ipcm® n. 64 - July/August 2020

ISSN 2280-6083

The smart journal for surface treatments

®

ipcm digital on

www.myipcm.com 2020

INTERNATIONAL PAINT&COATING MAGAZINE

11th Year - Bimonthly N° 64 - JULY/AUGUST

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CONTENTS JULY/AUGUST 2020

HIGHLIGHT OF THE MONTH

FOCUS ON TECHNOLOGY

32

ICC Wales, Newport. Tactile Finishes: The Colours of Stone

Evonik Officially Launched Virtual Formulation Assistant COATINO®

© Dürr Systems AG

© Aluminco

22

HIGHLIGHT OF THE MONTH

FOCUS ON TECHNOLOGY

44 05 06

Aluminco: The Greek Manufacturer of Architectural Aluminium Systems Installs the First Zero Liquid Discharge WWT Plant Without Evaporator

EDITOR’S LETTER ANALYSIS

14 28

Asahi Kasei Survey Shows Increasing Need Towards Functional Premium Surfaces in the Automotive Industry

08 10

IPCM IN REVIEW MARKET CLOSE UP Mexico Holds the Balance of Power in the Economic Agreements of the American continent and it Becomes its Defence Line Against the Challenges of the Global Health Emergency

58

Keep Production on the Right Track with DXQbusiness.intelligence from Dürr

BRAND-NEW

Efficiency Increase and Cost Reduction in Powder Coating

42

60

BRAND-NEW

FOCUS ON TECHNOLOGY A Waterborne, One-Coat Metallic Top Coat: The Revolution in Coating Large-Sized Drilling Rigs

BRAND-NEW FOCUS ON TECHNOLOGY

FOCUS ON TECHNOLOGY A Highly Automated Line Reveals the Future of Plastic Car Components’ Coating

INNOVATIONS: PRESENT&FUTURE Corrosion Protection with Zinc Flake Systems – Yesterday, Today, Tomorrow

34 36

50

66 70

BRAND-NEW FOCUS ON TECHNOLOGY Haas Strahlcenter GmbH Chose Italian Technology for the Largest Powder Coating Plant in Germany

by Parts’ Size

New 2020 2018

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Global and detail consumption report Maintenance management and costs reporting Annual budget allocation Direct comparison with actual costs incurred Your paint cost per square meter Specific cost of the lots produced Incidence of costs divided by plant area All data can be exported in .csv format IMEL SpA - Via Divisione Julia 10 - 33033 Codroipo, UD - Italy - T +39 0432 908578 - info@imelspa.com - www.imelspa.it

© ipcm ®

© Saima Sicurezza

CONTENTS JULY/AUGUST 2020

FOCUS ON TECHNOLOGY

84

An Exclusive Partnership with a Coating Supplier to Guarantee the Quality of Saima’s High-Security Doors and Gates

Giemmegi: A New, State-of-the-Art Powder Coating Booth

© Venjakob

© GettyImages_terex

78

FOCUS ON TECHNOLOGY

RAW MATERIALS

90 92

INNOVATIONS: PRESENT&FUTURE

™

PTFE Zonyl Micropowders Complying to New REACH Regulation

INNOVATIONS: PRESENT&FUTURE

112

Corrosion Inhibitors for Pickling Processes: Industrial Experiences – Part Two

98

SUCCESS STORIES

FOCUS ON TECHNOLOGY Pass-Through Shot Blasting Gives High Corrosion Resistance Properties to Officine Cristallo Srl’s Large-Sized Parts

Surface Coating of Plastic Parts Focus on Timewasters

HIGHLIGHT OF THE MONTH

128

The Global Value Chain and the Importance of Measuring and Control Tools to Guarantee Product Quality

118

Nissan Motor Company South Africa: The Successful Remote Start-Up of a New Chassis Cataphoresis Plant

102

108

FOCUS ON TECHNOLOGY

Paola Gallinatto’s Surrealism: Shaping Porcelain Through Materials and Colours

130

Growing from a Garage Operation to a Coating Specialist with State-of-the-Art Machinery

122

SPECIALIZED TRAINING Innovhub, a European Centre of Excellence for the Research and Development of Innovative, Multidisciplinary Projects

ART WITHIN SURFACES

STANDARD & LEGISLATION Automotive Industry: One of the Greatest (Industrial) Victims of COVID-19

132 134

TRADE FAIRS & CONFERENCES ZOOM ON EVENTS

Zaniolo CdA-2.20

ENV RONMENT advanced

Europolveri offers a wide range of powder coatings that are available in several different

solutions for

finishings and gloss level. A stock of approximately 1000 different colors is always available

metal surfaces treatment

and developed to assure the highest quality level as to satisfy the widest needs of the market.

R&D laboratory steadily works in the development of new products and performance improvement in order to enable the company to be an innovation leader and to give solutions to the many technical requests coming from the market.

Products development, their industrialization and their use are always directed to obtain the best results and the highest respect for the environment.

EUROPOLVERI S.p.A. - Sandrigo (VI) Italy - Ph. +39.0444.750643 - Fax +39.0444.750653 FILIALI/Branch Office: Cernusco sul Naviglio (MI) Ph.+39.(0)2.92148001 - Erbusco (BS) Ph.+39.(0)30.7704158 DEPOSITO/Depot: Iori Colori, Reggio Emilia Ph.+39.(0)522.327248

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

EDITOR’S LETTER

It is time to relax.

Richiedi la versione in italiano a info@ipcm.it

I know that it may not seem the right thing to say at a time like this. A few hours before I wrote this editorial, the European Recovery Fund was approved, worth 750 billion Euros in loans and subsidies to be allocated to the economic recovery of the twenty-seven Union members, which are weakened by a pandemic that still frightens people and prevents a return to normal consumption.

Yet, lightness is needed this year as never before. We need to restart our minds by distracting them from negative thoughts, which prevent an objective assessment of the situation and, above all, creative thinking. “Good ideas” are crucial for the dynamic management of business activities – and creative ideas often arise when we are relaxed, when our mind is free to wander.

Rita Levi Montalcini said that “creativity lies in curiosity and in keeping one’s own mind open to the world”. Well, we should all go back to opening up our minds and being receptive to the most varied sources of inspiration, while stopping chatting about COVID-19 and our fears for the economy. Of course, I do not want to suggest underestimating a problem that is far from definitively resolved, as it has become apparent in these days.

However, going back to exercising lateral, unconventional thinking, looking past the data, and observing them from different perspectives than those of logic can be extremely useful to restore our confidence in future and find new ways for our companies to continue to thrive. Edward De Bono, a Maltese psychologist specialising in individual and occupational psychology, introduced the concept of lateral thinking: he considered it a very useful approach to favour the “problem solving” moment, in whatever form or area this occurs.

This is the reason why, after two issues in which we dealt extensively with the impact of COVID-19 on the economy and with the ways in which the surface treatment sector has put its technologies at the service of the fight against this virus, this summer issue of ipcm® is simply aimed at offering you plenty of prompts to stimulate “good ideas”. Technological, process, management, and product ideas. Success stories, unprecedented systems, new lines started up through digital technologies, unconventional surface treatments (once again, also useful for sanitising surfaces), and research on better performing raw materials. In a word, a positive framework, clearly showing the European industry’s industriousness and dynamism.

Alessia Venturi

Our wish for this singular summer is that we may use the time that, for once, we will not lose in overcrowded vacation spots to focus on what is good and useful in technological innovation, so as to restart with more force, more awareness, and by only keeping the positive lessons that this unprecedented event has taught us.

Editor-in-chief Direttore Responsabile

Happy summer.

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

05

ANALYSIS

Asahi Kasei Survey Shows Increasing Need Towards Functional Premium Surfaces in the Automotive Industry Sebastian Schmidt Asahi Kasei Europe GmbH – Düsseldorf, Germany

sebastian.schmidt@asahi-kasei.eu

According to a new survey by Asahi Kasei Europe, automotive interior features such as premium, hygienic and sound-absorbing surfaces, will become a differentiating element and influence buying decisions.

C

ASE (Connected, Autonomous, Shared,

When purchasing the current car, the interior

Electric) megatrends, such as new

design (e.g. seats, surfaces, etc.) was important

The increasing importance of sustainable surface materials

mobility behaviours and the growing

to 54.8%, compared to 57.2% who paid more

Automotive interior surfaces need to be

autonomy of cars, will profoundly impact the

attention to the exterior design. Looking ahead to

attractive to the eye and smooth to the skin.

user’s driving experience and are bringing forth

the purchase of the next car, the interior is rising

They are the interface between the user and

an evolution in the automotive industry, with

by 5 percent points (59.8%) in its importance, the

the vehicle and play a role also in the driving

rising requests for more functional surfaces.

exterior by 4 percent points (61.4%).

experience.

In fact, due to the increasing autonomy of the

“Customer expectations are not changing over

One out of ten respondents (10.3%) sees the

car, passengers will have to focus less on the

night, but gradually and much faster than we

poor processing quality of interior surface

traffic and will have more time to spend on

have seen in the past. More than half of the car

materials as the most annoying factor in

work, in-car entertainment or just relaxation.

buyers in Europe are ready to change the brand.

the current car. 44.8% of all respondents

As a result, the functionality of automotive

A great chance for OEMs to win new customers

see a benefit in surfaces that look and feel

interiors will become increasingly important.

by implementing convincing technologies which

especially high quality – for example for

In October 2019, conducted a representative

are touching all senses, addressing human

seats, dashboards or headliners – compared

survey together with Cologne-based market

emotions and needs”, explained Heiko Rother,

to just 11.4% who do not. A third of all

research institute SKOPOS, interviewing a total

General Manager Business Development

participants (32.5%) would be willing to pay

of 1,200 car users in Germany, France, Italy

Automotive at Asahi Kasei Europe.

a reasonable price for these surfaces as

and United Kingdom to better understand future automotive interiors.

©Asahi Kasei

customers’ needs and their expectations form

Interiors will influence buying decisions When buying the next car, 18.3% of all respondents in the four main European automotive markets will not buy the same brand as the current car, 34,9% are still undecided.

The differentiating factor will not only be the exterior design, but also the interiors one: the passenger compartment is becoming an increasingly important factor next to exterior, drivetrain, driving performance and fuel economy.

06

Key decision factor for purchase of current and next car.

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

©Asahi Kasei

ANALYSIS

Survey on future automotive interior.

an extra equipment. While the word “reasonable”

again highly valued by the car users from 18 – 39

is of course strictly subjective, it shows the growing

years. While there is an overall need for hygienic

importance of interior surfaces.

surfaces, stronger demand can be observed within

Asked about the surface material itself, 57% of the

the younger age groups, who are also more willing to

respondents think that sustainable materials for seat

accept additional costs for these surfaces.

covers and surfaces will be becoming increasingly

The perception of sound and noise is evenly about

important in the next 5 to 10 years, while the need

to change as well. Already today 16.1% of the car

for real leather equipment will fall drastically.

users consider the driving noise as the most annoying factor of their current car. Looking ahead to the future

The rising needs towards hygienic and sound-absorbing surfaces

automotive, the suppression of road and engine noise

The results of the survey show an increasing need

even more urgent. While different materials and

towards interior surfaces with further functions,

technologies inside the car can tackle this problem,

with 49% of all respondents seeing a benefit in

visible interior surfaces can also play their part. 51.8%

antibacterial properties.

would see a benefit in noise-absorbing seat covers

Taking a closer look at the age structure, it turns

and surfaces, 35.9% are even inclined to book these

out that car users from 18 – 39 years are seeing a

surfaces for additional costs.

stronger benefit of antibacterial surfaces, especially

“With the passenger compartment moving more into

compared to the participants over 59 years.

the focus and becoming a key decision factor, we see

The same trend can be seen in regard to seat covers

significant potentials for differentiating technologies,

and surfaces with odour-inhibiting properties.

addressing the passengers’ senses and meeting

49.3% see a benefit in these surfaces, which are

highest demand”, said Heiko Rother.

– now a challenge to many car users – will become

segr@italgard.it - www.italgard.it

IN REVIEW

May and June in Review Barbara Pennati ipcm®

The calm after the storm: back to (the new) normality.

ay meant for many Italians

M

ipcm®_Academy courses also took

(and still means) to be an entrepreneur

the end of a lockdown that

place in May but in a slightly different

and do business at the times of

lasted almost three months

way than usual: trainees were trained

Coronavirus.

and the slow return to normal.

on corrosion, pre-treatment and

In May, we experienced the same

We too have finally been able to

water treatment online for the first

uncertainty and caution as those who

return to our editorial office where,

time ever. To know more about

set foot outside the house after a heavy

after the implementation of the

our training offer, contact us at

storm: assessing the damage is a must,

necessary security measures, all

corsi@ipcm.it.

but the desire to start over and get back

desks have been occupied once

Although our daily routine has

on track is great.

again.

been partly restored, what we have

The situation is made even more

In May we have published what

experienced is an unprecedented

peculiar and complicated by the fact that

we hope to be the last issues

historical period, which we have

while many countries have resumed a

created under lockdown: the ipcm®

not yet fully put behind us and

semblance of normality, others are still in

Automotive special, one of the most

which has left a grave impact on the

a state of emergency.

important numbers of the year,

industry. This is why we are working

with the supplement ICT_Industrial

on a project to give voice to several

And it is precisely with this awareness

Cleaning Technologies, and the

companies at an international level,

that in June we published the first

May editions of ipcm _Ibérica and

with the aim of offering a direct and

episode of Beyond The Pandemic, a

ipcm®_LatinoAmérica.

unfiltered testimony of what it meant

series of interviews that aims at bringing

®

Publishing these issues and those would not have been possible without the collaboration with

© ipcm ®

that preceded them during lockdown

our customers and partners, who demonstrated great proactiveness and willingness. And it is thanks to this synergy that, even in a period in which travelling was impossible, we were still able to publish exclusive articles and interviews, such as the report on the new automatic coating cells for the application of the basecoat on body interiors manufactured at FCA Group’s Pomigliano headquarters; or the one on the new powder coating line for Formas Descansos’ medical beds.

08

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

© ipcm ®

IN REVIEW

Hooks & CE Hooks

From the in-stock small and thin hook to the special hook Ø30 with EU certification and loading capacity calculation, for both small and heavy parts to be coated.

you a real and unfiltered testimony

these trips on the pages of the July issue

of how the sector is dealing with the

of ipcm®, which includes eight exclusive

pandemic. The first episode brought

articles. And even though we were able to

us the testimony of a company from

hit the road again, the virtual collaboration

northern Italy, one of the areas most

with our partners still played a pivotal role

affected by Covid-19. The next episode,

in the making of these case studies.

currently in the making, will instead bring

Another important news concerns the

you the point of view of an international

Academy division: the professional

company. We therefore invite you to

figure of Industrial Surface Finishing

keep following our social channels and in

Process Technologist (Tecnico dei

particular our YouTube channel so as to

processi di finitura industriale delle

not miss the next interviews

superfici), promoted by ipcm®_Academy

(https://www.youtube.com/channel/

in collaboration with ASP Mazzini

UCe9O_Ssqh99zPOYSoizllgA).

Institute, was officially recognized by the

In this new-found normality we have

Subcommittee of the Lombardy Region on

also published the first magazine

June 25.

post-lockdown: issue n. 34 of

Those who wish to obtain the certificate

ipcm®_Protective Coatings. In this issue

of Technician, which is recognized at

you can find several articles dedicated

European level, can take part in the

to corrosion protection technologies in

ipcm®_Academy training course, starting in

the energy sector and also a series of

September.

HOOKS & CE HOOKS

interviews with industry associations, which offer readers a 360-degree view of the surface treatment market.

In June, we also started to travel nationally

COMPLETE SOLUTIONS FOR HANGING AND MASKING

once again: you can read the results of

www.rostirolla.it

MARKET CLOSE UP

© 1xpert_AdobeStock

Mexico Holds the Balance of Power in the Economic Agreements of the American continent and it Becomes its Defence Line Against the Challenges of the Global Health Emergency Interview with Víctor Leal, President of Anafapyt (Asociación Nacional de Pinturas y Tintas de México)

10

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

MARKET CLOSE UP

O

ur analysis of the coating sector in

value of over 65 billion MXN, equal to

Which are the current needs and

the North American continent1 ends

3 billion US Dollars and 2.3 billion Euros.

characteristics of the paint and

with this interview with Víctor Leal,

It also generates more than 12,000 jobs in

coating sector?

President of the Mexican Paint and Printing

its plants. There are over 213 producers

Our association contributes to the

Ink Manufacturers Association (ANAFAPYT).

of paints and inks in Mexico, including

industrial, technological, economic,

Despite the fact that Mexico’s cultural and

several large companies: they constitute a

and social development of the paint

political history is rather different, compared

fundamental market for this country, as they

and ink sector, since one of the main

to that of U.S. and Canada, Mexico falls within

manufacture highly technological products

goals of Anafapyt is to promote the

their same economic area, due to both

that make it very competitive.

competitiveness of its members. We

geographical proximity and the industrial

Over one billion litres of paint are consumed

have three institutes located in the

development policies that the

per year nationwide, mainly for wall

main cities of the country: Mexico

US have implemented in Central America

construction, but also for other sectors such

City, Monterrey and Guadalajara

since the beginning of the last century.

as the automotive, aerospace, manufacturing,

(Instituto Mexicano de Técnicos en

With approximately 130 million inhabitants,

and petrochemical industries, among others.

Pinturas y Tintas, IMTPyT). Each of them

Mexico is the most populous

We are a part of the North American free

holds seminars, courses and training

Spanish-speaking country in the world

trade agreement between Mexico, the United

events about innovative technologies,

and the second most populous nation in

States and Canada, which has been in force

aimed at the constant skill updating

Latin America, after Brazil. The analysis

for over twenty years and which has been

and improvement of even the major

of its current economic situation cannot

renegotiated recently: it came into force since

global companies. At the same time,

ignore the consequences that the present

this month. It undoubtedly presents us as an

the experience and expertise of our

health crisis can bring in such a multifaceted

attractive country, in terms of investment for

producer and supplier members give

society, but neither the fact that this

different segments.

us a strategic vision of the innovation level of these sub-sectors.

overcome such circumstance and face any

We represent a fundamental segment

future challenges, thanks to the new paths

in the production chain of our country’s

taken during the pandemic. This clearly emerges from the answers of Víctor Leal,

© Extrategia

country’s industry has the tools required to

essential activities: coatings play a key role, because their main functions

who has managed to offer us a precious

include protection and economic

insight into the current economic and social

value to be added to the activities and

situation, by starting from the analysis of the

products manufactured in Mexico.

coating sector in Mexico and then extending

Virtually every manufactured product

the investigation to the entire American

has a coating that, in addition to

continent.

helping it maintain its value, gives it colour, protection, and durability

Which are the main characteristics of

characteristics.

your country’s paint, coating, and ink

Anafapyt is currently contributing to

sector? Which level of technological

the drafting of environmental standards

development has achieved?

that include similar requirements to

The Mexican paint, coating and ink industry

the US and European ones, which

produces over 1,100 million litres and has a

are recognised among those most in demand worldwide. We have worked on models in favour of the elimination

1 “From more functional and smart coatings to the challenges of regulatory alignment with the US and Europe: a closer look to the Canadian paint and coatings market” in ipcm® International Paint&Coating Magazine no. 62 (March/April 2020), pp.

8-12.

“A snapshot of the U.S. coatings industry amid economic disruption in 2020” in ipcm® International Paint&Coating Magazine no. 63 (May/June 2020), pp. 14-20.

of lead compounds from paints and of the regulation of Volatile Organic Compound (VOC) emissions. Through the direct and indirect participation Víctor Leal, President of Anafapyt.

of manufacturing companies and

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

11

Š Metalocus

MARKET CLOSE UP

A detail of the Unidad Panamericana mural, by Mexican artist Diego Rivera.

suppliers in these standardisation

SecretarĂ­a de Medio Ambiente y Recursos

developed the "Postura Anafapyt", a

processes, we want businesses and

Naturales (the Mexican Ministry of

complete strategic system through which

society in general to be made aware of

the Environment, Ed.). Faced with the

we are working on different fronts, with

the relevance of regulatory compliance

challenging scenario caused by the

the aim of reducing the impact of the still

and of the technological challenges

economic crisis resulting from the

on-going emergency and guaranteeing

associated with it. Finally, since 2015 we

COVID-19 pandemic, we are counting

the safety of our companies and

have promoted the use of the Globally

on the Mexican government to work on

employees, as much as possible. We are

Harmonised System of Classification and

an incentive program for small and

working closely with various chambers

Labelling of Chemicals (GHS) in Mexico, not

medium-sized enterprises, which generate

and associations to reaffirm that the

only in workspaces, but also in the labelling

at least 52% of the official jobs in our

activities related to coatings, paints and

of the most dangerous paints, in order to

country. We also want to maintain a close

inks are essential, and to ensure that

favour the correct use and management of

dialogue with all the operators involved,

all our members meet the production

these substances.

in order to preserve the certified quality

requirements, thus helping mitigate

standard protocols for safeguarding the

the effects of this health emergency,

Which are the effects of the

value chains and reduce social impact and

precisely given that our sector is an

international political and economic

unemployment issues, as much as possible.

important link of the production chain.

On the other hand, all the events

situation and of the economic agreements signed between Canada,

Which impact will the COVID-19 health

organised for this year were postponed,

the United States and Mexico on the

emergency have on the paint and

since it is fundamental for us to

paint and coating industry?

coating industry and on the events

safeguard the well-being of all our

Anafapyt actively participates in

organised by Anafapyt?

members, manufacturers, employees,

the development of the common

We are a compact sector, focused on

technicians and assistants. In line with

environmental strategy included in the

complying with the rules, as well as

the evolution of the current situation,

T-MEC agreement (USMCA in the United

providing excellent products and services.

our organising committee has decided to

States and CAUSMA in Canada), through

We immediately followed the regulations

schedule on March 24th until 26th, 2021

the Commission for Environmental

to help preserve everyoneâ&#x20AC;&#x2122;s health and

our Technical Days and to carry them out

Cooperation appointed by SEMARNAT-

safety as a priority. At the same time, we

in Guadalajara, Jalisco, whereas one of

12

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

MARKET CLOSE UP

our most important international events, the Latin American Coatings Show (LACS), will take place at the Citibanamex Centre from July 13th until 15th 2021. The decision was made by placing maximum importance onto the health and well-being of all participants, and as a part of a series of actions aimed for establishing the new normality. We are confident that the efforts we make today will have a positive value tomorrow, which will help safeguarding the work resources and profitability of companies and their employees.

As the President of LATINPIN, the Latin American Federation of Associations of Technicians and Paint and

AUTOMATIC POWDER COATING BOOTHS

Ink Manufacturers, which are the current challenges that you find in the Latin American market?

Latin America’s consumption of paints, coatings and inks accounts for over 9% of global figures and this is reflected on different aspects. The production corresponding to four countries -Brazil, Mexico, Argentina and Colombia- accounts for just over 76% of that of the entire region. However, some unexpected events might occur, as we all have learned in the face of a health emergency that has turned into a global economic, political, and social crisis, and each nation can manage them differently depending on its economy, organisation, culture and society. From our “trench”, LATINPIN reaffirms our will to encourage growth through actions, in line with our objectives. We know that the scenario will be completely different and largely unknown, but we will work together to reconfigure the world economy by finding new paths that will guarantee the economic and work well-being of all Latin America.

Which short-term developments do you think the paint and coating sector will be able to achieve, for example in terms of technology and production?

The wide offer of all types of paints and coatings confirms that the consumers’ demand is high, which in turn reflects on increased production. In the coating field, we constantly create new technologies and we are committed to innovate through new, high quality, environmentally friendly products that progress hand in hand with companies and the market. These include inventions, such us antimicrobial and hypoallergenic paints, photocatalytic coatings and paints with nanotechnology additives characterising different types of product, including powder coatings. We must develop items that pave the way for the constant innovation of these tools, in order to guarantee further industrial and economic progress.

G RT

BRAND-NEW

STEEL-LIFE #32: Perfectly Joining Art and the Metalworking Industry STEEL-LIFE #32 was the work of art offered by Lucrezia Roda on the auction organised

by EOS Mktg&Communication for its tenth anniversary.

the evening organised by EOS

These two projects

© ipcm ®

A

charity auction was held during

were also selected for the

Mktg&Communication for its

“MIA recommendations” category

tenth anniversary. The proceeds were

at the MIA Photo Fair in Milan,

donated to the Municipality of Monza

obtaining an RaM Sarteano 2018

for the restoration of the epigraphs of

award. In the same year, Roda was

the War Memorial monument installed

among the finalists of the Arteam

in Trento e Trieste square. The leitmotif

Cup award.

of the event “Art in Surfaces” was the

In 2019, this young photographer

relationship between art and industry,

inaugurated the personal

and this can also be found in the works

exhibition “STEEL-LIFE, la Materia

donated for the auction.

Immortale”, curated by Luigi Erba

STEEL-LIFE #32, the photograph which Lucrezia Roda donated to the charity auction

by EOS Mktg&Communication.

Lucrezia Roda’s STEEL-LIFE #32, a photograph taken on February 2019

and Barbara Cattaneo, which also included STEEL-LIFE #32. She was

to depict the billet continuous casting

also awarded the “AIF 2019 - Nuova

process performed by the Acciaierie

series, a research study on the

Fotografia” prize awarded by the

di Calvisano (Feralpi Group), was no

metalworking industry and metal as

Italian Photo & Digital Imaging

exception. Futura Convogliatori Aerei

an ever-transforming material.

Association (AIF) to emerging

owner Walter Longo purchased it.

This continued in 2018 through the use

authors.

The picture measures 50 x 75 cm; it

of microscope lenses in the “ABOUT

was obtained with the Giclée printing

METAL (about me)” project, composed

For further information:

technique on Baryta paper and

of videos, texts, and images.

www.lucreziaroda.com

protected by a 3 mm-thick Plexiglas

Lucrezia Roda is an Italian photographer

© ipcm ®

plate.

© ipcm ®

®

whose work has already been the subject of an article in the previous issue of ipcm®1. Always a lover of art in all its forms, with a penchant for conceptual art, in the last few years she has approached the world of fine-art photography. In 2016, she inaugurated her first personal exhibition curated by Roberto Mutti with her “STEEL-LIFE” 1 M. Fumagalli, “The hidden colours of the industrial world revealed by Lucrezia Roda’s photographs”, in ipcm® International Paint&Coating Magazine no. 63 (May/June 2020), pages 148-151

14

A moment of the auction of last 24 July.

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

Futura Convogliatori Aerei owner Walter Longo won the work of art during the auction.

BRAND-NEW

ST Powder Coatings Launches H3-ORIZON, a New Series of Super-durable Powder Coatings

© ST Powder Coatings

ST Powder Coatings, an Italian manufacturer of powder coatings, has launched a new line of super-durable powder coatings, with Qualicoat Class 2 approval.

The H3-ORIZON super-durable powder coatings series has 34 different colours.

T

he H3-ORIZON super-durable powder

historical phase, emphasizes our flexibility and

phases even in full Coronavirus emergency.

coatings series has 34 different colours

reorganization capabilities that allowed us

“The synergy between people, procedures

and smooth, matt and glossy, and

to be always running”, explains Marco Zadra,

and infrastructure enshrines what ST’s

wrinkled matt finishes mainly designed

CEO of ST Powder Coatings Group. “We can

philosophy is and its strong ability to fully

for the architectural sector. They are

say for sure that this product line will lead

support the customer even remotely”,

always available on-stock in every

the development of next generation product

concludes Marco Zadra.

ST Powder Coatings logistic warehouse and

series”.

can be ordered in minimum batches of 20 kg.

ST Powder Coatings’ technical staff has been

For further information:

“The launch of H3 series in this delicate

able to assist customers in pre and post-sales

www.stpowdercoatings.com

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

15

BRAND-NEW

The Role of Industrial Surface Finishing Process Technologist was Finally Recognised The Subcommittee of the Lombardy Region has finally recognised the new professional role of Industrial Surface Finishing Process Technologist and included it in the Framework of Professional Standards of the Lombardy Region. This concludes a long certification process started by ipcm®_Academy in collaboration with the ASP Mazzini Institute (Cinisello Balsamo, Milan, Italy) in order to overcome a gap in technical training and meet the professional culture needs of the industrial finishing sector.

T

recognised the new profession of Industrial Surface

The role of Industrial Surface Finishing Process Technologists

Finishing Process Technologist and included it in

The final quality of a coating and its “durability” are closely related

he Subcommittee of the Lombardy Region has finally

the Framework of Professional Standards of the Lombardy

to the correct management of surface finishing processes,

Region. The certification, which is valid at both the national

including corrosion protection. The premature deterioration of

and European levels, compensates for the previous lack of

coatings can be caused by various problems that may arise during

a recognised professional role involved in the management

the finishing processes, such as, for example, the use of defective

of the entire industrial coating process, which is a crucial

materials, the compliance with inadequate technical specifications,

production phase in numerous sectors including automotive,

the implementation of non-compliant or unsuitable processes

transport, aluminium profiles, mechanics, and furnishings.

with respect to the expected “durability”, and the improper use of

This important milestone, which opens up new scenarios for

products. Moreover, all the players involved in the development

professional training activities devoted to the finishing and

and management of finishing processes, as well as in the final

surface treatment industry, concludes a two-year process

use of products, may be responsible for their early deterioration,

undertaken by ipcm®_Academy, the professional training

including designers, paint manufacturers, applicators, inspectors,

division of ipcm publisher EOS Mktg&Communication, ®

operators since 2011. The recognition of the new professional role was obtained thanks to the partnership with the ASP

© ipcm ®

which has been organising training courses for coating

Mazzini Institute (Cinisello Balsamo, Milan, Italy), a well-established local professional training body, and to the active collaboration of Paolo Rami, a consultant, the director

academy

2020

of the ipcm®_Academy, and an industrial finishing expert, who

CORSI DI FORMAZIONE

defined the specifications and requirements of the role.

It is now possible to become a Surface Finishing Process Technologist by attending ipcm®_Academy's 100-hour course: upon passing the final exam, students will receive a Certification of Competences of Industrial Surface Finishing Process Technologist, as defined by the Framework of Professional Standards of the Lombardy Region.

Non-repayable funding from the Lombardy Region is available for this course.

16

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

TECNICO DEI PROCESSI DI FINITURA INDUSTRIALE DELLE SUPERFICI Corso di formazione riconosciuto dalla Regione Lombardia con valenza nazionale ed europea

IL CORSO RIENTRA NEGLI INTERVENTI DI FORMAZIONE CONTINUA DI REGIONE LOMBARDIA ED È ACCREDITATO PER IL FINANZIAMENTO A FONDO PERDUTO ATTRAVERSO L’EROGAZIONE DI UN VOUCHER FORMATIVO

Realizzato in collaborazione con ASP G. Mazzini - Associazione Scuole Professionali

ente accreditato ai servizi formativi e al lavoro da

© Regione Lombardia

BRAND-NEW

Bollettino Ufficiale

– 103 – Serie Ordinaria n. 28 - Giovedì 09 luglio 2020

6.27 TECNICO DEI PROCESSI DI FINITURA INDUSTRIALE DELLE SUPERFICI DESCRIZIONE PROFILO Il Tecnico dei Processi di Finitura Industriale delle Superfici è in grado di coordinare e gestire le attività produttive finalizzate alla corretta protezione dalla corrosione, finitura e decorazione di componenti e prodotti finiti, conformemente alla “durabilità” attesa nell’ambiente in cui dovrà operare o saranno collocati i componenti o i prodotti finiti stessi.

Definisce, in collaborazione con la progettazione e con l’ingegneria di produzione, il processo di protezione e finitura più adeguato rispetto alle specifiche tecniche alla resistenza alla corrosione e alla “durabilità” attesa, le tecnologie relative alla preparazione delle superfici e all’applicazione dei prodotti vernicianti. Inoltre, gestisce le attività di omologazione del processo stesso, la qualifica delle modalità applicative e la verifica dell’idoneità degli applicatori.

Esegue il riesame dei requisiti, valutando l’adeguatezza dei processi produttivi aziendali rispetto alla tipologia di protezione e finitura definita, e il riesame tecnico, verificando la congruità delle schede tecniche, dei cicli protettivi, delle istruzioni e dei cicli di lavoro.

Coordina il processo di programmazione della produzione, dei controlli del processo e di serie, delle attrezzature e degli impianti ed emette la documentazione di monitoraggio e controllo.

ELEMENTI DI CONTESTO Ambito di riferimento Trova collocazione in tutte le imprese produttive di ogni dimensione che eseguono processi di protezione e finitura delle superfici.

REFERENZIAZIONI Livello EQF:4 Classificazione Internazionale delle Professioni ISCO 8122 – Addetti ai macchinari per finire, rivestire, placcare metalli e oggetti in metallo Classificazione Nazionale delle Professioni ISTAT 6.2.2.3. - Attrezzisti di macchine utensili 7.2.2.1..-.Finitori di metalli e conduttori di impianti per finire, rivestire, placcare metalli e oggetti in metallo 6.2.3.7. - Verniciatori artigianali ed industriali Classificazione Nazionale delle Attività economiche ATECO 2561 – Trattamento e rivestimento dei metalli ADA.10.02.08 (ex ADA.7.51.154) - Finitura dei componenti metallici ADA.10.02.09 (ex ADA.7.51.155) - Trattamento superfici

maintainers, and users. The role of an Industrial Surface Finishing Process Technologist is to organise and manage the production activities aimed at the correct corrosion protection, finishing, and decoration of components and products, in line with the “durability” expected in the environment in which they will operate.

About ipcm®_Academy Since 2011, ipcm®_Academy, the training division of the ipcm®_International Paint&Coating Magazine, has dealt with the training and continuing education of industrial surface finishing specialists on the topics of greatest interest to those who deal with plants, paints, and coatings in their daily activities. ipcm®_Academy organises classroom courses that include both a theoretical part and the students’ participation in demonstrations and practical tests related to the quality control phase, with the use of professional tools and samples.

The courses are taught by highly trained teachers, all with many years of experience in the surface treatment sector.

This course’s program is available at the following link: https://issuu.com/ipcm/docs/corso_tecnico_2020_senza_ date?fr=sMWI0YzEyNDQyMTE For further information: www.ipcm.it/en/training/ | corsi@ipcm.it

BRAND-NEW

SAMES KREMLIN Launches Two New High-Performance Diaphragm Pumps SAMES KREMLIN launches two new pumps with an ultra-compact design for paint transfer. Adaptation to frequent colour changes, reliability and low cost are their main features and the reason why the two pumps have been chosen and tested at more than 100 sites worldwide.

Š SAMES KREMLIN

O

ne of the most important elements of assuring high-productivity of

coating plants is paint transfer.

The design of the new 01 and 04 D140 pumps from SAMES KREMLIN meets this requirement and ensures the lowest possible cost at the same time.

High durability, low maintenance In a test run at an automotive plastic parts manufacturer the pumps have been daily used for one year without stop.

The 01 and 04 D140 pumps strength is assured by the highquality and reliable materials of which they are made: all-stainless steel construction, ceramic air valve and long-lasting PTFE diaphragms.

In addition, the pump contains low-wear components which require very little maintenance.

If it is necessary to change certain consumables, maintenance is facilitated because access to the wearing parts is quick and easy.

Speed paint transfer These pumps are designed for high productivity up to 8 cycles/sec.

18

NEW 01D140 pump by SAMES KREMLIN - 'E' version for abrasive products.

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

Š SAMES KREMLIN

BRAND-NEW

Š SAMES KREMLIN

One of new D140 diaphragm pumps by SAMES KREMLIN, for pressure ratio 3.5:1 (04 D140).

The diaphragms have short and fast strokes which guarantee a high flow rate up to 8 l/min. The design of the pump and its chambers allows for quick and easy flushing which makes these pumps ideal for regular paint changes.

The internal design allows the suction and transfer of paints of up to 15,000 centipoises in circulating lengths of up to 50 metres.

The pump design is perfectly optimized to avoid paint shearing and ensures a perfect colour match during the paint application.

The quietest pumps For reasons of operator comfort it is very important to control the sound power. The 01 and 04 D140 SAMES KREMLIN pumps ensure low noise pollution thanks to their advanced design and integrated silencer. With less than 70 dBA they allow operators to work without noise protection equipment since the standard requires it above 80 dBA. The new pumps contain low-wear components which require low maintenance.

For further information: www.sames-kremlin.com

BRAND-NEW

Europolveri Supports its Territory Italian manufacturer of powder coatings, Europolveri, has committed to helping its territory by donating to health care NPO Fondazione San Bortolo (Vicenza, Italy).

I

the spread of COVID-19, Europolveri has

a future, the children. For this purpose

decided to keep pursuing its long-time

for several years the company has taken

corporate philosophy of being close to who is

part in the UNICEF “Universal Donation”

in need, and has decided to participate to help

programme.

its territory with a donation to Fondazione San

Europolveri marked its 25th anniversary

Bortolo for the health care and the cure of

by entering an open-ended child

COVID-19 patients.

sponsorship for twenty children from all

Alongside the humanitarian initiatives, this time

parts of the world, within the “Terre des

Europolveri commits to help its own territory,

Hommes” project.

this choice has been driven by the willingness

For its 30th anniversary Europolveri chose

to help people that has been taking part of the

also another initiative of the “Terre des

n this difficult and tragic period caused by

development and success of the company since

Hommes” programme and adopted a “House of Sun” in Namibia; these are

the concept of company social responsibility.

Europolveri’s social initiatives

Furthermore, Europolveri drew up an internal

This is not the first time

education, psychological and nutritional

protocol, following all the ministerial directives,

that Europolveri is involved in social

support, healthcare and vaccinations.

with the purpose of protecting and ensuring

initiatives, choosing actions aimed

the health of all of its employees and to avoid

at giving opportunities for growth to

For further information:

the spread of the virus.

who more than anyone else needs

www.europolveri.it

structures that offer children protection,

© Europolveri

© Europolveri

a long time. A gesture that aim to strengthen

20

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

SPECIALISTS IN PLASMA PVD COATINGS

ENJOY PVD TECHNOLOGY

Kolzer machines guarantee versatility in Metallization and PVD Sputtering treatments as well as repeatability in production.

Kolzer systems perform well in all conditions, with all materials and for processing on each substrate. PVD is totally eco-friendly process with low environmental impact.

www.kolzer.com

Cr

3+

Cr

6+

One of the characteristic elements of civil architecture in United Kingdom and beyond are stone block walls, usually in light limestone.

FOCUS ON TECHNOLOGY

ICC Wales, Newport. Tactile Finishes: The Colours of Stone Edited by Adapta Color SL Peñíscola - Spain

22

adaptacolor@adaptacolor.com

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

N

atural materials have inspired the colours, design, and look of the façade of a large conference centre in Wales, recently

renovated and modernised in order to meet the latest construction and energy control requirements.

Light stone was simulated with powder coatings from Adapta Color’s Patina series, which, despite not having any imitation purpose, call to mind the colour, effect, and opacity of natural stone.

Two of the requirements of the architectural construction field are components that guarantee defined building times, since the opening and maintenance of construction sites are expensive operations, and lighter structures, including façades, in order to reduce times and facilitate quality control.

The trend toward the definition of precise time schedules in the construction of buildings has led to the habit of assembling most of the components in the factory rather than on site. Even internal partitions are now generally dry-construction structures. This method, in turn, has required a significant reduction in the parts’ weight, especially for logistical and on-site handling reasons.

These solutions call for an analysis of the most suitable construction systems and, as a consequence, for the possible use of new materials.

The choice of materials Based on these premises, it is clear that the choice of materials is of growing importance in design, in terms not only of aesthetics, but also of cost control and operational times. The ability to control quality is also of strategic importance, both during building and afterwards, in order to define maintenance © Kingspan Façade

costs. All this allows designing new architectural components whose finishes also play a key role. Four main characteristics affect the choice of a material or component: aesthetics, performance/certified quality,

The renovation project of the International Convention Centre Wales (ICC Wales) in Newport (UK), designed by the Studio Boyes Reed Architects firm, included the makeover of its façade with a dry system supplied by Kingspan. This is composed of rectangular, aluminium sandwich panels, or “cassettes”, powder coated with a dark grey tint that simulates slate. Coatings from Spanish company Adapta Color’s Patina Stone Collection were used for this.

sustainability, and maintenance.

Local roots, contemporary solutions The International Convention Centre Wales in Newport (UK), designed by the Boyes Reed Architects firm, is located outside the city centre and strategically close to the highway, but, at the same time, it features some local buildings’ characteristics, revamping them with a contemporary take. For example, a key façade element inspired by local roots is the reinterpretation of the typical stone

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

23

© Kingspan Façade

block walls of civil buildings in the area and throughout the south of the United Kingdom.

© Kingspan Façade

The International Convention Centre Wales in Newport.

For this, the effects of dark grey slate and warm light grey limestone were implemented.

Light-coloured limestone – for instance, Portland stone, used in some iconic English buildings, such as St. Paul’s Cathedral and Buckingham Palace in London, or the City Hall of Cardiff, the capital of Wales – requires regular maintenance, as it reacts with the acid substances contained in polluted air.

Its main aesthetic characteristic is the presence of tiny fossils, shell fragments, and other fossilised debris, despite having a very fine grain.

How can this effect be achieved by using light and high-performance dry-construction systems? If we compare

24

The project has its roots in the architecture of British public buildings, while aiming at modernising it.

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

© Kingspan Façade

© Kingspan Façade

FOCUS ON TECHNOLOGY

A comparison between the rectangular panels of the façade and an example of local architecture with a stone block wall.

Introduced by Adapta Color at PaintExpo 2014, PATINACollection® is the technological answer for the finishes that try to imitate the oxidation of weathered metals. The collection consists of more than 48 selected decorations that combine optimal application, excellent features and high aesthetic level with a heterogeneous finishing, similar to natural oxidation.

These ranges pose imitations on the oxidation of metal and terracotta with irregular finishes pleasant to the touch that gives them a double dimension of realism and advanced aesthetic that suggests or take us to remote and exotic locations, an endless number of places which transport us and make us feel alive. Life which our Patina Collection wants to infuse in objects created by man.

Patina finishes have been grouped in 4 main ranges: Tile Patina, Oxide Patina I, Oxide Patina II and Soft Patina, among which we can find the copper oxidation, Cor-Ten steel, the imitation of hot-dip galvanized steel, aged bronze and the imitation of earth and stone colours, as well as fantasy colours.

These finishes, some of which were included in the A16 Collection for architectural application and are Qualicoat Class 2 compliant, provide the technological solutions for a very exclusive and, at the same time, highly demanded range of colours for the design of certain projects.

© Kingspan Façade

© Kingspan Façade

The building’s façade is built with a dry system consisting of rectangular, folded-corner panels, or “cassettes”, in different sizes.

visually a stone slab to a powder coated sheet with Patina Stone Collection products, the result is very interesting: whereas it does not © Kingspan Façade

“imitate” stone, the latter’s aesthetic effect is actually rather similar. In other words, it “calls to mind” stone, although it does not “imitate” it.

Not imitating, but rather recalling The Boyes Reed Architects firm found the solution in the use of aluminium sheets folded according to a precisely defined design that creates rectangular “blocks”, or “cassettes”, with different sizes. English company Kingspan supplied them. The panels are manufactured in-house and coupled to an exclusive hybrid insulating core with a closed micro-cell structure that can reach U values up to

© Kingspan Façade

0.08 W/(m2K). The symmetrical junction between male and female panels guarantees excellent air tightness, meeting both aesthetic and energy saving requirements.

Folded aluminium sheets in different sizes are then pre-treated to improve their corrosion resistance and, finally, coated with a powder from the Class 2 Patina Stone Collection of Adapta Color. In terms of performance, this product has an outdoor durability that exceeds twenty years, excellent colour stability, and excellent gloss retention, even exceeding international quality specifications such as Qualicoat Class 2, GSB Master, AAMA 2604, and others. This means that the façade will not require any maintenance operation for many years to come.

26

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

Some details of the façade. The light-coloured finish has an irregular, tactile effect made even more interesting by the coating’s opacity and unevenness, recalling those of natural stone.

NEW D140 DIAPHRAGM PUMPS

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NEW

01D140

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© Shutterstock

INNOVATIONS: PRESENT&FUTURE

Corrosion Protection with Zinc Flake Systems – Yesterday, Today, Tomorrow Detlef Stöckert Dörken MKS-Systeme GmbH & Co. KG – Herdecke, Germany

dstoeckert@doerken.de

Since Dörken MKS developed its first application of zinc flake coating in 1989, the German company became one of the leading partners for corrosion protection with numerous developments and innovations. In the following article Dr. Detlef Stöckert describes the history, benefits, possible applications, and the development of these systems.

28

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

D

urability, flexibility and further

bolt threads, without affecting the fit.

180-200°C – an advantage that

development have been

A further advantage is the inorganic

opened up the field of spring

writing the success story

binder system, which minimises setting

coating to the company. In 2000 the

of zinc flake technology since the

behaviour below the head for screw

Magni and Dörken firms went their

1970s. Numerous sectors employ this

and bolt coatings in particular. As zinc

separate ways, with the consequence

effective coating of steel components,

flake systems do not generate any

that three globally active providers

with continuous research ensuring

hydrogen in their application[1] and

have since existed on the market,

that they satisfy the constantly rising

consequently eliminate the problem

with the third being Dacral. Four

requirements of corrosion protection.

of hydrogen-induced stress corrosion

to five years prior to the entry into

One especially significant step: with

cracking that affects other coatings,

effect of the End-of-life Vehicles

the availability of zinc flake systems

these systems are used in particular for

Directive (Directive 2000/53/EC[2]),

that harden at room temperature

the corrosion protection of high-tensile

around 2002, chromium(VI)-based

it is not just small parts that can be

bolts and spring steel. In addition to

coatings were gradually replaced by

coated, but also increasingly large

small parts (“bulk parts”), zinc flake

chromate-free systems.

and heavy parts that cannot be

technology now increasingly also

heated in the furnace – a benefit for

protects larger components against

uses such as electromobility or bridge

corrosion.

construction.

Developments and areas of application The zinc flake system is frequently

Zinc flake - a success story

adapted to new applications

What are zinc flake coatings?

The invention originates with a small

and developed further to satisfy

start-up from the US, which sold its

changing market requirements.

Zinc flake coatings are so-called

development to the Japanese firm

These include:

dispersion coatings, they can be

Dacral around 1970. In 1974 Dacral,

Bolts and screws: Thin coats are a

applied with a variety of procedures.

a subsidiary of Nippon Oil Fat Comp

prerequisite here, in order to coat

For small parts, dip-spin coating

(NOF), began searching for a contract

diverse sizes and dimensions. Zinc

in centrifuge baskets is common

coater in America, finding Magni.

flake coatings have established

practice. After immersion in the

Dörken took over the Magni technology

themselves here over the course

liquid coating the excess material is

to adapt it to the requirements of

of many years and also offer good

spun off and reused. The remaining

the European market. At that time an

protection for smaller screws (<M6)

coat is then cross-linked to the

inorganic titanate-based binder system

and therefore very low diameters

part in a furnace - retaining a coat

was already in use, although cathodic

of threaded goods. In addition, the

of approx. 60-70 % zinc and up to

protection was provided via zinc dust.

coating also satisfies the significantly

10 % aluminium. When it comes to

Since the invention of the system, zinc

increased requirements of corrosion

bulk parts, this process is typically

flakes have been used as pigment in

protection. Where in 1980 240 h

repeated. The reason: agglomeration

coatings. Due to their “self-healing” or

in salt spray testing were standard,

points from the first coating are

passivating effect, chromium(VI)-based

today at least 720 h are expected.

reliably covered. The zinc flakes lie

systems were very successful in the

largely parallel to one another and

early phase. They enabled significantly

Engine components: As the majority

the surface, arranged in a polymer

thinner coats to be achieved than the

of motor vehicles have increasingly

film. This results in a primary barrier

chromium(VI)-free systems,

compact and encapsulated engines,

effect against moisture and oxygen.

with the consequence that the

an increasing level of heat resistance

Compared to conventional industrial

chromium-based Dacromet system

is required. The car industry has

coatings, the zinc flake coatings are

long enjoyed a monopoly in the

agreed on preconditioning of 4

characterised in particular by the fact

coating of screws and bolts. However,

days at 180°C with subsequent

that extremely thin coats of approx.

the water-based system requires a

corrosion testing. In contrast to

8-20 μm achieve excellent active

very high annealing temperature, at

passivated galvanic systems, zinc

corrosion protection. This means, for

300°C. In contrast, the solvent-based,

flake technology satisfies this

example, that they are ideally suited

chromate-free Delta Tone system

requirement and is therefore

for coating the thin flanks of nut and

developed by Dörken only requires

the preferred choice for the

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

29

© Dörken

sector was and remains an attractive appearance of black surfaces and components under service stress, or after corrosion testing. The contrast of the black topcoat to the white zinc oxide layer that forms with corrosion is noticeably disturbing. As damage to the black topcoat cannot be avoided with the coating of bulk products, the chemical make-up of the zinc flake base coat was altered to inhibit oxidation.

This results in two benefits: less unsightly white corrosion and more effective use of the zinc quantity solely for the cathodic protection of the component.

This is enabled by adapting the electrical resistance of the coat. The result is a dark black surface that after a long period of corrosive stress displays no more change than the “white haze” of a zinc-nickel coat.

Room temperature hardening systems: With specific parts the coating must occur with a very low annealing temperature (room temperature). This is the case, for example, with assembled parts in combination with plastic. In this case, lowering the temperature by just 20-30°C is enough, depending on the character of the plastic. This can typically be achieved

SEM image of a zinc flake coating.

via application technology adjustments.

The case is different with large components that do not fit in available

coating of components in the engine

coated with the spray procedure,

furnaces or that cannot be heated using

compartment.

more complex formed parts require

standard processes - for example the

a sophisticated approach to coating.

metre-sized cogs used in construction

Large components: After zinc flake had

As a result, for example, the

cranes or other large cast steel parts.

successfully established itself for small

square-metre-sized engine mount of

Coating systems that harden at room

parts, the aim was to use it increasingly

a German luxury limousine with its

temperature have recently come into use,

for larger and heavier parts as well.

complicated structures, perforations

with these applied using the spray process

In the case of bolts, M14 is already

and undercuts was serially coated

and offering superb protection.

too large for coating in the drum

using the adapted dip-spin process

process. The own weight of the parts

in 2017. This enabled 700 g of weight

(typically 180 g for M16 x 80) leads to

to be saved compared to standard

massive coating damage and hinders

coating, for just one part.

the formation of the coat. Against this background, the application process

Appearance of components: One of

in particular was adapted. Whilst wind

the most important requirements

energy bolts (M24-M38) can still be

of OEMs in the motor vehicle

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N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

Bibliography: 1. Belz, Hans W., DELTA-TONE, eine anorganische Beschichtung mit hohen Korrosionsschutzeigenschaften. Galvanotechnik 83(1992)1927 2. DIRECTIVE 2000/53/EC, End-of-life Vehicles Directive, 18/09/2000

booths

ovens

cataphoresis

tunnels

complete plants

eosmarketing.it

conveyors

IDEAS NEED TALENT C.M.V. srl - Via dellâ&#x20AC;&#x2122;industria, 2 - 61036 Tavernelle di Colli al Metauro, PU - Italy - T +39 0721 892274 - info.cmv@cmvimpianti.it - www.cmvimpianti.it

© Evonik

COATINO® provides AI-based additive recommendations to paint and coatings formulators.

HIGHLIGHT OF THE MONTH

Evonik Officially Launched Virtual Formulation Assistant COATINO® Thomas Lange Evonik Resource Efficiency GmbH, Essen - Germany

thomas.lange2@evonik.com

After about two years of development, Evonik officially launched COATINO®, the first digital assistant for paint and coatings formulators.

32

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

E

vonik’s virtual assistant

with each other so as to better

our common technical vocabulary.

COATINO®, is now available

understand the differences and

And they certainly don’t have any

to the entire paint&coatings

facilitate the decision-making

expertise in coating additives.”

industry for free.

process. The number of theoretical

“We had to implement both the

At www.coatino.com, paint and

property combinations is 1070,

necessary language processing

coatings formulators can obtain

plus around 1,900 existing guiding

and additive know-how nearly

AI-based additive recommendations

formulations. If no guiding

from scratch”, added Oliver Kröhl,

for several applications and individual

formulation exists yet, COATINO

project manager of the COATINO®

guiding formulations for pigment

calculates individual formulations

development team.

concentrates. COATINO® can be

for all types of pigment concentrates

used from any electronic device and

based on its constantly growing

The future of COATINO®

operated by voice control.

data pool. A total of more than

COATINO® was developed by

To provide a constant upgrade

300 products are available to

Evonik in cooperation with a

of COATINO®, Evonik operates a

choose from, including defoamers,

leading German supplier of

high-throughput equipment at its

dispersing additives, and matting

Big Data and AI solutions and

Essen site in Germany that tests

agents. If needed, COATINO® also

both companies are working to

and evaluates up to 120 coating

provides technical, regulatory, and

continuously expand the tool

formulations every day.

safety data sheets.

with new functions and even

“It was and is a great challenge

more comprehensive formulation

How it works

to teach COATINO the technical

calculations.

Formulators can choose from more

language of our industry,” explains

Evonik is currently researching

than 200 product properties and

Gaetano Blanda, head of the

its own smart speaker so that

effects in order to obtain tailor-made

Coating Additives Business Line.

formulators worldwide can access

and weighted recommendations,

“The language assistants available

the digital assistant even more

which can be dynamically compared

today simply do not understand

flexibly in the future.

®

Evonik’s virtual formulation assistant COATINO®.

© Evonik

© Evonik

®

The new virtual formulation assistant is reachable at www.coatino.com.

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

33

BRAND-NEW

Antibacterial and Antiviral Surface with Kolzer’s Machines for the Deposition of Copper Nanoparticles The new Kolzer machines allow to apply an antibacterial copper coating using the Sputtering technique.

Copper is a chemical element that, according to a research conducted by the University of Southampton, boasts antibacterial and antiviral properties.

A

With the aim of helping to tackle

“Sputtering is a fast, economic

of Southampton, United

the health emergency due to

and ecological process, which is

Kingdom, has shown that

the Coronavirus pandemic,

carried out in a vacuum and which

using antimicrobial copper contact

Kolzer is providing its skills and

allows copper to be deposited on

surfaces could not only disrupt the

machinery that allow to apply,

any surface with high efficiency,

chain of contamination, but at the

using the Sputtering technique,

uniformity and functionality.

same time reduce the possibility of

copper nanoparticles on the

Currently, about 6 industrial

developing antibiotic resistance.

surfaces with which we come

reactors for tests and trials are

“If critical environments are properly

into contact everyday. Door and

available at the Kolzer headquarters

cleaned, copper can be an excellent

window handles, handrails, light

in Cologno Monzese (Milan,

ally against viruses and bacteria,”

switches and lift buttons are

Italy),” explains director Antonio

says Professor Bill Keevil, chief of

just some of the objects that we

D’Esposito.

CORDIS of the Environmental Health

touch daily and which, especially

Department of the University of

in this particular period, we must

For further information:

Southampton.

constantly sanitize.

www.kolzer.com

© Kolzer

research from the University

34

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

© WELCO

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N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Efficiency Increase and Cost Reduction in Powder Coating Thomas Krauze Nordson Deutschland GmbH – Erkrath, Germany

ics.eu@nordson.com

Automotive and motorcycle exteriors are exposed to extreme conditions over a long period of time due to heat, cold, moisture, stone chipping, road salt, UV radiation and much more. At the same time, no other industry makes such high demands on the appearance and feel of surfaces as the automobile and motorcycle manufacturers. The visually attractive sheet metal and plastic parts of those conceal complex shapes. Since 2016 after many years of manual powder coating, the job coater WELCO, Germany, has been relying on the innovative combination of robot coating with dense phase technology.

A

nodizing, cathodic dip coating

optimization steps along the process

fluctuated greatly from coater to

or powder coating, since its

chain, which result in both technical

coater. There were high costs for

foundation in 2006, WELCO

and economic improvements to the

system maintenance, wear parts,

GmbH & Co. KG in Germany has

components and their manufacturing

repairs and downtime. “It was clear

dedicated itself entirely to “surface

methods.”

that only an automated powder

finishing in design quality”.

The success of such efforts can then

coating process could optimize

Well-known German automobile and

also be verified in the company’s

quality and reduce the effort to an

motorcycle manufacturers are among

own plant. The versatile supplier is

acceptable level.

its satisfied customers. The demands

QM-certified according to the highest

Three goals were important to us:

of these customers are high, not

European performance class ISO/TS

a high quality of powder coating,

only in terms of the quality and

16949:2016 and offers mechanical,

automatic handling of wear and spare

appearance of the finished surface,

chemical and climate change tests,

parts and the economic efficiency,”

but also with regard to “soft factors”

which are important for international

Nuber continues.

such as delivery performance,

vehicle construction.

After researching Nuber became aware of the Nordson dense phase

reliability, flexibility and economy.

“We are much more than an

Future-proof investment

technology. In order to test this

extended workbench for our

For powder coating, WELCO relied

technology for its own application,

customers”, is how WELCO Managing

on manual work and Venturi

the WELCO team gladly accepted

Director Richard Nuber describes

technology until 2015. “To achieve

the offer from dense phase pioneer

the relationship with his clients. “We

a decent coating quality was high in

Nordson to carry out initial tests in

are regularly involved in production

every aspect,” recalls Nuber.

their test lab in Erkrath. “We tested

planning at an early stage, develop

“We sprayed to waste and needed

our parts with the Encore® HD

individual solutions and then

two minutes or more to coat complex

manual coating powder guns and

implement them. The focus is

workpieces. Around 13% of the parts

the application itself immediately

not so much on ground-breaking

still had to go to post touch up.”

convinced us that a process that

innovations, but rather on targeted

Even after that, the film thicknesses

could be controlled completely and

WELCO relies on the innovative combination of robot coating with dense phase technology by Nordson.

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

37

© Nordson

ColorMax® fast colour change by Nordson.

safely with hardly any overspray at a high

CS Oberflächentechnik and southern German

The height of 2.50 m without substructure

penetration depth of the powder. However,

representative of Nordson). “We agreed to

was not allowed to be exceeded,” as

the conventional reciprocators were not

develop a completely individual solution for

Zimmerhackel describes the challenges

flexible enough for our complex parts. For

WELCO and were awarded the contract.”

of the planning and construction phase.

a high degree of automation, we had to

Even the configuration of the ColorMax® fast

“In addition, further openings in the booth

think of robots.”

colour change booth proved to be a difficult

had to be provided for the accessibility of

“This was also an exciting new task for us,”

task. “The available area for the booth was only

the robots. This made it difficult to create a

says Jörg Zimmerhackel, Project Manager

20 m . There had to be enough space for the

gentle, uniform air flow in the booth, but we

of the WELCO plant (Managing Director of

two robots and their movements.

were able to successfully build a solution.”

38

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N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

The booth was designed according to the customer’s specifications and the

© WELCO

FOCUS ON TECHNOLOGY

dimensions were transmitted to the robot manufacturer, who extensively simulated the mobility of the two compacts, staggered 7-axis robots. Only thereafter did the construction of the powder coating booth begin. “ColorMax booths that are modified in this way to meet customer specific requirements are given the suffix “E” for Engineered,” explains Zimmerhackel. “This one is designed for parts up to 1,200 x 600 x 600 mm in size and is equipped with standard components from the ColorMax3 booth”.

The floor and sides of the booth were made of powder-repellent coated panels, and the slight overspray at the floor is directly removed by the AirWash system.

Each of the two robots are equipped with an Encore HD automatic gun for the

The two compacts, staggered 7-axis robots.

powder application itself. The robots are point-to-point process.

The components of the system are

© Nordson

programmed quickly and easily in a

supplied with fresh powder from the Spectrum® HD powder centre. The self-cleaning HDLV® pumps and transfer pumps are used for powder delivery.

These pumps carry the powder from the hopper to the guns and gently return the reclaimed powder to the Spectrum HD powder centre. A Nordson self-cleaning twin-cyclone is used for gentle powder recovery, with an hourly output of 12,000 cubic meters. Impurities and micro particles are retained by the after filter.

To initiate one of the five daily colour changes in a three-shift operation, the operator must click on the touch screen of the PowderPilot® HD control system and the colour change starts automatically. The intuitive system also guides the operator easily through the process.

Also the rest of the installation is operated by the PowderPilot HD control system. “The handling is very intuitive.

The PowderPilot HD unit allows perfect and efficient control of application with robots.

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

39

© WELCO

What the operator needs to know or do is displayed almost seamlessly in easy understandable icons,” says Zimmerhackel, addressing the issue of the lack of skilled workers. “Good language skills and extensive training are not necessary for safe operation of the system. Even the controls of the robots were placed on the Windows-based PowderPilot HD”.

Better, faster and more economical For almost four years now, the fully automatic system has been coating aluminium, steel and magnesium components with great precision and reliability in three shifts at WELCO. “The interplay of robot technology and dense phase technology has been proven with a 100% process control.”

“The expected quality improvement has been achieved in all aspects.” The coating specialist attributes this to the uniform and consistent powder coverage on oddly shaped parts. This is achieved by the soft powder cloud that emerges from the powder gun at a low speed and from a short distance. Less

© WELCO

overspray produces a high penetration depth of the powder which is exactly how Nordson engineered its dense phase technology with HDLV pumps in the Encore HD spray system.

“In fact, the extremely precise application of the dense phase technology is further enhanced by the precisely controllable robots and with maximum repeatability.

The basis for this is the wide range of data recorded both by the coating system and the robots, which are stored in the recipes.

This makes the entire production process both very reliable and flexible and it results in uniform coatings and visible quality advantages.” Zimmerhackel added.

The effectiveness and efficiency of the coating process has also increased significantly and can be expressed in concrete figures, “Instead of over two minutes with the old technology, we now coat our workpieces in about one minute on average. At the same time the rework Robots are equipped with an Encore HD automatic gun for the powder application itself.

40

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

rate has fallen to 5%. We save around 25%

Nordson Dense Phase Technology Nordson’s patented HDLV® pumps use dense-phase technology with high-density powder, low-velocity air to pump more powder to the spray gun with a minimum of air, and maximum process control.

This results in superior efficiency, unmatched coverage, and reliable self-clean colour change, boosting productivity and reducing operating costs.

With more than 10 years of field-proven experience, Nordson remains at the cutting edge of dense phase pump technology in the powder coating industry: - Powder output stability and process control, for precise applied coating thickness and significant powder savings; - Highest application efficiency with soft spray pattern; - Superior coverage of recessed areas through optimized spray velocities; - Long-time wear life of the internal pump components significantly reduces maintenance downtime for maximum productivity; - Contamination free colour change of the entire spray system due to an automated purge clean system.

www.cmautomazione.it

hi-tech

FOCUS ON TECHNOLOGY

conveyors

to 35% of the powder through consistent recovery, with a consumption of around 40 tons per year, that is about 10 tons,” Richard Nuber continues. “This has enabled us to double our production output and achieve a significant increase in sales!”.

The time required for a colour change has settled down to well under 15 minutes. Since the complex colour change process is now largely automated, one operator can be saved in each shift. “But it was never our goal to rationalize jobs with the new technology. We advised our workers very early on in the planning phase and involved them in the change process.

This caused the workers to be highly motivated and concentrate on their new tasks,” says Nuber.

In conclusion, Richard Nuber mentions with a smile: “In addition to the cost savings and because of the absolute process control, the Nordson dense phase technology, with its very uniform coating quality, gives me great pleasure right from the start.

Recently, I received another request for a sample coating from a very well-known and high-quality automotive group. I just couldn’t help myself. I was looking forward to coating this sample myself again with our Nordson Encore® HD manual system and being able to present an excellent, very consistent result to the customer, who was also very enthusiastic about the quality”.

CM AUTOMAZIONE srl - FA Ganci

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

BRAND-NEW

SANYFOG, the New High-Frequency Nebulizer for a Sanitization Available for Everyone

buildings can be scheduled and

has shown that a disease

managed automatically by connecting

can spread on surfaces,

a perforated pipe to one or more

which become potential sources of

SANYFOG machines.

contamination. Personal hygiene is

Furthermore, the system consisting

certainly the first barrier against virus

of a SANYFOG machine connected

spreading, but environmental hygiene

to a tunnel allows to nebulize a

is equally important.

specific cosmetic product suitable for

Alit Technologies, specialized in

sanitizing people crossing tunnels or

chemical paint stripping solutions,

booths to reach a particular place or

recently launched SANYFOG, a

event.

sanitizing device able to spray 1 to

The SANYFOG system was conceived

5 μm-diameter particles. It is a

as a comprehensive sanitization

high-frequency nebulizer for dispersing

system. Indeed, Alit Technologies

sanitizing solution which, thanks to the

supplies not only the machines, but

innovative atomization technology, is

also the sanitizing solutions and

able to reduce the size of the atomized

cosmetic products to be applied.

particle up to 1 μm. So the product can

Products of the CLARIS series are

easily reach all surface’s areas, while

concentrated high cleaning power

remaining suspended in the air for

detergents, which have been created

only a minimum time. This results in a

by Alit Technologies R&D team

useful solution if compared with other

in order to help companies and

aerosol systems.

contribute to develop health and

Fog’s production speed, density, and

safety plans for employees to enable

even application with very low energy

them to resume their activities in

consumption make SANYFOG the

peace.

perfect system for using sanitizing

The application of CLARIS products

solutions in any environment, whether

with SANYFOG nebulizer provides

it is an office or an industrial building.

a comprehensive solution available

Offices sanitization can be done by

for everyone to sanitise any working

installing a chimney or a pipe:

environments.

SANYFOG device runs for sanitizing a working environment.

© Alit Technologies

C

urrent health emergency

© Alit Technologies

Alit Technologies, a company specialized in chemical products for metal treatment, has designed an innovative and cost-efficient system for sanitizing working environments - both offices and industrial buildings - consisting of the SANYFOG nebulizer and CLARIS detergents with high sanitizing power.

The nebulization system avoids to wet documents, furniture and

For further information:

computers. Sanitization of industrial

www.sanyfog.com

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N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

SANYFOG nebulizer can be connected to a booth for sanitizing people.

BRAND-NEW

BYK-Gardner Launches spectro2profiler to Measure Colour as You See It BYK-Gardner expands its range of quality control tools presenting spectro2profiler, a brand-new instrument to measure colour and gloss and analyse the 3D topography of the surface texture.

T

he colour, gloss and structure of

“The real innovation is represented by the

with the 3D image data to separate the

the surface influence our visual

3D-structure analysis. spectro2profiler

reflection of hills and valleys. The new

quality perception and together they

examines multiple images under different

measurement parameter, reflectivity

provide an overall judgment in terms of

illumination directions to estimate the

contrast Rc, is an ideal measure for

visual rating. Until now, the grain or surface

curvature of the surface. In this way, it is

production QC of injection or slush

structure could only be judged visually or with

possible to have objective measurements

moulded parts. To compare historical data,

highly sophisticated microscopes, but with

for the cell size (mm²) and perceived

the instrument also measures traditional

spectro2profiler everything changes.

cell amplitude (P-μm). Different types of

60° gloss according to international

The innovative instrument presented by

grains can be easily differentiated, making

standards.

BYK-Gardner, worldwide partner of the

it ideal for the design and approval of new

By using specific algorithms,

automotive, paint and plastic industries for

suppliers”, explains Dr. Christopher Groh,

spectro2profiler can be used to objectively analyse structures of

to measure all 3 parameters

different applications:

©BYK-Gardner

quality control of colour, is able simultaneously in a robust and portable tool.

leather-like for injection or slush moulded parts, coarse paint for powder coatings

spectro2profiler – supports you through ups and downs to achieve colour and grain harmony

and fine paint for plastic

The new BYK instrument uses

ensures intuitive operation.

a circumferential illumination at

Thanks to an integrated

45° with 0° viewing.

camera, it is possible to

The company’s proven and

have a live preview of the

innovative LED technology

measurement spot. This

guarantees exceptional

avoids false readings on

performance. Short-term,

imperfections or scratches.

long-term and temperature

A smart-chart software

parts or fine textured paint. spectro2profiler has a large colour touchscreen with an icon-based menu which

stability are unequalled in the industry. Highly

R&D Project Manager at BYK-Gardner.

analyses data relating to colour, gloss

repeatable and representative readings are

Additionally, the new spectro2profiler

and 3D topography. In addition, this

guaranteed by the extra-large measurement

provides a 2D camera-based reflectivity

tool boasts a powerful management

spot with homogenous illumination. All

measurement for structured surfaces. The

that allows you to determine Pass/Fail

together highest accuracy and inter-

perceived depth of a leather-like surface

tolerances for all these three parameters.

instrument agreement are ensured and allow

is dependent on the reflection behaviour

the use of digital standards – the key for

on the hills and valleys. Therefore, a

For further information:

global colour management.

2D reflectivity measurement is aligned

www.byk-instruments.com

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

43

© Aluminco

Innovative aluminium building systems by Aluminco.

FOCUS ON TECHNOLOGY

Aluminco: The Greek Manufacturer of Architectural Aluminium Systems Installs the First Zero Liquid Discharge WWT Plant Without Evaporator Alessia Venturi ipcm®

Aluminco, a Greek company among the major national manufacturers of architectural aluminium systems, is the first company in Europe using a zero liquid discharge wastewater treatment systems featuring the revolutionary technology PUR-ALL® Zero Zero by the Italian CIE Srl. The systems guarantees the elimination of 98% of dissolved pollutants, 100% recirculation of the treated water, and a conductivity value of the latter lower than 200 μS without any demineralisation process.

44

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

H

ow important is the quality of water

its first aluminium door panels. During

Currently, in its headquarters in Viotia,

in a surface treatment process?

the 1990s, Aluminco boomed and grew

North of Athens, Aluminco owns two

We tend to think about water in

internationally, thus expanding its product

1,850 t and 2,500 t extrusion presses, with

emotional, environmental, therapeutic,

portfolio and distribution network. In

a total extrusion capacity of 30,000 t;

healthy, and even financial terms, but we

2002, the firm had a 60,000 m2-wide plant,

five powder coating lines, including a

rarely talk about it in qualitative terms. Yet,

with advanced production systems, a

vertical one and four horizontal ones; one

the chemical quality of water is key to an

logistics centre, and administrative offices.

sublimation line for wood-like and special

effective surface treatment process. With

In 2015, new production units were added

effects; one automatic anodising unit

its conductivity and physical residue values,

with a multimillion-dollar investment

for profiles up to 7.5 m; one automatic

water affects the surfaces’ corrosion

in equipment, including a new vertical

warehouse with 1,700 slots; two thermal

resistance and paint adhesion

powder coating plant, in software, and in

bridge assembly lines; four door panel

characteristics and, ultimately, the aesthetic

research and development infrastructure.

production lines; one melting unit; four

quality and durability of industrial products.

In 2017, exports exceeded 50% of annual

profile machining centres; and two

“Good” water it is difficult to find in industrial

turnover – EMEIA and Americas are its

automatic packaging lines.

mains and also difficult to produce:

main markets – and Aluminco launched a

investments are needed in technologies

new generation of architectural aluminium

and plants that enable its purification

systems optimised in terms of safety,

and treatment in order to give it the most

design, and energy efficiency.

The framework for the ZLD treatment plant’s project: the pre-treatment cycle Aluminco produces 1.5 tons/hour of

That is why Aluminco, a Greek company

coated extrusions.

among the major national manufacturers of architectural aluminium systems, relied

© Aluminco

suitable characteristics for the task at hand.

The chemical pre-treatment cycle used on its vertical coating system is composed as

on CIE Srl’s almost forty-year experience

follows:

in the design of industrial water treatment

- Acid degreasing and first etching phase;

and recycling plants for the metal finishing

- Two rinses:

industry. The aim was equipping its

- Deoxidation;

profile coating department with a system

- One rinse;

guaranteeing total recirculation of water with

- Chromium-free surface conversion

a 98% reduction of pollutants (metals and

treatment;

acids). This collaboration between Aluminco

- One rinse with demineralised water.

and CIE resulted in the creation of the first

The waste water treatment plant designed

waste water treatment plant in Europe not

by CIE Srl treats liquids from all these

to use an evaporator in order to achieve the

pre-treatment stages, i.e. both active

zero liquid discharge goal.

baths and rinsing tanks. Before working with CIE, Aluminco already had a waste

About Aluminco

water treatment system, but the final

From extrusion to finishing, Aluminco

conductivity value of the purified water did

manufactures profiles for various

not meet the required quality standards

applications in the architectural field: hinged

and, therefore, it called for a further

and sliding doors and windows, sunshades,

demineralisation stage downstream of

grilled sheets for the aesthetic cladding of

the process. The Zero Liquid Discharge

skyscrapers, systems for façades and curtain

(ZLD) system designed and installed by

walls, railings, gates, and fences. Young

CIE integrates the old treatment plant

Theodore Karras established Aluminco in

with new, proprietary technologies that

Athens in 1982, as a small foundry with

guarantee the elimination of 98% of

few resources and full of enthusiasm. It

dissolved pollutants, 100% recirculation of

initially produced aluminium castings for

the treated water, and a conductivity value

public and commercial space lighting; then, it expanded its range by launching

Aluminco vertical powder coating installation.

of the latter lower than 200 μS without any demineralisation process.

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

45

© Aluminco

© CIE

CIE Srl technical manager Antonella Monaco.

Fotis Karvelas, Aluminco WWT System manager.

The CIE technology

(except for the demineralised water

“In these surface treatment lines, the

The aim of this WWT plant, started

rinsing ones, fed by the already existing

conductivity value of water is essential

in November 2019 at the Aluminco

closed-loop demineralisation system).

because it is related to the concentration

premises, was to consistently and

“Aluminco’s initial request involved

of salts,” says Franco Falcone, the CEO and

continuously produce high quality

the treatment of the water produced

general manager of CIE. “It can be defined

water (i.e. with very low conductivity)

by its pre-treatment stages up to the

as a value through which the Total Dissolved

with zero discharge of liquids. CIE

rinse preceding the chromium-free

Solid (TDS) value is understood: the more

achieved this goal, for the first time in

conversion process. Later on, we also

salty the water, the more conductive it is.

the European aluminium industry, only

included the plant’s conversion stage

Lowering the concentration of salts means

through a chemical treatment process

and the drag-out tank, because the

lowering the conductivity of water and,

of waste water. In fact, it implemented

contribution of pollutants from acid

therefore, producing cleaner and

its revolutionary technology PUR-ALL

degreasing and conversion processes

more effective water for our

Zero Zero, guaranteeing the recovery and

is generally 10:1,” explains CIE Srl

customers’ treatment purposes.

recirculation of all treated water and the

technical manager Antonella Monaco,

Our PUR-ALL® Zero Zero technology,

elimination of 98% of pollutants without

who worked at the project together

implemented for the first time in Europe at

the use of any ion exchange, reverse

with Aluminco WWT system manager

the Aluminco premises, ensures that treated

osmosis, or evaporation system. The

Fotis Karvelas. “Thanks to the

water is consistently recirculated with a

water exiting the WWT plant installed at

PUR-ALL® technology, our system treats

conductivity value of 150 μS and totally free

Aluminco has a constant conductivity of

water from the rinsing stations and the

of calcium at each cycle. The quality of such

150 μS. It is used for the replenishment

cleaner concentrates and sends it back

water is therefore significantly better than

of all the treatment and rinsing stations

to the plant with a constant conductivity

that of mains water, which, at best, has a

of the coating plants’ pre-treatment lines

value of 150 μS.”

conductivity of at least 400 μS.”

®

46

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FOCUS ON TECHNOLOGY

“The quality of the water used is of great importance for the purposes of pre-treatment,” says Falcone. “If water does not “clean” efficiently because it contains too many salts, then saline impurities remain on the parts’ surfaces, which in turn prevent the correct adhesion of the applied coating film. The use of hard water to pre-treat metal results in much more difficulties in rinsing. Consequently, the amount of demineralised water must be greater to compensate for the poor quality of mains water; active baths are also affected over time. Moreover, if such hard water also contains many chlorides and sulphates, which are dangerous in terms of corrosion, it will lower the quality of the surface treatment performed. Hard mains water rich in calcium and water with high salinity and a starting conductivity higher than 700 μS should always be pre-treated, for example through reverse osmosis, even before being used for the surface treatment of metals.

However, with closed-loop systems, this problem does not arise, because such low quality mains water is used only once and then it is purified by the WWT system, which recirculates it to the plant with adequate quality, without any additional supply of fresh mains water.

CIE’s waste water treatment plants employ our patented technology PUR-ALL® Zero Zero, which guarantees 98% reduction in sulphates while eliminating the need for any evaporators in the liquid treatment circuit, with a significant decrease in energy consumption and operating costs in general.”

System operation The acid pre-treatment liquids are pipelined to the PUR-ALL® reaction tank, where the product PUR-ALL® S20 is dosed; this is a proprietary chemical of MST Chemicals, an associated company of CIE. Here, the sulphates contained in waste water are eliminated. Then, the flocculation of residues and their sedimentation take place, in the first lamellar decanter. The clear fluid leaving the first decanter is sent to the second reaction tank, i.e. the neutralisation tank, and subsequently to the second lamellar decanter.

Finally, waste water passes through a sand filter. At this point, purified water is recirculated into the pre-treatment plant, whereas sludge is pipelined to a thickener followed by a filter press, which reduces its volume before final disposal. The plant is equipped with a filter rectification unit called “polishing system”, which is activated only when there is a need for an additional purification process, if the incoming water’s parameters achieved with the PUR-ALL®

we keep an eye on your AUTOMATION needs. vertical&horizontal axis reciprocators | color centers dimensional detection systems | control panels | accessories

system alone are not optimal in terms of the required conductivity.

www.reind.it

i gent asi a libere c r e c one z per

© Aluminco

© Aluminco

General view of the WWT system installed by Aluminco.

“The PUR-ALL® Zero Zero technology is based on the salt precipitation principle. The operating costs of the WWT plant are reduced because the most expensive part is eliminated, that is, the purchase and operation of an evaporator,” indicates Antonella Monaco. “The precipitation of sulphates and fluorides obviously creates a greater volume of sludge to be disposed of, compared with a traditional plant; however, the total absence of liquid sludge due to the lack of any evaporator is a further advantage. All waste water pollution is in fact reduced to solid sludge, without any liquid sludge or concentrates to be disposed of. CIE analyses show that the running costs of a WWT system without evaporator are much lower, even considering the sludge disposal cost.

Indeed, as it is not dangerous, toxic, or harmful waste, it can be disposed of with negligible costs,

The control unit of the WWT system.

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compared with the costs of energy required to

operate an evaporator. Not to mention that an evaporator takes up a lot of

© Aluminco

FOCUS ON TECHNOLOGY

space, which is another high-priced asset nowadays. For better sludge management, moreover, our waste water treatment plant ends with a filter press that reduces its volume up to 30-40 times.”

“We are very pleased with our collaboration with CIE and with its water treatment technology, because it guarantees constant supply of high quality water to our pre-treatment plant preceding the powder coating stations,” states Aluminco chemical technician Fotis Karvelas, also managing the WWT system. “We already knew CIE as an expert in this sector and we had no doubts in choosing them. Their technical assistance before, during, and after the plant’s installation was also excellent.

We have established a continuous collaboration relationship with Antonella Monaco, which is enabling us to maintain our excellent water conductivity results over time”.

Fields of application of the PUR-ALL® technology The PUR-ALL® system is advantageous for water treatment processes in both large and small plants. It has one limit: it only applies to the treatment of acid solutions. “Companies employing a combined acid-alkaline pre-treatment operation can only use PUR-ALL® for the treatment of fluids from the acid

Aluminco chemical laboratory.

stages. This applies to both coating and anodic oxidation systems.

The purification of alkaline waste water

water in general, regardless of the

with an integration to their existing

requires the use of an evaporator or

substrate nature. This includes, for

purification plant. In this case, the

a combined osmosis + evaporator

example, stainless steel pickling and

greatest difficulty encountered was

system, always preceded by a

any processes containing phosphoric,

the limited space available. However,

physical-chemical treatment unit.”

sulphuric, or hydrofluoric acids and

we managed to take advantage of

“On the other hand, the PUR-ALL

metals, from coil coating to the

several already existing elements,

technology does not apply to

production of wheels, radiators, car

such as the reaction tanks, and

aluminium treatment plants alone,

components, and much more,” states

we only added the necessary

but to the treatment of acid waste

Falcone. “We supplied Aluminco

equipment.”

®

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49

Auto parts coated by Verniciature Bresciane.

FOCUS ON TECHNOLOGY

A Highly Automated Line Reveals the Future of Plastic Car Componentsâ&#x20AC;&#x2122; Coating Monica Fumagalli ipcmÂŽ

Many are convinced that plastic is the future of the automotive industry: one of them is the owner of Verniciature Bresciane, a contracting coating company that has been treating plastic and metal parts for the automotive, home appliance, and bathroom furnishing sectors since 1998. Indeed, it has recently prepared for any future development by equipping its paintshop with a new, highly automated line, the result of the collaboration among CMA Robotics, which supplied five robots, Wagner Italia, which developed the coating management unit in partnership with CMA, and Futura Convogliatori Aerei, which provided the floor conveyor.

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© ipcm ®

F

or years now, the automotive

intensity, as well as to the interference

been able to overcome thanks to its ability

sector has seen an exponential

of metallic materials with the new

to foresee customer needs and be ahead

increase in the use of plastic

instrumentation’s electromagnetic

of the times. This is the reason why, in

materials, which now account for

waves. All these factors are certainly

2018, we decided to raise the automation

around 25% of a vehicle. In addition

challenging for the sector’s player, but

level of our paintshop, in order to make

to reducing the weight of cars while

they also clearly suggest that plastic is

it ready for any peak in the demand for

enhancing their performance, plastic

going to be widely used in future.

the coated plastic components that will

components are used for interior

“The automotive sector will

increasingly characterise the passenger

decoration because they improve

increasingly focus on plastic

compartments of conventional and

aesthetics, reduce noise and vibrations,

materials,” argues Gianluca Ghizzardi,

electric vehicles in future.”

and increase sound insulation. With the

the founder and sales manager of

ever more widespread use of electric

Verniciature Bresciane (Castegnato,

cars, plastic is going to play an even

Brescia, Italy), a contracting coating

more important role. First of all, it will

company that has been treating

be needed to reduce their weight,

plastic and metal parts for the

Choices against the current and ahead of their time: Verniciature Bresciane’s winning strategy

which is higher due to the integration of

automotive, home appliance, and

Verniciature Bresciane and its owner

different electrical systems. Secondly, it

bathroom furnishing sectors since

stand out for their resourcefulness and

will contribute to solve some problems

1998. “Over the years, especially

desire to get things going, which are

related to electric batteries, such

at the beginning of its activity, our

actually common characteristics in the

as resistance to high temperatures,

company has encountered many

province of Brescia, an area with dense

flame, high voltage, and high current

difficulties, which, however, it has

manufacturing activity. “When I started

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51

© ipcm ®

out, in 1998,” notes Ghizzardi, “I had no knowledge of the coating field.

I worked day and night to establish myself in this sector and, more than once, I had to correct unsuitable cycles for the commissioned products, which initially were mainly corkscrews and handles for Bakelite pots. Over time, together with my employees and our suppliers, I have managed to build a complete paintshop with which we can now obtain the best results for each process stage.”

This first phase of Verniciature Bresciane’s history ended with an intuition of its owner concerning the coating department’s conveyor.

“Our plant was equipped with an overhead conveyor,” indicates Ghizzardi, “which did not met our The new plastic coating plant.

needs in terms of process speed and space optimisation.

I understood that the solution could be a floor conveyor.

Therefore, we inverted the chain:

© ipcm ®

this solved our problems while also preparing the system for the integration of robots, which could apply coatings more effectively thanks to the rotation of parts; the new structure could also handle larger sized parts.”

Already at the end of the 2000s, the company started an automation project involving the existing plastic coating system. “We installed the first robot in 2010,” states Ghizzardi. “We immediately chose CMA Robotics (Pavia di Udine, Udine, Italy) as our supplier based on their machines’ ease of use and on their ability to offer an Italian-made technology that was already applied in the automotive industry, a sector that we were beginning to penetrate and that now accounts for 40% of our A detail of the floor conveyor installed by Futura Convogliatori Aerei.

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production.”

© ipcm ®

FOCUS ON TECHNOLOGY

The programming unit of the CMA Robotics robots.

The automation of the new coating department The project of the new coating department started in 2018 and it has ended recently with the construction of a new factory in Torbole Casaglia (Brescia). The new line, composed of a dust-free, pressurised plant, will work simultaneously with that of the Castegnato plant and it will exclusively treat interior and exterior car components, such as grilles, mouldings, and spoilers.

The coating process starts in the loading area, where the workpieces are placed on the two-rail floor conveyor installed by Futura Convogliatori Aerei (Robecco Pavese, Pavia, Italy). The software package records each product’s code, so that the five stations’ robots “know” what treatment program to perform.

“Originally, we provided Verniciature Bresciane with

© ipcm ®

self-learning machines,” says CMA Robotics sales director Marco Zanor, “Then, we replaced them with point-to-point programming robots from our GR 680 series. Their off-line systems allow developing and verifying the programs executed by the robots by detecting the three-dimensional conformation of parts and arranging points on their surfaces to determine the subsequent treatment paths.”

The first CMA robots along the coating line is located in the pre-treatment area. It features the quattroClean CO2 snow

jet technology developed by German firm acp systems

AG. This uses a dry, residue-free sublimation process for cleaning in-line the components’ surface areas that need to be coated. “acp’s system,” says Ghizzardi, “is composed of a central nozzle unit, performing the CO2 emission, and two

side nozzles that carry out a first ionisation process.”

Optionally, at this point, the components can enter an IR oven to increase their surface temperature before entering the second robotic station. Depending on the type of material to be treated, this performs a flame hardening or ionisation treatment on the parts’ surfaces.

“We can change the operation by simply replacing the tool mounted on the robot,” emphasises Ghizzardi. “We select the flame hardening operation for polypropylene workpieces and ionisation for ABS. “For the following process step, the paintshop is equipped with three booths, each featuring a robotic station for the application of one-coat, two-coat (primer+base coat), and three-coat (primer+base coat+clear coat) systems, according to customer specifications. Their paint mixing and dosing units were developed by Wagner Italia in collaboration with

A robot from the GR 680 series for the pre-treatment of parts.

The coating management unit communicates with the robotic automation system

© ipcm ®

CMA Robotics.”

“Verniciature Bresciane’s project was one of Wagner’s first partnerships with a robot manufacturer,” says Simone Mori, Wagner Italia Manager in charge for this project.

“We equipped each booth with a coating management unit composed of diaphragm pumps that feed paints, catalysts, and cleaning products at a low pressure. The feeding system also includes a colour change unit from the Valve DV100 series for low pressure systems, with a diameter of 4 mm. Finally, the coating management unit features CMA gear pumps that, combined with Wagner’s WA 905 guns, guarantee total control of the application phase thanks to the installation of proportional valves for managing of atomizing air and pattern.”

“One of the main advantages of controlled dosing through gear pumps,” notes Zanor, “is that it enables versatile

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A detail of the acp systems AG’s unit.

© Wagner

© ipcm ®

The robot during the ionisation phase.

The flame hardening process on plastic parts.

Diaphragm pumps installed by Wagner Italia.

© ipcm ®

© ipcm ®

FOCUS ON TECHNOLOGY

volumetric management of the application

pastel tints, and pigmented clear coats,

process, thanks to the brushless motor

especially with the colour application booth.

integrated in the robot. Different

The system is also ready for any future

thicknesses can be set at any stage of

implementation of further paint, catalyst,

the coating program, because the gear

and cleaning agent feeding systems.”

pump exploits changes in volume and not

After passing in each of the three booths,

in pressure, thus not being affected by

the components are subjected to

viscosity and flow rate. In this way, it can

a flash-off phase, the duration of which

guarantee constant thickness of the applied

varies according to the indications on the

film.”

products’ data sheets. Final drying takes

The primer application booth is fed by 2

place in a static, forced air oven.

flow circulators for the primers, 2 for the catalysts, and 1 for the cleaning product;

Future improvements

the base coat application one has 4 flow

“Thanks to the ability to totally rotate the

circulators for coloured coatings, 3 for the

inverted conveyor’s load bars and to the

catalysts, and 2 for the cleaning product; the

storage buffers already included in the

top coat application one, finally, is fed by 2

original project,” states Ghizzardi, “we

flow circulators for the clear coats, 2 for the

also have the possibility of integrating an

catalysts, and 1 for the cleaning product.

additional UV drying oven at the end of the

“The feeding system,” adds Mori, “was

line, as an alternative or completion of the

developed by taking into consideration the

hot air one we already use. This would allow

company’s need for coating unit flexibility,

optimising the coating cycle as much as

in order to be able to use metallic products,

possible and achieving significant savings in

Gear pumps supplied by CMA Robotics.

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55

© ipcm ®

© ipcm ®

The robot in action during the application of the clear coat.

Colour application.

terms of energy consumption. Incidentally, condensing boiler with inverter pumps, which we use to heat air in the booths and in the flash-off stations. A further future investment will involve two air handling

© Verniciature Bresciane

we have already reduced this with a

units, which will enable us to switch from high solid, solvent-based to water-based coatings.

“Currently, our oven reaches a maximum temperature of 80 °C, but it is already prepared to reach a 120 °C, as I am convinced that the automotive market will increasingly see a massive use of plastic materials as a replacement for sheet metal both inside and outside cars. The project for our new coating plant was conceived in this perspective and it became a reality thanks to the skills of our suppliers, which developed the most advanced technologies to meet all our challenging requests. We can now state that Verniciature Bresciane is ready for the future of plastic coating.”

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The Verniciature Bresciane’s team.

Your lasting colours. 3/5

We care.

Paint strippers

dn-chemicals.com

© Dürr Systems AG

DXQbusiness.intelligence is part of DXQcontrol, Dürr’s control technology for controlling an entire plant’s production.

HIGHLIGHT OF THE MONTH

Keep Production on the Right Track with DXQbusiness.intelligence from Dürr Kristin Roth Dürr Systems AG, Bietigheim-Bissingen - Germany

kristin.roth@durr.com

The best way of efficiently controlling production processes in the automotive industry is through the use of relevant, up-to-date, and transparent key figures. The new business intelligence application for control technology from Dürr makes this possible. DXQbusiness. intelligence saves information optimized for reading in a separate data warehouse, visualizes it using clear dashboards, and allows the user to create custom reports. This means that manufacturers always have a close eye on the availability, performance, and quality of their plants.

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S

olutions based on business intelligence (BI) functions provide a fast overview of production, and in this way support decision-making in plants.

© Dürr Systems AG

HIGHLIGHT OF THE MONTH

They do this by collecting important information, preparing it, and displaying it in a clear format.

What makes DXQbusiness.intelligence special? The historical production data is collated from different sources, transformed, and stored optimized for reading in the data warehouse so that it can be easily accessed later for analyses and reports. The separation of the data warehouse from the customer’s operational system has the big advantage that accessing the data warehouse does not cause any delays in production, unlike conventional servers which do not store data optimized

The preconfigured Production Line Dashboard shows the OEE and the associated key figures as well as further information belonging to a production line.

for reading.

© Dürr Systems AG

All key data on the screen The data warehouse provides structures and tables for long-term orderly data storage across division boundaries.

This is because DXQbusiness.intelligence is part of DXQcontrol, Dürr’s control technology for controlling an entire plant’s production. The new application from Dürr’s Manufacturing Execution System (MES) displays the production data in a clear, easily understood dashboard.

It works in a similar way to the instrument panel in the cockpit of an airplane, which shows the pilot all key data on one screen. Transferred to car production in a plant, the dashboards show the managers mission-critical data to keep production on the right track.

Sound basis for data-driven decisions

The Production Site Dashboard provides an overview of the OEE of individual production areas.

a basis. To get the right overview, the user can navigate purposefully with DXQbusiness.intelligence: across the entire site, limited to specific production areas such as cathodic electrocoating or focused on individual lines

© Dürr Systems AG

Every decision-making process requires different data as

like the cathodic electrocoating dryer. For production, the Overall Equipment Efficiency (OEE) as well as quality and quantity data is displayed, and for individual lines within the production area additionally the temporal progressions of the above-mentioned key figures.

Adaptable to individual needs Users can also create reports and arrange them individually according to their priorities and company standards. This gives them a solid starting ground for decision-making based on the specific production.

Situations that require particular attention can be quickly monitored and tracked using custom reports.

The Production Area Dashboard shows the availability, quantity data, and quality data as well as the overall equipment efficiency within a production area like the top coat area.

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59

Š Soilmec

One of the Soilmec drilling rigs at work on site.

FOCUS ON TECHNOLOGY

A Waterborne, One-Coat Metallic Top Coat: The Revolution in Coating Large-Sized Drilling Rigs Monica Fumagalli ipcmÂŽ

Soilmec, a major international designer, producer, and distributor of ground engineering equipment, since the 1990s has been using waterborne coatings supplied by Inver, belonging to The Sherwin-Williams Company. During the lockdown due to the health emergency, the R&D laboratory of this American multinational company has developed the formulation of a new metallic water-soluble top coat to be applied in one coat.

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FOCUS ON TECHNOLOGY

R

ecalling the story of a company

technologically advanced equipment,

offering small and medium-sized

means to go back not only

but it was also among the first to apply

drilling machines from 30 to 80

over history, but also over

water-based coatings on construction

tonnes,” says. “For ten years now,

the evolution of the production

site machines’ components. “Soilmec’s

however, we have also specialised in

technologies it has used and

paintshop was among the first to use

the construction of large machines,

developed in time while growing.

waterborne paints,” says Valentino

that is, from 90 tonnes and up,

Davide Trevisani established Soilmec

Vallicelli, a sales agent of Grosscolor Srl,

whose technological and qualitative

(Cesena, Italy), a company of the Trevi

the distributor of Inver products in the

characteristics place our products at

Group, in 1969. He was already the

Forlì (Italy) area. “This firm has always

the top of our sector.”

owner of Pali Trevisani, which had

been open to innovation. Therefore,

The Cesena plant assemblies all

specialised in special foundations,

when we formulated a customised

equipment weighing more than 20

tunnel excavations, and soil

metallic coating that met the new

tonnes.

consolidation since 1957, that is, in

market needs in terms of metallic

Soilmec has another production site in

the reconstruction period after World

effects, but also able to speed up the

Asolo (Italy) where it builds microdrilling

War II. “In our company, the story

application cycle, after assessing its

equipment, which is as technologically

goes that Trevisani was not pleased

positive results they did not hesitate to

advanced as that built in Cesena, but

with the machines used on his

use it immediately.”

uses piles with a smaller diameter and weighs 3 to 20 tonnes.

construction sites and that, therefore,

“Our factory builds, on average,

explains the firm’s Product Marketing

The advanced drilling systems supplied by Soilmec

Specialist Pietro Manenti. “Given

With 90% of its production intended

are then distributed all over the

the excellent results, he created a

for foreign markets, Soilmec is one of

world, particularly in North America,

company specialising in the design

the major companies in the world for

Europe, Australia, and China, where

and construction of drilling rigs for

the construction and distribution of

the latest Soilmec product series, that

large foundations. This is how Soilmec

drilling machines, machines for large

of hydromills with a very advanced

was founded.”

diameter piles, cranes, and, since 2007,

technological level and a weight

This firm was not only a pioneer

hydromills. “Initially, our company

of at least 300 tonnes, is highly

in the creation of unprecedented,

established itself on the market by

appreciated.”

The coating booth.

© ipcm ®

150-200 systems per year, which

© ipcm ®

he decided to build them himself,”

The inside of the coating booth.

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61

© ipcm ®

© ipcm ®

Primer application.

Primed parts waiting for the top coat application.

Coating smaller equipment

our QC department or at the supplier’s

“After a manual cleaning phase with a pressure

All Soilmec machines’ components are

factory. After these initial checks, each

washer, the components are placed on

designed in-house and manufactured by

component is classified with a code and

frames withstanding weights up to 45 tonnes,”

approved suppliers, which produce the parts

allocated to a warehouse. Nothing can

indicates Soilmec paintshop manager Enzo

according to strict specifications. “When we

be left to chance, given the complexity

Camporesi. “In our department, we apply

receive these individual components from

of our machines.” Some smaller-sized

primers and top coats in five standard colours,

our different providers,” states Manenti, “if

systems that require special coatings are

that is, blue, white, grey, yellow, and red, or

they are standard products we perform a

then painted in-house. The company’s

based on customer requirements.”

simple visual check to assess compliance

paintshop includes a workpiece

“Soilmec’s objective,” says Manenti, “is to be

with our technical office’s designs. On the

preparation area and a coating booth

open to any customer need, in terms of both

other hand, if they are special parts, we do

applying waterborne primers and top

product customisation and delivery speed.

not only check compliance with specifications,

coats.

Therefore, the coating phase is crucial.

© ipcm ®

but we also have them controlled by

© ipcm ®

Products manufactured with attention to the smallest details

Testing in the area outside the production factories.

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A machine during the manual touch-up phase.

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FOCUS ON TECHNOLOGY

At the same time, it can be hindered by long

evenly, thus avoiding any spots or

INVERPUR primer. Since it has the same

operational times and inadequate quality results

defects in the surface film. “The challenge

characteristics of the top coat, no waiting

due to the large size of the workpieces. This is

was guaranteeing the applicability

time is required, as is the case with epoxy

why we turned to Inver , with which we have

characteristics of pastel hues while

primers, which call for longer curing and

been collaborating since the 1990s, to find a

meeting the need for shorter coating

flash-off times. Indeed, the top coat can be

solution to these critical issues and improve our

times on large-sized parts, such as those

applied after only a short flash-off time, with

application process of metal-effect coatings,

treated by Soilmec,” states Vallicelli.

viscosity (D4/25 °C) values of 50-70" and with

whose demand is constantly increasing.”

“The result was surprising: this

dry thicknesses not exceeding 50-60 μm. In

“During the lockdown,” notes Vallicelli, “our R&D

two-component, waterborne, metallic

Soilmec’s case, given the need for very short

laboratory did not stop and, in a few weeks,

top coat based on acrylic resins,

production times, drying occurs in the oven

it formulated a metallic top coat that can be

belonging the INVERPUR series, is able

with a temperature up to 90 °C, but it can

applied in one coat, that is, without the need for

to form a very hard and elastic film

also take place in the air at a temperature

any additional clear coat layer.”

with excellent weather resistance and

of 20 °C and with relative humidity not

gloss characteristics. Thanks to proper

exceeding 60%. The enamel is always

Characteristics of the new INVERPUR top coat

adjustment, it also guarantees optimal

over-coatable; however, after more than

applicability by favouring the uniform

24 hours of air drying or after accelerated

In the automotive sector, the metallised

distribution of metal particles.

curing in the oven, a light sanding operation

effect is obtained by applying a base coat that

“The new metallic top coat can be applied

is recommended before the subsequent

enables the suspended particles to distribute

on substrates treated with primers from

application.” After coating, the components

the IDROXINVER, INVERPUR, and IDRAYON

are taken to area devoted to the pre-

series. Soilmec uses the RAL 7035 grey

assembly of the drilling rigs.

1

1

A brand of The Sherwin-Williams Company.

Manual or fully automatic?

Dürr supplies pre-installed and perfectly matched solutions for a wide range of painting tasks – from spray guns to robot systems. www.verind.it

© ipcm ®

© ipcm ®

Some macro-components in the assembly area.

A Soilmec machine finished and ready for delivery.

The assembly of drilling machines

health emergency can be an occasion for revitalising our sector, which

Soilmec machines’ main components include hydraulic skids and

has experienced some critical historical moments, including this one

electrical boxes. “In our hydraulic equipment,” says Manenti, “the

in March 2020. The innovation implemented in our paintshop thanks

hydraulic system is crucial for powering the pump that sends the

to the support of Sherwin-Williams, as well as guaranteeing a faster

hydraulic oil to the various system parts through a diesel engine,

process and a metallic effect that meets the taste of the market, can be

in order to enable the horizontal or oscillatory movement of

a starting point for the development of new ideas to be submitted to our

the machine’s arm. In our departments, we pre-assemble the

customers internationally.”

hydraulic skids and electrical boxes that are going to be inserted © ipcm ®

into the machines during the final phase of our production process.

“Pre-assembly operations also involve two other main units that enable drilling functions: rotary tables for telescopic kelly bars, as well as the winches for the ropes that lower the excavation tools into the holes. After pre-assembling the macro-components, the machines are brought to our most recently built factory, completed in 2012 and equipped with a geothermal plant, for whose excavations our drilling machines have been used.

Here, the systems are subjected to the final assembly phase and, finally, to testing in the reserved uncovered area.”

Conclusions Soilmec believes that the events capable of subverting the world order, such as the recent ones, are always followed by equally significant reactions. “Soilmec was established to contribute to the post-World War II reconstruction,” indicates Manenti.

“In the same way, we are convinced that the global COVID-19

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From left to right: Pietro Manenti and Enzo Camporesi from Soilmec, and Mauro Tassinari and Valentino Vallicelli from Grosscolor Srl, a Sherwin-Williams General Industrial Coatings specialised distributor.

Sanitization for everyone.

The current health emergency has shown that COVID-19 can spread XLVSYKL GSRXEGX [MXL HMǺ IVIRX QEXIVMEPW [LMGL FIGSQI TSXIRXMEP WSYVGIW SJ GSRXEQMREXMSR 5IVWSREP L]KMIRI MW GIVXEMRP] XLI ǻ VWX HIJIRWI EKEMRWX MRJIGXMSR FYX IRZMVSRQIRXEP L]KMIRI MW IUYEPP] MQTSVXERX SANYFOG produces a dry fog consisting of a sanitizing solution atomized MRXS XS ƌQ HMEQIXIV TEVXMGPIW 8LIWI IREFPI XLI TVSHYGX XS VIEGL XLI IRXMVI WYVJEGI EVIEW XS FI GPIERIH [LMPI VIQEMRMRK WYWTIRHIH MR XLI EMV JSV SRP] E QMRMQYQ XMQI GSQTEVIH [MXL SXLIV EIVSWSP W]WXIQW .X MW EPWS TSWWMFPI XS MRXIKVEXI E GLMQRI] SV TMTI XS WERMXM^I Sǽ GIW [MXLSYX [IXXMRK HSGYQIRXW JYVRMXYVI computers etc.

ERMXM^EXMSR STIVEXMSRW MR MRHYWXVMEP FYMPHMRKW GER FI WGLIHYPIH ERH QEREKIH EYXSQEXMGEPP] F] GSRRIGXMRK E TIVJSVEXIH TMTI XS SRI SV QSVI SANYFOG QEGLMRIW .X MW EPWS TSWWMFPI XS HMVIGXP] WTVE] TISTPI MR FSSXLW SV MRǼ EXEFPI XYRRIPW [MXL E WTIGMǻ G GSWQIXMG TVSHYGX

OFFICES

FACTORIES www.sanyfog.com

VENUES

TOWN HALLS

BRAND-NEW

A New 3D Colour Tool Has Been Launched

by Interpon for Powder Coatings Customers

C

hoosing the right powder coating has never been

© AkzoNobel

AkzoNobel’s Interpon brand introduced a new 3D imaging technology, designed to help architects and specifiers choose exactly the right coating for their needs.

easier: AkzoNobel’s new

tool is designed to help architects and designers choose the coating that best suits their needs. The company’s in-house digital colour expertise has been fundamental for the development of this new tool and for solving some technical challenges. Interpon’s new 3D colour tool allows not only to digitally rotate the coating samples, but also to zoom in and out and view them in different environments - providing a realistic preview of what the actual finish looks like in reality.

Furthermore, 3D colour tool allows to show metallic and pearl sparkle effects, which can seem almost as striking as the coating products themselves, as well as offer an incredibly realistic sense of colour, texture, smoothness and glossiness, “As the industry leader in powder coatings, we’re always looking to improve our products and digital

Business Unit Director for AkzoNobel

“Choosing the right colour, structure

tools to help customers find the

Powder Coatings.

and shine is crucial during the powder

perfect solution”. “Our 3D tool is

“We are very excited and happy

coating selection process”, concludes

as close to the real thing as it gets

to help customers improve the

Daniela Vlad.

and is just the latest example of

accuracy and efficiency of the work

3D colour tool is available via the

how we go beyond imagination

they do and to offer the creative

AkzoNobel Design app.

and work tirelessly to develop new

freedom that allows designers,

technologies that will benefit our

architects and the industry in

For further information:

customers”, says Daniela Vlad,

general to achieve the perfect finish”.

www.akzonobel.com

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BRAND-NEW

BYK-Gardner Launches smart-chart 7.1 BYK-Gardner has launched a new version of its data analysis software smart-chart.

B

YK-Gardner has announced an

The new version has a display of red and

an automatic saving and closing process

advanced version of its data

green tolerance lines based on the product

can be defined.

analysis software smart-chart,

Samples can be organized into different

can easily indicate a quality drift so that users

groups and each group is displayed in one

data in one data analysis software and

can proactively take measures to avoid costly

colour in the graphs.

offers new functions for efficient BIG DATA

rejects.

Further analysis of measurement results

management.

It also has a new drill-in function which shows

is possible thanks to an advanced sorting

the last 20 measurements of the same

function based on all the colorimetric

The new features

model, colour and painting line.

values shown in the data table.

The measured data in smart-chart is saved

The software also has a new User

smart-chart 7.1 supports the new

in a SQL database which allows handling

Management which allows definition of

BYK-Gardner instruments wave-scan 3 for

of large data sets over time, full network

various user levels with different access

orange peel control, and spectro2profiler

and server compatibility. Data can be easily

rights.

for the analysis of structured surfaces.

shared within the supply chain by extracting

Data can be saved in projects in order to

mini databases that can be sent by email

manage the lab work. Moreover, multiple

For further information:

and combined with other databases.

projects can be opened at the same time and

www.byk-instruments.com

Š BYK-Gardner

specifications in standard management that

which combines colour and appearance

Example of a display of red and green tolerance lines.

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

67

BRAND-NEW

AFFIX Labs Launches World’s First Long-Lasting Surface Treatment to Kill the Coronavirus Si-Quat by AFFIX Labs is a versatile anti-viral surface treatment that has been scientifically proven to last for months on any surface or textile while effectively killing the COVID-19 pathogen upon contact.

A

FFIX Labs’s team, among of leading

surface coating, to be an effective surface

as door handles and counters, Si-Quat will

chemical binding experts, has

treatment against the novel coronavirus,

be effective for about a month. On rarely touched surfaces like walls, it has the potential

(WHO), the US Environmental Protection

to protect for years. Since the product is

long-lasting surface treatment proven to

Agency, the American Chemistry Council

incredibly easy to brushing or spraying apply,

kill COVID-19. Si-Quat, which has been

(ACC) and the European Chemical Agency

technicians require minimal training and only

tested at Portugal’s Biochemistry Institute

(ECHA).

basic protection.

at the University of Lisbon, combines a

Si-Quat, which was invented in January 2020

AFFIX Labs has begun to roll out the

safe and well-established disinfectant and

by the AFFIX Labs’ Repeltec development

distribution of Si-Quat across the globe, with

a proprietary chemical binding technique,

team, is based on the trusted and safe

new regions being serviced every week. It is

so that the active ingredient can kill viruses,

disinfectant quaternary ammonium.

currently looking for distribution partners in

including SARS-COV-2.

Positively charged nitrogen particles actively

local markets.

Si-Quat has been tested to kill 99.99% of

attract viruses and bacteria, penetrating the

The project leading to the development of

microbes within minutes, while still being fully

membranes and killing them within minutes.

Si-Quat included funding from the European

safe to touch. The product is non-corrosive

Rigorous testing has shown Si-Quat to

Institute of Innovation and Technology, a body

and free from silver salts and heavy metal

adhere to almost any surface. Due to its

of the European Union, under the Horizon

nanoparticles.

incredibly strong layer, the solution only

2020 Framework for Research and Innovation.

Several major agencies around the

wears down on surfaces after thousands

globe have already accepted quaternary

of touches or multiple cleaning cycles. This

For further information:

ammonium, the main ingredient in the

means that on heavily used surfaces, such

www.affixlabs.com

© AFFIX Labs

including the World Health Organization

© AFFIX Labs

harnessed its global experience

in disease prevention to create the first

Si-Quat by AFFIX Labs is a versatile anti-viral surface treatment.

68

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

Si-Quat can adhere to almost any surface.

Haas’ semi-automatic powder coating plant is able to treat workpieces up to 21 metres in length.

FOCUS ON TECHNOLOGY

Haas Strahlcenter GmbH Chose Italian Technology for the Largest Powder Coating Plant in Germany

by Parts’ Size Alessia Venturi ipcm®

70

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FOCUS ON TECHNOLOGY

S

ometimes, the most brilliant ideas and the most disruptive products arise from the clash, or encounter, between two apparently opposite mentalities that actually share the

same vision, passion, and intent – innovating, that is. In 2015, for example, the encounter between a German coating contractor, specialising in the heavy-duty treatment of large-sized metal parts intended for different industries, and a renowned Italian coating plant manufacturer led to the installation, in November 2019, of what can safely be considered the largest semi-automatic powder coating plant in Germany.

For over twenty years, Haas Strahlcenter GmbH& CO KG has been a competent, reliable, and flexible industrial coating partner for the aesthetic and conservative surface treatment of large metal parts.

Its aim has always been to adapt its range of surface treatment services to the long-term requests of its customers. That is why this German contractor has offered metal sandblasting and glass bead blasting, spray galvanising, and liquid painting services since the beginning in 1998. Very soon afterwards, the company introduced its own logistic service with owned trucks to offers its customers transportation services. In 2003, Haas Strahlcenter integrated its offer with two further processes: application of passive fire protection coatings and on-site sandblasting and coating.

However, inspired by his own ambition to become a full-service supplier, founder and current owner Peter Haas realised that he had to add powder coating to his company’s portfolio in order to achieve his goal. Therefore, he started looking for a supplier to implement his pioneering project: building a powder coating plant that could handle the same working-piece dimensions of his liquid spraying plants, while at the same time meeting the highest technical and environmental standards possible (in fact, the current system guarantees a reduction by 90% in solvent consumption

© Haas Strahlcenter GmbH& CO KG

and by 80% in energy costs). This is when the encounter took place between Haas Strahlcenter (based in Heidenheim and sited in Ulm, both located in the federal state of Baden-Württemberg) and Eurotherm (Turin, Italy), specialising in the in-house design and construction of manual and automatic liquid and powder coating systems.

The boost to innovation of Haas Strahlcenter GmbH & CO KG, a service contracting company that offers coating among other services located in Ulm (Germany), found a concrete application in the technology provided by Eurotherm, an Italian company specialising in design and installation of painting systems. This supplied the German company with a semi-automatic powder coating plant considered the largest one in Germany.

“No German plant builder was able to provide me with what I had in mind: a very large-sized coating plant able to paint workpieces up to 21 metres in length,” states Peter Haas. “Everyone offered me booths and ovens up to a maximum of 17 meters. And yet, I was convinced that a technological solution existed to meet my needs. I realised I had to turn to an Italian manufacturer, more flexible and willing to design and build something that had never been designed and built before. I got to know Eurotherm through an advertisement in a technical magazine and, as soon as I made contact with it, and especially with Joe Kaut, commercial manager of Eurotherm Lackieranlagen GmbH, I knew that I would have achieved my goal. In Eurotherm, I found a technically expert, but

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

71

© Haas Strahlcenter GmbH& CO KG

© Eurotherm Spa

From left to right: Anna Dicke from Eurotherm Commercial Department for Germany, Eurotherm Project Manager Rocco D’Aloia, Eurotherm CEO Paolo Ghiazza, Haas CEO Peter Haas and his son, Benjamin Haas.

The new plant installed by Eurotherm Spa.

of Ulm (on the border between

with us.”

Haas Strahlcenter GmbH – The magic triangle

The result is visible to anyone visiting Haas’ factory

Established in 1997 as a small

2010 and relocating its headquarters

in Ulm. In November, Eurotherm completed the

sandblasting contractor with only five

in the city of Heidenheim/Nattheim

start-up of a plant co-designed with Peter that

operators, over the last two decades

in 2014. In 2018, it acquired

handles, pre-treats, dries, powder coats, and

Haas Strahlcenter has become one of the

Sandstrahltechnik Scherschel GmbH

cures metal parts in steel and aluminium with a

major players in the coating contracting

(in Kirchheim unter Teck, near Stuttgart

length between 8 and 21 metres. This makes it

industry of southern Germany. Its first

and in the centre of the one of the

the plant with the largest coatable workpieces’

growth steps were opening a second

largest industrial areas of southern

size in Germany.

production plant in the industrial area

Germany), specialising in metal

also visionary partner willing to take risks

Baden-Württemberg and Bavaria) in

stress-relieving heat treatments and © Eurotherm Spa

subsequent automatic shot blasting and shot peening operations.

This brought the number of its production sites to three within 100 km.

Currently, Haas is equipped with 7 manual liquid coating booths for large mass-produced workpieces, 4 manual sandblasting booths, 5 automatic shot blasting systems, 1 mobile sandblasting and coating plant, different passive fire protection application systems, 1 heat treatment furnace, and 1 semi-automatic powder coating plant. The latter allows treating both large series of medium and small parts and oversized individual components, all with the same quality degree.

“Thanks to its customer-oriented The conveyor handles workpieces with weights up to 15 t.

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sales and growth strategy, Haas is

a partner in great demand by the metal industry for the sandblasting, chemical pre-treatment, and coating of oversized workpieces, as well as the heat treatment of components

© Haas Strahlcenter GmbH& CO KG

FOCUS ON TECHNOLOGY

from the first metal processing phases to final assembly,” says Haas Assistant Manager Richard Moser.

“We are a powerful, experienced company with seventy employees, combining the expertise of three different sites; their location close to highways and their use of their own means of transport also speed up collection and delivery operations to and from our end customers. All this enables our customers to rely on a single-source supplier, thus saving time, energy, and management costs.”

The sorting buffer.

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© Haas Strahlcenter GmbH& CO KG

© Haas Strahlcenter GmbH& CO KG

The rollover washing system.

Characteristics of the powder coating plant

of energy, a perfectly insulated and

The powder coating plant designed by

of guaranteeing uniform circulation

Eurotherm consists of as follows:

of hot air. The static oven supplied by

- Overhead conveyor with an automatic

Eurotherm has an indirect, forced air

trolley and a lifting station for loading

circulation heating system with a hot

and unloading the parts;

air generator featuring a combustion

- Central buffer for the sorting of

defect-free oven is required, capable

chamber in stainless steel and methane

incoming and outgoing components,

gas supply. The oven chamber

which can house up to 15 racks;

consists of self-supporting sheet metal

- One-chamber manual cleaning tunnel

panels. This structure is intended to

with a suspended, automatic rollover

support the insulation of the oven

washing system and waste water

on the outside and to house the air

recovery and filtration skids;

recirculation ducts and the combustion

- Drying/curing oven between the cleaning and coating booths; - Powder coating booth with two

chambers on the inside.

The insulation consists of modular panels in galvanised or coated sheet

manual application stations and latest

metal, arranged to form an internal

generation Gema equipment.

and an external layer not thermally

As is well known, the most difficult phase

connected to each other, so as to avoid

of a powder coating process performed

thermal bridges. On the inside, three

on such large parts is curing. In order to

layers of high-density (100 kg/m3) rock

heat parts with a significant mass and

wool panels, with a total thickness of

reach a uniform surface temperature of

150 mm, are an effective barrier to heat

180° C without consuming huge amounts

dispersion.

74

© Haas Strahlcenter GmbH& CO KG

The workpieces' entrance into the plant.

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The interior of the oven.

FOCUS ON TECHNOLOGY

Two combustion chamber burners,

shaft and with high-temperature

As for the application of powder

arranged inside the air recirculation

bearings. The oven has a vent with a

coatings, mainly polyester or hybrid,

duct, heat up the air within the oven

fume extraction system, operating at

Haas chose two latest generation

chamber. The air heated by the

the end of each cycle and complete

manual, feed-from-the-box units

combustion chambers is sucked in by

with an adjustment shutter, in order

designed by Gema. The system

recirculation fans and conveyed to the

to remove any gases that could form

is managed by a touch-screen

distribution plenum, from where it is

during heating.

Siemens PLC enabling to monitor

blown into the oven through special

Another highlight of the Eurotherm

production progress. The operators

slits; air is then recovered through the

plant is its skid for the recovery and

running the plant take on the

grills on the inner wall at the bottom

filtration of waste water, installed

orders and assign each of them

of the oven and recirculated again.

on one side of the cleaning booth. It

a coating program. It is possible

Forced air circulation with reciprocal

includes a tank for the mixing of the

to adjust parameters such as

oven chamber-combustion chamber

phosphodegreasing product with an

pre-treatment specifications, RAL

movement takes place by means of

automatic dosing pump, two mains

colours, number of racks for each

four centrifugal fans suitable for high

water tanks for the rinses preceding

order, and amount of powder to

temperatures, with a statically and

the passivation phase, two tanks

be used. The system is also able

dynamically balanced, high-efficiency

containing the multi-metal passivation

to detect any quality problems that

steel impeller. The motor is mounted

product, and an osmosis system for the

may occur during the coating cycle,

externally on a spacer lantern and

production of osmotic water necessary

so as to trace the parts concerned

equipped with a cooling fan for the

for the last rinse.

and stop delivery.

© ipcm ®

© Haas Strahlcenter GmbH& CO KG

Conclusions

One of two burners with which the curing oven is equipped.

© ipcm ®

The powder coating booth.

By starting activities in 2020 with an advanced plant, which integrates advanced, clean and digital technologies and which is probably the largest semi-automatic powder coating plant in Germany by size of the treated parts, Peter Haas has concluded the ambitious expansion program he has pursued for the past ten years. This has created a crisis-proof company, ready to face any future industrial challenge.

“For this purpose, I have relied on the typically Italian characteristics of creativity and flexibility: Eurotherm has proved an expert and reliable technological partner. I have also established a fruitful and friendly technical and cultural exchange relationship with its CEO, Paolo Ghiazza.”

76

The waste water recovery and filtration skid.

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© Saima Sicurezza

Exit Lane corridors supplied by Saima Sicurezza to Rome Fiumicino Airport.

FOCUS ON TECHNOLOGY

An Exclusive Partnership with a Coating Supplier to Guarantee the Quality of Saima’s High-Security Doors and Gates Alessia Venturi ipcm®

Saima Sicurezza (Arezzo, Italy), a company specialising in the security sector for over forty years, has formed an exclusive partnership with paint supplier Salcomix, a brand of AkzoNobel, and with coating contractor C&L Verniciatura, in order to guarantee the design and finishing quality of its high-security door and gates.

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FOCUS ON TECHNOLOGY

S

aima Sicurezza Spa (Arezzo, Italy) is

certificate. We have always paid great

“The markets we have been penetrating

one of the companies constituting the

attention to design and finishes. Indeed, we

lately have very high requirements as

Saima Holding. It has been operating

have established preferential partnerships

regards performance, durability, aesthetics,

successfully in the security sector for forty

with Salcomix, a brand of AkzoNobel, now

colour matching, and so on. Coatings have

years. Saima conceived the first automated

the almost exclusive supplier of the coatings

also undergone a profound evolution in

anti-robbery door in 1982: in fact, that door,

we choose for the finishing of our products,

the last few years. In order to keep up

named “Rotant”, revolutionised the way high-

and with C&L Verniciatura (Arezzo), for

with their new performance levels, we

security doors are built by introducing the

their application in compliance with our

need to rely on our paint manufacturer’s

principle of ‘self-management’ with automatic

specifications.”

experience, because our staff does not have the necessary expertise. We have

access control. Now, every time we cross the

The importance of coating partners for Saima

found an excellent partner in Salcomix, and

through a Saima Sicurezza interlocked door or booth, as this Italian company holds a 75%

“We have a consultative relationship

ErreEsse, with which we interface daily,

share of the sector national market.

with our suppliers. We make many new

thanks to their quick reaction times, their

However, Saima did not stop there. Over

prototypes in a year and we manufacture

very high quality products, and their large

the years, its sound, advanced solutions

industrial products with a craftmanship

and dynamic research and development

have conquered new markets thanks to

approach. Therefore, relying on the advice

organisation, able to meet our requests for

investment in R&D, an excellent distribution

of our coating provider for the selection of

colour customisation in a very short time.”

network, and focus on quality. The firm now

our finishes is extremely important,” says

“The latter factor is very important,”

produces revolving doors, tripod and full-

Marraccini. “Another strategic choice was to

indicates Saima Sicurezza COO Federico

height turnstiles, exit lane corridors, and swing

have a single technical specification, suitable

Rinaldi. “We handle a high number of tints

gates for numerous applications: airports,

to guarantee the durability of our products

and, due to the ever-more widespread

underground stations, shops, entrances

both on the European and on the Far East

choice to mix different materials and

to prestigious buildings, museums, sports

and Emirates markets: in 2007, we set a

coating techniques within the same

facilities, prisons, post offices, and much

very high quality standard that, at the same

structure (aluminium, plastic, and steel to

more. The quality of its doors and gates and

time, can be adapted to any environment,

be powder or liquid coated), we often have

of their components is the cornerstone of

corrosion category, and market.

to solve numerous colour matching issues

threshold of a bank, we are probably going

especially in its local distributor, Colorificio

Saima Sicurezza’s success: the versatility and © ipcm ®

reliability degree achieved by its products has led it to be recognised among the world leaders in the access control sector, as well as the holder of numerous patents.

“Our philosophy has always been to tackle the development of each product and project by using our state-of-art technologies and the best suppliers on the market. We believe it is the best way not to make mistakes, although this production approach requires high investments in terms of both time and resources,” states Gabriele Moretti, the sales manager of Saima Sicurezza, belonging to the second generation of the management.

“This is also true for the surface finishes of our products,” notes Saima Sicurezza purchasing manager Filippo Marraccini. “We manufacture tailor-made products, which meet any customer need through personalised, quickly made solutions. In particular, all the parts that make up our security doors have a coating

In its plant, Saima Sicurezza deals with the assembly of its high-security doors and gates and the integration of the management software package, the core of its products.

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

79

© C&L Verniciatura

© Saima Sicurezza

Installation of Thesis coating system, which has always been an important feature of Saima Meccanica in the world.

The application of the epoxy base coat supplied by Salcomix on a steel component.

among our products and the other elements

During Salcomix’s tests, the samples coated

The accuracy of the Salcomix coating

of a project. This is why we need a very fast

with the Saima system achieved a salt spray

system’s application and surface preparation

response, when we ask for customised colour

resistance value of 500 hours. The 2 mm

processes is also crucial, in order to achieve

samples. We ask our customers to approve the

cross cut adhesion test showed a rating of

the quality required by Saima. These phases

samples’ tints and, based on this, we may even

GTO (excellent adhesion) and the QUV test

are entrusted to C&L Verniciatura, a coating

decide to supply products that do not comply

for colour retention resulted in a ΔE value of

contractor that is a well-established partner

their specifications, in order to guarantee

1.09 after 500 hours of exposure.”

of this company. “We place great trust in

for simple projects and orders.”

The coating cycle specified

by Saima

© C&L Verniciatura

colour catalogue, but we use it very little, only

© C&L Verniciatura

perfect colour matching. Saima has a standard

Saima and Salcomix have developed a two-coat system including a two-component epoxy base coat (with a thickness of 40 to 50 μm) and a semi-glossy, two-component acrylic top coat with an embossed effect (with a thickness of 50 to 60 μm). There is also an alternative system intended for the finishing of plastics, which includes a polyurethane primer with a high filling power. “The epoxy base coat gives corrosion resistance properties to substrates,” explains Stefano Baglioni, the Salcomix spokesperson for Colorificio ErreEsse, “whereas the acrylic top coat has the function of protecting the epoxy base coat and guarantee colour and gloss retention over time.

80

The frame of a security door during the application of the Salcomix acrylic top coat.

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

The film thickness control performed on all the workpieces coated by C&L Verniciatura for Saima Sicurezza.

FOCUS ON TECHNOLOGY © C&L Verniciatura

Efficient and reliable solutions for surface coating since 1988.

C&L Verniciatura uses Saima Meccanica booths for the application of both liquids and powders (in this photo).

the technical advice and operational support of C&L,” states

electrostatic systems for liquid painting

Filippo Marraccini from Saima. “We provided them with our specifications, but we completely rely on their experience: our technical office cannot keep up to date with all the technical aspects inherent in the production of our doors and,

electrostatic systems and spraying booths for powder coating

therefore, we expect our suppliers to do so.”

“In order to offer an even better service to Saima, we moved our company headquarters close to their factory,” says C&L Verniciatura owner Gianni Cincinelli. “We devise the right

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

finish for every special product in partnership with Salcomix.”

Saima: forty years of success

IR and UV drying systems

Established in 1977, in 1986 the company was taken over through a leverage buyout operation by the then CEO Paolo Moretti, technical director Rinaldo Rinaldi, and financial director Paolo Scoscini.

robot and reciprocators

The new corporate team created the Saima Holding and divided the company’s business into two main branches: Saima Sicurezza, for the production of automatic high-security doors and gates, and Saima Meccanica, for manufacturing bodywork ovens and complete coating systems. Saima is now undergoing a generational handover process, a necessary but smooth step, made possible by the personal skills and the mutual esteem of the second generation management.

Saima Sicurezza and Saima Meccanica share the financial independent in terms of operations, from marketing to R&D, from production to logistics. With an average turnover

www.cmspray.it

eosmarketing.it

management department, but they are completely

CM SPRAY s.r.l.

© Saima Sicurezza

© ipcm ®

A typical security booth provided by Saima Sicurezza to the major Italian credit institutions.

The Automatic Boarding Control models at the Nanjing airport.

of 32 million Euros, of which 80% is

The COVID-19 period led Saima to

ovens and booths for the auto and motorcycle

generated on the Italian market,

expand its offer with a range of products

bodywork sector and for the industry.

Saima Sicurezza’s short-term goal is to

for access control, temperature

In order to be competitive on foreign markets,

expand of foreign markets, where

measurement, and mask recognition

where Saima Meccanica competes with

we are currently present in a

that can be installed on already existing

local companies, it has focussed on a

non-homogeneous manner thanks

sliding or swing doors. The company is

just-in-time production method, on speed,

to some important projects, like the

also thinking of integrating products with

and on flexibility. All the components of

construction of the Nanjing airport’s

online seat reservation technologies

Saima systems is made in-house and this

exit lane corridors. Saima Sicurezza is

and with personal sanitisation systems.

enables the company to create robust,

focussing on innovation by offering, for

Another very important project that it

long-lasting products, so much so that these

instance, automatic passport control and

is following in collaboration with a few

two characteristics have been its marketing

person verification systems for border

universities and research centres is the

lever for a long time.

crossing, ticket control turnstiles (a sector

development of a robot for sanitising

Saima Sicurezza is currently involved in a

in which we hold an international patent,

trains and undergrounds with UVC

tender for the installation of security turnstiles

called WELC’ON BUS), and anti-fare

lamps.

in the Paris underground.

evasion turnstiles for mobile vehicles

Contrary to the Sicurezza division,

The company cares a lot about this project.

such as buses (which we sell to both local

foreign markets account for 85% of

In order to win, it is focussing on the quality

public transport companies and OEMs

Saima Meccanica’s turnover. Saima

that has distinguished its products for forty

such as Mercedes, Man, Daf, and others).

Meccanica designs and manufactures

years.

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

DISCOVER OUR SOLUTIONS www.graco.com/ďŹ nishingproducts

© ipcm ®

The loading area of workpieces ready for the 5-stage pre-treatment.

FOCUS ON TECHNOLOGY

Giemmegi: A New, State-of-the-Art Powder Coating Booth Marta Fumagalli ipcm®

Italian coating contractor Giemmegi S.r.l.s. installed a MagicCylinder booth with dense phase powder feeding pumps AP01, a dynamic shape recognition system with a 3D scanner, a quick-colour change coating management unit OptiCenter OC07, and a control unit MagicControl 4.0, provided by Gema Europe S.r.l.

This is one of the best application technologies currently available on the market and it will help the company offer high quality finishes to any industrial sector, above all the interior furnishing one.

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provide us with what we believe is the

Treviso, Italy) is a coating contractor

best application technology currently

established in 2015 by Gianni

available on the market,” indicates Targa.

Targa, who decided to put his twenty

“Initially, I had chosen to install a system

years’ experience in the coating field to

with a Venturi injector feeding unit, but

good use by renting the paintshop of an

during construction I decided that I only

aluminium profile manufacturer. Thanks

wanted the best and therefore, with

to the perseverance and ambition of its

the help of Gema’s team, we developed

owner, and with the help of its highly skilled

a new project that included the dense

employees, in just five years Giemmegi has

phase technology and 3D scanners.

seen its turnover triple. This is why, earlier

This has enabled me to make a further

this year, it acquired a new building, moved

qualitative as well as productive leap.”

into its new headquarters, and installed a

The Euroimpianti plant is equipped

new powder coating plant. “When I decided

with a one-rail conveyor that takes the

to buy a new system, I directly relied on

workpieces from the loading station

Euroimpianti and Gema because of the

to the 5-stage pre-treatment tunnel,

experience and expertise that distinguish

including trivalent degreasing, two

them,” states Targa.

rinses with mains water, one rinse

As it mainly works for the interior

with demineralised water, and a final

furnishings sector, in which coatings’

passivation phase. This is applied through

aesthetics is crucial and powder finishing

Euroimpianti’s Nebula system, which

is an ever-more common technology,

gives aluminium surfaces up to 1,000

Giemmegi needed the best technologies

salt spray hours’ resistance thanks to its

available on the market to meet the

treatment’s uniformity. “This multi metal

requirements of its customers. It chose to

pre-treatment is also suitable for iron.

invest in a new, state-of-the-art booth with a

Overall, the system is very simple but

dense phase application unit and a 3D part

very versatile: it allows coating parts with

scanner, supplied by Gema. Despite the

a maximum size of 4.5 metres in length,

difficult relocation, which took place in an

2.20 metres in height, and 1 metre in

unprecedented historical period due to the

width,” adds Targa. After pre-treatment,

coronavirus pandemic, the company was

the parts enter a traditional drying oven

soon able to reopen and put the new plant

that prepares them for the powder

into operation, thus immediately starting

coating process in the booth.

The Gema OptiCenter OC07 powder management unit.

© ipcm ®

G

iemmegi S.r.l.s. (Pieve di Soligo,

© ipcm ®

FOCUS ON TECHNOLOGY

enjoying its benefits. “In just two months, huge difference that this technology can

Technical features of the coating booth

make also in terms of quality. We still have

Giemmegi installed a compact, cylindrical

a long way to go, since we are currently

Gema MagicCylinder booth, equipped

exploiting only a part of the booth’s

with the system Laser Scanner 3D. Its

capacity, but with time we will learn to use it

dynamic shape recognition technology

to full potential,” says Targa.

is an innovative, simple, user-friendly,

I have had the opportunity to perceive the

and high-performance solution for

Giemmegi’s choice

powder coating processes, guaranteeing

Giemmegi chose Gema for the construction

a high level of finishing quality through

of its spray paint booth because it is one of

automation. It identifies even the more

the industry’s leading suppliers. “Our goal

complex part shapes and separately

is to offer the best possible quality to our

brings each of the guns mounted on

customers and thus stand out from the vast

the reciprocators in the most correct

competition in our area. Gema was able to

position for optimal surface coating.

The gun control module.

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

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MILAN, IT

© ipcm ®

ALLIANZ TOWER

PERFECT SINERGY » ITALIAN FACADE CONSTRUCTION » AUSTRIAN SURFACE SOLUTIONS » ANODIZED EFFECT POWDER COATINGS

Parts entering the booth after pre-retouching.

“No programming is required because the scanner at the

© Southbank Place

booth’s entrance detects the three-dimensional size of the workpieces. Part recognition is performed by the laser barriers located at the entrance to the booth, whereas the dynamic shape recognition process takes place through the measurement of the object’s distance aimed at accurately calculating its contours. Such data are then sent to the control unit MagicControl CM4.0, which adjusts the guns individually according to the shape of the workpiece to be coated. With this dynamic shape recognition system developed by Gema, we can say we have every single gun in the right place at the right time,” explains Francesco Lunardon, an Area Manager of Gema Europe S.r.l.

www.tiger-coatings.com

© Gema Europe

FOCUS ON TECHNOLOGY

WHEN IT HAS TO BE

3D scanner system by Gema Europe.

The advantages of Gema’s Laser Scanner 3D technology “The advantages of Gema’s Laser Scanner 3D technology – continues Lunardon – are the followings: - Significant reduction of powder consumption and overspray

PERFECT

- Better thickness uniformity - Better penetration into cavities and edges - Higher quality of the final coating - Significant reduction of automatic guns’ adjustment actions by the operator - Significant reduction of manual touch-ups - Significant reduction of waste - Possibility to increase processing speed.

The system installed by Giemmegi is also equipped with AP01 dense

© ipcm ®

phase pumps for feeding the guns with paint. This solution guarantees

HIGH

PERFORMANCE POWDER COATINGS

The coating plant supplied by Euroimpianti.

www.tiger-coatings.com

© ipcm ®

a further significant advantage in terms of powder saving, application consistency, and penetration. Indeed, compared with traditional systems, Gema’s dense phase pumps enable to dispense a very low amount of paint while still guaranteeing the minimum thicknesses required, thanks to their high powder transfer efficiency”.

Although the initial investment is higher than that required for conventional technologies, Gema’s dense phase equipment is becoming increasingly popular and more and more companies are grasping the benefits it offers. On the other hand, maintenance costs are equal to those of Venturi systems, because servicing is performed less frequently: in fact, maintenance operations take place every 800-1,000 working hours.

“Finally, the booth features the last version of the OC07 powder

From left to right: Nilo Battistella from Gema, Giemmegi owner Gianni Targa, Francesco Lunardon from Gema, and Gema technician Andrea Benigni.

management unit, complete with a spent powder weighing unit and an © ipcm ®

ultrasonic powder filtration system. This system automatically switches between the “recovery” and “non-recovery” modes depending on the process time set by the operator, who can also freely manage the mix between fresh and recovered powder within the fluid bed. Moreover, since we change ten to twelve tints per day, I needed a booth with a quick colour change system: Gema’s machine ensures that the booth is fully clean in less than ten minutes in the powder recovery mode and in less than four minutes in the non-recovery one,” says Targa.

“Through the development of powder management units, automatic shape recognition systems such as its 3D laser scanner, and dense phase powder transfer technologies with its AP01 pumps, Gema is leading the powder coating market towards a new way of working, guaranteeing a significant improvement in terms of process automation, finish consistency, and result repeatability. Once the plant has been The Gema MagicCylinder booth.

adjusted, its qualitative advantages are manifold, including significant

© ipcm ®

savings in terms of consumption and labour. This quickly translates into a consistent economic return for coaters,” states Lunardon.

Plans and projects “Currently, my dream is to maximise the investment in this plant and get to double our turnover in a couple of years,” reveals Targa. “We are now working on a nine-hour shift, but I do not exclude the possibility to extend it to ten hours: I do not want to operate on two shifts, because this would entail a loss of both quality and control, our two main strengths.” “We were looking for the best possible technology on the market and Gema met all our requirements, proving that you do not have to be a large company to provide excellent quality,” states Gianni Targa. “Lastly, I would like to take this opportunity to thank my wife Mavy and her parents, who have always supported me; my employees, without whom I would have never achieved these results; Attilio Pinali and Massimo from Euroimpianti; from Gema, Nilo Battistella, whom I have known for thirty years, and Francesco Lunardon. Finally, I would like to emphasise the excellent collaboration relationship that I have created Luca Villanova, Production Manager of Giemmegi (on the left) with Gianni Targa.

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with Gianluigi Baroni and with the whole Gema staff, which is helping us exploit the potential of our booth at best.”

© GettyImages_terex

RAW MATERIALS

PTFE Zonyl™ Micropowders Complying to New REACH Regulation Edited by Chemours International Operation SARL Le Grand Saconnex – Switzerland

melanie.balli@chemours.com

Zonyl™ PTFE Micropowders, developed by Chemours, are used in paint and coatings formulations.

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RAW MATERIALS

P

art of the Chemours family of

- Greases: PTFE Micropowders

fluoropolymers, this product

properties, such as chemical

is a white, free-flowing

inertness and non-flammability, are

polytetrafluoroethylene (PTFE) resin

key elements for greases to obtain

used as an additive in other materials

approval to operate in environments

and systems.

where gases and other hazardous

Unlike PTFE granular and fine powders,

products are present.

Zonyl™ PTFE Micropowders have: - Smaller particle sizes ranging from 2 to 20 μm;

- Coatings: The main benefits provided

by Zonyl™ Micropowders are abrasion resistance and anti-friction properties,

- Lower molecular weight;

especially important on coatings for

- Different particle shapes and

Industrial applications.

morphology designed to easily blend with other materials.

- Paints: the addition of PTFE Micropowders helps paints have

Depending on how they are handled

easier cleanability thanks to improved

and processed, Zonyl™ Micropowders

anti-fouling properties, and present

provide non-stick properties and

easier higher spreading rate thanks to

improve lubricity, wear resistance, and

the extra lubricity provided.

reinforcing properties.

Most PTFE Micropowders are made

Zonyl™ Micropowders are primarily

through a controlled irradiation or

intended for use as additives in

thermal degradation of PTFE feedstock

mixtures with other solid or liquid

to produce a low molecular weight

materials that can:

PTFE. This irradiation process has

- Enhance abrasion resistance;

the potential to produce low levels of

- Reduce the coefficient of friction and

perfluoroalkyl carboxylic acids in the

mechanical wear;

presence of oxygen and moisture,

- Reduce surface contamination.

one of which is perfluorooctanoic acid

- Modify appearance.

(PFOA).

A wide variety of industries depend

Recently, the EU has taken measures

on PTFE Micropowders for specific

to regulate PFOA, its salts and

benefits, such as their ability to infuse

related substances in a wide range

hosts with some of PTFE’s more unique

of products under the EU REACH

properties.

program. The new regulation requires

Some applications include:

that, subject to certain exceptions,

- Thermoplastics: parts made with

as of July 4, 2020, mixtures and

the addition of Zonyl™ Micropowders,

articles placed on the market in the

like gears, benefit from improved

European Union will have to meet

wear resistance, reduced friction, and

the concentration limits set under

elimination of stick-slip behaviour.

Annex I to Regulation (EU) 2019/1021

- Elastomers: Standard elastomer

(EU Persistent Organic Pollutants

processing methods can be used

Regulation).

to incorporate PTFE Micropowders

Based on rigorous testing of

to enhance wear resistance, reduce

representative samples, Chemours™

friction and facilitate mould release.

Zonyl™ PTFE Micropowders comply

- Lithographic, flexographic, and

with Annex I to Regulation (EU)

gravure inks: Zonyl™ Micropowders

2019/1021. Currently Chemours™

give better image protection and

has multiple Micropowders offerings

higher productivity, on top of better

that contain less than 25 ppb of

slip and surface smoothness.

PFOA.

INNOVATIONS: PRESENT&FUTURE

Corrosion Inhibitors for Pickling Processes: Industrial Experiences – Part Two Davide Buggio and Ernesto Caldana Quaker Sales Europe BV, Italian branch – Tradate (Milan, Italy) davide.buggio@quakerhoughton.com

92

ernesto.caldana@quakerhoughton.com

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INNOVATIONS: PRESENT&FUTURE

owns all the technologies required for the production of coils and, therefore, it can supply products for each phase of the steel working process, including as follows: - hot rolling lubricants; - inhibitors for pickling lines; - cold rolling oils; - degreasers for annealing, galvanising, and tinning lines; - passivating and anti-fingerprint products for galvanising lines; - products for coil coating lines.

Among these steel processing operations, Quaker Houghton has paid particular attention to the pickling phase, which is essential for obtaining a high quality metal surface suitable for the subsequent production phases.

The role of corrosion inhibitors in the pickling process As is well known, during hot rolling of steel, depending on the temperature reached by the material, thermal oxides are inevitably generated (Fig. 1). These must be completely removed from the metal surface, in order not to adversely affect subsequent stages such as cold rolling, annealing, galvanising, tinning, or coating. Moreover, it is essential to prevent wear of the squeezing rollers used downstream for ending the © phonlamaiphoto_AdobeStock

After the presentation of the study carried out by Quaker Houghton to define new analytical methods to develop pickling inhibitors, published on the last issue of ipcm®1, this article lists the characteristics of these new products and their possible industrial applications.

pickling phase and for performing the cold rolling one.

Typically, a pickling process occurs on a line composed of three or four tanks, containing hydrochloric acid with different free acid concentration values and at operating temperatures between 70 and 90 °C. In such a system, corrosion inhibitors are

A

key to the success of the treatment. Indeed, large company group with great

every phase of the metal production chain,

they protect the coil against the excessive

expertise and decades of experience

from processing to surface finishing. Over

attack of the acidic environment, i.e. the

was born from the recent merger of

the years, it has developed a wide range of

so-called over-pickling phenomenon.

Quaker and Houghton. Thanks to its whole

products that guarantee high levels of quality

They also bring other benefits to the

staff, Quaker Houghton can now provide

and customer satisfaction in various sectors.

process: for example, they greatly reduce

cutting-edge technologies and services for

In the steel sector in particular, the company

the consumption of acid, increase the service life of the pickling bath, and give the

1 D. Buggio and E. Caldana, Analysis of Corrosion Inhibitors for Hydrochloric Acid Pickling Processes – Part One, in ipcm® International Paint&Coating Magazine no. 63 (maggio-giugno 2020), pages 38-42.

surfaces a uniform, glossy appearance while also preventing hydrogen embrittlement.

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

93

© Quaker Sales Europe BV

Figure 1: A diagram showing the formation of thermal oxides in a hot rolling process.

Inhibitors are mixtures of multiple

The new Quaker Houghton inhibitor series

components, including species with a

As a world leader in the steel rolling industry, this company has carried out an in-depth study

metal protection function and species that

on the type of oxides present after a hot rolling process, which has resulted in the development

facilitate the detaching of the acid from the

of a range of innovative, highly technological products aimed at improving the quality of pickled

oxide layer, which are useful for obtaining

materials.

clean surfaces. Quaker Houghton has

Representative examples of products performances are showed in Figures from 2 to 5.

embarked on a path of continuous updating and improvement of its formulations,

The following products are already used by the most important steel mills in Europe

thus obtaining high quality products for

and beyond:

all the requirements listed above. With of its NP INIBIT and QUAKER INIBIT lines, it is

Product

Description

Acid type

able to serve the producers of the most

NP INIBIT 115 C

Inhibitor with a high inhibiting power > 96%

Hydrochloric acid

varied types of steel with different price

NP INIBIT 120 TA

Inhibitor for high copper content steel

Hydrochloric acid

QUAKER INIBIT 1130

Ecological, formaldehyde-free inhibitor

Hydrochloric acid

NP NORUST 2018

Anti-stain and anti-reoxidation rinse additive

ranges, as it can find the right compromise between performance and cost without ever

© Quaker Sales Europe BV

© Quaker Sales Europe BV

neglecting the high quality of results.

Figures 2 and 3: Steel coils after pickling with NP INIBIT 120 TA: the surface is uniform, shiny, and glossy.

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© Quaker Sales Europe BV

© Quaker Sales Europe BV

INNOVATIONS: PRESENT&FUTURE

Figures 4 and 5: Steel coils after pickling with traditional product: the surface is uneven and matte.

Thanks to the significant improvements made to its products, Quaker Houghton can now reach the high-end market segment by providing formulations that comply with all the REACH requisites for the management of chemical species, while at the same time paying special attention to the safeguard of the environment and of its users’ health. In particular, it has recently developed the QUAKER INIBIT1130 line, with excellent protective capabilities combined with a low environmental impact. This allows using these inhibitors even in countries where industrial waste management regulations have been further tightened. The absence of formaldehyde also makes the mixture safer in terms of management and application.

© Quaker Sales Europe BV

© Quaker Sales Europe BV

these additives allows keeping the surface of the coil clean and shiny, particularly during any machine downtime that may expose the metal to oxidising vapours.

Conclusions Quaker Houghton, therefore, can offer a “package of products” from its NP INIBIT, QUAKER INIBIT, and NP NORUST series to guarantee excellent performance levels in the manufacturing of high quality products with a low environmental impact (Figs. 6b and 7b). It can meet any requirement to guarantee excellent product quality and high customer satisfaction: in fact, for any production process involving metallic materials, it can provide its customers not only Figure 6a: A steel coil pickled after line downtime without NP NORUST.

Figure 6b: With NP NORUST 2018.

with innovative, constantly improved products, but also with continuous technical support. Thanks to that, it can manage both systematic, routine process controls and more delicate

avoid the possible reoxidation of steel by

interventions aimed at solving any

Their surfaces are cleaned with demineralised

chlorides, especially during slowdowns

problems, as well as being able to

water in order to remove any hydrochloric

or downtimes, since, after pickling, the

always recommend the best solutions

acid residues, which could damage them.

surfaces have no substantial protection

and make the most efficient changes to

At this stage of the process, the addition of

(Figs. 6a and 7a). The barrier created by

processes.

© Quaker Sales Europe BV

NP NORUST 2018 proves very useful to

After pickling, coils are rinsed in different tanks.

© Quaker Sales Europe BV

Coil rinse additives

Figure 7a: A steel coil pickled without NP NORUST.

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Figure 7b: With NP NORUST 2018.

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

Salcomix is AkzoNobel's brand for a modularly designed industrial coatings system that can be used to provide paints for a variety of small-industry applications, quickly and flexibly. This is possible thanks to a mixing system that offers superior color accuracy with maximum product diversity.

www.akzonobel.com infosalcomix@akzonobel.com

0087–04019

www.salcomix.com

SUCCESS STORIES

Nissan Motor Company South Africa: The Successful Remote Start-Up of a New Chassis Cataphoresis Plant

© IMEL SPA

IMEL Spa (Codroipo, Udine, Italy) consolidated its position among the sector leaders with the installation of a new cataphoresis coating line for pickup chassis at the premises of NISSAN in Rosslyn (South Africa).

Nissan South Africa’s plant is ready for industrial production thanks to the remote start-up performed during lockdown.

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© IMEL SPA

SUCCESS STORIES

Longitudinal section of the cataphoresis plant.

A

fter seeing an identical plant

characteristics but also to the way it was

control of IMEL’s technical department,

designed by IMEL for NISSAN Ibérica,

completed. “The agreement signed in

also with remote vision technologies,”

the management of the Japanese

March 2019 provided for the start-up

explains Stefano Bianchin.

giant’s South African branch decided

phase to take place in April of this year.

“Our greatest pride, however, is certainly

to entrust this Italian company with the

The recent events occurred worldwide

the fact that the start-up procedure was

construction of its new line, too.

due to the COVID-19 pandemic

successfully performed a few days ago

The positive feedback of the Spanish team,

forced IMEL’s technicians to stop the

(June 2020, Ed.) completely remotely.

which recognised the high production,

construction operations earlier than

This was made possible through a VPN

design, and service quality provided by IMEL,

expected and return to Italy. This issue,

connection that enabled IMEL software

was crucial for this order’s confirmation.

however, was solved thanks to constant

technicians to carry out the first no-load

The plant includes an immersion

collaboration between contractors: in

and production tests. This resulted in the

pre-treatment section with zinc phosphates

fact, we found a local, highly trained

first rack being coated within the required

and a subsequent cataphoresis station.

assembly team, which concluded the

time, while fully achieving the expected

The parts coming from the production area

construction stages under the constant

quality results.”

are deposited on a floor roller conveyor picked up by programmed trolleys dealing with the handling operations along the

© IMEL SPA

feeding the coating system. Here, they are

immersion line. Afterwards, the cataphoresis layer is cured in a bell oven with vertical entry and exit gates: following coating, the parts are deposited by the trolleys on another roller conveyor that brings them to an elevator placed in correspondence of the oven’s entrance; the step-by-step roller conveyor takes them inside the curing chamber. At its exit, an elevator similar to the first one deposits the frames on a third roller conveyor that takes them back to the beginning of the line, in the unloading area.

IMEL general director Stefano Bianchin’s understandably proud words emphasise that this plant has represented a turning point for his company, not only due to its technical

3D rendering of the ultrafiltration module.

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

99

© IMEL SPA

SUCCESS STORIES

David Chadinha, General Manager of NISSAN SA, is extremely satisfied and concludes: “The sudden suspension of the construction site due to COVID-19 has put everyone under pressure and caused great concern about the inevitable delays that would accumulate, knowing that our vehicle project start date could not be delayed. After an initial phase of natural loss, we were able to agree with IMEL on a plan to complete the assembly with a local team and we agreed on the possibility of carrying out the critical start-up phases remotely. This was made possible using technology such as wearable glasses (RealWear HMT-1) and by connecting the PLC by EWON router for IMEL to load and commission the software, and also with a working WhatsApp group to have real-time communication. I must sincerely congratulate all the IMEL staff for the way they conducted all the operations and concentrated their efforts towards the primary objective of achieving the contractual deadlines.”

At the time this article is being published, the work is continuing with the implementation of the final details, in order to soon complete delivery and put the plant

© IMEL SPA

The remote start-up performed during lockdown.

The general layout of the cataphoresis line.

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into full operation.

A tipper body assembled by Officine Cristallo.

FOCUS ON TECHNOLOGY

Pass-Through Shot Blasting Gives High Corrosion Resistance Properties to Officine Cristallo Srl’s Large-Sized Parts Giorgia Ricchiuti ipcm®

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FOCUS ON TECHNOLOGY

Officine Cristallo lies in the fact that the company manufactures products both as contractor and with its own brand. The company’s plant includes four departments, i.e. carpentry, sandblasting, coating, and assemblage. The latter is further divided into two areas: one for the processing of aluminium and wood workpieces and the other devoted to oil hydraulic components for trucks. Over the years, the firm has specialised in the application of anti-corrosion coatings.

This expertise helped it overcome the crisis of a few years ago and it has become a crucial strength, above all on the Swiss market.

“In addition to producing our Officine Cristallo-branded truck bodywork line, we work for third-party heavy carpentry companies to whom we provide coating services.” explains Luca Cornaggia, the owner of Officine Cristallo together with his sister Monica. “When we moved from car to industrial bodyworks, we found ourselves having to invest in an adequately sized coating plant for our parts. However, we did not exploit its full production capacity.

Therefore, we decided to start offering a contracting service. © Officine Cristallo

Being located in the mountain region of Valtellina entails a disadvantage in terms of logistics,

Officine Cristallo Srl installed a pass-through shot blasting machine with a maximum capacity of 7,000 kg supplied by Tosca Srl, with the aim of treating large-sized workpieces intended for the industrial bodywork sector.

O

but an advantage in terms of

car body shop. A little later, it started

undermine our market share.

approaching the industrial bodywork

This also enables us to collaborate

sector, specialising in the assemblage

with other coating contractors,

of trucks, tippers, and hydraulic

which do not have systems capable

cranes and designing and producing

of handling large-sized workpieces

special bodyworks with cranes, aerial

or which are equipped with finishing

platforms, demountable systems

technologies complementary to

for wastes and scraps, flatbeds,

ours, such as cataphoresis and

and semi-trailers. A peculiarity of

powder coating.”

fficine Cristallo Srl (Cosio

market potential, since there are

Valtellino, Sondrio, Italy) was

no competitors with a plant

established in 1962 as a

equipment equal to ours that could

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© ipcm ® © Officine Cristallo

A bodywork produced and designed by Officine Cristallo.

“Initially, we outsourced our sandblasting operations,” says Luca Cornaggia. “However, it was very difficult to monitor quality and guarantee result consistency, which is crucial to obtain effective anti-corrosion coatings. Therefore, in 2009, I decided to make a leap in quality by installing an automatic shot blasting machine, after much research and testing to understand if mechanical surface preparation or chemical pickling was preferable.” Cornaggia turned to Tosca Srl (Canegrate - Milan, Italy), which provided Officine Cristallo with an impressive automatic shot blaster The coating plant’s ovens.

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featuring 16 fixed turbines, with a

© Officine Cristallo

© Officine Cristallo

FOCUS ON TECHNOLOGY

The sandblasting degree obtained is SA 2 ½. © Officine Cristallo

The shot blasting system supplied by Tosca Srl.

useful operating section size of length 2.6 x 2.8 m and maximum capacity of 7,000 kilos (3,500 per hoist).

“Tosca gave us a complex but easy-to-use machine that, if properly maintained, guarantees excellent surface preparation results. We achieve a sandblasting degree of SA 2 ½, and, in ten years, we have never suffered any production stoppages due to our shot blasting machine,” states Cornaggia.

A plant designed to coat large workpieces The coating line that incorporates the shot blasting system was designed to treat parts up to 7,000 kilos.

The transport line feeds the shot blaster, whose hoist picks up the parts from the paintshop’s bridge crane.

Then, the components proceed through the paintshop, equipped with a static oven with a size of 16m x 6m x 6m in height, a smaller oven with a size of 12m x 6m x 6m in height, a manual cleaning booth coating booth. The Tosca shot blasting machine, in turn, includes a ranway with 2 in-line pulleys to move items, a loading area, an entrance zone, a blasting area with

The inside of the shot blasting chamber. © Officine Cristallo

performing a phosphodegreasing process, and a

16 turbines, an exit zone and an unloading area - where pieces are also cleaned - with a recovery system of abrasive located at floor level.

Officine Cristallo generally applies three-coat systems, but it may happen that customers ask for a one-layer system for products that do not require particular outdoor resistance properties. “We offer our customers two different systems: the one that we call standard, which includes 100 microns of epoxy primer and 60-70 microns of polyurethane finish, and the higher

A tipper exiting the shot blasting machine.

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105

© ipcm ®

Small shot blasted parts.

One of Officine Cristallo’s future objectives is to establish itself more and

of intermediate layer, and a polyurethane or, more rarely, acrylic

more as a contractor. “We currently supply various carpentries, which in

finish,” explains Luca Cornaggia. “We use Wagner application

turn offer to their customers to coat their parts, thus helping us expand

technologies: mixed air pumps, airless pumps, or, for large surfaces

our production. A second project we have in mind is to definitely switch

such as containers, an electrostatic gun.”

from solvent-based to water-based products,” says Luca Cornaggia.

© ipcm ®

Future projects

inorganic according to the type of workpieces), 100-120 microns

© ipcm ®

quality one, with 60 microns of galvanising primer (organic or

A frame during the coating phase.

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Monica and Luca Cornaggia.

®

View into the spray coating machine: Automatic colour changes can be set via the system control.

INNOVATIONS: PRESENT&FUTURE

Surface Coating of Plastic Parts Focus on Timewasters Nicole Mihlan VENJAKOB Maschinenbau GmbH & Co.KG - Rheda-Wiedenbrück, Germany

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nmihlan@venjakob.de

INNOVATIONS: PRESENT&FUTURE

S

urface coating in the industrial

via a central control panel of the machine. This

production of plastic components

enables a flexible interaction of all individual

for the automotive industry, among

components. Each product receives its own

others, is an important, possibly even

recipe. Each colour can be prepared parallel to

the most important part of the entire

the running production and activated within a

production chain. A lot of money can be

very short time.

spent here, and just as much can be saved. cleaning, compliance with environmental

High availability of the machine line

regulations and constantly changing trends

Regarding the amortization of the plant

in materials and paints require technical

investment, Venjakob placed the focus in the

equipment that offers the user the required

planning of the production line presented here

flexibility and thus investment security over

on the highest possible variability in the use of

the years.

the machines used. The technical equipment

Expensive paints, time-consuming machine

was chosen accordingly. In particular, the

Overall concept with optimized individual equipment

focus was on the spray coating process.

The overall system concept for surface

production and cleaning is typical for spray

treatment, described here, serves as an

painting. Here it is determined how efficiently

example of what modern coating lines can

and profitable the plant works. The advantages

achieve. Plastic parts are painted and dried

of the modular design evident in the spray

using wet paint systems. The individual

coating machine. Important â&#x20AC;&#x153;time robbersâ&#x20AC;?,

machines - from pre-treatment to painting

such as colour changes, can be carried out

and drying - were equipped with optimized

simultaneously to production as quickly as

individual equipment and assembled to

possible with minimal transport downtime.

The division of the total production time into

form a complete finishing line. Traditional and water-based lacquers and UV lacquers

Indispensable: Machine and process data

can be used.

Information about the processes, the

1-component and 2-component solvent

productivity of the system as well as The complete system can be configured

characteristic data documenting wear and tear

with the following modules:

are indispensable for consistent production

- Cleaning modules: CO2-cleaning,

quality, logistical planning, and plant

- Activation modules: flame, plasma, UV

acquisition include:

- Coating: Spray booth

- The maintenance department is informed

maintenance. The advantages of process data

high-performance dedusting/ionization

Š Venjakob

about necessary wear and tear work by

- Drying: flash off zone, infrared dryer, UV

Future-proof painting machines are characterized by economic efficiency and a maximum of flexibility using intelligent control and digitalized communication systems. The modular concept of Venjakob also allows the individual machines to be equipped according to requirements, which can be upgraded with additional functions at any time.

curing system, circulating air dryer, cooling

means of the characteristic data before the plant must be stopped due to an accident.

zone - Fresh air supply: supply air system, full air

- The production management receives reliable data on productivity and can thus

conditioning

meet the specified targets.

- Exhaust air purification: exhaust air

- Material flows and material requirements

purification systems RTO, TI.

planning are easier within the networked

Central control panel for all machines

information, since a need is recognized early on.

All relevant system parameters are available

- The entire supply and discharge logistics can

via the internal plant communication system

be flexibly planned since the productivity is

(Ethernet) and can be preselected and set

known.

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109

Š Venjakob

Coating line for plastic components with modular design, individually adapted. Here with loading and unloading station, CO2 cleaning, high-performance dedusting/ionization, gas flaming, spray-coating, evaporation zone, IR drying, UV curing, circulating air drying.

Process steps in surface treatment

The pre-treatment of the components

Spray painting

Material handling

The upstream pre-treatment removes

The spray coating machine conveys

At the infeed of the machine, the

contamination from the workpiece surfaces

the workpieces on work piece carriers

components, which are on specific part

by means of contact-free liquid CO2.

beneath the spray guns, which are

Downstream follows a high-performance

moving crossways to the running

the pallet conveyor and later removed as

de-dusting/ionization unit with

direction. Paint is applied in a continuous

a finished component at the same place.

consumption-optimized, rotating blow-off

flow without stopping. The machine can

If a coating on the reverse side of the

nozzles. The raised particles are removed

be equipped with an automatic colour

workpieces is desired, an optional turning

by an efficient suction system. Cleaning

change system. In interaction with the

device can be installed for this purpose.

is followed by neutralization of the static

higher-level system control, the colour

The conveyor chain of the pallet conveyor

surface charge of the workpieces by means

change takes place automatically.

travels at a constant speed through

of an ionizing system. The workpieces leave

The supply lines between the system

all system components. This has been

the pre-treatment in a clean and

and the spray guns have been kept

programmed specifically for the flash off

charge-neutral condition.

short to avoid unnecessary paint losses

skids, are placed in a horizontal position on

during rinsing. The Venjakob colour

drying sections to achieve the desired cure and holding times.

The activation of the components

management system also ensures

The advantage of this pallet conveyor is that

A surface activation for better wettability by

shorter set-up times and reduced

space-saving system concepts are possible.

flame, plasma or UV could be a next step

consumption of solvents.

On the one hand, this refers to the tall dryer,

in pre-treatment. The above-mentioned

A suction system adapted to the

which uses the space in height instead

processes increase the quality of the

application, in combination with a

of expanding in length. The pallets are

haptics and optimally prepare the plastic

sophisticated fresh air supply, enables

transported in circulation, according to the

workpieces for the absorption of the coating

optimum removal of the resulting

paternoster principle.

material.

overspray. The workpieces are detected

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INNOVATIONS: PRESENT&FUTURE

on the inlet side by a workpiece scanner

and the related size (length) of the dryer

during coating all year round. The full

and the machine control system

is adapted to the painting process. There

air-conditioning can be integrated into

generates a consumption-optimised

is a cooling zone below the system. There

the supply air system at any time.

spray-painting program for each installed

the components are conveyed back to

spray gun.

the infeed of the coating line. Optimal

Exhaust air cleaning

evaporation, drying, curing, or cooling are

The purification of organic solvents

Drying process

important process steps when it comes

from the exhaust air of the entire

The subsequent flash-off zone is

to achieving a high surface quality.

system is ensured by an exhaust air purification technology from Venjakob

designed lengthwise for the painting Fresh air supply

Umwelttechnik. This is adjusted and

speed. It is also possible to integrate

The supply of fresh air is independent

designed to suit the solvent consumption

infrared drying into the flash-off zone.

of the production facility. The supply

and the exhaust air volume. Different

Furthermore, a UV curing system can be

air systems suck in air from outside,

technologies such as regenerative

added downstream, using a robot that

filter, heat, and humidify it according

thermal oxidizers and thermal

moves at right angles to the conveying

to the climatic conditions of the paint

oxidizers are used here, if necessary, in

direction. The following circulating air

systems to be processed. At some

combination with a concentration rotor.

dryer is designed for six levels and

locations and when using miscellaneous

In this way, the strict limit values of the

is easily accessible for cleaning and

lacquer systems, full air-conditioning

international air treatment guidelines,

maintenance purposes by means of

of the supply air is a prerequisite for

such as the European VOC, can be

movable dryer elements. The drying time

maintaining constant climatic conditions

complied with.

Š Venjakob

process and the related coating

Gentle and targeted: Contact-free cleaning of workpieces with CO2.

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111

Š IBIX

A QNix coating thickness gauge produced by German manufacturer Automation Dr. Nix and distributed in Italy by Tecno Supply, a division of IBIX Srl.

HIGHLIGHT OF THE MONTH

The Global Value Chain and the Importance of Measuring and Control Tools to Guarantee Product Quality Adriano Antonelli IBIX S.r.l. - TECNO SUPPLY DIVISION, Lugo di Romagna, (Ravenna) - Italy

adriano.antonelli@tecnosupply.com

Measurement and control instruments are fundamental to check that the required coating layers have actually been applied and they can therefore guarantee adequate protection to the treated products.

Automation Dr. Nix develops and manufactures its range of coating thickness gauges exclusively in Germany, in order to ensure maximum quality throughout the entire production chain.

Tecno Supply, a division of IBIX Srl, distributes its thickness gauges in Italy.

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HIGHLIGHT OF THE MONTH

L

ately, we have come to realise

therefore a decisive operation to check

the world. In addition, rubies make

that the world production chain is

that the required coating layers have

the probes and the whole instrument

very fragile. In fact, we have gone

actually been applied and that they can

durable and robust.

from a framework in which the industrial

guarantee adequate protection to the

• Three-year guarantee.

districts supporting global companies

treated products.

were geographically close enough to be

Automation Dr. Nix’s QNix coating

The company’s already wide range has

controlled, managed, and financed to a

thickness gauges are characterised as

been recently integrated with two new

system composed of vertically integrated

follows (Fig. 1):

tools: QNix 9500 and QNix 5500.

districts where components come from

• No calibration: calibration is not

After a three-year design process, the two

multiple areas of the world.

necessary (although it is possible to

of them were launched on the market

The districts’ peculiarity and

carry it out, if needed). All gauges are

with the aim of offering cutting-edge

specialisation level has led to the

supplied with a calibration certificate.

measurement tools that can

reduction of costs on the one hand

simultaneously meet different needs in

• Reliability and sturdiness: their

and, on the other hand, to the loss of

proven technology enables these

multiple segments. They stand out thanks

know-how and production management

gauges with a built-in ruby to perform

to their unprecedented sturdiness and

capacity. In general, we assumed that

millions of measurements precisely

ease of use combined with the quality,

any component could be obtained

and accurately. Rigorous quality tests

versatility, and precision that have always

quickly. However, we found out how

guarantee their universal use all over

characterised the QNix gauges.

weak and fragile the value chain actually is. Any health, financial, or economic © IBIX

crisis in a given area is enough to stop the construction of a complex machine.

In these cases, how can a company reorganise its production chain to avoid production stoppages without affecting costs? How can it regain lost skills? Is it possible to have two separate supply channels to get all the necessary components? Currently, we can only answer these questions with hypotheses.

In this article, we would like focus on a company that decided to carry out its entire production process in-house: Automation Dr. Nix develops and manufactures its range of coating thickness gauges exclusively in Germany, in order to ensure maximum quality throughout the entire production chain.

Tecno Supply, a division of IBIX Srl, distributes its thickness gauges in Italy.

Measurement and control tools are crucial pieces of equipment for any firm dealing with surface treatments. Without proper instruments, it could not assess its products’ coating quality and, above all, understand the professionalism inherent in these processes. The measurement of coating thicknesses is

Figure 1: The QNix coating thickness gauge series.

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113

© IBIX

QNix 9500, for instance, is characterised as follows (fig. 2): Safety through precise and correct measurements • High accuracy over the entire measurement range; • High repeatability of measurement results; • Thermal compensation directly in the sensor; • Precise measurements also on curved surfaces and small parts; • Simple adjustment on rough, smooth, and curved substrates.

Sturdy and durable • Fibreglass-reinforced five-part body with IP65 dust and water resistance properties; • Three-layer protection to absorb shock; • H6 chemical and scratch-resistant LCD

Figure 2: QNix 9500.

screen; • Operating temperature from -20 °C to +70 °C;

© IBIX

• Stainless steel probes with an anti-dust membrane (IP65).

Speed through ergonomics • Direct feedback through the display showing the limit values and the probe’s RGB LED; • 2.4”, 600 lm, high light intensity IPS LCD colour screen with a reading angle of 70°; • Excellent readability even under direct solar radiation. Automatic or manual brightness adjustment; • Automatic or manual screen rotation by 0°, 90°, 180°, and 270°; • Large, soft touch keys and low centre of gravity.

Flexible and extensible • Future-proof thanks to interchangeable probes; • Portable instrument for Fe, NFe, and Dual probes; Figure 3: QNix 5500.

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• Quick switch to cable probes.

© IBIX

HIGHLIGHT OF THE MONTH

User-friendly and easy to use • Easy calibration; • Portable instrument and software user-friendly interface: only three clicks are required to get a report; • One quick-access button to be customised with a chosen function; • Pre-set regulations and standards.

QNix 5500 (fig. 3), a gauge with an integrated or interchangeable probe but without any internal memory, has the following features: Safety through precise and correct measurements • High accuracy over the entire measurement range;

Figure 4: One of the main characteristics of the QNix 5500 coating thickness gauge is its excellent ergonomics.

• High repeatability of measurement results;

Sturdy and durable • Fibreglass-reinforced five-part body with IP65 dust and water

© IBIX

• Thermal compensation directly in the sensor.

resistance properties; • Three-layer protection to absorb shock; • H6 chemical and scratch-resistant LCD screen; • Stainless steel probes with an anti-dust membrane (IP65).

Speed through ergonomics • 2”, 350 cd/m2, high light intensity IPS LCD colour screen with a viewing angle of 70°; • Automatic screen rotation by 0°, 90°, 180°, and 270° (fig. 4); • Low centre of gravity and a large contact surface for precise measurements.

Flexible and extensible • Portable instrument for Fe, NFe, and Dual probes;

Figure 5: QNix 8500.

• Integrated, interchangeable, and cable probes with one © IBIX

instrument; • Greater versatility thanks to the quick probe change operation.

Automation Dr. Nix’s range includes other very sound tools.

QNix 8500 (fig. 5), for example, can be used in several different industries thanks to its technical characteristics, which are as follows: • This measuring system uses interchangeable probes and it has a measuring range up to 5000 μm; • The wireless probe allows measuring even in difficult-to-reach areas, it is easy to use and it weighs only 30 g. It is available in Fe and NFe versions and even a combination of both for measurements up to 5000 μm. The probe is recharged through the gauge and it guarantees at least 2000 readings without the need for recharging;

Figure 6: The pen probe used for small parts.

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115

© IBIX

© IBIX

Figure 7: The special cover complete with Velcro strips guarantees the protection of the instrument.

• The pen probe (fig. 6) can be used for small parts. Its

Figure 8: QNix 1500.

washers, screws, bolts, nuts, and connections. For instance, it

robustness is guaranteed by its stainless steel finish and it

ensures reliable measurements on steel bolts and nuts used

offers a measuring range up to 500 microns.

for wind power plants or bridges and on window hinges. It also

• It is possible to perform accurate measurements on small parts, non-ferromagnetic metal coatings (e.g. chrome,

measures the thickness of PVD coatings such as TiN, TiCrN, CRN and TiAlN.

copper, and zinc), paint, enamel, or copper-based coatings

• Measurement speed: up to 120 measurements per minute;

on ferromagnetic substrates. This tool’s application fields

• A large memory allows storing up to 30,000 measurements

© IBIX

are the most varied, including the measurement of angles,

Figure 9: Coating thickness gauges from the QNix 4200 and 4500 series.

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and up to 200 measurement groups;

HIGHLIGHT OF THE MONTH

• It comes complete with software for analysis and statistics. The PC software package is easy to use and it seamlessly integrates the QNix 8500 system.

It offers options such as practical documentation and data analysis and configuration; • A special cover complete with Velcro strips protects the tool (fig. 7).

Get more from water

Automation Dr. Nix’ QNix 1500 gauge (fig. 8) is the only tool for the non-destructive measurement of coating thicknesses approved by Daimler-Chrysler and Volkswagen. This leading instrument in the automotive sector, however, is also appreciated in the coating field in general. Its particular shape and the two independent Fe and NFe probes also enable to measure in difficult-to-reach areas. It is used for large surfaces and it can measure up to 5000 microns.

This instrument is handy, easy to use, and above all reliable. It switches off and on automatically. It works

Turn key solutions for industrial wastewater treatment Design and manufacturing of plants and chemicals for industrial wastewater treatment Chemical-physical plants Sludge treatment and compactor systems

with a 9-Volt battery. Calibration is not required; it is

Ion exchange demineralization systems and reverse osmosis systems

supplied with a self-calibration certificate. Its weight

Oil separators

(only 150 g, including the battery) enables the operator

Filtering systems

to appropriately carry out hundreds of measurements.

Batch type systems

The three-year guarantee granted is proof of the quality of this gauge. It can also be supplied with a QNix 1500 M memory; in this case, a USB socket will be sufficient to interface the instrument to the computer and download the QNix software package in order to

Flotation units Chemicals and spare parts for water treatment Technical service, support and maintenance of wastewater treatment plants

record and store all the measurements performed. If only ferrous substrates are treated, it is possible to opt for the cheaper QNix 1200 version.

QNix 4500 (fig. 9) deserves to be mentioned due to some of its features, which make it one of the best-selling tools in its category: • Compact instrument; • Versions: integrated and cable probe; • Measurement speed: up to 120 measurements per minute; • Measuring range: up to 5000 μm (Fe) or up to 3000 μm (NFe).

With no internal memory, this gauge is very easy to use because it turns on and off by itself and it automatically distinguishes Fe and NFe substrates. It also has a cable version that can work with a probe connected via a 1-metre cable.

Finally, QNix Handy is the only gauge in this portfolio with a measuring range from 10 μm to 10 m. With basic functions, it is proven and reliable despite its very low cost.

info@waterenergy.it

www.waterenergy.it

© APO Small Parts Coating GmbH

APO Small Parts Coating GmbH is specializing in decorative and functional coatings with modern lacquer systems.

FOCUS ON TECHNOLOGY

Growing from a Garage Operation to a Coating Specialist with State-of-the-Art Machinery Antonio Pozo APO Small Parts Coating GmbH – Alsdorf, Germany antonio.pozo@apo.ac Frank Siegel Walther Trowal GmbH & Co. KG – Haan, Germany f.siegel@walther-trowal.de

Ever since it was founded as a small parts coating specialist, APO has relied on the Rotamat coaters from Walther Trowal and today is running ten units of this machine type. From modest beginnings this proverbial garage start-up developed into a coating job shop with, worldwide, the highest number of Rotamat coaters in operation. They work so cost-efficient that APO can easily compete with suppliers from low-wage countries.

Today the company coats about one billion parts per year.

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A

© APO Small Parts Coating GmbH

FOCUS ON TECHNOLOGY

PO Small Parts Coating GmbH is located in Alsdorf (Germany) and is specializing in decorative and

functional coatings with modern lacquer systems. From its foundation in 2002, the company carefully analysed which machines for coating of mass-produced small parts were available in the market. At that time drum coating was only available as a hot process for placing a coating on metal components.

It was still unthinkable to coat plastic parts with water-based lacquers.

However, APO quickly recognized the high potential for this process and decided to invest in drum coating equipment: Shortly after it was founded, the company purchased a R90 Rotamat from Walther Trowal – a German

The new production facility is equipped with ten Rotamat coaters from Walther Trowal.

company which manufactures standard and special machines for surface treatment - which quickly became an essential part of its coating operation. With the increased utilization of

for a cleaner and safer environment along with

water-based lacquers Walther Trowal and APO

a comprehensive occupational safety program

The partnership with Walther Trowal

jointly improved the technical features of the

are proof of the importance of safety and

Today APO handles a broad spectrum of small

Rotamat units, now allowing the coating of

environmental responsibility in the company.

parts made from metal, plastic, rubber and

not only metal components but also of plastic

APO is certified per ISO 9001 and ISO 14001.

wood. This includes components for such

parts. Since then drum coating has become

Moreover, the company was awarded the

diverse industries like automotive, cosmetics,

the generally recognized standard coating

quality seal “Safety achieved with a systematic

writing utensils, toys and hardware for shoes

procedure for non-metallic materials.

approach” by the professional association

and clothing, but also sealing and dampening

Wood and Metal (BGHM).

components.

Antonio Pozo founded the APO Small Parts Coating GmbH in 2002 in Alsdorf, Germany.

The company name reflects the company philosophy. It stands for “Absolut perfekte Oberflächen” (“absolutely perfect surfaces”).

In addition, it is engaged in cleaning of

© APO Small Parts Coating GmbH

The APO history

work pieces covered with contaminants that interfere with the lacquer adhesion.

To this end APO utilizes a patented plasma technology.

The APO Small Parts Coating GmbH and the APO industrial painting GmbH, located in the same building, employ 27 highly trained people.

A quality management system, based on the planning tools APQP and FMEA, guarantees a high quality of customer consultation, production planning & control and delivery.

The consistent management of the chemicals

APO is engaged in cleaning of work pieces covered with contaminants that interfere with the lacquer adhesion.

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119

Over time, driven by its increasing business

example the coating material flow volume and

The automatic HVLP spray systems

volume APO purchased nine additional

the spray pattern – are stored in the system

generate a minimum of spray mist and

Rotamat units. Today this company, located

and automatically assigned to the respective

overspray. A sensor combined with an

in the former coal region around the city of

production orders. This ensures a high process

electropneumatic valve at the spray gun

Aachen, Germany, operates the worldwide

repeatability and stability, batch after batch.

precisely regulates volumetric flow of the

highest number of Rotamat machines in a

All data regarding the actual production status

spraying media. This ensures that the

single plant and coats more than one billion

are available in real time throughout the whole

specified quantity of coating material is

parts per year, around half with water-based

plant. They can be easily called off per tablet or

applied on the work pieces at any time.

lacquers.

smart phone from practically any location.

The result is a highly homogeneous surface

A major focus is the coating of components

The shift leaders supervise the machines and

coating, a precise coating thickness and a

– for example sealing rings – with a dry

only intervene in case of special circumstances,

long-term stability of the applied coating

coat lubrication lacquer. This reduces the

for example, when a spray gun is plugged.

material.

adhesion tendency, eliminates friction and

For new components APO conducts

Upon request the machines can be

facilitates the assembly.

free-of-charge processing trials to determine

equipped with two spraying systems.

the operational parameters like air volume, air

This is very useful, when work pieces must

Integrated into the interlinked production system

temperature, drum RPM, the amount of coating

be coated with two materials in the same

material to be applied, optimum batch size and

drum, for example with base and top coat

Today APO operates ten Rotamat coaters:

the inclination angle of the drum.

or primer and cover.

Some lacquer systems require a quick, even

Eight R 90 units (usable volume up to 50 l)

abrupt, cooling of the work pieces after the

During the entire coating process filtered and

coating process. For this reason, the new

neatly visualizing the entire process.

heated air is conducted into the rotating drum.

Rotamat units are equipped with a bypass

For pre-treatment APO uses a new,

This heats up the small parts to a temperature

for the inlet air circumventing the heating

patented low-pressure plasma system that

that is perfectly matched to the material type

unit and thus allowing the injection of

significantly reduces the costs by shorter

and geometry of the work pieces and the

ambient (cooler) air into the drum.

cycle times. This is especially true for sealing

coating material. The work piece temperature is

This generates a pronounced cooling effect

rings.

constantly monitored and, if required, the inlet

with the result that the work pieces can

All coaters are linked to the central

air temperature is adjusted. This contributes to

be discharged from the machine without

computer and completely integrated into

a strong adhesion of the lacquer on the work

sticking to each other. The overall outcome:

the company’s production control system.

piece surface and allows a quick drying cycle

A much higher yield of parts in first-class

Recipes and other process parameters – for

after completion of the coating operation.

quality.

© APO Small Parts Coating GmbH

The coating process features

to 75 l). All are controlled with touch panels

© APO Small Parts Coating GmbH

and two R 90C models (usable volume up

A detail of the APO’s paintshop.

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Visual inspection of a part after coating.

© APO Small Parts Coating GmbH

FOCUS ON TECHNOLOGY

APO coats about one billion of small parts per year.

The work pieces are coated in the closed Rotamat drum with an easily adjustable negative pressure. This prevents hazardous vapours from escaping into the environment. Each Rotamat coater is equipped with a 4-stage exhaust air system including a Papp labyrinth filter, a filter mat and two pocket filters. This permits running the Rotamat systems with a minimum of emissions.

The right investment decision The decision to purchase the Rotamat coaters turned out to be a full success. They allow handling the complete APO product range, produce

The ultimate coating solution for large parts MagicCompact® EquiFlow® XXL

high quality surface finishes, require a minimum of maintenance, even with 3-shift operation, and are extremely dependable. The first machine, installed 18 years ago, still works reliably and will continue to so.

The Rotamat exchange drum program, only offered by Walther Trowal, has also proven to be an excellent technical feature. This program offers a high flexibility for different batch sizes. In addition, very small batches – for example, for sample processing – can be run under actual production conditions.

Of course, besides quality and reliability, the operating costs of the Rotamat coaters are also an important reason for the success APO enjoys in the market: Because of their low “total costs of ownership” the coating in Rotamat systems is so economical that APO can easily compete with suppliers from low-cost countries. Comprehensive

- Color change friendly solution for the coating of big parts - Superior EquiFlow technology - Perfect coating conditions inside the booth - Flexible design concept for any customized solution - Perfect integration with 3D Dynamic Contour Detections

coating know-how, easy and fast communication with the customers and on-time deliveries allow APO to continuously enter new markets with the Rotamat coater.

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SPECIALIZED TRAINING

Innovhub, a European Centre of Excellence for the Research and Development of Innovative, Multidisciplinary Projects Monica Fumagalli ipcm®

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SPECIALIZED TRAINING

I

nnovhub, or the “Innovation Hub”, has a recent history, but it has its roots in a distant era dating back to the dawn of professional training. In fact, in 2011, it was

created to merge four experimental stations (Fuels, Oils and Greases, Paper, and Silk) created between the late nineteenth and the early decades of the twentieth century with the aim of training new professionals for medium-small businesses in the area. The experimental centre has now expanded its mission, but without losing sight of its original purpose. A few days after the start of Phase 3 of the Italian health emergency plan, ipcm®

interviewed Gianmaria Gasperini, the Head of the Oils and Greases Business Area, to discuss this evolution.

Innovhub is a multifunctional organisation with several “souls”. Could you describe them briefly?

“Innovhub is now a limited liability company wholly owned by the Milan Chamber of Commerce. It currently has about 140 employees and it is the result of a merger of four experimental centres, which took place in 2011.

Since its foundation, the primary mission of this institution has been to train the operators of each target sector.

This activity has continued over time, but it was combined with those of contracting research, now carried out in our twenty laboratories, of standardisation, and of development of projects at the national and European levels. Innovhub’s institutional tasks include, for example, contributing to the entire standardisation process of products within each area, in terms both of review and of drafting of new test methods. Finally, it is also a partner of the Enterprise Europe Network, established in 2008 at the request of the European Commission to support © Alex_AdobeStock

SMEs in technological innovation and internationalisation processes.”

What are the main characteristics of your research

Innovhub - Experimental Stations for Industry is one of the most important European research centres. Based in Milan, it has combined training activities with the research and development of projects to support manufacturing companies for over one century.

Since the end of 2014, it has hosted the training courses organised by ipcm®_Academy, in order to provide specialised training to operators from the industrial coating sector.

activities and what differentiates you from other laboratories?

“The combination of skills relating to different research fields enables us to tackle multiple subjects, from energy to food, while always ensuring a high skill level.

In particular, our area devoted to coatings specialises in the study of processes meeting companies’ production needs and of products with improved performance or application characteristics. In the last few years, we have noticed an increasing interest from the industry in the use of low environmental impact technologies and of products that are less harmful to human health. Of course, this requirement also arises from the evolution of relevant

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

123

© Innovhub

regulations. Innovhub is a qualified partner for product characterisation and performance maintenance activities after any changes in the paints’ formulations. As is evident, the projects we deal with are diversified and this is one of the aspects that most characterise our business.

“Another factor that differentiates us from other research laboratories, as well as one of our flagships, is our multidisciplinary approach, facilitated by the merger of 2011, together with the resulting horizontalisation of analytical processes, which were previously verticalised within each area. Since then, each subject is no longer tackled specifically by a single area, but rather with a cross-sectoral approach. Our multidisciplinary skills enable us to offer an integrated service that takes all production phases and aspects into consideration. This has proved crucial for some of our most important projects, such

The Innovhub headquarters in Milan (Italy).

as, for instance, the drafting of specifications for the protective product used for Corten coating of the Design Museum Holon's façade in Israel. We have carried out several other

© Dr. Avishai Teicher

projects in the infrastructure field, such as the approval of the Venice MOSE’s coating and the certification of anti-corrosion products used in railway and motorway structures.”

What role does training play in this business support activity?

“Training professionals in our experimental stations’ areas is fundamental for us, as it is one of the core missions of this institution since its foundation. We consider our partnerships with universities critical: Innovhub presents itself as a bridge between the university and industry worlds, with the aim of combining the knowledge of the former with the needs of the latter.

At the same time, we also offer training courses that can be either developed by our teams, and in some cases carried out in collaboration with trade associations, or created by third parties, such as in the case of ipcm®_Academy, the training division The façade of Design Museum Holon in Israel: Innovhub helped draft specifications for the anti-corrosion product applied.

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of EOS Mktg&Communication, with which we have been working for years to train

SPECIALIZED TRAINING

operators specialising in each phase of

What types of tests do you carry

“By our very nature, we always combine

the industrial coating process. Hosting

out in your Paints and Coatings

traditional methods of analysis with the

events such as the courses organised by

laboratory?

research and development of technologies

ipcm _Academy is a precious opportunity

“In our lab, we mainly carry out tests

for which there is still no consolidated

to get in touch with difficult-to-reach

to assess the durability of materials,

background, but which we may well present

businesses and, above all, to focus on

especially weathering resistance tests to

to interested companies, if we find they

application processes that truly reflect

understand exactly what happens when a

are effective. In this case, for example, we

the actual needs of companies. In the

workpiece is exposed outdoors. Our other

believe that the ACET method has a high

training field, we try to stand out by

main activity is performing corrosion tests,

potential in the military field, because its

emphasising the importance of the

both in conventional test chambers and

speed and quality characteristics make it

hands-on approach based on laboratory

with more innovative equipment using

very interesting for companies in this sector.

tests, compared with the traditional

different methods than salt spray, such

“In addition to the analysis of mechanical,

academic offer. Incidentally, there are

as the ACET technique, which combines

chemical, and resistance characteristics,

only a few training courses offered in

electrochemical impedance spectroscopy

which is our core activity, we also deal with

the coating industry, and therefore it is

with cathodic polarisation. During

the chemical-physical characterisation of

even more important to find partners like

ipcm®_Academy’s course, we also discuss

paints by performing the typical tests required

ipcm®_Academy.”

this innovative method.

to verify compliance with the specifications

© Corriere del Veneto

®

The bulkheads of the Venice MOSE.

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

125

© Innovhub

© Innovhub

One of the accelerated ageing test devices of the Paints and Coatings laboratory.

Q-Fog chambers for cyclic corrosion testing.

included in the products’ technical

but it can be harmful to humans. Also in the

that need to redefine the properties of their

sheets, such as VOC content. We also carry

automotive sector, there is a trend towards

products, following any changes in standards.

out a public service, as we are the Italian

the development of technologies for sanitising

Innovhub’s multidisciplinary organisation

supervisory authority for the collection of

a car’s interiors after use. The main problem

guarantees that it can take care of an entire

information on the annual production volumes

in this area is the fragility of materials, which

research project in-house, from preliminary

of decorative and bodywork products (Italian

does not enable them to withstand this form

to final stages, thus offering a complete,

Legislative Decree no. 161), which we sent to

of radiation.

“turnkey” service. Its horizontal structure

the Ministry, which, in turn, communicates it to

“Another research topic in which we

favours the creation of interesting synergies

the European Community.”

have been involved is the formulation of

between different areas, with surprising

coating products with intrinsic sanitisation

forms of contamination from which innovative

What impact has the recent health

characteristics, thanks to the presence

ideas are born – especially for current hot

emergency had on the industrial research

of additives that reduce the life time of

topics such as sustainability. This reflects the

sector?

microorganisms. Last but not least, energy

concept of competence centre with which

“The impact of the lockdown period has been

saving has been one of our laboratories’ focus

we want to characterise our institution: a

disruptive in terms of industrial production,

areas for some time now, but it appears to be

heterogeneous organisation able to deal with

especially in the sectors that we follow more

considered of even more strategic importance

the problems submitted to us from all points

closely, such as the general industry and

after the global health emergency.”

of view, from the legislative and regulatory aspects up to the application and practical

automotive ones. After the initial uncertainty, however, very interesting ideas were

What are Innovhub’s short-term projects?

ones.

born. One of the research fields for which

“Even before the stoppage due to the

“Working in the field of research is an

companies are requesting our collaboration is

virus, we were laying the foundations for

advantage, because it allows grasping

that of materials’ resistance to UVC radiation,

transforming our institution into a full-fledged

current trends, as well as pre-empting them.

which they would like to use for sanitising

centre of excellence, by integrating applied

Therefore, being able to provide companies

surfaces. This is a very delicate issue, because

research with regulatory activities in order

with a complete collaboration service is, and

UVC radiation is effective against COVID-19,

to meet all the requirements of companies

will be, one of Innovhub’s main goals.”

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ART WITHIN SURFACES

Paola Gallinatto’s Surrealism: Shaping Porcelain Through Materials and Colours Monica Fumagalli ipcm®

The artistic activity of ceramist Paola Gallinatto is the subject of the fourth interview in our Art Within Surfaces series.

P

aola Gallinatto is an internationally renowned ceramist. She opened her atelier, “L’Esclusivo” (Chivasso, Turn, Italy), in 1989, and since then,

thanks to her intense activity of creation of porcelain works of art, she has obtained numerous prestigious national and international awards. In 2009, she got the “Artisan Excellence” recognition of the Piedmont Region in the “Decoration on various artefacts” field and, in 2018, she was the winner of the prize awarded by the IPAT-International Painting Artists and Teachers President in Miami (Florida, USA).

Her works of art elicit conflicting sensations, but always with a perfect balance: Solid matter is made almost evanescent thanks to the skilful combination of colours, effects, and shades, mixed in a unique, original way. One of the works of art of this ceramist, in whom critics recognise the influence of the surrealist current started in Paris in the 1920s, fascinated the guests of the event organised by EOS Mktg&Communication for its tenth anniversary1. The artist

herself described it in detail in the interview here below.

© Paola Gallinatto

1 “#acciaio: The metamorphosis of matter in the work of Paola Gallinatto” in ipcm® International Paint&Coating Magazine no. 63 (May/June 2020), pages 36-37.

A detail of “Tieni il tempo”, awarded at the Salon International de Peinture sur Porcelaine in Lyon (France).

© Paola Gallinatto

ART WITHIN SURFACES

because porcelain is commonly

of “what is possible” higher and higher.

associated with everyday objects, such

The colours I use react differently

as ornamental plates decorated with

during firing and, sometimes, it

floral or landscape subjects. In fact, I

happens to ruin the work at the last

must confess that, when you invited me

step, so that I am forced to redo it from

to participate in your charity auction with

scratch. I am very demanding and a

a work representing the link between

perfectionist: If I do not get the result

art and industry, at first I felt inadequate

I want, I keep the piece in order to

for such an assignment. Then, however,

bear my errors in mind. I also consider

curiosity prevailed and stimulated me to

myself an eclectic artist and I like to

contribute to such an original venture

experiment in all fields of ceramic art,

with my work. Therefore, I accepted the

including sculpture, both with the plate

challenge and started working on this

and lathe techniques. I take care of my

project by analysing every aspect of

works in detail: even the supports and

the material I had chosen to represent:

the smallest elements present in my

steel. My goal was to match steel’s hard

ceramics are designed and made

appearance with the vulnerability of

by me.

this material, which can be subject to Paola Gallinatto working at her lathe.

oxidation and corrosion, but also with

Can you describe a work or

the liveliness it can covey if painted with

an artist that was a source of

bright hues.

inspiration for you and why?

I do not recall any works or artists in

Can you describe your art and your How does your creative process

particular that may have inspired my

words?

develop?

art. On the other hand, several artistic

The three words that describe my

Generally, my starting point is the

currents are a source of inspiration for

art and, at the same time, my idea of

title of each piece, from which I take

my creations, such as Impressionism

being an artist are definitely “passion”,

a cue to build a visual path. I like to

(1860s), Surrealism (1920s), and

“innovation”, and “balance”. Passion

experiment with tactile features, which

Hyperrealism (1960s), although all

drives my creativity, characterised by the

I create using sand and glass, and with

adapted to modern times.

continuous search for new decorative

shades obtained through

techniques. Innovation is the result of my

precision airbrushes,

constant research activity in the field of

nib graphic designs,

porcelain decoration. And balance is the

and iridescent “stains”.

key element that should be perceived in

One of the most difficult

all my pieces.

aspects of my job is to

I like to integrate more or less evident

understand when it is

messages in my works, in order to

time to stop, in order to

intrigue their viewers. Generally, they

guarantee balance. Each

refer to life experience with which people

technique and type of

might identify, so much so that some art

colour used on porcelain

critics have called my art “Surrealist”, and I

has different melting

actually recognise myself in this definition.

temperatures, ranging

© Paola Gallinatto

idea of being an artist in three

from 800 °C to 720 °C. What relationship exists between

Sometimes, more than

art and industry and how does it

ten firing phases are

translate into your creations?

needed before reaching

To be honest, I had never thought of a

the desired effect.

link between my art and the industrial

Experience and curiosity

world before creating “#acciaio”, perhaps

lead me to move the bar

A detail of the “Fantastico fiore” piece, awarded in Miami in 2018: A ceramic sculpture with a porcelain plate, created with mixed techniques.

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

129

STANDARD & LEGISLATION - UCIF Informs

Automotive Industry: One of the Greatest (Industrial) Victims of COVID-19 Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

A

info@ucif.net

s we wrote in the article

Will this value be offset by a growth in

The ever-increasing integration of

published in the previous

purchases, once the economy has definitively

electronics and sensors in cars has been

issue of ipcm , 2020 has

restarted? It is difficult to say, but several

a further challenge for the automotive

already entered history and it will be

elements could act as a positive boost for

industry for some years and, after 2020, it

remembered as an annus horribilis.

the sector. The first one is the ever-growing

will be even more crucial. In fact, it would

We investigated the pandemic’s impact

trend towards electric mobility, not only

enable not only to differentiate one’s own

on the economy and its different

due to private individuals’ greater sensitivity

products and gain market shares, but also

effects, in terms of both market and

towards the environment and emissions, but

to offer advanced technological tools that

society. Lockdown, reduction of work,

also to the numerous incentives allocated by

are economic at the same time (the price

and consumption contraction have

the governments for this type of technology.

changes for raw materials are certainly

®1

greater than those of

economy and, unfortunately,

mechanical components,

some sectors have been more

© CLEPA

produced effects on the general

in terms of technological

affected than others have.

obsolescence), which would

These include the automotive

result in greater profit. It

one: the investment for the

should also be noted that

purchase of a new car or for

mobility has long been

the replacement of the current

experiencing profound

one has become a non-priority

transformation: The concept

for private individuals, in a time

of private cars is switching

when health, basic necessities,

to transport service (see

and savings have taken over

the numerous car sharing

the buying behaviour of many

or carpooling services

people. On the other hand, this

available, now also applied

sector’s crisis has also started

to two-wheeled vehicles).

on the supply front, as the first

This will most likely place

lockdown led China to stop its

a different importance

industries and, therefore, to halt

on accessories related to travel comfort, compared

the processes upstream of the main world manufacturers’ production

The greater autonomy of these

with factors linked to engine performance

chains. Already in March 2020, there

vehicles and their growing presence

and car aesthetics. It is therefore not

was a drop in registrations by 85% and

(Fiat has also focussed on the electric

necessarily true that the vehicles already

the estimated global data for the first

500, even donating the first unit

produced and waiting to be sold are

semester forecast a drop by 11 million

built to Italian President Mattarella),

adequate to face these new trends. On the

units (light vehicles only), down to 77.9

which definitely result in a drop in

other hand, these prove that, in this period,

million produced cars per year.

their selling price, are factors that

automotive manufacturers (and all their

bode well, although, at least in Italy,

satellite activities) cannot avoid to rethink

the nationwide urban recharge

their businesses and invest, in order to

infrastructure is still limited.

meet the new market requests.

1 M. Zinno, “Has the pandemic changed economic dynamics?” in ipcm® International Paint&Coating Magazine no. 63 (May/June 2020), p. 152.

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MP

ZOOM ON EVENTS

FABTECH 2020: Where the Finishing Community Comes Together

T

his year more than any other, FABTECH

© CCAI

FABTECH, the largest manufacturing event in North America this year, will take place on November 18-20 2020 at the Las Vegas Convention Center in Las Vegas, NV, USA.

is the place to be on November 18-20, at the Las Vegas Convention Center in Las

Vegas, NV, USA. The finishing industry, and the manufacturing community, are eager to get back together and get back to business. FABTECH promises to be the largest manufacturing event in North America this year and is the perfect venue to meet with suppliers, see the latest finishing products and technologies, learn from industry experts and network with others. If you haven’t planned your visit to this year’s show, now is the time.

To take advantage of all that FABTECH has to offer, attendees are encouraged to supplement their show floor experience by adding conference sessions to their agenda. “A continued focus on education and training is crucially important across the FABTECH industries,” notes Anne Goyer, Chemical Coaters Association International (CCAI).

“Recognizing the challenges manufacturers face this

© CCAI

executive director of FABTECH event partner

year, I am excited to share that the FABTECH event partners made a conscious decision to support training and education initiatives by offering the lowest rates ever for this year’s conference.”

CCAI’s FINISHING conference track is not to be missed and features more than 20 sessions, encompassing a wide range of technical presentations–from basic to advanced–addressing topics of interest for everyone involved in finishing technologies. Within the 90-minute sessions, attendees will learn about advancements and new technologies that cover many aspects of the finishing industry.

For further information: www.fabtechexpo.com

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N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

FABTECH 2020

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ZOOM ON EVENTS

PaintExpo 2020 Cancelled After All 8th World’s Leading Trade Fair for Industrial Coating Technologies, which was to take place from 12 to 15 October 2020 in Karlsruhe (Germany) has been cancelled.

D

ue to the still fragile corona

government are a further significant

situation, stricter hygiene

reason for deciding against holding

and distancing regulations

PaintExpo 2020.

for trade fairs in Baden-Württemberg

“We now intend to devote all of our

and sustained restrictions on

energy to preparing the next regularly scheduled PaintExpo in order to provide

international travel, PaintExpo 2020 will be cancelled after all.

to play a central role as well. As a result,

the industry sector with the best

The next world’s leading trade fair for

face-to-face contact and travel are

possible conditions for successful trade

industrial coating technology will take

being restricted to absolutely necessary

fair participation.”

place as scheduled in 2022.

interaction. What’s more, companies

The next world’s leading trade fair for

“Together with our exhibitors and

prohibit trade fair visits in some cases and

industrial coating technology will take

partners, we had hoped to hold

international travel is still subject to strict

place at the Karlsruhe Exhibition Centre

PaintExpo 2020 in October with

limits.

from the 26th through 29th of April, 2022.

corresponding health and safety

The requirements stipulated in the planned

measures for all participants.

“Corona Regulation for Trade Fairs”

For further information:

However, the circumstances have

issued by Baden-Württemberg’s state

www.paintexpo.de

other things due to new regulations for holding trade fairs in Baden-Württemberg, so that we now have to cancel the event after all,” reports Jürgen Haußmann, managing director of event promoters FairFair GmbH. This decision was taken on the basis of a survey of all PaintExpo 2020 exhibitors, a large number of whom were also against postponing the trade fair once again.

Many companies are currently struggling with the economic impact of the corona pandemic and trade fair participation is thus not at the top of their priority list. Beyond this, health protection and preventing the spread of infection continue

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N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

© FairFair GmbH

changed in the meantime, amongst

ZOOM ON EVENTS

Powder Coating Summit to Provide the Latest in Powder Technology

T

his powerful, annual event

© PCR

Paint & Coatings Industry magazine and the Powder Coating Research Group (PCR) have teamed up to develop the Powder Coating Summit (PCS). This year’s summit will be held September 24-25 at the Hilton Columbus Polaris, in Columbus, Ohio.

includes educational, technical lectures, exhibit

hall networking, as well as on-site lab demos at the PCR laboratory.

The PC Summit provides attendees with the most up-to-date powder technology and help companies keep up with the latest trends in the formulation and application of powder coatings.

Just prior to the PCS, on September 22-23, a powder coating short course called The PC Kitchen will be held at the PCR site.

This technical, hands-on course will introduce formulators, chemists of creating a powder coating from the ground up. The PC Kitchen short

© PCR

and scientists to the fundamentals

course is held in a working powder coating laboratory, which includes practical sample making and coating evaluation. The course culminates with having the attendees formulate.

Make and test a powder coating to meet a real industry specification.

For further information: www.powdersummit.com

international PAINT&COATING magazine - JULY/AUGUST 2020 - N. 64

137

ZOOM ON EVENTS

Postponed: ALUMINIUM World Trade Fair to Be Held From 18 to 20 May 2021

T

he decision was made after numerous discussions with the industry and partners, who were all in favour of

postponing the fair. The aluminium industry as well as international supply chains have been hit hard by the pandemic and the

© Reed Exhibitions Deutschland GmbH

ALUMINIUM, the world's leading trade fair for the aluminium industry, which was to take place in Düsseldorf from 6 to 8 October, has been postponed to 18 to 20 May 2021 due to the serious consequences of the COVID-19 pandemic. The accompanying ALUMINIUM Conference will also be postponed into the next year.

lockdown.

“Together with exhibitors and partners, we had long hoped to be able to get the industry back on track for October. Unfortunately, this hope has not been fulfilled. The vast majority of exhibitors have therefore expressed the wish that ALUMINIUM should be rescheduled to next year,” says Michael Freter, Managing Director of organizer Reed Exhibitions Deutschland GmbH. “In collaboration with everyone, we have agreed that by postponing ALUMINIUM to 2021, we can offer the industry the best customer benefits and the best conditions for a successful event at that time,”

Managing Director of Gesamtverband

General of the European Aluminium industry

Michael Freter continued.

der Aluminiumindustrie e.V. (GDA), the

association: “Our main focus is currently on

With the outbreak of the Coronavirus crisis,

supporting association of ALUMINIUM.

sustainable economic measures to overcome

demand for aluminium has fallen, in some

“Our industry is currently focused on

the crisis by the EU and its member states.

cases massively. Importantly, demand from

securing business and employment.

The aluminium industry can play a key role

the main application industries such as

Our materials and products are the

in the realisation of a green European action

automotive and aviation in new orders and

solutions to the challenges of the present

plan. Therefore ALUMINIUM is important for

call-offs fell sharply and, in some cases, have

and the future. Sustainable mobility,

us - especially next year, when the situation in

come to a complete standstill, according to

energy-efficient buildings, closed loop, we

the application industries will hopefully have

the German association Gesamtverband der

offer all of this. Nevertheless, at the moment

eased again,” said Gerd Goetz.

Aluminiumindustrie e.V. (GDA).

the focus is on stabilizing the economy. May

Every two years ALUMINIUM brings together

“The decision to move ALUMINIUM to May

2021 is the right time for when ALUMINIUM

1,000 exhibitors and around 23,000 visitors

next year is, in our view, absolutely the

can provide the important impulse for

from 100 countries in Düsseldorf.

right one. The markets for aluminium have

a new start. Also and especially for our

collapsed on a broad front. I do not yet see

customers,” Baader continued. This is also

For further information:

any recovery at present,” said Marius Baader,

underlined by Dr. Gerd Goetz, Director

www.aluminium-messe.com

138

N. 64 - JULY/AUGUST 2020 - international PAINT&COATING magazine

ALUMINIUM 2021 13th World Trade Fair & Conference

More than 40,000 subscribers in 100 countries – become part of the ALUMINIUM community! Register now for the ALUMINIUM Newsletter:

SAVE THE DATE 18 – 20 May 2021 Exhibition Centre Düsseldorf, Germany www.aluminium-exhibition.com

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