ipcm® n. 55 - January/February 2019 by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

ISSN 2280-6083

ipcm digital on In this issue :

SPECIAL ON RAW MATERIALS, PIGMENTS, PAINTS& COATINGS

INTERNATIONAL PAINT&COATING MAGAZINE

www.myipcm.com 2019

10th Year - Bimonthly N° 55 - JANUARY/FEBRUARY

S PAC E S H U T T L E L AU N C H

Our obsession with collaboration leaves us standing in awe. We know the result is only as good as those who make it, and we’d never dare to go it alone. We work so closely with our customers that we anticipate their needs before they do. Exploring all possible solutions together ensures that every vision illuminates exactly as imagined.

W E ’ R E O B S ES S E D W I T H C O LO R Visit: oem.sherwin-williams.com; Contact: inver@sherwin.com

EXPLO RATIO N TOWER AT PORT CANAVERA

L, FLORI DA

MOMENTS AFTER SUNRISE

CONTENTS JANUARY/FEBRUARY 2019

S P E C I A L O N R AW MATER I A L S , PI G MEN TS , PA I N T & C OATI N G TEC H N OLOG I ES

INNOVATIONS: PRESENT&FUTURE

HIGHLIGHT OF THE MONTH

Multi-Curing Waterbased PU Dispersion: Faster Drying, Robustness and Improved Performance Even Under Poor UV-Curing Conditions © Emil Frei GmbH & Co. KG

46 © ipcm ®

Euromask® Increases Its Hook Packaging Automation Level

S P ECI AL O N RAW M ATERI ALS , P I G M E N T S , PAI N T &CO ATI N G TECH N O LO G I E S

S P E C I A L O N R AW MATER I A L S , PI G MEN TS , PA I N T & C OATI N G TEC H N OLOG I ES

INNOVATIONS: PRESENT&FUTURE

HIGHLIGHT OF THE MONTH

54 03 04 10

Chemtec Expands its Plant and Develops a Laboratory Test Contracting Service

EDITOR’S LETTER

VOC-compliant Coating: Ultra-high-solid Platform Technologies

FOCUS ON TECHNOLOGY A New Application Technology with a 3D Part Scanning System and a Dynamic Reciprocator to Optimise the Production Time and Quality Level of Complex Products

BRAND-NEW HIGHLIGHT OF THE MONTH An Internationally Oriented, Technologically Advanced Company Closely Cooperating with Excellent Businesses: Lesta’s Success Story in the Field of Robotics for Industrial Coating

HIGHLIGHT OF THE MONTH The New ADAPTA APP, a Pioneer in the Powder Coatings Market as for Sustainability and Efficiency

24 25

BRAND-NEW SUSTAINABILITY

SUCCESS STORIES Ding Dong Merrily on High

33 34 38

S P E CI A L ON R AW M AT E R I A L S , P I G M E N T S , PA I N T & C O AT I N G T E C H N O LO G I E S

BRAND-NEW SUSTAINABILITY - 5 ON 5 Five on Five Interview: Sustainability According to the Industry Players

Orange Peel & DOI wave-scan

Multi-angle Color & EďŹ&#x20AC;ect BYK-mac i

Measure what you see.

BYK-Gardner your only choice for color & appearance control of metallic ďŹ nishes www.byk.com/instruments

Mottling cloud-runner

CONTENTS JANUARY/FEBRUARY 2019

S P ECI AL O N RAW M ATERI ALS , PI G M E N T S , PAI N T &CO ATI N G TECH N O LO G I E S

INNOVATIONS: PRESENT&FUTURE

The Evolution from Single Component to Plural Component Paint

Lacquering Before Polishing: Technical Coatings for Additive Manufacturing

INNOVATIONS: PRESENT&FUTURE

S P E C I A L O N R AW MATER I A L S , PI G MEN TS , PA I N T & C OATI N G TEC H N OLOG I ES

FOCUS ON TECHNOLOGY

108 58

HIGHLIGHT OF THE MONTH

Prifer and Solintellysys Develop an Innovative Compact Coating Line that Applies both Liquids and Powders

HIGHLIGHT OF THE MONTH

Novaresine: The Sustainable Approach of a Chemical Company Open to Everyone

HIGHLIGHT OF THE MONTH Research and Technological Innovation as the Cornerstones of Industrias Titan’s Philosophy

116

BASF Analyses the 2018 Automotive Colour Distribution

SUCCESS STORIES

96 102

BRAND-NEW HIGHLIGHT OF THE MONTH Deep Matt Powder Coatings with no Hazardous Substances

FOCUS ON TECHNOLOGY

106

Turning a Vision into a Reality: Eisenmann Builds First Skidless Paint Shop for Electric Vehicles

SUCCESS STORIES World Market Leader Kässbohrer Automates Production of its PistenBully with Painting Robot from Dürr

120 122 124

Electrical Cabinet Manufacturer Rittal Offers Insight into Their Production

SUSTAINABILITY BRAND-NEW STANDARD & LEGISLATION - UCIF INFORMS Ecodesign: Work on Electric Motors

128

ZOOM ON EVENTS

eosmarketing.it

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.

kwanchaiftÂŠfotolia

TO BE A TEAM

TO BE CLOSE TO THE CLIENT

TO BE FOR THE ENVIRONMENT

www.novaresine.com

TO BE NOVARESINE

A new generation coarse texture powder coating Our newly formulated Interpon Coarse Texture Low-E is a range of TGIC-free, polyester based powder coatings. This solution offers a consistent coarse texture finish across your product, and is excellent for use in situations where the quality of the substrate is low and small surface imperfections need to be hidden. It also offers the flexibility to use in both interior and exterior environments. As the product is part of our Low-E range, it can be cured as low as 150˚C, making it more energy efficient. • Uniform coarse texture effect • Enhanced coverage • Easy to apply • Low cure temperature (150-170°C) • Greater energy efficiency; environmetally friendly • 46 RAL shades, available from our Ready to Ship (RTS) range

www.interpon.it

EDITOR’S LETTER

Green Chemistry and Green Engineering Richiedi la versione in italiano a info@ipcm.it

lready in the middle of last year, in one of my editor’s letters I disclosed the creation of a new content section in the ipcm® magazine, devoted to one of the mega trends of our century: sustainability. Sustainable development is normally addressed with a triple bottom line approach, that is, as the interaction of three elements: economic development, environmental protection, and social equity. This section, therefore, includes news and articles not only on the sustainable technological and product innovations launched by companies in the surface treatment sector, but also on their efforts to ensure that production is environmentally friendly and guarantees the health and safety of workers and local society. With this first issue of 2019, our Sustainability section also introduces Five on Five interviews – 5 questions at a time asked to the senior managers of 5 international players in the field of surface treatment chemicals, with 15 questions altogether published on consecutive issues. An aspect in particular deserves reflection. When it comes to sustainability, we usually refer to the role played by the chemical industry. We speak of Green Chemistry, and rightly so. Decrease in the use of dangerous substances and their generation in synthesis reactions, development and synthesis of safer and more easily degradable substances, decrease in the use of solvents, use of renewable resources, and improvement of energy efficiency: these are some of the 12 principles followed by the chemical industry. What is the role of process engineering for sustainable development? Can we also talk about Green Engineering? Many elements underpinning the concept of sustainable development have been the prerogative of process engineering for years. The current development of technologies and production organisation methods is a big step forward in terms of sustainability. Green Engineering refers to the transformation of the disciplines and practices of engineering in order to promote sustainability. Indeed, the use of technologically advanced and economically valid products, processes, and systems can increase the well-being of humanity. Developing new concepts, optimising the use of raw materials, optimising production techniques, optimising distribution, reducing products’ impact during use, considering the actions required at the end of their service life, and preventing waste: these are the guidelines of the methodological approach to production and product sustainability, also in the surface finishing sector.

Alessia Venturi Editor-in-chief Direttore Responsabile

This issue of ipcm® delves into the topics of Green Chemistry and Green Engineering: we talk about innovation in raw materials for paints and coatings; investments made by chemical companies to strengthen their R&D labs to pursue sustainable innovation; and robotics and automation to simplify operational processes and material management. We also talk about the implementation of digital systems and machines to maximise process and consumption control; a pioneering application in the powder coatings industry where the latest versions of safety data sheets, analysis bulletins, and even one’s own coating warehouse situation are just a click away at any time; and a 3D scanning system for powder coating to optimise the finish and process quality of complex-shaped parts. But, above all, we talk about how important the human factor is in all this.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

BRAND-NEW

AkzoNobel Launches a New Range of Coarse Texture Products

innovations to our customers,” explains Mark

“Metal usually has to be treated and

coating technology that allows its

Reekie, Global Segment Manager, General

smoothed before adding a gloss coating,

customers to achieve coarse texture

Industry, for AkzoNobel’s Powder Coatings

but even then, the slightest imperfection in

surfaces while reducing the environmental

business. “The key to this new coarse texture

the surface will show through,” continues

impact.

range is the Low-E

Reekie. “Coarse texture powder coatings

Initially being launched in Italy, Interpon

label – known as low bake in the

give a dimpled finish. They are popular

Coarse Texture Low-E is especially good at

industry – which means it can be cured

because as well as looking good, they can

covering small defects on metal, while also

from 150-170°C, without losing quality or

‘hide’ any imperfections and save the time

offering greater energy and production

the properties of the coating. So, customers

and money involved in preparing and

efficiency compared with standard products.

can reduce their energy consumption and

protecting metal.”

It’s aimed in particular at industrial producers

increase productivity.”

The new product is available from stock

of shelves, electrical cabinets, gym equipment

He adds that the polyester-based product

throughout Europe in the top 46 most

and office furniture.

is ideal for any interior or exterior industrial

popular industrial RAL shades.

“As the world’s number one supplier of

application. It gives a consistent effect in any

powder coatings, we’re always looking to

colour and it also offers excellent weather

For further information:

innovate and take great pride in delivering

and light resistance.

www.interpon.com © AkzoNobel

kzoNobel launched a new powder

Figure 1: The new powder coating launched by AkzoNobel is aimed in particular at industrial producers of shelves, electrical cabinets, gym equipment and oﬃce furniture.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

BRAND-NEW

AkzoNobel Supplies Sustainable Coatings for Landmark Tanker Aircraft

Figure 1: The new A330 MRTT built by Airbus Defence & Space was coated with the AkzoNobel’s Aerowave 5001 water-based product.

double first has been landed by

which they have come to depend, while improving

AkzoNobel’s Aerospace Coatings business

sustainability and helping to ensure regulatory

after it supplied products for a new

compliance.”

long-distance tanker aircraft commissioned by the

The new A330 MRTT was built by

French Air Force.

Airbus Defence & Space, a global leader in

Featuring the company’s Aerowave 5001

designing, developing and manufacturing military

water-based coating, not only is it the French

aircraft. It’s considered to be the benchmark

Air Force’s first new generation A330 MRTT (Multi

for new generation, multi-role tankers, with 33

Role Tanker Transport) aircraft, it’s also the first

currently in operation – and another 27 on order.

aircraft of its size to be finished with an external

AkzoNobel has been collaborating with the

water-based topcoat.

Airbus Defence & Space team for nearly three

“We’re extremely proud of this substantial

years, helping to address the specific needs of

achievement, which is testament to the proven

their military program. The next milestone for the

performance of our coatings and our commitment

AkzoNobel and Airbus teams is to complete the

to sustainability,” said Maud Khelstovsky,

Airbus qualification process for Aerowave 5001,

AkzoNobel’s Key Account Manager for Airbus.

planned for all Airbus military airplane programs

“Aerowave 5001 is designed to provide all the

in early 2019.

benefits of a solvent-based coating, but with vastly lower VOC emissions. This allows aircraft to achieve

For further information:

the surface durability and chemical resistance upon

https://aerospace.akzonobel.com

BRAND-NEW

Freudenberg Strengthens Filter Business

he global technology group

(approximately 96 million EUR). The

especially in China, thanks to legislation

Freudenberg is expanding its filter

transaction still requires approval from

demanding stricter regulations and

business. The Freudenberg Filtration

increased environmental awareness.

“By purchasing the majority stake in

Experts estimate that the global

contract in China to purchase the majority

Apollo, we are strengthening our position

market for products of Apollo – filters

shares of Apollo Air-cleaner Co., Ltd.

in China’s rapidly growing market for

for room air purifiers, decentralized

The company is a leading supplier of air

filtration solutions,” says Dr. Mohsen Sohi,

ventilation systems and water

and water filtration solutions in China. In

Freudenberg Group CEO.

treatment – will have a total value

2017, Apollo had around 1,000 employees

Air and water filtration solutions are

of some 5 billion USD by the

and generated 750 million RMB in sales

enjoying strong year-on-year growth rates,

year 2022.

competition authorities.

Technologies Business Group has signed a

Figure 1: The Apollo Air-cleaner Co., Ltd.’s production site in Shunde, China.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

BRAND-NEW

from the transaction. Main examples are the complementary competencies in filter media and gas filtration, which is growing ever more important. “For nearly 20 years, Apollo has been offering innovative filtration solutions, improving the quality of life in China,” says Akihisa Yamamoto, CEO of Apollo Trading Group, and then adds: “The global development and production network and the more extensive portfolio of technological product solutions stemming from this joint venture will primarily benefit our customers.” For further information: www.freudenberg-filter.com

2 1

Figure 2: The production department at the Apollo’s factory.

“Apollo is a great fit for Freudenberg,” says Dr. Andreas Kreuter, CEO of Freudenberg Filtration Technologies. “It is an innovative technology company that complements our own portfolio of filtration solutions for indoor air and water purification. The company also has first class production expertise and excellent networks in the industry.” The product solutions of Apollo keep air or drinking water free of (ultra) fine particles, dangerous gases, odours and microorganisms and protect health. At its production site in Shunde, China, the company has established high standards for product quality, process efficiency and workplace safety, and is certified to ISO 9001, ISO 14001 and TS 16949. Apollo will continue as a joint venture between Freudenberg (major shareholder) and the current sole proprietor Apollo Trading Group, Japan, under the name Freudenberg Apollo Filtration Technologies. Freudenberg Filtration Technologies intends to bring its current consumer filtration business into the joint venture. Manufacturing, R&D and Customer Services at both Freudenberg Filtration Technologies and Apollo will benefit

BRAND-NEW

The Quality Is the Top Priority

rimatek Coatings is the

paints that will make metal surfaces

The labs of the plant have been

first powder coatings

look extra bright and vibrant. Future

equipped with cutting-edge

manufacturing facility in the

machinery, which will allow the new

include manufacturers of furniture

enterprise to develop quickly any

company will be sold to consumers

for Ikea, racks for supermarkets,

types of powder coatings.

in Scandinavia, the Baltic States

construction and warehouse

Primatek is an environmentally

and Northern Europe. The plant’s

equipment, components for cars,

conscious company that delivers

production capacity is up to 7,000

household and industrial equipment,

Environment Product Declarations

tons of powder coatings a year.

tools, aluminum windows and

(EPD) to its partners and customers

The output capacity of the plant will

architectural sections.

on a regular basis as well as verified

allow the new enterprise to occupy

The quality requirements established

and registered documents with

a dominant position on the market

at Primatek Coatings exceed

the transparent and comparable

of the Baltic States, and take up

considerably the quality management

data about lifecycle environmental

significant niches on the markets of

systems of most enterprises in the

impact of coatings pursuant to

Finland, Sweden, Poland and other

industry. Primatek is compliant with

ISO 14025 Standard.

European countries.

ISO 9001:2014 Standard. Primatek

The plant will manufacture a broad

powder coatings are also approved by

For further information:

range of durable and fade-resistant

Qualicoat and by GSB International.

www.primatek.eu

buyers of Primatek Coatings products

Baltic States. The products of the

Figure 1: The Primatek Coatings’ headquarters. It is the first powder coatings manufacturing facility in the Baltic States.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

ÂŠ Lesta

Opening photo: Lesta was established in 2010, in Dairago (Milan) and operates in the field of industrial robotics for coating.

HIGHLIGHT OF THE MONTH

An Internationally Oriented, Technologically Advanced Company Closely Cooperating with Excellent Businesses: Lestaâ&#x20AC;&#x2122;s Success Story in the Field of Robotics for Industrial Coating From an interview with sales manager Marco Morlacchi from Lesta Srl, Dairago (MI), Italy

info@lesta.it

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

“2018 turned out to be a great year

taly’s industrial fabric presents several examples of young companies that have managed to establish themselves

on the market as reliable and successful players in a relatively short time. These include Lesta, a firm established in Dairago (Milan) in 2010 and operating in the field of industrial robotics for coating.

Lesta started out as an industrial automation firm and its core business is the coating sector – for both wood and metal and with both liquid and powder paints.”

in terms of production and growth, regarding not only our turnover but also our technical knowledge. In fact, we have faced some new industrial sectors, working with important customers such as Luxottica; for them, we have developed a 3D vision system able to

For them, 2018 was a very positive year

read the position of workpieces on

in terms of economic, structural, and

their holders and to adapt the coating

technological growth (ref. Opening

Morlacchi. “We are active on the national

process accordingly to obtain optimal

photo).

market and on the main international

results. This has enabled us to expand

ipcm has had the opportunity to

ones, particularly in Northern Europe,

our know-how in a very particular, niche

interview Marco Morlacchi, the sales

where we can count on the collaboration

market segment,” says Morlacchi. “Also

manager of Lesta, who identifies

of various local plant engineering

the automotive sector has regained

the reason for this growth in the

companies, and in Eastern Europe, an

importance for Lesta: we operate in the

internationally oriented vision that has

area that is very important for us. Actually,

car interior part coating field and we have

always distinguished the company. “Lesta

we have numerous sales representatives

just installed a large carbon fibre coating

started out as an industrial automation

and technical sales experts located in

plant in Turkey.”

firm and its core business is the coating

Poland, thanks to whom we are able to

Currently, Lesta has about 20 employees

sector – for both wood and metal and with

offer an even more careful and timely

and relies on several external consultants

both liquid and powder paints,” explains

service to our customers.”

to offer a complete service to its

2 1

Figure 1 and 2: In March, the operational area was extended and new spaces devoted to robot testing and R&D labs were added.

2018 turned out to be a great year in terms of production and growth, regarding not only Lesta’s turnover but also its technical knowledge. In fact, the company has faced some new industrial sectors, working with important customers such as Luxottica; for them, they have developed a 3D vision system able to read the position of workpieces on their holders and to adapt the coating process accordingly to obtain optimal results. This has enabled Lesta to expand its know-how in a very particular, niche market segment.”

customers. In March, the company’s facility also underwent a reorganisation: the operational area was extended and new spaces devoted to robot testing and R&D labs were added (Figs. 1 and 2).

International partnerships Since 2017, Lesta has been cooperating with KUKA, a global manufacturer of robots and industrial automation solutions, as their Official System Partner (Fig. 3). “The growth of our company, the possibility to integrate our products according to the Industry 4.0 paradigms, and the know-how we have acquired, especially in the coating sector, have led us to collaborate with several leading companies in the industrial automation sector, including KUKA and ABB. Lesta develops and integrates software packages and control panels for the coating process management,” states Marco Morlacchi. “Our philosophy is to make the use of this equipment easier without sacrificing application accuracy and final quality.

In particular, we have developed a software package to be

3 1

Figure 3: Since 2017, Lesta is Oﬃcal System Parter of KUKA for the development and integration of software packages and control panels for the coating process management.

Currently, Lesta has about 20 employees and relies on several external consultants to offer a complete service to its customers. In March, the company’s facility also underwent a reorganisation: the operational area was extended and new spaces devoted to robot testing and R&D labs were added.”

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

4 1

Figure 4: The new LeCRob electrical control for Lebot MV robots.

HIGHLIGHT OF THE MONTH

robot: in this way, the robot

implemented on KUKA’s robots, which creates dedicated and easily accessible painting programs. Moreover, for the coating of parts requiring a greater accuracy degree during application, we equip the robots with an offline point-to-point programming mode that allows to adjust and define the coating process in detail, also in terms of gun distance from the surface, parameter management, and application angle. The aim is creating programming operations that are as easy-to-perform as possible and do not require any engineering skills, but at

Lesta’s philosophy is to make the use of the equipment easier without sacrificing application accuracy and final quality. In particular, they have developed a software package to be implemented on KUKA’s robots, which creates dedicated and easily accessible painting programs.”

already knows which and how many parts have to be painted with a certain program and when the program has to be changed,” says Morlacchi. In 2018, a new version of this software package has been tested, which was a great success and will be one of the company’s focuses in 2019. “The new software package is a development of the standard

the same time guarantee perfect coating

version and it requires the

results.”

presence of RFID antennas located at different points of

4.0-oriented management of production queues

simple and intuitive way (Fig. 4).

the coating line (e.g. loading,

“If different types of workpieces, with

masking, unloading, or robot

One of Lesta’s flagship products is

different sizes and shapes, need to be

stations), which receive the

LeCRob ProdManager, a software package

coated, it is possible to communicate

RFID tag signals. The tags

enabling to control production queues in a

all load-related information to the

contain all process information,

www.cieeng.com info@cieeng.com

www.mstchemicals.com info@mstchemicals.com

An increasingly attentive customer service “In just eight years, our company has grown a lot and we all feel that we have actively collaborated in this development: this has created harmony and a sense of belonging among all Lesta employees, an invaluable added value,” states Marco Morlacchi. “We are a young company with extensive experience and

5 1

Figure 5: The founding members of Lesta. From the right: Emanuele Mazza, Marco Bresciani and Federico Comini.

expertise. Our team building ability enables us to tackle even the most difficult

customisable according to needs, and they are mounted on special hooks positioned on the conveyor in correspondence with the batch to be treated. The antennas read the messages contained in the tags and communicate them to the robot management software, which selects the right coating program for the specific workpieces. Depending on the position of the antennas and the information stored in the tags, it is possible to automate all process phases,” explains Marco Morlacchi. “The operators are also supported and facilitated in their tasks by Smart TVs placed along the line on which they can view the instructions related to each process step, e.g. how to load the part correctly, how to mask it, or how to pack it.”

One of Lesta’s flagship products is LeCRob ProdManager, a software package enabling to control production queues in a simple and intuitive way. If different types of workpieces, with different sizes and shapes, need to be coated, it is possible to communicate all load-related information to the robot: in this way, the robot already knows which and how many parts have to be painted with a certain program and when the program has to be changed.”

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

challenges and to offer our customers optimal solutions in competitive times (Fig. 5).” “2019 has just begun, but we already have many projects in progress. The most important one is the further expansion of our operational area to make room for a coating test booth: we already offer this highly demanded service by relying on contractors, but now it is time to insource it. Moreover, we would like to devote a part of the new area to an automated warehouse, in order to make the supply of components and spare parts even faster. Finally, we will continue to cooperate more and more actively with national and international plant engineering firms, and we are getting ready to tackle new markets,” says Morlacchi.

G R

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

A New Application Technology with a 3D Part Scanning System and a Dynamic Reciprocator to Optimise the Production Time and Quality Level of Complex Products Monica Fumagalli ipcm®

“I

nnovation” is a recurring

the first company in Italy to install a

term when talking about

new powder coating system developed

manufacturing. Nowadays, for a

by Gema Europe. Through close

company, innovating means to equip

cooperation with Gema’s technical staff

itself with interconnected production

and thanks to the experience of its

systems managed through a perfect

operators applied on last generation

interaction between man and machine

devices, the company has been able

and, therefore, through the operator’s

to optimise its production times while

deep understanding of the new

maintaining a high finishing quality

devices’ features. However, in practice,

level, even for very complex-shaped

what does it mean for operators to radically change their work concept, and for companies to train professionals to manage their activities in a completely different way?

workpieces (ref. Opening photo).

Figure 1: From right to left: Pier Guido and Alberto Bianchi, the owners of Verniciatura Bianchi.

A high variety of diﬀerent products and applications Verniciatura Bianchi was established

Especially for small and medium-sized

in Montodine (Cremona) in 1977. It

companies, there are concerns not

started as a liquid coating contractor

only about the installation time of a new plant or device, and therefore of downtime, but also, and perhaps above all, about the time needed to adequately train their staff to use the new system. The development of user-friendly and easy-to-understand operating systems is therefore a decisive element for the choice of innovative machines and products. Here below, we present the case study of a coating contractor, Verniciatura Bianchi Pier Guido & C. This has been

Especially for small and medium-sized companies, there are concerns not only about the installation time of a new plant or device, and therefore of downtime, but also, and perhaps above all, about the time needed to adequately train their staff to use the new system. The development of user-friendly and easy-to-understand operating systems is therefore a decisive element for the choice of innovative machines and products.”

for products characterised by different shapes, materials, and types, and then expanded its business up to the implementation of a powder coating plant. “We now treat the most diverse products,” states owner Alberto Bianchi (Fig. 1), “mainly from the heavy carpentry, mechanics, and electromechanics sectors. We coat products in carbon steel and, more rarely, aluminium and stainless steel. We treat components whose dimensions range from the smallest

Opening photo: Examples of products powder coated by Verniciatura Bianchi.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

2 1

Figure 2: Verniciatura Bianchi coats a large number of boxed sections.

to the largest sizes (Fig. 2). That is why we have equipped our plant to make the production flow as quick and flexible as possible: the main bottleneck of companies like ours is the high number of colour changes required and of different part shapes treated.”

Plant equipment The coating line is equipped with two pre-treatment systems. The first one is a 5-stage pre-treatment tunnel installed in 2014 and linked to both one of the two liquid application booths (devoted to small components) and the powder application plant (Fig. 3). Its stages are as follows: phosphodegreasing, cleaning with mains water, cleaning with © ipcm ®

demineralised water, nanotechnology process, and final rinsing with demineralised water. On the other hand, larger components are treated with a 2-stage static pre-treatment plant performing a phosphodegreasing stage with more aggressive chemical products and a rinsing stage. Besides the static booth for the application of liquid coatings on small workpieces (1 x 1 x 1 m, Fig. 4), there is a second booth devoted to large-sized

3 1

Figure 3: Workpieces entering the

components (6 x 2 x 2.5 m). 5-stage pre-treatment tunnel.

FOCUS ON TECHNOLOGY

4 1

Figure 4: The liquid application stage in the static booth.

“As for the powder application,” says Bianchi, “we use epoxy-polyester paints for products intended for indoor use and polyesters for outdoor components, with a percentage ratio of 65:35. In most cases, these are one-coat systems; only 20% of our products require two coats, i.e. base coat and finish. Our previous powder plant, also provided by Gema, worked optimally for eighteen years. In August 2018, it was replaced by the new booth, equipped with an innovative application system. Our choice was motivated by the need to optimise our production flow and to innovate a department that was using an

outdated technology.”

Characteristics of the new application technology “One of the problems that Verniciatura Bianchi asked us to solve during the design phase of their new powder coating booth,” says Gema Europe Sales Manager Gianluigi Baroni, “was that the line speed was slowed down by the presence

5 1

Figure 5: A detail of the 3D part scanning device.

of workpieces with complex shapes and variable dimensions. The manual touch-

manual application cannot guarantee (Fig. 7).”

Dynamic reciprocator and robot: two application systems compared

There are 3 reciprocators in the powder coating

“The main advantage of Gema’s new

booth: in addition to the dynamic one, there

application system compared with the

are 2 traditional reciprocators and a robot for

anthropomorphic one,” says Bianchi, “is

coating series of identical products (Fig. 8).

the possibility to manage the entrance of

difficult-to-penetrate edges and subframes, and it provides a thickness consistency level that

different parts into the booth without being forced to pre-set the application program for the robot self-learning activities, starting from the workpieces’ hanging mode to ensure proper spraying. Indeed, with Gema’s new technology the components can be hung in any way, since the scanner detects the parts’ geometry in real time and the reciprocator adjusts its movement accordingly. Considering that identical products with the same shape only account for 2% of our entire

6 1

production, this clearly helps optimise our production times.”

Figure 6: The dynamic reciprocator in function.

Advantages of the new powder application system

ups required to perfect the coating of complex elements such as boxed sections and frames resulted in a loss of production efficiency. Therefore, Gema’s team developed a solution based on

“After almost twenty years of use of the old 7 1

Figure 7: The post-retouching of diﬃcult-to-penetrate areas.

coating plant,” states Bianchi, “our operators were worried about the implementation of the new system: despite the experience gained over the years, they raised doubts about the

the combination of a 3D laser scanning © ipcm ®

system, placed at the entrance of the booth, with a dynamic reciprocator equipped with 6 guns, which was able to reduce manual retouching operations by 40%. “The device placed at the booth’s entrance is a smart system using a three-dimensional object recognition laser scanner, which does not only detects the length and height, but also the depth of the workpiece (Fig. 5). Each of the 6 guns located on one side of the booth (Fig. 6) moves independently and, based on the detected shape, it can penetrate inside the product, e.g. in the cavities of electrical panels, while keeping the same distance between its dispensing point and the area to be painted. This facilitates the manual retouching operations, mostly limited to

8 1

Figure 8: The robot.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

correctly, it is not possible to proceed to the next one. The high simplicity of management has therefore solved our initial doubts. It also saves our coating staff’s time, because thanks to the scanner system they no longer have to re-set the spraying programs every time according to the different products on the line.” The high coating quality level has been guaranteed by replacing the old guns with new ones featuring a Venturi system and it has been further improved thanks to the high application efficiency of the dynamic reciprocator (Fig. 10). “The system settings were defined by Gema to obtain the best coating efficiency based on the conveyor speed, the guns’ application capacity, and the workpiece size: therefore, we can now be certain that the booth is working in the best way possible. Moreover, despite the transition

9 1

from a 6-gun to an 8-gun system, i.e. 14 guns in total, and despite

Figure 9: The control panel of the powder coating booth.

changed: this is a further advantage of our new system (Fig. 11).”

Conclusions

ease of handling a different

the greater production capacity, the consumption of powder has not

“We are very pleased with our choice,” states Bianchi. “Gema has

process than the one they

always been a guarantee of quality for us, so much so that when we

were used to. However,

decided to replace our old coating plant we contacted their team

Gema’s staff was willing to

directly, without assessing any alternative solution. Thanks to the

understand our concerns

installed system, we have managed to improve our productivity level

and look for a solution

for those workpieces that forced us to slow down our line; at the same

able to reassure us: their

time, we have simplified the management of the powder application

system is easy to use, not

process also for components with which we could maintain a good

only in terms of process

productivity level, but with the constant presence of an operator.

management but also of

However, what pleased us the most was Gema’s ability to train our staff

cleaning operations. With

quickly: for us, seeing our coating operators happy with the results

frequent colour changes

of their work is an extra incentive to strive for the optimisation of our

(even every 30 minutes),

production processes through technological innovation.”

the cleanliness of the system The operator performs this process following each step on the control panel (Fig. 9); if a stage is not performed

is very important for us. 10 1

Figure 10: A product detail highlighting the high quality level of the coating.

The Gema’s system is easy to use, not only in terms of process management but also of cleaning operations. With frequent colour changes (even every 30 minutes), the cleanliness of the system is very important. The operator performs this process following each step on the control panel; if a stage is not performed correctly, it is not possible to proceed to the next one.”

11 1

Figure 11: The 14 guns for the application of powder coatings.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

HIGHLIGHT OF THE MONTH

The New ADAPTA APP, a Pioneer in the Powder Coatings Market as for Sustainability and Efficiency David Pellicer

e live in the era of the fourth industrial revolution, of the digital revolution, of Industry 4.0. Yet,

adaptacolor@adaptacolor.com

Adapta Color SL, Peñíscola - Spain

companies are still required to produce mountains of paper. Be it to comply with the new privacy regulation or to perform a quality audit, it seems impossible to avoid generating a huge amount of paper documentation. Nowadays everything is just a click, scroll, or swipe away. Billions of pieces of information are available on our mobile devices: knowing the basics of keyword or hashtag searches is enough to find anything in a few seconds. Yet, classifying the coated products of a warehouse can still be a time-consuming and burdensome operation. Getting the data you need at the right time, always having the updated version of a document available while avoiding to

2 1

3 1

Figure 2 and 3: With ADAPTA APP powder coatings users will have all the necessary information at their disposal at any time in order to pass a quality audit or an inspection, fill out a technical specification, or respond to a dispute.

produce further paper documentation and

key elements for achieving these goals. The

to flood your suppliers with requests, or

new ADAPTA APP for mobile devices is the

simply choosing the product you want with

result of Adapta’s efforts to comply with

one click is now possible with the brand

all the requirements established by the

new APP of Adapta for all powder coating

Regulation (EC) No. 1907/20061 concerning

users.

the Registration, Evaluation, Authorisation, and Restriction of Chemicals (REACH) and

Adapta Color SL is very attentive to all safety and prevention-related issues

as tools to protect the integrity and Figure 1: The new ADAPTA APP makes the latest versions of safety data sheets (SDS) and product analysis bulletins available in real time.

the Regulation (EC) No. 1272/20082 Council

health of people interacting towards the sustainable development of their business. Information and training are

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

Regulation (EC) No. 1907/2006 of the European Parliament and of the Council concerning the Registration, Evaluation, Authorisation, and Restriction of Chemicals (REACH).

Regulation (EC) No. 1272/2008 of the European Parliament and of the Council on Classification, Labelling and Packaging of substances and mixtures (CLP).

on Classification, Labelling and Packaging of

HIGHLIGHT OF THE MONTH

Finally, the “My products” section allows the users to create a digital

Your Leaders in Zero Liquid Discharge

archive of all Adapta products

substances and

available in their warehouse. By

mixtures (CLP) and

scanning the barcode on the

its subsequent

powder boxes, the APP creates a

amendments (Fig. 1).

record with the related technical

This tool, a pioneer in

data and an icon corresponding to

the powder coatings

the colour of the scanned product.

market, makes the

This amount of information available

latest versions of

in real time on mobile devices will

safety data sheets

enable users to find the information

(SDS) and product

needed at the right time, saving

analysis bulletins

paper and archiving times.

Industrial Wastewater Treatment

available in real time. The user simply has

Complete and continuous

to scan the barcode

traceability of powders, simplified

of the box containing

warehouse management, and

a product and select

real-time availability of technical

a language. In this

information on products: these are

way, powder coatings users will have all the necessary information at their

the key advantages of ADAPTA APP,

4 1

without forgetting accessibility –

Figure 4: The APP oﬀers an overview of Adapta’s smart coating catalogues.

because, nowadays, being

Simple Principle

user-friendly is a must.

in order to pass a quality audit or an inspection, fill out a technical specification, or respond to a dispute (Figs. 2 and 3).

disposal at any time

The application has a wide range of additional features, such as the calculation of the theoretical yield of

Effective Result

specific coating products, the coding scheme of all products available for sale, and the list of Adapta’s licenses and (business, product, and environmental) certifications. The APP also offers an overview of Adapta’s activities and products: colour ranges, smart coating catalogues, flagship projects with the description of the finishes used, latest news, and much more (Fig. 4). The “RAL Classic” section enables the user to click on a colour code to verify its name in 5 languages, its RGB composition, and the list of Adapta products available for that tint (Fig. 5).

5 1

Figure 5: The “RAL Classic” section enables the user to click on a colour code to verify its name in 5 languages, its RGB composition, and the list of Adapta products available for that tint.

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

info@h2o-de.com www.h2o-de.com

BRAND-NEW

ondoroil Stainless offers complete and automatic

ÂŠ Condoroil

Giunone, the New Ultrafiltration Automatic Plant for E-coat ultrafiltration plants, such as

the Giunone model for e-coat (Fig. 1).

Ultrafiltration is a technique that allows the separation of molecules having different dimensions and, for this reason, it can be, as a first approximation, equated with a very thorough filtration process that uses special filters named membranes. Membranes have different construction configurations and, for economic reasons and flexibility, to process paints of e-coat systems the standard are the spiral membranes. The main use is to produce, starting from the painting bath itself, the first rinse water (or better the mixture water and solvent). However it is becoming always more frequent the use of reverse osmosis systems to get a more thorough purification of the permeate for the last rinse step. Membranes are made of modified

Figure 1: Giunone is the ultrafiltration automatic plant designed by Condoroil Stainless.

e-coat paints, both anaphoresis and

are collected as permeate

cataphoresis.

while the largest substances

Standard 4, 7.6 and 8 inches elements

are retained by the membrane

are available, as well as valid and

and recovered back to the

competitive spare parts for each

paint bath (Fig. 2).

ultrafiltration system.

The permeate is used in the

The plant consists of a monobloc unit

rinse ramps. This closed loop

assembled on a AISI 304 stainless steel

cycle is used to recover paint

skid.

solids (drag-out).

Ultrafiltration is a membrane process

The permeate can be deviated

able to separate components in

to purge to reduce paint

the solution based on molecular

conductivity.

measurements and shapes. Solvents and other small dissolved particles pass

For further information:

through an ultrafiltration membrane and

www.condoroil.com

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

ÂŠ Condoroil

PVDF and have a proven efficacy on

2 1

Figure 2: Ultrafiltration is a membrane process able to separate components in the solution based on molecular measurements and shapes.

SUSTAINABILITY

BASF is Most Sustainable Innovation Partner for BMW ÂŠ BASF

ASF was honoured with a BMW Supplier Innovation Award 2018 as the winner in the Sustainability

category. BMW Group said BASF achieved the best performance in CO2

emissions in the report published by the non-governmental organization CDP. BASFâ&#x20AC;&#x2122;s anchoring of the fight against climate change within the company were cited as another reason for the decision. In addition, BASF develops solutions that help its customers reduce CO2 emissions. One example for the

automotive industry is the innovative integrated coating process, which considerably reduces energy

consumption by eliminating one entire coating and curing step.

Figure 1: Dr. Martin BrudermĂźller (middle), Chairman of the Board of Executive Directors of BASF SE, at the awards ceremony with JĂśrg Willimayer (left) and JĂźrgen Westermeier of BMW Group.

â&#x20AC;&#x153;For more than 50 years, BMW and BASF have shared a common goal: sustainable mobility,â&#x20AC;? said Dr. Martin BrudermĂźller, Chairman of the Board

sustainability. As such, we have set ourselves

achievements and exceptional collaboration

of Executive Directors of BASF SE, at

the target of CO2-neutral growth until 2030.â&#x20AC;?

and named five winners in the categories

The awards ceremony took place on

Productivity, Sustainability, Efficient Dynamics,

award as both recognition of our

November 21 at the BMW plant in Landshut,

Digitalization and Emotional Experience.

longstanding collaborative partnership

Germany. BMW Group presented the BMW

as well as motivation to continue to be

Supplier Innovation Award for the fifth time.

For further information:

a pioneer and a trendsetter in terms of

It recognized a total of 15 suppliers for their

www.basf.com

the awards ceremony. â&#x20AC;&#x153;We see this

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SUCCESS STORIES

Ding Dong Merrily on High after 18 months

Figure 1: After 18 months, the Petersglocke of Cologne cathedral is ringing again.

inging out again of silence: the bell

“Petersglocke” of Cologne cathedral (Fig. 1). Traditional bell technology meets state-of-the-art construction and coating techniques. In the summer of 2016 an investigation by the European competence centre for bells ECC-ProBell revealed that uneven © Dörken MKS

striking of the clapper – as a result of the offset hole in the bell cover – meant that the “Dicke Pitter” was no longer emitting its

Figure 2: The even zinc flake coating protects the mount of the bell clapper as well as the clamping nut against corrosion. © Dörken MKS

customary sound. It was subsequently discovered that a repositioning of the bell clapper could not only result in an improved sound, but also contribute to the long-lasting protection of the Petersglocke. In collaboration with the Cologne University of Applied Sciences, the cathedral construction authority developed a new mount, to be realised by the company Dirostahl. The special feature of this mount? It is milled from a single forged piece and can be moved horizontally to the millimetre via two double eccentric components. In addition, it is also

2 1

equipped with a HEICO-TEC® clamping nut that guarantees a defined torque

Working together with inhouse

A particular benefit of the new product:

in the rod that carries the clapper and

and contract coater Lisi Automotive

The protective coat has a thickness

secures the bell. This mount is unique

BETEO Oberflächentechnik GmbH & Co. KG,

of just 4–20μm and dries at room

of its kind worldwide.

the company applied the newly-developed

temperature, eliminating the need for

It is all the more important that this

product DELTA-PROTEKT® KL 170 RT

a curing oven. This meant that it could

bearing element is protected against

to coat the mount. The sacrificial behaviour

be applied to the 780 kg component on

corrosion. This is where the corrosion

of the zinc flake coating delivers cathodic

site, in the belfry of Cologne cathedral,

experts from Dörken MKS came in.

corrosion protection (Fig. 2).

via spray application (Fig. 3).

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

Efﬁcient

SUCCESS STORIES © Dörken MKS

and reliable solutions for surface coating since 1988.

3 1

Figure 3: The ultra-thin protective layer was applied on-site via spray application.

The clamping nut is also securely protected against corrosion. After the mount and the approximately 600kg clapper were brought back into position, the nearly 100-year-old bell was able to ring out again to

electrostatic systems for liquid painting

mark All Saints. Equipped with a highly-efficient corrosion protection solution from Dörken MKS (Fig. 4). For further information:

electrostatic systems and spraying booths for powder coating

www.doerken-mks.de/en

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

IR and UV drying systems

robot and reciprocators

4 1

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

eosmarketing.it

Figure 4: From left to right: Prof. Dr. Klöcker (TH Köln), Alexander Kreicker (Dörken MKS), Jens-Paul Hänig (Lisi Automotive BETEO Oberflächentechnik GmbH & Co. KG), Thomas Schuhmacher (Kölner Dombauhütte), Pascal Jung (Dörken MKS) and Tobias Kleyer (Dörken MKS).

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

Euromask® Increases Its Hook Packaging Automation Level Simeone Maitan Finishing Group Srl, Lainate – Italy

info@euromask.com

uromask®, belonging

Euromask® manufactures

to the Finishing Group,

hooks with 1.5 to 5 mm-

is one of the most

diameter metal wire,

widely known brands for the

but it can provide other

production and distribution

cross-sections on

of masking systems for

request (Fig. 1).

all surface treatments,

The standard hooks with

such as powder and liquid

C and V bends (in their

coating, anodising, galvanic

3 versions: HV, Tipo5,

cataphoresis, and chrome-

and Tipo6) meet most

plating. For several years

operating requirements,

now, it has distributed a

but this company can

wide range of plugs, caps,

also create custom

coating hooks, tapes,

hooks with numerically

discs, tubes, and special

controlled wire benders

moulded products all over

in order to meet every

the world. Resulting from of Euromask products, the ®

company’s growth has led to

need and shape or size

the rapid market success

specification.

Figure 1: Euromask® manufactures hooks with 1.5 to 5 mm-diameter metal wire, but it can provide other cross-sections on request.

The manufacturing of Euromask® hooks

frequent changes of location

has always been

to solve the problems of

characterised by great

lack of space for machinery

rapidity and delivery

and operators: the current plant covers an area of 1600 m2 and it is the firm’s third headquarters in twelve years. One of the departments that have been further developed in the new factory is devoted to the production of iron and steel hooks for coating systems, which have always stood out in the market for their robustness and durability. The hooks are manufactured based on the designs of customers, which can select diameters, bends, bend rotation, and lengths.

speed. The latter is now even more efficient

Euromask®, belonging to the Finishing Group, is one of the most widely known brands for the production and distribution of masking systems for all surface treatments, such as powder and liquid coating, anodising, galvanic cataphoresis, and chrome-plating.”

thanks to the implementation of a second machine and a robot linked to it, which picks up the hooks and places them in the box, ready for shipping (ref. Opening photo). In the past, the most critical phase was the insertion of hooks with a length exceeding 300 mm inside the box: the operator was forced to stop production to take the components and place them manually in the container. Now, thanks to the installation of the robot, this is no longer necessary and it is even possible to continue producing at night (Fig. 2).

Opening photo: The robot’s arm picks up a hook to be placed in the shipping box.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

The new machine has a more advanced technological level than the one already existing in the plant. It has also solved the straightening issues found on hooks with a length of 400 mm or more, thanks to a torsion system that enables to produce straight workpieces with an extended length.” as that of aluminium profile vertical coating, where it is now competitive in terms of volumes produced and value for money. Italy remains the company’s target market, but there has been a significant increase in trade relations with foreign countries thanks to the opening of branches in Mexico, Poland,

2 1

Slovakia, and Romania, including the

The manufacturing of Euromask® hooks has always been characterised by great rapidity and delivery speed. The latter is now even more efficient thanks to the implementation of a second machine and a robot linked to it, which picks up the hooks and places them in the box, ready for shipping.”

soon-to-open one in Germany.

Figure 2: The new automatic system can work 24/7.

3 1

Figure 3: The new machine has solved the straightening issues found on hooks with a length of 400 mm or more.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

Oops...

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

INTERNATIONAL PATENT

NITROROBOT Eurosider, a company with vast experience of using various fluid carriers for liquid painting, has developed a new system to produce a high density carrier in order to obtain better atomization which brings the advantages listed below. Nitrorobot can keep all day long the same settings and guarantee the best working conditions, independently from the conditions of the environment. The equipment, in Touch Screen version, is provided with the system of control of various settings, possible to monitor from any coating system control panel. Ideal application for Nitrorobot is on automatic coating systems with rotary bells, or it can be applied on conventional pneumatic guns, HVLP or electrostatic guns.

NITROTHERM The performance is reffered to fluid enriched in nitrogen with concentration of 93% Âą 1%, at environment temperature of 20 Â°C and atmospheric pressure of 1013 mbar. Inlet compressed air must be free from impurities (water, oil, solid particles). We advise to use filter elements supplied by Eurosider. All the data and images are merely approximate and can be changed; the performance vary in accordance with environment and working process pressure and temperature. Eurosider reserves a right to make modifications, even without advanced notice.

EUROSIDER Piazzale Thailandia 6 | 58100 GROSSETO | ITALY ph. +39 0564 425117 | fax +39 0564 418833 www.eurosider.com | info@eurosider.com

S PECI A L O N R AW MAT E R I A L S , P I G ME NTS , PA I N T & C O AT I N G T E C H N O LO G I E S

BRAND NEW

SUSTAINABILITY - 5 ON 5

INNOVATIONS: PRESENT&FUTURE

HIGHLIGHT OF THE MONTH

Five on Five Interview: Sustainability According to the Industry Players

Multi-Curing Waterbased PU Dispersion: Faster Drying, Robustness and Improved Performance Even Under Poor UV-Curing Conditions

Chemtec Expands its Plant and Develops a Laboratory Test Contracting Service

HIGHLIGHT OF THE MONTH Novaresine: The Sustainable Approach of a Chemical Company Open to Everyone

INNOVATIONS: PRESENT&FUTURE

HIGHLIGHT OF THE MONTH

INNOVATIONS: PRESENT&FUTURE

VOC-compliant Coating: Ultra-high-solid Platform Technologies

Research and Technological Innovation as the Cornerstones of Industrias Titan’s Philosophy

Lacquering Before Polishing: Technical Coatings for Additive Manufacturing

The Evolution from Single Component to Plural Component Paint

S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES

BRAND-NEW

European Coatings Show 2019: BASF to Present New Solutions Covering the Needs of Customers

he broad range of products

fulfilling latest regulations and technical

that has been specifically designed

offered by BASF includes

properties. It does not contain

for classical ternary SLUs. This new

dispersions, resins, additives,

stenomeric monomers and Bisphenol

superplasticizer in powder form

light stabilizers, antioxidants, pigments,

A (BPA), offers immediate chemical

enables longer slump retention and

hardeners, cross-linking agents,

and scratch resistance and is very

improved temperature robustness as

reactive diluents and solvents.

compatible with mixing components

well as compatibility with all kinds of

(e.g. acrylic combination partners).

fruit-based acids. Due to a reduced

More durable waterborne coatings for white pigmented furniture

retarder dosage customer benefit

White coated furniture is becoming

Non-reactive but highly protective industrial floor coatings

more and more popular, especially in

The screeds used in industrial buildings

living rooms and kitchens. However,

such as warehouses and cellars must

in everyday life it can easily happen

withstand high levels of abrasion stress.

Adhesion all-rounder for 1K and 2K polyurethane primer applications

that coloured liquids such as coffee

Therefore, they are often coated with

Universal adhesion performance

or red wine leave irreversible stains

epoxy floor coating systems.

on various substrates, low solvent

on bright furniture surfaces – a major

From now on, there will be a

demand and formulation robustness

problem particularly for waterborne

waterborne alternative to conventional

combined all in one solution offers

coatings. This does not have to be:

reactive systems: The new dispersion

Basonol PU 1035 W. This very

Due to the new, physically drying

Acronal 5522 for mineral surface

flexible OH-functional aliphatic

resins, the recently launched Joncryl®

protection combines the required

polyurethane dispersion (PUD) is

95XX series, furniture coatings end up

performance with sustainability

suitable for 2K polyurethane (PUR)

with high levels of chemical resistance

features. Floor coatings based on

primer applications ideal for plastic

against aqueous stains even after

this acrylic composite polymer do not

and 1K melamine w/wo blocked

16 hours of exposure (according to

require labelling and can be applied

polyisocyanate crosslinking primer

DIN 68861-1B); they are also suitable

easily.

applications on metal substrates.

for DIY-applications. Furthermore,

from cost savings and achieve better hardening properties.

It does not contain any organic

agent for water-based systems,

Classical ternary self-levelling underlayments

supports excellent chemical resistance

Self-levelling underlayments (SLUs)

and can be used as universal blending

and leads to greatly improved storage

gain increasing acceptance, when

partner for acrylic dispersions.

stability and anti-sedimentation

it comes to ensuring smooth and

behaviour. For industrial UV

crater-free surfaces for subsequent

applications, where immediate

floor installations. No wonder, as they

Strong protective shield for coating surfaces

availability of properties is necessary,

can be applied easily and offer good

With regard to many coating

BASF developed Laromer® UA 9135

mechanical properties compared

applications customers increasingly

Aqua. The UV curable dispersion

with conventional methods.

require products that combine

is designed for the formulation of

Melflux® SELECT 4411 F constitutes

aesthetics with additional coating

highly resistant furniture coatings,

a new PCE based superplasticizer

functionalities such as improved

Dispex® Ultra PX 4575, a dispersing

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

solvents e.g. N-Methyl-2-pyrrolidon (NMP) or N-Ethyl-2-pyrrolidon (NEP)

SP E C I A L O N RAW M ATE RI A L S , P I G M E NTS , PA I NT & C O ATI NG TE C HNO LO G I E S

BRAND-NEW

Figure 1: Classical ternary self-levelling underlayment.

durability, reduced dirt pick-up and

such as new consumer requirements

easy-to-clean features. Hence, BASF

and environmental standards.

enhanced its Formulation Additives

The ECS trade fair is a welcome

portfolio with a novel concept of coating

opportunity for us to continue

surface modification: It is based on

the close ongoing dialog with our

fluoro-modified block copolymers

customers on market needs and drive

that crosslink with the binder matrix.

innovations,” says Christoph Hansen,

The block copolymers align at the top

head of the Dispersions & Resins

surface layers via self-organization and

Europe business unit.

are fixed in the right place, which leads to improved durability and weathering

BASF offers the broadest global range

resistance of the surface as well as

of raw materials for the formulation

additional functionalities such as an

of coatings and paints in the field of

easy-to-clean effect. The new concept is

architectural coatings, construction,

suitable for various types of applications

automotive, industrial coatings, furniture

such as automotive clearcoats or

and flooring as well as raw materials for

industrial top coats.

powder coating resins.

“Our customers in the coatings sector are facing diverse challenges resulting

For further information:

from ever-changing overall conditions

www.basf.com/ecs2019

S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES

BRAND-NEW

YK-Gardner - worldwide partner of the automotive, paint and plastic

Next Generation of BYK-Gardner’s Data Analysis Software smart-chart industries for quality control

of colour, appearance and physical properties - is announcing the next generation of their data analysis software smart-chart. In order to guarantee uniformity over time and be able to proactively take measures before colour or appearance start to drift, process stability has to be controlled. Therefore, a representative number of readings have to be taken and large data sets need to be analysed. The next generation of smart-chart software is built on a new state-of-the-art platform and offers advanced graphics and printout functionality as well as a streamlined user interface.

Dive into the new advanced graphical functionality of smart-chart

Figure 1: The new drill-in function shows history trend of the last 20 measurements of the same model, colour and painting line.

A new pan & zoom functionality allows to

Communication to the point with dynamic print layout

first enlarge the graph and then move it

Taste differs – not only in the case of food!

to the area of interest. For line graph, the

Which data is needed on the printout

zooming is even done simultaneously for

depends on the requirements. Therefore,

all charted parameters allowing to always

smart-chart 5 offers a dynamic print layout

smart-chart 5 – one software solution for all BYK-Gardner colour & appearance products

see the data for exactly the same day or

so that you can create your own template.

It can’t get any more efficient in organizing

individual.

The order of data table and graphs can

your QC system. Set-up of instruments, central

Brand new is the display of red and

be defined, line and page breaks can be

data storage and data analysis is streamlined

green tolerance lines. They are based on

inserted and it can even implement a

and the same for BYK-maci, cloud-runner,

your product specifications in standard

company logo, a footer and a comment.

wave-scan, micro-gloss and the recently

management and can easily indicate

set in Trend Report without the need to move to another report.

launched spectro2guide.

proactively take measures to avoid costly

Data analysis streamlined with new reports

rejects.

To make the software more user-friendly

available 1st quarter of 2019. Software

The new drill-in function shows history

reports are combined without losing the

smart-lab to follow approx. 2 months later.

trend of the last 20 measurements of the

functionality of previous software versions.

same model, colour and painting line: just

As an example, to compare data of different

For further information:

click on any point in the scatter plot.

check zones only a checkmark needs to be

www.byk.com

a quality drift so that you are able to

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

The software package smart-process including the new features mentioned above will be

S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES

BRAND-NEW

has organised its 13 Parts Cleaning

Experts answer all questions

Day, focussing on recycling and

How do we achieve the longest

urface treatment specialist SurTec th

media treatment, on March 13, 2019

bath life possible? What does

at its headquarters in Zwingenberg

optimal processing mean? How

(Germany, Fig. 1). All interested players,

does modern particle filtration

such as planners, cleaning system

work and what methods are

procurers, and plant operators are invited

available? SurTec’s professionals

to exchange ideas and make contacts.

will answer to this kind of questions

This event is not free.

during the event. Other experts

A guided tour will also offer the opportunity

from the industry will also be

to gain interesting insights into the company.

available to talk.

Parts Cleaning Day 2019 at SurTec: Focus on Recycling and Media Treatment

2 1 © SurTec

Figure 2: SurTec’s recycling process.

Legal requirements: achieving a long bath life In the framework of legal requirements on waste water discharge (AbwVO), it is increasingly important to tackle the issue of stable cleaning baths. Indeed, this German regulation requires plant operators to treat their process baths with methods that can guarantee their longest service life possible. If suitable, bath ingredients should to be recirculated from rinsing baths to process baths (Fig. 2). Actually, stable baths offer several advantages in terms of parts cleaning: they enable to save resources and they guarantee a consistent cleaning quality level and the required component cleanliness degree. 1

Figure 1: The key visual of the Parts Cleaning Day 2019.

For more information: www.surtec.com

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES

SUSTAINABILITY

Hel en

HMG er, ld

lenius, Tekn Ca o ik

Joel Sv

a, Tikkurila kul ar

elcome to the first of a series of interviews on the role of sustainability within the coatings industry. Ever more present in almost every press release or corporate communication, we wanted to dig deep to understand sustainability and what it represents to our sector. The most popular definition of sustainability is that from the Brundtland Report of 1987, which stated: “Sustainable development is development that meets the needs of the present without compromising the ability of future generations to meet their own needs”. Ever more important, environmental sustainability within all industries is set to have a fundamental role if we are to slow or reverse the environmental

, DSM ets M

Fred er

John Fa

Five on Five Interview: Sustainability According to the Industry Players

Elis aM

5 ON 5

impacts of global warming. The late eighties and early nineties saw companies eager to promote the “greenness” of their products as a marketing lever. From the mid-nineties until recently, green issues, while not forgotten, seemed no longer to be a priority for most industries. While there are some very notable exceptions, most green initiatives during this time were truly probably only financed as they were cost savings. Fast forward to the current decade and you cannot miss companies screaming out from the rooftops regarding their sustainability credentials. But is this the real deal? Are companies finally taking the issue seriously? ipcm®, in a series of interviews with senior figures from within the coatings industry, found everyone

to be very open and sincere on the topic: each company may be at a different point in their sustainability journey, but we happily found that the topic was a very high priority for everyone. Below, in the first of a three-part interview, you can find the answers to the first five questions from five senior industry contacts. There is no wrong or right answer and we believe the comparison makes for a great read as well as being thought provoking. A new feature within the ipcm® magazines, this section aims to provide an interesting read with the long-term hope that if we can showcase sustainability best practices then maybe, one day, one of these will be the inspiration for another organisation to make a difference.

For this first interview we were delighted to work with the following sector leaders: Joel Svendsen - President of Belzona 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. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

n, Belzona dse en

SUSTAINABILITY

How does your company define sustainability today?

Joel Svendsen, Belzona - If you look at sustainability as minimising damage to the environment, you can tackle it from a few different angles. The more traditional routes include using less energy, trying to reduce waste and improving recycling. We’re kind of in a fourth column. How can we preserve the life of machinery, equipment, buildings and structures? If you go back in Belzona’s history, we used to have the tagline “Conservation of Man-Made Resources”. Essentially, this is where we see ourselves. If we can extend the lifespan of these assets, replacement can be avoided and we’re able to reduce the environmental cost associated with replacing large pieces of machinery or structures. Helen Mets, DSM - DSM believes that sustainability involves the absolute responsibility and clear actions that must be put in place to address some of the major environmental and societal issues the world faces today. Our strategy is closely linked to the sustainable development goals and we are setting ambitious goals as business under 3 pillars: “Health” (creating healthy living environments), “Climate & Energy” (reducing impact on climate change) and “Circularity and Resources” (eliminating waste and enabling a circular economy). To achieve our goals and to push the industry forward we need to work in conjunction with organisations and companies across the entire value chain, as well as end consumers, to develop science-based and scalable solutions which make a positive impact on society without a negative one to our planet. It also involves delivering these goals while remaining a profitable, performance-focused and growth-oriented company, for which we do

S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES

not see any contradiction. In short, we want to deliver business excellence providing we can adhere to our core sustainability values which are at the heart of everything we do. As President of DSM Functional Materials and Resins, I personally have an intrinsic motivation to change the world, so sustainability for us is not a nice to have. It’s a must have. John Falder, HMG - Decent, Worthwhile and Secure are key HMG values and underpin everything the company does. The HMG mission statement reads: “To supply coatings that protect and enhance. Bought by customers who want to use it, produced by staff that want to make it and doing so in a sustainable, innovative and fair manner”. In this instance, it makes sustainability an integral part of the HMG business strategy and we are committed in being a socially responsible company. Fredrik Calenius, TEKNOS - For Teknos sustainability is a mindset and an integrated part of our strategy and business model. Teknos is highly committed to protecting the planet and making the world last longer. We constantly strive to create sustainable long-term value for society, our customers, employees and suppliers by both protecting the environment and the safety and health of our employees and others, while also using resources as efficiently as possible. Minna Avellan, Tikkurila - Sustainability is simply the way we conduct our business; it is the foundation of our values and brands. Sustainable development is a very material part of our strategy, deployment is strongly integrated in everything we do. Sustainability provides genuine business opportunities at the same time as it enables us to affect on what kind of planet we want to leave to the next generations. It benefits economically, reduces costs and minimizes risks.

What have been the biggest issues encountered in bringing theory into practice?

Joel Svendsen, Belzona - I would say that, if there is a challenge, it’s that you can make materials cheaper but at the expense of making them nastier. It’s not that difficult to make an inexpensive coating, at the expense of adding in lots of nasty solvents. You could look at it from a certain point of view and say, “That’s great, I’ve got this protective coating and it is a lot cheaper”. But it brings with it two problems: solvent systems generally don’t perform well compared to a non-solvent system; secondly, solvent systems have an environmental cost. With these chemicals evaporating into the air, they’re potentially harmful to the people breathing it in. Helen Mets, DSM - It’s easy to talk a good game on sustainability, but far harder to actually make it a commercial reality. From our perspective we encounter two main obstacles: firstly, there is still a lot of education and communication that needs to be done to convince industry sector customers that truly sustainable products can be high performance and available at the right price point. There is still significant miscomprehension around sustainable products and they can sometimes be a hard sell. This is evident by the fact that solvent-based paints are still dominant in certain parts of the world where an effective and cost comparable alternative is available. Secondly, the necessary conditions for sustainable product development need to be in place – so not only an open-minded market, but the right supply chain partnerships that share your vision and are prepared to take on the myriad of issues involved, from supply of sustainable resources and materials to energy efficiency and high performance. DSM uses its passion and energy every day to overcome these challenges.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

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S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES

SUSTAINABILITY

John Falder, HMG - Like any initiative, the initial rollout can generate issues, especially if it changes existing business practices. Thankfully though, the HMG staff is very engaged and understands the wider impacts and eventual benefits that introducing new practices can bring. Fredrik Calenius, TEKNOS - People involvement has been crucial. We had to first understand what our true sustainability goals were and translate these into a strategy that can be measured. Only once this was complete could we move to ensure the buy-in from all stakeholders at every level, from the ground up to the boardroom. We had to have this buy-in to ensure that sustainability became a truly integrated part of corporate policy. Minna Avellan, Tikkurila – Depending on the readiness of our stakeholders, we have seen differences both in people awareness and country practices. In order to get all relevant stakeholders to join your journey, the company needs to bring sustainability into practice – sustainability requires concrete actions. Furthermore, tightening legislation has a great impact on our operations.

players seem to be doing a reasonably conscientious job at “trying to do the right thing”. In third place, there is government regulation and you have be in compliance with the rules that are out there. Helen Mets, DSM - Without doubt, the key driver for sustainability in coatings must be volatile organic compounds (VOCs). The clue is in the name – these materials are “volatile”. They are being emitted as gases from the thousands of every day products that form part of our daily lives. The long-term negative health effects are now well understood and what is so alarming is that concentrations of many VOCs are consistently and very significantly higher indoors where coatings of all descriptions are used from wall paint to varnishes to adhesives (Fig. 1). This is where one of the key pillars of our sustainability strategy comes in – to positively impact the health of the population. The more we understand about VOCs, the greater the urgency becomes to take action, which is why DSM has worked so hard to help the industry migrate from solvent-borne to waterborne technologies.

What do you see as the key drivers of sustainability in industry today?

Joel Svendsen, Belzona - The biggest drivers are the natural drivers throughout industry: companies want to save money. If they can save energy and prolong the life of their equipment at the same time as saving money, that’s great. So, it’s a virtual circle. Since companies want to be more efficient, they want to behave in a more sustainable fashion. Second to that, companies don’t want to be seen as evil, but a force for good. The bigger

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

John Falder, HMG - Companies are now responding to pressure from regulators and the wider community to drive the sustainable conversation, which is fantastic. Social responsibility, commercial factors and perhaps, most significantly, simply doing the right thing for local and wider stakeholders are the key drivers. Fredrik Calenius, TEKNOS - Driving growth – sustainability can contribute to growth by improving our brand values and opening up new market opportunities (e.g. markets for low VOC or bio-based paints/coatings). Lowering costs – efficient use of raw materials and resources (e.g. energy, water) can reduce costs and improve profitability. Employees are easier to motivate to save resources when arguing about sustainability. Reducing risks – sustainable business practices can help us reduce risks. These include risks from increasing emissions taxes (energy, transportation), pollutants and toxic releases (energy, VOCs, various chemical compounds), shipment of hazardous materials (reagents, intermediates, raw materials, solvents), new and increasingly restrictive regulations, climate change, disruptions in supply chains, etc. Financial benefits – better risk

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S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES

SUSTAINABILITY

Minna Avellan, Tikkurila - The key drivers for our sustainability work are the expectations of our stakeholders and changing regulations as well as global and business environment trends, which are impacting on our operations considerably. Customer awareness – we are listening and work with our

5 ON 5

management through sustainability can help us to receive better loan interest rates from financial institutes. Attracting talents – employees, especially young generations, want to work for more sustainable and responsible companies. Strong sustainability commitment can help us attract and retain the best talents. For future generations – at Teknos we want to build the company which the next generations will be proud to lead and be part of in the future. Teknos wants to make choices, which bear to all the generations to come (Fig. 2).

customers with the aim to meet their changing demand. Customers want to choose products that cause a minimal environmental impact in production and in use and that are safe to use. People are increasingly concerned about well-being and health, as well as the state of the environment (Fig. 3). Changing legislation – we actively monitor the legislative development of our industry and meet the legal requirements regarding our operations and products. Megatrends – trends affecting particularly the paint industry and consumer-focused business operations include urbanization, the rise of the middle class, changes in consumption behaviour, aging of the population, exhausting natural resources, and climate change. Digitalization brings new opportunities for eco-innovation and service design, for instance.

What business value have you seen?

Joel Svendsen, Belzona - In the end, it means to save money over the life of that structure/ equipment, if you made it suitable in the first place. These third-party energy certifications help to drive this forward. If you take that approach further, looking at the smaller details of the industry,

they make people invest a little bit more up front, so you can save money, energy and time in the long run. Which falls nicely in line with how Belzona looks at things. Helen Mets, DSM - We have been the leader to transform the market from solvent based to water-based coatings, drastically lower the VOC emission and improving the health of, for example, workers. As a result, we have grown our business with high single digits y/y over the last decade. John Falder, HMG - Hard to quantify, as it’s been part of the business since it was founded. It’s evident though that throughout the years the culture has meant we’ve constantly improved our process and build long term relationships that have a fundamental foundation in sustainability. Fredrik Calenius, TEKNOS - With our program we aim to add value to our customers and customers’ customers. A few of our customers are now beginning to ask for more sustainable options, for example using less solvents, so it’s important that we adapt to be ahead of the curve even if it’s just a trickle of requests today (Fig. 4). Another very important value is that sustainability is becoming an ever more important factor in attracting new talent, particularly for the younger age groups. Elisa Markula, Tikkurila - There is a growing business case for sustainability, and thus, in our company it is embedded in everything we do

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES

SUSTAINABILITY

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as a part of our business strategy. We want design business models that create value for all stakeholders, including employees, shareholders and supply chains, also the planet. Sustainability as a part of our company DNA helps us mitigate risks, drive for more innovations and significantly reduce costs, like energy and water consumption, i.e. improve our operational efficiency. On top of this, there is a growing demand from our customers for more environmentally friendly solutions which will grow our sales. Also, investors are now tracking the high performers on ESG (environmental, social and governance factors) and are correlating better financial performance with better ESG performance.

How do you compare to the competition?

Joel Svendsen, Belzona - I would say we do more than our competition. You maybe pay a little bit more for a Belzona

product, but what you get is a solution for the long term. Helen Mets, DSM - A lot of development is not open to public scrutiny, so it can be hard to assess what is going on and determine exactly who our competitive peers are, although we debate this regularly. One thing I would say is that we have the same attitude as elite sports men and women, in that while we are aware there is competition, our focus is on ourselves and being the best, we can without needing to constantly look at who is beside us or coming up from behind. Sustainability redefines what competition means. It takes industries and value chains to work together to make the changes required to address the issue we face. John Falder, HMG - As a company we feel we fair favourably to competition, this is perhaps reflected in the fact HMG Paints was the first paint company to win the BCF Coatings Care award twice

along with Northwest Business Environment, Granada Waterwatch and Environmental Education awards and our links to the Red Rose urban woodland project. Fredrik Calenius, TEKNOS - Compared to some of the bigger players in our sector we have started our journey later, however we have the advantage of being a family run business, which allows us to be very flexible and to move quickly. So, we believe we will catch up very quickly and hope to be very shortly at the forefront, adding value for our customers and differentiating ourselves in the market. Minna Avellan, Tikkurila – Tikkurila has sustainability deep in its DNA. Responsibility and sustainability have been part of our business already for decades. We started training our customers in the late 1920s. We introduced the first water-borne products in the early 50s and met the stringent eco-label requirements already 20 years ago – just to mention a few strategic milestones. To move forward, our focus is on finding our own competitive advantages.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

Automatic SEASIDE endorsement

*Fully integrated in SATâ&#x20AC;&#x2122;s vertical coating plants

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26 â&#x20AC;&#x201C; 28 February 2019 DWTC, Dubai, UAE

Where the marketÂ meets See the latest products

5000+ attendees Unrivalled networking

Senior decision makers in 1 place

www.coatingsgroup.com/mecs

300+ exhibitors

WELCOME TO THE INDUSTRY’S LEADING TRADE SHOW NUREMBERG // GERMANY European Coatings Show: 19 – 21 March 2019 European Coatings Show Conference: 18 –19 March 2019

Most recently over 1,100 international exhibitors and over 30,000 visitors Accompanied by Europe’s largest and most important industry conference w Plan your visit online: european-coatings-show.com/shownavigator Organisation: NürnbergMesse european-coatings-show.com

Organiser: Vincentz Network european-coatings.com

Opening photo: The UV-curing waterborne PU dispersion enhaces the eﬃciency of the coating process even on diﬃcult geometries and in shadow areas.

INNOVATIONS: PRESENT&FUTURE

S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES

Multi-Curing Waterbased PU Dispersion: Faster Drying, Robustness and Improved Performance Even Under Poor UV-Curing Conditions Eva Tejada Rosales, Berta Vega Sánchez, Michael Ludewig and Matthias Wintermantel Covestro Deutschland AG – Leverkusen, Germany

www.coatings.covestro.com

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

V-curing waterborne polyurethane (PU) coatings

INNOVATIONS: PRESENT&FUTURE

bring clear benefits. But they

also have their disadvantages, e.g. inadequate UV curing in shadow areas or for pigmented paints, and a long water evaporation phase before UV curing. A newly developed multi-curing waterborne PU dispersion has been shown to overcome these problems and also offer important benefits. Evidence of the positive feedback, Covestro’s innovative technology has received came from the 2018 European Technical Coatings Congress in Amsterdam where it won the Alain Clause Award.

Figure 1: Limitations and pain points of UV systems.

Drawbacks defeated The ultra-fast curing properties and high productivity of UV curing technology are well-known. But up to now, the applicability of this technology has been limited by some drawbacks, e.g. insufficient curing in shadow areas (e.g. on complex furniture geometries) or difficulties in pigmented paints, and a longer drying period due to slow water evaporation in case of UV-curable waterborne systems (Fig. 1). Covestro overcame these challenges by integrating a second curing mechanism into a UV-curable PU dispersion to create a multi-curing technology (Fig. 2). The combination of an oxidative and a UV-curing mechanism leads to a

UV-curing waterborne polyurethane (PU) coatings bring clear benefits. But they also have their disadvantages, e.g. inadequate UV curing in shadow areas or for pigmented paints, and a long water evaporation phase before UV curing. A newly developed multi-curing waterborne PU dispersion has been shown to overcome these problems and also offer important benefits.”

Thanks to the excellent coating performance achieved with low UV energy this technology can be used even without UV curing or with less photoinitiator input. As a uniformly high coating performance is now possible – even on difficult geometries and in shadow areas – there are no coating-related limitations on the design creativity of furniture manufacturers, for example. What’s more, this UV-curing waterborne PU dispersion is manufactured in part from renewable sources and does not contain a reactive diluent (oligomer),

higher crosslinking density (Fig. 3).

resulting in a more environmentally

This multi-curing technology brings a

friendly solution with no hazard

performance, especially under low UV

Eﬃciency and eﬀectivity enhanced

dosage conditions. And even without

The technological breakthrough

less photoinitiator, it also requires

UV curing, it ensures sufficient coating

achieved by Covestro enhances the

less UV and drying energy. Last but

performance, though the properties

efficiency of coating processes in

not least, this dispersion is suitable

can be clearly enhanced when UV light

multiple ways. Speedy water release

for a wide range of applications,

is applied. It is the inherent crosslinking

enables to shorten the drying time up

e.g. clear and pigmented coatings,

of the polymer that offsets any lack of

to 50%, compared to other standard

exterior applications, and on-site

light, while the chemical constitution

UV-curable dispersions. Crosslinking

parquet (ref. Opening photo).

of Covestro’s multi-curing technology

the polymer chain improves the

So what chemistry makes this new

speeds up water release.

coating’s chemical resistance properties.

technology possible?

marked improvement in the coating

pictogram on the product label. This technology not only needs

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

S P E C I A L ON RAW M AT E RI A L S , P I G M E NT S , PA I NT & C OAT I NG T E C HNOLOG I E S

Secondary crosslinking chemistry Oxidative crosslinking is one of the oldest and well-established curing technologies for coatings. This is particularly true for applications where the requirements are relatively basic. Oxidative crosslinking is a generally low-cost, easy-to-use solution as the curing agent oxygen is instantly available once a surface has been coated. But the curing on its own does not produce a very high crosslinking density. In other words, it cannot be seen as an adequate replacement for an isocyanate-based or UV-crosslinking system in demanding applications. As oxidative crosslinking is also a slow-reacting curing method, the final properties are only obtained after a post-application delay of several days.

Covestro integrated a second curing mechanism into a UV-curable PU dispersion to create a multi-curing technology. The combination of an oxidative and a UV-curing mechanism leads to a higher crosslinking density. This multi-curing technology brings a marked improvement in the coating performance, especially under low UV dosage conditions.â&#x20AC;?

The solution the Covestro specialists came up with involves a combination of UV radiation and oxidative curing. The benefits of both technologies are thus incorporated into a single system: high productivity, very high crosslinking densities leading to good chemical and mechanical resistances in areas where UV curing is possible; and relatively good properties in areas where the effect of radiation is inhibited by a complex geometry or UV-absorbing pigments. Covestroâ&#x20AC;&#x2122;s innovative PU dispersion technology is highly flexible and gives resin developers much more freedom in designing products best suited to the application in question. What this means in practice is that extra weight can be given to the oxidative curing step for systems in need of a post-curing via UV radiation, for example. Alternatively, an applicator may want to give UV radiation a greater weight in order to achieve more robustness and excellent properties even in shadow areas. Whatever weighting is chosen, this mixture of oxidative and UV curing leads to an advantageous outcome, as tests have proved.

INNOVATIONS: PRESENT&FUTURE

The technological breakthrough achieved by Covestro enhances the efficiency of coating processes in multiple ways. Speedy water release enables to shorten the drying time up to 50%, compared to other standard UV-curable dispersions. Crosslinking the polymer chain improves the coating’s chemical resistance properties.” Shorter drying time The introduction of a second crosslinking mechanism enables the drying time for conventional water-borne UV-curing coatings to be reduced by up to 50%. Coating formulations based on Covestro’s multi-curing PU dispersion are dry enough to be exposed to UV radiation just 2 - 5 minutes after application at an oven temperature of 50° C. Other factors such as line speed, air flux, substrate and the application amount naturally influence the overall drying time. However, this multi-curing PU dispersion has been shown in tests to deliver an impressive physical drying performance and enable fast water evaporation. If a coating with the double crosslinking mechanism is compared with a conventional water-borne UV-curing coating – both applied at 100 g/m2 and oven-dried at 50° C – the coating featuring the double crosslinking mechanism is dry in about 3 minutes, whereas the conventional product needs some 6 minutes to be dry enough to avoid white pore effect, due to water remaining in the dried film.

Lower costs The improved drying behaviour of formulations based on the new Covestro dispersion is due to the dual curing mechanisms: conventional radical polymerisation as the basis of all UV-curing coating systems, and alkyd modification resulting from oxidative crosslinking in the presence of air. The secondary crosslinking

Oxidative crosslinking is one of the oldest and well-established curing technologies for coatings. This is particularly true for applications where the requirements are relatively basic. Oxidative crosslinking is a generally low-cost, easy-to-use solution as the curing agent oxygen is instantly available once a surface has been coated.”

HIGH

PERFORMANCE POWDER COATINGS

SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES

The introduction of a second crosslinking mechanism enables the drying time for conventional water-borne UV-curing coatings to be reduced by up to 50%. Coating formulations based on Covestro’s multi-curing PU dispersion are dry enough to be exposed to UV radiation just 2 - 5 minutes after application at an oven temperature of 50° C. Other factors such as line speed, air flux, substrate and the application amount naturally influence the overall drying time.”

2 1

Figure 2: Multi-curing possibilities.

With a coating based on Covestro’s

efficient coating process than with

water evaporates and continues for

new multi-curing technology, the cost

standard waterborne UV-curing PU

several days. A coating reaches its

of the coating process can be reduced

dispersions.

final properties after 3-7 days at room

for several reasons: a lower oven

temperature. As well as improving

temperature for water evaporation, less

coating properties, alkyd modification

UV source energy consumed, a longer

Previously unattainable robustness

also increases the hydrophobicity of the

UV lamp lifetime and less photoinitiator

Incomplete UV curing can negatively

coating, which in turn improves water

required. Generally speaking, the

impact the quality of wood coatings

release during drying.

outcome is a more cost-effective and

on complex furniture geometries

mechanism starts as soon as the first

Covestro’s innovative PU dispersion technology is highly flexible and gives resin developers much more freedom in designing products best suited to the application in question. What this means in practice is that extra weight can be given to the oxidative curing step for systems in need of a post-curing via UV radiation, for example.”

3 1

Figure 3: Idealized chemical structure of UV-curable polyurethane dispersions.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

With a coating based on Covestro’s new multi-curing technology, the cost of the coating process can be reduced for several reasons: a lower oven temperature for water evaporation, less UV source energy consumed, a longer UV lamp lifetime and less photoinitiator required.”

INNOVATIONS: PRESENT&FUTURE

4 1

Figure 4: Multi-curing UV-curing polyurethane dispersions for clear coatings.

or parquet coatings applied on site.

for resistance to a 48% ethanol solution during

shown to perform just as well as an

Coatings based on this new multi-curing

a one-hour exposure period. The coatings were

identical formulation with a more typical

dispersion, in contrast, have been shown

applied at 100 g/m2 on melamine, dried for

1% photoinitiator. Another advantage

to display a previously unattainable

10 minutes at 50° C and cured using an

for furniture manufacturers (and

robustness, as the oxidative crosslinking

80 W/cm UV Hg lamp (256 mJ/cm2). A clear

users) is that clear coats based on the

mechanism offsets any deficiencies in the

coat formulation based on the new dispersion

new dispersion are highly resistant to

UV-curing process. Tests were conducted

and containing only 0.5% photoinitiator was

everyday ‘threats’ such as water, red

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SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES

Complex furniture geometries

wine, coffee and hand cream – even if the

Bayhydrol® eco UV 2877, a Covestro product featuring the new multi-curing PU dispersion technology, is particularly suitable for coatings intended for industrial wood applications with complex geometries. The properties shown by Bayhydrol® eco UV 2877 include good chemical resistance without UV and very good resistance after UV curing, good hardness at a low UV dosage (shadow curing), and very good final hardness. Moreover, only 2 min 30 sec are required for the water release phase at 50° C. and 0.5% photoinitiator is sufficient. 40% solid content, 38% bio-based content (Fig. 6): Bayhydrol® eco UV 2877 is not only a high-performing solution for excellent wood coatings; it is also a more

environment-friendly one.

Incomplete UV curing can negatively impact the quality of wood coatings on complex furniture geometries or parquet coatings applied on site. Coatings based on this new multicuring dispersion, in contrast, have been shown to display a previously unattainable robustness, as the oxidative crosslinking mechanism offsets any deficiencies in the UV-curing process.”

As Dr. Matthias Wintermantel, Covestro’s Head of

coating has not been

Application Development

UV-cured (Fig. 4).

for Building & Infrastructure

The superiority of this

Coatings, points out,

multi-curing PU dispersion

secondary crosslinking

technology is also evident

does make a significant

in critical coloured

practical difference:

pigmented coatings, e.g.

“If a coating formulation

white or yellow: yellow

is based on our new

pigments are highly absorbent of UV radiation; white pigments are the most critical for good

multi-curing PU dispersion,

5 1

water is released faster so UV curing can

Figure 5: Performance of pigmented wood coatings.

commence earlier. As our © Covestro

chemical stain resistance. All the tests conducted

secondary cross-linking mechanism is based on

so far have shown that

fatty acid modification, our

formulations based on the

Bayhydrol® eco UV 2877

new dispersion perform

has over 38% bio-based

better than ones using

content. Alkyd modification

established products

raises the system’s

for pigmented coatings

hydrophobicity, which leads

(Fig. 5). Furthermore, the

to faster water release

product has also shown

and speeds up the overall

good weather stability, making it considerable for exterior applications.

6 1

Figure 6: Properties of self-crosslinking UV-curable polyurethane dispersions.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

process. The outcome is improved productivity with less energy required.”

Opening photo: Chemtec’s new laboratory has started a test contracting service.

HIGHLIGHT OF THE MONTH

S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES

Chemtec Expands its Plant and Develops a Laboratory Test Contracting Service From an interview with Carlo Guidetti Chemtec Srl, Corbetta (Milan) – Italy

c.guidetti@chemtec.it

“U

pdated tradition” is not

“The technologies developed by

products that comply with the increasingly

just a slogan for Chemtec,

Chemtec are advanced, revolutionary,

restrictive safety regulations. Our

a company established in

and characterised by a very limited

corporate philosophy has always been

2010 and specialising in the formulation,

environmental impact,” states Carlo

oriented to our customers. This is not

production, and distribution of complete

Guidetti, the owner of this firm

limited to the peculiar relationship created

products and technologies for the

located in Corbetta (Milan, Italy). “They

during commercial negotiations, but it is

pre-treatment and waste water treatment

are designed to bring new solutions

understood as a deep collaboration that

processes intended for the coating sector.

into a traditionally difficult sector

includes the analysis and understanding

It also reflects the mission of a business

with little innovation. We constantly

of the production environment in which

that, although recently established, can

develop new formulations in order

our technologies will be installed, in order

rely on thirty years of experience in terms

to improve the toxicological profile

to formulate products that are often

of formulations and expertise.

of existing technologies and launch

tailor-made.”

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

The company is currently expanding its

area in future. The laboratory, our greatest

corrosion resistance tests, but also

factory in order to provide its customers

pride, will be located on the upper floor. Its

provide information on the causes of

with a complete service. The aim is

team will continue to research and develop

corrosion: in this way, we can define

insourcing some processes, such as

new custom formulations, but it will also start

targeted actions to solve any problems

production and logistics, installing new

a new test contracting service (ref. Opening

or improve the finishing performance

machines, and making the laboratory

photo and Fig. 1).”

level.”

even more efficient through the

“Thanks to impedance spectroscopy,

that gives us more control on our

The development of formulations in Chemtec’s laboratory

production. Currently, we have an about

In addition to the complete management

sheet among those offered by different

1000 m2-wide area that houses our

of the water cycle from pre-treatment to

suppliers or the most oxidation

production department, laboratory,

discharge, the services offered by Chemtec

resistant powder coating among

offices, and warehouse and that will be

include coating quality control.

different products with the same nature

implementation of the most innovative tools. “We want to create a structure

specific studies to identify, for example, the most corrosion resistant metal

integrated with an additional

on the other hand, we can conduct

production department for

but manufactured by different firms. This is

water-based products (which

the kind of tests that

now account for half of

our laboratory has

Chemtec’s entire production)

recently performed

and a logistics department.

for our customers,

“We will continue to outsource

thus helping them to

the manufacturing of

improve the quality

solvent-based and powder

of their products in a

products, but we will ship

very short time and

them from our factory.

without drastically

Although these are not

changing their coating

solvents with high VOC

processes.”

contents, flammable, or

The laboratory tools

dangerous, we have chosen not to insource their production. As for water-based products, on

Figure 1: The technical staﬀ of the laboratory.

the other hand, we opted for

In addition to the devices used for salt spray resistance

an integrated production flow, from

“We perform a complete inspection of

analyses, Chemtec’s lab is equipped

the research and development of

coatings’ quality level, measuring the

with a cleaning machine for industrial

new solutions up to the formulation,

conventional parameters of adhesion,

tests and a 200 litre/hour reverse

production, packaging, and shipping of

impact, bending, etc. on the products treated

osmosis system with UV filters, entirely

end products.”

and coated by our clients. We also carry

conceived by the company’s technical

out neutral and acetic salt spray corrosion

staff (Fig. 2). “We are starting to

resistance tests and accelerated corrosion

offer our Chemtec-branded reverse

A new structure for a complete service

resistance tests with electrochemical

osmosis and demineralisation plants

By connecting two buildings, Chemtec’s

methods such as impedance spectroscopy

to the market (Fig. 3). We install these

factory will take a horseshoe shape.

and the ACET method.”

machines as a part of pre-treatment

“On one side, we will create a

“The latter technique enables us to quickly

and water treatment systems. In the

warehouse for raw materials, whereas

obtain objective and repeatable numerical

former case, these are devices for lines

the end product logistics department

data and to understand the causes of

not produced by Chemtec, whereas

will be located on the other side. We

corrosion. Indeed, in just 24 hours it is

in the latter they become accessories

will keep an empty area where we will

possible to obtain results that not only

or integral parts of physical-chemical

arrange a partly automated packaging

allow to predict the progress of salt spray

systems designed and installed by us.”

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

2 1

SP EC IAL ON RAW MATE R IALS, PIGMEN TS, PAIN T & COATING TECH N O LO GIES

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Figure 2: Analysis tools.

Figure 3: The Chemtec-branded 200 litre/hour reverse osmosis system with UV filters has been presented to the market recently.

For its analyses, the laboratory employs

Conclusions

- dynamic surface tensiometer: it

different techniques, as follows:

measures the dynamic surface tension

“We have chosen to invest in order to

- high performance liquid chromatography:

of a liquid to determine the exact

expand our plant and equip our company

it enables to detect the concentration of

concentration of a surfactant in a

with tools guaranteeing scientific,

oils and polymers in the baths of both

degreasing bath.

measurable results,” says Guidetti. “Such

Toran 3®, the one-stage cold pre-treatment

“Finally, our laboratory is equipped with

scientific approach obviously involves

system developed by Chemtec, and

a coating room including two 1 m -wide

high costs in terms of both tools and staff

conventional degreasing plants;

booths (one for liquids and the other for

training. However, although the hardest

powders) to coat samples and one drying

one, Chemtec has chosen this road to

technique is used to detect the

oven. Here, we can both formulate new

counteract the increasing spread of

cleanliness degree of surfaces.

products to be offered on the market

superficial solutions found in the

By measuring the surface tension, it is

and perform any coating quality control

pre-treatment and cleaning fields.

possible to detect the concentration

requested by our customers.”

Appropriate tools were necessary to achieve

- UV spectrophotometry: this analysis

this goal: the following

obtain scientific data related to the cleaning

of surfactants and thus

step was putting them at the service of any user requiring equally

level of the workpiece; - impedance spectroscopy:

accurate results for

analysis method used for

their tests. The aim

electrochemical systems,

is creating a more

including ACET;

scientific approach to the problems

- gas chromatography: employed for the control

that can arise in the

of raw materials and some

manufacturing industry

products (Fig. 4);

and, in particular,

- Fourier Transform Infrared

in the coating sector.

Spectroscopy (FTIR): used

The way is still long to

for the quality control of

“update tradition”,

some raw materials and to perform analyses for customer assistance;

4 1

Figure 4: The gas chromatograph for the control of raw materials.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

but it is based on well-established premises.”

Opening photo: Novaresine specialises in the formulation and production of alkyd resins and polyesters.

S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES

HIGHLIGHT OF THE MONTH

Novaresine: The Sustainable Approach of a Chemical Company Open to Everyone Interview to Bruno Franceschini and Francesco Tamburrino Novaresine Srl, Colà di Lazise, Verona – Italy

info@novaresine.com

ovaresine’s history started about

including can and coil coating, architecture

developing its manufacturing processes

forty years ago. With time, the

and decorations, transport, wood, and

in order to maintain the high quality level

company has specialised in the

natural stone, and they can meet any

of its truly Italian-made products.

formulation and production of alkyd

specific need (ref. Opening photo and

Last year, significant resources were

resins and polyesters, thus becoming a

Fig. 1).

invested in the R&D department, where

point of reference in the Italian chemical

Novaresine’s production plant covers an

the most qualified professionals work

market. Initially a part of the Tenax Group,

80,000 m area in Colà di Lazise (Italy), a

with sophisticated tools and cutting-edge

Novaresine is now an independent

stone’s throw from Lake Garda.

research techniques inside the Nova

high-tech company. Its products are

Over the years, the company has

Lab, the firm’s brand new quality

intended for the most diverse sectors,

focussed on strengthening and

control, research and development,

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

Figure 1: A bird’s eye view of the production site.

and instrumental analysis

complied with safety

laboratory inaugurated in

and environmental

2018. ipcm®’s staff has asked a few questions to Novaresine CEO Bruno Franceschini and Foreign Sales Manager Francesco Tamburrino to understand the current dynamics of the Italian chemical industry and the developments expected for

regulations to be

Novaresine’s history started about forty years ago. With time, the company has specialised in the formulation and production of alkyd resins and polyesters, thus becoming a point of reference in the Italian chemical market. Initially a part of the Tenax Group, Novaresine is now an independent high-tech company. Its products are intended for the most diverse sectors, including can and coil coating, architecture and decorations, transport, wood, and natural stone, and they can meet any specific need.

accused of the opposite. That is why Novaresine has chosen to adopt a policy of complete transparency and openness. Recently, we have organised an Open Day while the plant was in full production. We took the opportunity

coating (Fig. 2).

to explain the details of

the raw materials used in

ipcm®: What does it mean

our new co-incinerator project, which includes

to be a chemical company,

the installation of a

nowadays?

highly technological

Bruno Franceschini: For a

system for the thermal

firm, defining itself a chemical

destruction of reaction

company has a different

water and exhaust

weight and value than in

solvents produced by our

the past. Nowadays, more

resins’ manufacturing

and more attention is paid

process. The institutions

not only by customers and

and municipalities of

competitors, but also by

our neighbouring towns

public opinion. Thanks to

were invited, as well as

the new media, information

all people interested

communicated in the wrong way is enough to spread wrong beliefs and lead a company that has always

in understanding our

2 1

production processes

Figure 2: CEO Bruno Franceschini (right) and Sales Manager Francesco Tamburrino.

and their impact on the environment.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES

ipcm®: Did you invest a lot in

awards, such as the Certificate of

environmental safety?

Excellence that Certiquality assigns

BF: In the past six years, half

exclusively to companies awarded with

of the investments made by

the three certifications ISO 9001:2015

Novaresine have been aimed at

(quality), ISO 14001:2015 (environment),

optimising the safety level and

and OHSAS 18001:2007 (health and safety

reducing the environmental

of workers) and the EcoVadis certification

impact of our processes (Fig. 3).

obtained through the evaluation platform

These two aspects are a part

of Corporate Social Responsibility used

of our code of ethics and

worldwide by the largest companies to

they represent an added

assess the social, ethical, and ecological

value for our products on the

aspects of partners and suppliers, on which

market. Nowadays, if different

we aim at getting the Gold medal.

chemicals have the same

3 1

For a firm, defining itself a chemical company has a different weight and value than in the past. Nowadays, more and more attention is paid not only by customers and competitors, but also by public opinion. Thanks to the new media, information communicated in the wrong way is enough to spread wrong beliefs and lead a company that has always complied with safety and environmental regulations to be accused of the opposite. That is why Novaresine has chosen to adopt a policy of complete transparency and openness.”

ipcm®: How was this change

their manufacturers’ attention

implemented at the production level?

to environmental sustainability

Francesco Tamburrino: Over these

can make the difference

six years, we have made significant

and lead the customers to

improvements, our production volume has

choose one supplier rather

reached 26,000 tonnes, and turnover has

than another. Over the last

almost doubled. Thanks to the collaboration

ten years, Novaresine has

with some client companies, in particular

made a radical change in

from the can coating sector, we have

terms of environmental

increased the volume of water-based

policy, considering process

chemicals from 1% to 15%. In other words,

sustainability as its first goal.

saturated polyesters account for 12,000

Thanks to this project, we have

tonnes (of which 4,000 are water-based

obtained several international

products and 8,000 solvent-based, since

Figure 3: The new reactor is a part of the sustainable renovation project of Novaresine’s factory.

performance and quality level,

4 1

Figure 4: The Nova Lab.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

these are still often required, especially in

HIGHLIGHT OF THE MONTH

the coil coating sector) out of the 26,000 tonnes of products we manufacture. We still produce a good percentage of alkyd resins, mainly intended for the Italian wood and decorative market, and of unsaturated polyesters, used to treat natural stone. ipcm®: What is the characteristic that distinguishes the Novaresine products? FT: Certainly, our strength is our R&D department’s ability to timely and accurately develop and formulate tailor-made products by working side by side with customers. Our laboratory is the other element that characterises us: our factory renovation project will

5 1

end precisely with the updating of its tools.

Figure 5: The laboratory area devoted to quality control.

SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES

and instrumental analysis for application tests and test results. We are now equipping our 400 m2-wide lab with new machinery and equipment, not necessarily related to the formulation and analysis of resins. The goal is to obtain products that are as suitable as possible for their intended use through the results of our tests. In the quality control area (Fig. 5), we analyse raw materials, which are subjected to our internal controls to confirm their characteristics even if they are already certified, and finished resins, of which we verify the parameters included in the technical data sheet, such

6 1

as dry residue, solid residue,

Figure 6: The diﬀerential scanning calorimeter.

In the past six years, half of the investments made by Novaresine have been aimed at optimising the safety level and reducing the environmental impact of the processes. These two aspects are a part of the company’s code of ethics and they represent an added value for its products on the market.” BF: The ultimate goal is that our customers use the equipment made available by our lab as if it were theirs. We have decided to open the doors of our Nova Lab to all those wanting to collaborate with us for the creation of new chemical products. Previously, our activity was aimed at a niche target and limited to the formulation of resins (Fig. 4). Now, we have understood that the more the sectors involved in our projects, the higher the chances to learn useful skills from the mutual exchange of expertise: both our lab technicians and our customers can benefit from it. ipcm®: How is Nova Lab organised? FT: The laboratory is divided into three areas: quality control of raw materials and products, research and development,

7 1

Figure 7: The gas chromatograph for the purity and quali-quantitative analysis of raw materials and end products.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

8 1

Figure 8: The curtain coater for the paint application.

colour, viscosity, acid value, and all that

and coil coating sectors. For saturated

is required to check the products’ quality

polyesters, we have tools available to

level (Fig. 6).

determine the isothermal peaks of

The instrumental analysis area is the

reactions with a thermocouple system,

most innovative and sophisticated

devices for the optical evaluation of films

one in terms of equipment, including

applied on sheets, and a colourimeter

The ultimate goal is that Novaresine’s customers use the equipment made available by the company’s lab as if it were theirs. Novaresine has decided to open the doors of its Nova Lab to all those wanting to collaborate for the creation of new chemical products. Previously, its activity was aimed at a niche target and limited to the formulation of resins. Now, Novaresine has understood that the more the sectors involved in the projects, the higher the chances to learn useful skills from the mutual exchange of expertise: both the lab technicians and the customers can benefit from it.”

acquisition system and an ATR device with its related software package, centrifuges

a spectrophotometer with a data

for the separation of particles in solution, a gas chromatograph to determine the distribution of molecular masses through thermal analyses, and a classic gas chromatograph (Fig. 7). Finally, the synthesis area is equipped with two 2 kg stations and three 5 kg stations to produce resin prototypes in appropriate flasks. Here, production conditions are reproduced on a laboratory scale. ipcm®: How are coating resins analysed in your laboratory? FT: The application test area specialises in coating resins, especially for the can

Figure 9: The infrared spectrometer.

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international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES

to determine

ipcm®: How does the

the colours’

investment for your

components,

laboratory fit into the

aging process,

context of your factory

hardness and gloss

renovation project?

levels, and all the

BF: The lab’s renovation

characteristics

was the last step of the

useful for assessing

development project of

the aesthetic

Novaresine, although

and functional

the most important one:

characteristics of

our laboratory is the tool

resins.

with which we gain our

Our lab is also

customers’ trust and

equipped with a

loyalise them. It must be

curtain coater to detect the coating layers’ grammage (Fig. 8),

equipped with the most 10 1

advanced devices and our technicians must be ready

Figure 10: The Aalborg control system.

to perform tests of any

a spectrometer

kind for the most diverse

for UV colour analyses (Fig. 9) now also used for wood, an Aalborg

industries. We would like the Nova Lab to be known in our sector

control system to assess curing processes in an oven able to reach

for its ability to meet any request, its willingness to help customers develop and formulate suitable products, and the effectiveness of its results – with a focus on environmental sustainability, which

metal sheets and carrying out stress tests on substrates.

Novaresine has and will always advocate.

very high temperatures (250-260 °C, Fig. 10), a König pendulum to detect surface hardness (Fig. 11), and different tools for pressing

The lab’s renovation was the last step of the development project of Novaresine, although the most important one: the laboratory is the tool with which Novaresine gains its customers’ trust and loyalise them. It must be equipped with the most advanced devices and its technicians must be ready to perform tests of any kind for the most diverse industries.”

11 1

Figure 11: The pendulum for performing hardness tests with the König method.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

Opening photo: Cost savings with significantly reduced solvent consumption.

INNOVATIONS: PRESENT&FUTURE

S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES

VOC-compliant Coating: Ultra-high-solid Platform Technologies Oliver Zanner Emil Frei GmbH & Co. KG – Bräunlingen, Germany

info@freilacke.de

he conversion from solvent-based to

coatings, multi-layer structures are almost

costly ventilation and filter technology.

water-borne coating systems is often

always used – such as cathodic EC or 2C epoxy

FreiLacke, on the other hand, is now using

linked with high investment costs. The

primers which are combined with 2C-PU top

its new ultra-high-solid systems (or UHS for

new ultra-high-solid platform technologies

coats. These coating systems score in terms of

short) which entirely meet the demands for

from FreiLacke can significantly reduce

adhesive strength and corrosion protection as

a reduction in the VOC content in paints and

solvent consumption, even without system

well as very good UV and chemical resistances.

coatings. With a solids content of up to 80

conversions.

Their disadvantage: A high VOC content which

percent by weight, they have a VOC value of

In order to produce high-quality and efficient

has to be compensated with laborious and

less than 350 g/l.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

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.” High stability, fast drying The UHS systems also include two new primers and a high-gloss top coat. “Our new 2C polyurethane primer UR1937H is used wherever rapid recoating with a wide range of top coat systems is required,” explained Andreas Morlock, head of the Development and Application Technology Industrial Coatings group at the Baden-based coating manufacturer. The primer is characterised by high stability and fast drying; despite the high solids content, it can be applied by means of conventional air atomisation or the Airmix process. Adhesion is good on many substrates and the use of a single curing agent for both the primer and the top coat provides users with simple handling as well as appreciable savings in time and money (Fig. 1).

Use of renewable raw materials If very high corrosion protection is required, the new 2C epoxy UHS primer ER1936H demonstrates its strengths: “We were able to formulate the curing agent component HE0016 using renewable raw materials in such a way that the irritation typical of amine curing agents is very low. The primer and curing agent were brought to series production completely without reactive thinners,” explained the group leader. Besides fast recoating, the system also scores with its high stability and a sufficiently long pot life. And the new 2C polyurethane UHS top coat UR1409G – a high-gloss top coat system that boasts excellent flow properties and rapid drying – is now also available to coating companies. Together with the UHS primers UR1937H and ER1936H, it ensures a reduction in emissions, short cycle times as well as balanced application and surface properties (Fig. 2).

Total layer thickness in only one step Those who want to accelerate their coating processes even further can make use of the new single-layer UHS system UR1422 from the Black Forest coating experts (ref. Opening photo): FreiLacke has also formulated this 2C system with a solids content of around 80 percent by weight and employs the latest generation of raw material components. “The system meets the

SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES

A quarter less VOCs The values of the total emissions per coated surface indicate a reduction in the VOC content of around 25 percent. “Particularly worthy of mention is the very good corrosion protection of the single-layer systems as well as the popping limit of the single-layer system,” said the developer. The system is particularly suitable for industries such as vehicle construction because it resists deformation of the substrate without forming cracks. “Our new single-layer system boasts outstanding values with respect to deformation and stone-chip resistance. When performing the Erichsen cupping test (DIN EN ISO 1520), a deformation value of more than six millimetres is reached before initial cracks appear in the coating,” concluded Andreas Morlock.

Figure 1: UHS coatings for agricultural machinery.

highest requirements for high, popping-free

reduced and throughput increased with

layer thicknesses, drying that meets the

the new single-layer system. Additional

needs of real-life situations, good surface

application systems can be omitted

properties and high resistance levels to

and solvents – especially for cleaning

corrosion,” said developer Philipp Butkus.

purposes – can be saved. In addition, the

“The VOC content of the coating system is

handling of the coating materials is much

significantly below the limit value of 420 g/l.

easier with regard to logistics and storage;

The application of the entire layer thickness

mix-ups of the individual coating materials

up to a dry layer thickness of 150 μm

are ruled out.

is possible in just one operation. The thickness depends greatly on the type of application, but even with the airless method, which is often critical with regard to popping formation, a popping limit of more than 200 μm dry layer thickness is reached,”

maximum possible popping-free layer

explained Butkus.

Improved cycle times, simplified handling By eliminating intermediate flash-off and forced intermediate drying of the primer, the cycle times can be considerably

Figure 2: UHS coatings for use on motors, gears and pumps.

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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

The system is particularly suitable for industries such as vehicle construction because it resists deformation of the substrate without forming cracks. The new single-layer system boasts outstanding values with respect to deformation and stone-chip resistance.”

Opening photo: A detail of a laboratory in the Titan’s R&D Centre in El Prat de Llobregat near Barcelona.

HIGHLIGHT OF THE MONTH

S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES

Research and Technological Innovation as the Cornerstones of Industrias Titan’s Philosophy Ilaria Paolomelo ipcm®

he coating market is constantly evolving.

have an R&D department focussing on

of the Spanish company since its

It requires increasingly advanced

innovation, in terms of both products and

establishment in 1917. Thanks to the

solutions in terms of both aesthetics

manufacturing processes.

choices and investments implemented

and performance, which also comply with

For Industrias Titan, technological

in about a century of history, Industrias

ever-stricter environmental regulations.

innovation has always been synonymous

Titan has become a leading company

In order to meet market needs, therefore,

with constant research and development:

in the Spanish market of industrial and

for a coating manufacturer it is crucial to

this has been the corporate philosophy

decorative paints. In addition to its

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

company has three laboratories located within a single building and a staff of 40 specialised technicians who share tools, knowledge, experience, and skills to create synergies and operational efficiencies in a stimulating environment. Industrias Titan’s R&D centre is arranged on three floors, each devoted to a different sector as follows: • research and development of powder coatings (Fig. 1); • research and development of decorative and industrial liquid coatings (Fig. 2); • quality control, product analysis, and colourimetry (Fig. 3).

The powder coating R&D laboratory “In order to produce high quality coating solutions, as well as

conventional tools such as colourimeters and glossmeters, our lab

Figure 1: The laboratory’s department for powder coatings.

the reactivity of products, a dustmeter for measuring the size of the powder particles of all the

production facilities in Spain and

is equipped with more sophisticated tools such as DSC for analysing

products formulated by us,

Portugal, the firm has a modern

and a reduced-scale system

and innovative R&D centre in

for wood effect sublimation,

El Prat de Llobregat – a strategic

which also includes a vacuum

location near the airport and port

press (Fig. 4),” says Powder

of Barcelona, the Alta Velocidad

Coating Technical Director

Española (AVE) rail network,

José Antonio Arrieta. “Titan

and the largest waste water

is one of the companies that

treatment plant in Spain

has most focussed on the

(ref. Opening photo).

wood effect market and our

Industrias Titan has decided to

sublimation bases are among

further expand its research centre

the most performing ones

of Powder Coating R&D unit located in El Prat de Llobregat. Here, the powder products of the Titan range are reproduced on a

on the market. Moreover,

2 1

in the so-called “dirty area”

Figure 2: The R&D laboratory for liquid coatings.

of our laboratory, we have © ipcm ®

laboratory scale and numerous tests are performed to check the quality of coating systems and products and prevent post-production defects. Currently, the

The coating market is constantly evolving. It requires increasingly advanced solutions in terms of both aesthetics and performance, which also comply with ever-stricter environmental regulations. In order to meet market needs, therefore, for a coating manufacturer it is crucial to have an R&D department focussing on innovation, in terms of both products and manufacturing processes.”

3 1

Figure 3: The Quality control, product analysis, and colourimetry laboratory.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES

For Industrias Titan, technological innovation has always been synonymous with constant research and development: this has been the corporate philosophy of the Spanish company since its establishment in 1917. Thanks to the choices and investments implemented in about a century of history, Industrias Titan has become a leading company in the Spanish market of industrial and decorative paints.”

4 1

Figure 4: A diﬀerential scanning colourimeter in use by the powder coatings laboratory.

R&D Project Manager Jaume Solá. “In

says Solá, “and we carry out some

our liquid coating R&D lab, we design

application tests with different tools, such

not only industrial solutions but

as roller, brush, and gun, to check the

also, and above all, decorative liquid

aesthetic properties of the applied film.”

paints, which are our core business.

“In the near future, Titan intends to

At the end of the laboratory-scale

expand its range of liquid paints for

production cycle, a liquid product is

industrial use. Currently, these are mainly

subjected to numerous tests aimed

used for the industrial maintenance of

at checking both its optical properties

large structures. However, we will expand

a reduced-scale powder production line

and performance level. As for the latter, we

their range by the end of 2019 with the

composed of a mixer, a mill, and an extruder.

assess the film’s flexibility and weathering

addition of the OXIRON line, which will

Here, our staff takes care of the selection and

resistance with an impact meter and we

include both industrial and decorative

processing of raw materials, reproducing real

measure the paint’s viscosity with different

water-based formulations. In the

industrial manufacturing conditions to

types of viscometer. Finally, our products

decorative paint sector, this will not be

fine-tune the formulations (Fig. 5). Finally,

undergo salt spray corrosion tests (Fig. 7),”

a big change, as water-based products

customer’s curing conditions and analyse the behaviour of our paints in their ovens.

we have a gradient oven to simulate our

We can make an accurate evaluation of different characteristics like: such as degassing, mechanicals properties that our products will achieve in their installation (Fig. 6).” “In line with its corporate philosophy, Titan is constantly looking for innovative coating systems to be launched on the market. In particular, we are investing in two projects for the powder sector: a range of hyper-durable coatings to be Qualicoat Class 3 certified and graphene as an additive to create powders with an increased barrier effect, thus offering high performance coatings even in the most corrosive environments,” explains Arrieta.

The liquid coating R&D laboratory “The liquid paint range of Industrias Titan is very wide: for our formulations, we use about 2000 raw materials, which are all catalogued and stored in our dedicated laboratory,” says

5 1

Figure 5: The powder coatings laboratory has a reduced-scale powder production line composed of a mixer, a mill, and an extruder.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

6 1

Figure 6: The gradient oven to simulate customers’ curing conditions and analyse the mechanical resistance of the applied films.

are now widespread; however, the OXIRON line will certainly be an important innovation for the industrial sector, where solvent-based coatings generally prevail due to their ease of application and drying speed.”

The quality control, product analysis, and colourimetry laboratory “The third lab is mainly devoted to three services: colourimetry, quality control, and product analysis. In addition to checking the quality of both raw materials and end products, we carry out tests to verify that the products comply with current regulations. These include the control of emissions of volatile organic compounds. We use liquid chromatography tools to perform qualitative and quantitative analyses and infrared and mass spectrophotometry tools to separate the components contained in the liquid paint mixtures in order to detect and analyse the amount of VOCs in the formulation. Finally, a further research topic we are working on is the

Industrias Titan has decided to further expand its research centre of Powder Coating R&D unit located in El Prat de Llobregat. Here, the powder products of the Titan range are reproduced on a laboratory scale and numerous tests are performed to check the quality of coating systems and products and prevent post-production defects.”

SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES

7 1

Figure 7: Some instruments to analyse the physical, mechanical and chemical resistance of the film.

Titan performs bacteriological checks on all water-based products and makes sure that the coatings come out of the manufacturing cycle completely free of contamination. The production water cycle is monitored carefully: the water is purified, filtered, and only recirculated after a careful bacteriological analysis. Spain has very strict regulations concerning the percentage of biocidal additive that can be added to formulations.”

control of biocides contained in

is why it is crucial to monitor the quality

skills among our resources and the

liquid coatings, which must not

of water, especially in a warm climate like

company’s inclination towards the

exceed certain limits according

ours.”

continuous search for innovative solutions have enabled Industrias

to current law. We work closely with the bacteriological analysis

“In Titan’s R&D centre, each lab

Titan to position itself on the Iberian

laboratory in order to find the

collaborates closely with the other two.

market as a leader in its sector,” states

correct formulation of a product

The sharing of knowledge and technical

José Antonio Arrieta.

“Titan performs bacteriological checks on

(Fig. 8).”

all water-based products and makes sure that the coatings come out of the manufacturing cycle completely free of contamination. The production water cycle is monitored carefully: the water is purified, filtered, and only recirculated after a careful bacteriological analysis. Spain has very strict regulations concerning the percentage of biocidal additive that can be added to formulations. These additives cannot be used freely: that

8 1

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

Figure 8: Bacteriological analysis of the water-based coatings.

Powder coating lines since 1976.

EUROIMPIANTI SRL Via Cavour 44 - 37067 Valeggio sul Mincio (VR) Italy - Tel. +39 045 7950777 info@euroimpianti.com - www.euroimpianti.com

EUROIMPIANTI DO BRASIL LTDA SC 445, 16815 - 88-828 000 Pedreira Balneário Rincão (SC) Brasil

EUROIMPIANTI SL Baix Llobregat 18B Nave G 08759 Vallirana (BCN) España

EUROIMPIANTI USA LLC 1817 NW 79th Ave Miami, FL 33126 (US)

ÂŠ Fraunhofer IAP

Opening photo: Complex AM-fabricated parts dry after their metallization.

INNOVATIONS: PRESENT&FUTURE

S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES

Lacquering Before Polishing: Technical Coatings for Additive Manufacturing Sandra Mehlhase Fraunhofer IAP, Potsdam-Golm â&#x20AC;&#x201C; Germany

info@iap.fraunhofer.de

dditive Manufacturing (AM)

In a joint project, researchers from the

stereolithography (SLA) or material

has many advantages: custom

Belgian NPO Sirris and the Fraunhofer

jetting (MJ) play important roles in the AM

manufacturing, flexible production

Institute for Applied Polymer Research

market. While the first AM technologies

and easy customization, for example.

IAP have investigated technical coatings

were developed for rapid prototyping,

Yet many products have a high surface

for additive manufacturing (TCAM) with

today, AM is taking the leap into industrial

roughness and porosity. The post

promising results.

production. It is one of the important

processing of the thus fabricated parts is

AM describes the construction of

future technologies that will influence

time consuming and often a significant cost

an object layer by layer using a

the manufacturing market and beyond.

factor for manufacturers. Technical coatings

3D-model. The technologies vary but

The industry can profit from AM with its

open up new possibilities for the AM

3D printing is probably the best known.

production on-demand capabilities, its and

market, especially in industrial production.

However, selective laser sintering (SLS),

flexible adaptability and the possibility to

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

produce small quantities. However, the surface of the fabricated components is usually very rough and porous. To meet this challenge, two partners investigated technical coatings for additive manufacturing in a joint project: Sirris is an organization focused on finding solutions for technological challenges, usually in projects with universities, research centers, companies, associations and other institutions. Researchers at the Fraunhofer IAP,

Additive Manufacturing (AM) has many advantages: custom manufacturing, flexible production and easy customization, for example. Yet many products have a high surface roughness and porosity. The post processing of the thus fabricated parts is time consuming and often a significant cost factor for manufacturers.”

Technical Coatings enable smooth and sealed surfaces with specific functions With technical coatings, the Sirris and Fraunhofer researchers were able to significantly improve AM-produced parts regarding surface roughness and porosity. It turned out that the combination of lacquering and polishing is the most efficient technique for surface optimization in AM. In addition, components can be functionalized further by using special lacquers or

among other areas of expertise, have

surface treatments. In the current

long years of experience in

project, the scientists metallized the

technical coatings.

smoothed components. The metal

“Today, with the transition from rapid

quality is essential for industry producers.

coating is a visible example for the

prototyping to industrial production,

In addition, demands on the surface quality

functionalization process. Improved

the demands on AM-manufactured

are growing”, says Dr. Andreas Holländer,

scratch resistance, antimicrobial

components are growing (Fig. 1). Being

expert in surface technology at the

properties and many more features are

able to warrant consistent material

Fraunhofer IAP.

applicable.

EcoDose

Electronic dosing system for higher application efficiency The EcoDose 2K can be used in manual and automatic processes. Optimized for quick color changes and easy flushing, it enhances resource utilization and contributes to higher application efficiency. Fluids like 1 or 2K materials, water and solvent based paints, varnishes, lacquers and monolayer paints are measured consistently and precisely, even media with different viscosities.

www.verind.it

SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES

AM describes the construction of an object layer by layer using a 3D-model. The technologies vary but 3D printing is probably the best known. However, selective laser sintering (SLS), stereolithography (SLA) or material jetting (MJ) play important roles in the AM market.”

Patrick Cosemans from Sirris Flanders adds:

faster and more cost-efficiently. With AM, a

“If we only polish our finished components,

component that would conventionally consist

it takes a long time, and especially with fine,

of many individual parts and would have to

detailed features, we change their shape.

be assembled can be created in one step.

It comes to abrasion, which we want to avoid.

“It is important”, says Dr. Holländer, “that

With the Fraunhofer IAP we have developed

every part of the component’s surface

possibilities to overcome the current

has the required quality. In complicated

problems, especially the porous and rough

parts, some surfaces are difficult to reach.

surface, in additive manufacturing.”

With the appropriate surface treatment

Is combining AM with established technologies the future?

technology, which in future will even be integrated into the AM machines, we are able to functionalize even complex components

Conventional production methods often reach

completely.”

their limits with complex components.

Finishing the project both partners conclude

The more complex a component, the

that AM in combination with established

more difficult and expensive it becomes

technologies provides even better

Sirris provided different components

in conventional production. AM opens up

capabilities and more possible applications

made with SLS, SLA, MJ, and FDM (fused

possibilities to produce complex components

than AM alone.

deposition modeling = 3D printing). All methods pose different challenges to surface treatment. “With years of expertise in surface treatment, we are able to meet a wide range of requirements. We analyzed each part in the first step to determine the specific properties. Afterwards we were able to activate, paint, and polish and, in this case, metallize the respective surface with the appropriate method”, says Holländer, who leads the research group at

With technical coatings, the Sirris and Fraunhofer researchers were able to significantly improve AM-produced parts regarding surface roughness and porosity. It turned out that the combination of lacquering and polishing is the most efficient technique for surface optimization in AM.

the Fraunhofer IAP.

Figure 1: Today, with the transition from rapid prototyping to industrial production, the demands on AM-manufactured components are growing.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

Opening photo: Graco oﬀers products that are suitable for all three mixing common methods to mix plural component paint: sequential dosing, dynamic dosing and continuous flow.

INNOVATIONS: PRESENT&FUTURE

S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES

The Evolution from Single Component to Plural Component Paint Cristiano Giancola Graco Distribution BVBA, Maasmechelen – Belgium

cristiano.giancola@graco.com

hat advantages does plural

as multi component or 2K) paint. Single

In the last 20-25 years there has

component paint offer, what is

component paint consists of only one

been a very strong migration towards

the most optimal method to mix

material that reacts with various factors

plural component paint. Unlike single

it, and what mixing equipment do you need?

such as heat, evaporation, moisture in the

component paint, plural component paint

In the finishing business there are

air, UV etc. Plural component paint involves

has a potlife, which is the period of time

numerous types of paint, but the two most

at least two components – a resin and a

during which the paint is usable after

commonly found are single component

catalyst – mixed together in a certain ratio to

being mixed. Plural component paints can

(or 1K) and plural component (also known

start a reaction.

be solvent-based or waterborne.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

Epoxies are common plural component

the environmental benefits of plural

paints that are usually applied at high

component paint due to lower VOC’s

Ways to mix plural component paint

pressure as base coats to provide a

because you don’t have to evaporate

There are three common methods

protective layer; they typically contain

solvent.

to mix plural component paint:

a lot of fillers. Other common plural

Finally, plural component paints can have

sequential dosing, dynamic dosing and

component paints are polyurethanes,

a higher solid content, which leads to

continuous flow. Before describing

which are usually applied at low

better surface coverage.

them, it’s first necessary to understand © Graco

pressure as thin top coats to obtain a good quality

what are the different

finish. It is important to

components

note that epoxies and

being mixed.

polyurethanes use two

These are shown

completely different and

in Figure 1.

incompatible catalysts.

Component A

So if you are spraying

is the resin or

both epoxies and

base material.

polyurethanes you need

It can also be

two different mixing

a prepolymer,

machines.

polyol or lacquer. Component B

Benefits of plural component paint There are many advantages to using plural component paint. Compared to single component paint, plural

is the catalyst, which is also called the

accelerator,

Figure 1: The two (or sometimes three) components to be mixed to make a plural component paint.

mechanical strength which allows it to withstand abusive conditions better than other paints. It also has better chemical resistance, so can better withstand exposure to a wide range of abrasive chemicals. Plural component paint demonstrates increased flexibility. This means that painted polymeric substrates such as a car bumper are less likely to crack on impact. Another benefit is that less energy is required to cure the paint. Ovens can therefore be run at lower temperatures, which reduces cost. Faster cure times are possible with plural component paints, and curing is much easier to control. Increasingly important these days, especially with companies keen to enhance their green credentials, are

activator or hardener. In some plural

component paint displays improved durability. It has a higher

promoter,

In the finishing business there are numerous types of paint, but the two most commonly found are single component (or 1K) and plural component (also known as multi component or 2K) paint. In the last 20-25 years there has been a very strong migration towards plural component paint. Unlike single component paint, plural component paint has a potlife, which is the period of time during which the paint is usable after being mixed. Plural component paints can be solvent-based or waterborne.”

component paints, a third component (C) is added, such as a reducing agent. Mixing used to occur manually (and still does in some regions) but nowadays mainly occurs via mechanical or electronic mixers, also called proportioners. In the following diagrams, blue is the resin and yellow is the catalyst, which come together to form the green final paint product. The sequential dosing method of mixing In sequential dosing (Fig. 2), both resin and catalyst go through a flow meter with a metering valve, but never both at the same time. Either the resin valve or the catalyst valve is opened; never both together. This means that catalyst is shot into the resin in a sequential way. The mixed paint then enters an

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

integrator, a static mixer and then

SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES

In other words, the resin flows

exits along the hose and through the

continuously and the catalyst

gun.

is given in shots at regular

Figure 3 illustrates the machine

intervals and in different

opening the resin valve A for a certain

quantities, depending on your

amount of time and then closing it,

mix ratio (Fig. 5).

when catalyst valve B opens to give a

With dynamic dosing you

certain amount or shot of catalyst.

remove all the disadvantages

A key feature of sequential dosing

of the sequential dosing’s

is the use of an integrator, which

integrator. Dynamic dosing

has advantages and disadvantages.

is suitable for a wider range

One advantage is that you can easily

of paints, including

change the size of the integrator:

shear-sensitive paints,

50 cc is often a standard size, but you

primers with high amounts

can choose smaller (10 or 25 cc) or

of solids and/or abrasives,

larger (100 cc) integrators. This means

high gloss wood applications,

that with sequential dosing a large

and polyurethane and Iso

range of mixing ratios is possible. Sequential dosing is easy to control via a regulator, and is particularly suitable for solvent-borne paints

applications. The absence of

2 1

an integrator that needs to be

Figure 2: Sequential dosing.

flushed means it’s a very good method if you have multiple

with a low viscosity that are relatively

colour changes, and consequently you

straightforward to mix.

use less solvent to flush. It also means

The disadvantage of an integrator is that

that it’s much easier to handle material

if you have an application that requires

with different viscosities.

a lot of colour changes, for every new

However, dynamic dosing is not a perfect mixing method. You need to

colour you use you need to flush the integrator, which leads to a lot of waste

Epoxies are common plural component paints that are usually applied at high pressure as base coats to provide a protective layer; they typically contain a lot of fillers. Other common plural component paints are polyurethanes, which are usually applied at low pressure as thin top coats to obtain a good quality finish.”

material and high solvent use. This is particularly so with a 50 or 100 cc integrator; slightly less with a 10 or 25 cc integrator. In general, sequential dosing is fine for up to eight colour changes per day; more than that and it becomes less cost-effective. A further disadvantage of sequential dosing is that it is not suitable for high viscous fluids or shear-sensitive fluids such as water-borne polyurethanes because the integrator creates turbulence which can damage the paint.

carefully control the pressure of the resin and catalyst. In fact, the catalyst has to be at a pressure that is at least 10-15% higher than that of the resin. If the catalyst pressure is lower than this, it will not penetrate the resin. If the catalyst pressure is too high, it will block the flow of resin. This means that you need a resin pressure regulator and a catalyst pressure regulator. And also you need a regulator for the final mixed material. You also need a restrictor, which comes in a number of sizes depending on the mix ratio and the flow.

The most obvious difference with dynamic dosing compared to sequential dosing is the absence of an integrator; the catalyst is injected directly into the stream of resin (Fig. 4).

The dynamic dosing method of mixing

3 1

Figure 3: The mixing sequence of the two components during sequential dosing.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

4 1

Figure 4: Dynamic dosing.

There are many advantages to using plural component paint. Compared to single component paint, plural component paint displays improved durability. It has a higher mechanical strength which allows it to withstand abusive conditions better than other paints. It also has better chemical resistance, so can better withstand exposure to a wide range of abrasive chemicals.”

5 1

Figure 5: The mixing sequence of the two components during dynamic dosing.

SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES

The most obvious difference with dynamic dosing compared to sequential dosing is the absence of an integrator; the catalyst is injected directly into the stream of resin. In other words, the resin flows continuously and the catalyst is given in shots at regular intervals and in different quantities, depending on your mix ratio.”

6 1

Figure 6: Continuous flow.

Graco’s plural component paint mixers Graco offers products that are suitable for all three mixing methods (ref. Opening smooth mixing process that does not

photo). For sequential dosing, Graco offers

With the continuous flow method of mixing

damage the paint. It’s therefore ideal

two products. One is the Graco ProMix® 2KS,

plural component paint, you have a pump

for shear-sensitive fluids. It’s also highly

which offers precise and reliable electronic

and two lowers. Depending on the volume

suitable for high solids/abrasive primers,

proportioning for a broad range of

of your lowers you create a mix ratio that is

and for applications with multiple colour

solvent-borne, water-borne and acid catalyzed

defined by the displacement of the piston

changes as less solvent is required for

materials. From entry level to upgraded

(Fig. 6).

flushing. Another important advantage

applications, the ProMix 2KS provides

With continuous flow, the components

is that it allows you to mix at the gun if

flexibility and increased efficiency – including

– the resin and the catalyst – are mixed

your gun is a specially designed 2K gun.

optimized flushing sequences and an optional

continuously and smoothly. Figure 7

This minimizes waste and flushing and

third purge valve to properly manage

displays the mixing sequence of a 2:1 mix.

optimizes your return on investment.

water-borne urethanes for manual and

As with dynamic dosing, no integrator is

A challenge with continuous flow is that

automatic operation.

necessary. Continuous flow leads to a very

you have to balance the pressures of

The second product for sequential dosing is

your resin and catalyst very carefully,

the Graco ProMix 2KE flow meter system which

depending on your flow rate. You also

provides precise fluid volume measurements

need to size the hosing depending

to enable you to efficiently meet your target

on the hose length. Paint viscosity

mix ratios (Fig. 8). Designed to handle most

differences can also cause problems.

water-borne and solvent-borne materials, a

Volumes also tend to be lower due

neat feature of this product is that you can

to the need to clean the system,

automatically flush the exact amount of solvent

particularly during colour changes.

required, reducing waste and disposal costs.

In sequential dosing, both resin and catalyst go through a flow meter with a metering valve, but never both at the same time. Either the resin valve or the catalyst valve is opened; never both together. This means that catalyst is shot into the resin in a sequential way.”

The continuous flow method of mixing

7 1

Figure 7: The mixing sequence of the two components during continuous flow mixing.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

8 1

Figure 8: The Graco ProMix 2KE flow meter system for sequential dosing provides precise fluid volume measurements to eﬃciently meet the target mix ratios.

For dynamic dosing the same ProMix 2KS is available, but with additional proportioning technology to meet the needs of unique applications. Also for dynamic dosing, the Graco ProMix 2KE Pump-Based System is designed with reliable Merkur® pumps. It’s easy to run and comes ready to spray. For continuous flow, the Graco ProMix M2K is an easy-to-use plural component proportioning system that has all you need in one small package (Fig. 9). This fixed ratio machine keeps your mix ratio consistent while only mixing what you use. Plus it eliminates all of the wasted material and clean-up associated with hand mixing – saving you precious time and money. An exciting new addition to Graco’s plural component proportioning line is the ProMix PD2K which is designed for continuous flow mixing (Fig. 10). It allows you to mix

SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES

close to the gun, greatly reducing

of the main parameters to consider are:

mixed material waste and flush

• The type of material.

solvent waste generated during

• The viscosity of material.

the flush sequence. 100% positive

• Is there a viscosity difference between the

displacement technology allows for

resin and the catalyst?

accurate mix ratios and consistent,

• What is the solid content of the paint?

accurate performance.

• Is the material shear-sensitive?

Which method is best for my specific application?

• Are you using a low viscous fluid? • Do you want a long pot lifetime? • Is ease of control important?

There are many parameters Graco is able to satisfy each specific application

sequential dosing, dynamic dosing

requirements and suggest the most optimal

or continuous flow, and which Graco

mixing method and plural component

plural component mixer to use. Some

proportioner.

that influence whether to use

9 1

Figure 9: For continuous flow, the Graco ProMix M2K is an easy-to-use plural component proportioning system.

Graco offers products that are suitable for all three mixing methods. For sequential dosing, Graco offers two products: the Graco ProMix® 2KS and the Graco ProMix 2KE. For dynamic dosing the same ProMix 2KS is available, but with additional proportioning technology to meet the needs of unique applications. For continuous flow, the Graco ProMix M2K is an easy-to-use plural component proportioning system that has all needed in one small package.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

10 1

Figure 10: The ProMix PD2K is designed for continuous flow mixing.

Â®

ÂŠ Nordson Deutschland GmbH

Opening photo: It is often the coating that contributes to fulfill specific customer requirements of an enclosure. Those requirements arise, for example, from the installation site of an enclosure for photovoltaic or wind turbine systems, in the production halls of automotive suppliers, in the food and beverage industry, or in a data center.

FOCUS ON TECHNOLOGY

Electrical Cabinet Manufacturer Rittal Offers Insight into Their Production Mario Hahn Nordson Deutschland GmbH, Erkrath â&#x20AC;&#x201C; Deutschland

ics.eu@nordson.com

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

leading system suppliers for

Millions of square meters and intelligent standardization

enclosures, power distribution,

“Our goal is to use standardized products

ittal is one of the world‘s

Rittal’s goal is to use standardized products to meet customer-specific requirements faster and on a more timely basis. It is in the process of creating the conditions to achieve this, especially in the coating systems area and it is doing so despite the fact that the total number of square meters of powder coated surface area per year measures in the millions!”

climate control, IT infrastructure

to meet customer-specific requirements

and software & services. This global

faster and on a more timely basis. We are

player based in Herborn, Germany,

in the process of creating the conditions

offers insights into the configuration

to achieve this, especially in the coating

and processes of its state-of-the-art

systems area,” admits Heiko Denner,

powder coating systems.

Project Manager for Surface Finishing

In all markets, in countless industries,

Technology at Rittal, during the meeting

and in nearly every company,

in the company’s own Rittal Innovation

“Industry 4.0” is the next big thing:

Center, “and we’re doing so despite the

but does the investment in new

fact that the total number of square

equipment really pay off? What

meters of powder coated surface area per

conditions have to be met and what

year measures in the millions!”.

changes must be made in order to

In addition to Rittal’s standard Light Gray

manufacture high-quality products

RAL 7035, many other colours approved

that satisfy customer requirements

by Quality Assurance are available as

hygiene requirements in all areas.

cost-effectively today?

serial production to satisfy customer

Here the right housing design can help

Machinery and equipment from

wishes.

save cleaning and disinfectant agents,

Germany are a calling card of local

“For anyone offering such a broad variety

improve cleaning results and reduce the

industry and in high demand the

of colours, an intelligent, extremely flexible

risk of contamination. Other examples

world over. Wherever electronics

booth concept is absolutely vital.” Rittal

include wind turbine and photovoltaic

have to be protected, the chances

relies here on the highest standards of

systems, whose outdoor housings must

are good that the enclosures for the

Nordson ColorMax booth technology,

withstand wind and weather to protect

equipment control system, power

with special booth floor material and

sensitive control technology from extreme

distribution or climate control come

highly automated cleaning cycles that

temperature fluctuations and moisture.

from Rittal. Headquartered in the

enable extremely fast colour changes.

In much the same way, applications in

German state of Hesse, Rittal is a

“ColorMax booths are ideally suited for

IT, transportation technology, and – in

genuine global player employing

all our applications, no matter whether

extreme cases – machinery construction

over 9,300 people and operating 13

we run a single colour in a shift or have to

and process industries also impose

production facilities worldwide.

change colours frequently,” says Denner

special requirements.

(Fig. 1).

Once installed, an enclosure usually

It is often the coating that contributes to

then stays in its place for many years

fulfill specific customer requirements of

– where aggressive environments are

an enclosure. Those requirements arise,

not uncommon. That means a powder

for example, from the installation site of

coating must function reliably – and also

an enclosure for photovoltaic or wind

look good – for a long period and under

turbine systems, in the production halls

adverse conditions. “Our products can

of automotive suppliers, in the food and

achieve that only because we consistently

beverage industry, or in a data center (ref.

apply the highest quality coatings,” says

Opening photo).

Heiko Denner, returning to the subject

Along with the design possibilities of

of surface finishing. What matters to

Rittal enclosures, the company started

him here is not only the quality of the

already from an early stage to develop

finished surface, but also the efficiency

specific solutions for an extremely wide

of the coating process. “To enable us

range of applications. For the food

to deliver uniformly high quality – shift

and beverage industry, for example,

after shift, day in and day out, and totally

which is subject to uncompromising

independent of personnel – we defined

In all markets, in countless industries, and in nearly every company, “Industry 4.0” is the next big thing: but does the investment in new equipment really pay off? What conditions have to be met and what changes must be made in order to manufacture high-quality products that satisfy customer requirements cost-effectively today?”

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

our processes precisely and they are continuously monitored and adjusted.” And nothing is left to chance.

Maximizing process control by means of dense phase technology “We measure and record our powder consumption very precisely, of course – but the same also goes for air and energy consumption, as well. All consumption parameters are then calculated not just for the batch, but rather right down to the individual part – which enables us to achieve an extremely high level of transparency.” The data collected in this way helps us adjust the system efficiently using key parameters. At the same time, however, they also serve as the basis for further process optimization measures: large quantities amplify even the smallest potential savings. “We have already been relying on dense-phase technology for years now,” says the Project Manager. “Today the very consistent operation of the HDLV pumps provides ideal conditions for uniform processes, transporting the powder with extreme care from our 400 kg big bags to the powder feed center and to the guns and then returning the overspray back to the system again – thereby keeping the

quality of the material stable over an

Figure 1: ColorMax3 powder booths are ideally suited for all our applications, no matter whether we run a single colour in a shift or have to change colors frequently.

extended period (Fig. 2).” “Moreover, the low flow velocity and high powder content generate a ‘soft cloud’ that allows the powder gun to work very close to the workpiece. Together with low back

For anyone offering such a broad variety of colours, an intelligent, extremely flexible booth concept is absolutely vital. Rittal relies here on the highest standards of Nordson ColorMax3 booth technology, with special booth floor material and highly automated cleaning cycles that enable extremely fast colour changes. ColorMax3 booths are ideally suited for all applications, no matter whether we run a single colour in a shift or have to change colours frequently.”

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

corona discharge, that significantly increases the application efficiency while also providing the benefits of deep penetration, even with more complicated housing geometries.” The uniformity with which this technology distributes powder across the coated surface is apparent even

FOCUS ON TECHNOLOGY

Rittal has already been relying on dense-phase technology for years now. Today the very consistent operation of the HDLV pumps provides ideal conditions for uniform processes, transporting the powder with extreme care from our 400 kg big bags to the powder feed center and to the guns and then returning the overspray back to the system again – thereby keeping the quality of the material stable over an extended period.”

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.

to the naked eye. “Sometimes in the past we used to see the so-called ‘picture frame’ effect,” recalls Denner. “That was a small border right next to an edge. Today with the low powder consumption, the coating layer distribution is so uniform that this no longer happens, so now we meet Rittal QA standards.”

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

Achieving that level of uniformity takes great care. Even the fresh powder is sieved into the Spectrum® HD powder feed center, for example, because after extended storage or transport time, freshly supplied powder has been observed to form extremely fine clumps on occasion. “That could cause our sensitive processes to malfunction – and sieving eliminates the possibility of this happening.”

The “human factor” still matters! “Anyone who imagines that the highly automated systems of a state-of-the-art powder coating plant reduce production operators to mere extras couldn’t be more wrong,” assures Project Manager

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 system. aacquisition ac qu tem.

Denner, comparing their situation with that of a pilot in a modern cockpit. “Even the slightest anomaly demands a fast reaction – and the right one!” Consistently high-quality, efficient production therefore not only requires machine operators to be extremely vigilant and reliable, but also necessitates continuous advanced training. “It might sound like a contradiction,” explains Denner, “but the simpler a system’s operation looks, the more complex the processes behind it. And our operators must have a clear understanding of those processes in order to be able to take the

WWW.LESTA.IT

right action when necessary.” Experience shows the importance of informing the employees early about changes and bringing them on board right from the start – an approach followed systematically by the Friedhelm Loh Group, to which Rittal belongs. Recognized in 2018 as one of Germany’s Top Employers for the tenth consecutive time, this family-run business places a strong emphasis on continuing education.

LESTA S.r.l.

Via D. Chiesa, 42 - 20020 Dairago (MI) - Italy +39 0331.430817 +39 0331.1581053 0331.158 info@lesta.it

“When we need specialized knowledge

immediately cites yet another benefit of this

concerning coating, we’re glad to

system: “Especially for our situation, the icon-

take advantage of training courses at

based user interface has also proven very

Nordson’s technical center,” reports the

convenient. With an international workforce

Project Manager. “Our employees enjoy

made up of employees from more than 100

training under real conditions like that

countries, language-independent system

because it’s so much better than a dry

operation is clearly the most intelligent solution!”

classroom seminar.”

And when the system guides operators through

Operators also get a fortuitous

even complex procedures like colour changes

motivational boost from a completely

clearly and safely, their enthusiastic feedback

different source, however: from the

comes as no surprise.

coating system’s PowderPilot® HD

Rittal has a 50-year tradition of success, and

touchscreen control. “Many of the

customers have long valued the quality of the

employees today experience a

products. “Our industrial coatings meet their

full-blown enhancement of their job

specifications – on land, in the air and on the

when they use these modern terminals

water. Some of our enclosures are installed on

to perform their monitoring and control

super-yachts,” grins Denner, “that not only look

functions,” knows Heiko Denner, who

great, but also withstand harsh sea air.”

The uniformity with which this technology distributes powder across the coated surface is apparent even to the naked eye. Sometimes in the past Rittal used to see the so-called ‘picture frame’ effect. That was a small border right next to an edge. Today with the low powder consumption, the coating layer distribution is so uniform that this no longer happens, so now Rittal QA standards have been met.”

Figure 2: The very consistent operation of the HDLV® pumps provides ideal conditions for uniform processes.

2 1

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

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SUCCESS STORIES

Turning a Vision into a Reality: Eisenmann Builds First Skidless Paint Shop for Electric Vehicles

n Shaoxing, in China’s eastern Zhejiang province, Eisenmann is

Moreover, a range of other Eisenmann technologies are to

constructing a turnkey paint shop for electric-vehicle startup DEARCC.

be deployed at DEARCC. The Shaoxing facility will feature a

The carmaker employs highly flexible, state-of-the-art manufacturing

pretreatment and electrocoating zone equipped with compact,

technologies – and ordered a skidless paint shop from plant engineering

expert Eisenmann, headquartered in southern Germany. The solution

will supply spray booths and dryers complete with energyefficient E-Cubes for paint

uses VarioLoc conveyors

overspray removal – plus work

to link individual process

decks, and the ventilation

steps. The project will be

and exhaust air purification

completed in record time:

systems.

Eisenmann was tasked in the summer of 2018, and

The brain of the paint shop is

installation has already

the E-MES production control

begun. The first electric

system from Eisenmann

vehicles are expected to roll

Industrial Software Company

off the line from late 2019.

(Enisco). It supports intelligent

Eisenmann’s modular

management in the shape

VarioLoc conveyors are the

of online planning, material

heart of the highly efficient, agile smart paint shop for DEARCC (Fig. 1). Eliminating the need for heavy skids revolutionizes the

flows control and integrated

digital worker guidance –

Figure 1: Eisenmann’s modular VarioLoc conveyors are the heart of the highly eﬃcient, agile smart paint shop for DEARCC.

movement of car bodies.

customer-specific

The individual shuttles (dubbed “Locs”) travel along a rail in the floor (Fig. 2).

surfaces to be painted within a single facility.

Removing skids lays the foundation for far greater

“That is Industry 4.0

flexibility in production – in terms of cycle times,

in action: connected

throughput, capacity and vehicle architectures.

manufacturing,

In the Shaoxing factory, DEARCC will produce a new

where our flexible

E-SUV model named ME7 (Fig. 3). The new car is the

hardware and

first model under the high-end brand Enovate which

intelligent software

was released by DEARCC this November. Enovate

solutions are

ME7 uses a wide-body design while shrinking the

seamlessly linked,”

window section as much as possible to form an

explains Bruno

aerodynamic Gulfstream shoulder, lowering the drag coefficient and making the vehicle visually very dynamic.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

2 1

Figure 2: The individual “Locs” travel along a rail in the floor.

Casorati, Senior Vice President, Automotive

SUCCESS STORIES

Figure 3: The E-SUV ME7 is the first model under the high-end brand Enovate from DEARCC.

Systems at Eisenmann. “Eisenmann’s integrated, end-to-end approach for a highly flexible and efficient, smart paint shop has proved very popular with our customers. We offer them advanced, market-ready technologies that support Industry 4.0 imperatives. These not only deliver exceptional versatility in manufacturing, but also cut costs and save energy.” DEARCC is the second carmaker, after Mercedes-Benz in Kecskemét, Hungary, to take delivery of Eisenmann’s rapidly implemented, one-stop, smart and skidless solution for the paint shop of the

future.

3 1

Figure 4: The Shaoxing facility will feature a pretreatment and electrocoating zone equipped with compact, cost-saving E-Shuttle 200 conveyors.

BRAND-NEW

BENSELER Acquires BETEO

ffective January 1, 2019, the BENSELER

and bent parts as well as turned

“The company has many years of

group acquired LISI Automotive

parts. The customers are leading

know-how in the field of screw locking

BETEO GmbH & Co. KG, Gummersbach.

manufacturers of fasteners in Europe;

and the processes used there are an ideal

The surface specialists, headquartered

a large proportion of the corrosion

complement to what we already offer our

in Markgröningen (Germany), are thus

and safety coatings are intended for

customers as one of the largest contract

expanding their portfolio in the field of zinc

the automotive sector. As of January 1,

coaters.” The new BENSELER subsidiary

flake processes and screw locking systems.

2019, the new BENSELER subsidiary

rounds out the surface specialists’ service

The company LISI Automotive BETEO GmbH

will operate under the name

portfolio with zinc flake coating for

& Co. KG was founded in Gummersbach

Benseler BETEO GmbH & Co. KG.

components with smaller dimensions

(North Rhine-Westphalia) in 1982 and

“We are delighted that BETEO is

and/or complex geometries such as small

belonged to the French LISI Group until

part of the BENSELER group and

internal drive screws.

December 31, 2018. The company produces

represents an important building

“BETEO fits very well into the BENSELER

high-quality thread locking coatings,

block in our growth strategy,” says

group” says Jens-Paul Hänig, Managing

corrosion protection coatings and lubricant

Thomas Müller, Managing Director of

Director of Benseler BETEO GmbH & Co. KG.

coatings for threaded parts, stamped

BENSELER Holding GmbH + Co. KG.

“We agree that only excellent quality as well as an absolute

and flexible delivery capability in conjunction with best service form the basis for a reliable, customer- and future-oriented company.” Müller adds: “Just like BENSELER, BETEO is constantly adapting its production range to the growing demands of the market.” Jens-Paul Hänig will continue to be responsible for the development of the location as Managing Director. For further

information: Figure 1: BETEO has a lot of know-how in the field of screw locking - an ideal complement to the portfolio of BENSELER.

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

www.benseler.de

eosmarketing.it

do you need a CHAIN CONVEYOR?

BRAND NEW HOOK! loading capacity > 1,500 kg, it allows the rotation with an integrated lock system

TRAS-MEC iW XLI Ç»VWX GSQTER] to safeguard your system and contractually guarantee a downtime free production.

www.tras-mec.it

BRAND-NEW

Mobile and Fast Quality Control of Cleaning and Coating Baths

t parts2clean 2018, KRÜSS

at a glance. Moreover, the tendency

required or the bath will have to be

presented a novel solution

of the surfactant content becomes

renewed instead of having to react

for quality control of

immediately obvious thanks to the

quickly when a critical SFT value was

industrial baths that contain cleaning

automatic graphical representation

reached. Using measurements in the

or wetting agents. The new Bubble

of the course over any given time

Continuous mode of the instrument, it is

Pressure Tensiometer – BPT Mobile

period. Thus, predictions can be made

even possible to monitor the change in

is an instrument for determining the

about when further dispensing will be

SFT while dispensing a surfactant.

surfactant content by means the solution. Working independently from

Error-free quality control using reference values

a computer or the power grid and

How the SFT correlates with the

providing results within a few seconds, it

concentration and at which surface age

is particularly suitable for regular quality

dynamic surface tension (SFT) of a

the bubble pressure method works in

checks.

the most sensitive way depends on the

Whether an industrial bath obtains

kind of surfactant used.

the required cleaning or wetting

The BPT Mobile supports the important

effect depends on the concentration

preparation step of defining the analysis

of free surfactant, which decreases

parameters for the subsequent, quick

over time due to contamination of the

quality routine. For this purpose, the

bath or adsorption at the workpiece.

instrument has a mode for measuring

The dynamic SFT reacts particularly sensitively to changes of the surfactant concentration so that bubble pressure measurements with the BPT Mobile quickly and reliably reflect the bath’s quality.

Time-saving measurements and ergonomic use The BPT Mobile is equipped with a colour touch display for especially simple operation and ensures that every desired function is accurately triggered thanks to the comfortable size of 5’’. The display also responds to the touch with lab gloves without any problems. The instrument saves time particularly due to the ad-hoc analysis of the results. Whether the measured value lies within a defined quality range is visible

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

Figure 1: Bubble Pressure Tensiometer – BPT Mobile for quality control of industrial baths containing cleaning or wetting agents.

BRAND-NEW

the dynamic SFT as a function of the

for strongly contaminating samples.

necessary, the instrument can be

surface age over a wide range between

Thanks to intelligent control and

connected to a computer, behaving

10 and 30.000 ms.

precise measurement of the

like a mass storage device, to export

The parameters determined in this way

pressure, the instrument works

measurements to Excel with one click

can also be used for easy-to-create

independently from the immersion

in order to carry out customized data

templates in order to reliably measure

depth to the greatest possible

analyses. The user interface of the BPT

always under the same conditions â&#x20AC;&#x201C; also

extent and thus also accurately

Mobile orients itself towards the familiar

with optimized parameters for different

performs when held in oneâ&#x20AC;&#x2122;s hand.

control logic of smartphones so that

baths independently from each other.

Deviations when used by different

false measurements due to operating

persons are therefore virtually ruled

errors are practically excluded.

Technical solutions for precise, simple, and robust measurements

out. Moreover, the temperature for each data point can be documented

For further information:

thanks to the removable temperature

www.kruss-scientific.com

For creating the air bubbles in

sensor.

the course of bubble pressure

The internal memory of the

measurements, the instrument uses

grid-independent instrument has

disposable capillaries which are

room for more than two million

inexpensive and easily exchangeable.

measurements, which can be tidily

This feature is particularly advantageous

sorted into folders. Whenever

Dynamic contour detection Sophisticated coating solution

- High level automation of the application process - Automated recognition of complex geometries for both the front and rear of the object - Optimized coating quality - Powder savings and reduction in overspray - Drastic reduction of the manual coating operation - Automated programming of U-axes. No time consuming axes adjustments Gema Europe Srl | Via Goldoni, 29 Via Carlo Goldoni 29 | 20090 Trezzano Sul Naviglio (MI) | ITALY | T. +39 02 48 400 486 | F. +39 02 48 400 874

Industry 4.0 Ready

www.gemapowdercoating.com

BRAND-NEW

ACKER is to collaborate with Dynaplak, the

Dutch manufacturer of biobased raw materials for agricultural and industrial applications. Together, the two companies want to develop hybrid binders based on starch and polymers. The first products for interior wall paints are scheduled for market launch in the first quarter of 2019. WACKER is thereby responding to the growing demand for sustainable binders in the paint and coatings industry. “Our partnership with Dynaplak lays the foundations for increasing our

Koos Slor, managing director of

customers outstanding product quality,”

contribution to more sustainability in the

Dynaplak, says: “In our production

explains Nely. The new binders will be

binders market. We will be one of the

process, we utilize starch that would

manufactured at the Dynaplak site in

first chemical companies to expand our

otherwise be lost. Our innovative

Veendam in the Netherlands and are

portfolio with products based partially

technology increases the functionality

part of WACKER’s new VINNECO® line.

on renewable raw materials,” explains

of conventional starch, enhancing

It will present the first products from

Dominique Nely, who manages WACKER’s

its performance.” In an emulsified

this line at the European Coatings Show

binders for consumer goods and

form, starch reveals its properties

2019.

industrial applications in western Europe.

and helps to tie together components

“In the first phase, we will focus on interior

of a paint, such as pigments and

For further information:

paints - where demand for ecological

fillers. “By partnering with WACKER,

www.wacker.com

alternatives to petroleum-based binders

our sustainable products will also be

is growing strongly.”

available to customers from the paints

Dynaplak’s biobased technology together

and coatings industry,” Slor continues.

with WACKER’s decades of experience in

In technical terms, hybrid binders

manufacturing polymer-based binders will

meet the high-quality standards

result in hybrid starch and polymer-based

for WACKER products. “We want to

binders. The starch is a side-stream

act in an ecologically responsible

product from potato processing.

way, while continuing to offer our

100

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

Opening photo: The POLYFLEX® PAC-140-SD powder coating system is specifically designed for outdoor use.

HIGHLIGHT OF THE MONTH

Deep Matt Powder Coatings with no Hazardous Substances Karl Bubenhofer AG, Gossau – Switzerland

102

pulver@kabe-farben.ch

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

eep matt powder coatings are currently

employees and no mandatory training or special

very popular for both outdoor and

safety equipment is needed.

indoor use. Karl Bubenhofer AG has

The POLYFLEX® PAC-140-SD powder coating

developed a special formulation for these

system is specifically designed for outdoor use.

powder coatings using

It is highly resistant

no substances that are

to weathering, has

categorised as hazardous.

excellent colour

The ongoing process of reclassifying chemicals presents paint and powder coating manufacturers with new challenges. In particular in the case of deep matt coatings, it has become difficult to create formulations containing no hazardous substances. Karl Bubenhofer AG began its search for alternatives at

Karl Bubenhofer AG began its search for alternatives at an early stage and can now offer deep matt powder coatings for outdoor and indoor use with no constituents that are classified as hazardous. Users no longer have to take additional measures to protect their employees and no mandatory training or special safety equipment is needed.”

an early stage and can now

stability and is certified to Qualicoat Class 2. These factors are particularly important for architectural applications, because the long-lasting coatings help to maintain the value of the property (ref. Opening photo and Fig. 1). A special “anodised” range

consists of high-quality metallic coatings that

and indoor use with no constituents that are

are bonded and can therefore be processed

classified as hazardous. Users no longer have

reliably (Fig. 2). The POLYFLEX® PAC-135 system

to take additional measures to protect their

includes a selection of brightly coloured coatings

offer deep matt powder coatings for outdoor

Figure 1: The POLYFLEX® PAC-140-SD system is highly resistant to weathering, has excellent colour stability and is certified to Qualicoat Class 2. These factors are particularly important for architectural applications.

The aim of Karl Bubenhofer AG is to provide its users with modern, safe and sustainable solutions through its entire supply chain. They provide a simple, future-proof solution that meets the requirements of a variety of different users and is ideal for a wide range of applications.”

2 1

Figure 2: A special “anodised” range consists of high-quality metallic coatings that are bonded and can therefore be processed reliably.

with a standard level of weather

This makes cleaning easier, in particular for

The coatings have very high

resistance. The key advantages of

indoor applications, which is an additional

resistance to overbaking, with

this system include its consistent

advantage of this system over exterior

no reduction in their gloss

gloss level across components

powder coatings. The curing time is 10

level and no yellowing.

of different thicknesses and the

minutes at an object temperature of 180°C.

They also have good

option of curing it for 15 minutes

mechanical properties.

at an object temperature of only

The aim of Karl Bubenhofer AG

180°C. This combination of factors

is to provide its users with

is unique and keeps the cost of the application process to a minimum. The ideal solution for interior use is the POLYFLEX PES-50 Matt hybrid ®

powder coating system. It produces deep matt, velvety surfaces that feel pleasant to the touch. The coatings have good levelling properties and are available in plain colours and bonded metallic shades. The benefits of this cost-effective coating system include reliable processing and resistance to chemicals.

104

The ideal solution for interior use is the POLYFLEX® PES-50 Matt hybrid powder coating system. It produces deep matt, velvety surfaces that feel pleasant to the touch. The coatings have good levelling properties and are available in plain colours and bonded metallic shades. The benefits of this cost-effective coating system include reliable processing and resistance to chemicals.”

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

modern, safe and sustainable solutions through its entire supply chain. The comprehensive POLYFLEX® PAC-140-SD and PES-50 product ranges consist of smooth flowing, deep matt powder coatings containing no hazardous substances. They provide a simple, future-proof solution that meets the requirements of a variety of different users and is ideal for a wide range of applications.

SUCCESS STORIES

World Market Leader Kässbohrer Automates Production of its PistenBully with Painting Robot from Dürr

the process means greater efficiency in

the harsh environmental influences, two

groomers are now being painted

production and less exposure to paints

primer coats as well as the base coat are

by a Dürr robot. This halves

and solvents for workers.

applied – by an EcoRP L033 painting robot

the duration of the painting process,

Temperatures below freezing, sharp

from Dürr, which coats the metal frames

because application by robot is much

ice crystals, strong UV radiation: when

from the outside and inside (Fig. 1). “The

faster than manual application by a

used on slopes and cross-country skiing

most the robot needs to paint a cab is an

worker. For the internationally leading

trails, the surfaces of the PistenBully

hour. Compared to previous painting by

manufacturer of specialist vehicles

cabs are subjected to the most extreme

hand, this saves us so much time that we

for slope preparation, automating

conditions. To provide protection against

have been able to significantly increase our

ässbohrer PistenBully snow

Figure 1: The Dürr EcoRP L033 robot delivers an automated painting process at Kässbohrer Geländefahrzeug AG.

106

N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine

SUCCESS STORIES

2 1

Figure 2: An automatic turning and tilting frame moves the body into the correct position for painting.

output to 600 cabs per year,” says Uwe

solvent consumption. This is followed by

Thierer, Plant Manager at Kässbohrer

the intermediate drying stage before the

Geländefahrzeug AG’s Laupheim site.

third painting stage, the base coat as colour

Automation of painting increases occupational safety

Apart from the speed, the robot’s

application.

Health protection is another important

uniform and reproducible quality

Dürr’s scope of delivery also includes the

argument in favour of automating the

ensures a high efficiency gain in the

skid conveyor technology with turntable

painting process. When this is done

process. The paint layers are applied

and tilt function (Fig. 2). This ensures

by hand, the workers are exposed

in a combination booth. First, the

reproducible cab adjustment and correct

to paint and solvent fumes. When a

EcoRP L033 applies two primer layers

positioning of the cab for the painting

robot is used, this burden is removed

as a bonding agent and corrosion

process. The robot paints the cab body

from the workers. As part of the

protection wet-in-wet without drying

fully and by applying two primer layers also

automation process, Kässbohrer also

in-between. The colour changing and

looks after the corrosion protection, which

switched to chromate-free paint for the

dosing technology integrated in the

in automotive painting takes place in the

manufacture of the PistenBully.

front robot arm ensures minimal paint

tank. Five pressure pots for main colour,

losses when changing colour as well

hardener, and thinner are provided for the

For further information:

as short rinsing times with minimal

paint supply.

www.durr.com

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

107

Opening photo: The new compact coating line installed by Solintellysys at the premises of Prifer.

FOCUS ON TECHNOLOGY

Prifer and Solintellysys Develop an Innovative Compact Coating Line that Applies both Liquids and Powders Ilaria Paolomelo - Alessia Venturi ipcm®

he long and deep economic

sectors had to cope with the economic

companies choose to be the first to

recession occurred worldwide

crisis and adapt to new market needs; many

install a new technology or to rely on

during the first years of the

companies were forced to renew themselves

a new technological concept, because,

twenty-first century hit in particular the

in terms of both organisation and production.

although aware of the initial technical

Eurozone, and especially some countries

Such transformation calls sometimes

and management difficulties, they

such as Portugal. Several economic

for daring technological choices: some

also know that this will give them an

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FOCUS ON TECHNOLOGY

important competitive advantage

installing new technologies, and

on the market.

creating a new quality department

As John D. Rockefeller said, “The

to conquer new markets and

secret of success is to do the

expand internationally. Now, the

common things uncommonly well.”

Prifer Group exports 80% of its

That is what the Portuguese

production. From next year, it will

Group Prifer seems to have

also produce components for the

done when choosing to install a

automotive sector.

cutting edge plant supplied by

“Surface treatments play a key

the Portuguese plant engineering

role in our company,” says Group

company Solintellysys. Thanks to

CEO João Prior (Fig. 1), “because

the implementation of a robot

they both increase the added

at the centre of the line, this

value offered to our clients

compact line enables to apply both liquid and powder coatings

and enable us to distinguish

Figure 1: Group CEO João Prior (left) and Solintellysys Sales Manager Luís Rodrigues.

on metal workpieces with different sizes, while using one

ourselves on the market. Within our Group, we possess both the technologies and human

pre-treatment tunnel, one curing

resources to perform a wide

oven, and one double-circuit

range of finishes: from coating

one-rail conveyor (ref. Opening

Prifer decided to install a cutting edge plant supplied by the Portuguese plant engineering company Solintellysys. Thanks to the implementation of a robot at the centre of the line, this compact line enables to apply both liquid and powder coatings on metal workpieces with different sizes, while using one pre-treatment tunnel, one curing oven, and one double-circuit one-rail conveyor.”

photo).

The Prifer Group In 1978, Fundifás was established as a family business located in the Aveiro district; it specialised in the supply of die-cast non-ferrous alloys for the

to galvanic and PVD coatings, from polishing and cleaning to vibrofinishing and shot blasting.” The latest technologies installed by Prifer include a new compact coating line supplied by Solintellysys, a Portuguese company specialising in the design, development, and

surface treatment and finishing, and component assembly.

sectors of civil construction,

Over the years, Fundifás has heavily invested in technological innovation, thus becoming a learning organisation focussing on training, human capital development, and production process quality in order to constantly improve its activity and the added value offered to its customers. In 2012, after a deep crisis in the national market, especially in the civil construction sector, Fundifás was acquired by the Prifer Group. The Portuguese company thus began a long process of updating its already existing production plants,

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Figure 2: The loading area of metal components.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

109

installation of surface treatment plants. “Solintellysys and Prifer are tied by a long-standing collaboration. This has led us to develop a hybrid coating line, able to apply both powder and liquid products without any problems of part contamination,” states João Prior. “We have worked together with Solintellysys to come up with a solution perfectly suited to both our production needs and the space available in our factory.”

Plant features “This hybrid system features two conveyor circuits, a blue one (the main conveyor, devoted to the workpieces to be powder coated) and a red one (devoted to parts requiring a liquid painting process),” explains Solintellysys

Sales Manager Luís Rodrigues. “The line is completely

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Figure 3: The pre-treatment tunnel.

Surface treatments play a key role in Prifer because they both increase the added value offered to clients and enable it to distinguish itself on the market. Within the Group, Prifer possesses both the technologies and human resources to perform a wide range of finishes: from coating to galvanic and PVD coatings, from polishing and cleaning to vibrofinishing and shot blasting.”

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Figure 4: The inside of the pre-treatment tunnel.

FOCUS ON TECHNOLOGY

5 1

Figure 5: The robot managing the load bars depending on whether they must be powder or liquid coated.

with demineralised water, a surface

automated and it has a speed of 2 m/min. Its core is a robot that interfaces with the system software package and has the task to move the workpieces from one circuit to another. In order to keep the plant compact, the conveyor path has been designed in such a way that it does not directly enter the pre-treatment tunnel, but rather it runs clockwise around the machine and enters the pre-treatment tunnel on the opposite side to the loading station (Fig. 2 and 3). The pre-treatment cycle uses multi-metal chemicals provided by Chemetall and it consists of two degreasing phases, a rinse with mains water, a rinse

The latest technologies installed by Prifer include a new compact coating line supplied by Solintellysys, a Portuguese company specialising in the design, development, and installation of surface treatment plants. Solintellysys and Prifer are tied by a long-standing collaboration. This has led Prifer to develop a hybrid coating line, able to apply both powder and liquid products without any problems of part contamination.”

conversion phase, and a final rinse with demineralised water (Fig. 4).” “After drying in the oven, the conveyor proceeds towards the robot station (Fig. 5): its task is to transfer the parts assigned to the liquid process by the management system onto the red circuit and leave only the workpieces to be powder coated on the blue chain, working with a continuous flow. The coating areas are equipped, respectively, with a Solintellysys water veil booth (Fig. 6) featuring a Dürr EcoDose paint mixing and dosing system and two manual application stations and with a Wagner

international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55

111

ÂŠ ipcm ÂŽ

6 1

Figure 6: The water veil booth for the application of liquid paints.

The line is completely automated and it has a speed of 2 m/min. Its core is a robot that interfaces with the system software package and has the task to move the workpieces from one circuit to another. In order to keep the plant compact, the conveyor path has been designed in such a way that it does not directly enter the pre-treatment tunnel, but rather it runs clockwise around the machine and enters the pre-treatment tunnel on the opposite side to the loading station.â&#x20AC;?

FOCUS ON TECHNOLOGY

The powder coating booth is contained in a dust free chamber with a controlled suction system, in order to avoid any contamination between the application areas of the two different coating products. The entrance and exit of the curing oven are the only areas in which the two circuits, the red one for liquid coating and the blue one for powder coating, meet.”

powder application booth linked to a last generation SuperCenter powder management unit (Fig. 7 and 8),” says Luís Rodrigues. “The powder coating booth is contained in a dust free chamber with a controlled suction system, in order to avoid any contamination between the application areas of the two different coating products. The entrance and exit of the curing oven are the only areas in which the two circuits, the red one for liquid coating and the blue one for powder coating, meet (Fig. 9). In order to keep the plant compact, we placed the drying oven at the bottom of the line, while the curing oven occupies the upper part,” says

Luís Rodrigues.

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Figure 7: Wagner’s powder booth.

Figure 8: The powder management unit.

8 1

An unexpected solution Prifer produces a very diversified range of parts

The Group needed to install a system complete with both technologies in a very small space, which was not enough for two separate lines. The solution designed by Solintellysys entrusts the sorting of the workpieces to the two coating circuits to a robot and it features all the technical measures needed to avoid contamination among components painted with different technologies.”

for a wide variety of industrial sectors, some of which require a powder finish while others call for one-coat liquid systems. Therefore, the Group needed to install a system complete with both technologies in a very small space, which was not enough for two separate lines. The solution designed by Solintellysys entrusts the sorting of the workpieces to the two coating circuits to a robot and it features all the technical measures needed to avoid contamination among components painted with different technologies. Certainly, it will not be exempt from problems during start-up and industrialisation, but it could be a solution for any company looking for

Figure 9: The exit of the curing oven with the two parallel conveyors.

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Opening photo: BASF unveiled the Color Report 2018 for Automotive OEM Coatings.

HIGHLIGHT OF THE MONTH

BASF Analyses the 2018 Automotive Colour Distribution By BASF’s Coatings Division Münster - Germany

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HIGHLIGHT OF THE MONTH

Eﬀects create new colour variations in Europe

significantly contributes to the unique look

for Automotive OEM Coatings”, BASF’s Coatings

Nearly every fifth car in Europe is painted

were finished with an effect coating. The

division provides a global analysis of

grey (Fig. 2). The colour replaced black

larger the car, the more likely it was painted

the colour distribution in the 2018

as the second most popular colour.

with an effect. Dark colours such as black

automotive market (Fig. 1).

Buyers can choose from more than 110

and grey are mostly formulated to have

The achromatic colours – white,

variations ranging from light grey to dark

a metallic effect, whereby lighter colours

ith the “BASF Color Report

of a car. In 2018, two thirds of all vehicles

black, grey and silver – still dominate

are primarily solid shades. “The

the roads. They cover almost 80%

landscape of automotive coatings

of cars produced worldwide. White

effects evolves continuously and is shaped by new and inspiring

is the most popular colour among them. More than every fourth car in North America and nearly every third vehicle in Europe is painted white, while in Asia Pacific it is more than every second car. Silver’s popularity decreased slightly in comparison to the previous year. Among the diverse range of colour shades, blue is the most popular,

The achromatic colours – white, black, grey and silver – still dominate the roads. They cover almost 80% of cars produced worldwide. White is the most popular colour among them. More than every fourth car in North America and nearly every third vehicle in Europe is painted white, while in Asia Pacific it is more than every second car.”

followed by red. These chromatic

ideas,” said Mark Gutjahr, head of Automotive Color Design Europe at BASF’s Coatings division.

White is most popular in Asia Pacific but chromatic colours gain importance White is more popular in Asia Pacific than in any other region

colours tend to be more popular

(Fig. 3). 53% of all new cars are white. The colour’s popularity grew

such as compact and subcompact

more options. Approximately 140 shades

significantly in comparison to the previous

cars. The overall amount of chromatic

make blue the region’s most diverse

year. Among chromatic colours, red is still

hues drops off significantly in the

colour space. With a share of 11%, it

the most popular choice. Blue, however, is

larger segments. Here, there was a

overtook silver in 2018, becoming the

closing the gap. An interesting observation

considerable increase in black and

fourth most desired colour in Europe.

is that brown remains especially popular

white compared to the previous year.

A metallic or pearlescent effect also

with SUVs but has shown signs of slowing

Figure 1: Global analysis of the colour distribution in the 2018 automotive market.

metallic anthracites. Blue offers even

within the smaller vehicle segments,

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Figure 2: Automotive chromatic colours popularity in 2018 in Europe.

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117

3 1

4 1

Figure 3: Automotive chromatic colours popularity in 2018 in Asia Pacific.

Figure 4: Automotive chromatic colours popularity in 2018 in North America.

down, indicating that its importance in this

Among the achromatic colours, white

segment may have passed.

maintains its leading position. Besides

Trend competence and innovative colour concepts

Car buyers in Asia Pacific are increasingly

the achromatic shades, consumers

BASF’s Coatings division has an excellent

connecting their colour preferences to

continued to demonstrate a growing

understanding of what is trending in materials

their attitudes and lifestyles. For example,

affinity for red, specifically within the

and colours, and uses this to predict which

metallic and sparkling blacks have risen in

pickup and sports car segments. The

colours will play a key role in the future

demand across several body segments.

diverse blue colour space remained

automotive market. Every year, the Coatings

Even in subcompact cars, silvers and

nearly the same compared to the prior

division’s designers create Automotive Color

greys with dazzling effects are becoming

year.

Trends, an innovative collection of 65 new

more common. This can be seen in the

Over the last ten years, Crossover

colours based on extensive research and

Chinese market, where a broader palette

Utility Vehicles (CUV) have emerged as

in-depth analysis of global trends and cultural

of colours has emerged. “The diversity

a dominant vehicle segment in North

shifts that will influence automotive colours

of chromatic colours is evident, with

America. CUVs combine the qualities

three to five years into the future.

red, blue, yellow, brown and gold hues

of Sport Utility Vehicles (SUVs), like

appearing in almost every segment.

safety and driving convenience, with

Colour and Sustainability

Chinese consumers readily display their

other benefits such as fuel efficiency

Integrated into its colour design innovations,

coloristic tastes more so than in the

and therefore offer appealing features

BASF offers a range of sustainable coatings

past”, said Chiharu Matsuhara, head of

to a wide array of drivers. White is the

solutions for the automotive industry. Among

Automotive Color Design Asia Pacific.