ipcm® n. 49 - January/February 2018 by ipcm® International Paint&Coating Magazine

ISSN 2280-6083

The first international magazine for surface treatments

ipcm digital on Distributed at

www.myipcm.com 2018

9th Year - Bimonthly

INTERNATIONAL PAINT&COATING MAGAZINE

N° 49 - JANUARY/FEBRUARY

Collection Futura 2018-2021 Collection Futura is an inspirational range of special powder coatings for use on exterior architectural metal components, and a favorite with architects for over 20 years!

Collection Futura 2018-2021 marries the latest in global design trends with the ultimate in superdurable protection, creating a unique range of special effect powder coatings which meet the exterior weathering requirements of Qualicoat GSB, AAMA and BS.

www.interpon.com

We work with leading trend, brand-style and innovation consultants, PeclersParis, to help us forecast, create and anticipate trends in color and texture, bringing fashion to powder coatings.

27/30 Il salone di know-how della subfornitura industriale

SETTORI

rappresentati

MARZO

2 018 PA R I S - N O R D V I L L E P I N T E

CONFERENZE

strategiche

ATTIVITÃ&#x20AC;

a tema

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Caprari: Maximum Energy Efficiency and Minimum Environmental Impact for Coating Water Management Pumps With 72 Years of History © AkzoNobel

Fluoropolymer Coatings for High Capital Cost Infrastructure

FOCUS ON TECHNOLOGY

ANALYSIS

CONTENTS JANUARY/FEBRUARY 2018

38 05 10 18

FOCUS ON TECHNOLOGY

High-Quality Metal Pre-Treatment and Customised Finishes: FANTIN Furniture’s New Trademarks

EDITOR’S LETTER BRAND-NEW

BRAND-NEW

BUSINESS CARDS FOCUS ON TECHNOLOGY Metallveredelungswerk Sulz: the New Frontiers of Bulk Cataphoresis With the DELTA-eLACK® Process

HIGHLIGHT OF THE MONTH PILOT GA 9010 Marking for Sharp-Edged Markings

22 50

SUCCESS STORIES Dürr Creates Paint Shop for Electric Vehicles in China

HIGHLIGHT OF THE MONTH

Why Choose High Durability?

INNOVATIONS: PRESENT&FUTURE Active Cooling Using the Sun’s Radiation in One Energy Cycle. Investigations into the Possibility of Cooling of Solids Using Solar Radiation

CONTENTS JANUARY/FEBRUARY 2018

E-PASS Optimizes Commissioning of System Software

INNOVATIONS: PRESENT&FUTURE

No Chance For Rust

92 66

INNOVATIONS: PRESENT&FUTURE

Painting Trends in the Automotive Industry. Further Increases in Quality, Efficiency, and Flexibility for Automobile Painting

FOCUS ON TECHNOLOGY Two-coat Powder Coatings for Improved Resistance, Quality and Production Speed: the Response of Contractors to the New Market Needs

SUCCESS STORIES Automated Conveyor System for SEW Eurodrive

80 82

SUCCESS STORIES

104

STANDARD & LEGISLATION - UCIF Informs

2018 Budget Law: The “Business 4.0” Plan

BRAND-NEW

108 TRADE FAIRS & CONFERENCES

FOCUS ON TECHNOLOGY The Key Role of Sheet Metal Preparation in the Manufacture of Coating Systems and Outdoor Structures

100 ANALYSIS How Long Should You Run an Accelerated Weathering/ Corrosion Test?

110

ZOOM ON EVENTS

4 - 6 .12 . 2 018

Guangzhou

A FAST LANE TO CHINA & ASIAN FINISHING MARKETS

Halls 4.1 & 5.1, Area A, Canton Fair Complex

Statistics on SFCHINA2017, Shanghai

Comprising 3 Exhibit Zones Electroplating & Finishing Technology

Coating Applications & Coating Products

Environmental, Safety & Protection

EXHIBITOR No. of Companies Represented No. of New Exhibitors Regions / Countries Represented

Co-Located Show

w w w. s f c h i n a . n e t (852) 2865 0062

SHENZHEN

Hong Kong & Taiwan Regions

Domestic China

Total

89 19 -

25 6 -

224 60 -

338 85 20

VISITOR

9,941 1,156

Total No. of Domestic China Visitors Total No. of Overseas Visitors (Including Hong Kong & Taiwan Regions) Total No. of Visitors Follow Us

HONG KONG

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(86 755) 6138 8100

SHANGHAI

Sinostar-ITE

(86 21) 6150 4989 / 5877 7680

SFChinaShow info@sinostar-intl.com.hk

11,097

SFChinaShow

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

inding the extraordinary in the ordinary. Sometimes, this means to invent. To tune to a more subtle wave frequency in order to innovate where it seems that everything has already been invented. And to be able to see new potentialities in the common reality. For example, the sun can be exploited as a cooling source thanks to the invention of a new two-layer coating system that filters a part of the sun’s rays and converts heat into light, cooling below room temperature. It is as if the paint turned into a thin layer of ice that becomes thicker and thicker as the sun gets stronger. This is the topic of one of the articles that inaugurates the new editorial year of ipcm®. The January issue of a magazine reflects what is coming next, the mood of the market after the Christmas break, and even the laziness of the first weeks of a the new year, when there are twelve months of discoveries before us and it seems impossible to plan them all. Starting the new year with an issue full of brilliant articles is the best way to take stock of the year just ended. When the ipcm® project was born, one of our main goals was to offer knowledge and experience with a new perspective to our partners and readers all over the world. Nine years later, thanks to a long but constant growth that brought us to every corner of the world to show the highest achievements of the coating and surface treatment industry, we are pleased to say that we have made it. In this issue, we will continue to deal with both conventional and nanotechnology pre-treatment processes and their key role in surface treatment cycles in order to ensure quality, presenting two case studies about companies that have focussed precisely on pre-treatment to achieve success with their products. Again focussing on quality, we will also deal with corrosion protection: super durable coatings, new raw materials for anti-corrosion paints based on zinc powder, fluoropolymer coatings for high-value infrastructure. Finally, we will present the successful case of an Italian company, a world leader in the integrated water resources management field that maximised the energy, production and environmental efficiency of its finishing processes thanks to the design skills and expertise of a coating plant engineering firm and to a high automation level reached following 4.0 principles. Innovation in the ordinary to achieve the extraordinary. Globally connected, globally read. 45k visits/month, 23 pages per visit and 28 minutes average on www.myipcm.com.

Alessia Venturi Editor-in-chief Direttore Responsabile

The highest readership engagement of any sector magazine. Coloured in orange all the countries with active readership of ipcm® magazines.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

Opening photo: The National Australia Bank Headquarters is one of the first major projects undertaken in Australia using fluoropolymer coatings.

ANALYSIS

Fluoropolymer Coatings for High Capital Cost Infrastructure Ben Gillies Architectural and Industrial Coatings – Moss Vale, Australia

ben.g@aicoatings.com

&I Coatings have been formulating

A Brief Overview

The alternating copolymer structure gives

and manufacturing fluoropolymer

The world’s first solvent soluble fluoropolymer

excellent durability and chemical resistance,

coatings in Australia since the

for coating was developed almost 40 years

making fluoropolymer the coating of choice

year 2000. Fluoropolymer coatings are

ago, and the same chemistry remains at

for a wide range of applications. The energy

fast gaining greater recognition as the

the forefront of protective coating technology

of the alternative main chain bond between

coating solution for high capital cost

today due to the extremely durable

fluoroethylene and vinyl ether is higher than

infrastructure including towers, bridges,

natureof fluoropolymer coatings.

the maximum UV energy of sunlight, and so in

airports, roadside barriers, resource

Chemically a fluoropolymer coating is a

principal, it does not degrade. In contrast, other

infrastructure and marine and shipping

fluoroethylene-vinyl ether alternating

coatings such as polyurethane break down and

applications.

copolymer.

deteriorate due to their low bond energy.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

ANALYSIS

Figure 1: Each fluoro ethylene molecule has 3 fluorine atoms as opposed to two in PVDF or PVF2 coatings.

What is Fluoropolymer Technology?

Fluoropolymer Performance

The polymeric structure of a Fluoropolymer

retention in comparison to Polyurethane and

is a very systematic arrangement of

Polysiloxane.

fluoro-ethylene and vinylether molecules.

The testing details and regime are as follows:

The Figure 1 demonstrates the

Type 1 lamps (UVB-313) and the cycle is 8

The Figures 3 and 4 show the gloss

arrangement, and also shows that each fluoro ethylene molecule has 3 fluorine atoms as opposed to two in PVDF or PVF2 coatings.

Why is Fluoropolymer so durable? 1.

The fluoroethylene molecule derives terrific integral strength from its high frequency of fluorine atoms

The carbon-fluoride bond energy in fluoroethylene molecules is far

Fluoropolymer coatings are fast gaining greater recognition as the coating solution for high capital cost infrastructure including towers, bridges, airports, roadside barriers, resource infrastructure and marine and shipping applications.”

greater than the energy of UV rays 3.

A fluoropolymer coating is a fluoroethylene-vinyl ether alternating copolymer. The alternating copolymer structure gives excellent durability and chemical resistance, making fluoropolymer the coating of choice for a wide range of applications. The energy of the alternative main chain bond between fluoroethylene and vinyl ether is higher than the maximum UV energy of sunlight, and so in principal, it does not degrade.” Case Studies One of the first major projects undertaken in Australia using fluoropolymer coatings was the compressed fibre cement cladding used on the National Australia Bank Headquarters. The panels were

The fluoroethylene and vinyl ether

installed in 2003 (ref. Opening photo).

units are arranged in an alternating

hours UV at 60 degrees C followed by 4 hours

In this instance the fluoropolymer coating

sequence – this means that the

Condensation at 50 degrees C.

was spray applied to the compressed

strong and stable fluoroethylene

The Figure 5 shows the coating samples which

fibre cement using an automated spray

unit protects its neighbouring vinyl

were used to arrive at the two graphs above.

machine. The panels were prefinished

ether unit – just like the father

This photo displays the appearance of the test

before being delivered to site.

protecting his son below (Fig. 2).

panels after 2700 hours exposure.

The Commonwealth Science and

Industrial Research Organisation (CSIRO) reported on the colour retention of the all colours in October 2013. The Table 1 is an excerpt from the report. The coating was assessed in accordance with AS 1580 Methods 481.1 – 12 “Paints and related coatings _ Methods of test coatings - Exposed to weathering’ for the properties detailed in Table 1. In general

2 1

the rating ranges from 0 to 5 with 0 being

Figure 2: The fluoroethylene and vinyl ether units are arranged in an alternating sequence just like the father protecting his son below.

no change in the property with 5 being the maximum change in the property.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

Table 1: lnspection of Vitreflon after 10 Years Exposure.

ASl580 Method Properties

Vitreflon Colour Blue Violet Regatta Bay Bright Red

481.1.2

Discolouration

481.1.3

Dirt collection

481.1.4

Dirt retention

481.1.5

Gloss change

481.1.6B

Erosion 1

481.1.7

Degree of checking

481.1.8

Degree of cracking

481.1.9

Degree of blistering

481.1.10

Degree of flaking

481.1.11

Degree of chalking

481.1.12

Colour change

0/1

481.1.13

Fungal growth

One of the first major projects undertaken in Australia using fluoropolymer coatings was the compressed fibre cement cladding used on the National Australia Bank Headquarters. The panels were installed in 2003. In this instance the fluoropolymer coating was spray applied to the compressed fibre cement using an automated spray machine. The panels were prefinished before being delivered to site.”

Pricing of fluoropolymer coatings

The graph in Figure 6 displays the lifetime

coatings can be applied in a range of

Wet spray fluoropolymer coatings are often

cost advantage of a fluoropolymer coating.

weather conditions. General guidelines to

portrayed as unaffordable technology and

After just 12 years fluoropolymer coatings

go by state that Fluoropolymer coatings

only justifiable for extreme environments.

will begin to save the asset owner money.

can be applied in temperatures from 10 –

This is actually not the case. In recent years

45°C and up to 80% relative humidity.

affordable and will save the asset owner a

Performance in a range of environments

Chemical Resistance

lot of money through greatly lengthening

Fluoropolymer coatings typically perform

Fluoropolymer coatings in the Asia

the time to first maintenance. To provide an

well in a wide range of environments

Pacific are used mainly for architectural

approximate cost comparison for the Asia

and are not affected by fluctuations in

applications where chemical resistance

Pacific region, fluoropolymer coatings are

temperature or humidity. In the Asia

and/or abrasion resistance is not the

approximately 2-3 times the price of a good

Pacific market, Fluoropolymer coatings are

first priority. However, high solids

quality polyurethane and are mostly lower or

being used in Hobart – the southernmost

fluoropolymers are beginning to gain

equivalent in cost to a good quality acrylic/

tip of Australia which can get very cold

recognition in the market place for

epoxy polysiloxane.

and harsh weather conditions, through

their superior chemical resistance.

While the upfront cost of a fluoropolymer

to Townsville, Cairns and Darwin which

In Figure 7 there are three coating

coating is sometimes seen as prohibitive, the

all experience very hot and humid

technologies which were subjected

savings from reduced maintenance over the

weather and also experience monsoonal

Hydrochloric Acid 30% immersion for a

lifetime of the coating are enormous.

conditions. In addition fluoropolymer

period of 96 hours.

fluoropolymer coatings have become very

3 1

4 1

Figure 3: Gloss Retention - Accelerated weathering test.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

Figure 4: Colour Retention - Accelerated weathering test.

Results: High Solids

ANALYSIS

Applications for fluoropolymer

Fluoropolymer:

coatings:

• Minor Discolouration

• Bridges

• No loss of Film

• Noise walls

Integrity

• Airports • High-rise buildings

Polyurethane:

• Railway Stations

• Major discolouration

• Resource

• Blistering • Film softening High Solids Epoxy: • Major discolouration

Infrastructure

5 1

• Sculptures • Yachts

Figure 5: The appearance of the test panels after 2700 hours exposure.

marine applications © AGC

• Film softening

• Shipping and other

In summation,

Fluoropolymer

Coatings are not used

coatings

a lot in the chemical

are rapidly

and process industries

becoming

in India currently or

the coating of choice for

throughout the world. The overriding reason these products are not used extensively is due to the initial

almost any

6 1

Figure 6: The lifetime cost advantage of a fluoropolymer coating.

cost when compared

structure where long term asset protection is important.

Fluoropolymer coatings will keep the structure

the chemical and process industry market is currently a

looking better for longer and will provide

major growth area for fluoropolymers as asset owners

substantial savings through allowing a greater

are beginning to capitalise on the major cost savings

period of time to first maintenance and

achieved through reduced maintenance.

between maintenance cycles thereafter.

to standard polyurethane or epoxy coatings. However

7 1

Figure 7: Three coating technologies which were subjected Hydrochloric Acid 30% immersion for a period of 96 hours.

BRAND-NEW

Dürr Becomes Core Supplier of Groupe PSA

new final assembly shop at Sevel Nord in

the world was valued as a key competence.

the Dürr Group to become one of their

France, or the new paint shop in Kenitra,

Together with less than ten others, Dürr

major suppliers in their global network.

Morocco. PSA particularly appreciated the

is now PSA’s core supplier for capital

The core supplier status was announced

variety of skills and assets boasted by Dürr

expenditures, such as plants and machinery.

during a management meeting between the

and the cooperation in the mentioned

“We are happy about the new status as core

two companies at Dürr’s headquarters in

projects which were – although still on-

supplier, and both the appreciation and

Bietigheim-Bissingen (Fig. 1).

going – part of the motivation to Dürr’s

the challenge for our future cooperation

With its brands Peugeot, Citroën and DS

appointment as a core supplier. Another

that comes along with it”, says Dr. Jochen

Automobiles, and also with its newly gained

one was Dürr’s permanent innovation

Weyrauch, Member of the Board of

daughters Opel in Germany and Vauxhall in

effort for the improvement of products and

Management of Dürr AG. Bernhard Schmitt,

Great Britain, Groupe PSA has been one of

processes such as the new 7-axis robot or

Managing Director of Dürr in France, also

the major customers of Dürr for more than 20

the development of overspray-free paint

sees positive signs for future collaboration:

years. Dürr implemented numerous projects

application to achieve a more efficient and

“This is a great motivation for the whole

for the Groupe PSA, among them innovative

smart production throughout the plant.

Dürr team to intensify our partnership with

solutions like the integration of Dürr’s energy

Furthermore, the company’s healthy and

Groupe PSA and to get started with our next

efficient EcoDryScrubber dry separation system

stable financial situation was regarded as

projects”.

at the Sochaux plant in Eastern France. During

a main factor for the reliable long-term

the meeting in Bietigheim current projects

partnership. Last but not least, Dürr’s global

For further information:

of PSA and Dürr were discussed, e.g. the

expertise in safely executing projects all over

www.durr.com

he international Groupe PSA has chosen

Figure 1: The Dürr Group has become one of the major suppliers of Groupe PSA in their global network.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

BRAND-NEW

Arts Centre Enriched with Lumiflon Bridges Gap Between Traditional and Modern Architecture

he National Centre for the Performing Arts of

the building emphasizes, creating an extraordinary

China (Fig. 1) is an artfully-crafted masterpiece

theatregoing experience for visitors. The National

that sits in the heart of Beijing, next to the

Grand Theater’s eye-catching exterior was fitted

Great Hall of the People and close to Tiananmen

with approximately 462,848 square-feet of © anotherchinablog.wordpress.com

Square. Designed by French architect Paul Andreu, the $400 million art complex’s architectural design was meant to stand

ALPOLIC’s titanium composite material (TCM) in a natural metal finish. Each recyclable, lightweight panel

as a tribute to China’s

contains a Lumiflon

traditional

topcoat, which offers

image of heaven and

the structure as a

earth. The stunning structure, which features a curved shell that is comprised of titanium

whole a plethora of

benefits.

Figure 1: The National Centre for the Performing Arts of China.

Surfaces that are strengthened with FEVE-based resins

and glass, takes on the appearance of a floating

remain in pristine condition for decades. Coatings

pearl. Once guests pass through the building’s

that employ Lumiflon FEVE resin technology have

glass-enclosed entrance that sits underneath the

outstanding colour and gloss retention properties,

surrounding lake, they are greeted by the centre’s

in addition to outstanding weatherability and

equally extravagant interior. Inside the performing

durability (Fig. 2).

arts centre, theatergoers will have access to the For further information:

transparency, and space are three elements that

www.lumiflonusa.com

stunning performance halls and opera house. Light,

2 1

Figure 2: Coatings that employ Lumiflon FEVE resin technology have outstanding colour and gloss retention properties, in addition to outstanding weatherability and durability.

BRAND-NEW

t is just over one year since BASF’s Coatings division acquired

Chemetall® Becomes BASF’s New Global Brand for Innovative Surface Treatment Technologies Chemetall, a leading global surface treatment supplier. Being well-known within the industry for its high-quality products and

solutions, Chemetall will operate as a brand of the Surface Treatment global business unit of BASF’s Coatings division. During festive events at its headquarters in Frankfurt, Germany and facilities worldwide, the new brand image of Chemetall was officially introduced. Martin Jung, Senior Vice President, Surface Treatment, BASF’s Coatings division (Fig. 1), recognized this milestone: “One plus one is greater than two! Our new brand image reflects the impressive know-how of BASF in chemistry and coatings applications with the market-leading expertise in applied surface treatment from Chemetall. Together, the businesses will offer unmatched solutions competence to customers.” BASF has long been recognized as a global innovation leader. Chemetall enjoys a great history of global recognition for providing its customers with high-performance products and individual solutions. The combination of expertise and innovation power of two global market leaders will accelerate innovation and drive even more customer success. Julia Murray, Global Marketing Communications Surface Treatment, said: “The Chemetall brand is recognized for its technology leadership, and we take a great deal of pride in our customer-focused and customer-centric approach, locally and globally. Being part of BASF’s Coatings division creates opportunities to increase customer benefits from our combined expertise and commitment to continuous innovation. We expect to further advance our customers’ access to best-in-class technologies, systems, and solutions across the value chain, always with the goal of enhancing efficiencies and value for our customers.” Under the Chemetall brand, BASF develops and manufactures customized technology and systems solutions for applied surface treatment. The products protect metals from corrosion, facilitate forming and machining, allow parts to be optimally prepared for the painting process and ensure proper coating adhesion. These products are used in a wide range of industries and end-markets, such as automotive, aerospace, aluminium finishing, and metal forming.

For further information: www.chemetall.com / www.basf-coatings.com

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

Figure 1: Martin Jung, Senior Vice President, Surface Treatment, BASF’s Coatings division.

BRAND-NEW

Jotun Paints Invests More Than RM60mil in New Powder Coating Factory in Nilai

Figure 1: On 8th November 2017 Jotun Paints inaugurated a new Powder Coating factory in Nilai.

eading Norwegian paint company,

its presence in Malaysia. The new

product development to meet the ever-

Jotun Paints (Malaysia) Sdn Bhd

state-of-the-art Powder Coating factory

growing needs of environment-friendly

inaugurated a new Powder

will increase by more than double in

and high quality powder solutions.

Coating factory in Nilai, Negeri Sembilan

production capacity and contribute to the

The new state-of-the-art facility is in

(Fig. 1). The major paint manufacturer

company’s bullish ambition to increase

compliance to the highest health, safety

represented in over 100 countries made

market share.

and environmental standards and in line

an investment worth RM60mil in this new

Over a period of 30 years in Malaysia,

with Jotun’s ambition of building factories

facility, demonstrating its confidence in

Jotun Paints has continuously invested

with more energy saving features by the

the local economy while further anchoring

in people, manufacturing capacity and

usage of natural daylight and energy

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

BRAND-NEW

efficient inverter driven motors which

The new Powder Coating factory that boasts

expansion to over 10,000 metric tonnes per

significantly reduce the energy consumption

over 25,833 sq. ft. is positioned within the

annum, making this investment pivotal in our

of the plant.

existing Jotun Nilai facility. Aimed to double in

growth plans to increase in market share.”

Speaking at the launch of this new facility,

production capacity, the new powder coating

Over the last 30 years, Jotun Paints Malaysia

Odd Gleditsch, Chairman of Jotun Board

facility will manufacture up to 6,000 metric

has made a remarkable contribution,

of Directors, “Today we embark on a new

tonnes per annum and is capable of further

bringing in a host of innovative products

chapter and a huge step to an even brighter

expansion to over 10,000 metric tonnes per

that protects and beautifies property. Jotun

future with the opening of our state-of-the-

annum.

has the unique privilege of painting iconic

art powder coating factory in Nilai. Malaysia

According to Eric Mallace, Managing Director

buildings such as the majestic Burj Khalifa in

has been instrumental in being a stepping

of Jotun Malaysia & Singapore of Jotun, “The

United Arab Emirates, the prestigious Kuala

stone for Jotun to grow our business in

significant investment represents the single

Lumpur Convention Center in Malaysia and

the region. The success of Malaysia has

largest investment in global Jotun powder

the spectacular Eiffel Tower in Paris, among

spurred us to make a strategic move to

factory history - attestment to our confidence

others.

vigorously expand our presence further in

in the growth of the country’s economy and our

SEA. November marked as an eventful month

long-term commitment to Malaysia. Equipped

During the month of November, Jotun has

for us at Jotun, with factories opening in

with the latest in technology to improve output

also opened new manufacturing facilities

Myanmar, Philippines and Malaysia all within

and enhance the production processes, the

in Batangas,b Philippines and in Bago,

a span of a week.”

new powder coating facility will contribute to

Myanmar.

The Norwegian paint maker has two factories

fulfill the increasing needs of the market. With

in Malaysia - a waterborne factory in Shah

this, we will increase by double in production

For further information:

Alam and a solvent based factory in Nilai.

capacity and have the capabilities of further

www.jotun.com

ready2spray Pre-installed and ready2spray: the paintrobot EcoRP10 R1100 is fully equipped with verified, state of the art application technology. It is perfectly suited to the requirements of general industry and offers a unique combination in the market.

www.durr.com

BRAND-NEW

Dedicated Powder Coating Innovation Centre Opens

Figure 1: The new Extrusion Innovation Centre of Baker Perkins.

aker Perkins’ new Extrusion Innovation

facilities available, plus a full set of analytical

small batch production of applications

Centre is now open, offering full

instruments to check consistency and quality

including powder coatings and toners.

powder coating production facilities,

for characteristics including thickness, gloss

It delivers repeatable results that are

alongside research and development services

and imperfections.

accurately reproduced on a production

for a whole range of Industrial Extrusion

Customers from around the world can

scale machine, so recipes and settings scale

applications (Fig. 1).

work with their own raw materials and are

up precisely.

It is available for customers looking to develop

guaranteed complete confidentiality, working

This new Innovation Centre underlines

new products and processes, produce

alongside Baker Perkins’ technologists to

Baker Perkins’ capability as a full service

samples, or conduct feasibility trials.

supply data to enable smooth, uncomplicated

organisation committed to providing

The Centre, located at Peterborough in the

commissioning of new equipment or

complete process support.

UK, offers use of a MPX24 Integra twin-screw

development of new products.

extruder with feeder, chill roll and flaking

The centrepiece of the laboratory is the

For further information:

unit. There are grinding, spraying and curing

MPX24 Integra, designed for research and

www.bakerperkins.com

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

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

DISCOVER OUR SOLUTIONS

graco.com/ďŹ nishing

ÂŠ Wagner - Walther Pilot

Opening photo: The new spray gun for spot and line marking PILOT GA 9010 Marking.

HIGHLIGHT OF THE MONTH

PILOT GA 9010 Marking for Sharp-Edged Markings Matthias Mandal J. Wagner GmbH, Markdorf Germany

matthias.mandal@wagner-group.com

he new spray gun for spot and line

So Walther Pilot, a WAGNER Group company,

marking allows sharp-edged markings

has now released the PILOT GA 9010 Marking

Handy, lightweight signwriting gun

to be made in OK/NOK parts marking, in

(ref. Opening photo). It is lighter and more

The new spray gun has a length of 128

alphanumeric labelling and in food processing

compact than previous models and delivers

mm, 30% shorter and 20% lighter than

- with a smooth and seamless production

a reliable operation even with longer stand

the previous model, the PILOT Signier,

process.

times. In addition, it can be used for markings

which means that multiple models can be

Whether it be for marking rejects, weld seam

between 2.5 mm and 25 mm. Thanks to a

integrated easily into a single system.

tests on pipes and panels, labelling of different

shorter switching time between opening,

The PILOT GA 9010 Marking is available

identical-looking component types, markings

spraying and closing the fully automatic spray

as part of complete coating systems, e.g.

that can be read by machine following leak

gun is ideal for production processes with

comprising a gun, material pressure tank

tests or production line identification (e.g. of

short cycle times. This gun is also suitable

and control unit, and is expanded according

cutting and bending lines): lots of companies

for the automotive, pharmaceutical and food

to the application, for example with

depend on accurate spot and line markings.

industries.

three/two-way valves. The spray gun is also

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

available as part of complete coating systems from the WAGNER Group. Special flushing devices allow for consistently sharp, or if required point-accurate markings of the type that are important in adhesive processing, including with quick-drying inks. The robust and high-quality construction, on the other hand, safeguards smooth production processes in even the most difficult conditions. To allow the processing of abrasive or moisture-hardening materials as well as quick-drying inks, Walther Pilot has a variation of this product in its portfolio: the robust, fully automatic PILOT GA 9010 Marking Membrane has a membrane instead of a needle seal.

One signwriting gun for many applications While Walther Pilot has so far offered three spray guns and a complete system for line and spot marking, one gun now reliably covers the entire broad bandwidth of possible applications. Markings on cog wheels, for example, help make assembly errorfree. In steel production, thanks to the use of signwriting guns working in parallel, batch numbers can be written onto steel coils that are still decipherable even from a great height. In sawmills, on the other hand, the absorbent surface of tree trunks is marked for

The new spray gun for spot and line marking allows sharp-edged markings to be made in OK/NOK parts marking, in alphanumeric labelling and in food processing - with a smooth and seamless production process.â&#x20AC;? further processing - but the PILOT GA 9010 Marking can also mark smooth, non-absorbent surfaces such as ceramic or metal catalytic converters as required for precision installation in engines. The spray gun is also ideal for applications such as machinereadable line markings on pipes and profiles, or the colour marking of currency notes that are to be destroyed.

Special signwriting inks prevent blockages of the nozzle During spot and line marking with the GA 9010 Marking spray gun, signing inks are used which are ground to a high quality meaning these inks are less prone to blocking the nozzle than conventional coating materials. The inks are marketed by Walther Pilot and are available in all popular colours. Special colours are available on request. The signwriting inks can be used on wet, hot (up to 800Â°C), smooth, porous or even greasy surfaces. This means that they are perfect for marking on panels, pipes, plastics, textiles, glass not to mention also wood, paper, ceramic or rubber. They are quick-drying, provide good coverage, oil-resistant, light-fast and waterproof.

BRAND-NEW

he new SZ-Plus control panels minimize manual operations and simplify mass finishing processes,

Walther Trowal: New Modular Controls Enhance the Process Safety of Mass Finishing Applications especially when different work pieces must be treated (Fig. 1). At the Euroguss exhibition Walther Trowal presented a mass finishing system for finishing of castings equipped with a brand-new control panel.b This allows fully automatic finishing operations in the rotary vibrators of the model range CB, especially with interlinked systems. It helps not only to minimize manual process control but also increases the overall process safety. For the suppliers of mass finishing equipment so-called ‘cup-shaped’ castings can pose major challenges: upon completion of the finishing cycle such work pieces, for example battery housings, can contain a certain amount of processing media, which might be carried out of the machine with the work pieces. This can pose serious problems with downstream manufacturing operations. That is one of the reasons, why Walther Trowal developed the SZ-Plus control panel for the CB model range, which was introduced to the public at the Euroguss 2018 exhibition. It covers the entire surface finishing process including automation stages like work piece loading, the finishing step itself, discharging of the finished parts from the machine, work piece drying and work piece transport before and after the finishing step.

Figure 1: The mass finishing technology can be used for surface grinding, smoothing and polishing as well as for deburring of castings.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

Finiture Raggrinzate per risultati performanti Europolveri presenta la Serie 1R Arizona, sviluppata per andare incontro alle ultime tendenze ed esigenze del design contemporaneo. Disponibili in 44 diverse tonalità, questi prodotti permettono di ottenere risultati estetici di grande effetto ed al passo con le richieste del mercato.

• Finiture raggrinzate e morbide al tatto • Basso potere di riﬂessione • Grande valenza estetica • Disponibili a magazzino • Omologazione Qualicoat Classe 1

Zaniolo CdA - 7.18

Power Coatings series

Europolveri presenta la

Nuova Serie 1R Arizona Vernici in Polvere raggrinzate per finiture in linea con le esigenze del design contemporaneo. Europolveri presenta 1R ARIZONA, una nuova serie di Vernici in Polvere disponibili in 44 tinte RAL, con una finitura raggrinzata, semiopaca e morbida, che trova applicazione in molteplici settori, grazie alla sua versatilità: dall’architettura all’arredamento, dall’illuminazione alle porte e alle cancellate. La nuova collezione 1R ARIZONA mira a soddisfare le esigenze più varie, grazie alla sua valenza estetica, nonché alle sue caratteristiche di alta resistenza agli agenti atmosferici ed alla corrosione. La finitura raggrinzata garantisce la possibilità di nascondere i difetti dei supporti da verniciare, garantendo un risultato finale di pregevole impatto visivo. Tutte le 44 tinte a disposizione fanno parte della Serie Pural 1R e sono realizzate in conformità alle specifiche tecniche Qualicoat Classe 1 e garantiscono un alto grado di protezione e durabilità, trovando ampio utilizzo nel mondo dell’architettura. Tutti i 44 prodotti sono sempre disponibili a magazzino con un quantitativo minimo ordinabile di 25kg.

Per ulteriori informazioni potete contattare il servizio clienti a: info@europolveri.it

www.europolveri.it

BRAND-NEW

2 1

Figure 2: The processing media is safely removed during the separation phase, even from “cup-shaped” parts.

One major feature of the new control system is that, compared to the actual finishing step a higher vibratory amplitude can be programmed for the screening step, i.e. the separation of the finished work pieces from the media. This greatly facilitates the removal of media, which might have been carried out of the finishing machine by cupshaped work pieces (Fig. 2). The new control system helps automate finishing processes and eliminates many manual operations like, for example, the manual adjustment of the machine settings. In the program library the processing parameters can be easily selected for a wide variety of different customer work pieces. The new panel controls not only the timing of the different process stages but also ensures that compound and water are injected into the machine at the precise required quantities. This helps prevent operator errors and ensures absolutely constant and high finishing qualities. The CB rotary vibrators allow the processing of castings with dimensions of up to 380 mm (15”). Of course, they can also be used for finishing other high value work pieces that are processed in multi-stage processes with grinding and polishing pastes. This includes so-called “Trowapast” processes, which are employed for stainless steel work pieces and even, components made from ceramic. For further information: www.walther-trowal.com

BUSINESS CARDS

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

... On the road to

ipcm

Â®

n. 49...

La ďŹ era leader mondiale per le tecnologie di verniciatura industriale Worldâ&#x20AC;&#x2DC;s Leading Trade Fair for Industrial Coating Technology 17 - 20 April 2018 Exhibition Centre Karlsruhe, Germany

www.paintexpo.com In collaborazione con: In cooperation with:

Agenzia per Italia, Spagna e Portogallo: Agency for Italy, Spain and Portugal: EOS Mktg&Communication Srl Tel +39 0362 503215 info@eosmarketing.it

Â© Gruppo Caprari

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Caprari: Maximum Energy Efficiency and Minimum Environmental Impact for Coating Water Management Pumps With 72 Years of History Alessia Venturi ipcm®

observe the

In the early 2000s,

hen we

the trend was reversed and

irrigation

of fields or the

many industrial

snowmaking of ski

users developed

slopes, we immediately

systems combining

think about the water

solvent and

required for these

water-based

activities. However, we

products. Used

rarely wonder how it

with the proper

is transferred to the

application and

devices supplying it.

abatement

A key component for

equipment, such

these applications are

systems enable

the mechanical and

both to fully

electromechanical

meet aesthetic

pumps that take the

and corrosion

water and transfer it to the surface, or to the areas to be sprayed. They are

resistance

specifications

Figure 1: At the centre, Caprari’s Operative Director Donato Marchi, with Dario Zucchetti from Trasmetal and Caprari’s Manufacturing Manager Giovanni Rizzati on the right.

years, however, another issue has

components that must operate reliably Therefore, they need a functional as well as aesthetic coating, able to protect them from corrosion (ref. Opening photo). During the 1990s, some industry players began experimenting with one-layer systems with water-soluble products in order to reduce the environmental impact of coating operations.

emissions. In the last ten

complex mechanical in harsh environments for a long time.

and to limit VOC

In 2017, the plant builder Trasmetal, based in Milan (Italy), completed the project of a highly flexible, eco-friendly and energy efficient coating plant for a major Italian enterprise, the Caprari Group. Its products are now coated with a mixed system including a solvent-based primer and a water-soluble topcoat.”

forced itself to the forefront of the coating industry: energy saving. In 2017, the plant builder Trasmetal, based in Milan (Italy), completed the project of a highly flexible, eco-friendly and energy efficient coating plant for a major Italian enterprise, the Caprari Group. Its products are now coated with a mixed system including a solvent-based primer and a water-soluble topcoat.

Opening photo: A clear water pump produced by Caprari.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

2 1

Figure 2: The showroom displaying a part of the huge range of pumps produced by Caprari.

The Caprari Group: for 72 years, a leader in the integrated water resources management field A major Italian enterprise in the international sector of IWRM solutions has specialised, perfected and exported its pumping know-how in the world for over 72 years, led by the same family since three generations. Caprari Spa (Modena, Italy), now the leader of the homonymous Group, has continuously expanded and diversified its business to meet the specific and ever-changing needs of the water world with innovative products and services, while creating increasingly closer and more specialised partnerships with its customers. Mechanics enthusiast Amadio Caprari

opened a small workshop in 1945 and

Caprari Spa (Modena, Italy), now the leader of the homonymous Group, a major Italian enterprise in the international sector of IWRM solutions, has specialised, perfected and exported its pumping know-how in the world for over 72 years, led by the same family since three generations.”

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

started producing irrigation pumps. Over time, the activity extended to the design and construction of deep well, distribution, and civil and industrial waste water treatment pumps, thus offering an integral water management product range. The company currently owns a main production site in Modena with over 300 employees, a second production plant in Rubiera (Italy) manufacturing electric motors for submersible pumps, a small production site in Shanghai, and a production joint venture in Turkey. It also has commercial branches in Spain, Portugal, France, Germany, United Kingdom, Tunisia, Greece and Australia,

FOCUS ON TECHNOLOGY

3 1

Figure 3: Their certification for drinking water contact and corrosion resistance properties are two basic requirements for Caprari’s pumps along with a pleasant look.

The Caprari Group produces exclusively centrifugal water pumps. One of the main target sectors is the irrigation one, where the company started from: it represents the skill and knowledge heritage, and Caprari seeks to maintain and expand its position in this market. The company has then specialised in the industrial, deep well, water authority, water distribution, civil and industrial waste water sectors, but also in some very peculiar niches such as artificial snowmaking.”

a network of agencies with their own

that some of Caprari’s product ranges

warehouses on the Italian territory,

are the international leaders of their

A production process without any bottleneck

a commercial branch in Milan, and a

respective fields, for instance our line

The production process carried out

worldwide network of distributors.

of submerged well pumps, very wide

in Modena is not 100% verticalised.

In 2016, the group achieved a

and able to meet any application need

However, all strategic activities

consolidated turnover of 95 million

(Fig. 2).”

for the quality of products are

employees throughout its plants. “The Caprari Group produces exclusively

Euros with approximately 700

centrifugal water pumps. One of our main target sectors is certainly the irrigation one. That is where our company started from: it represents our skill and knowledge heritage, and we seek to maintain and expand our position in this market,” states Donato Marchi, the Operative Director of Caprari Spa (Fig. 1). “We have then specialised in the industrial, deep well, water authority, water distribution, civil and industrial waste water sectors, but also in some very peculiar niches such as artificial snowmaking. In the last few years, we have also started approaching new markets such as the oil & gas and offshore platform ones, which we supply with service pumps. We can safely say

4 1

Figure 4: A part of the new coating plant installed by Trasmetal (Milan).

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

steels, according to customers needs), supplied by our partner foundries. In terms of machining activities, we produce in-house about 70% of our total volume. The rest of the production is entrusted to external partners with which we have consolidated relationships.” After machining, the production process continues with a cleaning, rinsing and drying cycle of pumps’ individual components, the assembly of pumps, and the coating and packaging stages. “We chose not to clean our products after assembly and before coating because their morphological characteristics are not suitable to such a process at that production stage,” states Donato Marchi. “We clean and treat the parts contaminated with machine tools’ lubricants and machining shavings in a continuous flow basket tunnel, performing a phosphodegreasing, two rinsing, and

a passivation phase.” The coating stage follows.

5 1

Figure 5: Each load bar has a maximum capacity of 1800 kg, up to 1000 kg per hook.

performed in-house. “We have departments for the R&D, engineering and industrialisation of all our products and processes,” says Giovanni Rizzatti, the Manufacturing Manager of the plant. “Each new project is tested through prototyping, engineered by our technical office, and finally industrialised, that is, translated into operational activities. We manufacture our pumps by machining steel bars and castings in various metals (cast iron, bronze, stainless steels, and duplex and super duplex

Caprari cleans and treats the parts contaminated with machine tools’ lubricants and machining shavings in a continuous flow basket tunnel, performing a phosphodegreasing, two rinsing, and a passivation phase.”

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

6 1

Figure 6: The coating management unit linked to the primer application booth.

FOCUS ON TECHNOLOGY

Unlike cleaning, the coating phase takes place after the assembly of pumps. The operative choice to coat the products after assembly results in the impossibility to use powder coatings, because thermosensitive components, such as rubber gaskets, would not withstand the high polymerisation temperature.” Coating: a complex phase Unlike cleaning, the coating phase takes place after the assembly of pumps. This ensures film uniformity and good aesthetic quality finishes. “We cannot paint individual components due to our projects’ peculiarities,” states Donato Marchi. “The operative choice to coat our products after assembly results in the impossibility to use powder coatings, because thermosensitive components, such as rubber gaskets, would not withstand the high polymerisation temperature. It is also important to note that the coatings applied on our pumps must be compatible with drinking water contact, as required in numerous applications. We therefore need to use coating products certified according to the Ministerial Decree no. 174 for Italy, the WRAS approval in the UK, the CS approval in France and the KTW 270 certification in Germany.” “Our requirements to our coating suppliers are therefore complex: we need a product that can be applied with robots, is anticorrosive, ensures salt spray test values of at least 600 hours, dries in the required time, and is certified for drinking water contact,” states Giovanni Rizzati. “For all these reasons, after using a one-layer water-soluble system during the 1990s, we switched to a mixed system featuring a two-component solvent-based primer, surface tolerant and with good corrosion resistance properties, and a two-component water-based epoxy enamel. When we examined the project of the new coating plant with Trasmetal, we immediately clarified that the process had to be perfectly fine-tuned for the products already in use, since this mixed cycle has allowed us to meet the increasingly high quality requirements of the sector for some years now.” For the Caprari Group, coatings are applied primarily for functional reasons: they must be certified for drinking water contact and give the products the corrosion resistance required. Secondly, there are also aesthetic reasons, since nowadays the look of any kind of product must convey the perception of a high quality object (Fig. 3).

The realisation of the new plant For its new coating plant, Caprari imposed the following requirements to Trasmetal: 1. It had to accommodate a larger average physical dimension of pumps than the old system – designed and built twenty years ago according to the production needs of that time, it had a maximum load capacity of 250 kg per hook and a size capacity of 800x800. 2. It had to ensure better quality results, because the use environments of pumps are increasingly harsh, water

7 1

Figure 7: The monitors installed on a pulpit in the loading area display pictures of the incoming workpieces and their related hanging and masking instructions.

is harder and harder, and intake walls are increasingly deeper and often more polluted by brackish water. 3. It had to ensure a significant increase in production capacity. 4. It had to perform a low

Trasmetal designed and installed a plant that can meet the long-term needs of the Caprari Group in terms of both flexibility and productivity. It has a maximum load capacity of 1800 kg per bar and up to 1000 kg per hook, a size capacity of 1500x1500x1000 per hook, and the ability to coat components up to 2 metres in length per bar.”

environmental impact process in terms of both internal and external environment healthiness (VOC emissions) and energy efficiency. As for overspray, Caprari already had a proven dry filtration system with

Columbus paint collectors (Fig. 4).

8 1

9 1

Figure 8: Primer application.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

Figure 9: The flash-oﬀ tunnel between the primer and enamel application.

FOCUS ON TECHNOLOGY

Trasmetal designed and installed a

ratio: 30 out of 120 pumps per day are black.

reach the manual one,” says Giovanni

plant that can meet the long-term

Although the plant is able to automatically

Rizzatti. “The parts are loaded randomly:

needs of the Caprari Group in terms of

perform continuous colour changes, we

each load bar is equipped with three hooks

both flexibility and productivity. It has

decided to apply black in two phases every

that can and must be able to accommodate

a maximum load capacity of 1800 kg

day in order to minimise the colour change

different components with various

per bar and up to 1000 kg per hook, a

operations and therefore lower our cleaning

dimensions and shapes.”

size capacity of 1500x1500x1000 per

solvent consumption. The products requiring

The plant is in fact composed of three booths: a manual

hook, and the ability to

one for special

coat components up to 2 metres in length per bar (Fig. 5). The pumps are transferred directly from the assembly department, reaching

Each product to be coated is identified by a barcode. Thanks to CMA’s software, the operator reads the barcode on the tag applied on the pumps from assembly to packaging, and the monitors installed on a pulpit in the loading area display pictures of the incoming workpieces and their related hanging and masking detailed instructions.”

colours and touchup operations and two automatic ones, devoted respectively to the solvent-based primer and the

an area in front of the hanging station acting as a buffer.

special colours other than green or black,

water-based enamel. They feature robots

“We chose to plan the application

about 5% of production, go through the

supplied by CMA Robotics (Pradamano,

of colours: 95% of our products is

primer application booth and then bypass

Udine, Italy). Each booth has its own

coated in green or black with a 3:1

the automatic finishing booth in order to

coating management unit with Wagner

METAL SURFACE PRE-TREATMENT AND FINISHING PLANTS

T R A S M E T A L Tel. +39.02.27094.1 - Fax +39.02.27094.343

www.trasmetal.net - info@trasmetal.net

10 1

Figure 11: Enamel application on pumps with complex shapes.

11 1

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

Figure 10: The dry application booth devoted to enamel.

FOCUS ON TECHNOLOGY

Trasmetal also installed a booth separated from the main plant, equipped with a floor suction system and a saturated steam cleaning nozzle and linked to a 5-tonne crane. It is used to coat oversized pumps, up to 4 metre long and weighing up to 5000 kg. The non-in-line part of the plant also includes a devoted oven to complete the coating cycle.” dosing systems and pumps (stock meter pumps for the primer and volumetric meters for the enamel - Fig. 6). Each product to be coated is identified by a barcode. Thanks to CMA’s software, the operator reads the barcode on the tag applied on the pumps from assembly to packaging, and the monitors installed on a pulpit in the loading area display pictures of the incoming workpieces and their related hanging and masking detailed instructions (Fig. 7). The software program matches each part code with a hook; the operator confirms the loading operation is finished and starts the cycle. At the booth’s entrance, the system reads the load bar number and the barcodes associated with each hook, enabling the robot to select the coating program corresponding to each product and proceed with the paint application (Fig. 8). A 4-spot buffer was created in front of the primer application booth. When the cycle time of a load bar ends, the software program opens the booth and the robot identifies the following workpieces. A flash-off station performing a 48-minute process at 40 °C is located between the primer and enamel application booths. The load bars exiting the former are transferred alternately to the right and left lane to allow the flash-off phase to take place for the time needed even in a small space (Fig. 9). The booth for the application of

Visit US at PaintExpo 2018 Hall 1 Stand nr. 1341

water-soluble enamel could switch to solventbased enamel at any time, if it were necessary due to qualitative requirements (Fig. 10 and 11). The plant also features a manual application booth with a direct air expulsion system

+49 89 13928723

12 1

Figure 12: The manual application booth is devoted to special colours and touch-up operations.

(Fig. 12), a flash-off area to let the

Trasmetal also installed a booth separated

includes a devoted oven to complete

water contained in the enamel

from the main plant, equipped with a floor

the coating cycle.

evaporate, and a curing oven where

suction system and a saturated steam

parts stay at 85 °C for about 60 minutes. This oven uses the heat produced by the afterburner installed outside the building to treat the air emitted from the booths. There is only one burner for the whole

Automation and energy eﬃciency: the advantages The coating line designed and installed by Trasmetal of this plant cleaning nozzle and linked to a 5-tonne

has three main strengths: the automation of the application phase, the booths’ air recycling device, and the direct heating system using the heat produced by the afterburner.”

plant. Afterwards, the

The coating line designed and installed by Trasmetal

pumps reach a forced air

has three

cooling area and finally the unloading

crane. It is used to coat oversized pumps,

main strengths: the automation of

station, ready for immediate handling

up to 4 metre long and weighing up to 5000

the application phase, the booths’

and packaging.

kg. The non-in-line part of the plant also

air recycling device, and the direct heating system using the heat

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

VOCs. We considered various afterburning

produced by the afterburner. “When designing this plant, we primarily focussed on its ecological aspects,” states Dario Zucchetti from Trasmetal. “The coating cycle adopted was not completely water-soluble, which would have allowed for the emission into the atmosphere of the air from the booths. Given the mixed cycle employed by Caprari, it took us a long time to design the air treatment system in order to comply with regulations and at the same time achieve the main goal of energy efficiency. Once we decided to use automatic booths with an air recycling system, we had to find the most

technologies as well as activated carbons. Of course, the choices made for the emission treatment operations affected other plant engineering decisions.” “After assessing different options, we chose to install an energy recovery thermal afterburner without any concentrator to limit emissions (Fig. 13). This resulted in the need to limit airflows, too, and to use high concentrations of solvent in the booths (not more than 2 gr/m3). Consequently, both booths were conceived as completely automatic machines with an air recirculation system. The air

convenient device for the abatement of

A system structured like that of Caprari Spa, as well as fully complying with VOC regulations, enables to save energy. It consumes half the energy it would have required, for instance, with a ceramic afterburner and a curing oven, each with its own burner. Clearly, this choice is closely linked to the automation of the coating process, because no operator can access the booths due to the high solvent concentration in the air.”

13 1

Figure 13: The energy recovery thermal afterburner.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

emitted from the booths flows into the afterburner and the heat generated by the solvent combustion is completely recovered and used to heat the curing oven. The whole system, therefore, works with one burner,” explains Dario Zucchetti. “The overspray issue, on the other hand, was easily solved also thanks to Caprari’s experience. We opted for continuing with dry filtration.” A system structured like that of Caprari Spa, as well as fully complying with VOC regulations, enables to save energy. It consumes half the energy it would have required, for instance, with a ceramic afterburner and a curing oven, each with its own burner. Clearly, this choice is closely linked to the automation of the coating process, because no operator can access the booths due to the high solvent concentration in the air. “When an operator needs to enter a booth, for example for the robots’ self-learning programming operations, it is possible to open it and activate the direct air expulsion system,” says Zucchetti (Fig. 14). “From the operational point of view, however, we realised that it is easier for the operators to assess the products’ coverage by the robot in the enamel application booth, since most of our workpieces are already coated with a foundry primer in an oxide red colour identical to the one we apply.

14 1

Therefore, the operators perform the

Figure 14: One of the stations for the management of the robots installed by CMA (Pradamano, Udine).

self-learning operations in this booth and then transfer the programs to the primer application robot. In this way, there is no need to bypass the air recirculation system,” says Giovanni

The plant was installed in January 2017 and the start-up phase lasted a few months. Functional testing was performed in September and the plant is now working at full capacity. During the design phase, Trasmetal also supported us in the improvement of our internal logistics.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

Rizzatti. “This is a small plant, but the environmental aspect was very important for us,” states Donato Marchi. “Having opted for a mixed cycle, we needed certainty in terms of

FOCUS ON TECHNOLOGY

emissions. The usage limit of solvent-based

integration of a sufficiently long flash-off process

coatings on our territory is 50 kg per day: we

after the enamel application phase enables us to

consume an average of 50-60 per shift, so

consider the use of polyurethane or acrylic enamel

with a second shift per day we would have

in future, since these products have a higher UV

exceeded the limits. Moreover, since the

resistance than the epoxy one.”

whole plant was designed and manufactured

“We are pleased with Trasmetal’s plant because

in line with the ATEX standard, we have the

it meets all our main requirements: higher

consider using

production

possibility to

capacity

solvent-based

and greater

products.”

respect for the indoor

A plant for great flexibility

and outdoor environment,” says Donato

The plant was

Marchi. “The

installed in

possibility

January 2017

to exploit

and the start-up

the heat

phase lasted

produced

a few months.

to reduce

Functional testing

emissions

was performed in

doubles the

September and

ecological

the plant is now

benefits of the

working at full

plant because

capacity. “During

it enables

the design phase,

us to save

Trasmetal also

energy and to

supported us in

further lower

the improvement

our carbon

of our internal

footprint.

logistics,”

Above all,

says Giovanni

however,

Rizzati. “The aim

this line gives

was to avoid manipulating and moving the coated pumps within the factory. We

CONVEY YOUR SUCCESS

us greater

15 1

flexibility, a

Figure 15: Coated components transferred to the unloading station.

installed the new

crucial aspect to face any process changes

coating plant in an area including the refining

and the introduction of new product ranges with

and packaging stations placed immediately

different coating requirements in future.”

downstream to avoid any risk of small dents, surface defects or film detachment. Also this choice was motivated by a significant increase in the quality requirements posed by our customers and by the will to improve our internal logistics efficiency (Fig. 15). The

INTERNAL HANDLING SYSTEM IMPIANTI MOVIMENTAZIONE INTERNA

info@tras-mec.it www.tras-mec.it

Opening photo: The metal cabinets by FANTIN.

FOCUS ON TECHNOLOGY

High-Quality Metal Pre-Treatment and Customised Finishes: FANTIN Furniture’s New Trademarks Monica Fumagalli ipcm®

hromatic analyses are increasingly

ago but that are now appreciated and

trend and is aimed at making finishes the

finding that the colours chosen for

requested by an increasing number of

trademark of its products (ref. Opening

indoor furnishings can influence and

consumers.

photo). “In May,” says Fabiana Paulon, the

improve the lifestyle of their daily users, be

purchasing and HR manager of FANTIN, “we

they intended for the industry, offices, or

FANTIN, an Italian company producing

will celebrate fifty years of activity. Dorino

public or domestic spaces. In fact, there is a

metal furniture since 1968, has been

Fantin, the founder of the company, started

growing trend towards “bold” finishes that

focussing on a project related to coatings

a production of metal chicken cages at the

would have been unthinkable only a few years

for a few years, which reflects this new

end of the Sixties, and then expanded its

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

always been appreciated (Fig. 2). Currently, our company has a 5,500 m2 production site and, managed by the second generation of the

In order to optimise one of the most delicate phases, i.e. surface preparation, FANTIN turned to its long-standing supplier of pre-treatment chemicals, Kemmex, a company based in Cusano di Zoppola (Pordenone, Italy).”

Fantin family, it looks to the past with pride and to ambition (Fig. 3).”

FANTIN furniture: recyclable and authentically Italian-made

In anticipation

The entire production process is carried out

of its fiftieth

in-house, from the arrival of the semi-finished

anniversary,

products in the form of sheets or sheet tubes

the future with

Figure 1: One of the shelves produced by FANTIN.

target to include gates and outdoor railings.

the company wanted to send a message to

of different materials to machining operations

In 1973, the idea was born to manufacture

the market by making a decisive change in

such as punching, folding and assembly by

one of our most well established products, still

its offer and therefore in the quality of the

spot welding and welding, up to powder

in production today: fastener-based shelving

coating system and colour range utilized. In

coating, assembly, packaging and shipping to

systems, which at the time represented a great

order to optimise one of the most delicate

the end user. “The production cycle adopted

innovation able to replace the conventional

phases, i.e. surface preparation, FANTIN

by FANTIN,” states Eng. Rango Fantin, owner,

bolted shelves, less stable and more difficult

turned to its long-standing supplier of pre-

Sales and R&D Manager, “contributes to the

to assemble and install (Fig. 1). In the following

treatment chemicals, Kemmex, a company

flexible management of the manufacturing

years, other pieces of furniture for the

based in Cusano di Zoppola (Pordenone,

flow in terms of both customised products and

office, the industry and the community were

Italy). As for the new powder coatings to

number of batches, with different sizes ranging

developed, some of which are still present on

be used, on the other hand, it relied on

from one product to larger volumes for the

the market thanks to a few restyling operations.

the expertise of the designer Salvatore

contract sector. A short and selected supply

“In addition to the FANTIN-branded products,

Indriolo, one of FANTIN’s long-standing

chain, at the same time, guarantees the use of

we have always also produced custom furniture

collaborators, who is developing the most

high-quality materials and the production of

and even offered a contracting coating service.

suitable solutions for the new needs of this

authentically Italian-made products.

Such a structured production has allowed us to

Friulian company together with the major

“For customised projects, we carefully analyse

gain expertise in both machining and coating,

thermosetting powder manufacturers.

the designer or the architect’s plan and we

so much so that the quality of our finishes has © FANTIN

become one of the hallmarks of the FANTIN brand besides the robustness and durability characteristics for which our products have

FANTIN, an Italian company producing metal furniture since 1968, has been focussing on a project related to coatings for a few years, aimed at making finishes the trademark of its products.”

2 1

Figure 2: The quality of its coatings has become one of the trademarks of this Friulian company.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

3 1

Figure 3: From left to right: Gianni Zilli, Sales Director of Kemmex, Fabiana Paulon, Purchasing and HR Manager of FANTIN, Marco Bortolato, Plant Manager, Rango Fantin, Paintshop Manager, Dorino Fantin, the FANTIN’s owner, Sandro Fantin, Sales Director and R&D Manager, Stefano Fantin, Production Manager and Salvatore Indriolo, Art Director of FANTIN.

develop the most suitable industrialisation solutions together with the customer, according to the needs of both the designer and the end users. Moreover, each product is subjected to control procedures at all stages of manufacturing as proven by our ISO 9001 certification, an international certificate of conformity guaranteeing the presence of an optimised organisational structure and processes of adequate quality.” Finally, for several years FANTIN has been supporting an ethical project for strict compliance with all environmental requirements at every stage of the production process, thus respecting the environment and manufacturing 100% recyclable furniture.

The key role of pre-treatment for optimal coating operations “FANTIN’s new business strategy,” says Rango Fantin, owner and paint shop manager, “is centred around medium-high-end furnishings combining sturdiness and durability with aesthetically pleasing coatings. This can only be achieved with a perfect balance among machining, surface preparation and paint application. That is why we paid particular attention to the pre-treatment phase: it is often seen as secondary, but for us it plays a key role.” FANTIN has cooperated for over ten years with Kemmex, a supplier of chemical products for substrate preparation and consulting services on process optimisation. “During our partnership with FANTIN,” says Gianni Zilli from Kemmex, “we have switched from the supply of liquid products to that of high performance gel formulations: thanks to their higher concentration degree, these enable to work with smaller quantities of product and therefore create a lower risk of tank pollution. Moreover, the correct dosage

FOCUS ON TECHNOLOGY

FANTIN’s new business strategy is centred around medium-high-end furnishings combining sturdiness and durability with aesthetically pleasing coatings. This can only be achieved with a perfect balance among machining, surface preparation and paint application. That is why the company paid particular attention to the pre-treatment phase.” of high yield gel formulations used in synergy with a special highly degreasing additive based on surfactants and solvents enabled FANTIN to solve a major pre-treatment issue: the cleaning of metal sheets heavily contaminated by the difficult-to-remove oils necessarily used during processing.” “Solely following the addition of this particular additive in the appropriate doses,” says Rango Fantin, “we noticed a marked improvement in the workpieces’ cleanliness. This might be trivial, but sometimes it is sufficient to dose the chemicals correctly to achieve maximum efficiency in the pre-treatment process and therefore good-looking end products. And this is a crucial factor, especially at a decisive business stage such as our current attempt to gain a new slice of the furniture market.” The use of specific pre-treatment products also allows to remove contaminants from welded areas and give them the same film adhesion properties as the rest of the component, thus achieving © ipcm ®

100% coating conformity. “Sometimes,” adds Rango Fantin, “our salt spray test results were positive for some parts of our workpieces, whereas the surfaces near the welded areas presented problems of coating detachment. Therefore, together with Kemmex, we carried out a research study to develop a pre-treatment cycle ensuring a homogeneous degree of cleanliness on our 4 1

Figure 4: FANTIN coats both individual components and already-assembled furnishings.

workpieces’ entire surfaces, including bent and welded parts (Fig. 4).”

5 1

6 1

Figure 5: The range of colours oﬀered by FANTIN.

Figure 6: Other examples of colours intended for metal furniture.

A pre-treatment plant with reduced consumption

quantities and therefore limit pollution in

aimed at maximising efficiency, every two

both the active phase and the subsequent

months Kemmex’s technological laboratory

The pre-treatment cycle developed for

rinses. These are performed with industrial

performs surface quality controls such as

FANTIN is a 3-stage multi-metal process:

water. Nanotechnology passivation is

neutral salt spray (ASTM/B 117-ISO 9227),

phosphodegreasing, rinsing with mains water

carried out with a silane-based product

cross-hatch (ISO 2409), and impact tests (ISO

and nanotechnology passivation.

6272-ASTM D 2794). “Our most

An automatic chemical dosing

recent salt spray test results

system was integrated two

The pre-treatment cycle developed for FANTIN is a 3-stage multi-metal process: phosphodegreasing, rinsing with mains water and nanotechnology passivation.”

years ago. “This is very useful and functional if combined with a constant technical assistance

intervene manually when needed,” says

specifically developed to be compatible

Gianni Zilli. “Since the plant is flexible and

with mains water.

designed to treat any metal surface, from

In addition to regular plant inspections

steel to hot zinc plated and electro-zinc

and cleaning and maintenance operations

are also assessing the possible introduction of a new product

environmental impact.

Colours make a diﬀerence: the creation of new shades “The need to manage orders

alloys, FANTIN needed a dosing

says Rango Fantin, “and we

of vegetable origin with a low

service and the possibility to

coated steel, up to aluminium

were higher than 300 hours,”

from different customers,” states

system that could ensure excellent

Fabiana Paulon, “has prompted

cleaning results on different

us to quickly create a relevant

materials through constant

colour range as the starting point

monitoring of the bath’s acidity.

for the development of new

We have therefore customised

finishes.” “I have been working

a simple machine able to detect

with FANTIN for many years,” says

pH values in real time. Such

Salvatore Indriolo, the company’s

continuous monitoring enables

art director. “Switching from

the operators to intervene if the

neutral shades like grey, which

value deviates from the reference

characterised FANTIN’s metal

parameter, equal to 5.0. Thanks

furniture until some time ago,

to the use of highly concentrated products, moreover, the dosing system can feed smaller product

7 1

Figure 7: The coating system.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

to the current colour range was a leap in quality for this firm (Fig. 5). The personalisation of

FOCUS ON TECHNOLOGY

furniture through colour is a trend that is increasingly spreading and resulting in pressing demands from our customers. After a research study on the new trends in the fashion world, we have had 23 unusual RAL colours produced for the market. We were surprised that the coating manufacturers we contacted were available to produce even only small batches since, only until recently, it was necessary to order fairly high minimum quantities. Perhaps, this is a sign that also the relations with paint suppliers are changing radically. As FANTIN needs to align its production capacity to the functional and aesthetic concepts of designers and architects and to understand their requests, so the coating manufacturers grasp the applicators’ needs and meet them by offering innovative shades and effects that will become the future trends of the market (Fig. 6).” During 2018 FANTIN will add some new home furnishings to its catalogue, e.g. cupboards, tables and kitchens with metal components in different colours, and it will advance along the path of internationalisation in order to make known and distribute its

products worldwide.

8 1

Figure 8: FANTIN specialises in the manufacture of metal furniture and mobile shelving systems.

A new spray paint booth for a greater variety of applications The paintshop applies polyester, epoxy and epoxy-polyester coatings on the company’s indoor and outdoor furniture solutions. It operates for approximately 12 continuous hours per day and it is equipped with a monorail conveyor with adjustable speed according to the application needed (Fig. 7). The recently installed spray paint booth with a quick colour change system will enable FANTIN to apply an almost unlimited number of shades (Fig. 8 and 9). “We relied on Zeus (Argenta, Ferrara, Italy), which had already supplied our spray guns, for the design of the new booth,” says Rango Fantin (Fig. 10). “It is a quick colour change system with conventional Venturi paint feeding pumps. Its high

application efficiency ensures a lower consumption of powder,

Sandro Fantin and Salvatore Indriolo. “Attention to details is

whose recovery is also facilitated

their main characteristic. The

by the fact that the booth is built in

quality of our pre-treatment and

dielectric material. The cleanliness

coating cycles is high, so much

of the work environment accurately

so that customers ask us to

reflects the long-standing ethical

confirm that the piece of furniture

vision of our company.”

they are looking at is really

This booth was designed for

made of metal. This is our most

companies performing several

important achievement. Thanks

colour change operations per

to the decisive contribution of our

shift. Its Venturi-effect micro-hole cleaning system keeps the floor clean avoiding any accumulation of powder. Suction is intense

coating partners, Kemmex and

9 1

Zeus, we managed to convince buyers that even a metal-built

Figure 9: Other types of furniture.

furniture can be as nice and comfortable as a wooden one.

but delicate on workpieces: its

Our next challenge will involve the sense of

a healthy work environment. However, at the same time, the airflow analysis shows a well-distributed suction action, so as not to compromise the coating results. The maximum dimensions of the components treated by FANTIN are 4 x 2 x 1 m (L x H x W). The application process includes a manual pre-retouching operation and an automatic application phase with the use of reciprocators (Fig. 11). The guaranteed minimum thickness is 80 microns. For some

The paintshop applies polyester, epoxy and epoxypolyester coatings on the company’s indoor and outdoor furniture solutions. It operates for approximately 12 continuous hours per day and it is equipped with a monorail conveyor with adjustable speed according to the application needed.”

touch: we are already working to develop finishes that reduce the feeling of cold conveyed by metal, in order to offer furniture that makes environments even more pleasant to live in.” As is evident, despite the half century of history, FANTIN continues to surprise the market with new metal solutions featuring alternative designs and unexpected colours. © FANTIN

intensity reduces powder leaks and ensures

outdoor products, FANTIN applies a two-coat powder system including a grey zinc primer then polymerised in the oven at 190 °C.

Customised furniture for a more comfortable environment

The coating cycle lasts approximately 2 hours.

FANTIN started customising its products by

and a coloured topcoat. The workpieces are

offering different colour shades. Now, it can even modify the functional design of its standard furnishings. “For example, we have turned a locker into a lamp holder and transformed an industrial cart into a kitchen one: the potential developments of

10 1

our products are

Figure 10: The FANTIN’s staﬀ and partners and the new Zeus’ booth.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

endless,” state

11 1

Figure 11: Automatic application phase with the use of reciprocators.

Â®

Opening photo: The Mission Hospital’s project in California: Inspected in 2012, after 21 years the results were a measured colour change DE = 3 and a gloss retention of 59%.

HIGHLIGHT OF THE MONTH

Why Choose High Durability? Claudia Salomoni AkzoNobel Interpon - Como, Italy

claudia.salomoni@akzonobel.com

uperdurable products have excellent weathering durability compared to standard durability products, so the aesthetics of a building will last longer:

• Gloss retention and colour stability of the coating are far superior to standard durability coatings; • Chalking is limited compared to standard durability systems;

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

• Superdurable powders meet Qualicoat Class 2, GSB Master and AAMA 2604 specifications. AkzoNobel has the longest Track Record in Superdurable Technology, more than 20 years. Here follows a couple of examples of the application of superdurable Interpon D2000 series.

HIGHLIGHT OF THE MONTH

Figure 1: The Bridgewater Hall’s project in Manchester: Inspected in 2017, after 21 years, the results were a minimal colour change and a gloss retention >50%.

Project: Mission Hospital, California Coated in 1991, the powder coating was guaranteed to maintain 50% of its gloss for 5 years in Florida and the building had a 15-year Colour Warranty on it (ref. Opening photo). Inspected in 2012, after 21 years the results were a measured colour change DE = 3 and a gloss retention of 59%.

Upgrade to gain competitive edge

Project: The Bridgewater Hall, Manchester Coated in 1996, the building has a 15-year colour warranty on it and the powder coating was guaranteed to maintain 50% of its gloss in 5 years Florida (Fig. 1). Inspected in 2017, after 21 years, the results were a minimal colour change and a gloss retention >50%.

The Nordson spray systems utilize HDLV® (High Density Low Velocity) pumps to delivers unmatched performance through independent control of the powder and air volumes for soft, highly

Collection Futura 2018-2021: highly durable and sustainable colours and finishes

repeatable powder application

Collection Futura is a range of special finishes for use on exterior

Signiﬁcant powder savings due to higher efﬁciency and tight process control

architectural metal components. A favourite of architects for over 15 years, Collection Futura has been specified on numerous prestigious projects. The new Collection Futura 2018-2021, launched last

No pump maintenance up to 4,000 hours

November 2017, has been developed by AkzoNobel’s Interpon powder

Intuitive advanced controls for operator convenience

coatings brand together with leading trend, design and innovation © AkzoNobel

Fast, reliable and automated colour change For a new fast colour change system or easy integration with your existing cyclone booth, get in contact with Nordson for more information. ics.eu@nordson.com www.nordson.com/hdlv 2 1

Figure 2: Collection Futura moves towards a range of light tones based on coloured whites and softened neutrals, inspired by nature.

choose soothing living spaces designed with sustainable materials, capable of providing a sense of wellbeing. It moves towards a range of light tones based on coloured whites and softened neutrals, inspired by nature. Textures are matt or satiny, with a sort of frosted shine (Fig. 2). Glam City Modernist influences and baroque trends are back, but the mood is more sophisticated and precious. The inspiration today is intense, dark tones, centred on reds, blues and greens, in deep and sumptuous nuances. Textures are satiny or shiny, sequined or blackened reflections (Fig. 3). Treasured Light Following an overdose of bling, sensual

3 1

and more refined versions of metallic

Figure 3: Modernist influences and baroque trends are back, but the mood is more sophisticated and precious.

brilliance are the new must-have. A range of metallic nuances, including brass, pink gold, pale copper and silver. Luminous

consultants, PeclersParis, and is covered by

A dense range of colours, with mineral and

textures with delicate brilliance, an

Akzo’s Global Gold Warranty.

vegetable influences; earthy browns, peaty

anodized effect, discretely shimmering,

The Collection Futura features an extensive

khakis, anthracite greys and charcoal blacks.

brushed or with softly chromed

range of highly durable and sustainable

Textures and effects are matt, patina, grainy,

reflections (Fig. 4) .

colours: AkzoNobel is the first major powder

oxidized, or blurry amalgamated finishes.

The new range of finishes will enable customers to achieve just the right effect

coatings manufacturer to achieve a thirdparty certified Environmental Product

Time Out

in any environment while helping them

Declaration (EPD) for its Interpon D range

To offset frenzied urban routines, Collection

contribute to the future of green building

architectural coatings. An EPD includes

Futura looks to reconnect with the elements, to

and sustainable development.

used in the product, manufacture of the product itself, shipping to the customer and final application to the end of life and

a life-cycle analysis of the raw materials

re-cycle. For each stage, the carbon output, acidification of water, water usage and other elements are measured. AkzoNobel’s EPD has been verified as accurate by a third-party examiner. The new Futura selection is based on several globally-identified trends for 2018-2021. Wild Nature A new approach to “green” trends exploring a more primitive, wild expression of nature.

4 1

Figure 4: The new must-have are the luminous textures with delicate brilliance, an anodized eﬀect, discretely shimmering, brushed or with softly chromed reflections.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

Visit us at PaintExpo 2018

Hall 3, booth 3417

Alit Technologies Srl • Via Francesco Perlini, sn • 37047 San Bonifacio (VR) • www.alit-tech.com • info@alit-tech.com

ÂŠ Metallveredelungswerk Sulz GmbH

Opening picture: Coating metal surfaces protects them from corrosion and improves their aesthetic properties.

FOCUS ON TECHNOLOGY

Metallveredelungswerk Sulz: the New Frontiers of Bulk Cataphoresis With the DELTA-eLACKÂŽ Process Alessia Venturi ipcmÂŽ

orrosion is a widespread and burdensome

damaged components and machine downtimes

technologies is cathodic immersion coating, i.e.

problem that affects the steel components

are other issues that are very difficult to solve.

cataphoresis. For many years, this has been one

used in several industrial sectors such as

However, significant savings can be achieved

of the most commonly used methods in several

automotive, construction and aerospace, which

by applying corrosion-resistant coatings on

industries, especially the car one, to protect

coat their metal surfaces precisely to protect

components. By applying suitable coatings

metal parts against corrosion. This technology

them from corrosion as well as to improve their

on metal surfaces, it is possible to significantly

is typically used to coat large-sized workpieces

aesthetic properties (ref. Opening photo).

improve the service life of components and thus

such as car bodies, truck cabins, and agricultural

In industrialised countries, the estimated annual

reduce downtimes and repair or replacement

machinery, but also smaller components such

expenditure to counter corrosion accounts for

costs.

as finned batteries, pulleys, industrial fans,

around 4% of the GDP. The costs for replacing

One of the most common corrosion prevention

industrial furniture, and many more.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Figure 1: Dörken MKS-Systeme developed a bulk cataphoresis process called DELTA-eLACK® with a drum system.

Due to the characteristics of the cataphoresis process itself, requiring the workpieces to be hung onto frames, bars or skids, until some time ago it was unthinkable – or at least too burdensome in terms of labour and process times – to use cataphoresis to coat very small parts such as fasteners, screws, bolts, pins and washers. On the German market, the cost per cataphoresis-coated component is 3 to 10 cents (calculation based on the dimensions and size of parts). That is why, despite its exceptional strength and aesthetic properties, cataphoresis was never used as an anti-corrosion treatment for bulk small components. Dörken MKS-Systeme, a company based in Herdecke (Germany) and a leading manufacturer of zinc-lamellar anti-corrosion coatings, developed a bulk cataphoresis process a few years ago. It is called DELTA-eLACK® and it enables to coat small-sized components with a drum system (Fig. 1). Metallveredelungswerk Sulz GmbH (Sulz am Neckar, Germany), specialising in galvanic, zinc-lamellar and anti-corrosion coatings, was one of the first companies to implement the new DELTA-eLACK® process offered by Dörken by developing an eco-friendly treatment cycle. This ensures high anti-corrosion protection performance and the application of a black layer of uniform thickness on fastening parts intended for the

car industry.

2 1

Figure 2: A part of the coating process.

G RT

Metallveredelungswerk Sulz (Sulz am Neckar) was established in January 1997 by Bodo Langendörfer and Hans-Jörg Haible. It started with only 4 employees, but it shortly

The company

With other coating processes, small and very small workpieces are treated with difficulty and unevenly, whereas this new bulk cataphoresis technology ensures perfect corrosion protection,

managed to hire other 100 people thanks to

thin and uniform thicknesses, and a

the high quality of its galvanic and chemical

high quality look free of any defects or

coatings and to the numerous innovations

partial accumulations on surfaces.

introduced. Sulz installed two fully automatic

In combination with a zinc-lamellar

galvanising systems in 2003 and the next

coating, e.g. from the DELTA MKS

3 1

year it expanded its galvanic coating range to include the copper plating, nickel plating

series, DELTA-eLACK® offers the best of two worlds: high corrosion protection

Figure 3: Cataphoresis has become a standard procedure in the automotive industry because it allows to apply a protective basecoat that is also aesthetically perfect.

and chrome plating of high quality car parts. Metallveredelungswerk Sulz developed further innovative coating processes in the

performance and a very nice blackcoloured surface that is particularly requested by the automotive industry.

following years, thus becoming one of the

Moreover, should the DELTA-eLACK®

most successful companies in southern

completely new system technology.

topcoat be damaged, the cathodic protection

Germany (Fig. 2).

The workpieces – small or medium-

of the zinc-lamellar basecoat would remain

The firm currently produces galvanic

sized, flat with bends or three-

active.

coatings, combined with zinc and zinc-

dimensional – are transferred from the

Aware of the potential of the new system,

nickel substrates, zinc-lamellar coatings,

conveyor belt to a drum that is rotated

MV Sulz immediately decided to implement

phosphate coatings with zinc and

and immersed in the tank containing

it, thus becoming an applicator certified

manganese salts, cataphoretic coatings,

the cataphoresis product (Fig. 4). This

by Dörken and entering into a distribution

and powder coatings. One of the strengths

technology allows for the first time and

partnership. Thanks to this innovation,

of MV Sulz is its high degree of innovation,

in a very reliable way to subject bulk

Metallveredelungswerk Sulz GmbH won the

as demonstrated by the implementation of

components to a cataphoresis process,

“Dr. Rudolf Eberle” prize for the exemplary

Dörken’s DELTA-eLACK process. This also

obtaining excellent results in terms of

results achieved in the framework of the

enabled the company to enhance its other

aesthetic and protection performance

Innovation Award 2017 of the state of Baden-

strength: the ability to process batches of

and high economic efficiency.

Württemberg.

small components in a short time.

The cost of labour for the treatment

of components and, therefore, the

The solution to bulk cataphoresis problems: the DELTA-eLACK® system

cost per part are in fact dramatically reduced.

process developed specifically for parts with complex shapes. The component to be painted is immersed in a water-based coating and direct current is applied to enable the coating particles to deposit on the conductive metal substrate.

basecoat or on a galvanised surface with a

• Bulk coating in a drum system; • Application of thin and uniform layers; • Possibility to set and adjust the thickness of the coating layers based on customer

on specifications;

because it allows to apply a protective

that can be applied on a zinc-lamellar

• High resistance to white rust;

• Possibility to set friction coefficients based

procedure in the automotive industry

black, shiny and uniform (Fig. 3).

basecoat and a cataphoretic topcoat;

specifications;

Cataphoresis has become a standard

DELTA-eLACK® is a black organic topcoat

• High cathodic corrosion protection thanks to the combination of a zinc-lamellar

Cataphoresis is an electrophoretic coating

basecoat that is also aesthetically perfect:

The main features of DELTA-eLACK®

• Aesthetically pleasing black appearance; 4 1

Figure 4: The workpieces are transferred from the conveyor belt to a drum that is rotated and immersed in the tank containing the cataphoresis product.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

• High chemical resistance; • Sustainable and ecological process; • Threaded parts do not need further processing or finishing; • Good wettability behaviour.

SUCCESS STORIES

Dürr Creates Paint Shop for Electric Vehicles in China

he future belongs to electric cars,

and not installed in the body until the final

to apply the corrosion protection coating. The

since they allow an emission-

assembly line. The workflows in the painting

rotational movement of the bodies does away

free and sustainable mobility.

lines are adapting to these changes.

with the need for entry and exit inclines at the

The established car manufacturers are

Before the bodies are given their top

tank, saving a considerable amount of space.

increasingly being joined in the market

coat in the painting booth, they undergo

The smaller tank capacity means that RoDip

by new competitors, especially in China.

pretreatment (PT) and electro-coating (EC).

uses less energy, water, and chemicals, and

Dürr is currently building a fully automatic

The RoDip rotational dip process is used

in this way reduces the costs per unit. Then © Dürr

paint shop for a local OEM. The plant in Hefei is designed to

the seams on the underbody are sealed, a flat underbody

handle 100,000 units per year,

protection is applied, and

and will commence operation

sound deadening mats are

in June 2018. The integration

applied to the inside of the

of numerous digital@DÜRR

body. This is done using the

solutions turns the paint shop

new EcoGun2 3D applicator,

into a Smart Factory with

which is suitable for all sealing

extensive use of data.

materials and processes.

The new JAC (Anhui Jianghuai

The new channel layout in

Automobile) plant will produce

the applicator head results

battery-powered cars on

in a longer service life and a

behalf of a local electric car

lower pressure level during

manufacturer in the future. The

material feeding. The innovative

vehicles will be given a modern

applicators are mounted on a

two-tone color design in the

total of eight EcoRS 16 or EcoRS

fully automatic Dürr paint shop.

30L16 robots, and in this way

The plant in Hefei combines

apply the sealing material fully

advanced vehicle drives with

automatically to the bodies.

intelligent plant technology

The painting line itself consists

and modern painting concepts.

of a primer station as well as

The entire plant including data

one interior and two exterior

acquisition, data evaluation, and

painting stations for the top

plant monitoring is controlled

coat. Here the bodies are

by the Dürr software solution

removed in some cases and

iTAC.MES.Suite. The modular

returned to the top coat line for

MES system provides detailed

the two-tone roof painting. The

information on the production

final clear coat is also applied

workflows and the consumption

in fully automatic interior and

data at all times.

exterior painting stations. In

Electric vehicles are also increasingly featuring plastic and lightweight components, which are painted separately

Figure 1: First-time use by a local Chinese manufacturer: EcoBell3 Ci atomizers for eﬃcient paint application inside the body

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

order to reduce the solvent emissions as much as possible, the exhaust air flow is purified, not only from the clear coat

SUCCESS STORIES

booths, but also from the paint mixing

a local Chinese car manufacturer (Fig. 1).

exhaust air control with the ovens in

rooms.

They are particularly suitable for painting

Hefei. Dürr’s EcoSmart VEC smart air

Usually the painting process generates

interiors using water-based paints

management system operates fully

particularly large volumes of exhaust

and require no complex voltage block

automatically, delivering energy on

air which only contain low amounts of

systems. The compact design enables

demand. This technology significantly

contaminants. For this reason, a highly

the atomizers to get into each and every

reduces gas and electricity consumption

efficient VOC adsorption concentration

angle inside the body. The robust high-

when drying the freshly painted bodies.

system (Ecopure® KPR) with a downstream

voltage technology produces minimal

With conventional oven systems heated

thermal exhaust air control system

inherent soiling and delivers top quality

using purified gas, the fresh air supply

(Ecopure TAR) should be installed. The

and paint application efficiency. Short

system and exhaust air extraction

energy required for the Ecopure® KPR

system are operated with a

system’s desorption air is recovered

constant volumetric flow rate.

from the purified gas of the thermal

Durr’s EcoSmart VEC smart

exhaust air purification system. This reduces the energy requirement. The highly efficient Dürr Ecopure® exhaust air purification system reduces the solvent emissions by more than 95% and thereby ensures that the especially stringent emission limits are not exceeded.

Dürr is currently building a fully automatic paint shop for a local OEM. The plant in Hefei is designed to handle 100,000 units per year, and will commence operation in June 2018. The integration of numerous digital@DÜRR solutions turns the paint shop into a Smart Factory with extensive use of data.”

air management system, on the other hand, is a predictive control system. It controls the volumetric flow rate of the fresh and exhaust air depending on the current number of vehicles in the oven and their position (Fig. 2).

Fully automatic paint application is

The system therefore ensures

handled by a total of 26 EcoRP E/

that each individual oven zone

L033 and EcoRP E/L133 painting robots.

rinsing and color change times as well as

is optimally and individually supplied

Eight EcoRP 130 scara robots support the

fast cleaning intervals in combination with

with air at all times, and combines

painting process by opening the doors

the EcoBell Cleaner D2 increase the paint

energy efficiency and consistently high

and one EcoRP 133 opens the hood at the

shop capacity and the productivity.

paintwork quality. The exhaust air from

front. The trunk lid as well as the fenders

“Industry 4.0” is the keyword for the

the ovens is purified via the integrated

are made from plastic on electric vehicles,

digital evolution of classical production

Ecopure® TAR afterburning system with

and are not mounted on the body until

technology into the smart factory. With

heat recovery and then made available

late in the production process. There is

its digital@DÜRR approach, Dürr offers

again for the oven heating system.

therefore no need for a trunk opener at

a wide range of solutions. This includes

The new version of the EcoScreen

the rear.

not only the production control iTAC.

3D-OnSite operating software features

This paint shop is the first time the EcoBell3

MES.Suite, but also the integration of

further smart programming and

Ci atomizers from Dürr are being used by

a new software solution for fresh and

simulation options. The software

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SUCCESS STORIES

2 1

Figure 2: EcoSmart VEC controls the fresh and exhaust air volume of the oven in accordance with its current workload.

is the perfectly coordinated tool for

Another smart software function of

pump and needle. The sensor-based

parameterizing, programming, and

the EcoRPC controls the interaction of

paint pressure control system also

simulating Ecopaint robots. The new 3D

the main needle in the atomizer and

ensures minimal mechanical load on the

kernel supports all popular CAD data

metering pump. The self-learning system

pump, as well as a constant discharge

formats.

enables high-precision switching points

rate and therefore constant process

The EcoRPC robot controller provides

for the robots’ painting paths and at the

quality.

smart test functions like valve, brake,

same time determines the wear to the

The robot controllers can be easily

or pump tests, which provide a

incorporated into a centralized

detailed picture of the status of the

data network for the smart

plant technology at any time. The results of the tests are visualized using traffic light functions. This allows the paint operator to easily tell whether, for example, a valve needs to be replaced immediately or whether everything is working reliably in the green range.

The robot controllers can be easily incorporated into a centralized data network for the smart factory of the future, and have the capability to transmit all process-related information from the sensors and actuators as data stream to higher-level maintenance and control systems at the customer’s site or to the Dürr Service Cloud.”

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

factory of the future, and have the capability to transmit all process-related information from the sensors and actuators as data stream to higher-level maintenance and control systems at the customer’s site or to the Dürr Service Cloud.

AERTECH S.A.S. CHEMTEC NORTH AMERICA LLC CHEMTEC LATIN AMERICA LLC

Opening photo: Yaron Shenhav and his colleagues from SolCold, a start-up based in Herzliya, Israel, are developing a unique painting material.

INNOVATIONS: PRESENT&FUTURE

Active Cooling Using the Sun’s Radiation in One Energy Cycle. Investigations into the Possibility of Cooling of Solids Using Solar Radiation Alessia Venturi ipcm®

he sun - while it is our biggest source

the sun, the stronger the radiation, the

limits and raising energy bills.

of light, it is also the biggest source

hotter it gets. In hot weather, electricity

What if we could actually harness the

of heat. As the sun rises, its radiation

consumption soars as people turn on the

sun’s radiation, reversing this relationship

air conditioning, pushing the grid to its

from “more radiation means more heat in

is absorbed and creates heat. The stronger

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

SolCold is developing a unique painting material, no thicker than a piece of paper. Once applied to a surface of an object, the sun’s radiation triggers a reaction in the material. This reaction converts the heat accumulated in the object it is applied to - into radiation. This radiation is then emitted in a process called ‘antiStokes fluorescence’, thus providing the cooling effect.”

Figure 1: SolCold’s material consists of two paint layers: 1 nanofilter paint layer + 1 active cooling paint layer.

our buildings”, to a relationship of “more

the material. This reaction converts

cooling paint layer (Fig. 1). When

radiation actually means less heat in our

the heat accumulated in the object

applied to rooftops of buildings, it

building”’?

it is applied to - into radiation. This

can help save up to 60% in energy

Thanks to a new high-tech paint, developed

radiation is then emitted in a process

costs, which translates into annual

by Yaron Shenhav and his colleagues from

called ‘anti-Stokes fluorescence’, thus

cost savings of +$10,000 per

SolCold, a start-up based in Herzliya, Israel,

providing the cooling effect. Basically,

building (Fig. 2). There’s also a major

the sun itself could soon become a low-cost

SolCold’s material functions as if it was

positive impact on the environment

air conditioner (ref. Opening photo).

a thin layer of ice that gets thicker and

as saving on these energy costs

cooler as the sun gets stronger. The

means a considerable reduction in

new paint actually cools when exposed

CO2 emissions.

SolCold is developing a unique painting

to sunlight and can provide a better

SolCold can be applied to buildings,

material, no thicker than a piece of paper.

way to chill buildings.

cars, containers, and just about

Once applied to a surface of an object,

SolCold’s material consists of two paint

anything under the sun that needs

the sun’s radiation triggers a reaction in

layers: 1 nanofilter paint layer + 1 active

cooling.

The innovation

SolCold’s material consists of two paint layers: 1 nanofilter paint layer + 1 active cooling paint layer. When applied to rooftops of buildings, it can help save up to 60% in energy costs, which translates into annual cost savings of +$10,000 per building.”

2 1

Figure 2: When applied to rooftops of buildings, it can help save up to 60% in energy costs, which translates into annual cost savings of +$10,000 per building.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

because molecules in these materials absorb photons whose light is of one frequency while spontaneously reemitting higher-frequency photons, which also carry more energy. Since energy is lost, the temperature of the material is reduced in the process. “Heat from a building could be absorbed and re-emitted as light,” Yaron Shenhav says. “As long as the sun is shining on it, it would be continuously cooled.” The problem is that the sun’s spectrum is much broader than that of laser light. SolCold’s team had to create a material that could do the same trick using several frequencies of scattered light. The result is a double-layer paint with an outer layer that filters out some of

3 1

the sun’s rays and an inner one that does the

Figure 3: The average drop in temperature for the material was 1.2⁰C with about 1% of the total sun’s energy as a trigger.

heat-to-light conversion, cooling itself below the ambient temperature. So far, the material has been successfully tested in the lab, where the researchers have found that the effect is more pronounced on metal

According to SolCold, the total market size for the new material can be higher than 100 billion dollars: – Buildings: $50B – Cargo: $5B – Vehicles: $30B – Military: $25B Outdoor equipment: $5B

The technology is based on the counterintuitive principle of laser cooling, in which hitting specially designed materials with a laser can cool them by up to 150°C.”

roofs than on concrete, and works best over rooms with low ceilings. Simulations show that a room on the top floor of a house with the paint applied to the roof will feel up to 10°C cooler than of a house without the coating. According to SolCold, commercialization is due in about 1.5 years from now. © SolCold

In recent years, the increasing focus on the environment, together with the need to reduce the energy costs, has prompted the manufacturers of paints and coatings for metal to seek solutions for allowing to reduce the energy consumption. One example are the painting products for the so-called “cool roofs”, with which it is possible to considerably reduce the temperature of the interiors below. This kind of paint, mainly used for pre-painted metal, reduce the amount of heat that buildings absorb, but they can’t actively reduce the temperature in the building, whereas SolCold’s paint can.

How does it works? The technology is based on the counterintuitive principle of laser cooling, in which hitting specially designed materials with a laser can cool them by up to 150°C. It works

4 1

Figure 4: Main emission peak of the sample - Diﬀerence between measurements in the sample to measurements in the reference glass.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

Considering the quite high cost of SolCold

The average drop in temperature for the

SolCold has been conducting experiments

paint systems, early adopters will probably

material was 1.2⁰C with about 1% of the total

to determine whether cooling of solids using

be large commercial buildings. There, the

sun’s energy as a trigger (Fig. 3).

radiation could be accomplished using solar radiation. They found that their sample material

coating could lower energy consumption by up to 60 per cent, massively reducing bills

Using a spectrometer to detect anti-

on average was cooler than a reference sample

and carbon emissions.

Stokes scattering

and its environment. In addition, they have

The experimental system was similar except

observed anti-Stokes scattering from the sample

the replacement of the camera with a

material. SolCold’s team estimated that with

spectrometer (Oceanview USB 2000+) with a

further optimization of the system, combined

resolution of less than 1 nm.

with using 100% of the solar radiation will result

Experimental system for measurement Preliminary tests started January 2016.

in ~20W of cooling power per square meter.

For the cooling tests, SolCold’s team used an IR camera Gobi-640-Gige-4782 with a

Anti stokes cooling power showed

thermal resolution of 0.05 C, with sensitivity

1014nm – main wavelength in, 972.4nm –

to wavelengths between 8-14 micrometers.

main wavelength out (Fig. 4)

The filters used allowed the transmittance

Cooling efficiency: 1 − 972.4 1014 = 0.04

in desirable wavelengths band. The sunlight simulator had a total power of 10W.

SolCold used all the measurements with similar conditions in vacuum with filtered

First cooling showed

sunlight for their material, and for the

SolCold’s team normalized and extracted

reference material and performed a two-

the change in temperature of the material.

sample t test on the two groups.

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So far, the material has been successfully tested in the lab, where the researchers have found that the effect is more pronounced on metal roofs than on concrete, and works best over rooms with low ceilings.

SUCCESS STORIES

E-PASS Optimizes Commissioning of System Software

Automotive OEMs and their suppliers have

irtual commissioning and reliable

high expectations – not just in terms of

generation of software for the management of complex processes

are key to efficient digital engineering. E-PASS, a software standard developed by Eisenmann in cooperation with Siemens, forms the basis for the automated development of tailored control software, including, for example, for a state-of-the-art paint shop for truck cabs at

E-PASS, a software standard developed by Eisenmann in cooperation with Siemens, forms the basis for the automated development of tailored control software.”

DAF in Belgium (Fig. 1).

Figure 1: In Westerlo, Belgium, DAF invested in the most advanced truck cab paint shop in Europe.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

the performance of their paint shops, but also commissioning, functionality and ease of operation. Plant engineering expert Eisenmann offers a broad portfolio of solutions, including paint application systems, material flow automation, and cutting-edge control and visualization technologies. Its specialists design highly efficient automated

SUCCESS STORIES

The software is linked to the actual PLC and visualization system, and then thoroughly tested on a digital twin of the customer plant.â&#x20AC;?

engineering tasks, and accelerate project completion.

Collaboration between the two prestigious

(Totally Integrated Automation) portal,

companies has borne significant fruit. The

meets Eisenmannâ&#x20AC;&#x2122;s requirements for

automated generation of software, and

the development of standardized state-

support for the virtual commissioning of

of-the-art software. In 2013, E-PASS was

plants is now a reality. And the result is

deployed successfully for the first time for an

consistent data storage, standardization, and

Eisenmann plant.

hardware and software interfaces. In other

As a result of a technology partnership,

words, Eisenmann E-PASS enhances the

Siemens also benefits from the experiences

efficiency of software engineering, raises the quality of plant control software,

ÂŠ Eisenmann

processes, streamline software

1500 controllers, combined with its TIA

and increases flexibility (Fig. 3).

to minimize the time needed for

Bridge between physical and virtual world

development and commissioning.

To accelerate time-to-market

In addition, we have to take into

and ensure punctual production

account our customersâ&#x20AC;&#x2122; needs with

start-up, plant control software

regard to the quality and flexibility

is first virtually commissioned via

of control software. Consequently,

E-PASS. The software is linked to

we explore ways to improve the

the actual PLC and visualization

efficiency of the automation process.

system, and then thoroughly

And that starts with engineering,

tested on a digital twin of the

â&#x20AC;&#x153;Today, it is very important to try

in order to effectively address the

customer plant. Realistic testing

2 1

growing complexity of paint systems and equipment. Itâ&#x20AC;&#x2122;s a first step

and commissioning conditions

Figure 2: Andreas SchĂśller, Global Head of Electrical Engineering at Eisenmann.

towards agile, smart manufacturing,â&#x20AC;? explains Andreas SchĂśller, Global

are simulated on the basis of the virtual plant. The functions verified

Head of Electrical Engineering at Eisenmann (Fig. 2).

gained by Eisenmannâ&#x20AC;&#x2122;s project team in

To create a consistent software architecture,

real-world production scenarios, harnessing

Eisenmannâ&#x20AC;&#x2122;s surface treatment professionals

the insights to improve their own hardware

deploy an in-house solution: E-PASS

and software. Christoph Meyer, Vertical

(Eisenmann PLC Application Software

Sales Manager, Digital Factory, at Siemens,

Standard). The control software is configured

emphasizes: â&#x20AC;&#x153;Close cooperation has also

and programmed on a powerful engineering

helped us evolve the Siemens TIA portal,

platform. The Siemens SIMATIC S7-

and this is clearly a classic win-win situation.â&#x20AC;?

E-PASS has been employed for a large number of Eisenmann paint shops at vehicle OEMs, alloy wheel manufacturers, and for surface treatment of metal and plastic parts.â&#x20AC;?

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SUCCESS STORIES

3 1

Figure 3: Eisenmann E-PASS enhances the eﬃciency of software engineering, raises the quality of plant control software, and increases flexibility.

a number of

A tailored, end-to-end solution for DAF

innovative

E-PASS has helped DAF Trucks speed up

functions,

project execution for a complex paint shop

including mobile

at its factory in Westerlo, Belgium (Fig. 4).

visualization

DAF has invested with the goal of significantly

and control,

boosting capacity, and producing truck

transparent data

cabs with the consistently high-quality paint

management,

finish associated with premium cars. The

digital worker

144 m long, 58 m wide and 26 m high paint

guidance and

shop traverses three stories of a 25,000 m2

smart/preventive

production building. According to DAF, the

maintenance.

truck cab paint shop is the most advanced of

It was virtually

its kind in Europe. Production is sequencial,

commissioned,

just-in-time, in line with actual customer

and created by

orders. Eisenmann began developing the

interdisciplinary

corresponding control software in late 2016.

smart teams

Thanks to E-PASS, this work was completed

drawn from

quickly, enabling on-site commissioning

The shop features

in this way can then be implemented on the

multiple units, including Eisenmann

in good time for the commencement of

real-world plant, without further modification,

Industrial Software Company (Enisco)

production in summer 2017. A total of

by means of the E-PASS VCI (virtual

with its successful E-MES production

29 SIMATIC S7-1500 controllers were

commissioning) module. Consequently, virtual

control system.

incorporated for automation purposes. © Eisenmann

commissioning accelerates project completion. It helps ensure there are no unpleasant surprises at the construction site, or expensive delays due to shortcomings in software functionality. In addition, Eisenmann can familiarize the customer with the plant model from a very early project phase. The customer is actively involved in development, and change requests can be accommodated in a timely manner.

References from multiple industries E-PASS has been employed for a large number of Eisenmann paint shops at vehicle OEMs, alloy wheel manufacturers, and for surface treatment of metal and plastic parts. A flagship project is the large-scale paint shop at a maker of agricultural machinery.

4 1

Figure 4: E-PASS has helped DAF Trucks speed up project execution for a complex paint shop at its factory in Westerlo, Belgium.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

s.r.l.

CHAINS FOR CONVEYORS

Visit Us at

PaintExpo 2018 Hall 1 Booth 1332

Leader in Europe since 1962

M A D E

w .

I N

I T A L Y

Opening photo: Components coated by Cal.

FOCUS ON TECHNOLOGY

Two-coat Powder Coatings for Improved Resistance, Quality and Production Speed: the Response of Contractors to the New Market Needs Barbara Pennati ipcm®

pcm® has often dealt with the topic of pre-

to quality improvement and just as relevant in

and harsh environments. The subject is

treatment as a crucial process for better

the industrial coating field is the application of

perhaps of particular interest to coating

coating results. We have also highlighted that

two-coat powder systems. They represent an

contractors, for which versatility, production

the quality level required by different industrial

added value compared to conventional powder

efficiency and delivery speed make a

sectors has significantly increased in the last

coatings for any user requiring better quality

difference as well as quality, in an increasingly

few years. Another issue that is closely related

and resistance results, especially for outdoors

demanding and competitive market.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

Cal Srl is a company with a

FOCUS ON TECHNOLOGY

to invest in a new coating plant

2700 m2 production site in

integrated with a second in-line

Prevalle, Brescia (Italy), devoted

booth exclusively devoted to

to contracting coating activities.

the application of primer. This

In order to meet this growing

has enabled us to improve our

demand and obtain qualitative

production capacity, since we no

results also in line with the

longer need the workpieces to

requirements of new markets, it

go through the line twice – which

decided to invest in the upgrade

was uneconomical in terms of

of its paintshop in order to

both production and delivery

obtain the possibility to also

times.”

apply two-coat powder coatings

In operation since October

without any loss of productivity.

2017, the new coating line

An in-line booth devoted to primer application Established in the ‘90s and specialised in switch covers for some time, Cal installed its

was supplied by Euroimpianti (Valeggio sul Mincio, Verona, Italy). It is a development of

Euro90, an industrial powder coating plant for metal semi-

Figure 1: From left to right, Simone Costantino and Antonio Costantino from Cal, Attilio Pinali and Luisa Accordini from Euroimpianti, and Luigi Costantino from CAL.

finished and end products with completely automated process steps, suitable for companies

first robotised liquid coating

performing mass production and

plant in the 1996, managing to paint up to 3 million switch covers per year. “Following a change in market demands, we decided to switch to powders. In the last seven-eight years, we have specialised in the coating of aluminium,” says Antonio Costantino, the owner of Cal (Fig. 1). “Cast, die-cast and

for coating contractors needing

Cal Srl is a company with a 2700 m2 production site in Prevalle, Brescia (Italy), devoted to contracting coating activities. In order to meet this growing demand and obtain qualitative results also in line with the requirements of new markets, it decided to invest in the upgrade of its paintshop in order to obtain the possibility to also apply two-coat powder coatings without any loss of productivity.”

to ensure short-time deliveries even of large batches (Fig. 2).

The new coating plant “The coating cycle starts with a nanotechnology pre-treatment process including as follows: degreasing, two rinses with mains water, one rinse with

for 80% of our production.

demineralised water with self-

extruded components account They are intended for the

regenerating demineralisation

furniture and lighting sectors as

columns (Fig. 3), and one

well as for all industries requiring

passivation stage with the

highly corrosion resistant

Nebula system for the water

finishes (ref. Opening photo).”

veil application of the chemical

“We needed to keep our

product (Fig. 4),” states Luisa

production times short without

Accordini, the marketing

negatively affecting the delivery

manager of Euroimpianti.

times; at the same time, we

“Such system can reduce the

wanted to offer coating films

water consumption per nozzle

with higher mechanical and

to 4-5 l/h, keeping the water

corrosion resistance properties,

conductivity constant and

able to withstand even possible

limiting the drop cohesion

assembly inconveniences,” says Antonio Costantino. “While keeping our old line, we decided

2 1

Figure 2: The new coating line.

value to ensure the maximum effectiveness of the passivation treatment with the deposition

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

Figure 3: The demineralisation columns.

of a film of a few tens of microns (Fig. 5).” The degreasing tank features a recent technological innovation by Euroimpianti. “We use a system that enables the recovery and recirculation of condensation fumes in order to obtain energy savings through heat

3 1

recovery,” says Luisa Accordini.

The pre-treatment and drying stations are followed by the first coating booth, again provided by Euroimpianti, for the primer application stage; a hot–air oven for gelling the primer; a second booth with a quick colour change system, Wagner’s SuperCenter (Fig. 6); and a polymerisation oven (Fig. 7). “The Euroimpianti booth is activated only if the production cycle in progress requires the coats and it is only devoted to

application of two

the application of the primer in one colour,” says Antonio Costantino. The monorail conveyor is equipped with 651 hooks. It is a compact system with fully automated in-line booths featuring two touch-up stations each. The booths allow to treat parts with different shapes and a maximum size of 1800 x 1200 x 800 mm, thus ensuring total versatility

4 1

Figure 4: At the exit of the pre-treatment tunnel, there are the Nebula system’s nebulisation ramps for the passivating product.

FOCUS ON TECHNOLOGY

INTERNATIONAL PATENT

NITROROBOT 5 1

Figure 5: The control touch screen of the Nebula system.

(Fig. 8). “As coating contractors, we need to be able to handle different types of workpieces with 2 to 6 colour change operations per day,” states Antonio Costantino. “Moreover, since we treat furniture intended for both indoor and outdoor environments, we apply both polyester and epoxy paints, especially the metallic ones, from several suppliers including AkzoNobel, Pulverit and Europolveri. As for the pre-treatment chemicals, we require systems ensuring salt spray test results between

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

900 and 1000 hours.” The new line also offers greater environmental sustainability and a reduction in operating costs. “We stopped using liquid coatings five years ago, upgrading all our old equipment and switching to powders, not just to meet the market needs but also to limit our environmental impact as much as possible,” says Antonio Costantino. “Finally, this new system enables us to keep our energy consumption under control and minimise product waste thanks to the optical barriers placed at the beginning of each booth, detecting the workpieces’ dimension and adjusting the guns’ parameters and the reciprocator’s stroke accordingly.”

In order to improve their offer Cal has made this investment, which has increased the production capacity by 50%. In the future, Cal plans to upgrade the old line, too, in order to use both systems and make the company increasingly versatile and fast.”

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

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

and continuous assistance.” “The possibility to design each system starting from modular components also ensures a number of customisable configuration options, selected according to the specific needs of lower or higher

7 1

productivity and to the type of parts to be painted,” says

Figure 7: The entrance of the polymerisation oven.

Luisa Accordini.

Conclusions

The possibility to design each system starting from modular components ensures a number of customisable configuration options, selected according to the specific needs of lower or higher productivity and to the type of parts to be painted.”

“We started this project because we needed the possibility to apply a powder primer layer on

6 1

some components without slowing production down. In our market, the percentage of clients requiring two-coat systems

Module standardisation and industrial mindset

is around 15-20% and the trend

“We decided to rely on Euroimpianti

our customers have requested

for this upgrading project because we

us to apply them, because they

appreciated their industrial approach

ensure the highly resistant

translating into the standardisation

surfaces needed by markets

of their coating systems through

such as the outdoor furniture

modules. This is a strategic factor

one,” states Antonio Costantino.

for any future upgrade of the line,

“In order to improve our offer,

but also to obtain a timely technical

therefore, we have made this

assistance,” says Antonio Costantino.

investment, which has increased

“We design our plants to optimise

our production capacity by 50%.

their delivery, assembly and

In the future, we plan to upgrade

testing times though component

the old line, too, in order to use

standardisation,” states Luisa

both systems and make Cal

Accordini. “This enables us to

increasingly versatile and fast.

maintain a stock of

Offering a wider and wider range

delivery-ready spare parts and to

will enable us to further grow

face any problems or interventions

and specialise in the processing

quickly and efficiently, so as to

of aluminium, consolidating our

provide our customers with reliable

presence in new markets.”

Figure 6: The Wagner booth with a quick colour change system.

is undoubtedly growing. Many of

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

8 1

Figure 8: The new plant can treat products with dimensions up to 1800 x 1200 x 800 mm.

P O W E R F U L

I N

V E R T I C A L

T L E S S

I N

H O R I Z O N T A L

Powder coating lines since 1976. V E R O N A

I T A LY

B A R C E L O N A S A N T A

S P A I N

C A T A R I N A

F L O R I D A

U S A

B R A Z I L

SUCCESS STORIES

Automated Conveyor System for SEW Eurodrive

streamline the existing process for their

derivatives of geared motor units ranging

Eurodrive

range of drive equipment.

from 15kg to 1000kg, These units being

SEW Eurodrive are globally recognised

Working closely with the engineers at

loaded at one end of the factory and the

as market leaders in drive engineering

SEW Eurodrive, Amber Industries Ltd

system to have the ability for diverting

stretching across five continents and

developed a turnkey solution and was

product from daily business and coloured

employing 14000 people. When their

subsequently awarded the contract for

lanes together with a “Fast-Track lane”. The

new manufacturing facility at Normanton,

the new conveyor system utilising the

fast track lane that by passes normal daily

West Yorkshire was in the planning, SEW

standard Autotrack 500M Power & Free

business is very important to SEW as they

recognised this as an opportunity to

overhead conveyor (Fig. 1).

pride themselves upon their service of

introduce an automated conveyor system to

The brief given by Sew Eurodrive was

having the ability to deliver to customers

service the new paint plant facility that would

that the conveyor had to handle all

on an urgent basis.

utomated Conveyor System for SEW

Figure 1: Working closely with the engineers at SEW Eurodrive, Amber Industries Ltd developed a new conveyor system utilising the standard Autotrack 500M Power & Free overhead conveyor.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

SUCCESS STORIES

There was also the requirement of the conveyor having the capability of raising and lowering product within the spray booth and at the inspection area whilst allowing the operator to rotate the unit during the spray process. A multi height drop section at the inspection area allowed the operator to inspect the product thoroughly prior to despatching to the appropriate unload stations. In order to achieve all of SEW requirements, the system was designed with 2 loading stations having a stationary trolley set assembly in position that would allow the operator to attach the product onto the trolley load bar support points, smaller products being suspended from any of the rotation units on the load bar, whilst larger product would be suspended from the central rotation point. The operator at either of the two load stations scans the product(s) and then presses a button at his work station that determines if the loaded trolley is to be routed to normal business, colour or Fast Track. When the trolley arrives at the storage lanes, the conveyor switch point automatically diverts the trolley into the appropriate storage lane. A monitor within the spray booth allows the operator to view the jobs in hand, allowing him to select from the appropriate lane. The Fast Track lane can by-pass accumulating daily business enabling the unit to be painted without being held up by normal business. With the trolley now in the spray booth, the operator can lower the drop section as required to an ergonomic height due to the differences in product size to allow him to spray all the relevant aspects of the product whilst remaining stationary (Fig. 2). The load bar assembly was designed such that the products can be turned through 360 degree during the spraying operation and then locked after the spray operation to maintain correct product orientation. A major benefit of the drop section ensured that lowering of the product could be achieved within a small area compared to that of a conventional conveyor rise and fall. With the paint spray process now complete and the drop section in the raised and locked position, the operator again

Working closely with the engineers at SEW Eurodrive, Amber Industries Ltd developed a turnkey solution and was subsequently awarded the contract for the new conveyor system utilising the standard Autotrack 500M Power & Free overhead conveyor.â&#x20AC;?

SUCCESS STORIES

presses a button that determines once

automatically routed to the pre-requisite

more if the product routing is that of

unload destination. After unloading, the

standard daily business or if the trolley

empty trolley sets are routed back to the

route is that of “fast track”. The trolley set

loading stations. Using state of the art

that now contains the painted product

electronics enables the integration of the

would automatically be released back

conveyor system to work in conjunction

into the system where it will dry in the

with other plant and equipment ensuring

Drying Oven for a stipulated time period

correct product movement and timings

and temperature. Products are then

as and when required. Consideration

automatically accumulated and released

also had to be given to where products

out of the dryer once they have been in

passed over gangways, with this in

the oven for the allocated time.

mind and the weights involved, a heavy

As the overall paint plant facility has

duty walkable underside guarding was

automatic opening doors within certain

provided where necessary.

In order to achieve all of SEW requirements, the system was designed with 2 loading stations having a stationary trolley set assembly in position that would allow the operator to attach the product onto the trolley load bar support points, smaller products being suspended from any of the rotation units on the load bar, whilst larger product would be suspended from the central rotation point.”

on the conveyor system have to be synchronised with these elements to avoid clash conditions when opening and closing. Product then gets routed to the

parts of the plant, the electronic controls

main dry off oven where again they are accumulated within the oven for another differing stipulated time and temperature. Upon exit of the main curing, the trolley set complete with dried product would then be automatically diverted either into the normal business line or routed to the “fast track” lane. Products that are deemed for daily business would be diverted into a storage loop which in turn then continues to travel to the multi height inspection drop section, but trolley sets that are deemed as Fast Track (urgent orders) do not enter the normal business loop, these are diverted directly to the inspection drop section. The loaded trolley set is again stationary for the inspection process allowing the operator to raise and lower the product together with rotation through 360 degree for full inspection. Upon completion of inspection the operator determines if the product is to be transported to unload station 1 or 2. And the inspected unit is now

2 1

Figure 2: The operator can lower the drop section as required to an ergonomic height due to the diﬀerences in product size to allow him to spray all the relevant aspects of the product whilst remaining stationary.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

Opening photo: Whether on utility poles, expressways, bridges, buildings, water lines, or pipelines, corrosion is all around us.

INNOVATIONS: PRESENT&FUTURE

No Chance For Rust Dr. Philipp Albert Evonik Resource Eﬀiciency, Essen, Germany

philipp.albert@evonik.com

pecialists of Evonik’s Resource Efficiency

bridges, machines, and buildings, whether

annual global losses due to corrosion at an

Segment have developed novel silane-

of metal, concrete, glass, or plastic; in all

astounding US$ 3.3 trillion. So corrosion is a

based corrosion inhibitors that are

of these materials it is a serious problem

drain on the wallet as well as on the surfaces

particularly eco-friendly, easily applied, and

(ref. Opening photo). As long as six years

of materials. Industrialized countries lose

extraordinarily efficient.

ago, DECHEMA, the Society for Chemical

about three percent of their gross domestic

Corrosion gnaws its way stealthily through

Engineering and Biotechnology, estimated

product to corrosion each year. But according

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

Central Europe to DECHEMA, appropriate protective measures could save up to 30 percent of these costs, amounting to approximately US$ 1 trillion every year. These figures clearly indicate that today corrosion protection is an issue that cannot be ignored. Nonetheless, established methods of surface treatment, including chromating and phosphating, are increasingly coming up against limitations and are seen ever more critically, mainly for reasons of environmental protection. Application techniques for substances containing chromium (VI) are particularly problematic. The use of these substances is being banned in Europe in an increasing number of applications, through such provisions as the second RoHS Directive (Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment), which came into force in 2013. The US, Japan, China, and South Korea have adopted similar regulations. Alternative methods for protecting metal surfaces against corrosion are therefore urgently needed, and these methods

Specialists of Evonik’s Resource Efficiency Segment have developed novel silane-based corrosion inhibitors that are particularly eco-friendly, easily applied, and extraordinarily efficient.” must be eco-friendly as well as reliable. Evonik’s developers rely here on hydrolyzed and condensed silanes that form a binder: the formulation of such binders results in eco-friendly corrosion protection systems. During the curing process a protective film with a thickness in the nanometer to micrometer range is formed; although thin, the film is highly impervious and protects the underlying metal against water and corrosive substances. It can be formulated using other binders and fillers to form thicker corrosion protection systems. In recent years, Evonik’s specialists have developed, under the Dynasylan® SIVO brand name, a series of binders that have proved their worth in a very wide range of materials and application methods.

Environmentally friendly zinc dust paints Paints with an underlying zinc dust primer are the means of choice when long-term corrosion protection is called for and other coatings have reached the limits of their capabilities. Typical application areas include transmission towers, industrial plants, bridges, and shipbuilding. The zinc dust in the paint is deposited as a fine film on the surface of the materials, the particle density being so high that the individual metal particles are in contact with one another. The electrically conducting film so formed then serves as anodic i n f o @ w a t e r e n e r g y. i t w w w.w a t e r e n e r g y. i t

visit us at hall 2 - booth 2369

wece@wece.eu w w w.w e c e . e u

It may nevertheless be necessary to provide even these metals with additional corrosion protection if, for example, they come into contact with chloride. Corrosion inhibition primers based on Dynasylan® SIVO 160 are particularly suitable for protecting materials like aluminum, magnesium, and zinc-galvanized iron or steel against corrosion (Fig. 1). In contrast to the current solutions employed in this area, the binder contains neither heavy metals nor fluorides, which are highly objectionable from an environmental viewpoint. These additives are also not required in the formulation of the actual rust inhibition primer. A film thickness of just 100 to 200 nanometers of this water-based silane system is all that is needed to protect aluminum from further corrosion. For use in exterior applications, the system is formulated with additional additives 1

and stabilizers. Thanks to the high reactivity of

Figure 1: Corrosion inhibition primers based on Dynasylan® SIVO 160 are particularly suitable for protecting materials like aluminum, magnesium, and zinc-galvanized iron or steel against corrosion.

the organofunctional silanol groups, curing can take place at temperatures as low as 60°C.

corrosion protection. The current difficulty is

optimal miscibility with fillers and pigments.

Longer service life of structures and installations

that zinc dust paints have often used inorganic

Formulations can be adjusted for high or low

Dynasylan® based corrosion control coatings

binders with high solvent content, which

dry film thicknesses, depending on the area

have been tried and tested over many years—

release volatile organic compounds while

of application.

in Basel’s Picasso Center, for example, and

curing. This is seen increasingly critically on the

London’s “Gherkin” office tower, as well as

dust paints, on the other hand, are normally

When passivation alone isn’t enough

formulated with epoxy which do not tolerate

When metals rust, an oxide film forms

Dynasylan® SIVO offers a double benefit for the

excessive heat or UV radiation.

on the surface. This familiar iron oxide

environment: directly, by releasing fewer volatile

The water-based Dynasylan® SIVO 140 binder

(rust) film is porous. As a result, corrosion

organic compounds, and also by increasing

developed by Evonik’s researchers combines

penetrates even deeper into the metal.

the service life of structures and installations

the best of both worlds. Like the solvent-based

Many other metallic materials such as

as a result of its corrosion-inhibiting action.

inorganic binders, it is powerful and thermally

aluminum, zinc, and magnesium behave

This prevents waste and represents a genuine

stable. But it releases almost no volatile organic

differently, interacting with air on the surface

contribution to sustainability.

substances and is therefore as environmentally

to spontaneously

friendly as the water-based zinc dust paints.

form an oxide film

Dynasylan® SIVO 140 was designed especially

that, although thin,

for use in two-pack zinc dust paints. It is

is impermeable to

formulated with the zinc dust as the second

air. This passivation

component and then cures at normal ambient

protects the

temperatures. The organic-inorganic binder

underlying material

can easily be diluted with water without the

from contact with

generation of undesired ethanol; in addition,

oxygen and thus from

the active silanol groups are stabilized, ensuring

further degradation.

grounds of health and safety. Water-based zinc

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

in protective paints on innumerable bridges and ships all over the world. In all these areas

Corrosion as a cost factor 3.3 trillion US$: global losses estimated by DECHEMA due to corrosion six years ago; 990 billion US$ per year: global potential savings from using existing technology to reduce corrosion; Industrialized countries lose about 3% of their gross domestic product to corrosion.

Paint Engineering

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

Anticorrosive systems

Coil Coating Superdurable Superdurable coatings for sublimation effect Metallic bonding

www.titanpowdercoatings.com

BRAND-NEW

Datacolor ® Releases Match Pigment 4.0 Colour Formulation Software

atacolor®, a global leader in

our proven colour technologies to help our

batch corrections and overall costs.

colour management solutions,

customers maximize their product quality,”

With Match Pigment 4.0, our customers can

launched MATCH PIGMENT 4.0,

said Cheryl Johnson, Director of product

realize many additional benefits, such as:

the latest iteration of its colour formulation

management, Datacolor. “Because we know

• Shorten formulation time with up to 50%

software for paint, coatings and plastics

inaccurate colour can cost businesses

manufacturers (Fig. 1). Employing Datacolor’s

hundreds of thousands of dollars, not

innovative SmartMatch technology, Match

to mention delay to market. With Match

Pigment helps manufacturers most efficiently

Pigment, manufacturers can now have

and confidently achieve their desired colour

confidence in their colour quality, knowing

while saving time and money.

they have obtained it quickly and cost

MATCH PIGMENT 4.0 improves match

effectively.”

acceptance on the first try, optimizes the cost

The Match Pigment software is used by

and quality of recipes, and reduces the need

many of the world’s leading manufacturers

for physical matches. With a streamlined

of paint, coatings and powder coatings,

workflow and user-friendly interface,

where their products are held to the highest

manufacturers can expect up to 50%

of industry standards. It is critical for their

increase in overall speed and productivity.

formulation software to deliver fast and

For further information:

“We have spent over 40 years perfecting

accurate colour matching while minimizing

www.datacolor.com

increase in matching speed • Increase productivity with automatic transfer of multiple formulas to the dispenser queue • Support greater custom/individual needs with flexible matching criteria options • Improve product quality by assuring colorant compatibility for customer use cases • Streamline daily operations with enhanced

user interface

Figure 1: Datacolor® launched MATCH PIGMENT 4.0, the latest iteration of its colour formulation software for paint, coatings and plastics manufacturers.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

Â© Eurotherm

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The Key Role of Sheet Metal Preparation in the Manufacture of Coating Systems and Outdoor Structures Monica Fumagalli ipcm®

n our industry, attention is rarely

able to adequately treat the surfaces

paid to the processes related to

of our plants’ parts, made in different

The completion of the coating line

the manufacture of plants and

materials and with varying (and sometimes

As well as coating Eurotherm systems’

equipment intended for paintshops;

large) sizes and to achieve the quality and

components, Colortec performs

specialised magazines understandably

functional results we required. That is why

contracting treatment and coating

focus on divulging information about

we acquired Colortec. In 2011, we solved a

operations on iron, steel, aluminium and

the characteristics and performance

critical logistic issue by moving the company

galvanised sheet structures primarily

of such devices. This article,

intended for the sectors of machine tools

however, offers us the opportunity

and outdoor furniture and architecture.

to deepen some aspects related to the preparation process of the sheet metal used to build surface treatment plants as well as other metal structures requiring high durability and resistance to external agents (ref. Opening photo). We have visited Colortec (Volpiano, Turin, Italy), a coating contractor owned by Eurotherm and specialised in the construction of complete industrial coating lines for over fifty years. “We acquired Colortec in 2009,” says Paolo Ghiazza, the owner of Eurotherm. “At

The original layout of the coating line designed for the Volpiano plant included

As well as coating Eurotherm systems’ components, Colortec performs contracting treatment and coating operations on iron, steel, aluminium and galvanised sheet structures primarily intended for the sectors of machine tools and outdoor furniture and architecture.”

a cleaning booth featuring a pressure washer for manual pre-treatment and a water recovery system, two application booths (one for liquid and one for powder coatings), and a curing oven. “When we started production, however, we immediately detected a few problems related to the handling of large-sized workpieces,” says Ghiazza. “We solved this bottleneck by expanding the building and equipping it with a large central storage buffer for incoming and outgoing

that time, the company was located in

workpieces, with a capacity of 23 load

Avigliana, about 40 km from Volpiano,

bars (Fig. 1). We also integrated the line

and specialised in liquid coating. Our

to a new plant near Eurotherm’s base, in

with an automatic single-chamber tunnel

management was looking for a solution

Volpiano, equipped with new plants built

for parts up to 6 m in length (Fig. 2),

to the difficulties experienced in the

and installed by us. Then, we optimised

devoted the manual cleaning booth to

pre-treatment and coating of our own

both its pre-treatment process – with the

components with maximum dimensions

plants’ components. Until that moment,

collaboration of Chemtec, a Milan-based

of 7.5 x 4 x 3 m (Fig. 3), and added

we had always outsourced these

company specialising in the production of

a drying oven. At this point, our pre-

two phases. However, it was almost

industrial surface treatment chemicals –

treatment and coating line was complete

impossible for us to find companies

and its application phase.”

(Fig. 4).”

Opening photo: Parts coated by Colortec, ready to be unloaded.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

phosphodegreasing agent that ensures a more intensive cleaning process, especially suitable for galvanised and steel sheets (Fig. 5).” “We provided Colortec with a phosphodegreasing product with two components: a phosphating chemical and a degreasing agent for intensive cleaning,” explains Tommaso Giovenzana, the Technical Manager of Chemtec. “One of the main advantages is that, in the first pre-treatment tank, it is possible to dose the two agents (phosphating and degreasing) as needed.” The one-chamber spray cleaning system used by Colortec also has the drawback

that the contaminants removed from

Figure 1: The central storage buﬀer for the loading and unloading of materials.

both the workpieces and the walls and then collected in the water recovery tank can be dragged, thus increasing the

Doubled rinses for better pre-treatment

but the coating adhesion ones were not.

general contamination level (Fig. 6 and

Therefore, we replaced the alkaline product

7). “In order to solve this problem,” says

“Another issue,” says Ghiazza “was

with a slightly aggressive phosphodegreasing

Giovenzana, “we doubled the number

immediately detected in the pre-treatment

one; this solution proved to be effective for

of rinses in the cleaning tunnel. We

cycle. The management of an automatic

some time. In 2014, however, we turned

therefore switched from a 3-stage to

one-chamber cleaning system is not easy

to Chemtec to optimise our pre-treatment

a 7-stage process including as follows:

and we had to experiment a lot, before

cycle. They supplied us with an acid

phosphodegreasing, pre-rinse, rinse, pre-rinse no. 2, rinse no. 2, spray rinse

the most suitable process solution. The first

with osmotic water, and nanotechnology

cycle tested was composed of three stages: an alkaline degreasing process and two

Chemtec’s intervention allowed us to find

passivation. “The innovative concept is related to the recovery of the pre-rinse water, which is

rinses; the cleaning results were optimal,

channelled into the previous tank in both phases. This considerably reduces the

The innovative concept is related to the recovery of the rinsing water, which is channelled into the previous tank in both phases. This considerably reduces the contamination degree of the tanks that follow the two rinsing stages. Although these intermediate phases tend to be little considered their fine-tuning is often crucial to obtain the required results.”

contamination degree of the tanks that follow the two rinsing stages. Although these intermediate phases tend to be little considered their fine-tuning is often crucial to obtain the required results.”

The nanotechnology passivation system ORGASIL® “Compared with passivation through conversion, requiring an abundant 2 1

Figure 2: The entrance to the automatic cleaning tunnel for parts up to 6 m.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

rinse,” says Ghiazza, “nanotechnology passivation through nebulisation ensures a decisive advantage in terms not only of quality performance, thanks

POWDER PAIN TING BOOTH S

FOCUS ON TECHNOLOGY

3 1

ING BOOTHS

Figure 3: The inside of the manual cleaning booth with a pressure washer.

CURING OVE

LIQUID PAIN

TING BOOTH

SANDBLAST

ORGASIL 01® is a heavy metal-free nanotechnology product and a valid eco-friendly alternative to the microcrystalline or tricationic phosphating ones based on compounds of zinc or other metals, because it does not create toxicharmful waste. This product deposits a thin uniform and continuous nanometric layer on the metal substrate. Formed by organic silanes, this coating makes the film highly hydrophobic, so as to ensure excellent corrosion resistance and good adhesion between metal and paint.”

info@eurotherm.eu T + 39 011 98 23 500 F + 39 011 98 23 560 Via Pisa, 78 - 10088 Volpiano (TO) Italy

4 1

Figure 4: A bird’s eye view of the booths in the paintshop.

EUROTHERM SpA

EUROTHERM SAS

EUROTHERM GmbH

alternative to the microcrystalline or tricationic phosphating ones based on

ORGASIL 01® maintains its stability within a certain pH range (5 to 10): if the pH value falls outside this interval, the organic silanes irreversibly hydrolyse and they are no longer available for the creation of the nanometric coating; it will therefore be necessary to change the bath. That is why it is necessary to make sure that the pH of the bath is as stable as possible. This can be done through some precautions, such as the increase in the number of rinse stages to avoid the dragging of products that can alter the pH value (as in the case of Colortec’s pretreatment process) and the optimisation of the dripping stage required among the different phases, providing for suitable time and space for the conveyor movement.”

compounds of zinc or other metals, because it does not create toxic-harmful waste. This product deposits a thin uniform and continuous nanometric layer on the metal substrate. Formed by organic silanes, this coating makes the film highly hydrophobic, so as to ensure excellent corrosion resistance and good adhesion between metal and paint (Fig.

8 and 9).

5 1

Figure 5: Parts in diﬀerent sizes and materials entering the cleaning tunnel.

to Chemtec’s new passivating product ORGASIL 01®, but also of reduction in the amount of water that cannot be recycled © ipcm ®

since final passivation uses disposable water. In fact, the closed-loop system enables the liquid coming from the demineralised water rinse to be reused in the last tank to compensate for any water loss due to evaporation. Finally, the new system has enabled us to reduce our energy consumption and its related costs.”

6 1

Figure 6: The inside of the cleaning tunnel.

Giovenzana states: “ORGASIL 01® is a heavy metal-free nanotechnology

“ORGASIL 01® maintains its stability

product and a valid eco-friendly

within a certain pH range (5 to 10): if the pH value falls outside this interval, the organic silanes irreversibly hydrolyse and they are no longer available for the creation of the nanometric coating; it

Following the adoption of Chemtec’s process, Colortec decided to eliminate all liquid coating operations and replace their related application booth with a powder coating one.”

will therefore be necessary to change the bath. That is why it is necessary to make sure that the pH of the bath is as stable as possible. This can be done through some precautions, such as the increase in the number of rinse stages to avoid the dragging of products that

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

7 1

Figure 7: Workpieces inside the automatic cleaning chamber.

8 1

FOCUS ON TECHNOLOGY

9 1

Figure 8 and 9: The SEM analysis shows the 1 micron-thick surface of a standard steel sample before and after treatment with the ORGASIL® process developed by Chemtec.

for large workpieces; chemical pre-

pre-treatment occurs in two manual

Colortec’s pre-treatment process) and

treatment for components up to 6 x 2.5

booths equipped with Wagner guns and

the optimisation of the dripping stage

x 1 m; and manual shotblasting. 90%

managed by two operators (Fig. 12 and

required among the different phases,

of parts are treated with Chemtec’s

13). Both booths can treat components

providing for suitable time and space for

chemical process, ensuring high

with a maximum dimension of 7.5 x 5 x 3

the conveyor movement.”

cleanliness levels and perfect coating

m (Fig. 14). A curing phase follows, with a

adhesion on metal surfaces.”

variable temperature depending on the

The powder coating phase following

type of material treated (Fig. 15).

New Eurotherm systems integrated into the coating line Following the adoption of Chemtec’s process, Colortec decided to eliminate

can alter the pH value (as in the case of

all liquid coating operations and replace their related application booth with a powder coating one (Fig. 10). Recently, it has also integrated the layout of its paintshop with a manual shotblasting system using metal media (Fig. 11). For a decade Eurotherm has also been manufacturing manual shotblasting cabinets and compact suction sandblasting systems with a rotary table. The new plant is intended to treat structures that will be placed outdoors and therefore require the performance of a two or three-coat anticorrosion process including shotblasting, zinc primer application and topcoat application. “In summary, Colortec can currently

10 1

carry out three pre-treatment processes: manual cleaning with a pressure washer

Figure 10: The outside of one of the two powder application booths.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

Figure 11: Eurotherm’s manual shotblasting system.

11 1

Figure 12: A few perforated sheet pieces waiting to be painted.

12 1

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

to the variety of shapes and materials to be treated (Fig. 16). We are considering to automate a few production stages, such as shotblasting. Meanwhile, the control

“We chose a manual coating process,” states Ghiazza, “due

software that manages our entire production flow is essential to make the process flexible and coordinate the operators’ interventions.

Production progress control through a PLC The case of Colortec proves that the human-machine relationship is still crucial to better manage the material and labour resources available. The Colortec’s operators take charge of the incoming orders and selects the right pre-set treatment programs based on the customers’ requests (Fig. 17). There are different parameters to be set, such as pre-treatment specifications, RAL colours, number of bars, and amount of powder to be used. Once the required data are entered, the operators start the production process following all the parameters selected. They simply need to enter the indicated values on each management device of the plant. When the processing cycle ends, the customer is notified by e-mail that its order has been completed; in case there is any problem or surface defect, the system immediately detects it and the notification is blocked until the issue

Figure 13: The powder application phase in one of the two booths.

is resolved.

13 1

14 1

Figure 14: An example of a large component being coated.

Colortec can currently carry out three pre-treatment processes: manual cleaning with a pressure washer for large workpieces; chemical pretreatment for components up to 6 x 2.5 x 1 m; and manual shotblasting. 90% of parts are treated with Chemtec’s chemical process, ensuring high cleanliness levels and perfect coating adhesion on metal surfaces.” international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

The cooperation with Chemtec has encouraged the research and development of a suitable process for one of the most delicate phases of a coating cycle: surface preparation. Following their intervention, Colortec has no longer detected any adhesion issue. The quality and resistance of the coatings are constantly praised by the customers, whether it be the companies installing and using the Eurotherm’s systems or firms entrusting Colortec with the coating of their products.”

Conclusions “Colortec,” says Ghiazza, “works in 3 shifts for 5 days out of 7. This results in a sustained production flow, which took time to be optimised and which can certainly be further improved. However, we know that we are moving in the right direction, especially because numerous operators in the sector, above all customers from France and Germany, visit our plant in Volpiano

15 1

Figure 15: Components outside the curing oven.

to follow the training courses we offer.

production with highly customised

and profitably exploit the technical

“Eurotherm’s customers are typically

technical solutions: witnessing a coating

performance of Eurotherm’s plants

representatives of companies

cycle optimised at every stage such as

and they understand the appropriate

that, despite already knowing

Colortec’s one enables them to gain the

procedures for obtaining the qualitative

the peculiarities of the coating

right know-how. This gives them two

and functional results required by their

process, want to improve their

advantages: they learn how to manage

clients.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

PAINTING ROBOTS & SYSTEM INTEGRATOR The full range of articulated and cartesian robots for every painting need! LeBot A6: 6 axis articulated robot with self-learning, point to point and 3D offline programming, available also with carriage and carousel configurations. gurations.

16 1

Figure 16: The manual powder application phase on large-sized workpieces.

LeBot C5: 5 axis cartesian robot with shape acquisition scanner system. scan stem. “Our cooperation with Chemtec has encouraged the research and development of a suitable process for one of the most delicate phases of a coating cycle: surface preparation. Following their intervention, we have no longer detected any adhesion issue. The quality and resistance of our coatings are constantly praised by our customers, whether it be the companies installing and using our systems or firms

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

entrusting us with the coating of their products.”

WWW.LESTA.IT W WW.LESTA.IT

17/04/2018 – 20/04/2018 Karlsruhe, Germany

17 1

Figure 17: The touch screen of the PLC unit.

We invite you to visit our Booth Booth: Hall 3 - Booth 3525

LESTA S.r.l.

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

ÂŠ acp â&#x20AC;&#x201C; advanced clean production GmbH

Opening photo: Due to significantly reduced costs, space requirements and energy consumption, as well as easy integration into fully automated processes, CO2 snow-jet blasting continues to gain ground where the painting of plastic parts is involved.

INNOVATIONS: PRESENT&FUTURE

Painting Trends in the Automotive Industry. Further Increases in Quality, Efficiency, and Flexibility for Automobile Painting Doris Schultz Schulz.Presse.Text, Korntal, Germany

Doris.schulz@pressetextschulz.de

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

challenging. On the one hand, numerous

hanging customer requirements, ever-stricter quality demands, shorter and shorter model

lifecycles, increasing use of lightweight design technologies as well as advancing digitalisation and networking of manufacturing processes are occupying the automotive industry and its suppliers where vehicle painting is involved as well. Companies in the field of industrial painting technology are working on innovative solutions for all conceivable applications, in order to do justice to the challenges

Changing customer requirements, ever-stricter quality demands, shorter and shorter model lifecycles, increasing use of lightweight design technologies as well as advancing digitalisation and networking of manufacturing processes are occupying the automotive industry and its suppliers where vehicle painting is involved as well.”

intermediate steps such as grinding and puttying are still required in order to produce a class A surface. On the other hand, electrochemical corrosion at the edges of the CFRP components needs to be avoided, which can occur after processing if freestanding carbon fibres come into contact with metallic components. Various projects dealing with these issues are currently in progress with the goal of, amongst others, developing a process for appropriate edge sealing. For temperature-sensitive lightweight materials such as plastics and composites,

resulting from these trends.

An attractive appearance and ideal protection of the sheet metal exterior – these

high baking temperatures ranging from 100° to 200°bC after cathodic dip

are the traditional tasks

painting can also be

of automobile painting.

problematic. Paint

But the demands have

suppliers are working

changed dramatically.

on solutions to this

For example,

issue, for which

individualisation is

significantly lower

required to an ever

baking temperatures

greater extent for

suffice. However, it

both the exterior and

must also be assured

the interior, which

that other process

in the end will result

steps such as the

in a manufacturing

curing of adhesives,

lot quantity of 1.

sealants and bake-

Auto bodies and components are produced more and more frequently from material combinations

hardening alloys

can also be reliably

Figure 1: Skid-free transport of auto bodies results in energy savings, and increases flexibility in the painting process because transport speed can be matched to the respective process step.

executed at these temperatures. Timeconsuming quality inspection of cathodic

which contribute to reduced vehicle weight, and thus to lower

throughout global markets. Companies in

dip painting, which is still conducted by means

fuel consumption as well. Car sharing,

the painting industry are working towards

of destructive methods, can be reduced or

electromobility and autonomous driving

the improvement of existing solutions and

completely replaced with the help of suitable

trends, as well as advancing digitalisation

the development of new ones – in all steps

simulations.

and networking of production processes,

throughout the process sequence – in

The traditionally used power-wash system

are also resulting in new tasks and

order to achieve these goals.

with downstream retained water dryer is

requirements in the field of painting

being replaced to an ever greater extent

technology. Factors such as increasing

Matched Pre-Treatment

the first-run quota and improving system

Where composite designs are involved,

jet blasting, plasma processes and steam

availability, as well as energy and materials

in particular the use of carbon-fibre

cleaning techniques for the pre-treatment of

efficiency, are playing an important role

reinforced plastics (CFRP) in combination

components made of plastic and CFRP (ref.

in the implementation of these tasks

with metallic components is still quite

Opening photo). In addition to significantly

by alternative technologies like CO2 snow-

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

2 1

Figure 2: Manufacturers are taking advantage of various optimisation options in order to further increase the paint application eﬃciency of atomisers, for example adjustable spray jet widths as well as modification of the air control units and rotating bells.

efficient alternative for wet-on-wet applications

reduced costs, space requirements and energy consumption, reasons for this trend also include the option of being able to easily integrate and control these alternatives in a networked manufacturing environment.

Highly Eﬃcient Painting Processes Filler-free painting is not entirely new, but it’s still highly relevant. The function of the filler coat is usually implemented by means of a waterbased paint system for this so-called integrated concept. Depending on appearance, hue and the quality levels which can be achieved with the filler-free process, the conventional process with filler, basecoat and clear coat is the more

The traditionally used power-wash system with downstream retained water dryer is being replaced to an ever greater extent by alternative technologies like CO2 snow-jet blasting, plasma processes and steam cleaning techniques for the pre-treatment of components made of plastic and CFRP.”

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

without intermediate drying. Speaking of appearance, the current trend is moving towards more and more polychromatism and individualised painting. The goal is to be able to paint without masking and to significantly reduce required time and effort. Painting without masking has already been implemented in the aviation industry for tail fin coatings, to which decoration has been added without any overspray through the use of individual droplets. Spray film is another approach which can be applied with a very sharp edge and simply pulled back off again later.

INNOVATIONS: PRESENT&FUTURE

A new conveyor system which transports auto bodies through the paint shop without any skids makes it possible to reduce energy costs, because skids no longer have to be warmed up and cooled down.â&#x20AC;? A new conveyor system which transports auto bodies through the paint shop without any skids makes it possible to reduce energy costs, because skids no longer have to be warmed up and cooled down (Fig. 1). Furthermore, this increases the flexibility of the painting process because speed can be adapted to the respective process step. Cycle times and throughput can be laid out flexibly and optimised in this way. Decorative and functional parts for the vehicle interior, as well as trim moulding such as pillar trim in proximity to the body, are usually manufactured by means of plastic injection moulding. The surfaces of these components are subject to highly individual requirements with regard to optical and haptic characteristics, as well as durability. These requirements can be fulfilled with the help of advanced solutions based on the RIM curtain coating process. The two paint components are injected into the mould during the reforming or in-mould decoration process. If colour is added as a third component, 3-component mixing heads make it possible to inject it directly at the part, and colour changeovers are just as fast and simple as with spray painting. Coated components can thus be manufactured by means of a one-shot process. In the case of conventional spray painting of plastic parts for the vehicleâ&#x20AC;&#x2122;s interior, one-coat systems decrease the number of process steps, thus resulting in increased throughput in addition to time-savings and reduced material consumption. Newly developed paint systems are also available for the protection of fine wooden dĂŠcors. Top coating can thus be completed in roughly 3 hours - using either a manual or an automated spray painting process. As compared with previously used systems, this represents time-savings amounting to 5 hours, which constitutes a considerable increase in productivity.

Application Technology with Improved Eﬃciency

cleaning costs. Where cleaning of the paint

Atomisers for water-based paints can be used for painting various plastic components as well as for combination zones in the vehicle’s interior and exterior. Compact dimensions provide for easy access, even in geometrically complex areas.”

application systems is concerned, a new

painting various plastic components

in geometrically complex areas. Beyond

Innovative Dryer Technology

as well as for combination zones in the

this, the new atomisers are distinguished

New dryers are also making it possible to

vehicle’s interior and exterior. Compact

by rugged high-voltage technology and

save considerable amounts of energy and

dimensions provide for easy access, even

minimal contamination, thus reducing

space in the auto body painting process.

Where application is concerned, processes which permit coating without any overspray, or with significantly reduced overspray, are the goal. Until solutions of this sort are actually available, highest priority is assigned to increasing paint application efficiency. Companies make use of various optimisation potential to this end, for example modification of the air control units and rotating bells, as well as spray jet adjustability (Fig. 2). Thanks to their flexibility, these atomisers

colour and paint system changeovers, and thus increases the flexibility and productivity of the painting process. There’s a definite trend towards dry scrubbing systems for overspray. The air in the paint booth can be recirculated to a great extent in this way. Furthermore, dehumidification of the air as required for wet scrubbing systems is eliminated and the energy consumed for this purpose can be saved.

for water-based paints can be used for

VOC-free rinsing technology supports quick

3 1

Figure 3: In addition to significant savings where energy, footprint and manufacturing costs are concerned, new dryer concepts with heating integrated into the dryer tunnel and swivel nozzles are also making it possible to heat up various auto body types and areas in accordance with actual requirements.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

For example, an oven has been created

auto bodies, which is still frequently

for which the burner and the fans have

conducted visually by production

Paint Shop 4.0 and Machine Learning

been integrated into the drier tunnelâ&#x20AC;&#x2122;s

employees, results in fatigue and is

A high-performance MES (manufacturing

side panels, which not only makes it

thus a source of error. New solutions,

execution system) which monitors

compactor and more space-saving,

for example based on light tunnels

and controls production is the key to

but rather reduces flow loss as well.

equipped with energy-saving LED

efficient manufacturing. Integration of

Temperature and air flow can be ideally

technology in which the auto bodies

the data acquired by sensors from the

matched to various auto body types

are illuminated homogenously and

various areas of the paint shop makes

and areas through the use of swivel

glare-free to a great extent, permit

it possible to set the process up more

nozzles (Fig. 3).

ergonomic workstations and a

effectively. If essential data regarding the

In the case of electric vehicles, for

reduced error quota. At the same

condition of the system, the processes

example, this assures that the sill

time, inspection data can be acquired

and the products are analysed and

panel, with its increased material

automatically and transferred to

linked to each other, the systems

thickness, is heated up to the required

production control.

can also be rendered intelligent and

temperature to the same extent as

self-regulating by means of knowledge-

areas in which substrates with only

based algorithms. Corresponding

minimal material thickness are used.

solutions are already available for

An additional feature of the new dryer is load-dependent operation, which also makes a distinct contribution to reduced operating costs. Inspection of the coating film on

Temperature and air flow can be ideally matched to various auto body types and areas through the use of swivel nozzles.â&#x20AC;?

various functions within the paint shop, e.g. air management for paint dryers and preventive maintenance. And the self-programming painting cell for coating products with a

Dynamic contour detection Sophisticated coating solution

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

Industry 4.0 Ready

www.gemapowdercoating.com

4 1

Figure 4: In the case of the self-programming painting cell, the droplet trajectory is calculated by means of a multi-physical spray painting simulation – shown here using the body of a Volvo V 60 as an example.

A high-performance MES (manufacturing execution system) which monitors and controls production is the key to efficient manufacturing. Integration of the data acquired by sensors from the various areas of the paint shop makes it possible to set the process up more effectively.” manufacturing lot quantity of 1 is no longer fiction either (Fig. 4). It was developed during the course of a research project and makes an automatic painting process possible in five steps: First of all, the object to be painted is scanned three-dimensionally and a fluid-dynamic simulation is created on the basis of the scanning data. The trajectories of the paint droplets are ascertained and the ideal paint and air quantities for the desired layer thickness are determined. As a third step, the system works out the best possible robot path for the painting process on the basis of these data. This is followed by the actual painting process, after which quality inspection is conducted as the fifth step through the use of terahertz technology.

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

PaintExpo – World’s Leading Trade Fair for Industrial Coating Technology PaintExpo covers the entire process sequence for coating technologies and provides a comprehensive overview of the latest developments. PaintExpo’s exhibition programme covers coating equipment for liquid, powder, UV, immersion and coil processes, paints and enamels for all processes, application systems and spray guns, automation and conveyor technology, cleaning and pretreatment, drying and curing, environmental technology, pneumatics, compressed air supply and exhaust purification, water treatment, recycling and disposal, accessories, masking, measuring and test technology, quality assurance, identification, paint stripping, job-shop coating, services and technical literature. Nearly all renowned suppliers participate at the world’s leading trade fair for industrial coating technology. Comprehensive, representative offerings allow visitors to gather detailed information in a targeted fashion, and to make direct comparisons of various systems and processes at a single location. PaintExpo will take place at the exhibition centre in Karlsruhe (Germany) from the 17th through the 20th of April, 2018.

27-29 March

International Exhibition & Congress For the paint, printing ink, vanish, glue and adhesive industries

Paris Expo Porte de Versailles

France RAW MATERIALS COATINGS PIGMENTS

SOLVENTS ADDITIVES

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POLYMERS

FILLERS

CONSTRUCTION CHEMICALS PRODUCTION EQUIPMENT

MIXERS & MILLING LABORATORY EQUIPMENT CONTROL & MEASURING EQUIPMENT

COLORIMETRY TINTING SYSTEMS

PACKAGING & CONTAINERS LINERS FOR PACKAGING DRUMS, CANS, BUCKETS HANDLING EQUIPMENT & FREIGHT

APPLICATION EQUIPMENT

SERVICES

Visit the unique European event for coatings professionals in 2018! ] Meet 200 exhibitors to be aware of the coatings industry’s developments and be at the heart of innovation.

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An event co-organised by:

ANALYSIS

How Long Should You Run an Accelerated Weathering/Corrosion Test? Carly McGee KTA-Tator, Inc., Pittsburgh, Pennsylvania

www.ktauniversity.com

“I

would like to issue a 30-year warranty on

into one cycle may not prove beneficial,

because different types of materials react

my product. How long of a test should

but rather would complicate the analysis

in diverse ways, no one cycle can be

I run to correlate hours to years?” or,

when a failure occurs. Another aspect to

specified for every material. Laboratory

“Our engineering standard requires 2000

consider is the proportion of the duration

exposure is simply giving you a means

hours of exposure. Is that long enough?” and

and intensity of one stressor relative to

“what is the correlation in years?” these are important questions, and are challenging to answer. This article

to aspects of the simulated service condition(s). By evaluating the material’s susceptibility to

attempts to answer these and other

different aspects in separate

questions pertaining to accelerated

exposure regimes, you can rank

weathering testing.

the materials for resistance to

We first need to rewind and start

moisture separately from their

with why we run accelerated

resistance to corrosion, and so

weathering regimes. Any exposure

on.

test, from salt fog to ultraviolet

There are, however, instances

light exposure, simulates a limited

where the mechanisms work in

number of characteristics of a service

tandem; for example, straight

environment. We run a test to evaluate

UV light exposure from the sun

a material’s susceptibility to the usual

is rarely specified for exposure

suspects: corrosive conditions, solar

of exterior coatings as sunlight

radiation, sensitivity to moisture,

and rain (or condensation) work

temperature, pollution, windborne

together in nature to degrade

particulates, or a myriad of other, less

materials like plastics and

quantifiable powers (yes, even bird

coatings. Artificially generated UV

droppings). Exposure tests provide

light will destroy polymer bonds

us with a means to expose a material

and discolour pigments the

under very specific, measurable

same as the sun; rain and dew

parameters, and perhaps accelerate

then remove the degradation

the exposure compared to real-time.

products, exposing fresh polymer

Next, we need to touch on how to

and pigment. One exposure test,

run an exposure test to answer our questions. Some exposure regimes incorporate multiple stressors into one cycle, which should be done with

ASTM D5894, Standard Practice

for Cyclic Salt Fog/UV Exposure

Figure 1: Test panel subjected to UV and corrosive exposure.

of Painted Metal, (Alternating Exposures in a Fog/Dry Cabinet and a UV/Condensation Cabinet)

caution. If a material underperforms, there may be no means to pinpoint which

another. For example, porous materials may

combines ultraviolet light, heat, moisture,

stressor was the culprit. The mechanism of

experience a greater acceleration factor,

corrosive conditions, and temperature

degradation is different for each of these.

as they are more susceptible to moisture

cycling into one regime (Fig. 1). The

Attempting to combine degrative mechanisms

intrusion than less porous materials. And

corrosive portion of the Standard Practice

100

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

ANALYSIS

then be compared to the same material

incorporates nature’s by-products of pollution and naturally occurring salts, ammonium sulphate and sodium chloride, in a slightlyacidic (pH 5.0-5.4), low concentration solution. ASTM D5894 is often the go-to single exposure regime to simulate several aspects of a standard outdoor environment. Let’s say the “why” behind your test is that your

Exposure tests provide us with a means to expose a material under very specific, measurable parameters, and perhaps accelerate the exposure compared to real-time.”

from the actual service environment to judge if the mode of failure matches up. This is especially true for UV light exposure. If the problem in the field is chalking and the accelerated testing that is performed produces yellowing and blistering, the exposure may have been too hot or too

products are on display at retail stores along

moist, with not enough (or the incorrect

the coast, outdoors in the summer months

wavelength of) UV radiation. Spectral including a low-end performer and a high-

distribution and peak irradiance are

main entrance). After one season, corrosion

end performer of similar composition to the

important factors to consider. The output

is apparent along all the edges. You decide to

material under test is preferred to judge

of most UV-producing devices simulates

specify a salt spray regime to qualify all future

whether the exposure was severe enough,

only a very narrow band of wavelengths

materials used for that product. Your “how”

or too severe. Note that the exposure of

– typically the wavelengths that are most

is going to include products in the test with

the control specimens must be performed

deleterious to the material under test.

known susceptibly, starting with your one-

concurrently.

Irradiance in the UVA range of wavelength

season wonder as control sample #1. Ideally,

Performance of the control specimen can

(e.g., the coating on a canopy covering the

2 1

Figure 2: Q-Lab QUV cabinet.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

101

3 1

Figure 3: Q-Lab QUV cabinet in use.

Wavelengths in the UVB range, contrarily,

of the UV/heat/condensation devices, which

another entity or in the future, all without

can give erroneous results because the

is the QUV chamber - Fig. 2 and 3). Since

knowing just how many months your test

unnaturally short wavelength is found in small

I don’t want to disappoint the skimmers,

was intended to represent. This raises

quantity naturally, and is non-existent in the

references from various sources (most with

another point: can you compare results

winter months in some regions. If the intent

no professional reputation) have stated that

obtained in one apparatus to results from

is to design an exact regime to replicate (as

1000 hours (6 weeks) in a QUV chamber is

another (same model) apparatus, or to

close as feasible) actual service conditions, it

equivalent to anywhere from 6 months to 2

results obtained at a different time? Both

is important to gather data or measure the

years of natural exposure.

are generally not recommended, so it

meteorological parameters. Once you have

Of course, this is particularly dependent on

follows that establishing a pass/fail criterion

determined the correct spectral distribution,

the duration of your light and dark cycles,

should not be practiced. UV light exposure

you could intensify the natural sunlight (thus

temperature, lamp type, the latitude of

tests generally have good reproducibility,

accelerating your exposure) by concentrating

your location, and so on. Mother nature

if the test results are evaluated in terms

it into one area using mirrors.

is not calibrated, nor does she boast a

of performance ranking only. Attempting

Despite the “whys” and precautionary mumbo-

particularly robust coefficient of variation.

to evaluate a product for resistance to UV

jumbo, some of you may be skimming this

Rest assured, however, that your test will

light in a test chamber against an external

article looking for the numerical correlation

provide a reliable comparison of results

criterion will likely place more than just your

between accelerated testing and real-time

under specific test conditions, and those

coatings into hot water.

exposure (particularly for the most common

conditions could (potentially) be repeated by

The last question to answer is: how do you

102

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

ANALYSIS

evaluate the results of accelerated weathering? Visual effects such as chalking, blistering or rusting are obvious and straightforward, as there are corresponding ASTM standards that can be used to guide these evaluations. Less visible property changes such as sensitivity to moisture can be evaluated by a hardness test or solvent resistance. One of the more comprehensive methods is the evaluation of barrier properties using electrical impedance spectroscopy (EIS) or other electrochemical means. EIS involves applying an AC potential to an electrochemical cell, and then measuring the response. The result is the

Less visible property changes such as sensitivity to moisture can be evaluated by a hardness test or solvent resistance. One of the more comprehensive methods is the evaluation of barrier properties using electrical impedance spectroscopy (EIS) or other electrochemical means.”

change in resistance, as observed by change in magnitude and phase shift. Note however that detecting changes in barrier properties of coatings that are 15-20 mils or more using EIS can be quite time consuming and require long term exposures.

Conclusion: everything is relative. Just like every being on the planet, we are somehow related, and yet unarguably unique. Every service environment has a completely unique “DNA” of circumstances that will drive you crazy trying to replicate. Side-step the confusion by relying on low-end and high-end performers of known durability in all your exposure tests, and the required duration will reveal itself. Instead of searching for the perfect exposure regime and the ideal duration, save the frustration for another project, and break down the opposition into components that you can precisely measure and control.

Carly McGee is the Physical Laboratory Manager for KTA-Tator, Inc. where she routinely consults with clients on accelerated testing regimes and manages projects involving accelerated testing of high performance coating systems described in this article. She can be reached at cmcgee@kta.com

STANDARD & LEGISLATION - UCIF Informs

2018 Budget Law: The “Business 4.0” Plan Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan

info@ucif.net

he Italian 2018 Budget Law (Law no. 205 of December 27, 2017 –

December 31, 2018 the order must be accepted by the seller and a down

GURI no. 302 December, 27 2017) confirmed and strengthened

payment of at least 20% of the acquisition cost must be made. The benefit

some of the measures concerning the Industry 4.0 Plan (now

for intangible assets included in the Attachment B of the 2017 Budget Law

called Impresa 4.0, i.e. “Business 4.0”) passed by the Government in

was confirmed, too, with the following integrations:

September 2016. In particular, the hyper-amortisation plan was extended

• supply chain management systems intended for drop-shipping models

to 2018; the goods must be delivered by December 31, 2019, whereas by

104

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

in the e-commerce industry;

STANDARD & LEGISLATION - UCIF Informs

• software and digital services for

acquisition cost must be made; again, the

number of students in possession of

an immersive, interactive and

goods must be delivered by December 31,

skills enabling the use of advanced

participatory use, 3D reconstructions,

2019.

technological and organisational innovation tools also related to the

augmented reality; • software, platforms and applications

Further money was allocated for the

Industry 4.0, further funds were

for logistics management with high

“Nuova Sabatini” measure and the tax

allocated as follows:

integration of service activities (intra-

credit granted for training activities (40%

• 10 millions of € in 2018

factory communication, factory-field

of the expenses related to the sole cost

• 20 millions of € in 2019

communication with the telematic

of employees for the time period in which

• 35 millions of € in 2020

integration of on-field and mobile

they are involved in such activities). This

in addition to the Fund for higher

devices, telematic detection of

tax credit is granted up to a maximum

education and technical training

performance levels and failures of on-

annual amount of € 300,000 per

created with the 2007 Budget Law.

field devices).

beneficiary. UCIF, actively involved from the

The super-amortisation plan was

Funding for education was also provided.

beginning of works together with the

confirmed, too. Also in this case, by

In order to enable the technical and

ANIMA Federation, will continue to

December 31, 2018 the order must

applied technology high schools of the

follow this issue to provide support

be accepted by the seller and a

national education system to improve

and information to its members that

down payment of at least 20% of the

their offer and, therefore, increase the

manufacture and sell systems 4.0.

join us on

The Millennium Event The Aluspecialists’ Meeting

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9 – 13 APRIL 2019 Treviso, Italy

WHERE INNOVATION MEETS BUSINESS CALL FOR PAPERS ABSTRACT DEADLINE*: 30 APRIL 2018 Topics of the conference include (but are not limited to): Markets & Strategies - Alloys Billets & Related Equipment - Rolling Technology - Architecture & Special Uses - Transport & Automotive Industry – Extrusion • Process Sustainability • Process Management • Process Monitoring • Plant & Process • Process Simulation • Product Quality • Alloys • Dies • New Processes – Anodizing – Coating - Nano Technologies – Automation - Measuring, Testing & Quality Techniques Advanced Applications & Research - Environmental Protection & Recycling - Casting & Die Casting • Process Management • Process Quality • Process Monitoring • Process Innovation • Process Simulation - New Alloys * Send your Abstract to aluminium2000@interall.it following the template available on the official website For Information: Interall Srl, Via G. Marinuzzi 38, 41122 Modena, +39059282390 info@interall.it – aluminium2000@interall.it – www.aluminium2000.com

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FORNITORE OFFRESI

108

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media partner

GRINDTEC

Augsburg, Germany March 14-17, 2018 www.grindtec.de/en

WIN EURASIA

Istanbul, Turkey March 15-18, 2018 http://win-eurasia.com/en

SURFACE TECHNOLOGY EURASIA Istanbul, Turkey March 15-18, 2018 http://win-eurasia.com/en

Dubai, UAE March 26-29, 2018 www.surfacedesignexhibition.com

EUROCOAT

Paris, France March 27-29, 2018 www.eurocoat-expo.com

INDUSTRIE

Paris, France March 27-30, 2018 www.industrie-expo.com

MIDEST

Paris, France March 27-30, 2018 www.midest.com/en/Home/

LIGHT&BUILDING

MACHTECH&INNOTECH EXPO

MIDDLE EAST COATINGS SHOW

SURFCOAT KOREA

ST. PETERSBURG TECHNICAL FAIR

COATING KOREA

ESEF

SURTECH KOREA

Frankfurt/Main, Germany March 18-23, 2018 light-building.messefrankfurt.com

Dubai, UAE March 19-21, 2018 coatings-group.com/mecs/dubai/?p=show/mecs/

St. Petersburg, Russia March 20-22, 2018 http://en.ptfair.ru

Utrecht, The Netherlands March 20-23, 2018 www.esef.nl/en/Exposant.aspx

ipcm

media partner

ipcm

media partner

ipcm

media partner

Sofia, Bulgaria March 27-30, 2018 http://machtech.bg/en

Incheon, South Korea March 28-30, 2018 www.surfcoatkorea.org

Incheon, South Korea March 28-30, 2018 www.coatingkorea.com

Incheon, South Korea March 28-30, 201 www.surtechkorea.org

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

109

ZOOM ON EVENTS

Solutions for Trends in Industrial Coating Technology

Figure 1: With its comprehensive exhibition program, PaintExpo provides solutions to the challenges presented by liquid painting, powder coating and coil coating.

mproving material and energy efficiency,

a sharper competitive edge (Fig. 1). The

Changing requirements with regard to

optimizing quality, increasing flexibility,

world’s leading trade fair for industrial

product individualisation and digitalisation

reducing unit costs and digitalising

coating technology will take place at the

of manufacturing processes are being

manufacturing processes – these are a

Karlsruhe Exhibition Centre from the 17th

tackled on the other hand. Exhibitors at

few of the significant trends which are

through 20th of April, 2018.

the upcoming PaintExpo, being held at

occupying companies with in-house

Whether liquid painting, powder coating or

the Karlsruhe Exhibition Centre from 17

coating operations. PaintExpo exhibitors

coil coating is involved – running processes

to 20 April 2018, will offer a broad range

will present new products and further

more efficiently and sustainably, improving

of innovations and further developed

developments for the implementation

coating quality and enhancing productivity

products and services for the fulfilment

of these trends, which also contribute to

are being targeted on the one hand.

of these tasks. The list of participating

110

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

ZOOM ON EVENTS Improving Material Eﬃciency

matched to the object to be painted with

sector’s market and technology leaders.

Increasing material efficiency is an issue

devices for contactless, online layer thickness

“This makes it possible for job-shop coaters

for which the exhibitors present innovative

measurement. In addition to material savings,

and visitors from companies with in-house

solutions. Attention is focused on

this results in improved coating quality and

coating operations to gather comprehensive

application systems both with and without

minimal scrap rates. Optimal alignment of

information about the most up-to-date

electrostatic charging, which per se permit

the application system to the object to be

developments and trends in the field of

higher levels of material efficiency (Fig. 2).

painted also has a significant influence on

industrial coating technology.

For example, spray guns with electrostatic

material efficiency. Laser scanning systems

At the same time, corresponding

charging for manual and automatic

are available to this end for liquid painting

investment decisions can be prepared

application of liquid paints will be presented,

as well as powder coating, which precisely

and implemented which contribute to

by means of which significant material

detect the contour of the object to be coated

the firming up and expansion of one’s

savings can be realised. In the case of

and automatically compile the object’s shape

competitive position within the global

large automated painting lines, high-speed

in combination with the controller using 3D

market”, reports Jürgen Haußmann,

rotary atomisers – with adjustable spray-

software, correspondingly position the spray

managing director of event promoters

jet width as well – permit efficient material

gun’s axes and adjust the coating parameters

FairFair GmbH.

usage. And layer thickness can be ideally

(Fig. 3).

companies includes practically all of the

2 1

Figure 2: Application eﬃciency for liquid painting can be significantly increased with the help of new electrostatic spray guns.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

111

ZOOM ON EVENTS

A further approach to improving material

trend towards the automation of application

(horizontally), as well as through all process

efficiency involves pigment feeding. Savings

processes where series painting is concerned.

levels (vertically). This permits integrated data

are made possible in this regard through the

This is being driven by the development of

acquisition, analysis and graphic display in real-

use of systems for, amongst other things,

small, low-cost, easy-to-program robots.

time. If acquired data regarding the condition

intelligent control of colour changeovers and/

They permit high levels of reproducibility

of the system, the processes and the products

or rinsing processes, as well as improved

and process quality, and thus contribute to

are analysed and linked to each other, the

pigment dosing. Generally speaking,

improved efficiency and a sharper competitive

systems can also be rendered intelligent and

electronic monitoring of parameters such as

edge for companies with in-house painting

self-regulating by means of knowledge-based

pressure, temperature and output increases

facilities.

algorithms.

making it possible

PaintExpo’s

transparency, thus

complete

to set up processes

exhibition

more efficiently.

programme covers

Corresponding control

coating equipment

solutions will also

for liquid, powder,

be showcased at

UV, immersion

PaintExpo.

and coil processes,

As a result of the

paints and enamels

trend towards greater

for all processes,

individualisation,

application

demand for multicolour

systems, spray

coatings is continuously

guns and

on the rise. The goal

atomisers,

is to be able to apply

automation

coatings without

and conveyor

any masking at all,

technology,

or with significantly

cleaning and

reduced masking work

pre-treatment,

and less overspray.

drying and curing,

An application

environmental

implemented in

technology,

the field of aviation

pneumatics,

demonstrates that this

compressed air

is feasible. It’s used to

supply and exhaust

add decoration to an

purification,

aircraft tail fin without any overspray through the use of individual droplets. Spray film is another approach which can be applied

water treatment,

3 1

recycling

Figure 3: The geometry of the object to be painted, which is precisely acquired by the laser contour scanner, is automatically compiled by the controller with 3D software, after which the spray gun’s axes are positioned automatically and the coating parameters are adjusted for automated powder coating.

Automation and Industry 4.0

masking, measuring and test

Beyond this, high-performance manufacturing

assurance, identification, paint stripping, job-

execution systems (MES) will also be

shop coating, services and technical literature.

presented as a key component for efficient

Manual painting work will remain

manufacturing. They network the factory

For further information:

indispensable in the future, but there’s a

throughout the entire manufacturing process

www.paintexpo.com

112

accessories,

technology, quality

with a very sharp edge and simply pulled back off again later.

and disposal,

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

ZOOM ON EVENTS

SFCHINA Offers a Fast Lane to Reach the China & Asia Pacific Finishing Markets From Its 2018 Guangzhou Show! FCHINA welcomes all industry players to participate in this

Changhong Group, FAW-Volkswagen, Changan Automobile,

annual event. Its 31 edition is

Sany Heavy Industry,

scheduled to take place from

FAW Group, Dongfeng

December 4 to 6, 2018 at the

Motor, Geely

China Import and Export Fair

Automobile, Rohm &

Complex in Guangzhou

Haas, Shanghai Aircraft

(Fig. 1). As the exhibition scale

Manufacturing, China

gets bigger, SFCHINA2018 will

Aerospace Science &

move to Halls 4.1 & 5.1, Area

Industry Corporation,

A of the venue. The planned

etc. Thus, SFCHINA

total gross exhibition area will

is such an effective

reach 14,000 square metres. Comprising three exhibit

platform to enhance

Figure 1: SFCHINA 31st edition is scheduled to take place from December 4 to 6, 2018 at the China Import and Export Fair Complex in Guangzhou.

zones namely ‘Electroplating

brand image and test the water for potential business prospects.

& Finishing Technology’, ‘Environmental, Safety & Protection’ and ‘Coating Applications & Coating Products’, exhibitors will gain opportunities to present

Optimize Access to China and Asian Markets

their technologies and products to domestic and international

Pearl River Delta (PRD) region is the global manufacturing

visitors in one show within 3 days.

base and emerges as a world-class cluster for innovation,

SFCHINA is the Right Place for Exhibitors

driving domestic demand for finishing technology. For

SFCHINA has been the leading

foreign exhibitors

‘Finishing’ show since 1983.

eying entry or greater

Exhibiting companies can

market access into

expect to meet and have close

China and other Asian

engagement with a lot of target

markets, SFCHINA

visitors worldwide. The last

is the strategic

2017 Shanghai show closed

springboard to build

with a total of 11,097 trade

trading relationships.

visitors from 38 countries/

Booth allocation has

regions and 338 exhibitors from

just started. Book your exhibit space

20 countries/regions (Fig. 2). Visitors came from a wide range of industries, to name a few, such as Foxconn, Apple, Gree, Haier, Midea Group, OPPO,

2 1

now!

Figure 2: The last 2017 Shanghai show closed with a total of 11,097 trade visitors from 38 countries/regions and 338 exhibitors from 20 countries/ regions.

For further information: www.sfchina.net

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

113

ZOOM ON EVENTS

HANNOVER MESSE: the World’s Leading Trade Fair in Industry 4.0 Technology

Figure 1: From April 23rd to 27th 2018, HANNOVER MESSE will welcome 5,000 exhibitors from 70 countries, to outline the latest developments in relation to digital changes in production.

ndustry 4.0 is experiencing staggering

MESSE will welcome 5,000 exhibitors

Automation, Motion & Drives).

developments that are radically

from 70 countries, to outline the latest

Under the main theme Integrated Industry

transforming production scenarios.

developments in relation to digital changes

- Connect & Collaborate, the world’s

HANNOVER MESSE presents visions and

in production (Fig. 1). Participating

leading trade fair in industrial technology

solutions from countries all over the world

companies will be divided into five distinct

will show how the three pillars of the

and maps out a detailed identikit of the

but interrelated shows: Digital Factory,

factories of the future - man, machines

factories of the future.

Energy, Industrial Supply, Research &

and IT - can fully show their potential only

From April 23 to 27 2018, HANNOVER

Technology and the new IAMD (Integrated

through interconnecting (Fig. 2).

114

N. 49 - JANUARY/FEBRUARY 2018 - international PAINT&COATING magazine

In addition, the event will propose Industry 4.0 as an integrated system throughout the entire value chain: from development of

ÂŠ Hannover Messe

ZOOM ON EVENTS

ideas to the final product.

Innovation for digital factories All innovation available for the digital transformation of production processes, energy systems and our way of working will be offered at the show - a transformation that can be summed up in a series of key terms: robotics, integrated energy, predictive maintenance, intelligent components, smart supply, lightweight construction, cobots, big data, 3D printing, virtual reality, augmented reality, artificial intelligence, digital twins, IT security, clouds, drones, etc.

Collateral events The exhibition offer will be enriched by an

2 1

Figure 2: The main theme of the trade fair will be Integrated Industry - Connect & Collaborate.

articulated calendar of collateral events, including over 1,000 conferences and forums.

chain in mind, this year HANNOVER

the energy, technology and environmental

Initiatives such as Tec2You, Job & Career,

MESSE will be flanked by CeMAT - the

services sectors, demand for which

WoMenPower or Young Engineers Day will also

worldwide leading fair for intralogistics

is fostered in a country with high

generate interest in relation to technological

and supply chain management.

demographic and economic growth.

training paths and will provide precious

The two shows will take place

Mexico has recently begun negotiations

guidelines in terms of career development.

simultaneously in the Hannover

to update its current free exchange

Global Business & Markets will promote

fairgrounds and will trigger

agreements with the European Union and

business with markets abroad, foreign

important synergies, also in terms of

encourage transoceanic exchanges and

investments, financing and matchmaking.

collateral events. In this way it will be

investments. This also permits a forecast

Young Tech Enterprises will gather industrial

demonstrated how production and

of development of promising economic

start-ups facilitating meetings between

distribution chains can be fully and

relations with Europe.

young entrepreneurs and sector networks,

profitably integrated.

accelerators and economic development

Over 1,000 exhibitors from 44 countries

Optimum business prospects

promotion companies. Sector prizes such as

and 40,000 visitors are expected to

Over 200,000 qualified visitors are

the Hermes Award (for technology) and the

attend CeMAT.

expected at HANNOVER MESSE,

Robotics Award (for applied robotic solutions)

including both managers of small and

will be presented. 2,500 journalists from 50

Partner Country Mexico

countries will ensure global exposure for the

With over 120 million inhabitants,

from important international groups.

new products presented.

Mexico is the second largest economy

Their identikit is consolidated: one

in Latin America and one of the

in three are from abroad; one in two

most promising markets for the

is a top manager. Excellent business

HANNOVER MESSE flanked by CeMAT for the first time

medium sized businesses and CEOs

future. At HANNOVER MESSE it will

opportunities are appearing for both

In order to highlight the importance of logistics

propose technological development

exhibitors and visitors.

and intralogistics in smart factories and the

and research projects, innovative

potential of joint action between Industry 4.0

development strategies and interesting

For further information:

and Logistics 4.0 with optimisation of the value

investment prospects, for example in

www.hannovermesse.de

international PAINT&COATING magazine - JANUARY/FEBRUARY 2018 - N. 49

115

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