ipcm® n. 59 - September/October 2019 by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

INTERNATIONAL PAINT&COATING MAGAZINE

In this issue : SPECIAL ON ALUMINIUM FOR METAL ARCHITECTURE AND INDUSTRIAL DESIGN

ISSN 2280-6083

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10th Year - Bimonthly N° 59 - SEPTEMBER/OCTOBER

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CONTENTS SEPTEMBER/OCTOBER 2019

ART WITHIN SURFACES

Let There be Light!

EOS Mktg&Communication and ipcm turn 10! A celebration of Art, Nature and Industry to mark the anniversary © ipcm ®

ANALYSIS ®

S P ECI AL O N A L U M I N I U M F O R M ETAL ARCH I TECTURE AN D I N D U S T R I A L D E S I G N

S PEC I A L ON A L UMI N I UM FOR M E TA L A R C H I T EC TUR E A N D I N D US TR I A L D ES I G N

FOCUS ON TECHNOLOGY

74 03 16 26 28

Gutmann AG: Two Aluminium Profile Coating Lines to Improve its Time to Market and Expand its Production of Architectural Systems

EDITOR’S LETTER BRAND-NEW

46 48

SUCCESS STORIE

BRAND-NEW

Leaders in Industrial Process Fluids Combine to Form Quaker Houghton

INNOVATIONS: PRESENT&FUTURE

Aliplast: The choice of a Vertical Coating System for Aluminium Profiles in the Pursuit of Maximum Productivity and Quality

67 68 72

FOCUS ON TECHNOLOGY Greater Production Flexibility and Speed: The Conveyor as the Core of Sercolor’s Coating Line

ON THE ROAD TO ipcm n. 59 ®

SPECIAL ON ALUMINIUM FOR METAL ARCHITECTURE AND INDUSTRIAL DESIGN

BRAND-NEW HIGHLIGHT OF THE MONTH GSB General Meeting in Hamburg: Projects for High Quality Coated Aluminium

ANALISYS The Polarisation of the Market

SUSTAINABILITY HIGHLIGHT OF THE MONTH

BRAND-NEW

The Growth of the Direct-to-Metal Products

BRAND-NEW

WAGNER AquaCoat Saves 50% Paint on Couplings

30 34 42

FOCUS ON TECHNOLOGY

INNOVATIONS: PRESENT&FUTURE Tangea Tones: A New World of Colouration for Anodized Aluminium

CONTENTS SEPTEMBER/OCTOBER 2019

S P ECI AL O N A L U M I N I U M F O R M ETAL ARCH I TECTURE AN D I N D U S T R I A L D E S I G N

S PEC I A L ON A L UMI N I UM FOR M E TA L A R C H I T EC TUR E A N D I N D US TR I A L D ES I G N

FOCUS ON TECHNOLOGY

118

Insourcing Coating Processes in the Architectural Aluminium Profile Industry: Pasturi’s History

When Metal Becomes Wood. Characteristics and Evolution Trends of the Powder-on-Powder Technology for Wood-Effect Finishes on Aluminium © Verniciatura Maschietto

110

INNOVATIONS

S P ECI AL O N A L U M I N I U M F O R M ETAL ARCH I TECTURE AN D I N D U S T R I A L D E S I G N

FOCUS ON TECHNOLOGY

122 90

A new Pre-treatment System Helps Guarantee Perfect Paint Adhesion on Stûv’s High Temperature Stoves

FOCUS ON TECHNOLOGY Insourcing the Coating Process and Widening the Colour Range of Aluminium Profiles for Sun Protection Systems: Two Winning Choices for Improved Quality and Customisation of Pratic’s Products

106

FOCUS ON TECHNOLOGY

128

142

A New 4.0-Oriented Powder Coating Booth to Improve Sustainability and Workplace Ergonomics at Verniciatura Maschietto

FOCUS ON TECHNOLOGY

136

SUCCESS STORIE BMW Have Created the World’s First Vantablack Car

HIGHLIGHT OF THE MONTH Technology and Creativity in Colour Fan Decks and Files for the Aluminium and Powder Coating Markets

150

Aluminios Andalucía: Culture of Coating Quality in the Field of Powder Pre-Painted Metal

138

FOCUS ON TECHNOLOGY How to Make Paint Stripping More Sustainable, Safe, and Efficient: MEC Srl’s New Pyrolytic Oven

STANDARD & LEGISLATION Finishing Goes Beyond Surfaces (With a Conference)

152 154

TRADE FAIRS & CONFERENCES ZOOM ON EVENTS

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EDITOR’S LETTER

“There are no failures, only results.” Eric Thyrell, inspirational speaker Richiedi la versione in italiano a info@ipcm.it

wedish inspirational speaker Eric Thyrell started his speech on “The Future of Sales”, which we attended during an event organised by HangOn on September 19th1, with this sentence. Regaining motivation, igniting enthusiasm, rediscovering one’s own success vision, and understanding that it is possible to get good sales results even in difficult years by simply getting used to thinking outside the box were the key concepts of his lecture. By our nature, most of us are inclined to focus on negative rather than positive aspects, on what we lack rather than what we possess, and on what we cannot change. This attitude leads us to feed our brains with negative thoughts and enter a vicious circle in which such focus on negativity continues to overwhelm the optimistic part of our beings. This is true not only for our private spheres but also, and above all, for our professional lives, especially for entrepreneurs. The success of our companies and their capability to overcome difficulties depend on our ability to think outside the box, to get out of our comfort zones to explore new territories, to realise what is not working and try something different, even if far apart from what has been done up to that point. The seed of growth takes root in discomfort. In the contemporary development scenario, dominated by digitisation and its related aspects (automation, robotics, plant modularity, and so on) also in the surface finishing industry, companies should invest in four concepts to create an added value: - Service: it is more important than ever to exceed expectations in terms of service offered, in order to guarantee economic return; - Customer loyalisation; - Ethics, with both employees and customers, in order to create a professional and commercial environment that is satisfactory for both parties; - Sustainability. You will not be surprised to find all four concepts developed in the articles contained in this ipcm® issue, which also includes a special report on surface treatment technologies for metal architecture and design. Here, they go hand in hand with a high innovation rate, a common thread among the leading companies described in the numerous success stories we present.

In order to conclude this piece with which I accompany you in the reading of ipcm® every month, I would like to share with you another thought inspired by Eric Thyrell’s speech, concerning more our psychological sphere than the social one. Very often do we tend to attribute the causes of failure to ourselves, rather than to our actions. Actually, what we have done, and not what we are, has failed. Let us keep that in mind. Alessia Venturi Editor-in-chief Direttore Responsabile

A report will be available in the November issue of ipcm®.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

ART WITHIN SURFACES

EOS Mktg&Communication and ipcm® turn 10! A celebration of Art, Nature and Industry to mark the anniversary

24 July 2009 - 24 July 2019: 10 years in the multifaceted world of finishing

In this venue, we welcomed our 150 guests:

It symbolizes its history, what has been

To celebrate EOS’ 10 years anniversary

whom nothing we have achieved so far would

accomplished up to that moment, and

we chose a location that fully represents

have been possible (Fig. 1).

collaborates in tracing the path that leads to

this combination: the Rossini Art Site in

The guests were able to experience first-hand

those horizons yet to be explored.

Briosco (Monza and Brianza, Italy).

the link between industry, art and nature.

What we have observed in these first 10

This is a lush 10-hectare park set on the

First, with the guided tours (Figs. 2 and 3)

years of EOS, the publishing house of the

green hills of the Brianza area (North

that made them discover the beauty and

ipcm® magazines, is that lasting bond that

of Milan). It houses one of the most

the meaning behind the artworks that

unites the surface industry with art - just

important open-air art collections

entrepreneur and patron Alberto Rossini has

think about the colourful liveries of airplanes

of the late twentieth century, created

chosen for his park, with the aim of creating a

and cars, to the research hidden behind

by Alberto Rossini, an entrepreneur

unique, suggestive space, without any barrier.

those colours that are often loaned to

in our sector who was also a

Then, during the evening (Figs. 4 and 5), with

artists and architects or to the collaboration

patron for some sculptors

the charity auction of artworks donated or

with museums and art galleries to highlight

(ref. Opening photo).

created specifically for the event. Six artists

he anniversary of a company represents the encounter between past, present and future.

partners and suppliers who supported us, believed in us and in our work and without

have in fact experimented

with the natural world, which not only hosts

priceless artworks - and

with different techniques and materials - from

us but which has also

porcelain to metal, from

shaped, especially in

the Raku style to the use

recent years, the way

of painting robots or

we relate to it, helping

photographic lenses - to

promoting more and

create works of art that

more policies, solutions

analyse the art within

and products that respect

surfaces:

the environment.

• A table sculpture by the

That is why we wanted

international famous

to hold a special event

artist Giovanni Lamberti (AKA LeRond) (Fig. A)

to celebrate our first

• A brooch by the jewel

ten years of activity, an

creator Francesca Torri

event a little out of the ordinary, a party that paid homage to nature, art, and our surface treatment industry.

(Fig. B)

• A plate by the ceramist

Figure 1: EOS welcomed 150 guests, partners and suppliers that were able to experience first-hand the link between industry, art and nature.

Paola Gallinatto (Fig. C) • A couple of paintings

Opening photo: A view of Rossini Art Site in Briosco (Monza and Brianza, Italy), a lush 10-hectare park that houses one of the most important open-air art collections of the late twentieth century.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

ART WITHIN SURFACES made with anthropomorphic robots by Varnish Robot Art (Fig. D) • A picture by Lucrezia Roda, specialised in industrial photography (Fig. E) • A torso realized with the oriental Raku technique by the entrepreneur and ceramist Francesco Enrico Sioli (Fig. F). The proceeds of the charity auction were donated to the Municipality of the city of Monza for the restoration and the preservation of the symbolic Monumento ai Caduti, which since 1932 commemorates the 667 people who sacrificed their lives during the two World Wars. The speech by Simone Villa, deputy mayor of Monza, officially opened the auction, emphasizing the importance of private participation in the recovery and

2 1

preservation of the fundamental Italian artistic heritage.

Figure 2: EOS organised guided tours to discover the beauty and the meaning behind the artworks that entrepreneur and patron Alberto Rossini has chosen for his park.

Beside the bond between art and industry, the concept of the event wanted to highlight the importance of nature and sustainability.

As a matter of fact, plastics was completely banned during the entire evening and vegetal cadeaux were gifted to the guests: customized eco-cube containing Sunflower, Aloe and Forget-Me-Not seeds (Fig. G).

“Three friends walked into a bar. Yes, EOS was born just like that, in front of a happy hour among three colleagues and friends who had an ambitious idea: founding a new, internationally-oriented, fresh magazine with attractive graphics and the ability to offer objective information not only to professionals, but also to all those interested in discovering the development of the incredible industrial sector of surface treatments.

”

3 1

Figure 3: Guests visiting the park.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Alessia Venturi

It is just the beginning For over ten years, EOS Mktg&Communication, run by the three partners - Alessia Venturi, Paola Giraldo and Francesco Stucchi (Fig. 6) - has accompanied surface treatment companies along the path of globalization, providing communication and promotion strategies, marketing consultancy, content creation and problem solving. The ipcm® magazines represent one of the most important European publishing realities, known globally, in the field of finishing and surface treatments. The Academy division organises seminars and technical courses to train specialists in surface finishing, corrosion prevention, and quality

4 1

Figure 4: EOS Mktg & Communication’s team.

control. The Events division conceives and organises technical conferences, workshops and meetings

Air Pollution Control Experts Dürr is a leading global supplier of environmental control technologies. Our air pollution abatement solutions reduce emissions and improve efficiency for a variety of industrial processes.

www.durr.com

ART WITHIN SURFACES

5 1

Figure 5: The tasting experience: a journey through Italian flavours accompanied by live music.

“Three friends walked into a bar. Yes, EOS

“Balance is just one of the ingredients

was born just like that, in front of a happy hour among three colleagues and friends who had an ambitious idea: founding a new, internationally-oriented, fresh magazine with attractive graphics and the ability to offer objective information to professionals working in the incredible industrial sector of surface treatments” told Alessia Venturi, Editor in Chief of ipcm

during her keynote speech. “It might have seemed a suicide idea. It was 2009, when the economic crisis was hitting harder, the importance of the printed word was being questioned in favour of digital media, and the budgets for communication and marketing were becoming increasingly tight. Some (few, to tell the truth) would not have bet on us. However, we found many people and, then, many companies ready

that ten years ago made the creation of EOS possible and that are still with us today: commitment, perseverance, respect and mutual trust in taking on – each of us – a specific task. Passion and emotions never lacked, even when it comes to small, everyday successes. Successes that would not be possible without our collaborators, of whom I am honoured to be responsible for. With this evening we wanted to convey to you all the values that are an integral part of our company and above all of us, as people. We hope to have succeeded in this.

to invest with us. Now, we celebrate our first ten years” went on Francesco Stucchi, Sales Director of ipcm®.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

”

Paola Giraldo

“Ten years may seem few for those who run companies with a thirty, forty, or fiftyyear history, but for us they mean so much, because our success and survival were not to be taken for granted. Because it took us dedication, passion, ambition, and many efforts. Because we have created products and a team of which we are proud. Harmony was the key to making our ideas come true. Harmony of intents, feelings, and opinions. Harmony of values, even in disagreements. Harmony as the perfect combination to which all elements tend” ended up Paola Giraldo, Chief Financial Officer of EOS. When the auction ended, guests were able to preview the corporate video created especially for the occasion. It took months of work and a close collaboration with our partners who, once again, assisted us in making this video-testimony of who we are, of the passion and values that every day for ten years have been pushing us towards our goals.

“My business partners call me “the old partner” and this does not annoy me at all. Yes, because I have been in this world for thirty years. Some of you (and not a few) knows me since the end of the Eighties, when I introduced myself offering my cooperation without knowing anything about the paint & coating industry. Today you are here because you have never stopped believing in my work, my partners and our team.

”

Francesco Stucchi The video - dubbed in Italian, English, Spanish, Portuguese and German - will be available for everyone to watch from end of September, together with the launch of MyIpcm YouTube channel. A channel that, in line with our philosophy oriented towards the free use of contents, aims not only at projecting the world of ipcm® into a multimedia dimension, but also at collecting videos of surface treatment applications made during our on-site reports and videos of the innovations developed by our customers. What we do through the ipcm magazines, our events, and EOS’ services is precisely telling the thousands facets of this industry.

Because communication is the most beautiful of journeys. And we are ready to journey through the world for the next ten years.

For you and with you.

6 1

Figure 6: From left to right, Paola Giraldo, Francesco Stucchi and Alessia Venturi, founder partners of EOS Mktg & Communication.

A 1

ART WITHIN SURFACES

B 1

Figure B: The brooch by the jewel creator Francesca Torri.

Figure C: The plate by the ceramist Paola Gallinatto.

D 1

Figure A: The table sculpture by the international famous artist Giovanni Lamberti (AKA LeRond).

C 1

E 1

Figure E: The picture by Lucrezia Roda, specialised in industrial photography.

Figure F: The torso realized with the oriental Raku technique by the entrepreneur and ceramist Francesco Enrico Sioli.

Figure D: One of the two paintings made with anthropomorphic robots by Varnish Robot Art.

F 1

Figure G: Plastics was completely banned during the entire evening and vegetal cadeaux were gifted to the guests: customized eco-cube containing Sunflower, Aloe and Forget-Me-Not seeds.

G 1

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

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ART WITHIN SURFACES

impressions from the party

BRAND-NEW

Regeneration for Rolling Mill Lubricants

old forming processes utilize large

Net oils and isoparaffins are mainly

With the development of new

amount of net oils and isoparaffins

used in the rolling (of aluminium,

ultrafiltration lipophilic membranes

necessary mainly to cool down

yellow metal alloys and stainless steel

it is today possible to remove the

the tools, prevent the oxidation of the

Sendzimir) in the cold heading and in

listed pollutants keeping the oil

equipment and the material, reduce the

cleaning operations.

constantly clean and efficient.

friction and keep clean the processed

During the processes, even with

In particular the regeneration unit

surfaces.

the use of standard filtration and

model DIANA is applied in “dialysis”

During the use, the fluids get contaminated

purification technologies, the pollutants

mode to the rolling oil storage tank.

and a partial or total renewal of them have

increase in the time requiring a

According to the treatment capacity

to be considered.

periodical renewal of the entire volume

of the unit the pollutant is kept

With the development of new membranes,

of the products.

to a standard value that must be

the ultrafiltration technology can answer

The pollutants that mainly affect a good

a compromise between the cost

to the increasing demand in line with the

result in terms of quality of the surfaces

of the unit and the result of the

so-called “Circular Economy”.

and performances of the machine are

operation.

In particular with the use of membrane

the followings:

Obviously, the use of a regeneration

separation systems it is today possible to

- Total residue (>0,1 μ)

unit eliminates the need for the

minimize the waste production through

- Particles contamination (according to,

periodical renewal of the oil.

the regeneration of the fluid itself or,

for example, NAS 1638 table) For further information:

material.

- Metal complex (ICP).

www.condoroil.com

- Water content (KF-DIN 5177-1)

at least, the recovery of secondary raw

DIANA C 12 is the device by Condoroil for the regeneration of 1.000.000 litre/year of oil.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

BRAND-NEW

13,000th Dürr Robot Set for GM in Korea

he 13,000th robot manufactured by

The solvents are removed from the exhaust

cooperation between the headquarters

Dürr will be taking up residence in a

air using an Ecopure® RTO regenerative

in Germany and the Korean subsidiary in

new paint shop for General Motors in

thermal exhaust air purification system

Seoul. Having contact partners directly on

Changwon in Korea. This is the first installation

together with the Ecopure® CRC VOC

site means that Dürr can provide efficient

of the new Dürr robot generation for GM.

concentrator from Dürr.

and highly qualified service locally.

The robot equipment is part of Dürr’s biggest

In the existing factory in Changwon, Dürr

“We’re proud that GM chose us for this

order to date in Korea.

designed the plant to be over three levels

important project. This shows the high

The 13,000th robot manufactured by Dürr

with two painting lines for a total volume

customer benefit of the new features of

is an EcoRP E043i, and will be used to paint

of 60 vehicles per hour. GM thought one

the third-generation robots: top quality

the interior of passenger cars at GM in

step ahead when designing the plant

and availability with optimized costs,”

Changwon. The celebration of this specific

by providing space for a later two-tone

explains Dr. Lars Friedrich, member of the

robot is special to Dürr for many reasons: it

painting line.

Board of Management of Dürr Systems

is the first time Dürr’s new generation three

The construction of the plant also

AG and responsible for the Application

robots will be used at GM. GM relies on fully

represents Dürr’s biggest order in Korea.

Technology Division.

automated painting with the latest application

A decisive factor for GM was the

technology. The equipment for the new

geographical proximity. Dürr is

For further information:

paint shop, which Dürr was commissioned to

implementing the project in close

www.durr.com

build, includes a total of 78 third-generation robots. The total order is also the biggest © Dürr Systems AG

order Dürr has received to date as a general contractor in Korea. GM will put the planned plant into operation in 2021, and paint the new Chevrolet Spark as well as compact SUVs there using the 3-wet method. The EcoRP E043i and 033i painting robots will handle painting the interior and exterior of the vehicle’s car bodies in Changwon. Seven-axis robots with the latest EcoBell3 atomizer technology will paint the interiors of the vehicle bodies with extremely high precision and flexibility. Their enhanced mobility mean they can reach even difficult-to-access places effortlessly. The exteriors will be painted using six-axis robots. Dürr’s application technology, such as the EcoBell Cleaner D2 atomizer cleaner, stands for state-of-the-art processes with low VOC emissions. The interplay of the dosing pump, colour changer, atomizer, and atomizer cleaner ensures fast and efficient colour changes within just 15 seconds, thereby reducing paint loss and flushing agent consumption when changing colour.

Six-axis robot EcoRP L033i by Dürr in manufacturing.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

Adobe Stock © Carlo Toﬀolo

Opening photo: Colour perception is dependent on personal experience as well as illumination and surrounding observing conditions. As the ambient conditions are highly variable and not consistent at all, it is required to standardize common lighting situations.

ANALYSIS

Let There be Light! Tinka Zavcer BYK-Gardner GmbH – Geretsried, Germany

tinka.zavcer@altana.com

1. Colour harmony under various lighting conditions

The CIE defined several standard D illuminants

surrounding observing conditions. As the

with D65 being the most important one. The

ambient conditions are highly variable

Uniform colour is directly associated with high

lamps used in a light booth must simulate D65

and not consistent at all, it is required to

quality and influences our purchasing decision.

as close as possible. Until now, fluorescent

standardize common lighting situations

This is especially true for multi-component

tubes were used to simulate D65. A new unique

(ref. Opening photo). The illumination

products consisting of different materials

lighting setup is now able to achieve class A

should be easily switchable in order to

and or being produced by different suppliers.

quality by simulating CIE D65 with a smart

observe and avoid so-called “Metamerism”,

The human eye is often the final judge for

combination of filtered halogen lamps and LEDs.

i.e. differences in colour matching when

approving a new design. Therefore, the visual

lighting conditions change. In order to

to guarantee repeatable visual results. The

2. Standardization of visual colour evaluations

most important colour match is under natural

Colour perception is dependent on personal

testing procedures defining the following

daylight.

experience as well as illumination and

components: [1][2][6][7][10][12][13]

inspection conditions need to be standardized

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

guarantee reliable testing and evaluation conditions, international standards specify

ANALYSIS

2.1 Observer

used to let the observer’s eyes rest, are of high

The observer must have normal colour vision

importance for colour appraisals. The interior of

and should be properly trained in evaluating

the light booth should have a matte grey surface,

colours. To avoid eye fatigue the colour

and the appraiser should wear neutral coloured

3.1 Colour Temperature (CT) and

decision should be made within seconds.

clothing to avoid disturbing chromatic reflections.

Correlated Colour Temperature (CCT)

Additionally, small breaks must be taken

(CRI Ra) as well as spectral power distribution

(SPD) and metamerism index MIVIS.

The concept of colour temperature is based

between evaluations. As people describe colour

2.4 Illumination

on the fact that the colour of an object

differently, the following order should be used

The level of illumination at the colour-matching

changes when being heated because the

for communication and documentation of

position shall be between 1000 lx and 5000 lx,

emitted radiation changes. According to ISO/

colour: Hue -> Chroma -> Lightness.

depending on the respective international

CIE 10526:1991 (E) a colour temperature Tc

standard. A diffuser panel shall normally be used

is defined as “The temperature of a Planckian

2.2 Object

to avoid direct reflection and ensure a uniform

radiator whose radiation has the same

The specimens should be flat and uniform in

distribution of lighting over the entire inspection

chromaticity as that of a given stimulus.”

colour, gloss and surface texture. Standard

field.

and sample shall be placed next to each

Simply explained, the colour temperature

other without any distance in between and

3. Terms for characterization of light

be reversed from time to time. The preferred

Light is electromagnetic radiation within

characteristics of visible light based on the

sample size is approximately 10 cm to 15 cm.

a certain portion of the electromagnetic

temperature of a Planckian black-body. Figure 1

The viewing distance between eyes and the

spectrum.

shows the CIE x,y chromaticity space. The black

specimen should be 50 cm. This distance

The word light usually refers to radiation that is

line in the graph pictures the chromaticity

corresponds a 10° field of vision.

visible to the human eye (wavelength: 400nm to

values of black-body light sources of various

700nm). In order to characterize light emitted

temperatures.[8] [11][12][13]

2.3 Surrounding

by a light source several terms are used:

Colour temperature is usually expressed in

The visual field immediately next surrounding

colour temperature (CT) and correlated colour

Kelvins (K). The Kelvin scale is a measure for

the specimen as well as the ambient visual field,

temperature (CCT), colour rendering index

absolute temperature (0°C = -273K).

is a temperature describing the colour

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

The curve shows the radiant flux emitted by the light source at various wavelengths across the visible spectrum (amount of energy [E(λ)]). Mathematically the spectral power is written as:

lighting products. By proper definition, it should be called Ra – the General Colour

Rendering Index, or Ri – the Special Colour Rendering Index, corresponding to the

number of test-colour samples that are evaluated. The CRI is calculated by comparing the colour rendering of the test source to that of a defined source. For test sources with a CCT Formula 1: Calculation of relative spectral

under 5000K a black body radiator is used as

power

the defined source. For test sources above 5000K daylight (D illuminants) are used. The

Where: E (λ) is the spectral power/energy,

Figure 1: Planckian locus in the CIE x,y chromaticity space.

Φ is the radiant flux, A is the area over which the radiant flux is integrated and λ is the wavelength.

detailed calculation of Ri and Ra is explained

in the technical report of CIE 13.3-1995. [4]

The test method is using a set of eight (Ra) or

fourteen (Ri) CIE-1974 test-colour samples

from an early edition of the Munsell Atlas. The first eight samples are moderate in saturation, cover the hue circle and are approximately

Colour temperatures over 5000K are defined as cool colours, with hues of bluish

Quite often, the relative spectral power is

the same in brightness. The other six samples

white, where lower colour temperatures

indicated by the ratio of the spectral power at a

provide supplementary information about

(2700K – 3000K) are defined as warm

given wavelength [E(λ)] to the spectral power of

the colour rendering properties of the light

colours, with hues of yellow and red.

a reference wavelength [E λ0].

source.

Most natural light sources (e.g. sun, stars) very closely follow the Planckian locus.

3.4 Metamerism Index – MI

When sources are to be described, which

CIE publication 51.2 describes a method to rate

do not emit light exactly matching the

the quality of daylight sources. For the visible

black-body radiator, the term Correlated

range the method uses five theoretical sample

Colour Temperature is used. According

Formula 2: Calculation of relative spectral

to ISO/CIE 10526: 1991 (E) a correlated

power.

colour temperature, Tcp is defined as “The

pairs, where each pair consists of the standard and metameric sample with a MIVIS = 0

for standard illuminant D65. The higher the

temperature of the Planckian radiator

Therefore, the SPD curve is normalized (see

whose perceived colour most closely

Formula 3) at the wavelength of 560nm so that

resembles that of a given stimulus at the

the assessment is independent of the absolute

source, the worse is the quality of the light

same brightness and under specified

level of illumination.

source. [5][13][12]

viewing conditions.” [1][2][8][13][12]

mismatch between the MIVIS of standard

illuminant and MIVIS of the daylight-simulating

Pursuant to MIVIS for the visible range, the CIE

also defined MIUV for the fluorescent range, with

3.2 Spectral Power Distribution

three theoretical metameric sample pairs.

Colour and colour temperature are not

The formulas for MIVIS and MIUV are as followed:

unique parameters to describe a light source. Two light sources with the same

Formula 3: Mathematical normalization of

chromaticity coordinates xy and colour

a spectral power distribution curve.

temperature might have a different

Formula 4: Calculation of the metamerism

spectral characteristic and therefore, create

3.3 Colour Rendering Index – CRI

different colour impressions. Thus, the

The colour rendering index is a quantitative

most accurate way of characterizing a light

measure of a light source and its ability to

source or an illuminant is by their spectral

reveal colours of objects in comparison with

power distribution curve (short: SPD curve).

an ideal or natural light source. The term

[1][2][8][6][10][12][13]

CRI is often used on commercially available

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

indices MIVIS and MIUV. Where ΔEi and ΔEj are the L*a*b* (L*u*v*)

colour differences between the ith and jth pair of

metamers. The classification of MIVIS and MIUV is done according to the table 1.

ANALYSIS

Table 1: Categorization of MIVIS and MIUV depending on colour difference formula

A simple and proper explanation comes from “Billmeyer and Saltzmann”, where a light source is explained as “Physically

Category A B C D E

CIELAB

CIEUV

realizable light, whose spectral power

< 0,25

< 0,32

distribution can be experimentally

0,25 to 0,5

0,32 to 0,65

determined”. An illuminant is defined

0,5 to 1,0

0,65 to 1,3

1,0 to 2,0

1,3 to 2,6

> 2,0

> 2,6

as a “Light defined by a relative spectral power distribution that may or may not be physically realizable as a source.” 4.2 Standard illuminants

As there are no actual D65 light sources available,

The CIE (Commission Internationale de l’Éclairage)

the challenge is to develop a D65 simulator as close

defined a number of SPD curves to provide

as possible to the CIE D65 illuminant. The quality

reference spectra for colourimetric applications,

of a simulator is objectively assessed with the CIE

the so-called CIE standard illuminants.

Metamerism Index MIVIS, corresponding to quality classes

A to E with class A being the most accurate simulation.

4. Quality measures for simulating CIE illuminants by artificial light sources 4.1 Definition light source and illuminant When speaking about light sources and illuminants it is important to know what the

difference between these two terms is.

The CIE defined a number of SPD curves to provide reference spectra for colourimetric applications, the so-called CIE standard illuminants.”

2 1

Figure 2: CIE standard illuminant A and its simulation with tungsten halogen lamps in byko-spectra pro.

3 1

Figure 3: CIE illuminants F2 and F11 and their simulation with fluorescent tubes in byko-spectra pro.

4.2.1 CIE standard illuminant A

Table 2: Classification of standard illuminant F series [16],[17]

Standard illuminant A was introduced by the CIE in 1931 and represents an

Classified Groups

Lamp types

Colour Temperature Tc

CRI Ra

Standard group

F1 – F6

2500 – 7000 K

60 - 80

To simulate standard illuminant A in a light

Broad band group

F7 – F9

2500 – 7000 K

≈ 80

booth conventional light bulbs or nowadays

Three narrow band group

F10 – F12

2500 – 7000 K

80 - 95

incandescent tungsten filament lamp. Its relative SPD is that of a Planckian radiator at an approximate temperature of 2856K.

quartz tungsten halogen lamps (CT≈3000K) are used (Fig. 2).

Among these twelve, F2 and F11 are

4.2.3 CIE standard illuminant D65

most commonly used in the industry.

In 1964 CIE defined a series of daylight

4.2.2 CIE standard illuminant series F

F2, also named “CWF” (cool white

illuminants by numerous measurements

CIE defined 12 fluorescent lamp types,

fluorescent) has a CT of about 4000K

of real daylight (Table 3). Out of 622

named F1 to F12, classified into three

and a CRI Ra ≈ 60. F11, also known

measurements, the theoretical SPD

under TL84, has a CT of about 4000K

curves of daylight from 330nm until

groups. They differ in the bandwidth and wavelength peak of their emission spikes.

and a CRI Ra > 85. To simulate standard

700nm were constructed. CIE standard

Consequently, different colour rendering

illuminant F series in a light booth,

illuminant D65 is the most important

indices and colour temperatures are

commercially available fluorescent

representation of an average daylight at

achieved (Table 2).

tubes are used (Fig. 3). [11] [16] [17]

6504K corresponding to a midday light

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

ANALYSIS

Under theses condition our sample pair will show only a small

Depending on a product‘s usage, colour needs to match under a variety of illuminations. To be prepared for metamerism the light booth byko-spectra pro offers two daylights illuminants with class A performance, incandescent lighting, three fluorescent illuminants and a UV light for evaluation of fluorescent samples.”

difference like under natural daylight.

5. Best in Class Daylight with byko-spectra pro BYK-Gardner’s new light booth byko-spectra pro masters the challenge of bringing true daylight into the lab by a smart combination of filtered halogen lamps and LED array. This combination guarantees best in class daylight simulation – tested according to CIE. Additionally, the built-in sensors in the light booth permanently control the lamp performance and automatically adjust the voltage to guarantee lamp stability. In order to control the lamp condition and trigger lamp replacement actual colour temperature, light intensity and lamp operation time are shown on

in Western/Northern Europe, comprising both direct

the display of the light booth. To reduce maintenance

sunlight and the light diffused by a clear sky including UV

interval, the class A daylight lifetime is extended to

component.

600 hours. Depending on a product‘s usage, colour needs

Table 3: CIE standard illuminants D series, listed with CT and

to match under a variety of illuminations. To be

common name

prepared for metamerism the light booth byko-spectra pro offers two daylights illuminants with class A

Illuminant

performance (D65 and D75), incandescent lighting (A),

Colour Temperature [K]

Common name

D50

5003

Warm daylight at sunrise or sunset

D55

5504

Mid-morning or mid-afternoon daylight

D65

6504

Noon daylight

with a matte light grey colour to eliminate influence of

D75

7500

Overcast daylight

the sorrounding on the observer.

three fluorescent illuminants (CWF, TL84, U30) and a UV light for evaluation of fluorescent samples. As diffused light is essential in the evaluation of solid colours, diffuser panels mix the light to ensure uniform lighting over the entire inspection field. To comply with international standards, the interior walls are painted

Technical performance is not the only key criteria for a light booth. Efficient and comfortable operation also

In order to simulate daylight, different types of light sources are

play an important rule for the user. The large colour

used in commercially available light booths/luminaires for visual

display not only allows the switching of illuminants,

appraisals. Depending on how good the match between artificial

but also enables an easy menu guided operation.

light source and standard illuminant CIE D65 is, a sample pair

The included remote control allows switching

can look very different. In the following example, a sample pair

illuminants from a distance of up to 10 m. An Auto

is evaluated in light booth 1 with fluorescent tubes with a CT of

Sequence Mode progresses automatically through the

about 6500K and a CRI Ra of about 96.

user-defined sequence of illuminants for hands free

The daylight simulation is an approximation of the CIE defined

operation.

D65 with CIE MIVIS (see Chapter 3.4) Class B quality level (Fig. 4).

byko-spectra pro is available as a regular light booth

The difference between this sample pair is very significant under

and as luminaires (Fig. 6). The luminaires can be hung

these evaluation conditions.

from the ceiling as a set or as multiple units to outfit

Next, the sample pair is evaluated in light booth 2, byko-spectra

an entire colour harmony room to evaluate system

pro, using halogen lamps with a specially developed blue filter

components or complete products, e.g. car bodies.

glass combined with an LED array. This combination creates

Luminaires also have the same class A illumination

an excellent simulation of CIE D65 without any spikes (see

specifications as the light booth, ensuring the needed

blue curve in Figure 5) resulting in a CIE MIVIS quality class A.

precision in visual colour appraisals.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

Standards [1] DIN EN ISO 3668:2001-12: Paints and varnishes – Visual comparison of the colour of paints [2] ASTM D 1729: 1982: Standard Practice for Visual Appraisal of Colours and Colour Differences of Diffusely-Illuminated Opaque Materials 4 1

[3] ISO/CIE 10526:1991: CIE Standard

Figure 4: Daylight simulation with fluorescent tube.

Colourimetric Illuminants [4] CIE 13.3 – 1995: Method of Measuring and Specifying Colour Rendering Properties of Light

sources [5] CIE 51.2 – 1999: A Method for Assessing The Quality of Daylight Simulators for Colourimetry [6] CIE 15:2004, 3rd edition: Colourimetry [7] CIE DS 014-1.2/E:2004: Colourimetry – Part 1: CIE Standard Colourimetric Observers [8] CIE DS 014-2.2/E:2004: Colourimetry – Part 2: CIE Standard Illuminants [9] CIE S 014-3/E:2011: Colourimetry – Part 3: 5 1

CIE Tristimulus Values

Figure 5: Daylight simulation with combination of filtered halogen lamps with and without LEDs.

[10] DIN 6173 – 2: 1983-12: Colour matching: lighting conditions for average artificial light [11] CIE 192:2010: Practical daylight sources for

colourimetry [12] SAE J361TM – 04/2017: Surface Vehicle Recommended Practice: Procedure of Visual Evaluation of Interior and Exterior Automotive Trim, Chapter 4.1.3 Literature [13] Yuk Ming Lam, John H Xin, Kwan Moon Sin: Study of the influence of various D65 simulators on colour matching, Colour. Technol., 117, 2001 [14] Roy S. Burns: “Billmeyer and Saltzman’s Principles of Colour Technology”, Third Edition, 2000 by John Wiley and Son’s, Inc. [15] Wyszecki & Stiles: “Colour Science – Concepts and Methods, Quantitative Data and Formulae”, Second Edition, 1982 by John Wiley and Sons, Inc. [16] Wout van Bommel, Abdo Rouhana: “Lighting Hardware”, Philips, released September 2011 [17] Wout van Bommel, Abdo Rouhana: “The science of lighting – A guide about the

6 1

nature and behavior of light”, Published by

Figure 6: byko-spectra pro luminaire.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Philips Lighting University, 2016

Your Aluminium Powder

Coating Partner sataluminium.com · gemapowdercoating.com

Ta ke a l o o k a t o u r t e ch n o l o g i e s i n a c t i o n !

BRAND-NEW

osca 200 is the latest addition to the Tosca series, which now

ÂŠ Anton Paar

Anton Paar Launches Tosca 200: Premium AFM Technology Uniquely Combined with Time-efficient Operation consists of Tosca 400, a

large-sample, premium AFM, and Tosca 200, an AFM for medium-sized samples and budget-sensitive research. Both devices feature the same high level of automation, increasing the efficiency and significantly simplifying the handling of AFM measurements. Following the introduction of Tosca 400 in 2017 as the first AFM that combined premium technology with time-efficient operation for large samples, Anton Paar now launches Tosca 200, an AFM for medium-sized samples and budget-sensitive research but providing the same quality and flexibility.

The features that make the diďŹ&#x20AC;erence are: - Fast and safe cantilever exchange:

Tosca 200 is the new AFM for medium-sized samples and budget-sensitive research created by Anton Paar.

Probemaster is a unique tool specifically developed for cantilever

- The easiest engagement procedure:

user thorough every step of the

handling that saves time and

the integrated side-view camera enables

measurement so that the final results

guarantees the fast, safe, and correct

live tracking of the cantilever position with

are obtained faster and the user can

placement of the cantilever

respect to the surface on the main screen,

focus on the interpretation and further

- Automatic laser alignment:

so the coarse approach of the probe is fast

research.

Tosca carries out this procedure automatically with just two clicks in the control software

and safe. The auto-engagement is then performed within seconds - Magnetic sample carrier lock for fast

With their focus on performance and measurement efficiency, both

sample mounting: multiple samples can

instruments of the Tosca series are

navigation on an overview map only

be placed on the sample carrier outside of

the perfect nanotechnology tools for

by mouse-click. This facilitates the

the instrument and the lock guarantees a

scientists as well as industrial users.

- State-of-the-art sample navigation:

localization of the right measuring area, especially when working with more than one sample

stable position of the samples - Short time-to-result: the workflow-oriented Tosca Control software guides the

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

For further information: www.anton-paar.com

BRAND-NEW

byko-test Dry Film Thickness Gage Launched with Environmental Condition Measurements

YK-Gardner, worldwide partner of

point temperature is displayed to

The devices comply with SSPC PA-2 and

the automotive, paint and plastic

determine if the conditions are right for

ASTM D7091 for the measurement of

industries for quality control of

applying the paint or coating.

coating thickness, and the byko-test

colour, appearance and physical properties,

The byko-test Lite is economically

also includes a SSPC mode to assist the

is announcing the launch of byko-test

priced for routine applications without

operator on measurement protocols

Fe/NFe, and byko-test Lite, new dry film

environmental condition measurements

and calibration.

thickness measurement gages.

that the byko-test provides.

The new devices deliver accurate and

The byko-test Fe/NFe gage offers a

Both are designed with a large, rotating

repeatable measurement backed by

unique solution to monitor environmental

colour display readable in high or low-

BYK-Gardner quality and performance.

conditions while measuring dry film

light conditions with the large operating

thickness. Air temperature and humidity

buttons provide an easy-to-use solution

For further information:

sensors are built into the gage. The dew

for paint and coatings professionals.

www.byk-instruments.com

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UV Ray, R for f every challenge h ll

www.uvray.it

SUCCESS STORIES

fter only four months, the investment in a new liquid coating system with electrostatics paid for itself. 50% material

WAGNER AquaCoat Saves 50% Paint on Couplings savings, improved coating quality and high process reliability

make the AquaCoat system from WAGNER, realized by Mewes Oberflächentechnik GmbH, the perfect application solution for ZF in Bielefeld.

The challenge ZF Friedrichshafen AG, headquartered in Friedrichshafen (Germany), is a globally active technology group that supplies systems for the mobility of passenger cars, commercial vehicles, and industrial technology. The company employs 149,000 people worldwide at approximately 230 locations. In Bielefeld, ZF reconditions used clutch units for commercial vehicles. In June 2017, the Bielefeld location was awarded for its sustainable product refurbishment for the first time. To date, a large part of the product range has been certified according to the cradleto-cradle principle at the ZF location in Bielefeld. Around 95 percent of the materials used in an aggregate are reused for recycling purposes. Reprocessing includes first-class coating of couplings for trucks in order to prevent corrosion of the reworked parts in the long term. ZF has been using a water-based electrostatic coating system for several years. However, this installation no longer met the current requirements in terms of paint consumption and cleaning effort. ZF decided to invest in a modern, efficient and resource-saving system.

The solution

Figure 1: Interior view of the AquaCoat 5010 automatic system with feeding pump and hobbock cover with compressed air gear agitator.

ZF had already made positive experiences with Mewes Oberflächentechnik GmbH in other projects. In this case, too, the

adjust the atomizing and forming air of the electrostatic automatic

experts from Wedemark-Brelingen in Lower Saxony (Germany)

guns centrally and externally, as well as to adjust the spray material

proved to be excellent planners and project partners. They

quantities (Fig. 1). The exact and repeatable adjustment saves the

recommended ZF’s AquaCoat system from WAGNER for the

user time and increases the process reliability of the application.

electrostatic processing of water-based paints. In the laboratory at

WAGNER always sets a high value on easy handling when designing

Mewes, test coatings with clutches were carried out together with

its liquid paint equipment. The housing of the GA 5000 automatic

the users. The concept, coating results and handling of the WAGNER

gun can be removed quickly and safely (Fig. 2). The nozzle and air

application convinced the ZF managers right from the start.

cap are also quickly replaced and can be rinsed without switching

For ZF, an AquaCoat 5010 automatic system with two GA 5000EACW

off the material and compressed air (Fig. 3). The production

electrostatic automatic spray guns was custom configured. Mewes

process is thus only minimally interrupted. The AquaCoat 5010

also developed a pneumatic pre-air control system. The compressed

control unit has two safety systems with mechanical locking of the

air supply cabinet specially designed for this application is used to

interior during application.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

SUCCESS STORIES

hi-tech

1999-2019

conveyors

2 1

Figure 2: Electrostatic automatic gun GA 5000EACW in the coating line.

The customer’s experience

significantly reduced, which minimizes cleaning

In March 2019, Mewes installed the new painting

and filter costs,” confirms Alexander Biehl,

system at ZF Bielefeld within one day, and

Project Manager in Process Management at ZF.

operation started the following day without a

Overall, the VOC content and the associated

hitch. On-site user and service training with

disposal of solvents and paint residues dropped

ZF personnel rounded off the Mewes service

considerably.

package.

Thanks to the excellent economic efficiency,

The technical concept with the WAGNER

the investment paid for itself after only four

application, the excellent coating results at

months. The support and service provided by

Mewes, their competent advice in the planning

Mewes Oberflächentechnik GmbH and the

phase and the comprehensive after-sales service

high application quality and user-friendliness of

offer convinced ZF (Fig. 4).

WAGNER’s liquid electrostatic system consistently

WAGNER’s liquid paint application has also

meet the strict requirements that ZF places on its

proven itself in the field. “Material consumption

suppliers and their products.

alone was reduced by 50 percent thanks to system. In addition, the overspray was

www.wagner-group.com

For further information:

the high application efficiency of the AquaCoat

3 1

Figure 3: Regulator for the compressed air supply cabinet.

4 1

Figure 4: Reconditioned clutch units.

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

www.cmautomazione.it

BRAND-NEW

District Court of Stuttgart Appoints Joachim Exner as Preliminary Insolvency Administrator for Eisenmann

Joachim Exner is the preliminary insolvency administrator for the Eisenmann companies proceedings.

he District Court of Stuttgart appointed

administrator and looks forward to the

Eisenmann Group initiated the restructuring

Joachim Exner as preliminary insolvency

cooperation with great confidence. “A highly

and strategic reorientation of the company in

administrator for the Eisenmann

motivated team of employees”, Keppel said,

March 2019. The acquisition and completion

companies proceedings. By this decision, the

“will do everything possible to stabilize the

of various major projects in 2018 had led

court followed the petition of the companies.

company despite the difficult situation that

to a large year-on-year loss. “We had to act

Joachim Exner, specialist in insolvency law and

has arisen and to achieve the best possible

fast and consistently here. At the same time,

partner of the law firm Beck & Partner, is a

solution for creditors and employees under

we also wanted to create the strategic and

nationally recognized specialist for complex

insolvency conditions.”

structural foundations for the competitiveness”,

insolvency proceedings. The law office is

Eisenmann SE filed a petition for the

emphasized Keppel.

one of the leading law firms in the area of

opening of insolvency at Stuttgart District

The preliminary insolvency administrator will

insolvency administration in Germany. Exner

Court with the aim of accelerating the

now quickly analyse the current situation

has distinguished himself in the past above all

restructuring and strategic reorientation of

and will hold talks with the parties involved

by the successful support of various automotive

the Eisenmann Group, which began in March

at very short notice, in order to examine

suppliers.

2019. Applications were also submitted to

the restructuring options for the group of

Dr. Michael Keppel, who has been with the

Eisenmann Anlagenbau GmbH & Co. KG,

companies in whole or in part.

company since the beginning of April as

Eisenmann Lactec GmbH and ENisco GmbH

senior restructuring specialist, welcomes the

& Co. KG.

For further information:

appointment of the provisional insolvency

The owner and management of the

www.eisenmann.com

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

BRAND-NEW

ystral Strengthens its Management: Karl Prem Is Taking Over the Company’s Commercial Management

he German machine and plant

Karl Prem has already established himself

an important management task,” Karl

manufacturer ystral is fortifying

excellently at ystral and is presently taking

Prem continues. “I am very happy that

its management team. Karl Prem

on more responsibility. In the future, he will

I am allowed to accomplish this task

has taken over the function of commercial

assume responsibility for the commercial

at ystral. I greatly appreciate the trust

managing director. Primarily, his

management of the ystral Group and

placed in me.” One of Karl Prem’s first

appointment has the purpose of relieving

for improving efficiency throughout

major tasks is to increase the efficiency

the managing director, Peter Manke.

the company. “A company’s positive

of internal processes and to drive

Peter Manke will remain responsible for

development in the long term also depends

continued digitisation in all areas of the

ystral’s strategic development, in addition

on how efficient its internal processes

company. “We have resolved to inspire

to process and application engineering.

and structures are, so as to maintain

our customers, not only with our high

“We are very happy to have Karl Prem

cost and time advantages over market

technical competence, but also with

for this task”, says Peter Manke. “Due

competitors,” Karl Prem says. Especially

outstanding service. To achieve this,

to the past years’ growth, and in light

in fast-growing companies, processes

we need digitised, transparent and

of the strategic challenges facing us in

can quickly become more complex and

customised solutions.”

the future, it was obvious that we had

less transparent. “I believe that regularly

to broaden our base at the top. With

adapting and streamlining these processes

For further information:

Karl Prem, we have found the perfect

to be in line with the company’s needs is

https://ystral.com

candidate for this key function in our © ystral gmbh

company.” In addition to Peter Manke and Karl Prem, David Manke remains a member of ystral’s management board. His primary responsibility is in the field of research and development, as well as international business. Karl Prem, 49, already joined ystral as the commercial director in March 2018. Prior to this, he worked in a number of leading positions for the dental technician Renfert for more than two decades, which also included the position as commercial managing director. Most recently, the graduate business economist held a similar position at the German knife manufacturer Martor. Karl Prem is married and father of two children, aged 16 and 18. Being an enthusiastic runner, he also organises the weekly run at ystral, where many employees from all departments participate.

Karl Prem, Commercial Managing Director from ystral.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

BRAND-NEW

Rain Carbon Begins Commissioning Process at New Hydrogenated Hydrocarbon Resins Facility in Germany

ain Carbon Inc., a leading global producer of carbon-based

changing regulatory requirements and growing consumer demand for

products, initiated the phased start-up of its hydrogenated

cleaner, faster and lighter products.

hydrocarbon resins production facility in Castrop-Rauxel,

“Building on the spirit of innovation that has been part of the DNA here for the past 120 years, one of the products that will be manufactured

state-of-the-art plant will have a permitted resins production capacity

in Castrop-Rauxel is our new NOVARES® pure resins (Fig. 1),” Sweeney

of up to 50,000 tons per year and will serve as the cornerstone of

added. “These ‘water-white’ resins will match the purity of any competing

Rain Carbon’s Advanced Materials product segment.

products available, and they will provide customers with a cleaner

“Throughout the history of our company, innovation and ingenuity

alternative for such applications as food packaging and hygiene products

have enabled us to produce carbon-based raw materials that make

(Fig. 2). Innovation can also be seen in our proprietary technology for

countless products that people rely on every day possible,” said

resins production and in the environmentally friendly hydrogen plant

Rain Carbon President Gerry Sweeney during the commissioning

constructed by Messer Group.

ceremony. “Today, we are continuing a tradition that began here in

“These developments are important – and not just for Rain Carbon,”

1898, when the former RÜTGERS plant was producing raw materials

Sweeney continued. “They are significant for the entire region, creating

for preserving railroad ties and later when it supported the growing

21st-century jobs, including 30 new positions at Rain Carbon and another

BAKELITE industry. Our €60 million investment in this facility will enable

45 contractor and regional jobs. In addition, this facility is bringing new

Rain Carbon to produce advanced raw materials required to meet

products and technologies to the Ruhr Valley. Just as important is this

Germany. Once operational in the fourth quarter of 2019, the

Figure 1: One of the products that will be manufactured in Castrop-Rauxel is new NOVARES® pure resins.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Efﬁcient

BRAND-NEW © Rain Carbon Inc.

and reliable solutions for surface coating since 1988.

2 1

Figure 2: ‘Water-white’ resins will provide with a cleaner alternative for such applications as food packaging and hygiene products.

electrostatic systems for liquid painting

plant’s potential to attract new customers to the region, since its strategic location in western Germany offers European customers a shorter and more cost-effective supply chain for water-white

electrostatic systems and spraying booths for powder coating

resins and other advanced materials previously imported from Asia.” Professor Dr. Andreas Pinkwart, Minister for Economic Affairs, Innovation, Digitization and Energy of North Rhine-Westphalia,

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

said: “The hydrogenated hydrocarbon resins facility inaugurated today shows the innovative strength of the chemical industry in North Rhine-Westphalia. At the same time, it stands for an efficient approval procedure that took less than a year. This shows that

IR and UV drying systems

our policy of removing administrative barriers – our so-called ‘unleashing‘ – works and improves the conditions for the local industry. What succeeds in the chemistry sector also has positive

robot and reciprocators

effects on many other parts of the economy.” Regarding Messer Group’s role to the project – its first hydrogen plant constructed and installed in Germany – CEO Stefan Messer said: “Germany must continue to extend its leadership in research and development, and remain focused on the climate policy goals of the Paris climate accords. The strategic and ecological production and application of hydrogen brings both topics together.”

www.raincarbon.com

www.cmspray.it

eosmarketing.it

For further information:

CM SPRAY s.r.l.

SAL O M O NI IA

AU D CL

Five on Five Interview: Sustainability According to the Industry Players

MAR CO

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SUSTAINABILITY

SUSTAINABILITY L TA EN NM O R VI EN

IC M NO O EC

AL CI SO

ack in January 2019, to officially kick-start the Sustainability section in our magazines, we asked five key players of the industry if they were willing to answer 15 questions on the role of sustainability, its challenges and the different approaches to the practice. The result was an inspiring, in-depth interview on some of the Best Practices of Sustainability in the surface treatment sector. Back then we also promised we would do a series of interviews, involving other companies as well. Today we deliver on our commitment. After a brief summer hiatus, here we present the second instalment of the 5 on 5 Interview on Sustainability, which questions have been answered once again by five different companies that play a key role within our industry and that are at the forefront of the journey towards a greener and healthier environment for everyone. We are under no illusion: this journey is long and full of challenges, and we are running out of time. According to a 700-pages report1 by the Intergovernmental Panel on Climate Change (IPCC) – the United Nations body for assessing the science related to climate change – the impacts of global warming of 1.5 degrees Celsius will lead to unprecedented changes: from rising sea levels to more devastating droughts to more damaging storms. Pooling together more than 6,000 scientific publications, drawing contributions from 133 authors, and having more than 1,000 scientists review the findings, the IPCC report concluded that we have less than 12 years to make massive and unprecedented changes to the global energy infrastructure to limit global warming to moderate levels. We are glad to see that companies in our sector are not only acknowledging the issue but they are also putting words into action, by proving that being sustainable not only is possible but it can also provide for a great business value. We would like to thank AkzoNobel, BASF’s Coatings Division, Evonik, Perstorp and PPG for their commitment to participate to this interview and we hope it will make for an interesting, thought-provoking reading once again. For this second interview we were delighted to work with the following sector leaders: • Claudia Salomoni – AkzoNobel Coatings SpA Specification Sales & Marketing Coordinator • Marco Benen – BASF’s Coatings Division Sustainability Officer • Gaetano Blanda – Evonik Senior Vice President and General Manager Coating Additives & Stefan Silber – Evonik Senior Vice President Innovation Management Coating Additives • Cecilia Svensson – Perstorp Holding AB EVP Communications & Sustainability • Pedro Perez Vintaned – PPG EHS Director EMEA

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

“Global Warming of 1.5 ºC” – https://www.ipcc.ch/sr15/

Claudia Salomoni, AkzoNobel - AkzoNobel firm believes that sustainability is business, and business is sustainability. When people ask us, what sustainability means to AkzoNobel, we tell them that our success depends on it, as Powder Coatings inner force is to be eco-friendlier than any other coating in the world. We know only too well that our future hinges on our ability to do radically more while using less: - More innovative to less traditional solutions - More renewable energy and materials - Less fossil-based - More value chain focus and less introverted thinking.

Marco Benen, BASF - Our understanding of sustainability at BASF’s Coatings division is based on the three pillars of environment, economy and society. Acting responsibly in all of these areas ensures our success. We also take the whole value chain into consideration. From sourcing responsibly and a safe and efficient production to products and processes that help our customers to save resources. A holistic approach is key. Gaetano Blanda, Evonik - Sustainability is part of our corporate thinking and action, and it is firmly embedded in Evonik’s DNA. We provide innovative solutions that help to make our lives more sustainable, healthier, and more comfortable.

Cecilia Svensson, Perstorp - Sustainability is about pretty much everything we do, in our production, our products and our way of working. We also consider sustainability on several different levels. A lot of work is about the basics; developing the way we work with health & safety, leadership, supplier management, compliance etc. Another level is how we work with our products and how they are produced; LCAs, compliance and to build in sustainability as a default when we innovate. The ultimate level is our ambition to become Finite Material Neutral, a bold ambition that means switching to alternative resources that are abundant and/ or renewable, or to close the loops in order to recycle those that are finite.

SERIES

How does your company define sustainability today?

Adobe Stock © malp

SUSTAINABILITY

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

SERIES

SUSTAINABILITY

Pedro Perez Vintaned, PPG - The way we define sustainability at PPG is through our commitment to transparent reporting on our environmental, economic and social performance as a company. This is designed to cover all our areas of business, our employees, our customers, and the communities in which we operate. Not only does this allow us to be transparent, but it informs our guiding approach to sustainability today. PPG’s efforts in sustainability over the last year alone drove more than USD $6.5 million in total cost savings and offered additional growth opportunities. We consider sustainability a key foundation of our success.

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

Claudia Salomoni, AkzoNobel - In coatings in general, most of the raw materials implied in the formulation come from petroleum synthesis products. Thanks to a continued rationalization of products and suppliers on a regular control of the derivation (extraction and processing) of the raw materials, is possible to limit the carbon foot-print. Furthermore, we constantly check our production plants and processes to reduce the energy consumption per kilo.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Marco Benen, BASF - Products which looks at first glance “green” are not per se more sustainable. You need to consider all factors and the whole life cycle. Therefore, making the benefits measurable and tangible is crucial. Our actions should have a provable impact. Customers, for example, often ask what is in it for them, when they can choose between a traditional and a more sustainable product, which might be more expensive. Having reliable and comprehensible data can be an important selling point. Gaetano Blanda, Evonik - For Evonik as a specialty chemicals company, safety has always been top priority. We learned that in this

respect – apart from technical aspects – human behavior is crucial. We therefore launched a comprehensive “safety@Evonik” culture initiative several years ago. Today, Evonik has a good safety track record. Cecilia Svensson, Perstorp - We have had a fantastic response, both internally and with customers, after launching our Finite Material Neutral ambition which, of course, carries a lot of promise and responsibility. I would say the biggest issue today is to navigate the landscape of alternative routes to raw materials. Some solutions require big investments and what if you invest heavily in something that, all of a sudden, proves to be yesterday’s solution? The technical opportunities are developing fast, and some solutions might be groundbreaking, others not. Pedro Perez Vintaned, PPG - I would call them challenges more than anything else. We are trying to be at the front of the market where sustainable solutions are increasingly important. The main challenge in this is to continuously encourage our employees and the company to look into environmentally friendly developments. This also presents a challenge in how we can become better about bringing innovation into the company and the ways we demonstrate that to our customers. We are always striving to put strategic programmes in place that allow us to become more environmentally friendly.

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

Claudia Salomoni, AkzoNobel - Working with customers and suppliers to develop leading solutions that do more with fewer resources. It also means continuously improving ourselves. Thanks to this ongoing commitment, we are widely acknowledged as a leader in our industry, reflected by our performance in many of the world’s most prestigious sustainability rankings, in addition to the DJSI. For example, we are also listed on leading sustainability indexes such as the Carbon Disclosure Project, Sustainalytics, FTSE4Good, EcoVadis and Corporate Knights. While it is an honour to be recognized, we will not stop improving. We will continue to take our industry forward and ensure Powder Coatings provide many sustainability benefits compared to other coatings. Marco Benen, BASF - Three things come to mind: Firstly, we aim to minimize the usage of critical substances in our products. Secondly, we make sure to source responsibly, which means we pay close attention to good working conditions for

SERIES

SUSTAINABILITY

the whole value chain. Thirdly, eco-efficient solutions combine ecological and economic benefits. Shortened processes like our Integrated Process II for example save up to 20 % CO2 as well as energy costs for the customer. Stefan Silber, Evonik - First of all, we see a rising demand from our customers and their customers for products that demonstrate a good balance of economic, ecological, and social factors. Sustainability is becoming an increasingly important factor in purchasing decisions. Moreover, sustainability aspects are gaining significance on the capital markets. Financial analysts and investors base investment decisions more and more on the sustainability performance of companies. To them, extra-financial performance indicators are valuable pieces of information assessing the risk of exposure or future market opportunities of a company. Last but not least, global initiatives such as the

UN Sustainable Development Goals as well as stricter regulatory requirements triggered, for example, by the European Union are drivers for sustainability. Cecilia Svensson, Perstorp - The indisputable no. 1 driver is to find ways to lower the carbon footprint. Other important drivers are ways to get resource efficiency across global value chains and the implementation of circularity principles. Pedro Perez Vintaned, PPG - Without a doubt, environmental aspects are the key drivers of sustainability within our industry today. This is an area in which we are striving to innovate. In all our company forums it has become quite clear that we need to make better use of energy sources. We are also trying to minimise waste throughout our operations. We are focusing on these things because we are trying to more responsibly use our most important

and precious natural resources. One recent example of this is the waste mapping exercise that our Environmental Department at PPG Architectural Coatings-UK conducted last year, as part of our reduce, reuse and recycle campaign at two of our UK sites. The team held a workshop on reducing changeover waste left in the manufacturing tanks at the end of a batch. The brainstorm brought about an idea for a new method of tank scraping that has resulted in more than 100 tonnes of paint being saved from entering the waste system in a year. Whilst in our Birstall facility a new reclamation plant and recycling process has allowed PPG to reduce our waste intensity by 10 percent since 2016. These initiatives also have a positive financial element to them â&#x20AC;&#x201C; the more effective we become in our processes the more likely we are to use less energy and generate less waste. Ultimately that financial benefit is where we prove how well weâ&#x20AC;&#x2122;re doing on our sustainability initiatives. ÂŠ Perstorp

SERIES

SUSTAINABILITY

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

SUSTAINABILITY

What business value have you seen?

Claudia Salomoni, AkzoNobel - Working with customers and suppliers opens infinite possibilities in a finite world and means finding opportunities where there does not appear to be any! Marco Benen, BASF – Our refinish products that are certified with BASF’s biomass balance approach are a successful example for a sustainable product, that convinces our customers. The paint shops can promote these more sustainable solutions directly to their customers, who then decide whether they want to use a product that helps to reduce fossil resources in the production process. Our customers appreciate an opportunity to position themselves as environmentally conscious. Gaetano Blanda, Evonik - Evonik has defined four growth engines in its portfolio with a clear focus on sustainability: Specialty Additives, Animal Nutrition, Smart Materials and Health & Care. Businesses aligned to these growth engines (such as silica and silanes for the “green” tire, additives for eco-friendly coatings, or probiotics for animal nutrition) show above-average growth rates and play an important role in achieving our sales and earnings targets. Cecilia Svensson, Perstorp - I think you have to see business value both in the short and long term. One example of shortterm business value is the evolution of several of our customer relationships based on our portfolio of Pro-Environment (renewable) products. We now interact directly with more functions, such as sustainability and business development, which builds an increasing degree of partnership along the value chain. Long term is about the survival of our industry = 100% business value. Pedro Perez Vintaned, PPG - Some of the opportunities in which we have been successful have been because we developed products that are more environmentally friendly. For example, we developed a clear coat called the UHS Fast ClearCoat, which is a coating that dries quicker and emits lower volatile organic compounds. This allows for faster applications which provide benefits to the safety of our customers and the environment and has provided for greater efficiencies for our customers’ processes. This has brought value to our business from the customers we’ve gained because of the sustainable benefits our products provide to them.

How do you compare to the competition?

Claudia Salomoni, AkzoNobel - We use independent ratings such as the DJSI as a benchmark. It gives us objective insights into our performance and enables us to assess ourselves against the best of the competition. Thousands of companies are assessed each year and we are proud to be among the leaders for the 13th consecutive year. It is a recognition of the long-term value we create for all our stakeholders, while our consistently strong performance is a clear signal that we are always looking to improve. There is no room for complacency, however, so we are looking beyond rankings, because we are on a journey which requires us to look further and climb higher. In particular, we have adopted a sharper and more deliberate focus on the resource productivity of our operations, and on innovation to drive value selling. With resource productivity, we are creating a culture of care for all materials used, while eliminating waste. With value selling, we drive sales and growth through product portfolios designed to bring tangible benefits and deliver a positive social and environmental impact.

p © Perstor

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SUSTAINABILITY

Marco Benen, BASF – We do have a strong position in eco-efficient products and shortened processes. With the biomass balance approach, we even are a first mover. BASF’s Verbund concept allows us to replace fossil resources with renewables such as bio-naphtha right at the beginning of the chemical production process. That way, we can produce products with the same performance and quality but without using fossil resources.

strategy 2020+ endorsed by the executive board at the beginning of this year. Today, Evonik generates already around half of its sales with products for resource-efficient applications. More than 80 percent of the Group’s sales make a positive contribution to achieving the UN SDGs. Our businesses combine sustainability, innovative capability and efficiency to develop innovative products that enable our customers to meet the corresponding high requirements of the end markets. And the pipeline is well-filled thanks to our market-oriented R&D.

Stefan Silber, Evonik - Regarding sustainability, Evonik is well positioned. The latest milestone is our new sustainability

Cecilia Svensson, Perstorp - I would not like to compare ourselves with other companies in this area. We are all moving

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

forward with the ambition to become more sustainable, but the routes are slightly different. Ultimately, I think we have to collaborate more across value chains in order make an impact. Also, cyclicality will require a lot more collaboration within our industry. Pedro Perez Vintaned, PPG - Our goal is to always be out at the front lines with our competitors. While we always seek to compare our competitor matrix, we recognise that we often vary by definition and it can be like trying to compare apples to oranges. We believe that we’re still just as well placed as the rest to provide our customers with a competitive advantage.

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Adobe Stock © bas121

Opening photo: Quaker Chemical Corporation and Houghton International have combined to create Quaker Houghton, the global leader in industrial process fluids to the primary metals and metalworking markets.

HIGHLIGHT OF THE MONTH

Leaders in Industrial Process Fluids Combine to Form Quaker Houghton Mary Dean Hall Quaker Houghton - Conshohocken (PA), United States

hallm@quakerchem.com

uaker Chemical Corporation and

customers worldwide. Quaker was founded in

The company’s combined breadth of product

Houghton International have combined

1918 and Houghton in 1865.

and service offerings can be found in end-

to create Quaker Houghton (NYSE:

“We are rooted in companies commonly

markets such as aerospace, aluminium,

KWR), the global leader in industrial process

acknowledged as authorities in industrial fluids

automotive, machinery, can manufacturing,

fluids to the primary metals and metalworking

and valued experts in customer processes,”

industrial parts manufacturing, mining,

markets.

said Michael F. Barry, Chairman, Chief

offshore, steel, and tube and pipe industries.

Along with the new name, the company revealed

Executive Officer, and President of the new

With its expanded products and services

a new logo and brand representing the combined

company. Mr. Barry, who previously served

portfolio, the company expects that cross-

companies (Fig. 1). The company will continue to

Quaker Chemical in similar capacities, went

selling opportunities will facilitate continued

be listed on the New York Stock Exchange and

on to say, “Our similar cultures and values,

above-market growth. Specific products the

trade under the “KWR” ticker symbol.

combined with the talent and resources we

company offers include metal cutting and

bring to Quaker Houghton, create exciting

forming fluids, corrosion protection fluids,

opportunities to deliver innovative solutions

specialty hydraulic fluids, and steel and

The combined $1.6 billion revenue company

that will help our customers’ operations run

aluminium rolling oils. In addition,

employs 4,000 associates serving 15,000

even more efficiently and effectively.”

legacy-Houghton customers will benefit

A Strategic Combination is Formed

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

from Quaker’s strength in specialty greases, high-pressure die casting, mining specialties, surface treatment and bio-based lubricants, while legacy-Quaker customers will now have access to Houghton’s heat treatment quenchants, offshore hydraulic fluids, metal finishing products, and a broader metal removal fluids portfolio. “Our foundation will be the same customer-intimate operating model that has been key to the success of our customers,” Mr. Barry said.

Get more from water

“Moving forward together, we will draw upon our rich history and shared expertise to enhance our product and service offerings and continue to deliver value-added service expertise to our customers.”

Value Creation for Shareholders The combination of Quaker Chemical and Houghton International nearly doubles the size of either company with trailing twelve-month revenue as of June 30, 2019 of $1.6 billion.

Turnkey solutions for industrial waste water treatment

The company expects to achieve significant cost reductions as a result

Spraybooth water treatment systems and chemicals

of the combination and has increased its estimate of cost synergies to

Chemical-physical systems

$60 million from $45 million. The cost synergies are broad based and

Sludge compactors

are expected to come from three major areas: Asset Optimization (17%), Logistics and Procurement (35%) and Operational Efficiencies (48%). The cost synergies are expected to be fully realized on a run-rate basis by the end of year two; with ~$20 million being achieved in year one, ~$45 million in year two and the full $60 million in year three, reflecting 100% achievement as the company exits year two. On a calendar year basis, the cost synergies achieved are estimated to be ~$5 million in 2019, ~$35 million in 2020, ~$50 million in 2021,

Reverse osmosis & ion exchange water demineralization units De-oiling & degreasing units Filtering systems Water treatment chemicals & consumables Technical service & maintenance of water treatment systems

and $60 million in 2022. The company has utilized a top consulting firm over the past two years to help with its integration planning efforts and they will continue to assist the company during the integration. In addition to cost synergies, the company expects that its growth strategy will create additional value over time. Revenue-based synergies, such as cross-selling, will be an important contributor to growth going forward. The legacy product portfolios of both Quaker and Houghton can now be offered to the combined, complementary customer base, where 14,000 of the 15,000 total customers are unique to one company or the other. The company believes the revenue synergies are achievable and will be significant over time, beginning after year one. In the first year, the company’s focus will be to maintain service levels for its customers and ensure no supply chain disruptions, while successfully executing its integration plans. In year two, the revenue synergies will begin to be visible as the company expects to grow above the market by 2% to 4% as it has in the past. The company also expects to continue to grow through acquisitions which remain part of its core growth strategy. In the short term, the company will focus on paying down debt, but will continue to consider smaller acquisitions that can create value. Both Quaker and Houghton have long histories of building value through acquisitions.

info@waterenergy.it

www.waternergy.it

In addition, the company divested certain product lines at closing in compliance with the United States Federal Trade Commission and European Commission requirements. The company received approximately $37 million from the buyer, Total S.A., at close. The revenue of the divested product lines was approximately $50 million, approximately 3% of the combined company’s revenue.

Leadership and Governance In addition to Mr. Barry, Quaker Houghton’s management includes existing leaders from both legacy companies. The newly formed

executive leadership team is comprised of:

Figure 1: The Quaker Houghton drum featuring the new company logo.

Business Leaders: - Joseph A. Berquist, SVP, Global Specialty Businesses & Chief Strategy Officer

“Today is a historic day for our businesses,”

Transaction Details

Mr. Barry said. “We are finally beginning

The final purchase consideration at closing

our journey as Quaker Houghton, and are

of the combination was comprised of:

now the leading global supplier of industrial

1) approximately $170.8 million in cash;

process fluids to the metals and metalworking

2) the issuance of approximately 4.3 million

markets. Two years from now, we expect to

shares of common stock to the Hinduja

have an enterprise that will be integrated

Group and other former owners of Houghton

and generating over $300 million of adjusted

International, comprising 24.5% of the stock of

Global Functional Leaders:

EBITDA on a going-forward basis. More

the combined company; and 3) the refinancing

- Mary Dean Hall, SVP, Chief Financial Officer

importantly, we will be well-positioned to

of approximately $660 million of Houghton net

continue to achieve above-market growth

indebtedness. This purchase consideration

organically driven by our differentiated

does not reflect the cash proceeds from the

business model and the cross-selling

required divestiture which is discussed below.

opportunities created by our combination.”

To fund the purchase, the company borrowed

Mr. Barry continued, “While we are certainly

a total of $930 million at close under its new

a leader in our chosen markets, there

$1.15 billion credit facility as follows:

is significant growth potential for this

1) $600 million U.S. dollar term loan;

new company. We estimate that Quaker

2) $150 million (equivalent) euro term loan;

Houghton’s revenue of $1.6 billion represents

and 3) $180 million revolving credit borrowing.

less than 20% market share in a more than

The term loans and the multi-currency

Quaker Houghton now has an 11-member

ten-billion-dollar addressable market.

revolving credit facility each have a five-year

Board of Directors, consisting of the eight

The near-doubling of the size of the

maturity, and the revolving credit facility has

directors from Quaker Chemical and three

company today gives us greater scale to

remaining availability of approximately $220

directors nominated by the Hinduja Group.

invest in new technologies and make future

million for additional liquidity. The company

The three new independent directors of

acquisitions. We are very excited about the

estimates that its annual interest expense at

Quaker Houghton are the following former

future and the opportunities that lie ahead

today’s interest rates, including the cost to

Board members of Houghton International:

for Quaker Houghton and what it means

convert a portion of the term loan to a fixed

- Sanjay Hinduja

for our customers, our employees, and our

rate as required by the lenders, will be in the

- Ramaswami Seshasayee

shareholders.”

range of 3.4-3.6%.

- Michael J. Shannon

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

- Jeewat Bijlani, SVP, Managing Director – Americas - Dieter Laininger, SVP, Managing Director – APAC - Adrian Steeples, SVP, Managing Director – EMEA

& Treasurer - Kym Johnson, SVP, Global Human Resources, CHRO - Wilbert Platzer, SVP, Global Operations, EHS & Procurement - Dr. Dave Slinkman, SVP, Chief Technology Officer - Robert T. Traub, SVP, General Counsel & Corporate Secretary.

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

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

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

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

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I N T R O D U C I N G

T H E

N E W

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BRAND-NEW

Components Made by Additive Manufacturing - from Initial Design to Finished Work Pieces

M Solutions combines all activities of

rapidly expanding into all kinds of industries.

the tasks at hand. This applies equally to the

the Rösler group regarding additive

Be it in aerospace, medical engineering, the

complete engineering of components from

manufacturing. Beside the existing

automotive industry, the tooling industry or

scratch, the re-design of already existing

offerings in the field of 3D post processing

any other industrial applications, the need

work pieces for additive manufacturing, the

(AM Solutions - 3D post processing), this

for 3D printed components is growing at a

validation of a product design or a topology

company division expanded by AM Solutions -

brisk pace. The technical possibilities of AM

optimization.

3D printing services in September. The newly

regarding the creation of innovative and

The components can be printed from

founded company (AM Solutions S.r.l.) based

optimized components can best be exploited,

different materials, for example different

in Italy will offer a comprehensive service

when all critical additive manufacturing

types of stainless steel, aluminum and

package in the field of 3D printing (Fig. 1).

aspects are already taken into account during

titanium. The printing process takes place

These services not only cover engineering,

the design phase.

with state-of-the-art equipment like the

including optimization of the product design

EOS M 290 allowing component sizes

printing services, mechanical post processing,

Additive thinking - from design to the finished product

surface finishing and quality control (Fig. 2).

That is why the design phase is an essential

not only extremely high precision but also

Additive manufacturing offers numerous

part of the service portfolio of AM Solutions –

consistently high quality and absolute

advantages like the timely production of highly

3D printing services. Equipped with

repeatability of the printing results.

complex and individualized components

state-of-the-art electronic tools (for example,

If the 3D printed components require

without the requirement for expensive tooling.

the simulation tool Altair, CAD software

a subsequent machining step, the

Since the manufacture of such components

Siemens NX and GOM 3D scanner Atos) the

experienced specialists at AM Solutions - 3D

with conventional shaping methods is either

specially trained company experts ensure that

printing services have access to a range of

impossible or extremely expensive, it is not

the design flexibilities and possibilities of the

modern machining equipment like a 5-axis

surprising that additive manufacturing is

3D printing technology are fully utilized for

milling machine DMU 50.

of 250 x 250 x 325 mm (Fig. 3). The fully automatic 3D printing process guarantees

for additive manufacturing, but also actual 3D

2 1

Figure 1: The newly founded company AM Solutions S.r.l., based in Italy, will expand the existing oﬀerings of AM Solutions, a brand of the Rösler Group, in the field of 3D post processing as a service provider for 3D printing solutions.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Figure 2: The oﬀerings of AM Solutions – 3D printing services will not only cover engineering, including optimization of the product design for additive manufacturing, but also actual 3D printing services, mechanical post processing, surface finishing and quality control.

ÂŠ EOS GmbH

BRAND-NEW

This includes the complete portfolio of AM Solutions - 3D post processing, which offers numerous benefits. For example, already during the design & engineering phase an assessment can be made, whether the customer requirements for a certain surface finish can be met, or whether a design modification is necessary. Depending on the task at hand, it is also possible to tweak existing

3 1

Figure 3: Most modern software like the simulation tool Altair or the CAD software Siemens NX as well as state-of-the-art hardware like an EOS M290 or a 5-axis milling machine DMU 50 are used. Moreover the entire post processing portfolio of AM Solutions - 3D post processing will come into action.

Post Processing â&#x20AC;&#x201C; added value by professional expertise

processes or consumables in order to meet customer specifications. This know-how in the field of surface finishing helps prevent problems with the post processing stage and is key for a cost-effective additive manufacturing process. Last-but-not-least, the service portfolio also includes quality control of the components. The official launch of AM Solutions â&#x20AC;&#x201C; 3D printing services, located in Concorezzo in Northern Italy, took place during the RM Forum on September 11 and 12, 2019 at the Alfa Romeo Museum in Arese, Milan.

For post processing of the parts - the removal of powder residues and support structures to surface smoothing and polishing - the

For further information:

company is utilizing a wide range of technologies and processes.

www.solutions-for-am.com

Opening photo: DTM products have an acrylic/polyurethane nature and contain anti-corrosion passivating agents that allow to overcome the vast majority of the corrosion resistance requests made by the General Industry.

INNOVATIONS: PRESENT&FUTURE

The Growth of the Direct-to-Metal Products Massimo Bazzucco Coloriﬁcio Damiani Spa, Montecchio Emilia (Reggio Emilia) – Italy

marketing@color-damiani.it

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

hich is the reason why direct-to-

a workmanlike manner paying particular

The use of this new generation

metal (DTM) finishing products

attention to the thickness that we are going to

products also allows to reduce the

end up increasing every year

deposit (apply), as the product is able to satisfy

warehouse stock of primers and related

their market shares?

certain resistances only if it is applied on a clean

hardeners, thus simplifying not only

Surely, one of the answers is that the

surface and with the suitable thickness (Fig. 4).

the reorders’ management but also

market has changed, but how has it

The meaning of “one coat” is not to be intended

reducing possible eventual errors in the

changed?

as “just one simple coat of product and the job

use of some hardeners compared to

Nowadays end-users request to reduce

is done”, but it is intended as a single product

others.

application times, consequently reducing

able to cover the function both of a primer and

This, unfortunately, can generate very

the handling costs and the costs related to

of an enamel; therefore the final thickness must

high repainting costs also due to the

the continuous washing of the application

comply with the customer’s requests.

high work schedule.

systems. © Franchi&Kim

DTM products have an acrylic/ polyurethane nature and contain anti-corrosion passivating agents that allow to overcome the vast majority of corrosion resistance requests made by the General Industry (ref. Opening photo and Fig. 1). The new technologies used on resins also make it possible to obtain an excellent adhesion not only on steel surfaces but also on light alloys or galvanized steel and even on some plastic surfaces. The ability to adhere to a wider range of surfaces, from metal to some types of plastics, is a great advantage for these types of paints as today products are made up of many different substrates (Figs. 2 and 3). Being able to paint without worrying too much about the type of surface is a certain advantage for the end-user. However it is very important to pay attention to the surface preparation, which must always be carried out in

Figure 1: DTM products’ manufacturing is addressed to many diﬀerent sectors, such as the storage industry.

In order to avoid these mistakes more and more operators prefer to the use 2K mixing

2 1

Figure 2: The ability to adhere to a wider range of surfaces, from metal to some types of plastics, is a great advantage for these types of products.

Damiani was a pioneer in the development of DTM products. Initially the range consisted of a gloss enamel and a semi-gloss enamel. Nowadays the Damiani range is developed on as many as 8 products dedicated to the one-coat painting, each with different features with the aim to satisfy the customers’ requests.”

systems, therefore having the possibility to use just a single mixing machine which facilitates application (just make it easy the application job). Damiani was a pioneer in the development of DTM products. Initially the range consisted of a glossy enamel and a semi-gloss enamel. Nowadays the Damiani range is developed on as many as 8 products dedicated to the one-coat (DTM) painting, each with different features with the aim to satisfy the customers’ requests. In fact, it is possible to find high solid traditional

3 1

products, structured, matt, glossy or highly thixotropic products.

Figure 3: The ACE’s field is one of the sectors where the DTM products are widely used.

Furthermore, keeping into consideration the developed based on the customer personal demands, once again demonstrating the great listening skill of our research team.

customers’ needs, tailor-made products were

Right now Damiani’s range is composed by the below products: - H0181 FOSFATIX: glossy enamel with excellent verticality; - H0155 FOSFACRYL: DTM glossy enamel; - H0161 FOSFACRYL: semi-gloss 50–60 gloss; - H0169 FOSFACRYL: textured finish; - H0209 LUXACRYL MATT10: DTM matt enamel. In addition the DTM range is completed by many other products.

4 1

Figure 4: The product is able to satisfy certain resistances only if it is applied on a clean surface and with the suitable thickness.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

dn-chemicals.com

4/5

Your perfect cleanliness.

We care. Interoperational cleaners

ÂŠ HangOn

Opening photo: The design of flexible, tailor-made hanging and masking systems for each companyâ&#x20AC;&#x2122;s needs can help reduce production costs and times.

ANALYSIS

The Polarisation of the Market Adriano Antonelli Tecno Supply - Ibix Srl, Santa Maria in Fabriago (Ravenna, Italy)

adriano.antonelli@tecnosupply.com

e are facing an atypical phase

measures; they favour the American

by economically colonising many African

of the market, in which conflicts

manufacturers but, at the same time, these

countries and strongly influencing European

among the major economic

continue to sell their products in other

countries, which constitute the third

blocs are also affecting national markets.

markets. The Chinese bloc, on the other

economic bloc.

Currently, there are three main economic

hand, is effectively fighting to become the

Due to historical and geographical reasons,

blocs. Despite their negative trade balance,

first global economy. China has managed

Italy finds itself in the middle of this macro-

the United States are trying to boost

to gain control of its domestic market, i.e.

economic conflict. The balance of the Italian

exports with often ineffective and unsuitable

the Asian one, and it is now expanding

market, which is a priority for both the

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

ANALYSIS

manner, however, coordination among all the

are the recent major acquisitions occurred

actors involved is needed. The occurrence of

two nations does not seem close to its

in the fashion, food, and automotive

a fault in a single production station or with

conclusion. Finally, many other countries

industries. The “polarisation” of large

one of the partners in the chain can in fact

with strong, advanced economies, such as

groups is an increasingly widespread

affect the relationship between a customer

Russia, India, and Japan, are trying to take

trend, as proved for instance by the latest

and a supplier. At the same time, constantly

advantage of the confrontation between

acquisition attempt of Renault-Nissan by

keeping all production phases under control,

the two main contenders.

the FCA Group.

also considering that more and more firms now

How can a company be competitive and

One of the characteristics that companies

tend to reduce their stock as much as possible,

at the forefront of its industry, within such

should possess nowadays to be able

is an important, but difficult-to-achieve goal.

increasingly complex markets? How can it

to continue to operate on the market,

That is why this article will describe how to

acquire and convince large contractors in

therefore, is the reliability of their value

efficiently manage a coating department in

such a climate of growing competitiveness?

chains. As most Italian companies are small

order to reduce process times, inefficiencies,

A common response of the market

and medium-sized and do not control

chances of error, material handling operations,

appears to be paying increased attention

their entire supply chains in an integrated

and extra costs. In the framework of coating © HangOn

to economies of scale. An example of this

At the same time, the conflict between the

United States and China, is still precarious.

FTBK 1200

HCFL

Figure 1: The shuttle is composed of a standard base and optional wheels and a handle for transport.

2 1

FTG 2

FTW 1

FT 1

Description

Date

Complete FT 1

2008-10-14

Product code

Edition

FT 1 - FTW 1 - FTR - FTG 2 - FTBK 1200 - HCFL

This drawing is Hang On property. It can't be reproduced or communicated without our written agreement.

FTR

Figure 2: A drawing of the shuttle designed by HangOn.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

3 1

4 1

Figure 3: The frame also enables to unhang the workpieces, with due care and attention.

Figure 4: The shuttle can be used as a workbench for both material preparation and masking operations.

processes, it is possible to act on many

due to organisational issues is a waste that

The dimensions of the profiles determining its

segments of the production flow. For

should be avoided. On the other hand, paying

height can range from 1500 mm to 2300 mm.

example, the frames that are not being

attention to these details enables to consume

Its horizontal base, whose size can range

used should be stored in a coherent,

less paint and reduce the costs of the curing

between 800 and 1200 mm, can be

orderly fashion on shuttle units, which

and pre-treatment phases.

customised through many options, depending

should also offer additional functions such

The development of flexible shuttle units that

on the coupling system of the load bar.

as, for instance, the possibility to hang and

can be built according to each customer’s

In this way, the frame is stable and allows

unhang the workpieces out of the line.

needs thanks to the numerous accessories

pre-hanging the workpieces out of the line,

However, the design of frames guaranteeing

available has represented a significant

as well as unhanging them, with due care and

maximum hanging efficiency with respect

design challenge for HangOn, distributed in

attention (Fig. 3). The shuttle can be used as

to the available space is often hindered by

Italy by Tecno Supply, a division of Ibix (ref.

a workbench for both material preparation

other factors, such as employee number

Opening photo). Our shuttle is composed

and masking operations (Fig. 4). The range

and chain speed. Losing the opportunity

of a standard base and optional wheels and a

also includes the FV1 shuttle unit, with less

to optimally hang one’s own components

handle for transport (Figs. 1 and 2).

flexibility but a few peculiar characteristics,

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

ANALYSIS

such as strength and stability, thanks to its

the number of workpieces that could be hung,

four swivel wheels and adjustable height for

we have implemented simple projects able to

an optimal workstation.

double and sometimes triple the customers’

In the articles written for this magazine in the

productivity. Welded bars allow hanging

past, we have already dealt with the issue of

the parts as products consisting of a single

universal frames’ flexibility.

wire, which can be painted albeit facing one

The possibility to use interchangeable load

another. Thanks to their design, our standard

bars, and, in some cases, accessories that

toothed bars also allow hanging workpieces in

can be inserted on them depending on the

a staggered manner within the same area in

workpiece to be hung enables to significantly

order to save space (Fig. 6).

reduce the number of different frames needed for the storage of the frames and

approached in such a way as to guarantee

for their handling. Sometimes, however, a

proper insertion, easy removal, and adequate

special frame can be required for particular

recovery. In addition to its standard products,

components (Fig. 5). For example, we

HangOn develops and designs masks that can

were recently required a frame able to

reduce the time required for this operation

handle significant weights. Thanks to our

avoiding any reworking. The main goal is

interchangeable accessories, it was still

to offer masking systems that ensure that

possible to guarantee perfect grounding.

the component is ready to be packaged

In other cases, in order to increase the space

immediately after the cycle or to be assembled

available under the conveyor and therefore

without any reworking.

5 1

Figure 5: One of the frames specifically conceived for special hanging applications.

In this perspective, masking should also be

required and, therefore, limit the space

6 1

Figure 6: Thanks to their design, toothed bars also allow hanging workpieces in a staggered manner within the same area in order to save space.

7 1

8 1

Figures 7 and 8: Designing the right mask is key to reduce the time required for this process phase.

Some of the factors to be taken into

According to the type of coating plant

be hardly solvable in the immediate

consideration at the beginning of a project

and, in this case, of hanging system, it

future otherwise. In the hanging and

are as follows:

should also be found a way to prevent

masking field, checking all products

- the reduction of the number of masks by

any shadowing effect on the painted

enables to guarantee that the coating

surface, accumulation of paint between

process will occur properly. Hanging

the workpiece and the mask, and powder

systems can be easily subjected to hook

penetration where not expected (Figs. 7

strength and bending tests. In order to

and 8).

guarantee consistent results, plugs and

incorporating them in a single design; - the possibility to insert them with simple tools; - the need to prevent any transfer of liquids

As pointed out at the beginning, the control

caps should be checked for adequate

- the masks’ colour;

of the process, its phases, and its quality

configuration, weight, and moulds’ size

- the masks’ stability on the workpiece;

level is a crucial factor. Through

consistency (Fig. 9). Finally, tape should

- their ease of removal through handles able

pre-planned, constant monitoring, it is

be tested for adhesion, glue resistance,

possible to anticipate problems that would

and shrinkage during curing (fig. 10).

during pre-treatment;

to avoid damaging the cap.

9 1

10 1

Figure 9: When testing a cap, its configuration, weight, and moulds’ size consistency are checked.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Figure 10: A control test on masking tape.

Opening photo: Railings and pantographed sheets for gates are among Sercolor’s most appreciated products.

FOCUS ON TECHNOLOGY

Greater Production Flexibility and Speed: The Conveyor as the Core of Sercolor’s Coating Line Monica Fumagalli ipcm®

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

he concept of industrial culture commonly refers to a set

FOCUS ON TECHNOLOGY

of notions acquired through experience and study, which, if properly applied, enable the development of a company’s

activity. However, it should not be limited to this: the experiences gained on the field and implemented after a course of study should be integrated with the most up-to-date information on different aspects of business management, such as internal organisation, production flow, and the plants and devices that make up a firm’s productive equipment. The technical publishing industry has the main purpose of spreading this kind of news to help create a shared industrial culture: this is what our magazines have strived to do in the coating field for over ten years.

We know we are achieving our goal when we meet entrepreneurs like Luciano Serravezza, production manager of Sercolor Srl

Figure 1: Sercolor’s galvanising plant is one of the largest in Southern Italy.

(Melissano, Lecce, Italy). His company specialises in the contracting galvanising and powder coating of components intended for

different sectors, especially the construction, agricultural, and automotive ones. “My passion for coating started many years ago,” says Serravezza, “and keeping up-to-date is fundamental. Thanks to the information I get from specialised magazines and the experience gained with this company, which my family has been managing since 1997, I was able to design and install a new coating plant to be added to our old one, which was already working at full capacity. I personally assumed the role of prime contractor, carefully choosing the right suppliers for each device and closely cooperating with them to achieve the results we had set ourselves with this huge investment.” The main players chosen by Serravezza were as follows: CM Automazione (Giussano, Monza e Brianza, Italy), specialising in the design and installation of handling lines; Avin (San Vito al

2 1

Tagliamento, Pordenone, Italy), belonging to the Imel Spa Group, for the supply of the pre-treatment plant, the coating line, and the curing

Figure 2: A bird’s eye view of the new coating system designed by Avin.

oven; and Wagner and Nordson for the powder primer and top coat

Galvanising and coating, the two pillars of Sercolor’s production

application equipment.

Sercolor is a business of excellence in Southern Italy: since the 1990s, it has evolved by changing its core business, continually updating its equipment, and exploiting it in different ways according to the current market needs. “We initially sold aluminium profiles,” says Serravezza. “In 2004, we installed our first automatic iron coating system while continuing to market profiles. We abandoned this activity in 2007, when we integrated our painting line with a galvanising plant. Since then, our growth has never stopped, as evidenced by the fact that we have gradually moved into ever-larger factories while constantly updating our equipment. We reached such a point that, in order to meet the increasingly demanding requests of our customers, in October 2018 we opened a further plant to house a new coating line.”

3 1

Figure 3: A detail of the CM Automazione’s conveyor in the pre-treatment area.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

4 1

Figure 4: Flying bars moving by the CM Automazione’s conveyor toward the unloading area.

Currently, the Apulian company operates in two adjacent buildings. The first one is equipped with a manual sandblaster, a pre-treatment plant (performing phospho-degreasing and cleaning with mains water), two electrolytic and hot-dip galvanising systems (of which one is static and the other is a barrel machine for small workpieces, capable of treating up to 10 tonnes of parts per day), and a static coating plant (with a manual handling system). “The static galvanising plant,” says Serravezza, “has unusual dimensions for this kind of machine: it is 6.5 m long, 0.6 m wide, and 1.25 m high (Fig. 1). Actually, it is one of the largest in Southern Italy. Our target customers for this process are companies from the automotive and heavy carpentry industries, which are increasingly choosing our services. We perform two types of hot-dip galvanising processes, one with an acid zinc coating and one with an alkaline zinc coating, in order to give greater corrosion resistance to parts subjected to a high wear degree or intended for harsh outdoor environments. Gates are an example of this: for this kind of product, we often treat pantographed sheets, which our customers particularly appreciate (ref. Opening photo).” The powder coating line located in the first building is devoted to large-sized, complex-shaped parts. Its dimensions are 2.10 x 6.5 x 2.8 m. “In our second building,” explains Serravezza, “we installed the new coating line, which was necessary to handle the production peaks that the old installation was no longer able to support and maintain our distinguishing delivery times, equal to a maximum of seven days.”

FOCUS ON TECHNOLOGY

5 1

Figure 5: The automatic lubrication system of the CM Automazione’s conveyor chain.

The complex structure of the new coating line With a size of 6.5 x 5 x 2.5 m, the new coating plant is smaller than the other one (Fig. 2). “I have personally designed the layout of the new line based on the experience I have gained over the years,” states Serravezza. “Besides personally following the installation of each device, wherever possible I recovered parts of the old system that could be reused in the new line. The complexity of its structure reflects that of the painting cycle we perform in a limited space. This is the reason why one of the key players for the success of this project was the supplier of the handling system. Indeed, the conveyor is the core of a coating line (Fig. 3). Not only does it connect its different elements, but it also determines its pace and speed. An effective design that is functional to user needs is fundamental to manage both the plant’s operating and storage areas and to create an optimal production flow. Our CM Automazione two-rail conveyor is now the core of our whole paintshop (Table 1, Figs. 4 and 5).” Table 1: Technical characteristics of the conveyor system.

Pitch

10 units/hour (equal to 1/6’)

#1 section conveyor speed (booth) with 1.3 m/1’ a continuous movement #2 section conveyor speed (tunnel) with 1.3 m/1’ a step-by-step movement #3 section conveyor speed (service) with a continuous movement

8 m/1’

Number of transport units

Maximum load per transport unit

Kg 500

Maximum workpiece size

6500 x 500 x H 2500 mm

6 1

Figure 6: The outside of the pre-treatment tunnel.

“Although we deal with large

along 3 lines of the conveyor, is driven by 4

components, the space available was

The two-layer coating system for galvanised parts

caterpillars,” says CM Automazione owner

limited,” notes Serravezza. “It was

The coating cycle performed is different

Stefano Crotti. “The capacity of each load

precisely in the definition of the spaces

depending on the type of product treated.

bar is 500 kg and it was specifically designed

for the conveyor installation that

“We are the pioneers of two-layer powder

for the heavy carpentry parts that Sercolor

CM Automazione’s team found the most

coating for galvanised workpieces,” adds

processes in high percentages. This completely

innovative solutions: the placement of

Sercolor owner. “We subject all parts to

automatic handling system is managed through

the buffers for the drying of materials

a pre-treatment process that includes

an Industry 4.0-oriented PLC and it has 19

was their main challenge, but they

phospho-degreasing, cleaning, cleaning

stations.”

managed to solve it in the best way.”

with demineralised water, and a no-rinse

7 1

8 1

Figure 7: Pantographed sheets inside the pre-treatment tunnel.

“The two-level chain, which runs over 500 m

Figure 8: The inside of the primer application booth.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

9 1

Figure 9: The inside of the IR oven: the panels were supplied by Infragas Srl.

FOCUS ON TECHNOLOGY

10 1

Figure 10: The bar no. 16 gets ready to travel the bypass system in order to start the second application cycle.

nebulisation system. As the nanotech product, we

the application of the primer; this was recovered

use Dollcoat SA 119, supplied by DN Chemicals

from our old painting plant and adapted to its new

(Caleppio di Settala, Milan, Italy - Figs 6 and 7).

function with the integration of new guns (Fig. 8), a

If required, we then sandblast the parts in our

cyclone, and a filtration system.

automatic tunnel shot blasting machine, with a

“Subsequently, the galvanised components would

dimension of 6.5 x 1 x 2 m. Hot-dip galvanised

have had to enter the IR oven (Fig. 9), as we had

components, which account for 90% of our

chosen a dry-on-fused cycle, that is, the application

11 1

Figure 11: Nordson guns applying a top coat.

production, than reach our first Wagner booth for

nanotechnology conversion stage with the Soft Rain

12 1

Figure 12: The powder control system.

of the second coat of powder on the only-gelled primer layer; however, we immediately started finding surface defects due to degassing bubbles, and we decided to opt for a dry-on-dry technology that calls for the complete polymerisation of the primer layer in the curing oven. In August, CM Automazione’s staff returned to modify our conveyor based on this new workflow.” “For large-sized companies like Sercolor, the flexibility of the conveyor is a crucial factor,” adds Crotti. “It enables them to work simultaneously and continuously on different levels, for example

13 1

pre-treating components while others are inside the curing oven. It also allows intervening quickly and

Figure 13: A component coated in white, which is one of the most required colours for galvanised products together with ivory and anthracite.

effectively to change the line if new needs arise, such as in this case: in order to prevent the conveyor from © ipcm ®

taking the flying bars along the entire path only to return to the curing oven, we created a bypass option that enables to keep the workpieces in the application and curing area (Fig. 10).” The components are then sent to the second booth for the application of the powder top coat and, finally, to the unloading station. This second booth is equipped with Nordson powder application guns (Fig. 11) and automatic and manual control systems (Fig. 12); Siver, the exclusive reseller of Nordson powder application systems in Italy, provided the powder management unit.

14 1

Figure 14: The whole Sercolor staﬀ with Alessia Venturi. From left to right: Rocco, Maria Rita, Chiara, Luciano Serravezza and Matteo Morieri, from the Sercolor’s purchase oﬃce.

Conclusions “It is impossible to find another coating system as flexible as the one we installed in our paintshop,” states Luciano Serravezza. “This installation has

provided us with a production speed and flexibility degree that our old system was unable to guarantee. Our products’ coating quality have also benefited from this, so much so that we have started the procedure for obtaining the Qualisteelcoat certification for the components on which we apply powders provided by Europolveri (Sandrigo, Vicenza, Italy), i.e. the Qualisteelcoat C5-M high-performance primer, specifically developed for our process, and two Qualicoat white paints (Fig. 13). The activity of Sercolor is constantly evolving (Figs. 14 and 15) and it will always be. It is essential to continue to keep abreast and gain new experience, in order to contribute not only to create but also to

15 1

spread industrial culture as the backbone of every

Figure 15: Small parts painted by the company.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

manufacturing activity.”

ON THE ROAD TO ipcm

Â®

n. 59

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

S P E C I A L O N A L U MI N I U M F O R M ETAL ARCH I T E C T U R E A N D I N D U S T R I A L D E S I G N

68 72

BRAND-NEW HIGHLIGHT OF THE MONTH GSB General Meeting in Hamburg: Projects for High Quality Coated Aluminium

FOCUS ON TECHNOLOGY Gutmann AG: Two Aluminium Profile Coating Lines to Improve its Time to Market and Expand its Production of Architectural Systems

INNOVATIONS: PRESENT&FUTURE Tangea Tones: A New World of Colouration for Anodized Aluminium

FOCUS ON TECHNOLOGY Aliplast: The choice of a Vertical Coating System for Aluminium Profiles in the Pursuit of Maximum Productivity and Quality

106

HIGHLIGHT OF THE MONTH Technology and Creativity in Colour Fan Decks and Files for the Aluminium and Powder Coating Markets

110

FOCUS ON TECHNOLOGY Insourcing Coating Processes in the Architectural Aluminium Profile Industry: Pasturi’s History

118

INNOVATIONS: PRESENT&FUTURE When Metal Becomes Wood. Characteristics and Evolution Trends of the Powder-on-Powder Technology for Wood-Effect Finishes on Aluminium

122

FOCUS ON TECHNOLOGY A new Pre-treatment System Helps Guarantee Perfect Paint Adhesion on Stûv’s High Temperature Stoves

FOCUS ON TECHNOLOGY Aluminios Andalucía: Culture of Coating Quality in the Field of Powder Pre-Painted Metal

128

S P E C I A L O N A L UMINIU M FOR M E TA L A RC HI TE C TURE A ND I ND US T RIAL DESIGN

BRAND-NEW

‘C

olor Design’ is not only colour, but also finishes. Innovative finishes

Metallic or pastel? ON/OFF able to revolutionise the interior

design canons, playing with light. You had a shape in your mind, you planned and you implemented it. You have thought this through, but you haven’t decided yet: metallic or pastel? While being deep in doubts you meet ON/OFF, the finish from the Acromatica collection of Lechler Tech. Its chemical composition creates a unique changing effect: in diffused light the finish appears pastel, in direct light aluminium sparkling

Figure 1: The ON/OFF finish from the Acromatica collection of Lechler Tech creates a unique changing eﬀect, playing with light.

particles stand out and the finish turns into metallic (Fig. 1). Where paint matters Color Design

In Acromatica all colours are neutral in order

proposes solutions able to confer objects

to present three new finish effects in five

the power to move, as the mixer from the

variations of gloss level:

Gessi collection shown in the Figure 2.

- SILK: ultramatt and semigloss effect that

It is conceived to characterize objects in minimalist spaces. - ON/OFF: an absolute innovation for paints, it gives an object the ability to

In the last few years Lechler has presented

gives surfaces a total matt or semigloss

switch from pastel to metal depending on

the collections Pastelli, Polineutri,

finish; it is ideal for irregular products,

the light around it. It is presented in both

Golden Shades and Classics, the most

creating interesting appearance contrasts.

high glossy and semigloss versions.

popular colour proposals able to satisfy

- STARGLASS: diamond effect that “lives” © Lechler

expectations of designers in various contexts of design and production of industrial products for the Habitat sector.

and “communicates” with the direct light it receives; ideal to make simple surfaces glam too.

The new collection ACROMATICA, in contrast with other collections, studies

The absence of colour in this proposal

for first time interaction among new finish

should not mislead us: the Acromatica

effects, taking into consideration also

collection is a guide for the combination

interior lighting.

of finishes which can be used alone

Furthermore, this collection aspires to meet

or together, but do not preclude also

the demands of multi-functional spaces,

their use in combination with colours.

such as home-offices, open-plan houses,

It is for this reason that a new colour

etc. In these areas visual complexity is very

collection is now under study and it will

high, because objects with very different

be presented soon. It proposes a range

shapes and functions live side by side.

of the most suitable colours to meet new

When you use Acromatica finishes, colours vanish to make integration easier: in this way, attention moves on new finishes that range from ultra matt to super gloss on a scale from white to absolute black.

specific effects, so that their peculiar 2 1

Figure 2: The mixer from the Gessi collection shows eﬀects of the ON/OFF finish by Lechler.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

characteristics are underlined. For further information: www.lechler.eu

S P E C I A L O N A L UM I NI UM FO R ME TA L A RC HI TE C TURE A ND I ND US TRI A L D E S I G N

BRAND-NEW

he irresistible itch to innovate has resulted in AkzoNobel

New Finishes Help AkzoNobel Scratch Itch for Innovation in Powder Coatings developing a scratch-resistant

powder coating for the architectural market in both matt and satin finishes. Responding to customer demand, the company got to work and has now added the pioneering dual functionality to its Interpon D range. Known as Interpon D X-Pro, it’s available in both standard and superdurable formulations. To prove its toughness, the product was subjected to rigorous testing using industry standard Martindale1

AkzoNobel’s architectural customers – particularly fabricators of aluminium windows and doors – wanted a scratch-resistant powder coating, especially for darker colours, and Interpon D X-Pro is exactly what is suited right for them.

test equipment. The high gloss retention scores are proof of the

wanted a scratch-resistant powder coating,

coating’s improved scratch resistance.

especially for darker colours, and that’s

“We’ve listened to our customers, learned from

exactly what we’ve delivered.”

them and delivered exactly what they want,”

Products coated with Interpon D X-Pro

explains Daniela Vlad, Managing Director of

are less susceptible to abrasions during

AkzoNobel’s Powder Coatings business. “Our

handling and transportation. They now

product innovation is all about going beyond

arrive at the end of their journey looking as

expectations and we believe we can now provide

good as they did at the start.

the best possible scratch resistance solution.

Customers have already come to trust

This way, the coated surfaces can be handled,

and rely on the company’s Interpon D

assembled or transported with better scratch

range, which has been verified by an

resistant protection.”

Environmental Product Declaration.

Adds Jean-Paul Moonen, the business’ Segment

AkzoNobel was the first global powder

Manager for Architectural Coatings: “Interpon D is

coatings supplier to obtain the

already recognized for its durability, now we can

EPD certification back in 2015. A recently

add a scratch resistance solution to the mix. Our

renewed EPD for the Interpon D range

architectural customers – particularly fabricators

of architectural powder coatings lasts

of aluminium windows and doors – told us they

until 2023. Interpon D X-Pro can be supplied from

Scratch resistance is assessed by means of the “Martindale test” method. It’s the most widely used and most objective method for testing scratch resistance. In accordance with standard CEN/TS 16611, an abrasive object with a defined weight is applied to the test surface and rubbed across the surface in cycles. The impact is assessed both visually and especially by measuring the residual gloss, i.e. the diﬀerence between the gloss measured before and after the surface has been exposed to scratching.

stock throughout Europe. For further information: www.interpon.com

S P E C I A L O N A L UMINIU M FOR M E TA L A RC HI TE C TURE A ND I ND US T RIAL DESIGN

BRAND-NEW

Colourful, Functional, Customized: Qualisteelcoat Approved Anti-Corrosion Systems

he phenomenon of corrosion is

Structural deterioration, maintenance and

commonly associated with metallic

replacement of parts subject to corrosion

materials. Metal corrosion can

have a significant impact on costs.

ECO-STEELCORR painting systems: Qualisteelcoat approvals

be defined as a degradation process

A study by the WCO (World Corrosion

ECOPOLIFIX has been providing with

under certain environmental conditions.

Organization) in 2017 calculated that the

anticorrosive primers ECO-Primer O195

Corrosion indicates a natural and

costs related to corrosion are around

for many years. These, in combination

irreversible process of slow and continuous

2.5 trillion dollars/year and that it

with suitable Top-coats, such as the

consumption of a material, which results in

affects 3–4 % of the PIL of industrialized

Qualicoat-approved polyesters of

the deterioration of the characteristics or

countries. The same study also estimates

the various Helios powder coating

physical properties of the material initially

that a reduction of 875 billion dollars

series, offer a very high protection

involved. Durability, functionality and safety

per year of these costs is potentially

against corrosion. The Qualisteelcoat

are the most important and required

possible through: harmonization of

specification adopts parts of the

features of metal materials and structures.

regulations and standards, training of the

ISO 12944 standard that can also be

Thus, the protection from corrosion of

various professional figures and through

applied to powder coating.

metal artefacts is a necessary requirement

the use of appropriate anti-corrosion

The Qualisteelcoat approvals of the

for the steel construction industry.

technologies.

ECO-STEELCORR systems are the

result of the research and work of the ECOPOLIFIX laboratory in synergy with the HELIOS TBLUS laboratory in Ljubljana for the numerous physical and instrumental tests performed on the samples over the years. All ECOPOLIFIX’s staff in Italy and in the whole Helios Group in Europe are engaged in the continuous search for solutions that the market today solicits and requires in terms of quality, durability and warranty levels, making its trading partners available to the knowledge and synergy of a global group. For further information: www.ecopolifix.it and www.helios-powdercoatings.com

Durability, functionality and safety are the most important and required features of metal materials and structures.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Every surface has its own individual structure!

Look forward to getting the optimum solution for the chemical reďŹ nement of metal surfaces.

We have been committed to the development, manufacture and GLVWULEXWLRQ RI FKHPLFDO SURGXFWV DQG SURFHVVHV IRU UHĂ&#x20AC;QLQJ metal surfaces for more than 40 years.

$OXĂ&#x20AC;QLVK Â˛ WKH SDUWQHU \RX FDQ UHO\ RQ É&#x201C; &RDWLQJV IRU DOXPLQLXP VWHHO DQG ]LQF É&#x201C; $QRGLVLQJ No matter which pre-treatment process is the ideal one for \RXU QHHGV SHUVRQDO FRQVXOWDQF\ DQG LGHQWLĂ&#x20AC;FDWLRQ ZLWK \RXU WDVN LQ KDQG DUH ZKDW FRXQW DW $OXĂ&#x20AC;QLVK 2XU KLJKO\ FRPSHWHQW VWDII DUH WKHUH WR DWWHQG WR \RXU VSHFLĂ&#x20AC;F UHTXLUHPHQWV ZLWK DQ RSHQ HDU IRU \RXU ZLVKHV DQG NHHSLQJ DQ H\H RQ WKH HVVHQWLDOV Alufinish GmbH & Co. KG Otto-Wolff-StraĂ&#x;e 7-15 Â&#x2021; D-56626 Andernach

,QQRYDWLYH HQYLURQPHQWDOO\ VDIH VROXWLRQV WKDW PHHW WKH KLJKHVW demands of your customers are vital to us.

Tel. + 49 (0)2632 - 9297 - 0 E-Mail: info@alufinish.de Â&#x2021; www.alufinish.de

We build on trust!

Opening photo: One of the projects carried out according to GSB quality guidelines: the oﬃce building in Munich.

HIGHLIGHT OF THE MONTH

S P E C I A L O N A LU MINIU M FOR M E TA L A RC HI TE C TURE A ND I ND USTRIAL DESIGN

GSB General Meeting in Hamburg: Projects for High Quality Coated Aluminium Edited by GSB International e.V. Düsseldorf – Germany

info@gsb-international.de

SB International is an association for

association, the representatives for the Board

demonstrated the potential and limitations of

surface coatings in architecture and

and Quality Committees for the next 4 years

the current possibilities.

industry. Its task is to ensure quality

were appointed.

in relation to coatings of workpieces as well as

This year once again provided a varied

The new project seal of GSB: application,

pre-treatment and coating materials used in

programme of events with interesting

features and benefits

the process. To this end, GSB creates quality

presentations.

Hans Georg Eder from Akzo Nobel Powder

guidelines and monitors their application

Coatings GmbH (Arnsberg, Germany)

(ref. Opening photo).

Digitalisation in coating companies:

presented the new GSB website and focused

GSB International invited members to attend

utopia or the future?

in particular on the functions of the planning

the 22nd General Meeting in Hamburg on 8th

Wilfried Rapp from STOBAG Alufinish

tool and the seal generator in conjunction

and 9 April 2019. Over 100 members from

GmbH (Wutöschingen-Horheim, Germany)

with the value chain. He described succinctly

all over Europe accepted the invitation to

and Fabian Luccarini from e.Luterbach AG

the particular strengths of the new system

find out more about the work GSB has been

(Hildisrieden, Switzerland) explained how

and explained the resulting benefits for

doing and the latest news from the coatings

the digitalisation of a coating company as

coaters and end customers. He concluded

industry. In addition, future-oriented changes

part of a site expansion can be implemented

his presentation with a forecast of future

were agreed and, in line with the articles of

efficiently and effectively. They also

additional application options.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

Challenge: generation change in SMEs in

“robust processes” along the value chain, as

generation. We need to face facts!

the coating industry

well as the creation of ideal prerequisites

Sustainability and environmental awareness

In his presentation, Dr. Johannes Schmidt

for the generation change in medium-sized

is once again of great significance within

from INDUS Holding AG (Bergisch Gladbach,

companies.

GSB thanks to the Green GSB commitment.

Germany) explained the current situation

This is already being tackled through

For example, our pro-active foresight in the

for company succession in medium-sized

the Young GSB project, which has had a

past with the long-term external testing

companies in Germany. By 2020, there is

promising start with a workshop in March this

of Cr-VI-free pre-treated profile samples © GSB International

expected to be a succession plan for over 227,000 of German SMEs (small and medium-sized companies). The statistics showed

means that GSB is now able to verify weathering results for 10 years of natural weathering. GSB is therefore currently the

that around 65% of SMEs have

only quality association on

not yet finalised a succession

the market which meets the

plan. In addition to current trends,

requirements of the relevant

Dr. Schmidt presented various

European standards.

possible succession options and

In order to remain equipped

made clear recommendations for

for the future, GSB is using

preparing for them.

research and development to create the knowledge transfer for the necessary innovation

Digital transformation “show” On the evening before the AGM,

climate in the industry and

Andreas Axmann, “The media magician”, entertained guests

thereby open up new markets for its members.

Figure 1: The GSB’s board elected during the meeting.

Through networking in

during dinner. With his charming

European and international

demeanour and unique show on digital transformation, the slick “iPad magician”

year. Linking digitalisation and marketing as

standardisation bodies, the guidelines of

rounded off the evening and provided a

well as developing both areas were identified

GSB International can be disseminated

successful start to the overall event.

as the challenge for the years ahead. The use

worldwide as supplier qualifications or

of social media networks such as Facebook,

production guidelines and thereby offer a

LinkedIn and Twitter in particular will play

further benefit. This will create a decisive

At the internal General Meeting, the Chairmen

a central role in future for the exchange of

competitive edge.

of the Board, Willem Beljaars and Werner

knowledge. A research project in partnership

It follows from this that GSB will continue

Hillebrand, reported on projects from the last

with the South Westphalia University

to offer the opportunity for its members to

two eventful years and gave an overview of

of Applied Sciences demonstrated that

acquire new knowledge or expand existing

future plans for GSB (Fig. 1). The focus was

members currently have a lot of catching

knowledge through training courses,

on the mission statement of GSB, which is

up to do when compared internationally for

workshops and continuously harmonised

increasingly aimed at the establishment of

this form of communication and knowledge

testing.

Report from the Board

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FOCUS ON TECHNOLOGY

S P E C I A L O N A LU MINIU M FOR M E TA L A RC HI TE C TURE A ND I ND USTRIAL DESIGN

Gutmann AG: Two Aluminium Profile Coating Lines to Improve its Time to Market and Expand its Production of Architectural Systems Alessia Venturi ipcm®

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

“A

nything is possible, here at

a considerable manipulation degree of

“Gutmann now has a fully integrated production

Gutmann.”

our products, with negative consequences

process, which starts from the extrusion of

on quality levels and delivery times.

profiles, continues with machining (cutting,

That is what Bruno Fijten (Fig. 1), a member

A long delivery time is not acceptable in

welding, and drilling), thermal break assembly,

of the Board of Directors of the Gutmann

this market, where a just-in-time approach

anodising, and coating operations, and ends

Group, immediately tells us. Based in

is required because decisions on colours

with the quality control, packaging, and shipping

Weiβenburg (Germany), this company

and finishes are taken at the last minute,”

phases. We combine a just-in-time flow with

has specialised for eighty-five years in

explains Fijten. “That is why we decided to

an excellent quality level and a maximum cycle

the production and sale of aluminium

establish Color/G Aluminium, a company

time of 4 days from cutting to packaging,” says

architectural systems and custom

entrusted with the coating of the entire

Simon Brunauer, the architectural system

aluminium profiles for several different

Gutmann production.”

production manager and the coating manager © ipcm ®

industrial sectors (ref. opening photo).

of Color/G. “In order to achieve our lean production and excellent

“The variability of products

quality goals, we decided

that we are able to offer

to rely on one supplier for

on the market is potentially

both our new coating lines

limitless: we already provide

and we chose Trasmetal

almost 10,000 possible

(Milan, Italy), which provided

combinations and we are the

us with two high-quality,

market leader of the DACH

technologically advanced

area . Our way of doing

plants while distinguishing

business is unique but also

for its design accuracy and

very complex. We specialise in

on-time deliveries. The first

the production of aluminium/ wood systems, which are very exclusive because they combine the warmth of wood with the high outdoor

plant we installed was the

horizontal one, which was

Figure 1: From left to right: Bruno Fijten from Gutmann, Alessia Venturi from ipcm® and Simon Brunauer from Color/G.

started in January 2018 and reached full production in one year (Fig. 2). We chose

resistance performance of

to begin with this because it

aluminium, thus eliminating

would have ensured higher

the need for maintenance. We have ambitious plans for this market: we want to double our volume of business. Therefore, we must reduce our time to market and improve our production capacity. Our investment in two aluminium profile coating systems, a horizontal one started in 2018 and a vertical one recently completed, was a part of this expansion project.” “Up to 2018, we worked with several local contractors for coating our profiles. This production flow was not lean and it entailed 1

Germany, Austria, and Switzerland.

Gutmann now has a fully integrated production process, which starts from the extrusion of profiles, continues with machining (cutting, welding, and drilling), thermal break assembly, anodising, and coating operations, and ends with the quality control, packaging, and shipping phases.”

flexibility in terms of workpiece type and size than the vertical one: indeed, Color/G also coats sheets, accessories, and components for our architectural systems (Fig. 3). One year after the start of the project, however, the subcontracting issue remained, as the horizontal line was not sufficient to handle our whole coated profile volume: our aluminium/ wood systems alone require us to produce 1 million m2 of window profiles in 2 colours. We needed a second, high-productivity coating line. We chose a vertical system, again supplied by Trasmetal, with last generation MS Powder System booths (Fig. 4).”

Opening photo: Based in Weiβenburg, the Gutmann Group has specialised for eighty-five years in the production and sale of aluminium architectural systems and custom aluminium profiles for several diﬀerent industrial sectors.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

“In order to further streamline production and guarantee total quality, we also chose to only rely on two powder coatings suppliers, except for projects for which customers have different specifications,” emphasises Simon Brunauer. “We have developed our own colour range including about 20 tints. Customers that select one of these colours can count on a delivery time of 1 day; the choice of any other colour among 200 standard shades provided entails a delivery time of 2 days, while for special colours the delivery time rises to 3 days, which is also our maximum time-to-market for coated products. Syntha Pulvin, a brand of The Sherwin-Williams Company, is our main supplier of

2 1

architectural powders.” “Gutmann currently uses GSB/Qualicoat Class 1 powders,

Figure 2: A detail of the horizontal coating system installed at the factory of Color/G Aluminium by Trasmetal (Milan).

but plans to soon switch to Class 2 ones,” says Thorsten Reif, technical-commercial specialist of The Sherwin-Williams

Company. “Our Inver2 factory in Italy provides it with about 190 colours with different effects, including glossy and matt smooth, fine textured, and glossy and matt metallic finishes. These belong to three different groups, i.e. 111 (smooth/glossy), 119 (fine textured), and 123 (smooth/ matt), within which each colour is defined by a code. This system enables Gutmann to quickly order tints and finishes using their codes, with no risk of mistakes. Custom colours are formulated in our laboratories in Minerbio (Italy) and Thouars (France), following the classification and performance characteristics of each coating group. Finally, we provide Color/G with a consultancy service and technical assistance within 8 hours from their requests, deliveries

3 1

within 48 hours, and above all the support of our two laboratories in Italy and France for any R&D activity.”

Figure 3: Color/G Aluminium coats sheets, accessories, and components for the architectural systems produced by the Gutmann Group.

The horizontal system: maximum flexibility in production planning The horizontal profile coating line installed by Color/G at the end of 2017 and entered into production in January 2018 was a greenfield project. “We started completely from scratch,” says Brunauer, “in terms not only of the building which was to house the plant, but also of staff training, IT solutions, paint stripping operations, and management of powders, chemicals, and water supply. Typically, a company entering the aluminium profile coating market starts with a vertical system because the management of a horizontal one is much more complex. On the other hand, a vertical plant cannot treat small parts, accessories, and sheets, which, as stated, are an integral part of our production.”

4 1

Figure 4: The vertical system supplied by Trasmetal.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Inver is a brand of The Sherwin-Williams Company.

FOCUS ON TECHNOLOGY

5 1

Figure 5: A detail of the two-rail conveyor provided by Conveyors Nord on the horizontal line.

The horizontal system designed by Trasmetal allows coating frames with maximum length of 6400 mm, height of 2400 mm, and width 300 mm, with a capacity of 300 kg per load bar. It has an average hourly productivity of 17 frames and a takt time of 3.5 minutes. It is equipped with a two-rail conveyor built by Conveyors Nord (Inzago, Milan). Its layout includes two loading and two unloading stations, both equipped with elevators for more ergonomic handling operations without the need for platforms (Fig. 5). The conveyor features several storage buffers in different sizes, located along the line and inside the drying and curing ovens to ensure maximum planning flexibility (Fig. 6). “The plant’s software program interfaces directly with the company’s management system. Daily production is programmed and managed through a touch screen station

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

6 1

Figure 6: The conveyor of the horizontal line features several storage buﬀers to ensure maximum planning flexibility.

it has 26 slots. Since a load of frames can

that enables the operator to select the right painting cycle to match each flying bar,” explains Trasmetal product manager Renzo Elli. “Once a flying bar is matched with a coating program, its handling is automatic. The operator can only integrate the production plan with any reworking operation needed by picking the flying bar directly from the bypass storage buffer.” “Each loading and unloading station has a buffer with 5 slots (Fig. 7). The first buffer after the loading station is in front of the pre-treatment tunnel and

The conveyor has a bypass option between the loading areas and the coating booths, which Gutmann uses whenever it loads parts that must not undergo pre-treatment, such as two-tone profiles, pre-anodised profiles, or damaged parts to be reworked.”

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

range from 2 large-sized profiles to 500 small accessories, and given that we want to maintain our takt time of 3.5 minutes in any case, we must make sure that we always have enough material ready to enter the pre-treatment tunnel,” says Simon Brunauer. “The conveyor has a bypass option between the loading areas and the coating booths, which we use whenever we load parts that must not undergo pre-treatment, such as two-tone profiles, pre-anodised profiles, or damaged parts to be reworked (Fig. 8).”

eosmarketing.it

FOCUS ON TECHNOLOGY

“The flying bars that must be subjected to

must work at a temperature of 26 °C ± 1 °C,

pre-treatment, on the other hand, are sent from

we have decided to add a chiller with a heat

the loading stations to a tilting device (Fig. 9) that

pump instead of two separate machines, i.e. a

favours water drainage during the cycle. Afterwards,

heater and a cooler (Fig. 11). The drying oven

the flying bars move from the main plant chain

has a 8-slot storage buffer. After drying at 120 °C

to the tunnel circuit. The tunnel’s step-by-step

for 20 minutes, the flying bar passes through a

chain swings forward and backward by 500 mm to

straightening device that takes it back to its normal

guarantee a uniform treatment quality degree on

position before proceeding toward the coating

the profiles’ entire surface (Fig. 10).”

application station.”

The pre-treatment process is a chrome-free cycle

“At the end of the drying cycle, the conveyor

conceived by Alufinish, including two acid attacks,

reaches an 8-slot storage buffer, located opposite

two rinses with mains water, one rinse with

to the pre-treatment tunnel’s bypass one,” says

demineralised water, and a no-rinse conversion

Simon Brunauer (Fig. 12).

stage. Both coating lines require the same

“As suggested by the line operators, both these

pre-treatment chemicals.

buffers feed the ones preceding the coating booths

“We have built the pre-treatment tunnel in

according to the daily production plan. Colour,

AISI 316 L stainless steel with some parts in AISI 316

batch, and coating program controls are carried

T steel, because pre-treatment products are both

out in the pre-booth buffers. The booths are

very effective and rather aggressive,” says Michele

equipped with an optical scanner to determine the

Leonardi from the Commissioning Department of

beginning and end of the spraying phase with the

Trasmetal. “Since the conversion chemical product

aim of reducing consumption (Fig. 13).”

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7 1

Figure 7: Each loading and unloading station of the horizontal line has a storage unit with 5 slots.

. sas

www.pspsverniciature.it

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

8 1

9 1

The two automatic coating booths with a

There are two further 5-slot storage

The demineralised water production

quick colour change system are symmetrical

buffers right after the automatic

plant and the chemical dosing system

and work simultaneously, each equipped

booths. A hot air pre-curing chamber

are linked to both coating lines

with 16 spray guns, 8 per side. Each booth

enables Color/G to apply any colour

through separate feeding circuits,

has a large platform for any pre-retouching

simultaneously while avoiding any

which prevent the line operators from

activity. Color/G has also chosen to install a

contamination among different tints on

coming into contact with chemicals.

manual booth for touch-up and sampling

the workpieces. The line ends with the

The water treatment plant is also

operations (Fig. 14).

curing oven with a 12-slot storage buffer.

shared (Fig. 15).

Figure 9: The tilting device favours water drainage during the pre-treatment cycle.

Figure 8: The conveyor of the horizontal line has a bypass option between the loading areas and the coating booths, which is used whenever the loaded parts must not undergo pre-treatment.

10 1

11 1

Figure 10: The step-by-step chain swings forward and backward by 500 mm to guarantee a uniform treatment quality degree on the profiles’ entire surface.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Figure 11: The pre-treatment tunnel of the horizontal line is equipped with a chiller featuring a heat pump instead of a heater and a cooler.

FOCUS ON TECHNOLOGY

The vertical system

(Giussano, Italy), enables to hang the

“The next, almost necessary step after

components through hooks with a 100, 133,

our investment in this horizontal plant

or 200 mm pitch and a maximum loading capacity of 50 kg per hook. The average

was the purchase of a vertical one,” states Simon Brunauer. “We actually carried out this project concurrently. In one year, we constructed a new building and installed the plant, which is now in its ramp up phase. It is going to guarantee a production capacity of 3 million m2 per year, a much greater volume than that ensured by our horizontal line. On the other hand, it is much less flexible than the other one.” Color/G’s vertical profile coating system, also designed and installed by Trasmetal, allows

Color/G’s vertical profile coating system, also designed and installed by Trasmetal, allows treating extruded profiles up to 150 mm in thickness, 400 mm in length, and 7200 mm in height.”

productivity of the plant is 675 profiles/hour using hooks with a 133 mm pitch, equal to about 19 tonnes of coated aluminium in an 8-hour shift. In addition to the main conveyor, the plant includes a secondary circuit for feeding its two quick-colour change booths that work simultaneously. “The loading operator matches each hook with the right coating program through a bar code. The system knows the location of all hooks and determines their transfer toward one booth or the

treating extruded profiles up to 150 mm

other as well as the start of the pre-

in thickness, 400 mm in length, and

treatment tunnel pumps, with the aim of

7200 mm in height. The line speed is

saving energy and resources,” Michele

1.5 m/min (Fig. 16). The one-rail conveyor,

Leonardi from Trasmetal explains while

manufactured by CM Automazione

describing this line.

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

12 1

13 1

Figure 12: The drying station of the horizontal line is followed by an 8-slot storage buﬀer, located opposite to the pre-treatment tunnel’s bypass one.

Figure 13: The booths of the horizontal line are equipped with an optical scanner to determine the beginning and end of the spraying phase with the aim of reducing consumption.

reducing heat dispersion, which is typical of vertical systems

We installed a self-contained oven performing three

as they cannot be partitioned like the horizontal ones.

processes, i.e. drying, gelling, and curing, with only two

Trasmetal is aware of the importance of the consumptions’

heat exchangers. The purpose of integrating a gelling

control and it developed and patented a system that allows

chamber was to save energy. In fact, it is heated both by

to gel the powder layer onto the coated items, without the

exploiting the oven’s heat losses and by irradiation: hot

need of the traditional IR panels or complex and expensive

air circuits, heated through the same heat exchanger of

mechanical closing systems of the components transfer.

“We have implemented a number of solutions on this line for

14 1

15 1

Figure 14: The manual booth for touch-up and sampling operations.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Figure 15: The water treatment plant shared by the two lines.

FOCUS ON TECHNOLOGY

16 1

Figure 16: The vertical system allows treating extruded profiles up to 150x400x7200 mm with a speed of 1.5 m/min.

the oven, warm the irradiation surfaces through which the coated profiles pass.”

The GSB-project seal for coated aluminum.

“Another design peculiarity of this line are the partition walls between the areas crossed by treated and untreated parts, in order to avoid contamination,” adds Leonardi. “The pre-treatment process occurs with cascade stages except the third one, which is the first acid rinse. Each stage features a small water renewal Ap

ater

Approved Quality. M

and the sixth), bring it back to its liquid state, and precipitate it.”

Coated Aluminium.

tin

out the steam produced by the hot stages (i.e. the first, the second,

m en

pressurises a channel located below the conveyor in order to not let

ved Pre -Treate

one side of the tunnel, the other three on the opposite side. A fan

a A p p rove d C o

the demineralisation system. The first three stages take place on

p ro

reverse cascade coming from the cleanest one, fed directly by

e ri

GSB: Quality and safety for coatings of aluminum components.

The pretreatment process occurs with cascade stages except the third one, which is the first acid rinse. Each stage features a small water renewal reverse cascade coming from the cleanest one, fed directly by the demineralisation system.”

Added value for builders, architects and metal workers.

··

The new GSB-project seal contains all required quality statements Pretreatment Coating Material Coater GSB International e.V. / Fritz-Vomfelde-Straße 30 D - 40547 Düsseldorf / www.gsb-international.de

Ap C oa t e p r o v e d d A lu PREM minium IUM A p p ro C r- fr e ve d P retre atm e / Lic ent en

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se 3 0 v F lo ri d ed C oating M 2 b a5 /L ateria l ic e n se A p pro 170 c P re m iu ved C oater m Sea P ro o f L ic e n se

P rojec

435789 02.03. 18

08.52.

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

higher consistency and quality degrees. This is the first vertical system in the world to have them installed (figs. 18 and 19).”

A full range of services Thanks to the GSB Seaproof and Qualicoat Seaside certifications for its horizontal and vertical plant respectively, Gutmann can currently offer maximum quality in terms of surface finishing and corrosion protection. The very high production capacity and flexibility degree achieved by combining these two systems enable Gutmann to apply almost 1000 different tints, perform

17 1

colour change operations in less than

Figure 17: From left to right: Michele Leonardi from Trasmetal, Alessia Venturi and Simon Brunauer.

4 minutes, and guarantee a lead time of less than 4 hours even for special requirements. “Thanks to the integration of these two coating lines, the Gutmann Group can now provide its customers with extruded and coated or anodised

advanced solution supplied by MS Powder

longer, softer, and more enveloping than

profiles, welded sheets, and complete

System,” points out Simon Brunauer (fig. 17).

the conventional one. Powder distribution

frames that are fully built in-house,”

“These X-shaped booths feature 4 paint

is thus more homogeneous and the

states Bruno Fijten from the Gutmann’s

spraying spots, each with 5 guns. This peculiar

coatings’ colour and thickness have much

Board of Directors.

arrangement makes the powder cloud

“For our coating booths, we chose an

18 1

19 1

Figures 18 and 19: The X-shaped booths feature 4 paint spraying spots, each with 5 guns. This arrangement makes the powder cloud shorter, softer, and more enveloping and, therefore, it guarantees a more consistent coating process.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

HIGH - PERFORMANCE POWDER COATINGS FOR ALUMINIUM BUILDING PRODUCTS

Syntha pulvinÂŽ - premier architectural powder coatings brand in Europe setting the industry standard in terms of innovation, quality and service

Come and meet us!

Project description: Raycap Pavilion Commercial booth for Light plus Building Exhibition, Frankfurt, 2018 Ballian Techniki for Raycap Electrostatic Coating Product Syntha Pulvin: powder coating Ral 3004 FTX, Class 1 Architects: Kois Associated Architects Lighting design: Eleutheria Deko Photographer: George Sfakianakis

Contact: gi.emeai.marketing@sherwin.com Visit: www.synthapulvin.co.uk

Â© Alsan

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

S P E C I A L O N A LU MINIU M FOR M E TA L A RC HI TE C TURE A ND I ND USTRIAL DESIGN

Tangea Tones: A New World of Colouration for Anodized Aluminium Juanjo Gonzalez Alsan - Alvarez Schaer SA – Paterna (Valencia), Spain

alsan@alsan.es

he processes of electrolytic

has continued working along the line

under standard QUALANOD

colouring of aluminium anodizing

of obtaining new colours on anodizing,

conditions, to create an anodic layer

are described and are well known

which allow to maintain this metallic

consisting of regular and uniform

since a long time, industrially applying

finish so characteristic of aluminium

pores, where we will deposit the

technologies based on 2 phases DC / AC

and create a new and wide range of

different salts that will give us the final

to achieve loads with good uniformity

chromatic tonalities, which we have

colouration.

and penetration.

called Tangea Tones.

Once the anodic layer is formed,

Although currently there are few

These colour tones range from purple

we pass to the TANGEA electrolyte,

metallic salts being used in electrolytic

orange to copper and up to chocolate

where we carry out the electrolytic

colouring baths, many metallic elements

brown, and can produce many

colouration. The baths are worked with

are susceptible to be deposited

intermediate tones, according to the

DC / AC technology, where in a first

electrolytically in the pores of the anodic

needs of the customers (ref. Opening

phase we control the blockade of the

layers. Some of them were used years

photo).

pore, reinforcing to a greater or lesser

ago, other used in very specific countries

Thus, two new electrolytic baths have

extent the barrier layer. Then, in the

or companies, and others practically not

arisen that allow us to obtain the

second AC phase, when the metal salts

used at industrial level due to their high

colourations described above, “TANGEA

are deposited, the ELCOSAN RAINBOW

cost.

NATUR” for dark tones and “TANGEA

technology, allows us to work with

Among the metals capable of colouring

CLAY” for the clear ones.

complete AC waves or asymmetric AC

anodized aluminium are metals such

Both baths are formed by a mixture

waves or trimmed waves, so that we

as Fe, Co, Cu, Ni, Ag, Au, Se, Mn and the

of several metal salts, thus achieving,

control the deposition speed of the

most used, tin salts, for the colours inox,

under certain electrical conditions, a

metals, thus giving rise to the different

bronzes and black.

synergy that produces the co-deposition

TANGEA TONES colourations.

These metals provide a restricted range

of different metals, with preferential

The Tangea Tones baths are operated

of colours, although the techniques of

deposition of some of the salts

at temperatures of 20-21˚C and the

colouring by optical interference have

depending on the chemical adjustment

colouring times are reduced, without

allowed us, using the same bronze bath

of the electrolyte and the conditions of

exceeding 5 minutes for the darker

with tin salts, to expand the palette with

DC / AC programming used for colouring.

shades that logically require a longer

new colours such as blue, grey and

In this way, we regulate the different

time in the AC deposition phase.

green, which are already in production at

combinations that allow us to achieve

As examples of the different shades

many plants.

certain chromatic tones.

that can be achieved, chromatic coordinates obtained in industrial

The R&D department of ALSAN, specialist in the development of new products,

To work with TANGEA electrolytic baths,

baths for different finishes are shown

processes and colouring techniques,

it is necessary to anodize the aluminium,

in the Table 1.

Opening photo: New and wide range of chromatic tonalities for aluminium products by Alsan is called Tangea Tones.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

Figure 1: The chromatic features can vary according to the mechanical pre-treatment, being polished or re-polished finishes those that best show the intensity and liveliness of Tangea Tones.

Table 1 - Chromatic coordinates obtained in industrial baths for

The chromatic coordinates can vary according to the

different finishes.

mechanical pre-treatment, being polished or re-polished

L 45.2 32.3 23.8 58.2 48.6 45.1

a 11.1 12.6 6.7 13.1 19.5 22.1

b 17.2 13.2 5.7 21.9 14.5 22.2

finishes those that best show the intensity and liveliness of these colours. The results shown in the previous table have been measured on polished finishes. Visually Tangea Clay tones turn orange colours, simulating elements such as clay. After the electrolytic colouring process, it is necessary to seal the pore correctly, in order to keep intact the chromatic properties of these new developed tonalities (Fig. 1).

Colour Tangea Light Natur Tangea Medium Natur Tangea Dark Natur Tangea Light Clay Tangea Medium Clay Tangea Dark Clay

2 1

Figure 2: Tangea’s colour tones range from purple orange to copper and up to chocolate brown, and can produce many intermediate tones, according to the needs of the customers.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

As is known, according to Qualanod

Guidelines, which allows to ensure that all

control to maintain uniformity and

guidelines (Ed. 2017), the resistance

these new shades made with the ELCOSAN

repeatability in the colours we want to

of anodized aluminium colourations

TANGEA electrolytes, the TANGEA light and

obtain.

suitable for use in exterior carpentry,

the darkest colours TANGEA Dark have an

The consumption of the different

must overcome a number of light

excellent light stability.

salts in the baths is moderate, and the technology can be classified as

resistance of at least LE8 according to ISO 2135 -2017: â&#x20AC;&#x153;Anodizing of

Table 2 - Light stability of TANGEA clay

a technology that requires working

aluminium and its alloys - Accelerated

and TANGEA natur tones.

conditions between conventional

light resistance test of coloured anodic coatings using artificial lightâ&#x20AC;?.

COLOUR

LE9

All TANGEA CLAY and TANGEA NATUR

Tangea Light CLAY Tangea Medium CLAY Tangea Dark CLAY Tangea Light NATUR Tangea Medium NATUR Tangea Dark NATUR

OK OK OK OK OK OK

tones have been tested in the official Qualanod laboratory in Germany: FEM (Forschungsinstitut Edelmetalle + Metallchemie) in chamber Atlas model CPs + (with xenon arc lamp), obtaining

colouring and colouring by interference. This new range of colouration is already implemented at industrial level in several companies that have Qualanod certification. Tangea Tones present new electrolytic colourations that provide the anodized

in all tones of the TANGEA range, a light resistance of LE9 (Table 2).

The control of the baths is carried out

aluminium market with New, Unique

This result is higher than the

through simple analytics. This is important,

and Unlimited colours, which are, most

minimum specified in the QUALANOD

because there must be a very rigorous bath

important, fully tested (Fig. 2).

eosmarketing.it

ALU MIN IUM

ve r t i c a l p l a n t s

over 60 years of experience in surface finishing lines

www.trasmetal.net

Opening photo: Since 1960, Pratic has specialised in the production of sun protection systems. Its flagship product are bioclimatic pergolas, whose cover consists of adjustable aluminium slats and whose design makes them a real outdoor furniture piece.

FOCUS ON TECHNOLOGY

S P E C I A L O N A LU MINIU M FOR M E TA L A RC HI TE C TURE A ND I ND USTRIAL DESIGN

Insourcing the Coating Process and Widening the Colour Range of Aluminium Profiles for Sun Protection Systems: Two Winning Choices for Improved Quality and Customisation of Pratic’s Products Elisabetta Venturi ipcm®

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Its headquarters located in Fagagna, in the

ery few people probably know the history of the retractable awnings that protect the oldest

shops of any city in the world from the sun. It all started in Italy in 1960, when Bruno and Giuseppe Orioli established the company Pratic F.lli Orioli to produce handcrafted awnings with a wooden frame. After only five years, they patented their first retractable awning, an absolute innovation soon to be adopted by the best Italian craft shops. Nowadays, after almost sixty years, the firm is still led by the Orioli family. Dino, the president and a passionate yachtsman, and Edi, the vice president, a motorbike champion and a 4-time winner of the Paris-Dakar Rally, have poured their dynamic and sporty spirit into the company. The generational change has brought new ideas, new technologies, and new patents over the years. Pratic is now an excellence in the field of sun protection systems, with a

province of Udine (Italy), is an example of this. Consisting of a 20,000 m2 production area and an 800 m2 office area, it won the Gold Medal for Italian Architecture award in 2012 and it was included among the most significant architectural projects in Europe by the Mies Van Der Rohe Award in 2013, thanks to its wellbeing and sustainability-oriented design (Fig. 1). The continuous search for innovation – its products were the first to be tested in the Pininfarina Wind Tunnel in 2005 – enables Pratic to offer products of excellence with a sophisticated design and adaptable to any architectural context. This makes them real furnishing pieces able to embellish any outdoor space. On 15 June, Pratic’s colour range expanded considerably thanks to the collaborations with Tiger Coatings, with which the company has developed a new range of 30 colours. The company installed simultaneously a last generation coating line (the first one in Pratic’s history), supplied by Imel (Codroipo, Udine, Italy) that took two years to design and required a huge investment.

strong focus on design in all its aspects.

Pratic is an excellence in the field of sun protection systems, with a strong focus on design in all its aspects. Its headquarters located in Fagagna, in the province of Udine (Italy), is an example of this. Consisting of a 20,000 m2 production area and an 800 m2 office area, it won the Gold Medal for Italian Architecture award in 2012 and it was included among the most significant architectural projects in Europe by the Mies Van Der Rohe Award in 2013, thanks to its wellbeing and sustainability-oriented design.”

Figure 1: Pratic’s headquarters in Fagagna (Udine, Italy), which won the “Gold Medal for Italian Architecture” award in 2012 and was included among the most significant architectural projects in Europe by the Mies Van Der Rohe Award in 2013.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

The need to simplify the logistics flow, reduce the lead time, and above all significantly improve the firm’s colour range and the durability of its finishes led Pratic to invest in a state-of-the-art coating plant.”

“Our logistic/production flow is based on three main warehouses devoted respectively to profiles, accessories, and textiles,” says Pratic controller Giacomo Liva (Fig. 2). “The raw profiles are picked up

2 1

from an automatic compactable warehouse

Figure 2: From left to right, Alessia Venturi from ipcm®, Giacomo Liva and Elisa Stefanutti from Pratic.

and sent to the paintshop where they are coated to order; then, they are sent to the machining department, where CNC machines perform milling and cutting

motorised cover in packable fabric.

operations. The fabrics are tailored by the

Pratic’s range is divided into three large

Three years ago, the firm’s portfolio was then

textile department, where pieces of raw

product categories: vertical awnings,

enriched with a highly innovative product:

fabric are joined (sewn or heat-sealed),

folding arm awnings, and pergolas,

bioclimatic pergolas whose cover consists of

squared, and hemmed to obtain a semi-

launched ten years ago and made up

adjustable aluminium slats rather than fabric

finished product that is then sent to the

of aluminium structures leaning against

(ref. Opening photo).

assembly department.” The machined

existing buildings or self-supporting, with a

The product portfolio and the production cycle

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Figure 3: A bird’s eye view of the coating plant supplied by Imel (Codroipo, Italy).

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Figure 4: Spraying profiles with the dense phase technology.

FOCUS ON TECHNOLOGY

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profiles, the finished fabrics, and the

Figure 5: Some shades from the new colour range of Pratic, consisting of 30 Qualicoat Class 2 polyester powders from Tiger coatings.

accessories picked up from the accessory warehouse all reach the pre-assembly department. Each product is first assembled internally and subjected to quality controls, and then sent to the packing department that prepares it for shipping. “Until last year, we did not coat our profiles in-house: the extrusion company sent them directly to a coating contractor chosen by Pratic. We had only five standard colours in our catalogue. All other colour requests were managed to order,” states Liva. “The addition of bioclimatic pergolas entailed a considerable increase in the aluminium components to be coated and greater demand for non-standard colours that we did not have in stock. Moreover, this product includes extruded components of considerable size, i.e. up to 7 metres in length, whose outsourcing coating operations had become burdensome in

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Figure 6: Profiles with diﬀerent shapes coated and ready for assembly.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

S P E C I A L ON A L UM I NI UM F OR M E TA L A RC HI T E C T URE A ND I ND US T RI A L D E S I G N

terms of logistics.” The need to simplify the logistics flow, reduce the lead time, and above all significantly improve the firm’s colour range and the durability of its finishes led Pratic to invest in a state-of-the-art coating plant (Fig. 3) designed and supplied by Imel. “We no longer wanted to handle already-coated profiles because we considered it a limitation, given the few colours in our stock and the response times of our suppliers applying non-standard coatings. We decided to completely insource our processes. Now, all that is made to order is coated in-house, with a considerable reduction of our lead time. Despite the high variability of the production batches, Imel’s i4paintshop solution allows us to manage the coating process with a lean-manufacturing approach and to record and analyze all process parameters. Part of our production is still coated by contractors, but this plant has certainly laid the groundwork for the implementation of a just-in-time production flow in future,” states Liva.

A study on colours The company chose to insource the coating process primarily in order to offer a wider choice of colours (Fig. 4). Its current flagship product, the bioclimatic pergola, is indeed characterised by the possibility to select customised tints – which led Pratic to decide to further differentiate from its competitors. The new colour range was developed together with TIGER DRYLAC ITALIA to offer something new to the market. It includes only Qualicoat Class 2 polyester coatings to guarantee maximum outdoor resistance and colour retention.

The company chose to insource the coating process primarily in order to offer a wider choice of colours. Its current flagship product, the bioclimatic pergola, is indeed characterised by the possibility to select customised tints – which led Pratic to decide to further differentiate from its competitors. The new colour range was developed together with TIGER DRYLAC ITALIA to offer something new to the market.”

FOCUS ON TECHNOLOGY

Figure 7: Edi (on the left) and Dino Orioli.

The range is divided into five colour families (dark and light grey, white, beige, brown, and green) each with different shades, for a total of 30 colours (Fig. 5). “At the moment, our customers can choose among the 30 tints of the Tiger Qualicoat 2 range as well as the 8 AkzoNobel standard colours that we used previously. However, we would like the market to move towards the new colour range because we have noticed a trend away from smooth finishes and towards wrinkled and metallised colours, which are included in our new colour portfolio (Fig. 6). “We got to know Tiger because one of our geographical target markets includes Upper Germany, Austria, Switzerland, Belgium, and Holland, where Tiger’s products were explicitly requested by customers. In Italy this does not happen yet, but in many other countries the powder supplier is a discriminating factor that can make you win or lose an order. That is why we had no doubts in the choice of our partner.”

A winning choice Dino and Edi Orioli (Fig. 7) also recognise the results obtained: “We decided to invest in technology and service both for Pratic’s customers, i.e. retailers, and for the end consumers. Our new coating line proves this. From now on, our structures will be able to be customised also in terms of colours and to meet the most complex project requirements. The type of plant created and the development plan launched for the next few years are fully in line with the highest quality standards of our products and of our design and production processes.”

HIGH

PERFORMANCE POWDER COATINGS

Opening photo: Aliplast Poland extrudes, anodises and powder coats aluminium profiles for architecture.

FOCUS ON TECHNOLOGY

S P E C I A L O N A LU MINIU M FOR M E TA L A RC HI TE C TURE A ND I ND USTRIAL DESIGN

Aliplast: The choice of a Vertical Coating System for Aluminium Profiles in the Pursuit of Maximum Productivity and Quality Alessia Venturi ipcm®

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

n all our magazines with a special

years ago to enable the company to

insert on the finishing of aluminium

penetrate the Southern European market

profiles, intended either for metal

with a warehouse, a dedicated office

architecture applications or for the car

and a horizontal powder coating line).

and transport industry, the question

Aliplast’s strategic objective is to increase the comfort and architectural value of

has arisen as to whether it is more convenient, efficient, and economical to choose a vertical or a horizontal coating system (ref. Opening photo). Aliplast Poland, like many other extruding firms presented on the pages of ipcm , ®

chose not to choose and to equip its production plant with both vertical and horizontal lines, thus exploiting the process peculiarities of both. With its

It is more convenient, efficient, and economical to choose a vertical or a horizontal coating system. Aliplast Poland chose not to choose and to equip its production plant with both vertical and horizontal lines”

buildings through high quality, effective, and customised aluminium systems designed in collaboration with the R&D, marketing, and distribution departments of the various companies belonging to the Group. In 2009, Aliplast Poland moved to its current building in Lublin with the aim of reducing its time-to-market and

last investment in a latest generation

logistics costs by integrating its whole

vertical line designed and installed by

production flow under one roof. Since

SAT (Verona, Italy), dating back to the

2011, when it installed its first press,

beginning of 2019, Aliplast raised the

the company has also included the subsidiary firm Aliplast Extrusion. “Aliplast

number of its coating lines to four, aluminium systems for windows, doors,

Poland’s strategy is to provide high quality

ones; the first vertical system, installed in

sliding elements, curtain walls, and

profiles with a lead time of just four

2011, had been designed by SAT, too.

roofing systems. Aliplast Poland (Lublin)

days, including thermal bridge assembly,

was created in 2002 and it belongs

CNC machining, and coating. This is the

to the well-known CORIALIS Group,

key to our growth,” states Director of

established in Lokeren (Belgium) in

Operation Rafal Podlaski (Fig. 1). “And

1984. With time, the Group has made

the proof that this is the right strategy is

substantial investments in various

the huge increase in production volumes

Aliplast is one of the European market

companies in France (Profile System),

we have witnessed in the last few years.

leaders in the development, marketing,

UK (Smart Systems), and Serbia (Aliplast

That is why we needed to install a new

and distribution of high quality

Serbia, a subsidiary established two

high-productivity coating line. After eight

Aliplast: long-standing expertise in the extrusion and coating of architectural aluminium

Figure 1: Rafal Podlaski with Alessia Venturi.

including two horizontal and two vertical

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Figure 2: Profiles hanged onto the anodising line.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

years of experience with a SAT vertical plant, we decided to buy a second one that included all the latest plant innovations developed by this Italian company and was even more powerful than the previous one.” “Aliplast Poland currently has an extrusion department with three presses, a machining area, four powder coating lines, an anodising line (Figs. 2 and 3) and a sublimation machine for the wood effect decoration (Fig. 4). Our first horizontal line was installed in 2009 and it enabled us to be very flexible and treat profiles, sheets, and accessories with one system (Fig. 5). The first vertical line was installed two years later to have a high productivity plant to devote to profiles alone (Fig. 6); we chose the Italian company SAT as our partner.

3 1

Figure 3: The anodising installation.

In 2015, we decided that it was necessary to allocate all our die-cast aluminium coating to a compact horizontal line with a dedicated pre-treatment cycle. On the one hand, a large

industrial line was not efficient enough for finishing small workpieces; on the other hand, die-cast aluminium requires a different chemical treatment than extrusions, in order to obtain high quality coatings,” adds Podlaski. “We have used our first vertical line intensively for eight years, on two shifts a day: last year alone, it coated 2.2 million m2 of aluminium. Thanks to the extensive expertise gained with it, we perfectly knew what aspects were to be improved and what system choices were not to be repeated. Therefore, when we turned to SAT again for the installation of a second vertical coating line, we actively collaborated with their designers to make it specifically tailored to our needs. At the same time, SAT’s technology had evolved, too, as proved by their new

4 1

V-shaped booths and the measures taken in the construction of the drying oven to avoid stagnation of pre-treatment liquids.”

Figure 4: The sublimation system.

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Figure 5: One of the two horizontal painting installation used by Aliplast.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

“Aliplast Poland currently has an extrusion department with three presses, a machining area, four powder coating lines, an anodising line and a sublimation machine for the wood effect decoration.”

FOCUS ON TECHNOLOGY

POWDER COATING SOLUTIONS

COLORFUL. FUNCTIONAL. CUSTOMIZED.

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Figure 6: The first vertical coating line installed back in 2011.

The start of the project Before making the new investment, Aliplast Poland carried out

More than 300 RAL shades available from stock.

a small revamping operation to increase the efficiency of the already-existing vertical coating line. “We had to increase the conveyor’s speed to handle the increase in production while waiting for the new line,” explains Rafal Podlaski. “We expanded the drying unit and added a burner to support the original boiler. In this way, we increased the line speed from 1.3 to 1.7 m/min.; in terms of coated aluminium, this resulted in an increase in our daily production by 560-600 m2. Meanwhile, together with SAT, we were carrying out the customised, advanced project of a second line, which would have enabled us

to further increase our coating capacity and keep up with sales.

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Figure 7: The dosing modules of the pre-treatment tanks of the new vertical installation.

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

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

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Figure 8: The pre-treatment tunnel is divided into two parts: the initial steps and the alkaline etching process occur on one side, while the acid-based Oxsilan conversion steps are performed on the opposite side.

The first critical issue faced by SAT was

to the production of profiles for the entire

the height of the building that was to

European market. Moreover, whereas the other lines use a titanium/zirconium-based

house the line. Since our production organisation requires that all our painting systems be grouped in the same building to facilitate the work of line and quality controllers, SAT had only 10 to 11 meters of height available below the beam, and not 12 as necessary. The pre-treatment cycle was also improved. The supplier remained Chemetall, but the new line performs a more intensive acid-alkaline process, suitable to meet

The new line performs a more intensive acid-alkaline process, suitable to meet the demands of the French market; the objective, in fact, was to devote this line to the production of profiles for the entire European market.”

passivation cycle, the surface conversion operation on this new line is done with the Oxsilan technology, highly efficient and with wider tolerances (Fig. 7).”

Technical solutions The pre-treatment tunnel is unique, because it is divided into two parts (Fig. 8): the initial steps and the alkaline etching process occur on one side, while the

the demands of the French market; the

acid-based Oxsilan conversion steps are

objective, in fact, was to devote this line

performed on the opposite side.

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FOCUS ON TECHNOLOGY

The conveyor runs for about 1.5 metres out of the tunnel to cover the junction curve between the two parts. In order to improve operating conditions, SAT grouped all heat sources in the same area of the plant, whereas, on the previous line, the application booths manned by operators were located right in the two ovens’ heat zones. The conveyor is longer than normal in the section between the pre-treatment and drying stations, in order to facilitate mechanical water drainage from the workpieces and, therefore, the subsequent drying phase. The application booths are SAT’s new generation, V-shaped booths (Fig. 9). “In the old U-shaped booths, much kinetic spraying force was needed for optimal coverage and penetration,

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Figure 9: The enclosed area containing the two application booth of the new installation.

OptiCenter® OC07 Fastest colour change and stable powder output

Clean, efficient and superior application technology The OptiCenter OC07 powder management center combines stateof-the-art OptiSpray application pump technology with automatic fresh powder feed for fast and clean color changes. The system is the basis for constant and reproducible coating results and significant powder savings.

www.gemapowdercoating.com

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

because the profiles exposed one

replaced the original Venturi injector

face at a time toward the group of

technology installed on the old line

guns. In these V-shaped booths,

with dense phase pumps – first in one

however, the guns are arranged on both profile sides, the powder cloud is very soft, and the parts pass through the plant without the need to rotate (Fig. 10),” observes Rafal Podlaski. “Suction was also improved, as the V-shaped booth’s ducts are located behind the guns, so that overspray suction also contributes to paint the profiles.” Aliplast Poland’s coating booths

The dense phase spraying process is more stable. The powder speed in the feed tubes is ten times lower; therefore, the coating does not degrade before reaching the nozzle, as there is no air to destroy its particles.”

booth and then in the other, in order to compare the qualitative and operational results. I believe that the dense phase spraying process is more stable,” says Podlaski. “The powder speed in the feed tubes is ten times lower; therefore, the coating does not degrade before reaching the nozzle, as there is no air to destroy its particles. By using less kinetic and more electrostatic force, the dense phase also guarantees better penetration in difficult-to-reach areas

dense phase pumps. “We had already

and Faraday cages (Fig. 11).”

are equipped with Gema OptiSpray

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Figure 10: In the V-shaped booths the guns are arranged on both profile sides.

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As with all its coating lines, Aliplast Poland uses the two V-shaped

This allows for a faster and more flexible cleaning process

booths simultaneously: one is devoted to bright colours and the

(Fig. 12).

other to the dark ones, so that colour changeovers are even faster.

“We found improvements also in the design of the

Thanks to their rotating mats, the booths are constantly cleaned

drying and curing ovens,” states Podlaski. “They are

during spraying. However, the colour change operations occur

better insulated and they show better, softer, smoother,

differently on these new V-shaped booths and they call for a few

and more uniform distribution of air, since it comes

manual operations, such as the cleaning of the floor and the guns,

out from numerous holes in the ovens’ bottoms with

which were automatic in the previous version.

the same speed. Therefore, air flows in a fragmented

Figure 12: The touch screen for the complete management of the plant.

Figure 11: Aliplast Poland’s coating booths are equipped with GEMA OptiSpray dense phase pumps.

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Figure 13: The revolving doors at the entrance and exit of the drying and curing units.

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Figure 14: Anodised profiles.

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S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

our production is directly or indirectly

Conclusions

this avoids collisions between the

intended for foreign markets: this

Aliplast Poland’s investment in a second

profiles and the so-called “snow

leads us to increase controls and

vertical line was driven by an increase

effect” of powder coatings, which

reduce waste. That is why we perform

in production volumes and sales. “We

causes dust inclusions on the parts’

checks both on the lines and in our

continue to use the largest horizontal

surfaces. Gas consumption is lower.

internal laboratory (Fig. 14).”

line as a service line, for coating metal

Another important design detail is

Aliplast is a Qualicoat member and

sheets, bent profiles, and small lots of

the position of the fans at floor level,

its coating cycle is Seaside certified.

maximum 3 m2, equal to 2 profiles,”

which facilitates maintenance. The

The company offers two colour

states Podlaski. “We are constantly

oven chambers feature rotating

collections, one with Qualicoat 1

improving our processes. We also

doors, an excellent solution because

powders (Life Colours) and the other

intend to expand our building and

they give the profile time to gel, with

with Qualicoat 2 powders (Timeless

increase our staff, which currently

very positive effects on the coating

Colours). “Actually, we can apply any

includes about 700 people. Production

quality and the reduction of any dust

tint requested, especially with fine

must keep up with sales and, besides

inclusions (Fig. 13).

textured finishes: this forces us to

predicting the extent of their growth, we

For this purpose, we also requested

always keep 50 tonnes of powder

must equip ourselves to sustain it in the

the installation of filters inside the oven

in stock, i.e. about 1400 different

best way (Fig. 15).”

to further prevent the “snow effect”.

coatings,” indicates Podlaski. “This is

Finally, we invested in an excellent

essential to maintain such a short

ventilation system in our paintshop to

lead time, because, although our

manage correctly the volumes of air

suppliers (mainly TIGER and IGP)

intake and outtake, as well as in a good

are very rapid, we would lose one or

lighting system to help quality control.

two days only for the delivery of the

Quality is our focus, because 70% of

painting products.”

manner and with a constant flow:

15 1

Figure 15: The production team led by Rafal Podlaski (far right)

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Opening photo: MDM specialises in creating colour fan decks and files for the aluminium market.

HIGHLIGHT OF THE MONTH

S P E C I A L O N A LU MINIU M FOR M E TA L A RC HI TE C TURE A ND I ND USTRIAL DESIGN

Technology and Creativity in Colour Fan Decks and Files for the Aluminium and Powder Coating Markets Francesco Stucchi ipcm®

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HIGHLIGHT OF THE MONTH

stablished as a small workshop assembling mosquito net kits and furnishing articles, MDM is now a family-run company very well known among the powder paint manufacturers and in the

aluminium architectural profile coating sector. Based in Grottaglie, a small town in the heart of the Puglia region famous throughout the world for its ceramic workshops, MDM is one of the leading Italian companies in its field. “Originally, our small firm mainly offered an assembly service of aluminium mosquito net kits,” explains Giuseppe Stallo, one of the owners of MDM. “Our job included assembling the components, applying the adhesive supplied by the manufacturing company, and packaging the products. The whole process was manual. We then decided to make our first investment in technology and purchased a laser marker to replace those anti-aesthetic adhesives with engravings. Due to the increase in the cost of our service, albeit equal to a few cents apiece, our customers initially did not like the idea of replacing the old,

distinguishing adhesive with a modern, customised marking. However, that experience led us to further develop our business. An important local company asked us to produce a prototype for a new colour sample collection consisting of metal sheets, each with a different tint. We created a deck of sheets with laser-engraved codes. Besides laser engraving, we also offered to perform a mechanical cutting operation on the painted sheets to guarantee more accurate results and to avoid that the edges have been burnt. The customer really liked our idea and confirmed its order.” “For us, this entailed a transformation from a small family-run workshop to an actual artisan company,” adds Giuseppe Stallo. “All the four most important companies in that sector, located in South Italy, became our customers. Then, we began extendingbourbgeographicalbcoverage not only in the local market but also in Central and Northern Italy, where

numerous paint and coating manufacturers are based.

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Figure 1: Among the services oﬀered by MDM, its colour files include all the eﬀects and hues currently made possible by the powder coating technology.

ics.eu@nordson.com www.nordsoncoating.com/robot

Performance by design

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

Currently, MDM specialises in creating colour fan decks and files for the aluminium market, from powder coating manufacturers to coating contractors, and to final users, like as producers of door and frames, mosquito nets and shutters (ref. Opening photo). We boast a customer base of around 280 companies in Italy and Europe. They all recognise the quality of our work, so much so that we contribute to the creation of the most prestigious catalogues in the paint manufacturing sector, offering colour files that include all the effects and hues currently made possible by the powder coating technology (Fig. 1). Finally, we collaborate with our customers

2 1

that, in turn, create colour sample

Figure 2: MDM’s team.

collections for their end users (Fig. 2).” “Each fan deck we produce is personalised with marking on both sides and an innovative PP cover, unbreakable

Each fan deck we produce is personalised with marking on both sides and an innovative PP cover, unbreakable and customisable with graphics chosen by the customer in any quantity.”

and customisable with graphics chosen by the customer in any quantity” states Stallo. “Our strength is the fact that all the production process, from cutting to sheets perforation, from printing to

cover bending until to assembling of the sample collection, is realized with non-standard but entirely designed and built in-house equipment, tailored to our needs (Fig. 3). By next January is foreseen a short-term investment for a coating plant to integrate in our workflow. This plant will allow to avoid possible bottlenecks caused by the existing providers and will improve the quality of our final products thanks to the direct control of this delicate production phase” concludes Giuseppe Stallo. “Through MDM’s sample collections, our customers get to show the effects ensured by their paints and finishes: It is unthinkable to present market a coating through an imperfect sheet”. “Our mission is to meet each need of

3 1

the customer with the maximum of

Figure 3: A detail of the production equipment used by MDM.

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quality”.

Zaniolo CdA - 1.19

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info@europolveri.it www.europolveri.it P O W D E R C O AT I N G S I N C E 1 9 8 2

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FOCUS ON TECHNOLOGY

Insourcing Coating Processes in the Architectural Aluminium Profile Industry: Pasturi’s History

n the last few years, ipcm® has often

Ilaria Paolomelo ipcm®

Our extrusion department includes

reported on the choice of increasingly

three lines with 3,250 and 1,800

more manufacturer to insource their

tonne presses that treat profiles up to

coating operations. These companies

8,250 mm in length and with different

typically decide to invest in cutting-edge

automatic profile handling systems,”

plants, solutions, and technologies in

states Simone Pasturi, production

order to improve their finishing quality

manager and son of the company

and shorten their delivery times. One

founder. “After extrusion, we can

of them is Pasturi Srl (Cigole, Brescia,

perform further machining operations

Italy), a company extruding aluminium

on profiles to meet any customer

profiles for several different sectors,

need, such as precision cutting, drilling,

including architecture and design (ref.

milling, shearing, thread cutting, Velcro

Opening photo). Thanks to the insight

application, rolling, deep drawing,

and multi-year experience of its founder,

bending, and tumbling (Fig. 1).

since 2001 this firm has made numerous

In order to offer an even more

investments that have led it to turn from

complete range of services and meet

a simple commercial warehouse into

our customers’ requests promptly and

a production plant equipped with the

flexibly, we recently decided to also

most modern technologies available

insource the coating phase (Fig. 2),

on the market. Thanks to its expertise and pragmatism, Pasturi has been able to grasp a constantly evolving market, standing out from its competitors with innovative offers and timely responses. Indeed, its order management

which was carried out by a contractor

until a few months ago.”

Figure 1: Extruded profiles with a particular section.

The coating cycle with Eurovertical “When it came to choosing a supplier

on the aluminium market. In this

Fully integrated production: from extrusion to finishing

framework, the coating plant designed

“The core of our production plant is an

installed a unique vertical system,

by Euroimpianti (Valeggio sul Mincio,

advanced extrusion line with a capacity

specifically tailored to our space

Verona, Italy) was needed to further

of 18,000 tonnes per year, which enables

requirements (Fig. 3),” explains Pasturi.

improve the high versatility and flexibility

us to guarantee high quality standards

“Due to the particular geographical

levels that have always characterised

to all our clients thanks to its innovative

conformation of this area, it was

Pasturi.

features.

not possible to dig the pits normally

speed is its distinguishing element

for the new coating line, our choice immediately fell on Euroimpianti. We

Opening photo: Pasturi Srl extrudes and coats aluminium profiles for several applications, including architecture and design.

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S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

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Figure 2: A bird’s eye view of the coating plant recently installed by Pasturi.

Figure 3: Pasturi has installed Euroimpianti’s Eurovertical coating system in order to improve the versatility and flexibility of its production plant.

The goals for the pre-treatment phase were as

management,” observes Simone Pasturi.

time, our building, which had not been

follows:

“After pre-treatment, the profiles enter the

conceived to house ten-metre high plants

• Qualicoat directive-compliant results;

drying oven, designed to maintain constant

twenty years ago, did not have the right

• Automated management of chemical

temperature and ventilation. Once dry, the

required for this kind of plants. At the same

height for working according to standards.

parts reach the coating booth designed by

product dosages;

Euroimpianti. It is equipped with 16 guns and

measures as to exploit all the space available in

• Process management freedom.

a powder management unit SuperCenter

our factory.”

“Thanks to our excellent teamwork with Alit

EVO with the Venturi technology, supplied by

The coating process begins with a chrome-free

Technologies’ technical staff, we have achieved

Wagner (Fig. 5). This booth boasts a peculiar

pre-treatment phase including an acid and

all our objectives, guaranteeing treatment

diamond-like shape, which allows avoiding

alkaline stage, whose products are supplied

results that comply with the Qualicoat

rotating the profiles inside it, as they expose

by Alufinish GmbH, represented in Italy by Alit

standard in a wide range of conditions

all their faces to the gun groups while running

Technologies (San Bonifacio, Verona - Fig. 4).

and simple and safe chemical process

along the chain (Fig. 6).

• Reduced water consumption;

Euroimpianti, however, took such design

4 1

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Figure 4: A detail of the automatic dosing system for the pre-treatment phase.

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Figure 5: The core of the coating booth is the new SuperCenter EVO powder feeding unit.

FOCUS ON TECHNOLOGY

It also features an automatic cleaning system with five rotating mats. The cycle ends with conventional curing and cooling steps,” adds Pasturi. “The potentialities of this new coating system include the possibility to coat up to 7 m long aluminium

SIMPLIFY COATING.

bars with only one point of contact between profiles and hooks, thus minimising waste and optimising paint distribution on the extruded parts.” “We completed our Eurovertical plant with the innovative paint stripping system Fastrip ISP (Inline Stripping Process), developed by Alit Technologies (Fig. 7). This in-line plant strips our profile hanging hooks in less than three minutes, between one coating cycle and another. This helps increase the line speed, significantly reduce energy consumption and process costs, and promptly meet our customers’ needs,” states Pasturi. “The Fastrip In Line system installed at Pasturi features a 6 metre long chemical stripping tank with a capacity of 2 tonnes

Your information and management platform for simpliﬁed coating 4.0.

of product and a hook immersion depth of 30 cm (Fig. 8).

6 1

Figure 6: The coating booth boasts a peculiar diamond-like shape, which allows avoiding rotating the profiles inside it, as they expose all their faces to the gun groups while running along the chain.

wagner-group.com

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

7 1

Figure 7: The innovative paint stripping system Fastrip ISP, developed by Alit Technologies, allows stripping the profile hanging hooks in less than three minutes, between one coating cycle and another.

circuit fed with electrically heated diathermic

The coating booth’s core: the SuperCenter EVO powder management unit

oil, in order to guarantee low operating costs

“Guaranteeing high quality finishes, maximum

Completely built in stainless steel, this horizontal tank is jacketed and it contains a

and optimum temperature maintenance. The peculiar design of this plant allows flexibly managing various components and options, from the ultrasound arrangement to the type of recirculation pump and suction system: everything must be adaptable to an ever-evolving process flow,” notes Alit Technologies sales manager Michele Merlo. “The eclectic nature of the Fastrip In Line system perfectly matched that of the Euroimpianti coating plant: it just

Guaranteeing high quality finishes, maximum productivity, and versatility means using the most modern technologies currently on the market. These include the new powder feeding unit SuperCenter EVO installed in Pasturi’s paintshop.”

productivity, and versatility means using the most modern technologies currently on the market. These include the new powder feeding unit SuperCenter EVO installed in Pasturi’s paintshop. This new 4.0-oriented Wagner technology is completely automated and ensures high coating quality, time reduction, process reliability, and cost monitoring,” says Wagner Group Italy sales manager Michele Maffoni. “The whole system is controlled through a PLC, which eliminates the need for

took a few expedients to integrate it in the

specialised personnel and any chance of error,

painting process and obtain a plug & play

as well as guaranteeing consistent colour

solution.”

change times.”

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FOCUS ON TECHNOLOGY

The powder management unit SuperCenter EVO is managed through one device with a high resolution colour touch screen interface, using symbols, buttons, and commands via text messages for safe operations (Fig. 9). The Wagner Data Software® program enables colour changeovers to

UHS platform technologies

start automatically, end in less than seven minutes, and happen with an interactive user guide. It also calculates

VOC-compliant coating

hourly production, plant downtimes due to colour change operations or technical problems, and the number of coated frames, thus allowing monitoring performance and the actual powder consumption for each tint and/or for each batch. This allows user to keep accounting records for each customer. The powder consumption data can be downloaded via a USB interface and modified on a PC or laptop. The system also calculates the times and spare parts needed for maintenance

operations. Finally, SuperCenter EVO can be analysed and

UHS-Systems The conversion from solvent-based to water-borne coating systems is often linked with high investment costs. The new ultra-high-solid platform technologies from FreiLacke can signiﬁcantly reduce solvent consumption, even without system conversions. 8 1

Figure 8: Fastrip In Line has a 6 metre long chemical stripping tank with a capacity of 2 tonnes of product and a hook immersion depth of 30 cm.

FreiLacke is now using its new ultra-high-solid systems (or UHS for short) which entirely meet the demands for a reduction in the VOC content in paints and coatings. With a solids content of up to 80 percent by weight, they have a VOC value of less than 350 g/l. www.freilacke.com

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

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Figure 9: The powder management unit SuperCenter EVO is managed through one device with a high resolution colour touch screen interface, using symbols, buttons, and commands via text messages for safe operations.

Figure 10: The pre-treatment tanks are equipped with an automatic bath management and maintenance system and with a waste water treatment plant designed by SAITA, in which eﬄuents are treated within a closed circuit to avoid wasting water.

Achieved objectives

managed remotely and with a just in time approach, thanks to Wagner’s e@assistance through VPN, a service installed on the customer Internet network to offer immediate technical support. “The cleaning cycle occurs automatically with the following stages: gun internal cleaning, IP pump cleaning, gun external cleaning, booth internal cleaning, start of the cyclone and powder recovery device, and connection to a new box of fresh powder,” explains Maffoni.

Pasturi has always paid particular attention to the issue of environmental sustainability, as proved by both the photovoltaic panels installed on the roof of the plant and the production technologies it has chosen over time.”

“We decided to insource our coating operations following the exponential growth of requests for finished profiles from our customers. When we calculated that over 20% of our aluminium profiles had to be painted, we realised that it was the right time to take this step. Increased versatility and flexibility are among the first goals we have achieved. More and more often, our customers order batches with small quantities of

“The replacement of the boxes is also

parts and different colours. As we no

automatic; the system fills with the

longer have to rely on a contractor,

powder the 5 kg container supplied with

we can handle any request and

the SuperCenter EVO, which can be

thermal energy expenditure. Its ovens

meet any customer need, down to

integrated with the ultrasieve device.”

are equipped with mechanical seals

the slightest colour shade. Finally,

to minimise heat loss and keep their

avoiding relying on a third party

internal temperature stable, the

inevitably reduces lead-time – a

The importance of sustainability for Pasturi

pre-treatment tunnel cleans the profiles

goal achieved above all thanks to

“Pasturi has always paid particular

with a special low-pressure cascade

the extreme colour change rapidity

attention to the issue of environmental

system, and its tanks are insulated.

of the Eurovertical booth” Pasturi

sustainability, as proved by both the

Moreover, the pre-treatment tanks

adds. “In terms of expenses, with the

photovoltaic panels installed on the

are equipped with an automatic bath

installation of the new coating line

roof of our plant and the production

management and maintenance system

we have halved the costs related to

technologies we have chosen over time.

and with a waste water treatment plant

both outsourced coating operations

Euroimpianti’s Eurovertical system is in

and logistics and transport. Last but

line with our business philosophy, since

effluents are treated within a closed

certainly not least, we have found

it features solutions aimed at minimising

circuit to avoid wasting water (Fig. 10),”

a noticeable improvement in the

electric energy consumption and

states Pasturi.

quality of our coatings.”

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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)

Opening photo: General Trade has patented a machine, currently for exclusive use and not available on the market, for applications on round surfaces, e.g. outdoor metal fences.

INNOVATIONS: PRESENT&FUTURE

S P E C I A L O N A LU MINIU M FOR M E TA L A RC HI TE C TURE A ND I ND USTRIAL DESIGN

When Metal Becomes Wood. Characteristics and Evolution Trends of the Powder-on-Powder Technology for Wood-Effect Finishes on Aluminium Alan Leveni General Trade Srl, Meda (MB) - Italy

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INNOVATIONS: PRESENT&FUTURE

he powder-on-powder coating

The Italian industry has always been

create wood effects on metal and other

process allows reproducing the

a world leader in the development of

materials started in 2003, as the market

effect of wood, marble, or other

finishing technologies, especially for the

required decorative finishes that were

materials on surfaces by transferring

aluminium sector. Experimentation with

more outdoor resistant and cheaper

polyester powder paints in different

the powder-on-powder technology to

than those obtained by sublimation

colours directly in the powder base

(Fig. 1). At that time, the only

coat layer. This gives the best aesthetic,

powder-on-powder technology on the market was scarcely automated and

but also UV and weathering resistance properties to the applied finish. In the last few years, surface decoration by both powder-on-powder and sublimation techniques has played a fundamental role in the creation of new design styles and in opening up new markets for aluminium, steel, iron, glass,

its qualitative results were affected by both the operators’ manual skills and the environmental conditions (humidity, temperature, etc.). General Trade’s R&D activity immediately focussed on automating the powder-on-powder coating process, in order to make it reliable in terms of

and special plastics.

General Trade’s R&D activity immediately focussed on automating the powder-on-powder coating process, in order to make it reliable in terms of production, more stable, and easier to use.”

Figure 1: Experimentation with the powder-on-powder technology to create wood eﬀects on metal and other materials started in 2003, as the market required decorative finishes that were more outdoor resistant and cheaper than those obtained by sublimation.

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production, more stable, and easier to use. Over the years, the company has developed five patented machine types for powder-on-powder applications, called Realwood® systems (Figs. 2 e 3), to meet the demands not only of the Italian market, where customers typically require high productivity and extreme automation degrees, but also of foreign markets, with different needs and budgets.

Realwood® performance One of the advantages of the Realwood® system is the extreme outdoor, and especially UV resistance of the finishes applied, which makes it the ideal technology for use in Mediterranean countries,

2 1

the Middle East, North Africa, or Central and South America and in all countries where the weathering is

Figure 2: Realwood® standard machine.

particularly aggressive. As only Qualicoat Class 1 and

2 polyester powders for outdoor use are employed, i.e. with 10 to 20 years durability properties, the possible colour changes in the wood effect are very limited. Moreover, the effect is very realistic thanks to the high penetration of the powder into the substrate and, optionally, it can be tactile as well as visual, increasing the grain’s thickness. Wood grain is obtained through the deposition of polyester powder paints, specifically formulated through print matrices that General Trade designs and manufactures with dielectric material not susceptible to electrostatic charges (Fig. 4). This guarantees finishing consistency and repeatability regardless of the climatic or operating conditions. It

3 1

also gives the line operators more peace of mind, as

Figure 3: Realwood® Fastwood machine.

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Figure 4: Wood grain is obtained through the deposition of polyester powder paints, specifically formulated through print matrices that General Trade designs and manufactures with dielectric material not susceptible to electrostatic charges.

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One of the advantages of the Realwood® system is the extreme outdoor, and especially UV resistance of the finishes applied, which makes it the ideal technology for use in Mediterranean countries, the Middle East, North Africa, or Central and South America and in all countries where the weathering is particularly aggressive.”

INNOVATIONS: PRESENT&FUTURE

The role of powder paints in the Realwood® technology

Vicenza, Italy) have been recently launched

operating parameters of the machine. The matrices can be customised upon request:

Whereas the paints for the application of

union are being improved in order to obtain

this allows developing “tailored” wood effects

the base colour of the powder-on-powder

the highest definition.

through the synergy among General Trade,

wood effect have only a slightly different

Not all powder coatings on the market work

the customer, and the powder coating

formulation than conventional powders,

with the Realwood® powder-on-powder

manufacturer.

the products creating the grain call for

application systems; indeed, only a few

they do not have to continuously adjust the

and the performances ot the machine/powder

The Realwood technology can apply wood

special formulations and production

companies in the sector have invested in

effects on flat (sheets) and linear surfaces

machines. Grinding, for example, cannot

research and development on these products.

(profiles). General Trade has also patented

be done with normal plants, since the

The powder-on-powder technology should

a machine, currently for exclusive use and

grain size must be highly controlled and

not be treated as a simple painting process

not available on the market, for applications

consistent; fluidisation in the application

with RAL colours: the machines should be

on round surfaces, e.g. outdoor metal

phase must be perfect to maintain a

constantly checked from the beginning

fences (ref. Opening photo). The use of

highest print definition.

to the end of the process and only used

the Realwood method onto components

General Trade has developed the

with specially formulated powders. For its

for outdoor use is very convenient because,

Realwood® technology in cooperation with

part, General Trade tests its machines and

in addition to mechanical and weather

Pulverit (Milan, Italy).

guarantees their functionality only with

resistance, it also guarantees anti-graffiti

New wood grain effects developed

powders made in Italy, specifically by Pulverit

properties and no need for maintenance.

in collaboration with Europolveri (Sandrigo,

and Europolveri.

Opening photo: Stûv was established in 1983 in Bois-de-Villers (Belgium) and it has specialised in the design and manufacture of wood, gas, and pellet individual heating solutions.

S P E C I A L O N A LU MINIU M FOR M E TA L A RC HI TE C TURE A ND I ND USTRIAL DESIGN

FOCUS ON TECHNOLOGY

A new Pre-treatment System Helps Guarantee Perfect Paint Adhesion on Stûv’s High Temperature Stoves Barbara Pennati ipcm®

he charm of a fireside is timeless.

relaxed atmosphere especially when it is

sustainability and superior performance

Although habits and technologies have

rainy and cold outside. Of great aesthetic

goals. Indeed, they can integrate into

evolved and, in many cases, fireplaces

value and able to adapt to both rustic and

already-existing heating systems, act as a

and stoves are no longer an actual need, their

modern-design homes, stoves and fireplaces

source of energy for heating water, or even be

presence in our homes remains a source

also maintain a functional value that has

used to cook, just like in the past.

of charm, able to create a warm, cosy, and

evolved over time to embrace environmental

Stûv (Bois-de-Villers, Belgium) designs,

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FOCUS ON TECHNOLOGY

produces, and sells wood, gas, and pellet

It represented a revolution for the market as

individual heating solutions (ref. Opening

well as the ultimate success of this company.

photo) by focussing on high quality,

Currently, Stûv has three plants in Belgium (Bois-de-Villers, Thuin, and Floreffe),

aesthetics, and functionality since 1983, when Benoît Lafontaine and Gérard Pitance established it. The latter was an industrial designer who found no acceptable solution on the market for his projects and, therefore, decided to design, build, and market a stove that still fully represents Stûv’s philosophy: combining the pleasure of a fireside with a high-performance heating system, thanks to an enclosed fire device that can also work as an open fire one. In 2000s, they launched Stûv 30, a wood-burning stove with three modes of

Stûv designs, produces, and sells wood, gas, and pellet individual heating solutions by focussing on high quality, aesthetics, and functionality since 1983, when Benoît Lafontaine and Gérard Pitance established it.”

branches in America, Switzerland, and the United Kingdom, and a global market presence. With the addition of new product types able to reach operating temperatures up to 580 Celsius degrees, however, the need arose for a pre-treatment system guaranteeing perfect paint adhesion. Therefore, Stûv installed a Prometeus nebulisation system supplied by DN Chemicals (Caleppio di Settala, Milan, Italy), a company specialising in the production and distribution of surface treatment chemicals.

which can be switched by simply pivoting

nanotechnology solution, for the metal

the drum (Figs. 1 and 2).

surface conversion phase prior to coating.

It uses Dollcoat SA 115, a silane-based

use, i.e. open fire, glass door, and solid door,

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Figures 1 and 2: Stûv 30’s glass door and solid door options.

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From design to delivery: all-round production to meet every need

Figure 4: The Prometeus system guarantees continuous process control.

Figure 3: DN Chemicals’ Prometeus pre-treatment line for the application of nanotech products.

Problems linked to high operating temperatures “Quality is Stûv’s priority: that is why we

“Stûv’s production flow starts with the

perform tests and checks in each process

design phase and it includes the whole

phase. With the creation of new stove

metal sheet processing cycle,” explains

types able to reach very high operating

Production Manager Michel Collignon.

temperatures, however, we had to deal

“Each plant specialises in a particular

with the issue of paint adhesion. The

phase: the Thuin and Floreffe ones deal

phosphating product that we used for

with machining, i.e. cutting, folding, and

our pre-treatment process was no longer

punching, and manufacture accessories.

able to guarantee the necessary adhesion

The Bois-de-Villers one, on the other

degree, which resulted in several

hand, handles the pre-treatment,

problems in terms of quality and coating

coating, pre-assembly, and assembly

durability,” explains Collignon.

phases, as well as managing the

Stûv turned to DN chemicals to find the

warehouse and dealing with logistics

best solution for its new needs.

and shipping operations.”

“In collaboration with them, we performed

“With the launch of Stûv 30 on the

various tests with an alkaline product,

market, our production volumes

obtaining excellent results,” states

enjoyed significant growth. We went

Michel Collignon. The new pre-treatment

from producing 7,000 stoves per year

process is a spray cycle exploiting the

to 14,000,” adds Collignon. “We now

Prometeus system, which is composed of

manufacture about 50 stove types

nebulisation modules that optimise the

following the make-to-stock method,

conversion product application (Fig. 3).

preparing batches of about 15 products

The cycle includes the following steps:

of the same type to guarantee prompt deliveries.”

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Figure 5: Manual coating operations.

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alkaline degreasing with Dollclean AS series products, rinsing with mains water,

FOCUS ON TECHNOLOGY

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Figure 6: The Stûv P-10 pellet stove won the 2016 Red Dot Design Award in the Product Design category.

rinsing with demineralised water, rinsing with osmotised water, and no-rinse conversion with the nebulisation of Dollcoat SA 115, nanotechnological surface conversion with synthetic oligomers obtained from silanes. “The silane oligomers, which resist temperatures up to 600 °C without deteriorating, guarantee maximum paint adhesion. This treatment solved the coating quality problems we had with the old phosphating product and caused by the high operating temperatures of our stoves,” explains Collignon. “The Prometeus system also guarantees continuous process control (Fig. 4) and the possibility to evenly apply an always-fresh product on the whole workpieces’ surfaces, thus reducing consumption and operating costs.” After pre-treatment, the parts are liquid-coated in a manual booth, in order to ensure they are uniformly painted irrespective of their geometry (Fig. 5).

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

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Figure 7: From left to right: Stûv Product Manager Michel Collignon and Communication Manager Serge Alhadeﬀ.

A worldwide-recognised aesthetic and quality value

customers with a reliable service able to

“Functionality, aesthetics, sustainability,

“In our Bois-de-Villers plant, we paint

and quality are very important factors

parts for the whole Group. Our

for Stûv and they have characterised our

Floreffe factory is also equipped with a

products since the beginning. They have

powder coating system, but this does

in fact enabled us to establish ourselves in the international market and even obtain prestigious awards, such as the 2016 Red Dot Design Award assigned to our pellet stove Stûv P-10 in the Product Design category (Fig. 6),” says

meet every need.”

Functionality, aesthetics, sustainability, and quality are very important factors for Stûv and they have characterised its products since the beginning.”

not achieve the technical and quality degree required by our high-operating temperature stoves, yet. That is why it was crucial to make sure that our pre-treatment plant, and therefore our coating process, could meet all our

Communication Manager Serge Alhadeff

production needs. We can safely say

(Fig. 7). “Our production is controlled

that our cooperation with DN Chemicals

at every stage through a 4.0-oriented

and the installation of the Prometeus

management system. We especially

line have enabled us to achieve this

focus on innovating and providing our

objective,” states Alhadeff.

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Opening photo: The warehouse with polyester-powder coated coils.

S P E C I A L O N A LU MINIU M FOR M E TA L A RC HI TE C TURE A ND I ND USTRIAL DESIGN

FOCUS ON TECHNOLOGY

Aluminios Andalucía: Culture of Coating Quality in the Field of Powder Pre-Painted Metal Alessia Venturi ipcm®

luminios Andalucía, the oldest company

the development of benchmark products in

in the processing of aluminium, especially

in Europe to perform continuous

all major industrial sectors. Already a leader in

for the sectors of construction, architecture,

polyester-powder coating processes on

the treatment and finishing of aluminium, this

decoration, transport, and industry (ref.

aluminium, has recently celebrated its forty-firth

multinational firm is located in Fuenlabrada,

Opening photo), and in the production of

anniversary. Its vision is to be the European

near Madrid (Spain). Its factory covers an area

adhesive films for the protection of treated

leader in the aluminium treatment field and in

of 42,000 m2. It belongs to a Group specialising

surfaces, marketed under the brand Coefilm®.

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FOCUS ON TECHNOLOGY

Thanks to the experience gained since

rapidity is essential. The quality of its

its establishment in 1974, a team of

service is a pillar of this firm’s philosophy,

professionals, and the constant evolution

in which technology and production,

of the treatments offered through its

talent and management are aligned

R&D activities, Aluminios Andalucía

while maintaining a customer-oriented

develops solutions tailored to the specific

approach.

needs of each customer by focussing

Founder D. Santiago Martín Venegas

on technological innovation, continuous

began to work in the aluminium sector

development of new coatings and

with the creation of an aluminium

finishes, and, above all, product and

profile production business; willing to

delivery service quality. This company

constantly evolve, it started specialising

aims in fact at reaching a position of

in the rolling field in 1974. The company

leadership by optimising its own quality

is currently managed by the family’s

and technology standards. Certifications

third generation, specifically by his sons,

help it consistently put its production

each with responsibilities in different

processes to test. Its customers’ requirements are constantly changing: always improving and constantly adapting to them with flexibility and

Figure 1: Jesús (left) and Santiago Martín Martín (right).

departments and overseeing all the main business areas, i.e. raw material purchase, production control and management, R&D, sales, and marketing.

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Figure 2: One of the two continuous coating lines that produce architectural aluminium with thicknesses between 0.6 and 3 mm.

powder pre-painted aluminium

Marketing and Sales Director Jesús Martín Martín (Fig. 1) says: “Aluminios Andalucía constantly focusses on quality and customer satisfaction in all its processes. In our warehouses, we have an average stock of more than 3,000 tonnes of aluminium, in order to immediately meet the needs of our customers and flexibly adapt to the most demanding requirements in terms of finishes and sizes. Thanks to this philosophy, strongly promoted by founder and president D. Santiago Martín Venegas, our delivery times in Europe for products with standard sizes and RAL colours are equal to 2-3 weeks and we always guarantee a high-quality service. “Sales in Spain, where we are the first

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Aluminios Andalucía constantly focusses on quality and customer satisfaction in all its processes. In its warehouses, it has an average stock of more than 3,000 tonnes of aluminium, in order to immediately meet the needs of customers and flexibly adapt to the most demanding requirements in terms of finishes and sizes.”

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

manufacturer, account for 35% of our turnover. Europe mainly accounts for the remaining 65%, although we are currently expanding towards other continents such as Asia and America. Our ApliMAX (Fig. 2) and ApliLAC (Fig. 3) brands also ensure high performance and quality levels for the subsequent bending, drawing, and forming processes – a unique offer on the market. As the result of focussed R&D, quality orientation, and constant adaptation to the evolving market, our products can now be seen in iconic buildings such as the Torre Iberdrola in Bilbao or, at international level, the Student Housing designed

by the firm Te Kiefte Architecten (Borne) in the Netherlands. In every project, they guarantee innovation, advanced

FOCUS ON TECHNOLOGY

technology, and environmental protection. “In Spain, we can identify two types of market. One is that of liquid pre-painted metal, which has lower production costs that are reflected in lower UV resistance, corrosion protection, and flexibility degrees compared with our polyester-powders pre-painted finishes, which are superior finishes characterised by a three times thicker protective layer. One of the advantages of our powder pre-painted metal, in terms of eco-friendliness, is that we do not use any solvents nor heavy metals to produce it, but rather a VOC-free technology (i.e. without volatile organic components). We can apply an average of 70-80 microns

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per coat, a result that liquid paints cannot achieve without multiple layers.”

The paint performs even under high pressure. Surface coating expertise on many levels – that‘s where Rippert has been making a name for itself for over ﬁve decades. We conceived surface coating plants for PILATUS for the ﬁnishing individual components and complete aircraft. We are delighted to accompany a successful company with our ideas and technologies. We make brands shine. Find out more at www.rippert.de

Figure 3: Examples of coated aluminium sheets.

S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

example, in a continuous product

VOC-free technology, and a lower cost,

development activity with TITAN, a

because it is a one-layer system and

High quality is a must for Aluminios

firm with which we started working

not a four-layer system like its liquid

Andalucía. The company only uses

about twenty years ago, when we

counterpart.

first-choice aluminium produced by

began to develop specific powder

“We are currently developing a special

the major European foundries, which

paints and special and custom coating

treatment to protect even more the

it then enriches with a high-quality

systems in order to supply sheet

products of our customers from countries

corrosion-protection pre-treatment

and coil aluminium for the most

where the corrosion risk is higher due to

developed in collaboration with large

ambitious architectural projects in

adverse weather conditions, proximity to

multinational companies from the

the world,” adds Jesús Martín Martín.

the sea, and so forth, such as the Northern

chemical sector, and polyester powders

“Another result of our collaboration

European ones. This special coating

for architecture supplied by a few

with coating suppliers is a joint project

offers high durability and protection levels

leading international manufacturers.

to manufacture a treatment that is

and safeguards even more the treated

“Aluminios Andalucía has always

similar to PVDF application in the liquid

components by ensuring the highest

worked in collaboration with leading

pre-painted metal field, but whose

corrosion protection level that we can

providers of polyester powder coatings.

production has a lower environmental

currently achieve. This is obtained by

This cooperation has resulted, for

impact, as it uses our innovative

combining a more corrosion-resistant alloy

Quality: a must for both producers and users

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Figure 4: Aluminios Andalucía’s aluminium sheet anodising line is the largest in Europe.

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FOCUS ON TECHNOLOGY

substrate, a 5-micron anodic pre-treatment layer, and an architectural polyester powder coating. Thanks to our high flexibility and to this combination of anodising (Fig. 4) and coating operations, Aluminios Andalucía can meet this need for higher performance with only slightly higher costs than a conventional outdoor-resistant system.” Research and Development Manager Santiago Martín Martín adds: “Northern European markets ask for finishes with excellent quality, corrosion protection, and durability degrees; however, their cost is higher, since we combine special alloys with a flash-anodising pre-treatment process (Fig. 5) and a pre-painting phase with hyper-durable powders supplied by TITAN. That is why we believe that it is vital to educate customers about these products and their advantages in markets requiring higher quality levels. “We have two continuous coating lines applying polyester powders and primers, with which we treat aluminium with a thickness between 0.6 and 3 mm and a width between 500 and 1,620 mm, marketed under the brand ApliMAX®; a powder coating plant for aluminium sheets with a thickness of 0.6 to 5 mm, a length up to 6,500 mm and a width up to 2,000 mm, marketed under the brand ApliLAC®; and an aluminium sheet anodising line that is the largest of its kind in Europe, with which we treat aluminium with a 0.7-5 mm thickness, up to 2 m in width and 7 m in length, marketed under the brand ApliBAND®. We also have a drilling line, four coil and sheet cutting lines, and a slitter, in order to diversify our products.

Aluminios Andalucía has always worked in collaboration with leading providers of polyester powder coatings. This cooperation has resulted, for example, in a continuous product development activity with TITAN, a firm with which Aluminios Andalucía started working about twenty years ago, when it began to develop specific powder paints and special and custom coating systems in order to supply sheet and coil aluminium for the most ambitious architectural projects in the world.”

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S PECIA L O N ALU MIN IU M F O R META L AR CH ITE CTUR E A N D IN DU STR IAL DESIGN

Another result of the company’s collaboration with coating suppliers is a joint project to produce a treatment that is similar to PVDF application in the liquid pre-painted metal field, but whose production has a lower environmental impact, as it uses an innovative VOC-free technology, and a lower cost, because it is a one-layer system and not a four-layer system like its liquid counterpart.” 5 1

Figure 5: The flash anodising stage of the pre-treatment cycle creates a layer of anodic oxide ranging from 2 to 5 microns.

“The two continuous coil coating lines produce complementary finishes: one performs degreasing, brushing, and primer

application operations and reaches a process speed higher than 30 m/min; the other applies powder coatings with a production speed exceeding 25 m/min. As for our productive capacity, we have a potential of more than 10 million m2 of coated aluminium and more than 5 million m2 of anodised aluminium.” “Another success of our R&D department that we would like to emphasise is our decorated aluminium, marketed under the brand ART-Luminium. We obtain it through the application of a polyester-powder base-coat, the sublimation of high-resolution images over it, and the final application of an anti-graffiti or super-durable transparent coating,” says Santiago Martín Martín. “In 2014, we participated in a very important project with this product: the Rotterdam Market Hall, the Netherlands’ first covered market, containing shops, restaurants, and relaxation areas (Fig. 6). Aluminios Andalucía powder-coated and sublimation-decorated over 100,000 m2 of aluminium for it.”

Conclusions This company’s philosophy is based on offering a wide range of aluminium surface treatments, developed with the highest quality and technology levels and the best raw materials available on the market, in order to ensure maximum product durability and quality. “Aluminios Andalucía has also created a guideline for its customers, specifying the key points that distinguish our products from the liquid pre-painted ones and explaining the correct conditions to protect, handle, and store the coated material,” states Jesús Martín Martín. “In the same way, we 6 1

believe that it is fundamental to know the intended use

Figure 6: The Rotterdam Market Hall, the Netherlands’ first covered market, is one of the projects carried out with the ART-Luminium product.

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of the metal we paint, so that we can correctly advice our customers and always provide them with the high quality level that characterises us.”

powder coatings Paint Engineering

Premium quality Formulation, design and manufacture adapted to technical requirements, and highly complex facilities.

Anticorrosive systems

Coil Coating Superdurable Superdurable coatings for sublimation effect Metallic bonding

www.titanpowdercoatings.com

SUCCESS STORIES

BMW Have Created the World’s First Vantablack Car

HE FRANKFURT MOTOR SHOW

appearing two-dimensional (Fig. 2). This can

new BMW X6 to perfection. Asked whether

was the backdrop for the unveiling

be interpreted by the brain as staring into a

he was pleased with the final car, Ben Jensen

of the first and only vehicle in the

hole or even a void.bTherefore, coating the

commented: “I think it went beyond all our

world to feature a Vantablack VBx2 coating

BMW X6 has the effect of hiding some of the

expectations because of the size of the car,

in a collaboration between BMW, Surrey

trademark curves and accentuating other

its distinctive shape and how imposing it is”.

Nano Systems and Levitation 29. The

design features such as the optional Iconic

showcasing of the car, known as the BMW

Glow kidney grille, distinctive twin headlights

The BMW VBX6 marks the latest in a string of

VBX6, coincided with the world premiere of

and striking taillights.

high-profile collaborations between Surrey

the third-generation BMW X6 Sports Utility

The new BMW X6 is the first and only vehicle

NanoSystems, the inventors of Vantablack

Coupé (Fig. 1).

in the world to feature a Vantablack VBx2

coatings, and Levitation 29 the technical

Since they started working together in 2018,

world, absorbing more than 99% of visible

the Vantablack VBx2, which visually alters

Surrey NanoSystems and Levitation 29 have

light and almost completely removing all

the viewers perception of the car’s

produced a number of high-profile

reflections. In a playful and cutting-edge take

three-dimensional nature. Ben Jensen,

world firsts from a blackout house for

on the tradition of concealing key design

Vantablack inventor and founder of

Activision’s Call of Duty to a 40ft high

features by keeping cars under cloth or

Surrey Nano Systems said: “VBx2 with its

Vantablack monolith at Coachella music

covering them with decals, BMW celebrate

one-per-cent reflectance provides just

festival for the Techno DJ and Producer

the launch of the iconic X6 by showcasing a

enough of a hint of shape”. The spectacular

Gesaffelstein. The VBX6 collaboration with

Vantablack version. A surface coated with a

one-off vehicle highlights the expressive

BMW however held a special place with

Vantablack VBx2 coating loses its defining

and precise design language and confident,

fans of Vantablack. Benjamin Males from

features to the human eye, with objects

dominant and muscular appearance of the

Levitation 29 says: “We get contacted by a

and creative agency behind the project.

provides fascinating contrasts to offset

paint finish. The design of the BMW X6 Vantablack coatings are the blackest in the

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Figure 1: BMW VBX6 is the new car by BMW coated with the Vantablack® VBx2 paint finish.

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Figure 2: A surface coated with a Vantablack VBx2 coating loses its defining features to the human eye, with objects appearing two-dimensional.

SUCCESS STORIES

lot of people wanting to use Vantablack in

bigger car, which makes the effect even

surfaces and lines. The Vantablack

their projects - the idea of total blackness

more stunning”. During the development

VBx2 coating foregrounds these

is something that really captures the

process the Levitation 29 team met with

fundamental aspects of automotive

imagination. We have lost count of the

Hussein Al Attar, the designer of the X6

design, without any distraction from

number of times people have asked us

who helped to describe the DNA at the

light and reflections”.

to coat a car in Vantablack, so it’s great to

core of the design of the car. Hussein said:

finally be making it a reality with BMW”.

“Internally, we often refer to the BMW

Benjamin Males from Levitation 29

X6 as The Beast. I think that says it all.

said: “We really can’t wait to see where

The concept of the first Vantablack

The Vantablack VBx2 finish emphasises

this collaboration with BMW and

BMW was devised by Christophe

this aspect and makes the BMW X6 look

Surrey NanoSystems will take us next.

Koenig, Spokesperson for the BMW X

particularly menacing. Moreover, the BMW

The first Vantablack car is certainly a

models. He first proposed the idea back

X6 has always been the most provocative

big tick in the box when it comes to

in 2018 and it took over 10 months

and in-your-face model in our portfolio. So

dream projects and opens the way for

to come to fruition. “My thoughts of

why not emphasise this even further, with

even more large-scale concepts- like a

having a Vantablack BMW gets back

a finish that simply captivates the viewer’s

stadium! To create the effect of infinite

to the preparation of the BMW X2

attention? After all, that’s what the BMW

darkness on that scale would truly be

launch. Back in the days we wanted to

X6 has always been about. Vantablack

spectacular.”

have a kind of stealth painting, but we

VBx2 opens up new possibilities for us as

couldn’t make it happen. Therefore, I’m

designers. We often prefer to talk about

For further information:

very excited we were able to do it on a

silhouettes and proportions rather than

www.surreynanosystems.com

We create chemistry that makes lines love curves. Coatings give a car more than just long-lasting protection. Brilliant gloss and innovative colors transform contours into dynamics and design into emotion. Lines and curves are united and edges and contours are brought to life. When color and shape come together, and paint evokes passion, it’s because at BASF, we create chemistry. www.basf-coatings.com

Opening photo: Specialising in the paint stripping field since 1991, MEC Srl has recently designed and installed a pyrolytic oven devoted to thermal stripping.

FOCUS ON TECHNOLOGY

How to Make Paint Stripping More Sustainable, Safe, and Efficient: MEC Srl’s New Pyrolytic Oven Ilaria Paolomelo ipcm®

fundamental but often little

applications, such as chemical, cryogenic,

these devices collect several layers of paint

considered aspect of the production

mechanical, and thermal.

on their surfaces, which can compromise

flow of companies operating in the

Hanging systems, including hooks, bars,

their conductivity thus jeopardising

industrial coating sector is the paint stripping

frames, grilles, protective casings and

painting quality. In fact, about 40% of the

phase. This process enables to remove

so on, are often subjected to this type

sprayed coating accumulates on them,

any trace of paint from the surface of a

of treatment. Used to hang workpieces

resulting in considerable problems in

metal product without altering its physical

onto overhead conveyors prior to coating,

terms of both quality level and costs. It is

properties, through different types of

especially with electrostatic application,

therefore extremely important to remove

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FOCUS ON TECHNOLOGY

MEC Srl has distinguished itself in the paint stripping sector thanks to its commitment, innovation degree, and search for sustainable solutions. Established in 1991, it has immediately specialised in the cryogenic paint stripping field, obtaining numerous and important patents and certifications at the European level.”

such deposited paint layers, in order to improve the painting process quality, extend the service life of hanging accessories, and reduce the costs to repurchase them. Finally, paint stripping also allows recovering components with coating defects in order to recirculate them into the production cycle. In Italy, MEC Srl has distinguished itself in this sector thanks to its commitment, innovation degree, and search for sustainable solutions. Established in 1991, it has immediately specialised in the cryogenic paint stripping field, obtaining numerous and important patents and certifications at the European level. Over time, it has implemented other paint stripping and part recovery technologies, such as pyrolytic thermal stripping, rubber and plastic coating removal, and

so on. MEC also designs and builds devices and systems for technical cleaning by solid carbon dioxide sandblasting, as

Figure 1: The new pyrolytic oven is intended for the thermal stripping of heat-sensitive metal products able to withstand temperatures above 400 °C.

well as prototypes for use in the cryogenic field at very low ipcm® has recently visited its plant, located in Caltignaga (Novara, Italy), to see the latest innovation designed by

temperatures.

this company: a sustainable and efficient pyrolytic oven (ref. Opening photo) for stripping metal products able to withstand temperatures above 400 °C (Figs. 1 and 2).

Characteristics of the new pyrolytic oven “Thanks to our many years of experience in the sector and knowing the issues and shortcomings of our old pyrolytic system, we decided to draw up detailed specifications for the new oven, so that it would have fully met our needs,” explains company owner Attilio Bernasconi. “The operating principle of the pyrolytic oven is based on the overheating of metal parts (Fig. 3) through a high temperature pyrolysis process (380 to 450 °C), which leads to the decomposition of organic substances into volatile compounds. In this way, the paint layer is carbonised by heat and comes off the surface.”

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Figure 2: Among the metal items treated by MEC, there are masking systems and accessories such as hooks and bars.

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Figure 3: A bird’s eye view of MEC’s new pyrolytic oven.

average by the pyrolytic ovens currently on the market,”

two standard-sized trolleys simultaneously. After pyrolysis, the

adds Bernasconi. “Our afterburner is also equipped with an

workpieces are taken to a cooling chamber adjacent to the

oxygen measurement and control system installed in the

oven. A suction system takes air from outside and feeds it into

post-combustion chamber and with an air injection system

this cooling chamber. The air used is then sucked and filtered

that prevents any temperature rises and the formation

to remove any ash and dust created by the pyrolysis process.

of harmful fumes. The chimney contains a heat recovery

The fumes produced by the pyrolytic process are sent to

system.”

an afterburner with a 50% bigger size than those used on

takes place in a large chamber (4 x 2 m) able to accommodate

“In the new oven we have designed, the pyrolysis process

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Figure 4: In order to improve workplace safety, MEC has designed a system with fully automatic loading, unloading, and handling phases.

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Figure 5: The oven is also equipped with a PLC with an HMI interface with which consumption is periodically checked.

FOCUS ON TECHNOLOGY

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Figure 6: MEC owner Attilio Bernasconi and Alessia Venturi from ipcm®.

Eco friendliness, energy efficiency, and workplace safety are the factors that have led MEC to design this new pyrolytic oven. In order to improve safety, it has designed a system with fully automatic loading, unloading, and handling phases.” Sustainability, energy eﬃciency, and workplace safety “MEC has always been active in the search for ecological and innovative paint stripping solutions. Eco friendliness, energy efficiency, and workplace safety are the factors that have led us to design this new pyrolytic oven,” states Bernasconi. “In order to improve safety, we have designed a system with fully automatic loading, unloading, and handling phases (Fig. 4): this results in less physical effort on the part of the operators and in greater protection from the risks associated with heat exposure. That is why INAIL, the Italian National Institute forbInsurancebagainst Accidents at Work, chose to cofinance the project. As for eco friendliness, we aimed at achieving lower fuel, and especially methane consumption levels and greater control and recovery of waste heat. The oven is also equipped with a PLC with an HMI interface with which we periodically check consumption, Fig. 5).” “We have tried to combine these three factors because they are crucial for MEC as well as for more and more companies. Our goal is to design and produce increasingly sustainable and flexible paint stripping systems, in order to tailor-make them for any firm that wishes to rely on the expertise and experience of MEC,” states Bernasconi (Fig. 6).

FOCUS ON TECHNOLOGY

A New 4.0-Oriented Powder Coating Booth to Improve Sustainability and Workplace Ergonomics at Verniciatura Maschietto Monica Fumagalli ipcm®

owadays, SMEs as well as large manufacturing companies are implementing business strategies aimed at reducing their processes’

environmental impact and improving their employees’ conditions by making their workspaces more ergonomic. Being a sustainable company no longer simply means to equip a factory with systems that meet the increasingly stringent regulations on the environment and safety, but also to be far-sighted in developing production by implementing Industry 4.0 principles in a structural and convenient way. “I am personally involved in my company’s daily life and, therefore, I want it to have certain characteristics while protecting everyone’s health and safety,” says owner Piergiovanni Maschietto to explain the reasons behind his business strategy for Maschietto Mario Eredi Srl, a coating contractor specialising in both powder and liquid treatments with 40 employees managed by Piergiovanni and his brothers, Valentino and Giuliano. “It has always been so: Maschietto was one of the first companies to install an afterburner for the abatement of volatile organic compounds.”

Opening photo: Requirements in terms of application performance and coating quality are now extremely demanding, in the contracting coating field.

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FOCUS ON TECHNOLOGY

Figure 1: The powder coating system provided by Zeus.

The long-standing environmental vocation of Verniciatura Maschietto

treats spent solutions produced by

streamline the factory management process,

a phospho-degreasing unit, which

thanks to the constant monitoring of

recovers distilled water and recirculates

production data and the further reduction

Established in 1954, Verniciatura

it into our production flow, as well as

in energy and material consumption. That is

Maschietto (San Vendemiano,

an energy-saving led lighting system

why we have automated all our production

Treviso, Italy) has obtained the most

and inverter equipment distributed

lines, equipping them with automatic

important certifications that attest

throughout the building to convert

overhead conveyors and 6-axis robots,

to the quality of its management

electricity according to production

and updated our coating plants with new

system. “We are probably one of the

needs, and - last but not least- a high

spray guns. We have also invested in a new

few coating contractors to be ISO

efficient cogenerator powered by

powder application booth supplied

9001, ISO 14001, and OHSAS 18001

methane which produces thermal

by Zeus Electrostatic System Srl (Argenta,

certified and we were among the

energy and electricity.”

Ferrara, Italy), which was started in August

first ones to install a photovoltaic

This factory has been recently

2017 (Fig. 1). This investment belonged

system, able to produce 30% of

integrated with Industry 4.0-oriented

to a corporate restructuring plan that also

our annual electricity demand.

systems and devices. “The innovations

involved our IT system, developed to achieve

Our environmental management

brought by the fourth industrial

complete and perfect interaction among

system also includes a distiller that

revolution,” states Maschietto, “help

machines and operators.”

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

143

2 1

3 1

Figure 3: The conveyors’ automation has made it easier for the operators to handle components.

Cutting-edge coating lines

points out Maschietto, “and they are equipped

and harmful movements: our staff

This company produces high quality finishes

with 6-axis robots supplied by Lesta Srl

currently focusses above all on loading,

through 4 coating lines, of which 2 for liquid

(Dairago, Milan, Italy), featuring remote controls

unloading, and line management tasks

paints and two for powders, arranged over

(Fig. 2). This automation solution, along with

(Fig. 3).” After picking up the workpieces

its 10,000 m2-wide covered area. “The 2

the choice to install overhead conveyors on all

from the warehouse and loading them

liquid coating lines are fully pressurised,”

lines, enables our operators to avoid repetitive

onto a conveyor, the employees prepare

Figure 2: One of the Lesta robots operating on the 2 liquid painting lines.

Verniciatura Maschietto produces high quality finishes through 4 coating lines, of which 2 for liquid paints and two for powders, arranged over its 10,000 m2-wide covered area.” 4 1

5 1

Figure 4: Powder application in a booth with Venturi injectors.

144

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Figure 5: The control module of automatic guns.

FOCUS ON TECHNOLOGY

the coating products and configure

and 4000x2000x1000 mm; the

never been simple precisely due to the

the systems according to the required

department also includes an area for

variety of parts to be treated and the

finishes (e.g. high temperature

the surface treatment of workpieces

colour customisation degree required,â&#x20AC;?

resistant, soft touch, antibacterial,

exceeding 5 metres. After loading, the

states Maschietto. â&#x20AC;&#x153;Now, however, such

antigraffiti, anticorrosive, etc.) by

parts enter a 4-stage pre-treatment

requirements have reached levels only

selecting the right hardware and

tunnel: phosphating or alkaline

comparable to those of the automotive

software settings.

degreasing, two rinses, and a rinse

and motorcycle industries, especially in

The liquid finishing cycle starts in a

with demineralised water. The drying

terms of coating quality (ref. Opening

deionising chamber; then, the parts

phase occurs at a temperature of

photo). Combined with our customersâ&#x20AC;&#x2122;

enter the coating plant consisting

130 Â°C. Coating is performed in two or

just in time production flows, adopted

of two pressurised booths: one is

three booths, depending on the partsâ&#x20AC;&#x2122;

to avoid stocking up, these client needs

devoted to the robotic application

dimensions.

have led to the creation of increasingly

of base coats and the other applies

smaller batches of material to be

checked, packaged, and labelled.

Workpiece variety and colour customisation: the critical issues of a coating contractor

The powder finishing cycle, on the

The company had to acquire a third

that not only guaranteed quick colour

other hand, occurs in two lines,

booth in order to meet the growing

change operations without wasting

devoted to components with a

demand for colour diversification.

time for cleaning, but that also perfectly

maximum size of 2000x2000x800 mm

â&#x20AC;&#x153;The contracting coating activity has

fitted into our environmental policy

top coats (after a flash-off stage). After further flash-off and drying, the workpieces are ready to be unloaded,

painted and, therefore, to an increase in the number of colour change overs to be performed â&#x20AC;&#x201C; currently about 50 per day. We had to find a solution

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and our 4.0-oriented updating project, obviously without losing sight of coating quality. “That is why we turned to Zeus, one of our long-standing partners: indeed, this company has manufactured all application devices installed on our systems. All our guns use the Venturi injector technology (Figs. 4 and 5). We already knew that Zeus has a highly professional approach with its customers, but on this occasion it also showed a fairness level that we greatly appreciated. Our choice fell on the Zeus3 booth, the latest type developed by this company,

6 1

equipped with the most advanced monitoring devices and interconnected

with our factory management system. We chose it in the version featuring a cyclone and a 20,000 m3 final filter for powder recovery (Fig. 6).”

Features of Zeus3 The booth installed at the premises of Verniciatura Maschietto is built in dielectric material for easier and faster cleaning and greater powder recovery efficiency. “This machine type has been conceived precisely to meet the needs of coaters performing a high number of daily colour change overs,” says Zeus Electrostatic System Srl CEO Massimo Ricci. “As is well known, plastic helps prevent any powder accumulation on booth walls, thus guaranteeing the maximum efficiency of the recovery system and facilitating the cleaning operations. The micro perforated Venturi-effect cleaning system keeps the booth floor clear by avoiding accumulations of powder (Fig. 7). The suction unit has been designed to avoid powder leaks and create a healthy work environment.” The system provided by Zeus is completed by the Super Color Center, a powder and colour change

7 1

management unit interfacing with

Figure 7: The booth is equipped with a micro perforated Venturi-eﬀect cleaning system that prevents powders from accumulating on the floor.

146

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

Verniciatura Maschietto’s management software package (Fig. 8).

FOCUS ON TECHNOLOGY

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.

8 1

Figure 8: The Super Color Center unit managing the powders.

The evolution of coating booths in terms of Industry 4.0

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

“Zeus3 improves our standard booths’ functions,” adds Massimo Ricci, “in order to provide our customers not only with greater ability to connect the machine with their management system and therefore to streamline their production flows, but also with more information. From powder and energy consumption to emissions and filter clogs, all data is monitored and transferred to the control panel, which in turn is connected with the central system. Its benefits compared with a stand-alone system are clear. First of all, the control panel is connected to the spray control module. There are functions such as Ethernet and cloud connection, remote assistance, on-site and remote programming, and software

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.

updates, all enabled by the presence of innovative, Industry 4.0-oriented devices. Finally, information on programs and malfunctions, which in a stand-alone system can only be displayed locally, is managed by the central PLC.”

WWW.LESTA.IT Zeus3 provides customers not only with greater ability to connect the machine with their management system and therefore to streamline their production flows, but also with more information.”

LESTA S.r.l.

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

9 1

10 1

Figure 9: Some components coated in white.

Figure 10: The backside of a booth.

Conclusions

“We have made our department

After installing the new booth,

Verniciatura Maschietto and Zeus have the same vision in terms of eco-friendliness and plant safety: in their respective sectors, the 2 companies strive to make sure that all devices and equipment are 100% safe not only for workers, but also for the environment.”

Verniciatura Maschietto has devoted one of its two already-existing booths to the application of white only and the other to that of black (Fig. 9). Zeus3 applies all other colours linked to the choice of a latest generation booths,” observes

the continuous monitoring of production parameters enables us to manage the plant as we wanted. Working with Zeus is a guarantee of excellent service because, as well as providing professional consultancy, its team is always available to perform

(Fig. 10). “Besides the advantages

healthier for our operators, and

extraordinary interventions.

Maschietto (Fig. 11), “such as

Finally, we have the same vision

increased productivity thanks to

in terms of eco-friendliness and

rapid colour change operations,

plant safety: in our respective

we have also reduced product

sectors, we strive to make sure

consumption. We have switched

that all devices and equipment are

from minimum 100 kg powder

100% safe not only for workers,

for each booth to 25 kg for each

but also for the environment. We

colour. Considering that our

intend to gradually replace all our

catalogue includes over 400 tints,

outdated systems with others of

this is a remarkable achievement, which is reflected in our inventory planning and, of course, in our powder purchasing costs.

148

11 1

Figure 11: Massimo Ricci (left) with Piergiovanni Maschietto.

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

the latest generation, following the environmental and workplace ergonomic strategy that has always characterised our company.”

20Â° SALONE DELLE TECNOLOGIE E DEGLI UTENSILI PER LA LAVORAZIONE DEI METALLI 20TH EXHIBITION OF TOOLS AND TECHNOLOGY FOR METALWORKING

06/07/08.02.2020

STANDARD & LEGISLATION - UCIF Informs

Finishing Goes Beyond Surfaces (With a Conference) Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

info@ucif.net

urface treatments have made

numerous requests for registration. We

As UCIF President Marco Leva stated, “We hope

great strides in recent decades.

have now formalised the participation of 14

there will be an exchange of opinions and ideas

Continuous research and innovation,

following our guests’ speeches. This conference

diverse topics related to finishing. Many

will be not held for commercial purposes:

of these solutions, have led the treatment

of them will be accompanied by their own

we expect this message to be grasped and

industry to constantly evolve. Automation,

customers, who will illustrate the benefits

to attract new potential UCIF members.” The

environmental sustainability, energy saving,

brought by these innovations to their

conference will be called “Finishing becomes

production efficiency, Industry 4.0, 3D

production.

SMART”, where SMART is the acronym of

printing, and chemical advances are just

That is why the UCIF conference will not

Surface, Manufacturing, Advanced, Research,

some of the aspects that will be explored

only be an important occasion to take stock

and Technology.

on November 6 during the conference

of the technologies available for individual

Participation will be free upon registration

organised by UCIF, the Italian Surface

sub-processes: it will also be an opportunity

and places will be limited. We wish to bring all

Treatment Equipment Manufacturers’

for customers and suppliers to understand

different players of this industry and its satellite

Association, at the Fondazione Cariplo

the trends in the sector and the objectives

activities together, with the aim, in future, to

Congress Centre in Milan.

of applied research, which will hopefully

develop a dynamic supply chain that will enable

After this was announced a few months

provide all participants with useful ideas,

finishing to acquire ever-greater importance in

ago, the UCIF secretariat has received

knowledge, and inspiration.

the industrial production processes.

companies, which will report on the most

strongly supported by the target markets

150

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

SURFACE MANUFACTURING ADVANCED RESEARCH TRENDS

smoothadv.com

La finitura diventa SMART

6 novembre 2019 Centro Congressi Fondazione Cariplo. Appuntamento UCIF: Le nuove frontiere tecnologiche della finitura

www.ucif.net

la partecipazione Ã¨ gratuita previa registrazione obbligatoria fino ad esaurimento posti. Tel. 02 45418.519 - info@ucif.net Con ilpatrocinio di:

UNIONE COSTRUTTORI IMPIANTI DI FINITURA

ASSOCIAZIONE ITALIANA DI METALLURGIA

速

TRADE FAIRS & CONFERENCES

INTERNATIONAL PAINT&COATING MAGAZINE

: MEDIA PARTNERSHIP - ipcm

速

OCTOBER 2019 ABRAFATI

EXPO FERROVIARIA

ISK-SODEX

INMEX SMM INDIA

KOMPOZYT EXPO

DEBURRING EXPO

CANWEA ANNUAL CONFERENCE

ALUEXPO MEDITERRANEAN OFFSHORE CONFERENCE K

EXPO COATING

PARTS2CLEAN

152

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

S達o Paulo, Brazil October 1-3, 2019 Rho Fiera, Italy October 1-3, 2019 Istanbul, Turkey October 2-5, 2019 Mumbai, India October 3-5, 2019 Cracow, Poland October 8-9, 2019 Karlsruhe, Germany October 8-10, 2019 Calgary, Canada October 8-10, 2019 Istanbul, Turkey October 10-12, 2019 Alexandrya, Egypt October 15-17, 2019 D端sseldorf , Germany October 16 -23, 2019 Moscow, Russia October 22-24, 2019 Stuttgart, Germany October 22-24, 2019

www.abrafati.com.br

www.expoferroviaria.com

www.sodex.com.tr

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www.kompozyty.krakow.pl

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ZOOM ON EVENTS

At the 2019 Coatings Innovation Summit PPG Presents “Paints with Purpose”, the Next-Generation Paint and Coatings Technologies Barbara Pennati ipcm®

rom August 29 to August 31, PPG held

ensuring a low environmental impact, like PPG

energy, Xylan® can be applied on bolts, thus

its second annual Coatings Innovation

Envirocron™, a new polyester powder coating,

reducing the variance of load, bolts’ size and the

Summit in the beautiful setting

100% solvent-free, which delivers superior

number of bolts used, while ensuring a higher

provided by the Grand Hotel Suisse Majestic in

protection in extreme environments and has

corrosion protection”, explains Mark Poland,

Montreux (Switzerland – Fig. 1).

been specifically formulated to cover sharp

Technical Manager PPG-Whitford UK.

The event aims at highlighting the company’s

edges for an improved corrosion protection

latest innovations that are advancing coatings

with just one coat.

technology around the world.

Another product presented was Xylan –

This year’s summit showcased advancements

produced by Whitford, a coating manufacturer

Productivity – Innovations that are helping reduce complexity, time and waste

in three key areas – Sustainability, Productivity

founded in Pennsylvania and recently acquired

The Productivity area presented solutions that,

and Mobility – sharing also success stories from

by PPG – which provides a range of low friction

by helping reducing complexity, time and waste,

a variety of sectors, from automotive to marine,

and release coatings (Fig. 2). “This product

contribute to maximising productivity.

packaging, architectural and other industries.

can be applied in several different sectors to

Among others, PPG RAYCRON™ UV &

These areas are the focus of PPG’s

ensure better friction control. In the renewable

electron-beam coatings, designed for flat

“Paints with Purpose” campaign, which is

energy sector, for instance, where tidal power

panels and floorings, combine improved

designed to highlight applications of

can be used to produce huge amounts of

mechanical and chemical resistance with an

These include paints that can cool asphalt

next-generation paint and coatings technologies.

temperature on a hot day to protect pets’ paws; coatings that can absorb sound or help reduce pollution; and paint that helps self-driving cars see the surrounding infrastructure. Journalists and costumers have been guided through the different areas by PPG’s global technical experts, who presented with live demonstrations the different products and technologies.

Sustainability – Technologies that drive eﬃcient use of the world’s natural resources In the Sustainability area attendees could know more about different products that contain low VOC levels and are water- or bio-based,

154

Figure 1: From August 29 to August 31, PPG held its second annual Coatings Innovation Summit in Montreux, Switzerland, to showcase the latest innovations that are advancing coatings technology around the world.

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2 1

Figure 2: Xylan®, produced by Whitford, a coating manufacturer founded in Pennsylvania and recently acquired by PPG, provides a range of low friction and release coatings.

environmentally friendly, heat and solvent-free curing process, giving architects and designers increased possibilities and a higher finish quality for substrate applications. The next generation of PPG’s passive fire protection system was also introduced. “PPG PITT-CHAR NX® is a flexible epoxy intumescent coating system, designed to resist the most severe hydrocarbon hazards, like pool fires, jet fires and explosions”, explains Kees Van Vliet, Technical Director, Protective & Marine Coatings, EMEA of PPG. “The new PPG PITT-CHAR NX® substantially reduces both the thickness and weight of Passive Fire Protection coating allowing for lower costs and significantly faster application, which of course helps enhancing productivity. Being suitable for a number of applications, both onshore and offshore, it is also been designed to eliminate the risk of cracking and delamination during fabrication, transportation and construction”. Attendees could also experience the innovative PPG MOONWALK™, an automated paint mixing system which offers body shops cutting-edge refinish paint mixing technology (Fig. 3). Launched in July, this new system replaces manual mixing processes with a more efficient, easy-to-use, automated mixing system that helps eliminate waste and mess, maximizes accuracy, automates the process and generates profit for customers.

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3 1

4 1

Figure 3: PPG MOONWALK™, an automated paint mixing system which oﬀers body shops cutting-edge refinish paint mixing technology.

Figure 4: PPG SIGMAGLIDE™ Foil is an eco-friendly, 100% biocide-free fouling release foil that helps to reduce drag on ship hulls by up to 10% and that makes for an easy-to-apply fouling release solution.

“This system was created with a

easy-clean composite coatings that help keep

applied, then increases resistance at a

costumer-centred approach. In fact, by

sensors and lenses clear in adverse weather

pre-determined temperature, lowering current

directly observing our customers, we noticed

conditions.

flow and preventing runaway heating”.

that manual mixing often contributes to

A new printable Positive Temperature

Aside from providing cars with safe, efficient

a dirty and unsafe environment, to more

Coefficient (PTC) ink with a target

heating, many industry visionaries have

product waste and to reworks”, explains

temperature range that is limited to 40°C

proposed integrating PTC heating as radiant

Alberto González, PPG Business Solutions,

to 60°C, developed by PPG’s Conductive

heating for vehicles of the future. This is being

Digital Marketing, Communication and

Materials business and Coatings Innovation

driven by the move toward E-vehicles, which

Branding Manager Automotive Refinish

Center in Allison Park (Pennsylvania),

unlike traditional cars powered by internal

EMEA. “We wanted to transform the ‘pains’ –

was presented as well. The new PTC

combustion engines, have no naturally

that is, all those situations that may cause a

inks underwent months of testing that

occurring heat source to supply heating to the

loss of time or value – into ‘gains’ – beneficial

demonstrated their more consistent resistive

passenger compartment.

situations for both our customers and their

print range (+/-5%), a far stronger and

“By replacing battery-generated heat with

customers. With MOONWALK™, body shops

more consistent PTC effect (15-20 times), a

radiant PTC heating, passengers can feel

can count on a cleaner environment and on

superior print quality and improved

comfortable and warm while minimizing the

a more effective production, both in terms of

long-term storage life.

impact on E-vehicle range”, states Thierry

costs and lead time”.

“Traditional printed resistive heaters warm up

Destruhaut.

when a current is applied but the reliability

An innovative solution impacting mobility has

of these systems has been hampered by

been presented to the marine industry as well,

their dependence on complex interactions

thanks to PPG SIGMAGLIDE™ Foil, an

between sensors, controllers, and advanced

eco-friendly, 100% biocide-free fouling release

Mobility has undergone great changes in the

power supplies that can cause failures when

foil that helps to reduce drag on ship hulls by

past few years, especially with the advent

even one part of the system fails”, explains

up to 10% in comparison to other technologies

of electric cars. In this area, PPG presented

Thierry Destruhaut, Project Portfolio Director

and that makes for an easy-to-apply fouling

its technologies that impacted all aspects of

Global Architectural Coatings. “Printable,

release solution (Fig. 4).

Mobility, like advanced coatings that enhance

carbon-based, PTC inks were developed to

and enable autonomous vehicle sensor

address this need. PTC heaters are printed

More than 160 customers and journalists

detection of other vehicles and oncoming

and operated like a traditional printed heater,

attended the three-day summit, which was held

obstacles. These include coatings that

but with the added benefit of a self-regulating

in conjunction with the PPG-sponsored Omega

improve dark vehicle colour detection by

safety and stability feature: a resistive carbon

European Masters golf competition in

LiDAR and radar systems, and

coating that heats up when a current load is

Crans-Montana, Switzerland.

Mobility – Technologies for autonomous and electric vehicles. And not only.

156

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SFCHINA2019 – Always A Great Platform for The Industry!

he 32nd edition of SFCHINA exhibition will take place at Shanghai

Ekem, Electron Coating, Empire Chem, Ensoo Chemicals, Excilon, Gema,

New International Expo Centre (SNIEC), China again on November

Graco, GSTC, Jadechem, Jinchuan, Joihey, KCI, Nordson, PAT, Raschig,

18-20, 2019, spanning 1.5 exhibition halls (Halls E1 & E2). The size

Reach, SAMES KREMLIN, Super Polish, Vale, Wagner, Winstar, WIN-WIN Technology, Yu Tung, Zi Yi, etc.

of the show sets a new record: with over 17,000 square metres of gross exhibition space (a rise of 5% and 23% against 2017 and 2018 editions respectively). Over 320 exhibitors from 22 countries/regions (as of August 5,

Achieve success through learning

2019) will come together to present their products and services in 3 exhibit

SFCHINA2019 will feature a number of technical programmes onsite to

zones, namely ‘Electroplating & Finishing Technology’, ‘Environmental,

provide visitors with information on innovations and future trends.

Safety & Protection’ and ‘Coating Applications & Coating Products’. Total net

2 Technical Forums with topics ‘Coating Applications & Technologies for

exhibition area of the ‘Electroplating & Finishing Technology’ exhibit zone

Automotive Lightweight Materials’ and ‘Technologies for VOCs Control,

continues to expand noticeably (a rise of 28% against 2018 Guangzhou

Monitor & Treatments’ will be held on the first and second day of the show

show), resulting from diverse applications and emerging innovations,

period. Technical Seminars will give visitors opportunity to obtain

particularly in industries like electronics, automotive, aerospace & defense.

up-to-date information from exhibitors, such as greener solutions, latest trends and markets, electroplating and coatings application technology, etc.

A platform to showcase industry’s future To address a range of environmental problems, most countries have

Visitor registration is now open!

enforced or strengthened various regulations and policies. Environmentally

Visitors can now pre-register on SFCHINA’s official website

friendly surface finishing materials, processes, applications and effective

www.sfchina.net to receive visitor pass in advance so as to avoid queuing

recycling management system are becoming keys to stay relevant in the

during opening hours. Visitors can also follow official WeChat account

evolving marketplace, as well as to keep up with consumer demand and to

(ID: ChinaCoat_SFChina) to pre-register there. Follow SFCHINA on

meet regulatory requirements. SFCHINA has been a strategic destination

Facebook, Twitter, LinkedIn and YouTube to receive first-hand information.

for technological highlights and innovations of the industry, attracting www.sfchina.net

The 32nd edition of SFCHINA exhibition will take place at Shanghai New International Expo Centre (SNIEC), China on November 18-20, 2019.

For further information:

include Anest Iwata, Aobang, Atotech, Bostar, Dörken, Ean Sheng/Hante,

market leaders for their presence in Shanghai. Confirmed participants

SFCHINA has been a strategic destination for technological highlights and innovations of the industry, attracting market leaders for their presence in Shanghai.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

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PaintExpo 2020 - Adjusting Painting Processes to New Requirements

urface finishing is the decisive criterion

personalisation of products, regulatory

offerings than anywhere else in the world at

for the success of products, and thus

changes, the digital transformation and

the Karlsruhe Exhibition Centre from the 21st

for a company’s competitive edge.

more rigorous goals with regard to energy

through the 24th of April, 2020.

Consequently, industrial coating technologies

efficiency and climate protection. Industrial

On the one hand, a glance at the list of

make an essential contribution to value

coating technology is being impacted by this

exhibitors demonstrates that PaintExpo lives

creation. Companies with in-house painting

as well.

up to this claim. By the end of August 2019,

operations and coating job-shops are faced

more than 450 companies from 22 countries

process adjustments. PaintExpo will present

High Levels of Complexity Necessitate Comprehensive Information

the world’s most comprehensive and future-

Although some of the issues are by no

trade fair for industrial coating technologies.

oriented solutions to this end at the Karlsruhe

means new, the competitiveness of coating

They’ve already reserved 98% of the exhibition

with changing and new requirements as a result, which necessitate corresponding

– including all of the market and technology leaders – had already made firm bookings for their booth locations at the world’s leading

Exhibition Centre from the 21 through the

operations will increasingly depend on how

floor space occupied at the event in 2018.

24th of April, 2020. The exhibition portfolio

well and quickly they can respond to these

On the other hand, it illustrates the extent of

covers everything from pre-treatment, right

changes. As a prerequisite, the coating

the exhibition offerings: the portfolio covers all

on up to quality control and packaging.

process has to be adapted or optimised.

process sequences for powder coating, liquid

The great complexity of painting and coating

and UV painting and coil coating technologies.

Companies in all industry sectors are

processes with numerous interlinking work

The spectrum of materials to be coated ranges

currently being confronted with a wide variety

steps makes comprehensive information

from metals, plastics, wood, wooden materials,

of trends and changes. Amongst others these

concerning trends, technologies, new

glass and ceramics, right on up to material

include new manufacturing technologies,

developments and the suppliers throughout

combinations. “This targeted concentration

the use of new and modified materials and

the entire process sequence indispensable.

of suppliers and technologies makes it

material combinations, the realignment

PaintExpo will present a corresponding

possible for job-shop coaters and visitors from

of entire industry sectors, shortened

cross-technology, cross-industry overview

companies with in-house painting operations

product lifecycles and smaller lot quantities,

with more comprehensive and up-to-date

to inform themselves efficiently and in a

158

N. 59 - SEPTEMBER/OCTOBER 2019 - international PAINT&COATING magazine

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targeted fashion about solutions to their own

energy and material-efficiency in the fields

of systems, applications and conveyor

individual tasks, and to arrive at appropriate

of equipment and application technology.

technology, drying and cross-linking, paints,

investment decisions,” reports Jürgen

Attention is also being focused on increasing

automation and digitalisation, as well as

Haußmann, Managing Director of FairFair

flexibility and productivity in this regard.

quality control. For example, innovations

GmbH and promoter of PaintExpo.

Improved energy-efficiency is also the

which permit increased efficiency and

primary focus of solutions for conventional

process reliability will also be presented

circulating-air drying, as well as alternative

in the fields of compressed air supply,

methods such as IR, condensation and

hangers and masking solutions, as

Exhibitors will present future-oriented

UV drying. Robot painting is playing an

well as packaging. “The comprehensive

solutions for meeting the increasing demands

increasingly important role for mid-sized

spectrum of new and improved products,

now being placed on quality, flexibility and

and small painting operations in order

technologies and processes provides

productivity, as well as material, energy and

to ensure reproducibly high quality. New

visitors with a wide variety of impulses and

cost-efficiency. For example, these include

automation concepts make it possible

approaches for designing or adapting their

new and further developments for classic

for these companies to get started with

processes to meet future requirements,”

wet chemical pre-treatment, as well as

flexible, cost-effective solutions. However,

concludes Jürgen Haußmann.

alternative processes. New and optimised

exhibitors at the upcoming PaintExpo will

solutions, including the simulation of painting

not only present innovative developments

For further information:

and coating processes, provide for improved

for process optimisation in the fields

www.paintexpo.de

From Pre-Treatment to Quality Control

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2019 - N. 59

159

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The first international magazine for surface treatments

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ISSN 2280-6083

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The first international magazine for surface treatments La prima rivista internazionale sui trattamenti superficiali

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