales network form the basis for success. “Through our presence in distant markets such as China, we are close to our customers and learn early new trends and requirements through a direct dialogue”.

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Figure 3: Overview of the HEMO GmbH cleaning system.

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

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A New Cleaning Tunnel for Tramec’s High Added Value Production Barbara Pennati ipcm®

Opening photo: Tramec (Calderara di Reno, BO, Italy) has specialised in the production of gearboxes since 1986.

earboxes are mechanical

most cross-sectoral and dynamic ones in

So, how should this potentially

components used in any sector

the world. This played in favour of many

unlimited market be addresses?

that employs either hydraulic

manufacturers during the recession: the

Tramec (Calderara di Reno, BO,

or electric machines. Their application

growth of an industry often compensated

Italy), a company specialising in the

field potentially knows no geographic

for the crisis of another. However, such a

production of gearboxes since 1986,

nor sectoral boundaries. The types of

huge potential market also entails the need

has focussed its strategy on highly

gearboxes available are also numerous,

to assess one’s own production strategy

customised production, making it its

thus making their market among the

very carefully to avoid wasting resources.

main feature (ref. Opening photo).

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intended for both the national and

of our customers without slowing down

and covers any industry,” states

international markets,” says Girotti. “They

our processes and lengthening delivery

Tramec CEO Leo Girotti. “Tramec has

differ from one another in terms both of

times,” explains Girotti. “We always try to

chosen to avoid mass production

type and intended use and of materials

balance the internal production flow with

and rather offer a high customisation

used (aluminium, cast iron, or bronze)

the outsourced one. However, all parts

degree. This results in a very

and, therefore, of processes required.

return to our factory for the final cleaning

fragmented production and in the

The choice to provide our customers

phase. That is why we have recently

need to constantly apply the acquired

with tailor-made products also entails a

needed to replace a few old cleaning

knowledge to always ensure a high

significant effort in terms of design and

machines in our plants in Calderara

quality level.”

production.”

di Reno and Padulle (Italy).” Tramec

“Tramec currently manufactures about

In addition to its in-house production

chose Union (Sala Bolognese, BO, Italy),

14,000 products per month, from the

flow, Tramec also relies on a few

specialising in the design of industrial

smallest types weighing a few kilograms

contractors. “By outsourcing a part of

cleaning systems, as its technological

to the largest ones up to 300 kg (Fig. 1),

our production, we can meet the needs

partner for this investment.

“The gearbox market is very wide

Figure 1: One of the largest gearboxes produced by Tramec.

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

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The new cleaning tunnel

Figure 2: Tramec’s production plant in Calderara di Reno.

Tramec has different branches and distribution offices in Italy e in Europe, but all its products are manufactured in the two plants of Calderara di Reno and Padulle (Fig. 2). “The Padulle plant handles all machining operations. Its work stations are linked to cleaning systems that treat all the manufactured parts,” says Girotti. “We installed our first Union cleaning machine precisely in this factory, about five years ago. It is a hydrokinetic system with a vacuum drying unit for cast iron parts. In December, we replaced the old cleaning tunnel of the Calderara di Reno plant with a Union system for the cleaning of the parts machined by contractors (Fig. 3).” “The tunnel performs three stages (water and detergent spray cleaning,

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Figure 3: The new three-stage cleaning tunnel supplied by Union.

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anti-oxidant protective immersion

Union adapted the entrance and exit

Flexibility and quality

treatment, and air-jet drying) and

of its tunnel to enable us to clean even

“The cleaning phase is very important

it is equipped with an oil separator

the largest parts (Fig. 4).”

for our production process. Our

for oil recovery,” explains Tramec

“The ability to set the cleaning

gearboxes are assembled with gears

warehouse manager Corrado Iorio.

programs and to activate or deactivate

and other components needed for

“The tunnel was designed with an

some cycle stages has resulted in the

an engine to function: if there are

Industry 4.0-oriented approach.

reduction of our production times

swarf or other machining residues on

It allows setting different cleaning

and in the less frequent replacement

any part’s surface, the components

programs depending on the type of

of process water. This, in turn, has

coming into contact with the

part to be cleaned, as well as activating

resulted in higher cost and energy

gearbox would be damaged and the

or deactivating the cleaning and

efficiency and lower environmental

functioning of the whole unit would

protective treatment stages according

impact,” says Leo Girotti. “From the

be jeopardised (Fig. 5),” explains

to specific needs. A cleaning cycle

operational point of view, our cleaning

Leo Girotti. “Moreover, in order to

lasts 20 minutes on average, but the

process is much more efficient. We

be even more competitive in terms

tunnel allows adjusting the conveyor

have also solved a few drying issues:

of delivery times, we assemble our

belt’s speed depending on the shape

in the past, a final manual operation

workpieces only upon customer

of parts, which are placed in baskets

was needed, whereas the swivelling air

request, picking them up from our

or directly on the belt itself. Due to

jets now enable us to reach even the

warehouse; therefore, an effective

the high variety of workpieces treated,

deepest holes and cavities.”

cleaning process and the application

biokavitus TM

SOC IETA’ D EL GRUPPO

P N E U M A T I C

ICT - CASE STUDY

Figure 4: Union adapted the entrance and exit of its tunnel to enable Tramec to clean even the largest parts.

also developed a new series for the food and pharmaceutical industries by using a special silver ion treatment that gives anti-corrosion and anti-bacterial properties to workpieces, patented for Europe by GHA Europe. By investing in new projects and cooperating with reliable partners that help us make our technological choices,

4 1

we have managed to give an added value to our production, in line

of a protective coating allow us to store

widen our range of bevel helical gearboxes,

with the corporate image that we have

them at best and have them ready for

worm gearboxes, and precision planetary

created for ourselves over the years as

use without the need to treat them

gearboxes, with significant investments in

an innovative company that produces

again.”

new machines and control tools. We have

quality,” states Girotti.

now. That is why we decided to turn to them when we started the gradual

“We have known Union for many years

replacement of our old cleaning plants. Also thanks to their technology, we are now much more competitive in terms of production speed and flexibility, delivery times, and quality degree. Therefore, we are very pleased with our collaboration,” adds Girotti. “It is not easy to assess the productivity of a gearbox, as it is just one component of a more complex mechanism. However, it is possible to assess its quality level in terms of durability, resistance, seal, and yield. In the last few years, we have strived to

Figure 5: An assembled gearbox.

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ICT - TECHNOLOGY OVERVIEW

Innovative Developments for Ultra-Fine Cleaning and Activation - New Cleaning Solutions for Altered Requirements Rainer Straub Ecoclean GmbH, Filderstadt - Germany

rainer.straub@ecoclean-group.net

oating, adhesive bonding, sealing, painting – these are just some manufacturing operations calling for profoundly clean, and sometimes activated, part

surfaces. It is with these requirements in mind that Ecoclean has developed a set of new cleaning solutions. One of them combines wet chemical and low-pressure plasma cleaning in a single machine. Another innovation consists in integrating diverse applications for partial or full-surface cleaning or activation – e.g., atmospheric pressure plasma treatment, laser, CO2 snow blasting and/or surface inspection operations – into

one processing system. This toolkit enables operators to cover virtually all pre-treatment needs. In automotive manufacturing and its supplier industries, mechanical engineering, aerospace applications, precision and micro-mechanics, medical and optical systems, electronics and other fields of industry, component parts are subjected to cleaning in order to prevent quality problems in downstream processes and to ensure flawless product performance.

Opening photo: For workpieces made of steel, aluminium, glass, ceramics and some other materials that are cleaned in batch processes – whether in bulk or arranged in part carriers – the company has developed a combination cleaning technique merging wet chemical cleaning with a subsequent plasma cleaning step.

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Ultra-fine degreasing by a combination cleaning process with integrated low-pressure plasma treatment For workpieces made of steel, aluminium, glass, ceramics and some other materials that are cleaned in batch processes – whether in bulk or arranged in part carriers – the company has developed a combination cleaning technique merging wet chemical cleaning with a subsequent plasma cleaning step (ref. Opening photo). To this end, a low-pressure plasma cleaning operation is integrated into the wet chemical cleaning line. Since virtually all components needed for this cleaning technology – e.g., vacuum, measuring and control equipment – are already in place in the manufacturer’s wet chemical cleaning machines, the additional cost and engineering

effort remains modest. The advantages of the

Figure 1: The advantages of the integrated plasma cleaning process in ultra-fine degreasing are substantial, on the other hand, including a high operating flexibility, reduced process times, low investment and operating costs, plus very compact equipment build.

integrated plasma cleaning process in ultra-fine degreasing are substantial, on the other hand, including a high operating flexibility, reduced process times, low investment and operating costs, plus very compact equipment build

In recent years, the focus in many

even fingerprints – is gaining increasingly

(Fig. 1).

industries lay on removing particulate

in importance. This is because such

Cleaning is initially performed as usual by a

contaminants. However, given new or

residue can impair the quality of

solvent-based wet process, followed by vacuum

modified production, joining and coating

subsequent processes, e.g., coating,

drying of all workpieces.

technologies as well as improved materials

welding, adhesive bonding, sealing,

The work chamber is then rinsed and its

and combinations thereof, the elimination

painting or heat treatment. Ecoclean

internal pressure is reduced to less than 1

of film-type residue – e.g., of machining and

(formerly Dürr Ecoclean) addresses these

millibar, whereupon the process gas (e.g.,

preserving media, release agents, silicones,

evolving requirements with a number of

filtered ambient air or oxygen) is introduced

other auxiliary production compounds, or

new solutions.

and the plasma is ignited. Due to excitation

by the process gas, a plasma of high-energy ions and free electrons – plus other reactive

ICT - TECHNOLOGY OVERVIEW

is to solve each of the various surface treatment requirements with the most technically

particles – is thereby formed in

and economically beneficial

the vacuum. Contaminants on

technology. Thus, the use of the

the part surface, such as grease

new Disc-Jet atmospheric pressure

or oil residue, are chemically

plasma source developed by the

attacked and transformed into

Fraunhofer Institute for Surface

volatile compounds. At the same

Engineering and Thin Films (IST)

time, the plasma’s UV radiation

permits laminar and contoured

likewise exercises a cleaning effect,

as well as depth processing. Due

e.g., by breaking down long-chain

to the so-called “cold” surface

hydrocarbons. The gaseous

discharge (30 to 60°C), even

decomposition products of the

temperature-sensitive substrates

plasma treatment are extracted

can be treated in this manner.

from the work chamber by suction.

An atmospheric pressure plasma,

Thanks to the combination of

for instance, allows part surfaces

wet-process and plasma cleaning

to be selectively fine-cleaned,

operation, the free surface

activated and coated with an

energy that is key to achieving an

adhesion promoting agent. Where

optimum adhesion strength can

the surface is to be textured as

be raised to 50 to 80 mN/m

well as cleaned, laser treatment is

in one single process step.

the method of choice, depending

Integration of different pre-treatment methods into one system The partial or full-surface cleaning and activation – and, in part, coating – of individual metal or plastic products is central

on the given material. EcoCbooster technology provides a

2 1

pre-treatment method for the selective, effective and efficient

Figure 2: Compact application systems can be fitted with different treatment technologies such as atmospheric pressure plasma, EcoCsteam, laser or CO2 snow blasting processes, whether configured as an automated standalone unit or integrated into a production line.

in the expansion of Ecoclean’s

activation of surfaces prior to,

process portfolio. For these diverse objectives, compact application systems were

requirements and application situation. Thus, robot-based solutions can be realized just as readily as multi-articulated

developed for integration into a

handling systems and CNC linear

host of requirement-focused

drive units. Across all variants,

equipment concepts. Each

either the workpiece, the tool

system can be fitted with

or both can be moved to match

different treatment technologies

the given task definition. Thanks

such as atmospheric pressure

to this high flexibility, the new

plasma, EcoCsteam, laser, CO2

surface treatment toolkit is the

snow blasting or EcoCbooster

processes, whether configured as an automated standalone unit or integrated into a production line (Fig. 2). The company’s aim

180

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Figure 3: EcoCbooster technology provides a pre-treatment method for the selective, effective and efficient activation of surfaces prior to, e.g., thermal spraying.

N. 57 - MAY/JUNE 2019 - international PAINT&COATING magazine

perfect solution for diverse applications in electromobility, medical equipment technology and numerous other fields of industry.

AUTOMATIC SYSTEMS FOR GRINDING AND POLISHING Impianti automatici per smerigliatura e lucidatura DAN di DE ANTONI srl 25 03 0 Cocc a glio (BS) - Via G a zzolo 2/4 Tel. +39 030 77 21 850 - +39 030 77 22 477 s a l e s @ d e a n t o n i . i t - w w w. d e a n t o n i . i t

ICT - CASE STUDY

An Automated and Eco-Friendly Cleaning Cycle for High Quality Oil Hydraulic Components Ilaria Paolomelo ipcm®

Opening photo: Officine Vica has produced automotive components, including pump bodies for diesel engines, since 1958.

here are about one billion two

by Original Equipment Manufacturers

components while interacting with the car

hundred million cars in the world

(OEM), whereas the remaining 70%

manufacturers themselves.

and each of them is composed of

is manufactured by other companies

Producing a component for the

a large number of different components

known as Tier I suppliers. These firms

automotive sector means to meet

aggregated in systems and sub-systems,

mainly specialise in machining processes

high quality standards and the strict

often more than ten thousands. Only

and they design and produce from the

regulations of today’s market. A crucial

30% of these is produced directly

smallest to the most complex automotive

process phase for the achievement of

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such quality levels is the cleaning of

ICT - CASE STUDY

including more than one thousand

these parts, which enables to remove

different parts and, whenever possible, to

any residual dirt and contamination

design new components in synergy with

traces generated on their surfaces

our customers. Our approach has led us

during machining. That is why Officine

to establish ourselves as an industry leader

Vica has recently turned to STS

and to collaborate with the main world car

(Ravenna, Italy), a company specialising

manufacturers,” says one of the Officine

in the design and production of

Vica owners, Piero Merlin.

cleaning systems and industrial washing machines for over twenty-five years,

The cleaning cycle

for the installation of two new cleaning

“The factory where we are now is mainly

plants for diesel engine pump bodies.

devoted to the production of aluminium pump bodies for the fuel system of

About Officine Vica

diesel engines (ref. Opening photo).

Established in Rivoli (Turin, Italy) in

The complex shape of these oil hydraulic

1936 as a machining contractor for

components forces us to perform two

the aeronautical sector, Officine Vica

cleaning cycles. The first, gentler one has

underwent a profound transformation

the task of removing most of the oils,

in 1958, when it changed both its corporate structure and its core business and it started devoting exclusively to the manufacture of components for cars, industrial vehicles,

Figure 1: A detail of an oil hydraulic component.

and earth moving machines.

shavings, and cutting liquids produced by the previous machining processes and trapped in small holes (Fig. 1). We then carry out a meticulous visual check with an endoscope to assess the residual contamination degree, followed by a fine

“Over the years, our company has

departments equipped with machine

cleaning cycle with our new STS machine.

experienced continuous growth in

tools such as vertical and horizontal

After this, we carry out a further gravimetric

terms of both turnover and facilities.

machining centres, numerical

and dimensional sample check to verify

We now have seven production plants

control lathes, grinding lines, transfer

the surface cleanliness level. Finally, the

covering an area of 26,000 m².

machines, and robotic work stations,

component is wrapped, tracked, and

Each of them is dedicated to a

as well as assembly, cleaning, and

shipped to the customer,” explains

different production process, in

finishing departments. This sound

Piero Merlin.

order to favour the material flow and

organisation enables our company

“Following a growth in the demand for

logistics management. They all include

to produce a wide range of products

these components, we decided to invest in

with

DRY CLEANING

to perfect

advanced clean production

PAINTING ! Cleaning with CO2 - snow jet www.acp-systems.com Phone: +49 7156 48014-0

ICT - CASE STUDY

Figure 2: Officine Vica has recently installed an Aquaroll® cleaning machine supplied by STS.

unloading phases. Each workpiece is loaded in the basket, it is automatically transferred within the plant to be cleaned, dried, and cooled, and then it is taken to the unloading station (Fig. 4). Afterwards, the basket automatically returns to the loading area,” says Piero Merlin.

“In line with Officine Vica’s needs, we have integrated a high pressure phase to ensure that the cleaning solution penetrates into all the pump channels and blind holes and we have implemented the ultrasound technology to guarantee consistent cleaning results on all parts,” adds Mauro Ballo from STS. “Moreover, we have selected a water-based system to solve the contamination issues arising from some machining operations,

2 1

particularly the a cleaning plant that combined

electrochemical deburring one: after this process,

productivity and quality. Our

the components have

choice fell on the Aquaroll

small grains of salts on

system supplied by STS (Fig. 2).

their surfaces, which must

It is a fully automatic rotary

be eliminated with water

plant designed for cleaning,

because they are polar

rinsing, and drying metal

contaminants. Finally,

components.”

Officine Vica has always

“The cleaning cycle in the

paid great attention to

system’s single chamber

environmental sustainability.

lasts about 11 minutes and it

That is why we have chosen

includes as follows: immersion

this type of machine,

cleaning with ultrasound, high

which saves energy and

pressure spray cleaning, a

water because there is no

further immersion cleaning

evaporation, as it is a

3 1

stage, ultrasonic rinsing with osmotic water, vacuum drying

closed-loop system,” states

Figure 3: A bird’s eye view of the Aquaroll® system.

holes, and cooling (Fig. 3). The machine allows cleaning up to six workpieces at the same time at

to remove moisture from blind

a temperature of about 50 °C. Moreover, it exploits a “flood effect” that generates continuous emptying and refilling of the chamber,” explains Mauro Ballo from STS.

Automation and environmental sustainability “We have turned to STS for two main reasons: their high customisation level and the eco-friendliness of their plants. Although STS designed Aquaroll® with manual loading and unloading units, by collaborating with them we have managed to make it fully automated. This results in a reduced need for labour in the basket loading and Figure 4: The unloading of finished parts.

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Piero Merlin.

Impianti di lavaggio aquar oll e aquat unn Washing machines aquar oll and aquat unn ®

aquaroll® EE40 Impianto di lavaggio automatizzato Automatic washing machine

aquatunn® Impianto di lavaggio a tunnel Tunnel washing machine

aquaroll® EE30 Impianto di lavaggio Washing machine

aquaroll® MR7 Macchina rotativa robotizzata multistadio Rotational robotized multistage machine

aquaroll® AF Impianto di lavaggio ad asse orizzontale Horizontal axis washing machine

Efficace, Ecologico, Economico e... Sicuro Effective, Ecological, Economical and... Safe STS Srl - Via L. Galvani, 8 - 48123 Ravenna RA (Italia) Tel. +39 0544 456731 - Fax +39 0544 456733 we b : w w w. s t s i t a ly. i t - e m a i l : i n fo @ s t s i t a ly. i t

ICT - CASE STUDY

Opening photo: By the perfectly tuned de-oiling and mass finishing operation the brake pad carrier plates receive the perfect surface finish for the subsequent bonding process.

Linked Cleaning and Mass Finishing Solution for Brake Components: Continuous Processing of Parts that Must be Glued Together Julia Lips Rösler Oberflächentechnik GmbH – Untermerzbach, Germany

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j.lips@rosler.com

ICT - CASE STUDY

gentle processing and complete automation

pad manufacturer, presented

De-oiling, deburring and surface roughening

Rösler with the challenge of

As a result of changing the production

stages in continuous feed operation (Fig. 1).

finishing a surface in order to maximize its

method for the brake pad carrier plates,

LUMAG decided to partner with Rösler for this

adhesion characteristics for a subsequent

from casting to stamping, LUMAG decided

important project, because Rösler not only

bonding stage. Rösler offered a solution

to install a new in-house manufacturing

enjoys an excellent reputation in the industry,

for de-oiling and surface finishing of brake

line for these products. This included a

but was also able to supply the equipment for

pad carrier plates directly linked to a punch

solution for de-oiling, deburring and surface

both processes including the finishing media

press.

roughening of the stamped carrier plates

and compounds from one single source.

LUMAG Sp. z o.o., founded by Mr. Marek Zak

with lengths of 210-250 mm and widths

in 1988, is specialized in the production

between 90-110 mm. It should be noted that

of brake pads for drum and disk brakes

the components have a slit or drilled hole for

for commercial vehicles. For the latter

placing a sensor, which monitors the wear of

Intelligent media selection allows cleaning without the need for drying

the company, located in Budzyń, Poland,

the brake pad. These steps were intended to

After the stamping process a conveyor belt

developed its own manufacturing

ensure that the delicate stampings provide

transfers the work pieces to the drum washing

technology resulting in significant quality

optimum adhesion characteristics for the

machine equipped with an internal transport

improvements. In addition, LUMAG

following bonding of the brake pads. Another

auger. In the drum the carrier plates are

develops, produces and sells brake

requirement presented by the customer

initially passed through an un-perforated

pads for passenger cars and motorbikes

was to directly link the finishing equipment

zone into which cleaning liquid is injected by

under the trade name Breck.

with the punch press, maintain extremely

flat spray nozzles. This creates an immersion

UMAG, a well-known Polish brake

of the cleaning (de-oiling) and mass finishing

Hybr-hidow Know 1999

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The VAIOCS and SOLVACS hybrid technologies are in use in hundreds of machines for demanding customers throughout the world for the highest possible component cleanliness. Because ˮlike dissolves likeˮ is best as double act. And certainly ˮMade in Germanyˮ. We look forward to your challenge. Phone: +49 7041 937400 www.hemo-gmbh.de

ICT - CASE STUDY

bath for de-oiling (ref. Opening photo).

reducing the operational costs. For proper

continuously cleaned in a fully automatic

In the following perforated drum section

maintenance of the cleaning liquid the

peeling centrifuge Z 1000 equipped with

the cleaning liquid is drained, and in a

washing machine is equipped with filtration

automatic sludge discharge.

secondary de-oiling step the work pieces are

units and an oil separator.

spray washed. This cleaning zone is followed

As international market leader Rösler

by a drip-off section, a rinse station and

Gentle mass finishing process

another drip-off section. Subsequently, a

Deburring and surface roughening of

solutions in the field of mass finishing

conveyor belt transfers the work pieces into

the work pieces takes place in a linear,

and shot blasting, painting & preservation

the mass finishing machine.

continuous flow vibrator R 550/6600 DA

systems and mass finishing consumables.

Replenishment of the cleaning liquid

with a specially adapted work piece loading

In addition, Rösler offers a broad

takes place with a Dosatron proportional

system. Loading actually takes place at the

spectrum of surface finishing technologies

dosing pump. Since the cleaning liquid

rear end of the processing bowl instead

(deburring, descaling, desanding, polishing,

and the compound for the mass finishing

of on the lateral bowl side with greatly

surface grinding,…) for work pieces

process have practically the same chemical

reduced dropping heights. An equally

made from metal and other materials.

characteristics – including the placement

gentle work piece transfer process was

Headquartered in Germany with plants in

of a temporary corrosion protection –

incorporated in the vibratory screening

Untermerzbach/Memmelsdorf and

carryover of the cleaning liquid into the

unit and the dryer filled with Supervelate

Bad Staffelstein/Hausen, the Rösler group

mass finishing machine presents no issue.

drying media. After drying a certain work

also maintains sales and manufacturing

This clever trick eliminated the need for

piece quantity, which is precisely measured

branches in Great Britain, France, Italy,

a drying stage after the cleaning process,

by weight, the work pieces are discharged

the Netherlands, Belgium, Austria, Serbia,

resulting not only in significant savings in

into a transport bin. The process water

Switzerland, Spain, Romania, Russia, Brazil,

the overall capital expenditure but also

from the mass finishing machine is

India, China and the United States.

Oberflächentechnik GmbH offers total

Figure 1: The fully automatic de-oiling/washing and mass finishing system is directly linked to the punch press and allows for continuous feed operation. The only manual operation is the replacement of the full transport bins every few hours.

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ICT - TECHNOLOGY OVERVIEW

Trybex ÂŠ Shutterstok

Becoming Greener and Greener: Reusing Instead of Disposing! Rossano Conidoni Biokavitus Srl, Concesio (Brescia, Italy)

conidoni@biokavitus.com

n an increasingly less sustainable world,

company. Biokavitus, which has always

a manufacturing and consumption model

attention to ecological compatibility has

promoted environmental commitment in the

focussed on the regeneration and recycling of

become of primary importance in the

industrial sector, manufactures equipment

available resources for as long as possible, in

industry. Being eco-responsible manufacturers

and systems that enable to rationalise the

order to reduce waste and disposal costs.

is not just a great green marketing-oriented

resources used in production cycles through

The consistent use of Biokavitus equipment

publicity opportunity, but also, and above

constant optimisation of operating costs and

guarantees several advantages, particularly in

all, a matter of civil responsibility for every

production processes. This company promotes

the management of cooling lubricant emulsions

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and industrial cleaning water. The technology developed by this company naturally increases the efficiency of processes through a resource with a very low cost and environmental impact, which often results in the minimisation or even elimination of chemical additives and in the reduction of energy costs. Finally, Biokavitus’ systems are characterised by a low investment cost, which is also reflected in their management costs. Indeed, these machines take advantage of the formation of nano bubbles, air, and different gases within the fluid to be treated; their technology can be applied to all industrial sectors, such as automotive, mechanical engineering, aluminium die-casting, precious metal processing, textile, food, and many more. The flagship product of Biokavitus’ range is the Phoenix equipment (Fig. 1), intended for the regeneration of industrial liquids and already adopted as an innovative technology by some of the leading European automotive companies. When used to regenerate cooling lubricant emulsions, Phoenix guarantees the effective separation of pollutants, such as oils and metal particles, from fluids. The nano bubbles generated by this system act as a natural “filter”, which captures and brings to the surface all extraneous oil, thus allowing a subsequent removal not only of the decanted particles, but also of the suspended ones. Similarly, it guarantees the effective separation of extraneous oil linked to metal particles produced during machining, which can thus be removed through filters designed specifically for this application. The formation of nano bubbles of air into the process fluid leads to its over-saturation, very different from conventional oxygenation occurring through standard technologies. The nanometric dimensions of the air bubbles multiply exponentially the benefits obtainable, such as for instance the effective control of odours correlated to bacterial charge. Moreover, Biokavitus’ technology ensures better cleaning of machine tools, thus reducing the plants’ cycle time and improving the skimmers’ performance. This improves the entire production cycle through greater economic savings, performance level, and environmental protection. Besides being used for treating cooling lubricant emulsions, Biokavitus technology allows performing effective and accurate cleaning processes, even at low temperatures. The washing water is cleaner thanks to the induced flotation of suspended particles and extraneous oils, which results in a clean and odourless process. When used to regenerate industrial cleaning water, the Phoenix device guarantees better purifying action on difficult-to-clean parts and better skimmer performance, but it also reduces the use of detergents, water consumption, waste water disposal costs, and energy costs for heating the cleaning water itself.

ICT - TECHNOLOGY OVERVIEW

Figure 1: The Phoenix device is the flagship product of the Biokavitus range: intended for the regeneration of industrial liquids, it has already been adopted as an innovative technology by some of the leading European automotive companies.

For example, one of Biokavitus’ customers, a

Another user of Biokavitus products is

stabilise the cutting emulsions used for

world leader producing millions of automotive

an international company that designs

its sheet plastic deformation processes.

valves per year, uses such equipment both

and manufactures sheet metal pulleys

Combined with a Biokavitus oil separator,

in its Italian factories and in its production

by cold plastic deformation, for use in

it can totally remove extraneous oil from

sites in Poland. The Biokavitus technology

the light and heavy automotive sector.

emulsions, thus restoring optimal working

enables it to carry out its cleaning operations

It uses Phoenix devices to check and

conditions for presses and ensuring a healthier and cleaner working environment.

rejected parts due to unsuitable cleaning was

The removed extraneous oil is sent to the

found on its dimensional control machines.

appointed consortium with no additional

Biokavitus’ devices are integrated into its

expense, but rather with general process

without using any detergent; no increase in

production process, guaranteeing the following advantages: total elimination of chemicals,

savings. The Phoenix device also guarantees effective cleaning of machine tools and an

reduction of waste water in its chemical-

extension of the service life of emulsions

physical state, and elimination of bad odours

by avoiding the proliferation of bacterial

in warm periods due to the presence of oil and

colonies.

water and to the formation of bacteria. The use

Currently, Biokavitus takes care of the entire

of the Biokavitus technology has also allowed

use process of industrial fluids and it is able

reducing the number of operators needed to assist with the daily operation of machines

2 1

workload for the purchasing department and the warehouse involved in orders and product deliveries (Fig. 2).

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and recovery, up to pre-disposal treatment. Its Phoenix devices integrate perfectly with

(skimming cycles) as well as the biweekly concentration check; it has also resulted in less

to provide solutions to optimise their usage

Figure 2: The use of Biokavitus’ technology has made it possible to reduce the number of operators needed to assist with the daily operation of machines as well as the biweekly concentration check.

other systems designed by Biokavitus, such as advanced self-cleaning filters and oil separation systems for the management of both water-based and oily industrial fluids.

INFO: VDW – Generalkommissariat EMO Hannover 2019 Verein Deutscher Werkzeugmaschinenfabriken e.V. Corneliusstraße 4 · 60325 Frankfurt am Main · GERMANY Tel.: +49 69 756081-0 · Fax: +49 69 756081-74 emo@vdw.de · www.emo-hannover.de

Informazioni e biglietti: Hannover Fairs International GmbH – Branch Italy Via Paleocapa 1, IT-20121 Milano Tel.: +39 02 70 63 3 29 2, Fax: +39 02 70 63 3 41 2 E-Mail: info@hfitaly.com

ICT - TECHNOLOGY OVERVIEW

Deburring and Cleaning PPS Plastic Parts in a Single Process - CO2 Snow Jet Technology for Innovative Lighting Technology Components Doris Schulz Schulz.Presse.Text, Korntal, Germany

doris.schulz@pressetextschulz.de

ÂŠ acp systems AG

Opening photo: For the deburring and cleaning process, a Scara robot guides a blasting unit fitted with six nozzles over the parts. After the blasting time, which is individually defined for each component, the parts are then rotated 180 degrees in order to blast the underside.

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nnovative developments in

media nor blasting with dry ice were able to

Gentle but effective process

headlamp technology like matrix

achieve the required surface quality. In some

The modular cleaning system uses

LED headlamps are contributing

cases, these methods even caused damage

liquid carbon dioxide as a medium.

to increased driving safety, but the

to the parts. Following the publication of

With a practically unlimited shelf life, it is

necessary components must meet high

an article about it, the project managers

generated as a by-product of chemical

requirements in terms of cleanliness

decided to carry out deburring tests with the

manufacturing processes and of energy

A parts manufacturer deburrs and cleans the injection-moulded parts made from glass

production from biogas, thus

ÂŠ acp systems AG

and the absence of burrs.

making it environmentally neutral. The carbon dioxide is supplied via cylinders or

fibre-reinforced polyphenylene

tanks.

sulfide (PPS) with the quattroClean

A key component of the

snow jet technology in a single

quattroClean system is a

fully-automated process.

patented, wear-free

To optimally adapt the cleaning

two-component ring nozzle.

system to the task, the

Non-flammable and

manufacturer of the quattroClean

non-toxic CO2 is fed through

system conducted the run-up

the nozzle and expands

to series production on its own

premises. As with many other new developments in the automotive industry, innovations in the field

on exiting to form a core jet of fine CO2 snow.

This is bundled by a jacketed

Figure 1: The numerous small apertures in the separators pose a particular challenge because each one has to be deburred.

jet of Class 3 compressed air and accelerated to

of lighting technology often entail

supersonic speed. When the

higher production requirements.

non-abrasive jet of snow

2 1

and compressed air impacts

of matrix LED headlamps made

at a temperature of minus

from PPS MX 50, a glass

78.5Â°C onto the surface of

fibre-reinforced plastic that

the part to be processed,

retains its shape even at high

a combination of thermal,

temperatures, have to meet

mechanical, sublimation and

more than just high demands

solvent effects take place.

regarding the absence of particles

Deburring is achieved

and film-like contaminants. Fine

through the local

burrs from the injection-moulding

embrittlement of the burrs

ÂŠ acp systems AG

The two injection-moulded parts

process also have to be reliably removed. With their numerous fine apertures, separators pose a particular problem because each one has to be deburred (Fig. 1).

Figure 2: The fine burrs on the apertures of the PPS components are reliably removed by the CO2 snow jet process.

due to the thermal effect. Simultaneously, the volume of the CO2 multiplies almost instantly as it sublimates,

resulting in micro pressure waves. The force created

CO2 snow jet cleaning chosen after extensive tests

quattroClean system from acp systems AG.

by the spread of the pressure waves is

The results, which were verified through

sufficient to remove burrs reliably from

The parts manufacturer was looking

optical measurements and residual dirt

the PPS components (Fig. 2).

for a suitable technology to solve this

analyses, confirmed that this technology was

In addition, the interplay of the four

problem. Tests showed that neither

capable of deburring and cleaning the parts to

mechanisms of action ensures an effective

conventional blasting with solid

the standards required.

and homogeneous cleaning performance.

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Particulate contaminants, such as the detached burrs, dust and particles, are removed

components are then rotated 180 degrees in order to blast the underside (ref. Opening

just as effectively and reliably

photo). A powerful extraction

as filmic contaminants, for

system removes the burrs and

example residues of separating

impurities from the booth to

agents. The deburring and

prevent recontamination.

cleaning process is so gentle

The table then rotates to the

on materials that it can also

third station, where the parts

be used on delicate and

are marked as “cleaned”. At the

finely-structured surfaces. The

present time, the fourth station

quattroClean system is therefore

is still in reserve for a later

suitable for use with virtually all combinations.

System concept for fully-automatic deburring and cleaning process

automatic loading and unloading

3 1

technical materials and material

process, which has already been

Figure 3: To keep to the required process times of 7.5 seconds per frame and 12 seconds per separator, two parts are deburred and cleaned at the same time. The parts are placed in the system by hand.

developed from the system technology aspect. In the current version, parts are unloaded in the first station. One criterion that played a

major role when developing the

Once it became clear that the

system was the need to clean parts

quattroClean system was able to

quickly and effectively. This also helps

reliably achieve the surface quality

to prevent them from becoming

needed for subsequent processes, a

recontaminated. The system also

system concept was elaborated.

features excellent noise insulation

The concept also had to enable a high

properties.

throughput. To keep to the required and 12 seconds per separator, acp

Run-up to series production on acp’s premises

developed a tailor-made system based

The quattroClean system is operated

on standard modules (Fig. 3). The

in a plant belonging to the parts

compact, closed system comprises a

manufacturer in Southeast Europe.

rotary indexing table with four stations.

To ensure smooth series production

In the first station, two separators or

at the plant without the usual

frames are placed by hand in

start-up phase for special equipment,

specially-designed holders and fixed.

acp commissioned the system

The exact position of the parts is

on its own premises.

monitored by sensors; only if they have

Over a period of around ten weeks,

been positioned correctly, can the

the company deburred and cleaned

operator rotate the table to the next

the parts as a service provider in

station. This is a closed, flow-optimized

two-shift operation six days a week.

booth (standard module) into which the quattroClean process is integrated (Fig. 4). A Scara robot guides a blasting unit fitted with six nozzles over the parts. After the blasting time, which is individually defined for each part, the

196

process times of 7.5 seconds per frame

This solution enabled the system 4 1

to be optimized during the run-up, both with regard to the process

Figure 4: The tailor-made system based on standard modules consists of a rotary indexing table with four stations. This includes a closed, flow-optimized booth into which the quattroClean process is integrated.

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and the consumption of CO2 and

compressed air, thus leading to later savings in series operation.

ICT - TECHNOLOGY OVERVIEW

Solutions for Surface Finishes on Additively Manufactured Metal Parts Doris Schulz Schulz.Presse.Text, Korntal, Germany

doris.schulz@pressetextschulz.de

ÂŠ RĂśsler

Opening photo: Various automated and automatable post-processing methods are available for treating the surfaces of additively manufactured parts, by means of which required surface finishing quality can be reproducibly assured.

he diversity of printing technologies

reproducible, automated post-processing

addition to the most widely used methods of

and materials used for additive

(ref. Opening photo).

laser melting (SLM/DMLS) and electron beam

manufacturing is growing steadily.

Additive metal processing is currently

melting. These printing technologies make

Nevertheless, cleaning and surface finishing

undergoing rapid development. In the

it possible to produce parts using, amongst

of printed metal parts still represents a

meantime, processes which make use

other materials, traditional MIM powders and

challenge in many cases. New and further

of binder-based systems such as metal

to sinter them subsequently, or to melt down

developed processes permit reliable,

injection moulding (MIM) are available in

MIM-bound metal rods.

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Processing Component Surfaces – a Multifaceted Task

ICT - TECHNOLOGY OVERVIEW

Although the surface quality of the component depends on the utilised printing technology, design and material, post-processing is nevertheless indispensable in most cases. This involves a great variety of tasks. They range from removing the build plates, support structures and residual powder, as well as processing the usually rough surface – for example by means of smoothing, polishing and rounding – right on up to cleaning the workpieces in order to assure the required cleanliness for downstream processes (e.g. coating, bonding or welding). These manufacturing steps are still frequently executed manually which is costly and time-consuming, and leads to inadequate reproducibility of the final result.

Reproducible and Efficient Post-Processing The first step required for processes based on powder beds is to separate the workpieces from the build plate after coarse removal of the powder, for which vibration systems with targeted oscillation

Figure 1: This plug&play solution permits quick and reliable smoothing and polishing of the surfaces of metallic AM parts. Equipment included in the system, as well as its process medium, are adapted to the respective task.

excitation and automatic swivelling of the component are available. Erosion or sawing can be used for

fully automated removal of sintered-on

This technique even makes it possible

separation and, depending on the

particles and support structures in a

to remove supports from inaccessible

utilised process, burrs occur and

single work step (Fig. 1). The procedure

areas such as channels and undercuts

contamination with cooling lubricant

is based on a chemical/electrochemical

in just a few seconds.

accumulates which also have to be

process by means of which the workpieces

On the one hand, wet chemical cleaning

removed.

are smoothed without any loss of edge

processes with ultrasound or cyclical

Various solutions are available

sharpness. Advanced T.E.M. (thermal

nucleation (CNp), as well as aqueous

for removing sintered-on powder

energy method) represents a further

media or solvents which are matched

particles and support structures

development for the removal of support

to the material, can be used where

quickly and reliably. For example,

structures from parts manufactured by

residual powder which adheres to the

a plug&play machine permits

means of DMLS technology.

part needs to be removed (Fig. 2).

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2 1

Figure 2: Residual powder can be removed, for example, by means of wet chemical cleaning processes combined with ultrasound.

Amongst other processes, CO2 snow

external, readily accessible surfaces

blasting is used as a dry alternative

this is made possible by means of

blasting technique. It’s based on a waterjet

for removing residual power. Powder

milling, erosion, lapping, barrel finishing

process which is used in combination with

particles can also be removed from

or laser polishing, as is also the case

a minimally abrasive blasting medium.

delicate contours, undercuts and

with conventionally manufactured

Correct matching of the parameters

complex shapes with the help of this

workpieces. However, these processes

including type and size of the blasting

easy-to-automate process.

are quickly pushed to the limit in the

On the other hand, this task can also be executed by means of a newly developed

medium, water pressure and treatment

case of internal contours and surfaces,

that the powder is fully removed even

Surface Finishing – Fast and in Compliance with Component Requirements

from complex geometries and undercuts,

Whether smoothing, polishing,

developed and optimised in order to

without leaving any blasting medium

rounding or the production of defined

meet the requirements of additively

behind or changing any contours.

edges is involved, in the case of

manufactured parts.

duration, as well as motion of the parts to be cleaned, make it possible to assure

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as well as difficult to access areas of 3D printed parts. Existing technologies have been appropriately further

ICT - TECHNOLOGY OVERVIEW

These include barrel finishing

workpiece, which nevertheless retain their

Process parameters are continuously

processes with process media which

sharp edges. Processing times of just a

monitored in order to assure

are individually matched to the specific

few hours are typical for electrochemical

reproducible results.

task. They make it possible to achieve

processes.

The number of automated

the desired degree of smoothing and

Flow grinding, also known as abrasive

post-processing procedures, as well

the required finish with very short

flow machining (AFM), is also used for

as the options they offer, are growing

processing times – from high-gloss

finishing the surfaces of 3D printed

continuously. However, it’s advisable

to satin-matt surfaces. In the case of

metal parts (Fig. 4). The part is clamped

to take available post-processing

components whose surfaces have to

for processing in a fixture at the AFM

solutions into consideration already

fulfil various requirements, suitably

machine. The processing medium – a

while the respective part is being

adapted system variants can be

carrier material with defined viscosity

designed, with which the required

implemented so that only the required

and embedded abrasive particles whose

surface characteristics can be

workpiece areas are immersed into the

type, size and concentration are adapted

achieved.

abrasive medium.

to the respective task – is caused to

Coolpulse ECM is also laid out for

flow through or over the component

processing additively manufactured

area(s) to be processed in alternating

metal parts (Fig. 3). Like conventional

directions at a defined pressure level by

ECM, it’s also based on the principles of

means of hydraulically powered pistons.

Figure 3: Micro and macro structures on inside and outside surfaces can be processed with the Coolpulse method, which is based on ECM technology.

anodic dissolution of metal. However, a special, pH-neutral, environmentally friendly electrolyte is used in this case. Micro and macro structures on inside and outside surfaces can be improved through processing with this treatment, and defined surface characteristics can be reproducibly produced. Beyond this, support structure remnants and surface defects can also be removed. Electrochemical processes which have © Extrude Hone

been specially adapted for finishing the surfaces of 3D printed parts, as well as processes such as electropolishing, are also available as further processing alternatives. This processing option makes it possible to smooth and polish surfaces in delicate “valleys” in the

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ÂŠ 4MI GmbH

ICT - TECHNOLOGY OVERVIEW

4 1

Figure 4: The contours of this mixer component were smoothed and polished using an AFM process.

DeburringEXPO Leading Trade Fair for Deburring Technology and Precision Surface Finishing Which processes ensure reliable and economically efficient post-processing of additively manufactured parts? Which new technologies are available to this end? Which criteria need to be taken into consideration for the selection of an ideally suited

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process? Answers to these and many other questions will be provided by DeburringEXPO at the Karlsruhe Exhibition Centre (Germany) from the 8th through the 10th of October, 2019. The exhibition portfolio includes equipment, systems and tools for belt grinding, brushing, abrasive flow machining, vibratory grinding, blasting with solid and liquid media, abrasive water-jet blasting, magnetic-abrasive deburring, ultrasonic deburring, chemical bath deburring,

electrochemical machining (ECM), electron beam machining, thermal energy machining (TEM), mechanical deburring, buffing, polish honing, electrolytic polishing, plasma polishing, laser polishing, immersion and brush polishing, solutions for industrial parts cleaning, as well as measuring, test and analysis systems for quality control, and technical literature. Further information is available at www.deburring-expo.com

Automatic sealed ultrasonic cleaning machine 2S 90/24-P-F PCT AC Our machine requires only 5 kW (about 20% of the normal power requested by type Ib machines).

The future of green technology.

MEG S.r.l. Via Rometta, 13/G - S. Martino di Lupari (PD) - Italy Phone +39 049 9461165 - Fax +39 049 9461133 e-mail info@meg.it â&#x20AC;&#x201C; www.meg.it

PRECISION CLEANING

1989-2019

ICT - ZOOM ON EVENTS

DeburringEXPO: Efficient Solutions for Long-Standing and New Requirements for Component Surface Finishing

hether traditional or new

quality criterion in many industry sectors such

to enhance performance and extend service

manufacturing processes are

as the automobile and automotive supplier

life. Downstream processes such as joining,

involved, none of the available

industries, aerospace and aviation, machinery

sealing, coating and assembly also necessitate

technologies make it possible to produce

manufacturing, medical engineering,

burr-free and in some cases rounded edges

component surface finishes in the required

metrology, precision engineering, sensor

for various reasons. And thus for example in

quality. Process steps such as deburring,

technology and drive technology, as well

the field of sheet metal processing, deburring

rounding and cleaning, as well as targeted

as in the field of electro-mobility. “Reliable

minimises the risk of injury due to sharp

functional or decorative surface finishing,

deburring, during which extremely fine burrs

edges and reduces tooling wear for edging

are thus indispensable. Solutions by

and flash must also be removed depending

means of which these tasks can be executed reliably and economically will be presented at DeburringEXPO at the

On the other hand, good deburring and well-defined edge rounding make it possible to enhance

Karlsruhe Exhibition

painting quality at the

Centre (Germany) from

edges. “Relying solely

the 8th through the 10th

on experience gained

of October, 2019. Beyond

with previously used

this, the 3rd leading

processes for these

trade fair for deburring

tasks can quickly

technology and precision

lead to a competitive

surface finishing will

disadvantage.

provide valuable

Benchmarking is thus

know-how at its bilingual

advisable which focuses

expert forum.

central attention on searching for the most effective, reliable

Parts manufacturing is currently faced with new tasks in numerous areas.

DeburringEXPO will take place at the Karlsruhe Exhibition Centre (Germany) from the 8th through the 10th of October, 2019.

and economical technologies,” explains Hartmut Herdin.

Due to more and more complex geometries and finer structures,

on the degree of required cleanliness, is a

Companies are also being confronted with

machined, formed, primary formed, forged,

fundamental prerequisite for complying

new tasks in the area of surface finishing

sintered and moulded workpieces are

with cleanliness specifications,” explains

which result from innovative production

not only resulting in stricter requirements

Hartmut Herdin, managing director of

processes such as additive manufacturing

where actual parts production is

fairXperts GmbH & Co. KG, promoters of

(AM). The removal of residual powder and

concerned, but rather during deburring

DeburringEXPO. Furthermore, in some cases

supporting structures, as well as the rough

and surface finishing as well. The technical

surfaces are required which minimise friction,

and porous surfaces produced by these

cleanliness of components is an essential

wear and noise, and which make it possible

processes, are challenging.

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Bilingual Expert Forum – Know-How as Added Value Due to its unique character and its highly practical orientation, the 3-day expert forum integrated into DeburringEXPO is an extremely popular source of knowledge. Presentation focal points include fundamentals, approaches to process and cost optimisation, reports on best practice applications and current trends. Talks on special issues such as the process sequence for sheet metal deburring, post-processing of AM parts and cleaning after deburring round out the forum programme. All talks held at the DeburringEXPO expert forum

will be simultaneously interpreted

Cross-Industry, Cross-Technology Information

With its comprehensive spectrum,

(German-English/English-German).

DeburringEXPO not only covers the entire

Participation is free of charge for

The above mentioned tasks and many others

process sequence for deburring and the

visitors at the leading trade fair.

as well will be explored at the upcoming

production of precision surface finishes, it

DeburringEXPO, which will be held at the

also identifies trends and imparts practical as

For further information:

Karlsruhe Exhibition Centre from the 8th

well as theoretical knowledge.

www.deburring-expo.de

through the 10th of October, 2019. As of the end of March, 125 exhibitors from eleven countries, including numerous market and technology leaders, had already made firm booking for their booth floor space. Offerings for solutions involving deburring, rounding and the production of precision surface finishes, which are unparalleled at any other event around the world, will await the trade fair visitors. The exhibition portfolio covers products, systems, processes and services for deburring, the production of precision surface finishes and cleaning after deburring, as well as measuring and test technology quality assurance for components made of practically every conceivable material in nearly all industry sectors. Opportunities for further qualification and technical literature will also be found at the event.

and analysis systems for quality control and

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n light of global trends such as electromobility, autonomous vehicles, lightweight construction,

miniaturization, automation and digitization, the industrial parts and surface cleaning sector is facing new challenges. parts2clean 2019 shows how these challenges can be met. The 17th International Trade Fair for Industrial Parts and Surface Cleaning will be held from 22nd to 24th October 2019 at the Stuttgart Exhibition Center. Areas of current interest include new and modified production technologies, such as the growing use of adhesive bonding, laser welding and coating processes, as well as the additive manufacturing of components. At the same time, there is increased demand for the cleaning of workpieces made from new materials or material combinations,

parts2clean will take place at the Stuttgart Exhibition Center (Germany) from 22 to 24 October 2019.

as well as complete assemblies. And then there are the tougher regulatory

proves the point, for it already includes

easily. Some will be looking for the right

requirements, such as those contained in

virtually every market and technology leader

process engineering and plant to remove

the new European Medical Device Regulation

from each of the show’s display categories,

particulates or film-type contaminants

(MDR).

all of whom traditionally use parts2clean as a

efficiently and with consistent results

These changes are forcing business

prime opportunity to unveil their latest new

in order to comply with new, tougher

enterprises to review existing processes

products and innovations.

standards. Others will be more interested

and question old ways of doing things.

in technology for cleaning parts made from

businesses to gather the information they

Meeting specific requirements reliably

need for positive changes,” says Olaf Daebler,

The range of leading-edge exhibits allows

be solutions for the control and monitoring

Global Director of parts2clean at Deutsche

visitors from many different sectors such

of cleaning, rinsing and drying processes, as

Messe. “As a global meeting place for industry,

as the car and component supply industry,

well as systems for checking and quantifying

the event and its exhibitors not only showcase

medical technology, mechanical engineering,

the degree of cleanliness achieved. Another

the very latest technological advances in

the aerospace industry, precision engineering

major interest is the automation of cleaning

industrial parts and surface cleaning, but

and micro-engineering, optics, electronics,

operations and associated parts handling,

also highlight key trends and offer best-fit

semi-conductors and coating technology – to

e.g. using robots and suitably designed

solutions.” A glance at the exhibitor lineup

find the information they need quickly and

workpiece carriers. And yet another matter

“parts2clean is the perfect place for

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new materials, or parts with highly complex geometries. Also popular with visitors will

ICT - ZOOM ON EVENTS

of growing importance is the intelligent integration of cleaning processes in networked manufacturing environments and cloud solutions, which make it possible to retrieve large quantities of information at any time, and from any location. Rounding off the coverage of this theme is the special QSREIN 4.0 display, the main focus of which will be on the future of process management in water-based parts cleaning. For the all-over or selective cleaning of surfaces in various © Deutsche Messe AG

situations, there is now a growing trend towards the use of dry cleaning processes. parts2clean reflects this development with a broad range of offerings, which include systems for CO2 snow blasting, plasma cleaning, laser cleaning, vibratory finishing and

cleaning with compressed air. The Guided Tours will be offered in English on all three days of the show. Focusing on selected exhibitor stands, they give visitors the opportunity to gather information about specific areas of interest in industrial parts and surface cleaning at every stage of the process chain. For them it is a quick and easy way to discover relevant solutions and innovations and identify likely suppliers who can solve their problems. The Guided Tours are also an excellent business opportunity for participating exhibitors, who can present their products and innovations directly to a pre-selected target audience at their stands, resulting in additional contacts and sales prospects. For further information: www.parts2clean.de

parts2clean Industry Forum and Guided Tours add value for visitors “The three-day Industry Forum is a favorite destination, and therefore a must for visitors,” Daebler reports. “The program of talks, available in simultaneous translation (German >< English), offers a wealth of valuable information about current trends and innovations.” Organized in association with the Fraunhofer Cleaning Technology Alliance and the German Industrial Parts Cleaning Association (FiT), this knowledge-sharing event offers lecture-style talks and discussions on © Deutsche Messe AG

technology basics, strategies for optimizing processes and costs, quality assurance, best-practice applications, and the latest trends and developments.

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MECSPE 2019 is a Great Success

ECSPE: another great success.

skills, exhibitors and visitors saw the

revolution. This transformation was palpable

The 4.0 manufacturing trade

trade fair as an important business

in the Innovation Tunnel, created thanks to

fair organised by Senaf,

opportunity and a fruitful moment for

collaboration with the Intelligent Factory Cluster

a reference event at national and

discussing and updating on innovation

(IFC, Fig. 2) with the presentation of four

international level, took place at Fiere

topics which are increasingly central

lighthouse projects by Ansaldo Energia, ABB

di Parma from 28 to 30 March,

for the competitiveness of Made in Italy

Italia, Tenova/Ori Martin and Hitachi Rail Italy,

confirming itself once more in 2019

businesses.

selected by the IFC on behalf of the Ministry of

as a synergistic link between the latest

The excellent results achieved by the

Economic Development.

manufacturing technologies and different

event also come down to the even

“Collaboration with the Intelligent Factory

industrial chains (Fig. 1). The 18th edition