ipcm n. 45 Magazine (May/June 2017) - English Version by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

ISSN 2280-6083

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www.myipcm.com 2017

8th Year - Bimonthly N° 45 - MAY/JUNE

Italian Excellence

Arsonsisi is a supplier of complete solutions for coating any type of product, with traditional industrial paints, powder coatings and electro-

Italy’s cutting-edge colour technology for all industrial applications.

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100% made in Italy

deposition paints. All Arsonsisi products are designed and manufactured in Italy.

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Drawdown Test Charts

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Applicators

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Measure what you see.

BYK-Gardner complete QC solution for testing physical properties from wet to dry www.byk.com/instruments

CONTENTS MAY/JUNE 2017

High Automation and Continuous Monitoring via PLC for the Efficient Outsourcing of Coating Operations

SUCCESS STORIES

Adapta Among the Protagonists of Materials Village 2017 at the Milan Design Week

FOCUS ON TECHNOLOGY

34 05 06 12

FOCUS ON TECHNOLOGY

A Unique Concept for the Cataphoresis + Powder Application Process of the Ravaglioli Group, thanks to the Technical Solutions Adopted

EDITORIAL BRAND-NEW HIGHLIGHT OF THE MONTH An Amusement Park Ride Served as Idea for Gentle Finishing of High Cost Work Pieces. New Drag Finishing Machine Works with Overlapping Rotational Movements

30 46 56

HIGHLIGHT OF THE MONTH

“The way of Classics” – Color Design by Lechler at Fuorisalone 2017

BRAND-NEW

BRAND-NEW SUCCESS STORIES Alesta AP from Axalta Coating Systems Specified for Prestigious French Project La Marseillaise. Axalta Develops New Colors to Enhance the Exquisite Superstructure

FOCUS ON TECHNOLOGY A Cataphoresis Wastewater Treatment System Optimised for the Refrigeration Industry: Sest Spa’s CATOCOAT Process

INNOVATIONS: PRESENT&FUTURE NEA 430: an Innovative Pneumatic System for the Low Pressure, High Density Precision Feeding of Powders

CONTENTS MAY/JUNE 2017

BASF Presented Ground Breaking New Pigments Technology at ECS 2017

104

SUCCESS STORIES

Achieve Production Confidence with Nordson Dense Phase Technology

PRODUCT INNOVATION

110 72

FOCUS ON TECHNOLOGY

Shorter Takt Times thanks to Special Maskings for Different Workpieces

FOCUS ON TECHNOLOGY Pre-Treatment and Nanotechnology Conversion for Excellent Finishes and High Corrosion Resistance: The Case of SMA Serbatoi

SPECIAL ECS 2017 PRODUCT INNOVATION

116

FOCUS ON TECHNOLOGY

A Record-large Production Hall Got Pekotek’s Surface Treatment System

100 FOCUS ON TECHNOLOGY Automation and Industry 4.0 for a Cutting-edge Coating Process in a “Made in Italy” Project

106 FOCUS ON TECHNOLOGY “ediVer” Electrodialysis Membranes: Technological Solutions for Electrophoresis Plants

120

BUSINESS TRAINING Customer Satisfaction Analysis & Management – Part 2

123

STANDARD & LEGISLATION - UCIF Informs Noise Pollution: Harmonisation of National Legislation

124 126

TRADE FAIRS & CONFERENCES ZOOM ON EVENTS

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EDITORIAL

nnovation, understood as the implementation of new systems and criteria or as a radical change in a consolidated practice, is the driving force of society and economic development. Those who say that the coating industry is increasingly stagnant, wrapped up in its habits and less inclined to innovation will be certainly proved wrong by this issue of ipcm®. The numerous case studies presented, which describe innovative processes, products and technologies, actually paint the picture of a field in a ferment at any level, from raw material chemistry to plant engineering. As is clear, “innovation” is not synonymous only with “Industry 4.0”. The link between sustainability and innovation in the field of surface treatments, in which the former can be seen as both the driving force and the subject of the latter, is increasingly consolidated. The last edition of the European Coatings Show in Nuremberg has outlined a green economy model aiming at the reduction of the environmental impact through sustainable development technologies: use of renewable raw materials for the formulation of resins and additives for biocoatings; reduction of the dependence on fossil-based products; and development of raw materials that further encourage the use of water-based coating systems, which are considered the “true centre of gravity” of this sector. Increasingly often, “innovation” also goes hand in hand with “optimisation”. Even the most innovative painting system can turn out to be a bad investment if poorly managed and not fully exploited. High automation, technological solutions suited to quality and productivity goals, and the constant and automatic control of process parameters are the keys to optimising plant performance. An example is the experience of two large Italian companies that have chosen different, but effective routes for an excellent finishing quality level and a highly efficient process. One has chosen to entrust an industrial outsourcing company with the management of its coating system; the other has made a big investment in what is currently one of the most advanced plants in the world in terms of technology, efficiency and safety. The leitmotiv of all the articles you will find in this issue of ipcm® is the awareness that the true wealth of a business is its process expertise. “Innovation”, therefore, is first and foremost the development of an adequate industrial culture relating to every aspect of the coating process in all industrial segments, not just the high-end ones.

Alessia Venturi Editor-in-chief Direttore Responsabile

international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

BRAND-NEW

Adapta Prepares the Environmental Product Declaration for its VIVENDI Collections

dapta colour is staying true to its commitment to provide proper environmental information about our products, as outlined in our management policy. There is a clear and transparent policy to disclose the environmental profile of our operations, and thus the declaration has been drafted regarding the new line of products ADAPTA VIVENDI and ADAPTA VIVENDI SDS. Environmental Product Declarations (EPDs) are a means of transparently disclosing information in a way that is independently verified by a third party regarding the environmental characteristic of the product on the basis of an Life Cycle Analysis (LCA). The information is split into several impact categories (global warming, depletion of the ozone layer, acidification, etc.), as well as additional information, such as emissions generated, waste generated, etc. The EPD allows the environmental information of different products and services to be compared against other similar options. In our case, AENOR was selected as the organisation to verify the EPD according to ISO 14025 in accordance with the Product Category Rules (PCR) 2014:05 UN CPC 3511 Paints and varnishes and related products (version 1.0 from the 17/04/2014) drawn up by the International EPDÂŽ System. When comparing EPDs of similar products, it is very important to check the reference PCR followed. The PCRs define the rules that must be followed by the LCS studies, as well as what information must appear in the EPD, which means that it is possible to see the operational parameters followed to calculate the various indicators.

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The Carbon Footprint, which is a contemporary indicator that provides information about the impact on climate change, is one of the indicators calculated during the preparation of the EPD and measures the amount of greenhouse gases associated with that product or activity. In reality, the carbon footprint is a simplified version of the Life Cycle Analysis (LCV), which takes into account a single category of environmental impact, that of global warming. Version v4 of the LEED system (Leadership in Energy and Environmental Design) for sustainability in constructions gives up to two points for the use of products that have an EPD in construction or equipment. Architectural studios, specifiers, and building owners will directly benefit from the use of these products that allow the building to achieve a higher sustainability rating. The ADAPTA VIVENDI and ADAPTA VIVENDI SDS (super durable) have been especially designed to meet the specifications required by the most demanding architectural briefs. The entire range of colour effects are available in our Vivendi catalogues, A08, A12, and in the new A16, which compiles the latest trends in surface coatings. In addition, these collections have been tested according to the ISO standard 16000-9:2006 regarding the determination of the emission of volatile organic compounds from building and furnishing products. In light of the results the company has received the distinction of an A+ (very low emissions) for its wall, ceiling, window, and door panels. For further information: www.adaptacolor.com

BRAND-NEW

Binks Launch the New DX200-3, 3:1 Ratio Diaphragm Pump

ÂŠ Carlisle Fluid Technologies

performance air valve gives a faster, smoother arlisle Fluid Technologies is pleased change-over which in turn gives a higher fluid to announce the launch of the output at a lower air consumption rate than any newest edition to its Binks DX range of the main competitors. of diaphragm pumps (Fig. 1). The Binks The modern design allows unobstructed access DX200-3 is Carlisleâ&#x20AC;&#x2122;s all new air operated, to critical components such as the air valve and 3:1 ratio double diaphragm pump. diaphragms making on-site maintenance easy This new pump has been designed to and fast. perform in tough applications and has the Carlisle Fluid Technologies showed new Binks flexibility to fit easily into direct-to-sprayDX200-3 at Surface World 2017. gun, paint circulating systems or transfer For further information: www.carlisleft.com applications. Like all Binks products it is built to last and has many advanced features which make it hard working, low maintenance and frugal to operate. An exciting feature of this pump is the new Eazi-Swap outlet, which can be configured as a standard outlet or quickly adapted with Binks manual fluid regulator or active surge chamber options. The outlet can even be changed with the pump in-situ. This innovation provides the flexibility for connection to systems or direct to spray guns without the expense and complication of external fluid handling components. Like all its siblings in the DX range, the DX2003 provides consistent fluid delivery over its 1 operating pressure Figure 1: The new Binks DX range diaphragm pump. range. The high-

BRAND-NEW

Product Innovations for Automotive and Industrial Coatings by BASF

o accommodate the growing demand for more sustainable, high performance coatings in the automotive and industrial market, BASF has developed innovative products that offer greater performance. Besides saving time in the production process and making the workflow more efficient, these solutions contribute to conserve the environment while using as little resources as necessary.

Catalyst for solvent-based 2K PU coatings Basionics™ Kat.1 was developed for the use in the curing process of clear coats, topcoats and primers in a low temperature range of 10 to 80°C. The catalyst is suitable for solvent-based 2K PU coatings and does not contain any metal. It offers a high reactivity pot life ratio compared to standard metal catalyst systems.

Liquid light stabilizer for extending the coating’s lifespan

to faster curing speed and increased pot life. Both products are suitable for 2K PU systems and improve the final hardness, chemical resistance and reflow behavior which result in high weather resistance. Basonol HPE 1170 B and HPE 1265 B feature an early block resistance and allow for a faster sandability with minimal impact on VOC.

Acrylic dispersion for corrosion protection of industrial metal coatings The new water-based Acronal® PRO 7600 acrylic dispersion provides light to medium corrosion protection (C2 to C3) for industrial metal coatings. The binder is an environmentally compatible drop-in solution that does not contain APEO and replaces Acronal® PRO 760, the current market standard. It can be used for all current applications such as airless, brush, roll or dip.

Tinuvin® 249 is a liquid light stabilizer that gives high durability to the coating due to its good weathering performance, broad compatibility and very good color stability during shelf life. Tinuvin 249 does not contain solvents and allows for an easier handling since its low viscosity, volatility and basicity. For outdoor applications, Tinuvin 249 needs to be combined with a UVA of the hydroxyphenylbenzo-triazole or hydroxyphenyltriazine class.

Wetting and anti-cratering agent based on ﬂuoro blockcopolymer technology

Performance enhancements for high solid 2K PU systems

Polyamide wax for solventbased coatings

Basonol® HPE 1170 B and HPE 1265 B provide performance enhancements for high solid 2K PU systems when it comes

Efka® RM 1469 is a polyamide wax for solvent-based coatings that is superior in anti-sagging and shows enhanced

Efka® WE 3050, a wetting and anticratering agent for solvent-borne and solvent-free systems based on block fluoro-copolymer technology, is designed to provide a strong reduction of surface tension. Additionally, it offers low foam stabilization and has no influence on surface slip.

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orientation to improve flip/flop in metal paint. It has a minimal effect on colour and gloss and allows a long-lasting thixotropic effect without seeding.

Dispersing agent for inorganic pigments and extenders Efka® FA 4609, a dispersing agent for inorganic pigments and extenders, combines a strong reduction of mill based viscosity, improved rheological behavior and high pigment loading. It has a broad compatibility in a wide range of resin systems and is suitable for high gloss solvent-based systems.

Silicone surfactants for water based-coatings Hydropalat® WE 3220 and 3221 are silicone surfactants for water-based coatings with strong reduction in surface tension resulting in improved substrate wetting and prevention of surface defects (anticratering). Both products offer good surface levelling and do not increase surface slip. For further information: www.dispersions-pigments.basf.com

BRAND-NEW

Dörken MKS at the Fastener Fair

t the Fastener Fair 2017 Parts with this system in Stuttgart Dörken structure offer highest MKS-Systeme GmbH & corrosion resistance, with Co. KG, Herdecke, presented its peak values of up to 2,000 complete portfolio of products hours in salt spray testing for the surface coating of screws (SST) according to and other fasteners, under the DIN EN ISO 9227. slogan “The Corrosion Experts”. Special plant technology The spectrum ranged from zinc enables the material to flake coating to KTL technology also be applied to screws 2.0 and on to the and other fasteners, DELTA-PROZINC® galvanic as the application of protection system. DELTA-eLACK® in the drum To illustrate the performance enables the coating of 1 small to medium-sized capabilities of the individual systems coated parts that had components as Figure 1: In Stuttgart Dörken MKS-Systeme presented its full product portfolio in been subjected to various test bulk goods. the ﬁeld of zinc ﬂake, electroplating and KTL. cycles were displayed on the All surface coating stand (Fig. 1). Screws protected systems from the portfolio displaying comparable values to standard by zinc flake systems not only proved of Dörken MKS feature high performance zinc nickel systems. The process-safe, their capability in the DIN EN ISO 9227 and a global quality standard, assured salt spray test, in which they displayed highly-efficient system offers an overall through a worldwide network of 150 licensed package of pre-treatment products, zinc no white rust formation compared to coaters (Fig. 2). baths, passivation and top coats with no galvanic coatings, even after 240 hours. For further information: The benefits of cathodic corrosion need for nickel and cobalt. DELTA-PROZINC® www.doerken-mks.de also features protection with zinc flake systems were superb fastening particularly evident in screws subjected to cyclical tests such as the ACT I and characteristics and can be adjusted II climatic extremes tests (Accelerated to the respective Corrosion Test) of Swedish vehicle coefficient of friction manufacturer Volvo or the VW PV 1209 requirements via top corrosion protection test. Despite their coats with integrated superb corrosion protection properties, lubricants. zinc flake systems only have a total coat The KTL 2.0 system thickness of 8 to 12 μm on average and are combines the therefore particularly well-suited to use in organic top coat components requiring a maximum fit, such as screws with metric threads. DELTA-eLACK® with ® its premium, deepThe DELTA-PROZINC electroplating system 2 performed well in comparison to yellow black appearance chromating, with corrosion resistance with the cathodic Figure 2: The Corrosion Experts: the combined manpower behind this times of up to 720 hours in salt spray corrosion protection slogan is illustrated by a collage on the stand, depicting the Dörken MKS-Systeme team in action. testing according to DIN EN ISO 9227, of zinc flake coating.

international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

BRAND-NEW

ECCO 51AS - When Every Gram and Cent Counts

n continuation of Ecco Finishing’s tradition of highest material and design standards, the company is proud to introduce the low weight, all stainless steel automatic spray gun Ecco 51 AS. With a weight of around 300g and a length of 10 cm, it’s truly a compact gun (Figs. 1 and 2). Besides being the most compact and lightest needle operated stainless steel gun ever designed by Ecco (Fig. 3), it is also the most cost effective. The outstanding performance/value ratio is a further sign of Ecco’s innovative approach. Examples of applications: Precision Industry (plastics) and general industry.

Advantages with Ecco 51AS • Extremely compact and lightweight • Ecco’s advanced air caps and fluid nozzle design • Easy to flush and to keep clean • Easy to install on fixed positions or reciprocators • Fast and repeatable opening/closing time • Extended lifetime and lowest spare part consumption in this segment • Minimal number of components reduce parts inventory. © Ecco Finishing

Figure 1: The external design of ECCO 51AS.

Technical data – ECCO 51AS Weight: 300 g Size with air cap (excl. connectors): L=95mm, Ø 41mm Body: Stainless steel Nozzle: Stainless steel or Tungsten carbide Air cap: Aluminium with special surface treatment Sealings: PEHD.

3 Figure 3: The internal design of ECCO 51AS.

For further information: www.eccofinishing.com

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

2 Figure 2: The ECCO 51 AS.

BRAND-NEW

VOC-free Purge Cleaning of Paint Application Equipment

hemetall, a leading global surface treatment supplier and a global business unit of BASF’s Coatings division, has introduced a VOC-free purge cleaning technology to the automotive market. Gardostrip® P meets the required Automotive OEM environmental standards and offers significant process cost savings. Chemetall’s purge cleaners enable paint shop managers to efficiently exchange colors and paint systems of their application equipment and thus supports a high flexibility in the production process (Fig. 1). “As a pretreatment specialist we have a close relationship with the automotive industry and are well aware of their adjacent production processes and challenges”, says Namhun Lee, Global Key Account Manager at Chemetall. “To enhance their paint shop operations, we developed a new purge cleaning technology providing environmental, financial and quality benefits for our customers.” Gardostrip® P does not contain any Volatile Organic Compounds (VOC) and complies with environmental regulations. All ingredients are water-soluble and easy to recycle. Another benefit is the low usage concentration. Compared to conventional products, Chemetall’s purge cleaner can be operated at only 3-5 percent concentration while achieving at least a similar high cleaning performance. This very low concentration results in a low product consumption offering not only considerable process but also disposal cost savings. Gardostrip® P is suitable for all 1K- or 2K-water-borne primers and base coats. Excellent purging performance in combination with environmental benefits has convinced more and more leading automotive customers to convert their paint shops to Chemetall’s VOC-free purge cleaners. For further information: www.chemetall.com

Figure 1: Spray bell, perfectly cleaned with Chemetall’s VOC-free Gardostrip® purge cleaner.

Opening picture: The “Octopus” ride we all know from amusement parks provided the idea for the new machines.

HIGHLIGHT OF THE MONTH

An Amusement Park Ride Served as Idea for Gentle Finishing of High Cost Work Pieces. New Drag Finishing Machine Works with Overlapping Rotational Movements Meik Seidler Walther Trowal GmbH & Co. KG, Haan, Germany

m.seidler@walther-trowal.de

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

The functional principle: A rotation within the rotation In standard drag finishers the work pieces are mounted to rotating work stations and “dragged” through the grinding or polishing media. This movement creates a high processing intensity and produces excellent results on many parts. In the new machines the work stations

consist of multi spindle heads with each spindle holding one work piece (Fig. 2). In addition to the carousel and work station rotation each spindle has its own rotational movement. In other words: The spindles move in a circle within two larger circles formed by the carousel and work station rotation.

alther Trowal developed the new drag finisher line M-TMD for processing work pieces requiring perfect surface finishes. The work pieces, mounted to rotating satellite stations, undergo multiple overlapping, pre-programmed, rotational movements. This rotational variation produces optimum finishing results. Walther Trowal developed the new drag finisher specifically for finishing high value components, which must be handled with extreme care. Typical work piece examples from the medical engineering industry are hip and knee implants requiring a high gloss polish. In the aerospace industry turbine blades and other components must receive a first-class finish with precise edge radiusing and very smooth surfaces. Examples from the automotive industry include the vanes of turbo chargers, which must not be nicked or damaged during the finishing process. Christoph Cruse, General Sales Manager at Walther Trowal, foresees a big demand at those customers, who produce high precision, high value components: “With our new equipment line we address precision component manufacturers, who want perfect surface finishes, and where any blemishes like scratches could require scrapping a part. We also target manufacturers demanding tolerances of just a few microns. For these work pieces the M-TMD drag finishers with their optimum flow characteristics open entirely new possibilities (Fig. 1)”.

1 Figure 1: The new machine is compact and has a small footprint.

This is similar to the movement of the cabins in “Octopus” rides that can be found at any amusement park (ref. Opening picture). The drag finisher M-TMD 4 is equipped with 4 multi spindle heads (work stations) with each head containing 3 spindles. In the M-TMD 6 up to 18 work pieces can be processed at the same time. The independently adjustable rotational speed and rotational direction of the spindle heads and spindles creates a wide range of different movement patterns. In addition, the spindle heads can be tilted in different angles. This allows adjusting the flow characteristics to the specific shape of the various work pieces. With the PLC controller multi stage processing programs can be easily implemented. During the finishing process the work bowl is vibrating for the optimum mixing of the grinding or polishing media. This guarantees a high degree of process consistency (Fig. 3). The media fines and undersize media, along with the metal fines from the work pieces, are continuously discharged from the machine; another contribution towards process stability and consistency.

Form surface grinding to high gloss polishing

With our new equipment line we address precision component manufacturers, who want perfect surface finishes, and where any blemishes like scratches could require scrapping a part. We also target manufacturers demanding tolerances of just a few microns. For these work pieces the M-TMD drag finishers with their optimum flow characteristics open entirely new possibilities.”

The new Trowal machines can be operated in wet as well as dry processing mode. For surface grinding and smoothing, as well as for certain polishing operations, compound and water are used. In the case of targeted edge radiusing with tolerances of a few micron, for example, hard metal drill bits and milling heads, a dry process with special grinding granulate is utilized. Dry processing with organic polishing media and paste is also suitable for high gloss polishing.

international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

ÂŠ Walther Trowal

specifications can be fully met. Once the trials have yielded a viable process, the work piece range and quantity is analyzed to determine machine type & size, media & compound type, process water treatment system and drying method.

Background: Drag Finishing

ÂŠ Walther Trowal

The drag finishing technology, developed by Walther Trowal about 30 years ago, has been continuously refined and, today, is an established finishing method that is ten to twenty times more efficient than conventional mass finishing systems.

2 Figure 2: The multi spindle heads allow attaching up to 18 parts. In this photo different parts were mounted onto one spindle head.

Multiple finishing steps, from pre-grinding all the way to the final polishing stage, can take place in one single machine without the need to remove and remount the work pieces to the work stations: One work bowl filled with a certain finishing media can be easily and quickly removed with a pallet truck and replaced with a bowl containing another media (Fig. 4).

Processing trials guarantee proven results The first unit of the new machine generation has been installed in the Walther Trowal test lab in Haan/Germany. It is available for processing trials with customer work pieces allowing the customers to prove their finishing process, before making an investment decision. This ensures that the customer

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

3 Figure 3: A work piece shortly before being lowered into the grinding medium.

The work pieces are individually mounted to rotating work stations integrated into a rotating carousel. During the process the parts never touch each other. Once the parts are mounted, the carousel with the work stations is lowered into a work bowl filled with grinding or polishing media. The work stations with the mounted work pieces are then “dragged” through the stationary media mass. This translates into a highly efficient use of the kinetic energy between work pieces and media. The new machines of the M-TMD series enlarge this effect by the addition of a third rotational movement of the spindles.

Figure 4: All process steps take place in one single machine: Work bowls containing different media types can be easily and quickly exchanged with a pallet truck.

HIGHLIGHT OF THE MONTH

Opening photo: The gearboxes produced by Bonﬁglioli and coated in the paintshop managed by Pieffeci.

FOCUS ON TECHNOLOGY

High Automation and Continuous Monitoring via PLC for the Efficient Outsourcing of Coating Operations Monica Fumagalli ipcm®

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

“Sometimes, we deal with a n every industrial sector, an situation in which the paintshop element that many manufacturing has been properly structured, but companies have in common is the qualitative and productive the lack of in-depth information results are not the ones hoped for the analysis and management for. Pieffeci’s expertise, developed of a key stage of the production in over fifteen years of work flow: surface treatment. Whereas alongside large industrial groups, as far as machining is concerned comes into play here.” the knowledge of the production Since its establishment in 1997, specifications and the staff skills Pieffeci has taken on contracts have reached good levels and the for the coating departments of plant solutions are effective and the then-called Pianfei Group, functional to the product type, in a supplier of Fiat, Daimler and many cases the same does not apply BMW based in Mondovì (Cuneo); to the field of coating technologies. the bridges-axles coating lines Pieffeci Spa, a company based in of the Iveco plants in Turin (now Turin, was established precisely to CNH Industrial – FPT Industrial overcome this lack and contribute Driveline) and Pregnana to the creation of an adequate Milanese (Milan); the gearbox industrial culture related to all the painting, packaging and shipping stages of a coating process. Since departments of Bonfiglioli Spa the late 1990s, Pieffeci takes on (Forlì); the paintshop dealing contracts for its client companies’ with the earth moving machinery coating departments, optimising frames and components the production capacity of existing manufactured by Komatsu Utility plants whose performance is Europe (Este, Padova); and the not that expected at the time of 1 plant treating the surfaces of the investment. It also performs metal tanks, frames and panels for various activities related to the Figure 1: From left to right, Manuel Liverani, Pieffeci’s Engineering industrial machines manufactured coating process, such as packaging, and Maintenance Manager, Gian Luca Casoni from AS Divisione by Intek CM (Settimo Torinese, handling, small assembly operations, Verniciatura, Alessia Venturi, Miranda Houbrechts, Graco’s Content & Advertising Lead, Marco Caporello, Graco’s Business Turin). labelling and shipment. Development Specialist, and Gianluca Nati, Pieffeci’s Plant “We have been present for some “Outsourcing ensures several Manager. years at the Fiat Powertrain economic and organisational Technologies plant in Turin and benefits to the firms requiring our at the Bonfiglioli plant in Forlì with our intervention,” says Gian Luca Nati, the operational and consulting services,” says Pieffeci Plant Manager at the premises Experience has taught Manuel Liverani, Pieffeci’s Coating Plant of Bonfiglioli. “These advantages can be Manager at the Bonfiglioli premises summarised as follows: reduction of time us that the key elements (fig. 1). “Experience has taught us that and waste, reduction of production costs, to optimise a plant’s the key elements to optimise a plant’s highly qualified management of the process performance are high performance are high automation of the aimed at preventing any impact on the automation of the treatment treatment process, constant control of the environment linked to waste management process, constant control various phases via PLC, and trusted partners and atmospheric emissions, and “turnkey” of the various phases via for supplying or updating the equipment professional plant maintenance. Pieffeci PLC, and trusted partners needed to achieve the required production can design new plant solutions or retrofit for supplying or updating capacity. We have achieved this goal with the already existing ones, developing, the equipment needed the collaboration of Graco and its distributor implementing and automating any coating to achieve the required AS Divisione Verniciatura.” system. production capacity.” international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

2 Figure 2: A detail of the gearboxes.

Case study: Bonﬁglioli Spa’s coating department

Bonfiglioli’s customers include the world’s leading players in the wind energy and earth moving machinery sectors. “With clients like these, the coating specifications are very stringent,” Nati states. “Together with Bonfiglioli, we carry out all the laboratory tests needed to meet such specifications. Some customers,

Our painting results have reached the level required by the most demanding clients thanks to the use of appropriate devices, already present on the plant and updated by us. These include the dosing, mixing and application equipment provided by Graco Distribution BVBA through its distributor AS Divisione Verniciatura (Ozzano dell’Emilia, Bologna) and the high degree of automation brought to the line by Pieffeci thanks to the robots installed by CMA Robotics (Pradamano, Udine).”

Bonfiglioli Spa’s plant of Forlì manufactures three main types of product: gearboxes for self-propelled machines (rotation of caterpillars and excavator turrets), electromobility devices and gearboxes for wind turbines (ref. opening photo).

particularly the major producers of the Agriculture & Construction Equipment (ACE) sector, require us to certify our process and, in this way, they provide guidelines also for the products intended for other buyers. “Lately, the demands for high quality and performance standards have been constantly increasing. This is a challenge for Pieffeci, but also a spur to improve our work for Bonfiglioli. We have set a very restrictive tolerance limit for noncompliance and, thanks to our control of the coating parameters, we have not had any discarded part for a long time. Our painting results have reached the level required by the most demanding clients thanks to the use of appropriate devices, already present on the plant and updated by us. These include the dosing, mixing and application equipment provided by Graco Distribution BVBA through its distributor AS Divisione Verniciatura (Ozzano dell’Emilia, Bologna) and the high degree of automation brought to the line by Pieffeci thanks to the robots installed by CMA Robotics (Pradamano, Udine).”

3 Figure 3: The two-rail conveyor supplied by Futura Convogliatori Aerei Spa has a maximum capacity of 1250 kg.

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

From the loading to the packaging phase, the process has been automated to be faster and more manageable. The joint management of the painting, packaging and shipping departments offers a further benefit: we control the entire final part of the production cycle and, therefore, we can perform in advance, combine and modify the operations that are typical of each phase to improve overall process efficiency.”

4 Figure 4: The cleaning tunnel.

Pieffeci’s intervention When Pieffeci entered Bonfiglioli’s plant in November 2009, the situation was very different. Liverani says: “They were particularly worried about the actual production capacity of their manual coating system, which treated no more than 250-300 components while being designed to handle 500 parts per shift. The addition of five CMA robots enabled us to streamline the production cycle, fill the gap and increase its capacity by 40%.” The automation intervention has involved the whole process, starting from drying (blowing stations), coating and protection of the non-coated surfaces (oiling). The path followed by the gearboxes is monitored at every step. A screen provides visual instructions that are updated according to the workpiece on the line. “From the loading to the packaging phase, the process has been automated to be faster and more manageable,” Nati explains. “However, the control of the technological management staff remains crucial: although the whole

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

Step-by-step line is managed monitoring of the automatically and robots coating process receive directions for the The coating of gearboxes programs to run through is complex because of the identifying barcode the weight and shape of with which each part is the parts, but also due labelled, the operators to the difficulty in evenly can continually check protecting their surfaces, that every automatic exposed to extreme wear operation is performed and corrosion (fig. 2). correctly. Moreover, the “Once the material to joint management of the be handled reaches painting, packaging and our department, we shipping departments assign a barcode to offers a further benefit: each product, with we control the entire final 5 which we can monitor part of the production every step,” Liverani cycle and, therefore, we Figure 5: The exterior of the painting system, installed by Tecnoﬁrma (Monza). says. “In order to reduce can perform in advance, the number of colour combine and modify the change operations, we group the components are then finished by the customers. In order operations that are typical of each phase according to the shade to be applied. After to obtain a more durable coating system and to improve overall process efficiency.” preparing the hanging hooks and the masking higher quality thicknesses, however, we are Another feature of Pieffeci’s work caps, the cycle begins with the loading of the asking our customers to choose only twofor Bonfiglioli has been the choice to material. The two-rail conveyor provided by component products.” keep using the water-based coatings Futura Convogliatori already selected Aerei Spa, with a by the company maximum capacity before the arrival of 1250 kg, handles of the Turin-based parts with different firm. “The paints dimensions (fig. 3); are all water-based the weight of each and supplied by workpiece ranges Inver-Valspar,” Nati between 10 kg and says. “We use the 1 ton. Idroxinver basecoat “To remove the oils and the Inverpur/A remaining on the topcoat; the latter surfaces after the has been chosen assembly stages, because it has a very we transfer the small percentage parts into a cleaning of solvent. We use tunnel performing an both one-component alkaline degreasing, and two-component a rinse with fresh products: the water, and a rinse former, in most with demineralised cases, is used for 7 6 water and an amine the application of a passivating agent single primer layer Figure 6: The robotic application of the Figure 7: The robotic application of the primer. topcoat. that improves paint on components that

FOCUS ON TECHNOLOGY

Robotic spray paint booths

The third one can apply both: in the event of any productive peaks, this enables to allocate the production volumes evenly and keep the takt time constant. The coating robots are installed in the first three booths (fig. 6 and 7), while in the fourth one the operator applies the paint manually, in case of small lots or prototypes or for a touchup if the result of the visual control on a component has not been positive.

The automation of Graco’s dosing systems Bonfiglioli’s paintshop is equipped with Graco systems provided by the area

Together with the staff of Pieffeci and the management of Bonfiglioli, which made the investment, AS performed an assessment of the plant aimed at exploiting its full potential. It was therefore decided to place the mixer inside the booths, unlike the previous arrangement. We have thus reduced the length of the pipes and the amount of catalysed product circulating, as well as improving the use of space.”

adhesion (fig. 4). We have installed an ultrafiltration system and an oil separator for the first alkaline degreasing bath, since the gearboxes reach the cleaning phase with a large amount of oil on their surfaces, and an inverse osmosis system for the demineralised water of the third washing stage. This is followed by a double robotic blowing station, where most water is removed, and by an oven, which dries the residual moisture at 70°C. For masking, preparing and arranging the surfaces that do not have to be coated, the operators can see all the operating instructions on dedicated monitors.”

an unavoidable choice, because Promix Auto’s The coating system replacement includes 4 spray paint electric booths separated by a components will flash off tunnel (fig. 5). be soon difficult The thicknesses required to find (fig. 8). for this type of product However, this range from 40 to 400 provided the microns in one to four opportunity to coats; only one system, install a new, more however, requires the powerful system application of a single ensuring more coat, that of a 40-micron reliability in terms shop primer used if the of both quality and client is to finish the part. capacity. Together Normally, the first with the staff of two booths apply the 8 Pieffeci and the basecoat and the last two the topcoat. management Figure 8: The Promix Auto dosing system previously installed at the Bonﬁglioli premises. of Bonfiglioli, which made the investment, AS The thicknesses required performed an assessment of the plant distributor, AS Divisione Verniciatura, with aimed at exploiting its full potential. which Pieffeci’s engineers have established for this type of product range It was therefore decided to place the a trusted relationship that has enabled them from 40 to 400 microns in mixer inside the booths, unlike the to constantly develop and implement new one to four coats; only one previous arrangement. We have thus and more up-to-date application solutions. system, however, requires reduced the length of the pipes and the “Last August, in Bonfiglioli, we replaced the application of a single the Promix Auto dosing system of the first amount of catalysed product circulating, coat, that of a 40-micron shop as well as improving the use of space booth, used for over ten years, with a Promix primer used if the client is to (fig. 9, 10 and 11).” 2KS,” Gian Luca Casoni from AS says. “It was finish the part.” international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

Figure 10: A detail of the pumps.

Figure 9: The new Promix 2KS dosing system.

The primer’s dosage is managed by 2 Promix Easy systems (fig. 12). One is devoted to the standard light grey basecoat and the other to the yellow and black primers required by some specifications to ensure that the surface is protected and the colour remains the same as the rest of the component even in case the topcoat is scratched. “The Promix Easy dosing systems have been installed with a manual handling process in mind,” Casoni explains. “When Pieffeci integrated the robots, they could not interact with them. A PLC able to manage the two Promix Easy devices was

Figure 11: Promix 2KS’s PLC.

therefore added: in this way, we turned the two machines into semi-automatic systems able to interact, although in a limited manner, with the coating robots (fig. 13).”

The beneﬁts of an automated application process “Our catalogue includes a range of 60 topcoats,” Nati says. “At the moment, the most used ones are 17. These are kept within our coating management unit, in tanks equipped with a stirrer and a pump that are managed by the Promix 2KS dosing system together with the catalyst (fig. 14). A “wildcard” pump handles the rest of the

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

colour range by directly drawing the products from the paint drums. We perform checks on the viscosity of the paints and ensure that the temperature and humidity of the heated chamber of the coating management unit are adequate.” Pieffeci has also changed how the product volumes are managed by switching, where possible, from 30 kg to 200 kg drums and consequently installing a few lifters, which has facilitated the work of the staff involved and increased their safety. “As for the application phase, we use Airmix G 40 automatic guns. The robots have 2 guns each, one for the one-component and

FOCUS ON TECHNOLOGY

The waste of paint was halved, while the time needed for the colour change operations was decreased from 75 to 43 seconds. Considering the high number of daily changes, about 40, the benefits are unquestionable.”

the other for the two-component product, with a usage rate of 50% each,” Liverani says. “This choice was motivated by the need to avoid any continuous cleaning and loading operations of the guns. We now have two devices that are always loaded and ready for use.” “The greatest advantages achieved were the saving in paint and the reduction in the colour change times,” Nati states. “The waste of paint was halved, while the time needed for the colour change operations was decreased from 75 to 43 seconds. Considering the high number of daily changes, about 40, the benefits are unquestionable.”

The protection of the gearboxes

The drying oven installed after the coating plant polymerises the gearboxes’ surfaces for about one hour and a half. The following tunnel cools the workpieces before unloading, so that they can be immediately handled for packaging. “We always verify that the paint has cooled down and has reached a temperature below 40 °C, so that the gearbox can be positioned on the base of the box with which it will be

12 Figure 12: The Promix Easy system for dosing the primer.

shipped,” Nati states. “In the unloading area, the last monitor of the line shows the operators the number of parts to be placed in the packing unit, with what arrangement, and which packaging unit to use according to the characteristics of the customer (fig. 15).” Before the unloading station, there are an unmasking station to remove the films and tapes that protect the flanges during treatment and an automatic station equipped with a robot for the application of a rustproof oil, useful to prevent the flanges from oxidising. Graco has also been involved in the automation of the protective oil application station. “Once we installed the robot in this station, the biggest difficulty was related to the choice of the pumps and the type of float,” Liverani says. “Also in this case, we relied on Graco for the

14 Figure 14: The coating management unit.

The AirPro gun is frequently used in the automotive industry to treat limited surface areas where a high quality level is required. This is a very powerful gun, selected by Pieffeci because the various kinds of oil used have very different viscosities.”

13 Figure 13: CMA Robots’ control unit.

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

development of the best solution. We initially assessed the possibility to apply two different oils with two guns located on the robot’s wrist. Due to weight problems, however, we finally installed only one gun, choosing the AirPro type to have the possibility to fine-tune the spray fan and thus be able to apply a minimum amount of well-sprayed product on small parts (about 10-20 cc/min) and a greater amount on the larger ones.” “The AirPro gun,” Casoni adds, “is frequently used in the automotive industry to treat limited surface areas where a high quality level is required. This is a very powerful gun, selected by Pieffeci because the various kinds of oil used have very different viscosities. This also complicated

Our collaboration with Bonfiglioli is solid and will continue in the future. Their satisfaction is proven by their request for our consultancy services also for the design, construction, testing, start-up and management of the coating systems of other production plants.”

the choice of the flow metre checking that the nozzle is not clogged and therefore that the application has taken place, since it is impossible to understand whether the gearbox has been fully coated or not through a visual inspection. After several trials carried out at our test centres, we have mounted proportional valves that regulate the flow and pressure of the product so as to ensure the high variability of the fan amplitude and of the flow rate.”

Conclusions “In general, we can say that Pieffeci’s intervention is convenient for all any company experiencing qualitative and productive efficiency issues, but above all wherever the paint consumption and the number of operators needed for the line are significantly high,” Nati states.

Pieffeci will certainly not stop here: we must continue to spread the idea that a proper surface treatment can be an added value for the Italian manufacturing industry. In order to do so, we need partners like Graco and AS, able to provide adequate support for the updates, implementations and innovations to be introduced in our processes”

“Our collaboration with Bonfiglioli is solid and will continue in the future. Their satisfaction is proven by their request for our consultancy services also for the design, construction, testing, start-up and management

Bonfiglioli Spa’s gearboxes: the creation of a well-established brand* Bonfiglioli Riduttori was established on April 16th, 1956 based on the entrepreneurial idea of Clementino Bonfiglioli to make the most of the experience he had gained in the design and construction of gears and gearboxes for the agricultural machines and motorcycles of firms such as Ducati, Gilera and Moto Morini. Its first name was “Costruzioni Meccaniche Bonfiglioli”. During the first years, its production focused on gears for the agricultural and motorcycle field, a driving sector in the industrial fabric of the Bologna area at that time. Towards the mid-60s, there was a profound transformation in the local business environment: the growth of the automated

of the coating systems of other production plants. This proves that we are working well and that we deliver the results required by the companies with which we are cooperating. However, Pieffeci will certainly not stop here: we must continue to spread the idea that a proper surface treatment can be an added value for the Italian manufacturing industry. In order to do so, we need partners like Graco and AS, able to provide adequate support for the updates, implementations and innovations to be introduced in our processes.”

Figure 15: A ﬁnished gearbox.

machine industry, especially for the packaging sector, lead the city and its region to becoming the world’s most important district in the field, now called “Packaging Valley”. The company immediately grasped the great opportunity that such an evolution could offer and it began to design and manufacture products that would have soon become market leaders. A two-stage epicyclic gearbox was designed and patented, whose success has remained unaltered for the next fifteen years. The company grew even further thanks to a careful expansion of its product range and to some important takeovers. In 1975, the acquisition of Trasmital, a Forlì-based company producing epicyclic gearboxes intended for earth moving machines, enabled Bonfiglioli to become a leader in this sector.

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

Bonfiglioli is now a multinational company with more than 3,600 employees, 21 business branches in 16 countries, exclusive distributors in more than 80 countries, and two major plants in India and Vietnam. It is a leader in the global wind market with a 30% share. In 2017, the company is going to carry out a 5,000 m2 expansion of its plant in Forlì, which currently has a 36,000 m2 wide covered area. This will enable it to implement several logistic processes, a sign that the company’s development continues on the research path that has characterised it so far, thanks to its ability to “look into the future” and to identify always new and innovative markets and growth sources.

*Source: Bonfiglioli Spa

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

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graco.com/ďŹ nishing

Adapta Among the Protagonists of Materials Village 2017 at the Milan Design Week

SUCCESS STORIES

Opening photo: Adapta Color presented its new collection of ﬁnishes for architecture, A16, in the exhibition space of Materials Village 2017.

materials to improve the functioning of the city and the lives of its inhabitants: solutions for the urban and domestic comfort and for the exchange of information and data in the urban sphere, but also smart and sustainable building materials. This included the powder coatings produced by Adapta, a company that is now an example at the European level of integration © Ilaria Lagioia

dapta, the Spanish leading manufacturer of smart and specialeffect powder coatings for metal architecture, was among the protagonists of Materials Village 2017, one of the most anticipated events of the Milan Design Week 2017, held from 4 to 9 April (Fig. 1). Materials Village is a “hub” created by Material ConneXion Italia to deal with materials, new technologies and sustainability. This year’s most important event was the exhibition “New Materials for a Smart City”, curated by Material ConneXion Italia with the sponsorship of the municipality of Milan. This provided the visitors of the Milan Design Week with an overview of the latest material innovations for the creation of a smart city (Fig. 2). Divided into thematic areas, it presented useful technologies and

Figure 1: Materials Village 2017 took place from 4 to 9 April during the Milan Design Week.

among experience, dynamism and propensity to innovation in the manufacturing of powder coatings. In the “boxes” that characterise the exhibition format of Materials Village, Adapta presented its new collection of architectural finishes A16, launched at the end of last year (ref. Opening photo and Fig. 3). The A16 catalogue consists of 32 collections with a very wide spectrum of colours, including 8 shades each. Each collection is inspired by an iconic building or a famous place on the planet, used by Adapta to develop and choose the various colour combinations.

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

2 Figure 2: The exhibition event “New Materials for a Smart City”.

KMU LOFT – because resources are limited

Adapta was included among the 250 brands and events of the Archiproducts Design Selection, the Milan Design Week’s latest route that Archiproducts – the largest source of information to find inspiration on design and architecture online – suggested to architects from all over the world to discover the best of the international design (Fig. 4). It did not follow a district-based logic, but rather focused on quality, excellence, innovation and technology.

Based on the proven technology Adapta VIVENDI for architecture, which has been recently tested according to ISO 160009:2006 achieving an A+ rating for indoor emissions, this catalogue also includes interference colours from the Dichroic ranges as well as textured and oxidised metal effects from the Patina collection. All hues have been developed with the last generation Adapta Bonding System® technology, which ensures a homogeneous optical effect. This is crucial for complex designs and projects with high quality standards. Many of the new colours are already available also in their superdurable versions, which in any case can be requested for all other shades.

SUCCESS STORIES

3 Figure 3: The new collection of Adapta’s A16 catalogue.

Moreover, most hues can be integrated with some of the functions listed in Adapta’s smart coating catalogue, such as insect repellency, bacterial proliferation reduction, easy removal of stickers (Stickers Proof technology), self-cleaning ability (BioNox), the Adapta Tracker technology against the counterfeiting of paints, photoluminescence, abrasion resistance, easy removal of graffiti, and many more.

4 Figure 4: Adapta has been included among the 250 brands and events of the Archiproducts Design Selection.

Impresa leader nel trattamento dei reﬂui industriali e artigianali attraverso la tecnologia dell’evaporazione. Offriamo • tecnologie di evaporazione a basso consumo energetico e ridotta manutenzione; • esperienza e know how ventennale nella realizzazione di piu` di 2200 progetti; • soluzioni economicamente all’avanguardia nella riduzione degli scarichi e nel recupero delle risorse

www.kmu-loft.it

BRAND-NEW

Waterborne Products News from Condoroil for the Coil Coating Industry CROMCOAT CR 646 Passivating for galvanized coil

CONDORBOARD LV Waterborne Paint: for coil with blackboard effect

The trivalent chromium deposit to be applied varies between 15 and 40 mg / m2 (Figs. 1 e 2), depending on the treated substrate, the corrosion resistance that you want to give or that the customer requires. The product is also compatible with the majority of fluids used in the skinpassing phase.

Condoroil has recently developed a new Board effect is a must for the home décor. formulation for the passivation of galvanized coils. In the market there are different paints DIY with “board” effect that can be used to The product has been named with the acronym CROMCOAT CR 646 and it differs from the decorate homes, walls, furniture, cabinets, appliances, light fixtures, doors. current CR 644 since it has a double active Everything can be painted giving new life to components concentration. furnishings, proving to be very With the use of the formulation useful to write memos, shopping there are no technical changes in the lists, appointments etc. application and / or performance Condoroil Chemical, but simply a reduction in the cost always in step with the times of use of the product resulting and fashions, created the from lower specific purchasing and new CONDORBOARD LV, a logistics costs. “board” coating effect for CROMCOAT CR 646 is a product coil coating (Fig. 3). specifically formulated to give a high The CONDORBOARD LV product yield, in the passivation of hot-dip is mainly used on metal coated galvanized surfaces (HDG). steels (eg. Hot-dip galvanized) The high yield of CROMCOAT CR 646 or aluminum in order to obtain a ensures a strong reduction of the coating with blackboard effect. concentrated product consumption 1 2 Once dried, it is possible to compared to the trivalent chromium write on the coil surface with passivating normally in use. This Figure 2: Cr 40 mg/m2 after 96 Figure 1: Cr 15 mg/m2 after 24 h normal blackboard chalks. facilitates the customer in having of NSS. h of NSS. The inscriptions are cleared a reduced handling of tanks and consequently it reduces the space quickly by simply using a dry cloth. CONDORBOARD LV is a water-based for storage. product which can be applied as it is, It is usually used with a roller applicator, chemical coater or spray and squeege. After dipping, spraying or by the use a chemical passivation with CR 646 the galvanized coil coater. A perfect drying of the product is must be dried in such a way that the surface obtained reaching a PMT of 80°C. reaches a PMT higher than 50°C. If applied on HDG it presents the advantage CROMCOAT CR 646 is a passivating totally free of obtaining a magnetic blackboard effect of hexavalent chromium and fluorides. product, thus allowing the application It allows to ensure a corrosion resistance that of memo and pictures with the help of a exceeds the highest demands of the market simple magnet. 3 ensuring excellent wettability and uniformity of the support (WR <5% after 100 h NSS with 30 For further information: Figure 3: The blackboard effect of the new 2 paint for coils. mg / m deposit). www.condoroil.com

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

BRAND-NEW

Eisenmann Wins Surcar Innovation Award

ÂŠ Eisenmann

flexibility, can be tailored to various batch isenmannâ&#x20AC;&#x2122;s Paint Shop of the Future technologies include VarioLoc and E-Shuttle sizes, and support automated predictive concept has been honored by judges at conveyors for highly versatile material and Surcar in Shanghai. The German plant process flows. Moreover, E-Cube, a highly maintenance and quality assuranceâ&#x20AC;?. In their description of the prize winner, engineering enterprise received the Surcar efficient paint removal system, and new, Innovation Award at the third Asian edition of intelligent dryers, help to significantly lower the Surcar judges highlighted ease of implementation and the congress. the way the individual The Surcar Innovation Award is solutions could be linked the highest accolade granted to create an integrated by the organizersâ&#x20AC;&#x2122; technical committee and reflects the paint shop in line with Industry 4.0. theme of the conference. The The Surcar Congress has event was held in Shanghai, been held for almost 30 China, on 12 and 13 April, and focused on current automotive years in Cannes, France. It is a highly regarded painting issues: smart factories, information platform and the latest technology trends a key date in the calendar in the paint industry, and for vehicle, paint and plant ways of saving energy in the manufacturers worldwide. painting process. The judges Since 2014, there has been were impressed by the total an Asian edition of the number of intelligent solutions 1 conference. Surcar Asia submitted by Eisenmann that is held in Shanghai every can be combined to create an Figure 1: Jan Hammermann presenting Eisenmannâ&#x20AC;&#x2122;s skidless painting concept 18 months, and enables end-to-end paint shop in the at Surcar in China. decision makers, solution spirit of the fourth industrial providers and users to revolution. energy consumption. As Hammermann share ideas and insights on all aspects As Jan Hammermann, who presented the skidless painting concept at Surcar in China explains: â&#x20AC;&#x153;We developed a range of resourceof automotive painting technology and friendly solutions that can be interconnected trends. on Eisenmannâ&#x20AC;&#x2122;s behalf, emphasizes, â&#x20AC;&#x153;Our to offer our customers a complete paint shop For further information: pioneering digitized systems make smart paint shops possible todayâ&#x20AC;? (Fig. 1). Featured 4.0. Together, these systems ensure process www.eisenmann.com

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BRAND-NEW

All Information Close at Hand in a Matter of Seconds with EcoDocu

ully digitized, linked, and interactive, the EcoDocu smart documentation system greatly simplifies commissioning, operation, and maintenance in a paint shop. All information is stored end-to-end, easy to locate thanks to a user-friendly navigation system, and also available on the move via a tablet. EcoDocu lays the foundation for Industry 4.0 applications such as predictive maintenance.

ÂŠ DĂźrr

Digital documentation makes processes involved in system operation more efficient, from straightforward commissioning to fast parts ordering. Up to now, the technical documentation for a paint shop took up around 150 ring binders. EcoDocu stores this substantial amount of information digitally on a data carrier so that it is immediately available on a PC, at any time and in any desired language. EcoDocu structures the data into manageable units for the user. The main sections such as the parts catalog, the circuit diagrams, and the actual documentation are visible at first glance. They are also

interlinked for ease of handling. Examples of this are the colored hotspots in the system diagram. When a user selects one of these hotspots, the corresponding component, for example a turntable or solenoid valve, is displayed automatically in the navigation and parts list area with the correct designation and material number. The mouseover function also opens a separate window containing device-specific details. The user can access documents like the technical data sheet or the full operating or assembly instructions with just one more click. The selected product can also be added directly to the basket from the parts catalog, speeding up the purchase of spare parts. EcoDocu runs as a mobile application on the DĂźrr tablet EcoPad or other mobile devices, which means that the system documentation is available everywhere in production. Especially convenient: when the QR codes (Fig. 1) on machines and systems are scanned, the app navigates directly to the corresponding functional part in the parts catalog. This means no more tedious searches, for example for the right serial number. For further information: www.durr.com

Figure 1: Scanning the QR codes on the equipment navigates directly to the corresponding functional part in the parts catalog.

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

Opening photo: An example of a lift by Ravaglioli Spa.

FOCUS ON TECHNOLOGY

A Unique Concept for the Cataphoresis + Powder Application Process of the Ravaglioli Group, thanks to the Technical Solutions Adopted Monica Fumagalli ipcm®

fficine Meccaniche Sirio, based in in Ostellato (Ferrara, Italy), is a company of the Ravaglioli SpA Group, a leading manufacturer of lifts, wheel balancers, tyre changers and wheel aligners for garages all over the world (ref. Opening photo). The new coating system installed at its premises occupies about two thirds of a plant that is almost as large as a soccer field (about 4400 m2). The layout of this new paintshop overcomes the concept of conventional coating lines.

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

“Such an investment was motivated by the changing needs of our customers,” says Flavio Villa, the Industrial Director of the Group (Fig. 1). “Until a few years ago, vehicle repair equipment was chosen based on high performance, but the aesthetic quality of products has now gained increasing importance even in this sector. Partly, this is due to the fact that the selection of garage equipment, which used to be totally managed by the private workshops, is now carried out by the large automakers, which impose the finishing parameters required for car components even

FOCUS ON TECHNOLOGY

reconditioned several times on these devices. High coating over the years, apply one coat quality and longer service life were of primer with an immersion Ravaglioli’s two main goals for the process and one of powder installation of a new plant and the topcoat. implementation of a cataphoresis “The experience we have gained + powder application process. thanks to these two plants The new paintshop has become that are still operating,” Villa our best calling card, enabling us adds, “has provided us with to be more competitive especially the tools to accurately and in the northern part of the world, precisely determine the details where the massive use of salt on 1 of the new line. In Sirio’s plant, streets increases the chance of we treat every product with a corrosion on the components of Figure 1: Flavio Villa, on the left, with Stefano Sartori. cataphoresis + powder coating our machines.” process, including some of the This fully automated coated The start of a great project steelwork components manufactured by line, operational since January 2017, is Ravaglioli installed a coating plant at the other companies of our Group.” However, majestic – it took months only for the headquarters of the Group, in Bologna, not all that is produced in Sirio’s plant creation of its foundations – and it is the towards the end of the Eighties, followed by undergoes this cataphoresis + powder result of perfect interaction between a second system selected in 1996 to handle application process: the lifters’ components the suppliers of the plants, devices up to 3 m long workpieces. The two plants, need such a treatment because they are and products constituting it. They were subject to corrosion problems, but coordinated by Radial Group Srl, a the tyre changers and the wheel company based in Badia Polesine We wanted the new line to meet balancers can be finished with (Rovigo, Italy) with extensive powder only. experience in the design, construction three crucial requirements: a non-inline “For our new coating plant,” and installation of industrial plants. shotblasting plant, a cleaning system that Villa says, “we have focused on The peculiarities of Ravaglioli’s plant could effectively remove the residues of the anti-corrosion efficacy that a are as follows: treatment flexibility, the sheet metal laser treatments even cataphoresis treatment is able to achieved thanks to the ability to from non-sandblasted parts, and a high guarantee: we are convinced that programme different cycles; efficiency performance cataphoresis plant.” it is the ideal way of the production to decidedly solve cycle, ensured by all the problems storage buffers placed related to corrosion strategically along the resistance and entire line in order to to the coating of eliminate unnecessary difficult-to-reach waiting times; high areas with good safety degree, ensured aesthetic results. by several technical When, back in 2015, tricks; and high we had to choose energy efficiency, the characteristics achieved thanks to of the new system, the air and waste which had become treatment systems necessary to cope designed to minimise with the production energy consumption 2 spikes that the two in compliance with all plants in Bologna the environmental law were no longer requirements. Figure 2: The layout of the coating line.

international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

Figure 3: The loading area with the Power & Free conveyor and the descenders supplied by Futura Convogliatori.

Figure 4: The touch screen for programming the treatment cycles.

able to handle, we turned to Radial Group Srl, which had already dealt with the revamping of the systems installed at our Bologna premises. “We wanted the new line to meet three crucial requirements: a noninline shotblasting plant, a cleaning system that could effectively remove the residues of the sheet metal laser treatments even from non-sandblasted parts, and a high performance cataphoresis plant. The line also had to be placed in a pre-existing environment. Radial Group Srl’s cooperation has led to the realisation of an important project not only in terms of dimensions, but also of complex integration among different systems. They have been able not only to identify the exact features of the equipment to be provided by other suppliers, but also to integrate them to achieve the high yield required by Sirio-Ravaglioli.” “After the design of the initial project, we spent a few months perfecting the structure to get the definitive design of the plant,” says Francesco Soragni, the owner of Radial Group Srl. “Meanwhile,

we continued to gather information and visit companies to select the ones that would have formed the coating line team. The choice of Sirio-Ravaglioli fell on each field’s leading company and was motivated more by their reliability than by economic reasons.”

The loading stage and the programming of the treatment process

The layout of the new coating plant is characterised by a number of storage buffers that contribute to making the production flow more fluid and cancelling the waiting times due to any stoppage in the handling of the parts (Fig. 2). The Power & Free conveyor installed by Futura Convogliatori Aerei (Robecco Pavese, Pavia, Italy) can handle 62 loading bars – a number that will soon increase. These carry the Sirio lifters’ components with a chain speed of 8 m per minute and an interval of 5 minutes per bar. The workpieces are up to 6500 mm long, 1200 mm large and 2700 mm high; each bar can carry a weigh up to 2000 kg.

Figure 5: The sandblasting plant.

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Figure 6: The storage buffer preceding the pre-treatment process.

FOCUS ON TECHNOLOGY

cataphoresis.” Futura Convogliatori Aerei’s conveyor automatically manages the bars’ flow according to the parameters set. Here, the conveyor splits in two for the first time. One branch takes the components that cannot be shotblasted due to their characteristics and shape directly to the pre-treatment line, running to the side of the shotblasting system. The other branch takes the other workpieces to the shotblaster, supplied by Cogeim Europe (Casorezzo, Milan, Italy, Fig. 5).”

The layout of the new coating plant is characterised by a number of storage buffers that contribute to making the production flow more fluid and cancelling the waiting times due to any stoppage in the handling of the parts.” The coating process starts in the loading area, equipped with a multi-level descender that enables to hang the material in the upper part of a bar and also in the lower part of the following one, in case the 5-minute interval is not enough (Fig. 3). “When loading the bar,” Soragni says, “the operator also defines the processing parameters for the components (Fig. 4). It is even possible to select mixed cycles, including or excluding sandblasting, phospho-pickling during pre-treatment, and

Sandblasting as a guarantee of corrosion protection

7 Figure 7: The ﬁrst pre-treatment stage is an immersion alkaline degreasing process.

“The machining operations we carry out on sheet steel with our laser cutting machines,” so Stefano Sartori, Ravaglioli Group’s Technology Manager, “leave difficult-to-remove residues on the surfaces. Moreover, due to space, storage and handling issues, most of

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Figure 9: One of the fumes extraction chimneys of the pre-treatment tunnel.

Figure 8: The pre-treatment tunnel.

Then, it reunites in one branch located before the tunnel itself (Fig. 6). The bars loaded with non-shotblasted components precede the others. The first pre-treatment stage is an immersion alkaline degreasing process performed through a descender at 50°C for 3 minutes, in order to remove any surface residue (Fig. 7). “Ravaglioli treats a large amount of tubes,” Soragni states. “That is why the parts are loaded on the bars obliquely: when the workpiece is

Effective pre-treatment for a thorough surface cleaning After loading, the conveyor splits in two, thus creating two storage buffers devoted, respectively, to the shotblasting system and to the pre-treatment tunnel.

immersed, water passes through the tube by cleaning it on the inside, where iron slags resulting from the sawing operations may remain”. Then, the parts enter a 5-stage spray pre-treatment tunnel built by Silvi (Lesmo, Monza e Brianza, Italy, Fig. 8). The first step includes a spray alkaline degreasing process at 50°C and two rinses with fresh water. Then, a spray phospho-pickling stage is performed at 50°C, followed by one rinse with fresh water and one with

our workpieces are stocked outdoors. We knew we needed a sandblasting treatment in order to increase the cleanliness of our substrates and their subsequent protection and weathering resistance.” The Cogeim GTU shotblasting system consists of a tunnel divided into four sections: - an inlet area with rubber curtains to prevent any leakage of grit; - a shotblasting chamber in which the parts are exposed to the media flow generated by high efficiency centrifugal turbines; - an outlet area with multiple rubber curtains to prevent any leakage of grit; - a blow-off station where the operation is performed with a nozzle by an operator, in order to remove any dust or grit remaining on the workpieces. There are 12 turbines installed, each with a power of 15 kW. The plant is equipped with a system featuring an auger and a lifter for the automatic recycling and cleaning of media. The chamber’s ventilation and dust collection system is equipped with a selfcleaning cartridge filter.

10 Figure 10: The cataphoresis tank and, in the background, the dialysis cells.

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The pickling stage, enables us to remove any laser machining residue from the parts that cannot be sandblasted. On the other hand, if the components have already been sandblasted and the phospho-pickling process has been excluded during the initial programming phase, the pumps do not turn on and the workpieces remain for 5 minutes in that section of the tunnel without undergoing any treatment.”

FOCUS ON TECHNOLOGY

demineralised water. All the pre-treatment the extractor fan, the fumes pass through a The cataphoresis process and the curing oven: technical chemicals are provided by Chemetall. cyclone that lets them decant and makes the arrangements “The pickling stage,” Stefano Sartori adds, water mass fall into the tunnel itself, in order At the end of the pre-treatment tunnel, “enables us to remove any laser machining to recover as much product as possible the bars enter the cataphoresis plant, residue from the parts that cannot be (Fig. 9). also built by Silvi. Here, sandblasted. On the other the descender picks up the hand, if the components have still wet workpieces and already been sandblasted and immerses them directly into the phospho-pickling process the 8.5 m long cataphoresis has been excluded during the tank with a capacity of initial programming phase, 60 m3 (Fig. 10 and 11). the pumps do not turn on and Depending on the selected the workpieces remain for 5 cycle, the descender may minutes in that section of the move down and start the tunnel without undergoing any cataphoresis process or, treatment. if this treatment is not “The last step is the required, stand still while spray application of a waiting for the parts to nanotechnology passivation 11 leave towards the following product, Oxsilan. This is able stage. The product used is to act on the metal sheet by Figure 11: The outside of the cataphoresis tank. the grey CathoGuard® epoxy creating an about 60 nm thick coating supplied by Basf, conversion layer based on characterised by high thickness, metal oxides, which improves This oven has the peculiarity that, even excellent edge protection and the adhesion of the paint and the absence of lead and tin in its significantly increases the corrosion though it consists of one chamber, in the formulation. resistance of the parts.” The prefirst two stations the temperature does not After cataphoresis, the parts treatment ends with a last rinse rise above 110°C, while the following station undergo an immersion and with demineralised water. already operates at 180°C. This enables the a spray rinsing stage with The suction system of the precataphoretic coating to begin to flash-off and ultrafiltrate. A demineralised treatment tunnel has been the component to absorb heat more gradually, water tank with a closed designed so that, before reaching thus avoiding any blistering on the surface.”

12 Figure 12: The hydraulic seals’ ﬂow panel on the pumps.

13 Figure 13: The storage buffer preceding the powder coating application area.

international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

After the cooling tunnel, Futura has added a 9-bar storage buffer that we use to empty the cleaning tunnel and the cataphoresis tank at the end of the process. Every morning, the conveyor turns on and takes the bars to the powder coating station. This eliminates any waiting time for arrival of the first bar from the cooling tunnel.”

loop system and a special pump feeds the pumps involved in the flow of the hydraulic seals on the ultrafiltration module’s coating feeding pumps and on the cleaning pumps after cataphoresis. Each hydraulic seal is fitted with two needle valves for pressure regulation and a pressure gauge (Fig. 12). The following station is an oven 14 for the curing of the cataphoretic Figure 14: Gema Europe’s OptiCenter powder coating at 180°C or, management unit with powders supplied by Inver-Valspar. if the cataphoresis process has not been performed, for the drying of the components. Futura’s conveyor splits into two parallel branches within the oven in order to enable the storage of the bars and reduce any obstruction, thus lowering the consumption of energy. The bars enter the oven every 5 minutes. “This oven,” Soragni states, “has the peculiarity that, even though it consists of one chamber, in the first two stations the temperature does not rise above 110°C, while the following station already operates at 180°C. This enables the cataphoretic coating to begin to flash-off and the component to absorb heat more gradually, thus avoiding any blistering on the surface. In order to achieve this result, we have designed a combination of controlled drive shutters that bring in fresh air and mix it with the warm one by opening and closing, thus changing the chamber temperature and protecting the workpieces against

FOCUS ON TECHNOLOGY

any thermal shock during the curing of the cataphoretic coating. This is possible thanks to the independence of the ventilation systems of the two separate temperature zones. Another important element for the proper functioning of the system is the fact that, even if there was only one bar in the oven, this could not exit before the end of the 50-minute time cycle.” In the forced cooling tunnel, the outside air is sucked in and sent to a lower plenum where the cooling blow cones are lined with sheet metal to ensure staff safety during maintenance. “After the cooling tunnel,” Sartori adds, “Futura has added a 9-bar storage buffer that we use to empty the cleaning tunnel and the cataphoresis tank at the end of the process. Every morning, the conveyor turns on and takes the bars to the powder coating station. This eliminates any waiting time for arrival of the first bar from the cooling tunnel. Another storage buffer has been placed just before the spray paint booth, again to avoid any loss of productivity (Fig. 13).”

INTERNATIONAL PATENT

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

NITROTHERM The performance is reffered to fluid enriched in nitrogen with concentration of 93% ± 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.

15 Figure 15: The manual pre-retouching operation.

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controlled shutter system connected to an external temperature probe enables the extract air to be sent to the outdoor or the indoor environment. If the outdoor probe detects a temperature below 15 °C, during the winter months, the air is recovered and used to heat the plant (Fig. 18); with an outside temperature greater than 15 °C, the air is ejected.

Futura Convogliatori has also created a “parasitic” branch of the conveyor to take the bars needing to be inspected outside the line.

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t a a e S o

The powder coating booth has been provided by Gema Europe (Trezzano sul Naviglio, Milan), a well-established supplier of Ravaglioli’s plant (Fig. 14). It features The technical compartment reciprocators with 6 guns per side operating The uniqueness of this new coating plant also lies in a few technical arrangements with the Venturi technology as well as designed to a station for any ensure maximum manual touch-up safety for Sirio’s before and after coating (Figs. 15 and employees 16). Sirio performs, working on the on average, 3 colour line. A “technical compartment” change operations has been built per day, with a outside the plant maximum peak where the line of 6. In case the service equipment powder application is installed. This is unnecessary houses Riello because the boilers with a cataphoresis heat exchanger treatment is enough, to warm the the bars are carried alkaline and directly to the pickling baths; unloading area. a wastewater Officine Meccaniche treatment system Sirio applies a and tanks for particular kind 16 17 of masking on the distillates its components. supplied by KMU Figure 16: The post-retouching station after the Figure 17: The gelation oven. “Immediately after Loft (Bolzano, powder application booth. coating, we carry Italy, Fig. 21). out some sort of The wastewater “reverse” masking,” Sartori explains. Finally, the bars reach the unloading area treatment plant is a closed-loop system: “In other words, we remove the powder (Fig. 19). “Between the loading and the all liquid waste, except for paint, flow where it is not needed before curing. unloading descenders,” Soragni says, “we into it. The storage tanks are devoted, Ravaglioli had already applied this method have built a footbridge for the storage respectively, to the active baths (alkaline to other plants. We use a particular of empty bars and a hook-holding grille degreasing, phosphating and passivation), aspirator with interchangeable specialunderneath it (Fig. 20).” the eluate of the demineralisation plant shaped nozzles that remove the and the cataphoresis anolyte. powder coating product from the The rinsing liquids are stored in areas that do not need be covered.” separate tanks. In another tank, Officine Meccaniche Sirio applies The coating station is followed by the rinsing liquids are mixed with a particular kind of masking on its two air gelation stations and an oven, the active bath ones, and the pH components. Immediately after coating, where maximum 10 bars can stay for value is adjusted. Subsequently, they carry out some sort of “reverse” 50 minutes at 180°C (Fig. 17). The next wastewater is aspirated through masking. In other words, they remove cooling stage is performed with blow a DESTIMAT LE 1000 evaporator, the powder where it is not needed before cones using outside air. A servofeaturing an evaporation capacity curing”.

o p v w in b a F c h a s r w r T t W in o c

The powder coating process and a particular masking device

FOCUS ON TECHNOLOGY

The uniqueness of this new coating plant also lies in a few technical arrangements designed to ensure maximum safety for Sirio’s employees working on the line.”

The whole plant is surrounded by a protective fence and access is only allowed through one opening. Operators do not run any risk within this new department, neither during the production phases nor when performing maintenance tasks. This is another reason for satisfaction and proves the validity of such a large investment.”

of 1 m3/hour and working according to the principle of mechanical recompression of vapours; it uses 60 kWh to purify 1 m3 of wastewater. The plant is fully automatic, including the chemical cleaning of the tube bundle and the dosage of the defoaming agent carried out by a special system. From here, the distillate is transferred to a drums to be used when the tank needs coalescence separator where the volatile maintenance and the suction filter of the hydrocarbons left in the distilled product Gema booth, which we chose to locate are removed; then, it is pumped to the outside the plant. The outside location of storage reservoirs. The treated liquid is these systems has been designed together recirculated to the pre-treatment plant with IM.TECH (Bologna), which has dealt 18 with a cascade in the rinsing tank. The with all safety aspects in cooperation with residual concentrate is then disposed of. Radial. The whole plant is surrounded Figure 18: The cooling area for the treated components. The technical compartment also houses by a protective fence and access is the demineralisation plant installed by only allowed through one opening. Our operators do not run any risk within this new department, neither during Water Energy (San Pietro in Casale, Bologna, Italy, fig. 22). “We have the production phases nor when performing maintenance tasks. This is installed two 10 m3/hour demineralisers,” says Sartori, “so that when one is being regenerated, the other can keep operating. In the technical another reason for satisfaction and proves the validity of such a large compartment, we have also placed the cataphoretic paint storage investment.”

19 Figure 19: The unloading area.

20 Figure 20: The hook collection area.

international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

21 Figure 21: The evaporator provided by KMU Loft.

“Another interesting aspect of the plant is the zero discharge concept. The wastewater treated with KMU Loft’s system is recirculated to the pre-treatment tunnel, while the evaporator concentrate is conveyed into tanks and then disposed of,” Sartori states. “Also regarding emissions, IM.TECH provided us with the necessary information to fully meet all reference standards already during the line design stage.”

The Four Cornerstones of Ravaglioli SpA Ravaglioli SpA is one of the world’s topranking companies in the garage equipment industry. It is Europe’s leading manufacturer of lifts and among the major producers of tyre and test equipment (vehicle testing and wheel alignment). Established in Bologna in 1958, it has devoted its production to the construction of equipment for the assistance and repair of means of transport, developing all aspects of vehicle lifting for both cars and commercial vehicles. In 1981, it moved to its current plant in Pontecchio Marconi, housing the production site as well as the executive, technical and administrative offices, a show room and several rooms for meetings and training courses. Subsequent extensions and upgrades carried out on its 80,000 m2 wide

Figure 22: The demineraliser installed by Water Energy.

Conclusions “I can state that we have realised a cutting-edge project for Sirio,” Villa says, “especially given the technical solutions adopted to obtain optimal finishing results in adequate production times while ensuring the health security of our operators. This is the result of a strict and accurate selection of our suppliers and, above all, of the high-level cooperation among the companies that

premises have led to the creation of a 32,000 m2 covered area. Four companies are currently part of the Ravaglioli group: the parent company Ravaglioli, Butler Engineering & Marketing SpA, Officine Meccaniche Sirio Srl and Space Srl. Each one specialises in the production of a particular line of products. Sirio has joined the Ravaglioli group in 1997 as a new production unit with an area of 60,000 m2, 9,800 of which were covered – they became 18,000 in 2006. Here, there are the production lines of tyre changers and wheel balancers as well as a large area devoted to the processing of metal sheets and hydraulic cylinders. Another unit, Space Srl, is operational since 1998. It specialises in the production of wheel aligners and revision lines and it is based in Trana, in the province of Turin, with an area of 10,000 m2, 4,500 of which are covered. The plant of Butler SpA, in the province of

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have participated in the implementation of this project. The project has fully met our demands for an efficient and productive coating line that will still be technically advanced even in the future.”

Reggio Emilia, has been added to the Group more recently. It specialises in the design and production of top range tyre changers and accessories for tyre specialists. In order to ensure the high quality of its products, the company invests a significant percentage of its turnover in research and design and it has a highly professional and experienced technical staff. The over 270,000 two-post lifts sold until now, together with the several thousand four-post, scissor and mobile column lifts supplied for cars, industrial vehicles and motorcycles, testify to the specialisation degree and the importance gained by Ravaglioli, currently present in 130 Countries outside Italy with a capillary distribution network. Its garage equipment is approved by the most important international automakers, including BMW, Citroën, Renault, Mercedes, Ferrari, Maserati, Lamborghini and many more.

BRAND-NEW

xalta Coating Systems (NYSE: AXTA), a leading global supplier of liquid and powder coatings, has introduced a collection of colours for its Alesta® Super Durable powder coatings. ICONICA contains 40 colours across four distinctive colour palettes - Eden Garden, Energy Manifesto, Arty Fusion and Techno Precious – that are designed to protect and enhance iconic buildings around the world.

1 Figure 1: The ICONICA architectural installation.

Courtyard where the ever-changing natural light and the manual rotation of the piece will reveal the subtleties of the collection’s colour palette (Fig. 3). © Axalta Coating Systems

Axalta has synchronised the ICONICA launch with the 56th annual Salone Internazionale del Mobile, the world’s leading

Axalta Coating Systems Featured its New Powder Trend Offering ICONICA in Milan during the 56th Annual Salone Internazionale del Mobile The piece captures the dynamics and energy of architecture in the age of mobility. Visitors to the Palazzo Litta were encouraged to interact and to explore the installation’s array of 40 colours under the constantly changing light conditions. The selection of 40 UV and weather resistant colours was developed and curated in collaboration with trend forecasting agency NellyRodiTM, based in Paris, France. In addition to the ICONICA architectural installation, a group of European designers showed their latest furniture trends, which will be painted with Alesta Super Durable powder coatings.

Markus Koenigs, Marketing For further information: Communications Manager for www.powder.axaltacs.com Axalta’s powder coatings in Europe, Middle East and Africa, says, “our ICONICA architectural installation displays the 2 entire Collection’s colours, which have been inspired Figure 2: ICONICA contains 40 colours across four by new aesthetic concepts distinctive colour palettes. that include global issues, technology, the digital furnishing fair, in Milan, Italy, that run from revolution and augmented reality. April 4 to 9, 2017. The company commissioned They address the new architectural Meiré und Meiré Design Department from understanding for nature and 3 Cologne, Germany, to create an ICONICA humanity while maintaining the architectural installation that celebrates environmentally sustainable, super Figure 3: Visitors to the Palazzo Litta were the fusion of design, quality and innovation durable attributes our customers encouraged to interact and to explore the (Figs. 1 and 2). It was exhibited during the expect from Alesta powder installation’s array of 40 colours under the constantly event, Fuorisalone, in the Palazzo Litta Clock coatings.” changing light conditions.

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CONVEY YOUR SUCCESS

BRAND-NEW

iTAC.IoT.Suite – the New Generation of Production Control at Dürr ürr is combining its expertise in plant engineering and IT to create the next generation of production control systems. The new Industry 4.0-focused iTAC.IoT.Suite is a combination of the production-related Manufacturing Execution System (MES) EcoEMOS and the highperformance software solutions from iTAC Software AG, which was acquired at the end of 2015.

the basis for future Industry 4.0 applications. An optional cloud connection enables the combination of data from different production facilities across a plant as well as the subsequent evaluation using modern analytical methods like Big Data Analytics. Processes and key performance indicators can thus be tracked in real time. The insights obtained can be used in a targeted manner to optimize the production workflows.

Dürr has invested strongly in the future of industry 4.0 with iTAC Software AG, a leading MES provider for the electronics and automotive supply industries and an innovation driver in Industry 4.0 platforms. iTAC was recently named one of the five leaders in the field of “Industry 4.0 platforms” by the Experton Group as part of the study “Industry 4.0/IoT Benchmark 2017”. The acquisition of iTAC was part of the Industry 4.0 strategy “digital@DÜRR”.

Data acquisition and storage with the iTAC.IoT.Suite guarantees comprehensive traceability of all production processes. The modern software architecture improves production monitoring, efficiency, and quality. To ensure that all data is kept within the company, the iTAC.IoT.Suite offers maximum IT security: Dürr uses software technologies that utilize state of the art cyber security reinforced by regular updates.

The iTAC.IoT.Suite represents a joint development between Dürr and iTAC based on a modern software architecture which can be adapted to different production control requirements in the automotive, electrical, and component industries (tier 1). With a modular structure users are able to select individual functions and create a tailored solution for their entire production chain. New functionalities have been added to the proven EcoEMOS modules - e.g. SCADA, stock control, vehicle tracking as well as energy and quality management - for controlling automotive production. These includes business intelligence, machine monitoring, and order management. The traceability module also provides add-ons for detailed material tracking. As a state-of-the-art system, the iTAC.IoT.Suite also includes a comprehensive order planning module.

These work with security measures on the customer side – e.g. firewalls and separation of office and production networks – to maximize security. For the customer, the fail-safe system offers a wide range of functions with high scalability. The flexible program structure permits individual combination and fast availability of the functional modules as well as easy software releases. The iTAC.IoT.Suite opens up a new dimension in the management of plants and production data. The platform forms the backbone for end-to-end networked and digitized processes in production. The Dürr support teams in Bietigheim-Bissingen and other locations will continue to support existing EcoEMOS installations, both around the clock and around the world. INTERNAL HANDLING SYSTEM

All the functions can be clearly visualized on screens. The iTAC.IoT.Suite also offers a comprehensive analysis of all plant parameters, and therefore forms

Dürr showed its new software solution on Hanover Fair at the booth of “Smart Electronic Factory”. For further information: www.durr.com

IMPIANTI MOVIMENTAZIONE INTERNA

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

BRAND-NEW

Quaker Chemical and Houghton International to Combine

uaker Chemical Corporation (NYSE: KWR) and Houghton International Inc., companies with a combined 250-year history as providers of process fluids, chemical specialties, and technical expertise to the global primary metals and metalworking industries, today announced that they have executed a definitive agreement to combine the companies. Both Quaker Chemical and Houghton International are headquartered in the Philadelphia area. “The proposed combination of Quaker Chemical and Houghton International represents the next phase of our evolution, and stays true to the vision of growing in our core specialties,” said Michael F. Barry, Chairman and Chief Executive Officer of Quaker Chemical. “Joining forces with Houghton International combines two highly complementary businesses, each having a long history of building tremendous expertise, technology and customercentric cultures dedicated to delivering long-term sustainable value to customers, shareholders and associates. The new company will capitalize on best practices and expertise from both businesses”. Sanjay Hinduja, Chairman of Houghton International, which is owned by the Hinduja Group through its Gulf Oil business, said, “We are pleased to enter this agreement to unite these two distinguished and global companies. Together we will strengthen our capabilities and business models to better serve the global market and all our stakeholders”. Under the terms of the agreement, Houghton International shareholders

will receive $172.5 million of cash and 24.5 percent ownership of the combined company, representing approximately 4.3 million shares of newly issued Quaker Chemical stock. In addition, Quaker Chemical will assume Houghton International’s debt and cash, with net debt of approximately $690 million at year-end 2016. The agreement has been approved by both Quaker Chemical’s board of directors and Houghton International’s board of directors with full support of the Hinduja Group, which will become Quaker Chemical’s largest shareholder. Houghton International and Quaker Chemical are both known for a commitment to innovation in a highly specialized and technologically demanding industry. “In addition to our complementary businesses,” said Mike Shannon, Chief Executive Officer of Houghton International, “we are each committed to creating solutions for our customers through innovation, strong technical expertise and global reach with localized applications expertise”.

Highly Complementary Transaction Combining Quaker Chemical’s and Houghton International’s product solutions and service offerings will allow the new company to better serve customers in the automotive, aerospace, heavy equipment, metals, mining, machinery, marine, offshore, and container industries. The business will have one of the world’s most expansive metalworking platforms comprised of specialty products that include removal fluids, forming fluids, protecting fluids, heat treating fluids, industrial lubricants and greases. The expanded portfolio is expected

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to generate significant cross-selling opportunities and allow further expansion into growth markets that include India, Korea, Japan, and Mexico. By combining resources, the new company will increase the breadth of its innovative technology, accelerate its product development initiatives and time to market, and diversify its long-term R&D pipeline. The company’s customer-intimate business model will be further strengthened with an expanded chemical management offering. The enhanced portfolio, industry-expert associates and applications expertise will enable the combined company to bring additional value to its customers’ overall performance and operations.

Value Creation For Shareholders For 2016, Quaker Chemical had revenue of $747 million, $107 million of adjusted EBITDA, and $22 million of net cash. During the same period, Houghton International had revenue of $767 million, $120 million of adjusted EBITDA, and $690 million of net debt. After the close of the transaction, shares of the combined company will continue to be listed on the New York Stock Exchange. The company anticipates achieving cost synergies of approximately $45 million, the majority of which will be realized within two years of closing. These synergies are expected to be driven primarily by supply efficiencies and cost reductions. Additional value creation is expected through crossselling opportunities and the ability to provide an expanded array of products and solutions for customers. Post-transaction, the combined company expects to continue to maintain its dividend

BRAND-NEW

and use its strong cash flow generation to quickly reduce debt, improving its pro forma net debt to adjusted EBITDA ratio from approximately 3.7 times at close to approximately 2.5 times within two years after close.

Financing, Governance And Leadership Quaker Chemical has secured $1.15 billion in committed financing from Bank of America Merrill Lynch and Deutsche Bank Securities Inc. to support the transaction, which includes $200 million of additional liquidity for future needs. The company estimates that the annual ongoing interest costs of the financing will be in the 3 percent range at today’s interest rates. The completion of the transaction, which is expected by the end of 2017 or early 2018, is subject to customary closing conditions, including regulatory approvals and approval by Quaker Chemical shareholders. The companies will continue to operate independently until the transaction is completed. Following closing of the transaction, the new company is expected to have a 12-member board of directors, consisting of 9 directors from Quaker Chemical and 3 directors to be nominated by the Hinduja Group. Michael F. Barry will continue as Chairman and Chief Executive Officer of the new business, and the structure of the company will be determined in the period between signing and closing. Deutsche Bank Securities Inc. is serving as Quaker Chemical’s lead financial advisor. Drinker Biddle & Reath LLP are acting as its legal advisors. The Valence Group provided a fairness opinion to the Board of Directors. RBC Capital Markets, LLC is serving as exclusive financial advisor to Houghton International. Mayer Brown LLP are acting as its legal advisors.

For nearly 100 years, Quaker Chemical has helped customers around the world achieve production efficiency, improve product quality, and lower costs through a combination of innovative technology, process knowledge, and customized services. Headquartered in Conshohocken, Pennsylvania, USA, Quaker Chemical serves businesses worldwide with a network of dedicated and experienced professionals whose mission is to make a difference.

About Houghton International Houghton International is a global leader in delivering advanced metalworking fluids and services for the automotive, aerospace, metals, mining, machinery, offshore and beverage industries. Headquartered in Valley Forge, Pennsylvania, Houghton International operates research, manufacturing and office locations in 33 countries around the world delivering solutions that increase productivity, reduce operating costs and improve product quality for our customers. Houghton International is a Hinduja Group Company, which has owned more than 95% of Houghton International since 2012.

Spare Parts for Industrial Plants Catalytic panel for ﬁxing oven Components for pre treatment tunnel Transport systems, Water treatment Electric Motors, Electrical components Filtering elements for Industrial Filters Gearboxes for various applications Normal and special Fans for high temperature Oven Burners, Pumps Spare parts for conveyor

About Hinduja Group The Hinduja Group is one of India’s premier diversified and transnational conglomerate. Employing nearly 100,000 employees, with presence across 38 countries, it has multi-billiondollar revenue. The Group was founded over a hundred years ago by Shri P.D. Hinduja whose credo was “My duty is to work so that I can give.” The Group owns businesses in Automotive, Information Technology, Media, Entertainment & Communications, Banking & Finance Services, Infrastructure Project Development, Oil and Gas, Power, Real Estate, Trading and Healthcare. It also supports charitable and philanthropic activities across the world through the Hinduja Foundation.

About Quaker Chemical Quaker Chemical is a leading global provider of process fluids, chemical specialties, and technical expertise to a wide range of industries, including steel, aluminum, automotive, mining, aerospace, tube and pipe, cans, and others.

For further information: www.quakerchem.com

ANTARES S.r.l. Via F.lli Cervi 12/B - 37036 San Martino Buon Albergo (Vr) ITALY T. +39 045 8780567 F. +39 045 994606 email: info@anteresitaly.net WWW.ANTERESITALY.NET

BRAND-NEW

RHOPOINT TAMS™: Next Generation Paint Quality Instrument - Setting New Standards in Appearance Measurement

Individual new values for contrast, sharpness, waviness and dominant structure size fully describe the visual perception. Consequently, the new values for Quality and Harmony allow a fast and reliable pass-fail decision in the final production inspection stage. Surface appearance is of paramount importance to automotive manufacturers as the first visual impression of a vehicle can directly affect a customer’s ultimate purchasing decision. The painted surface finish should have the most appealing Visual Appearance Perception to the customer, and this can only be achieved if the overall car surface finish exhibits both high Quality and Harmony values. Existing measurement instruments produce complex results that rely on the user interpreting values in the form of real life visual appearance. Difficulties with interpretation often lead to inefficient communication regarding surface appearance between the manufacturer, coating supplier and tier suppliers of OEM parts. Difficulties correlating measured values to visual impression can result in a finish appearance which does not match the manufacturer’s expectations although the measured parameters are within tolerances. To improve painting processes, the Volkswagen AG initiated a major innovation project to investigate and improve the fundamental process of car finish measurement. The project required

development of a completely new instrument technology based on collaboration with a specialist company in the field of appearance measurement, Rhopoint Instruments Ltd. (UK). A significant part of this project involved extensive Human Perception Studies performed at AUDI AG, and collaboration in defining and computing fundamental parameters that fully describe the human perception of automotive surface appearance. This innovative project has led to the development of the Total Appearance Measurement System (TAMS™). The TAMS™ technology is designed to mimic the human eye and brain mechanism using a dual-focus vision system combined with a high-technology imaging and computing system. The TAMS™ captures images with different focuses and computes characteristics that are closely correlated with human perception. Consistent results fully describe visual appearance. Intuitive measurement parameters have been chosen to enhance communication between all internal and external parts of the automotive supply chain regarding appearance finish. The TAMS™ emulates the Eye and Brain Mechanism and replicates the natural Vision – Perception – Emotion process. TAMS™ uses four new parameters to fully define visual perception: Contrast, Sharpness, Waviness and Dominant Structure Size. A significant advantage of the TAMS™ is that these parameters are combined into two new values: Quality and Harmony. These values predict the emotional response that occurs subconsciously 1 in the mind of the

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

customer; does each individual part look good? Do adjacent parts look sufficiently homogeneous? Based on optical metrology, the TAMS™ is a significant step forward for the measurement of automotive coatings by quantifying visual perception and aiding understanding and resultssharing. TAMS™ technology makes it possible to obtain a totally clear view of diverse surfaces (starting with the steel substrate, followed by E-coat, basecoat and topcoat), improve surface finish, establish new Quality Criteria and remove subjectivity in visual assessment. As a long-time distribution partner of Rhopoint Instruments Ltd, Konica Minolta’s Sensing Europe B.V. will take the responsibility of commercialising and distributing TAMS™ through its sales and support network. TAMS™ represents the perfect complement to Konica Minolta’s extensive line of colour and light measurement solutions for the automotive industry and supply chain. For further information: www.konicaminolta.eu, www.rhopointinstruments.com

hopoint Instruments Ltd., together with specialists from Volkswagen AG and AUDI AG, has developed the next generation instrument to check automotive paint appearance in perfect correlation with the visual perception, the Rhopoint TAMS™ (Total Appearance Measurement System) (Fig. 1).

Figure 1: TAMS™, the next generation instrument to check automotive paint appearance.

Shaping a Sustainable Coatings Future. Together. At DSM we take our responsibilities very seriously. Especially towards the planet. So, we collaborate closely with our partners to produce resins that go way beyond today’s expectations and legislation to create a brighter, more sustainable future for everyone.

We use innovative science to create plant-based resins for longer lasting paints, revolutionary powder and waterborne technologies that bring our carbon footprint right down and UV solutions to provide the most sustainable, best-performing resins on the market. Your customers will still enjoy a full spectrum of the highest performing paints available – they’ll just all be a lot greener. For more information visit www.dsmcoatingresins.com

Opening photo: With “The way of Classics”, Lechler reveals the depth of its technological know-how by revisiting classical colors through the use of innovative pigments and ﬁnishes.

HIGHLIGHT OF THE MONTH

“The way of Classics” – Color Design by Lechler at Fuorisalone 2017 Communication Oﬀice Lechler Spa, Como, Italy

communication@lechler.eu

n absolute preview at the Fuorisalone 2017 (held in Milan, April 4-9, 2017), the second event organised for ‘The Way of…”, Lechler’s concept focused on specific trendy chromatic sequences, which revisits individual Color Design projects to seek innovative thematic links. The theoretical foundations of Color Design, Lechler’s concept that links the progress of chemistry with the evolution of the language of color, were revealed at the Fuorisalone 2015, while the first edition of the series entitled “The way of Gold” was presented at the Fuorisalone 2016.

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

The latter observed the new trend of using warm metallic paints for interior décor. The effects created by “The way of Gold” series endow objects with extraordinary charm for living solutions designed to enhance Glamour. A new style has now been noticed by Francesca Valan, who is a color designer specialised in colors, materials and finishes design (CMF). In this period of transition and uncertainty, it represents a significant return to classical hues. “Classical” colors are typical of the history of art, and are instantly recognisable. Red, Blue, Green and White are an intrinsic part of

HIGHLIGHT OF THE MONTH

PLASTICGRIP, which is rapid and economical, endows the object with a pleasant glossy effect that is resistant to both scratches and cleaning. They are suitable to highlight some object’s parts or for small manufactured items aimed at emphasising space. This range has been With “The way of Classics” (Ref. opening photo), conceived for monochromatic or polychromatic Lechler reveals the depth of its technological patterns and has been designed to create an know-how by revisiting classical colors through optimised four-variant range. the use of innovative pigments and finishes. For “METALLIC CLASSICS”, a double It introduces painting cycles that layer solution has been created transfer color to artefacts with with a supergloss (90 Gloss) effect sustainable, high performance, achieved by applying metallic and industrialisable application pearly shades in a double layer cycle techniques. True to the concept of with products 2K HIGH MATT BASE + “The way of…” series, the project TIXO KLARLACK 09. The supergloss establishes a dialogue between cycle enhances the effect of colours the individual programmes of Color by ensuring the utmost resistance to Design di Lechler. Already in 2015 scratches, light and cleaning. Color Trend Habitat anticipated a Pearl and metallic effects create series of classical colors with a 60 surface depth effects bringing out gloss finish for furnishings and a three-dimensional shapes. They are series of neutral hues for furnishing suggested for single colour patterns complements featuring classical 1 or, in case, single colours patterns accents. This collection is now coupled with the respective Accents. perfected with the latest shades of Figure 1: Red, Blue, Green and White convey the impression of “90 GLOSS CLASSICS” are produced Color Trend Consultant Classics with solidity, favouring the dynamics of extension of the life cycle of with a solution that ensures direct 60 and 90 gloss in solid colors and artefacts. adherence on metal with a supergloss metallic and pearly hues for furnishing effect (90 gloss) and pastel shades complements, domestic appliances with the product ACRYL 2K. The gloss finish especially, application costs that meet the and artefacts for the living environment. ACRYL 2K, with direct adhesion to the medium requirements of industrialisation. White opens the collection with three cold conveys excellent aesthetics and resistance to For “60 GLOSS CLASSICS”, a single layer 60 shades: Pure, Pearl and Off White. Red, Green atmospheric agents. Gloss solution can be used with direct adhesion and Blue are graded by saturation and finish: These colours are the classics par excellence, on plastic, compounds, metal and glass. Pastel - Accent: solid, pure and glossy hues; shades are achieved by using the product “2K renewed by a new super gloss finish. The range - Metallic: shades that create a high saturation has been designed to allow more variants of PLASTICGRIP”. The choice of this cycle with 2K effect; - Dark: dark and supergloss colours. Classical shades prefer monochromatic solutions but the range also allows monochromatic, bicrhomatic and polychromatic shades (Fig. 2). Every colour is associated with a painting cycle that ensures, besides the desired tone, adhesion on plastic, compounds, metal and glass, even adequate resistance and,

the western culture’s chromatic DNA. They convey the impression of solidity, favouring the dynamics of extension of the life cycle of artefacts (Fig. 1).

PASSION FOR MASKING SOLUTIONS

CUSTOM MASKS

STANDARD MASKS

info@global-mask.com international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

single colour patterns. It is suggested to limit the variant number to 3, for example White, Red and Blue or Blue, Red and Green. Colors and finishes in the above project visualise the idea of classical, but project ‘Color Trainer NEW DECORATIONS’ illustrates new decorative techniques for environments, giving free reign to personal creativity. Spaces have been transformed to present less bulk with bare walls. The new decorations fill this void without occupying precious space. The classical world’s idea of perfection, which we are introducing to homes with the ultimate decorative trends, is based on the study of geometry, proportions, and the use of the golden ratio.

Figure 2: White opens the collection with three cold shades: Pure, Pearl and Off White. Red, Green and Blue are graded by saturation and ﬁnish.

Visitors could experience “The way of Classics” along a path defined also by audiovisuals that have been meticulously created by the director Paolo Lipari and participate, interact and share their experience. It was not a merely nostalgic journey, focused on self. The perception of color was rather the driving force of an exciting study that from the past reached present day trends and project on the tomorrow (Fig. 3). A path centred on the culture of colour. Its impressions, stimuli and suggestions inspired and supported designers, industries and consumers too.

To underpin and perfect the project, the experience of Fuorisalone 2017 visitors was enriched by Comfort Line, the ultimate

line of Chrèon finishes for the house, which captures and revisits the perfect combinations suggested by nature, precisely matter for unique tactile, visual and olfactory experiences; and outdoors to enhance indoor settings too with pleasant feelings of wellness.

Figure 3: Visitors could participate, interact and share their experience.

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Alesta AP from Axalta Coating Systems Specified for Prestigious French Project La Marseillaise. Axalta Develops New Colors to Enhance the Exquisite Superstructure

SUCCESS STORIES

xalta Coating Systems has been specified to provide its Alesta® AP Architectural Polyester powder coatings for one of the largest urban planning projects in Europe – La Marseillaise – which is scheduled for completion mid-2018. The superstructure in Marseille, France, will be 135 meters high, have 31 floors with 35,000m2 of office space, and the capacity to house 2,500 people. When complete, La Marseillaise will contain an estimated total of 18,800m3 of concrete and 16,000m2 of coated façades, including aluminum profiles and 3,800 sun shields made of ultra-high performance fiber-reinforced concrete (UHPC). The color of the external façades will vary depending on the height of the storey - from red ochre to white clouds - that will aim to increase the brightness of the structure. The project is the brainchild of real estate developer Constructa and architectural firm Ateliers Jean Nouvel (Fig. 1). Ouest Alu, a well-established French company that designs and manufactures façades, was commissioned to work on this prestigious project. At the beginning of 2015, Ouest Alu approached Axalta to ask for the creation of tailor-made colors in Alesta ap matt finishes. In total, 15 unique products were specified, manufactured and delivered. “We regularly use Axalta products in our construction projects, especially where very technical or high-quality requirements are

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

1 Figure 1: The La Marseillaise superstructure will be 135 meters high, have 31 ﬂoors with 35,000m2 of ofﬁce space, and the capacity to house 2,500 people.

involved. The team at Axalta listened to our needs and perfectly understood the architect’s requirements. This has been a long-term endeavor that has involved developing 27 new colors before selection of the final products by the architect. The availability and responsiveness of the Axalta team has been greatly appreciated and has resulted in a successful outcome,” says Christian Chevrel, Sales Manager at Ouest Alu.

SUCCESS STORIES

Axalta offers a complete range of environmentally-responsible architectural powder coating products under the Alesta AP brand, all of which have been formulated especially for application on aluminum, steel and galvanized steel. The entire line has excellent mechanical and weathering resistance properties and is therefore very well-suited for durability in demanding climates. Alesta AP is Qualicoat and GSB approved.

The Axalta architectural grade products are manufactured and individually tested in accordance with ISO 9000 quality systems to ensure excellent performance and color consistency. Philippe Leire, Axalta Sales Manager for powder coatings in France, says: â&#x20AC;&#x153;The La Marseillaise project is a double success. It is first of all the faith of a partner customer who entrusts us with the development of unique colors for a

majestic project. It is also an exceptional showcase of a design that will engage the public in Marseilles, the city of the sun, which is the showpiece of this architectural gem.â&#x20AC;?

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FOCUS ON TECHNOLOGY

A Cataphoresis Wastewater Treatment System Optimised for the Refrigeration Industry: Sest Spa’s CATOCOAT Process

Monica Fumagalli ipcm® he industrial conditioning and 1996; last October, we have further refrigeration sector is crucial to optimised it with the replacement of our the preservation of food and the old treatment plant with a new generation sustenance of society. The delivery of one, also ensuring a significant reduction in products with a long shelf life and the the environmental impact of our production excellent operation as well as nice look processes. When we have had to change of the systems are the leitmotifs of this our coating plant, we sought a solution that industry. could ensure lower energy consumption and Sest Spa is one of the most important the total recovery of the water used. The European manufacturers of evaporators prime contractor of this engineering project, and condensers for refrigerated counters Imel (Codroipo, Udine, Italy), involved one and it is one of the largest producers of of its strategic partners to design a suitable heat exchange finned coils (ref. Opening wastewater treatment system for our photo). This company, headquartered coating process: that is how we came into in Limana (Belluno, Italy), has recently contact with the Italian branch of KMU Loft celebrated forty years of activity. Since Cleanwater, a German company specialising 1991 it belongs to the LU-VE Group, a in the development of process water multinational Italian company listed on recovery technologies.” the Milan Stock Exchange. 1 “Our reference market,” says Nicola The peculiarities of Sest’s heat exchange products Decet, Sest’s Engineering Manager Figure 1: From right to left: Alessia Venturi Sest’s finned coils for heat exchangers (Fig. 1), “requires products that can from ipcm, Klemens Schwienbacher, KMU Loft Italia’s managing director, and Doris D’Incà withstand severe operating conditions are made up of components of different from Sest (Coating Technical Supervisor). and aggressive climatic materials and typologies. They agents. That is why the anticorrosion are produced with The prime contractor of this engineering project, aluminium continuous surface treatment of our components is so coils and copper Imel (Codroipo, Udine, Italy), involved one of its important. We have been tubes with different strategic partners to design a suitable wastewater diameters; the tubes offering to our clients treatment system for our coating process: that is how are fixed into the CATOCOAT, a tried and we came into contact with the Italian branch of KMU conical holes of the tested cataphoretic Loft Cleanwater, a German company specialising in the tubular plates by coating process, since development of process water recovery technologies.”

Opening photo: A detail of a ﬁnned coil produced by Sest Spa.

international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

widening the end of the tubes themselves with a mechanical spindle. This system ensures perfect adherence between the tube and the coil even in case of high temperature differences and contributes to creating the best conditions for heat exchange between the primary fluid and water. The metal sheet used for the fins can be treated with different machining operations to obtain three surface types: louvered, in order to increase the heat transfer capacity through the creation of air turbulence; corrugated, with a lower load loss on the air side compared with the previous one; or flat, with minimal airflow resistance and reduced ice formation. After machining, the workpieces, which are up to 1,000 mm wide, 4,200 mm long and 1,200 mm high, are loaded on the 18-bar Power & Free conveyor designed by Futura Convogliatori Aerei (Robecco Pavese, Pavia, Italy). This takes them to the pre-treatment stations and to the subsequent cataphoresis one at a 5-minute rate (Fig. 2).

GANCI | HOOKS

TELAI | RACKS

MASCHERATURE | MASKING

PER INFORMAZIONI E ORDINI VI INVITIAMO A CONTATTARE: PLEASE CONTACT:

Cecilia Ghizzi Gola ghizzi-gola@emptmeyer.it

Fon: +39 02 947 58 58 2 Figure 2: The coil loading area.

www.emptmeyer.it

The coating process In order to overcome the difficulties that may arise when cleaning such complex shaped parts, Sest uses an evaporating oil during machining. “In this way,” Decet adds, “the coils reach the pre-treatment station with a good cleanliness grade, since most of the processing oil has already evaporated. The pre-treatment stage is used to clean the parts from hydrocarbon residues and

At Sest’s premises, we have implemented a very compact, closed-loop wastewater treatment system, located alongside the pre-treatment plant. All the active bath fluids, the rinsing water, the anolyte and the demineralisation plant’s eluate reach the evaporator, which has a capacity of 500 l/hour (about 22 m3/day) and is equipped with two wastewater storage tanks made in fiberglass.”

FOCUS ON TECHNOLOGY

SURFACE TECHNOLOGY “MADE IN GERMANY”

3 Figure 3: The pre-treatment tanks.

metal dust as well as improving paint adhesion and corrosion resistance. It includes an alkaline degreasing phase for 3 minutes at 58°C (Fig. 3) followed by two rinses (using water treated with the KMU Loft evaporator and then recirculated into these two process stages), and a spray rinse with demineralised water (Fig. 4).” After pre-treatment, the coils are blow dried so that no degreasing product residue remains on their surfaces during the immersion into the cataphoresis tank (Fig. 5). After the cataphoresis treatment at 32°C, the parts are brought to two ultrafiltrate cleaning tanks and to the final spray cleaning and blow drying stations. They are transferred to a traverser through an automatic system (Fig. 6) and then to an overhead monorail conveyor taking them to the cataphoresis curing oven where they remain for 30 minutes at 180°C. Finally, they are unloaded.

The wastewater treatment plant “At Sest’s premises, we have implemented a very compact, closed-loop wastewater treatment system, located alongside the pre-treatment plant,” says Klemens Schwienbacher, the managing director of KMU Loft Italia. “All the active bath fluids, the rinsing water, the anolyte and the demineralisation plant’s eluate reach the evaporator, which has a capacity of 500 l/hour (about 22 m3/day) and is equipped with two wastewater storage tanks made in fiberglass (Figs. 7 and 8). One tank contains only fluids from the rinsing stages, the other treats the alkaline degreasing wastewater, the eluate of the demineralisation plant and the anolyte of the cataphoresis tank. All wastewater is mixed in a third tank for pH correction; this is managed through a PLC with which the operator can set different percentages and control the process (Fig. 9). The distillate produced by the evaporator is sent to a coalescence separator where the volatile

The cataphoresis process that we have been using on our products for over twenty years – so much so that we have certified it with CATOCOAT – and that we have recently improved with the new Imel system enables us to solve this problem because it applies a uniform paint film on the entire surface of the workpiece, with deep penetration even in the difficult-toreach areas.” www.emptmeyer.it

Another benefit for our customers is the very thin coating film applied, an indispensable feature to avoid altering the thermal exchange performance. We also perform some tests, including the salt spray test, essential for meeting the needs of the market. ” environments or with aggressive climatic agents. The coating of our coils is a critical phase of our production process due to the issues related to the particular shape of the workpieces: the coating of their edges and the penetration in their cavities have always been the most significant

Figure 4: The spray cleaning process with demineralised water.

hydrocarbons left in it are eliminated. Subsequently, it is recirculated to the pre-treatment plant with a cascade in the degreasing and the first rinsing tanks. The effluents of the demineralised water rinse, on the other hand, reach the water treatment plant with a conductivity of about 20-30 microsiemens, a value that enables to avoid the evaporator stage and send them directly to the distillate tank. The residual concentrate from the wastewater treatment process, about 3% of the total volume of waste processed, is then disposed of.”

CATOCOAT: the approved cataphoresis process

“We treat most of our products with our cataphoresis process,” Decet explains, “in order to increase their corrosion resistance, especially for the devices operating in deteriorating food

5 Figure 5: The cataphoresis tank.

6 Figure 6: The traverser for transferring the parts to the monorail conveyor of the cataphoresis curing oven.

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problem. The cataphoresis process that we have been using on our products for over twenty years – so much so that we have certified it with CATOCOAT – and that we have recently improved with the new Imel system enables us to solve this problem because it applies a uniform paint film on the entire surface of the workpiece, with deep penetration even in the difficult-to-reach areas. Another benefit for our customers is the very thin coating film applied, an indispensable feature to avoid altering the thermal exchange performance. We also perform some tests, including the salt spray test, essential for meeting the needs of the market. We have also purchased the necessary equipment to carry out these tests in-house (Fig. 10). The 1,000 hours salt spray test was certified by the Trento University. Other important advantages include the compatibility of the cataphoretic coating with food products

FOCUS ON TECHNOLOGY

The quality of the distillate recirculated into the cataphoresis plant is excellent, and the good results of the new process are proof of it. This zero-liquid discharge system is a big advantage in terms of economic saving, but, above all, it has no impact on the environment.”

7 Figure 7: KMU Loft’s evaporator.

8 Figure 8: The inside of the evaporator.

The advantages of a zeroliquid discharge system “The quality of the distillate recirculated into the cataphoresis plant is excellent,” Decet states, “and the good results of the new process are proof of it. This zeroliquid discharge system is a big advantage in terms of economic saving, but, above all, it has no impact on the environment. With our old cataphoresis plant, it was not possible to treat and recover any process water (Fig. 11). We had an average of 15,000 litres of wastewater per month, which were disposed of as special waste: our evaporator now treats 270 m3 of water per month, we have no sewer discharge, and we dispose of the concentrate as normal waste.

“We have noticed a remarkable economic saving also in the production of demineralised water: the water cleanliness degree is so high that the resins make a lesser effort and therefore have longer regeneration intervals. Another aspect of KMU Loft’s intervention

and the low environmental impact ensured by the use of advanced plant solutions, such as the wastewater treatment unit integrated into the coating system.”

9 Figure 9: The eluate collection tank.

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

We have noticed a remarkable economic saving also in the production of demineralised water: the water cleanliness degree is so high that the resins make a lesser effort and therefore have longer regeneration intervals. Another aspect of KMU Loft’s intervention that we have greatly appreciated, in addition to the ease of management of the plant, has been their ability to integrate the system into our cataphoresis plant without the need to use any additional spaces for the water treatment process.”

FOCUS ON TECHNOLOGY

10 Figure 10: The salt spray test machine.

Thanks to our new cataphoresis plant, we have considerably increased our production capacity from 4,000 m2 of metal sheet per day in three shifts to 8,000 m2 in two shifts: the higher yield goal, therefore, has been achieved”.

that we have greatly appreciated, in addition to the ease of management of the plant, has been their ability to integrate the system into our cataphoresis plant without the need to use any additional spaces for the water treatment process (Fig. 12). The plant is so compact that it has not required any type of expansion”.

11 Figure 11: Skids with the anolyte (bottom) and ultraﬁltrate (top) tank.

G RT

The whole new line has been designed for maximum energy efficiency as well as time and cost saving. “We recover the air exiting the oven with an air-to-air exchanger, sending one part back to the oven itself and the other to an air-to-water exchanger used to heat the degreasing bath. We have also installed a post-combustor that prevents any VOC emission.”

Conclusions “Thanks to our new cataphoresis plant, we have considerably increased our production capacity from 4,000 m2 of metal sheet per day in three shifts to 8,000 m2 in two shifts: the higher yield goal, therefore, has been achieved. However, another important aspect for us, in line with the philosophy of the LU-VE Group (which has always been sensitive to environmental issues), was the possibility to increase our products’ quality with the use of environmentally friendly substances and plants. Now, we can offer a

SEST: the Largest European Manufacturer of Finned Coils SEST belongs to the LU-VE Group. Listed on the Milan Stock Exchange, on the AIM Market since 2015 and on the MTS Stock Exchange since June 2017, this Group operates in different sectors: commercial and industrial refrigeration; civil, industrial and precision air conditioning; industrial applications; power generation; and glass doors and closure systems for refrigerated counters and display cases. Altogether, the LU-VE Group has more than 2,400 employees (about 700 in Italy), manufacturing facilities in seven different countries (three in Italy, but also China, India, Poland, the Czech Republic, Russia and Sweden) and a firm specialising in IT, IoT and computing software for refrigeration. Its 2016 aggregate turnover was over € 250 million, with 76% of production exported to

12 Figure 12: In the foreground, the wastewater treatment tank and, beside it, the evaporator. On top, the Futura Convogliatori Aerei Power & Free conveyor and, in the background, the traverser taking the workpieces to the oven’s monorail conveyor.

version of our CATOCOAT process that has been improved in some of its most distinctive aspects, such as our very low environmental impact alkaline degreasing

100 countries. The LU-VE Group owns a total area of 340,000 m2 (145,000 of which are covered) and 99 production lines. Its research and development laboratories (2,350 m2) are the largest in the industry in Europe and the only ones who can perform tests with CO2. The R&D activities of the Group have always been carried out together with the Politecnico di Milano since 1986, and later collaborations have been developed with 21 other universities and research institutes, in 13 countries of 3 continents. In 1974, its establishment year, SEST specialised in the manufacturing of tailormade evaporators intended for refrigerated counters; it then extended its production to other applications. Thanks to the intelligence and passion of a determined team, its growth has led it to evolve from a manufacturer of semi-finished products to a service provider, also accessing other market niches.

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

process and the complete and uniform coating coverage of our coils. Our collaboration with Imel and KMU Loft has been profitable under all points of view,” Decet states.

Acquired by the LU-VE Group in 1991, SEST has become the largest European and one of the global major manufacturers of heat exchange finned coils for the commercial refrigeration and air conditioning sectors. SEST is part of the “Components Business Unit” including as follows: Sest LU-VE Polska, Sest LU-VE (Russia) and HTS (Czech Republic) for the production of static evaporators for refrigerated counters and display cases; TGD (Italy) for glass doors and closure systems for refrigerated counters and display cases; and, since September 2016, Spirotech (India) for heat exchangers intended for domestic appliances, refrigeration and air conditioning. In 2016 it also started producing coils in China, at the LU-VE Changshu plant near Shanghai. The “Components Business Unit” currently manages 35 production lines of finned coils, which manufacture over 1.2 million units a year.

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ÂŠ Verne Technology

Opening photo: The NEA 430 pump produced by Verne Technology.

INNOVATIONS: PRESENT&FUTURE

NEA 430: an Innovative Pneumatic System for the Low Pressure, High Density Precision Feeding of Powders Carlo Perillo Verne Technology Srl, Milan, Italy

c.perillo@vernetechnology.it

EA 430 is an innovative, compact and fully pneumatic system for the transport of powders, granules and polymers. It has been developed by Verne Technology, a young Milan-based company established by people with different skills

who have been operating in the pneumomechanical sector for years. The design and implementation stages of Verne Technologyâ&#x20AC;&#x2122;s products are carried out by a qualified staff in a flexible production facility, which enables to turn an idea into

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

an end product by quickly transitioning from the design step to the construction of a pneumo-mechanical device. The NEA 430 pump has been conceived to meet the powder feeding needs of the chemical and pharmaceutical sectors, but it

INNOVATIONS: PRESENT&FUTURE

NEA 430‘s features

The NEA 430 pump has been conceived to meet the powder feeding needs of the chemical and pharmaceutical sectors, but it has now extended its application fields to the food industry and to the surface treatment sector using powder coating products.”

has now extended its application fields to the food industry and to the surface treatment sector using powder coating products. NEA 430 is a multipurpose device, with interchangeable components suited to the needs of all manufacturing sector, with any powder feeding requirement (ref. Opening photo). Since Verne Technology’s new pump has been launched on the market, it has revolutionised the way the powder feeding systems, especially those intended for coating plants, are designed, operated and used. In this field, NEA 430 can handle different applications, such as: - cyclone recovery; - dust filter emptying; - virgin loading; - powder unit feeding.

Since Verne Technology’s new pump has been launched on the market, it has revolutionised the way the powder feeding systems, especially those intended for coating plants, are designed, operated and used.”

Its fully pneumatic operation eliminates the need for electrical power inside the pump and therefore the risk of accidents related to the passage of electricity into the system. All NEA 430’s components are Atex certified.

NEA 430 is a very compact pump able to transport powder with a maximum flow rate of 4 kg per minute (Table 1). Table 1: NEA 430 pump’s technical features Maximum flow rate Powder feeding Powder collection CE conformity Minimum input pressure Maximum cleaning pressure Feeding pressure Air consumption

4 kg/min up to 30 m up to 3.5 m Atex II 3 D c T6 6 bar 7 bar 0.8 bar 330 l/min outer diameter 16’’ polyethylene 400 x 542 x 220 mm 14.5 kg 4.8 bar

Suction-feeding tube dimension NEA 430 dimension Weight NEA 430 constant pressure control

The main functions of the NEA 430 pump, some of which are currently patent pending, are as follows: - fully pneumatic operation; - compact structure: it enables its rapid installation in new plants or integration into existing ones; - 4-stroke operation: it ensures a constantly high flow rate; - cyclonic valve: it enables to accurately clean the pump in less than one minute; - 3 regulators with a pressure gauge: they enable to read and adjust the operating, feeding, transport and pinch valve management pressures with an immediate visual control of the parameters set.

Its fully pneumatic operation eliminates the need for electrical power inside the pump and therefore the risk of accidents related to the passage of electricity into the system.”

The 4-stroke operation The NEA 430 pump consists of four tanks that alternatively collect and transport the powder on a continuous 4-stroke basis. Contrary to conventional 2-stroke systems, thanks to its double vacuum stage system, NEA 430’s 4-stroke operation ensures a constant and continuous supply with a high density and a very low pressure. This avoids any problems associated with the possible application of uneven thicknesses on the workpieces’ surfaces. The amount of powder is the same in and out of the pump, thus ensuring less coating consumption and higher productivity. Moreover, compared with other systems where the powder enters the peristaltic pump by gravity, NEA 430 collects the painting product through pulses. Therefore, the powder does not suffer from any environmental problems related to moisture as happens with other kinds of pumps, since it does not stay permanently in the collection tank. In order to start the device, three regulators with a pressure gauge set the pump pressure (SUPPLY), the product

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contact with the silicone O-rings, as is the case with other types of pumps. Dielectric material devices, in fact, have been added to prevent direct contact between the powder and the seals, thus ensuring maximum safety.

A user-friendly pump: ease of reading and calibration The whole NEA 430 system has been designed to provide easy access and enable an immediate visual inspection of all its active components. The three regulators’ pressure gauges are visible and allow the user to effectively control the pressure calibration. Moreover, whereas the conventional systems have two

1 Figure 1: The inside of the pump, where the three pressure gauges can be seen.

The cyclonic valve for quick cleaning The double cyclonic valve developed by Verne Technology emits impulses of compressed air that enable to clean the pump and the transport hoses in less than a minute and speed up the product changes. This system is more efficient than a conventional Venturi-type one, because a very small amount of the air used to operate the pump mixes with the powder flow. Indeed, only the air used to move the powder out of the pump and in the dispensing tube enters the paint flow.

During cleaning, the compressed air flows through the fluidisation pipes, the pinch valves and the collection-transport sections. If the cleaning air is provided by a feeding centre or a drum delivery system, it is usually pulsed; the pulses are activated for 500 milliseconds and stopped for a few seconds. If the cleaning operation is started manually, however, the air is not pulsed; the cleaning command must be pressed repeatedly in order to provide pulsed air. Another benefit of cleaning with Verne 2 Technology’s cyclonic valve is that the Figure 2: A detail of the pneumatic system: in the foreground, the powder is not in direct transparent structure of the pump body.

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transport pressure (TRANSPORT) and the closing pressure of the pinch valves (PINCH VALVES, Fig. 1). After the operating air supply is switched on (minimum 0.6 Mpa, 6 bar), the three regulators are set as follows: - SUPPLY regulator: 4.8 bar; - TRANSPORT regulator: 0.7 - 1 bar; - PINCH VALVES regulator: 2.4 - 2-7 bar.

The transparent structure of the pump body, which encloses the pinch valves, enables to immediately detect any leakage of powder; if there are traces of powder or cracks in the pinch valves, these can be quickly replaced.”

INNOVATIONS: PRESENT&FUTURE

volumetric timers, this pump’s four pneumo-mechanical timers enable to verify the operation of the control valve for activating the cycle, of the fluidisation pipes and of the pinch valves. The transparent structure of the pump body, which encloses the pinch valves, enables to immediately detect any leakage of powder; if there are traces of powder or cracks in the pinch valves, these can be quickly replaced (Fig. 2). Finally, their small size and highly functional design ensure a longer service life of the valves themselves, which are replaced two or three times a year, compared with those of conventional pumps, with an averagely higher chance of breaking.

Components’ protection and maintenance This system has been designed to ensure that no part of the pump is damaged in any way in case of malfunction. In case of breakage of one of the valve membranes, the specifically designed safety system prevents the powder from reaching the valves, which can continue to operate. Should any worn components or the body pump be replaced due to production needs – in the pharmaceutical field, for instance, this can happen if different powder coatings need to be handled – it is possible to disassemble the whole pump or just one section very quickly by simply removing a few fixing screws.

Verne Technology’s future projects Verne Technology has a few more innovations in store: the “Control Panel” and the “Trolley” devices, designed to provide their users with additional and efficient technical support. The Control Panel is fully pneumatic and powered by compressed air. It can immediately start to operate thanks to a quick and easy installation on one side of the machine or on the pneumatic Trolley, versatile and easily movable in any work environment in compliance with the Atex Directive. Moreover, the Trolley’s structure can indistinctly house raw materials in boxes or cylindrical drums, so as to ensure perfect operation even in the presence of different containers. Finally, the technical-production staff of Verne Technology is close to completing a high density powder transport system for the high performance management of coating guns.

Verne Technology has a few more innovations in store: the “Control Panel” and the “Trolley” devices, designed to provide their users with additional and efficient technical support.”

Opening photo: The SMA Group’s customers include numerous and renowned manufacturers of industrial vehicles requiring its fuel tanks.

FOCUS ON TECHNOLOGY

Pre-Treatment and Nanotechnology Conversion for Excellent Finishes and High Corrosion Resistance: The Case of SMA Serbatoi Luca Antolini ipcm®

n the field of hydraulic oil and fuel tanks intended for lorries, boats and other means of transport, it is essential to combine a flexible production process with a high quality product to meet the diverse needs of customers: some of them give more importance to the products’ functional aspects, but others equally focus on aesthetics. That is why leading manufacturers should possess the best skills and tools to meet both these requirements. On the one hand, these tanks should be highly resistant to corrosion and to mechanical stresses because of their intended use; on the other

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hand, the appearance of their finishes becomes crucial if, for instance, they are considered by the client as an integral part of the bodywork of an industrial vehicle. As a consequence, as well as the coating process, their pre-treatment stage is of high importance, since it should adequately prepare the surfaces of the workpieces by giving them excellent paint adhesion properties and a good barrier effect. SMA Serbatoi S.p.A. (Ref. opening photo) is a company specialising in the design and manufacture of metal tanks for lorries, boats, rail vehicles and other means of transport, a leader in Italy and among the

FOCUS ON TECHNOLOGY

SMA Serbatoi

On the one hand, these tanks should be highly resistant to corrosion and to mechanical stresses because of their intended use; on the other hand, the appearance of their finishes becomes crucial if, for instance, they are considered by the client as an integral part of the bodywork of an industrial vehicle.”

SMA Serbatoi S.p.A. started its activity in 1963 in San Prospero di Parma (Italy), where it is still headquartered, thanks to the Rampini brothers. Over the years, this small workshop has turned into a Europeanlevel company exporting about half of its for the pneumatic systems of means of production. Today, its staff consists of 170 transport such as industrial vehicles and people and it has a network of distributors trains, on the other hand, are exclusively and collaborators at the national and made of aluminium. The size of our products international levels. varies greatly depending on the industry for The SMA Group operates in different which they are intended: the hydraulic oil production facilities with a total area of ones have a capacity of 50 to 250 litres, the 2 2 over 75,000 m , 16,000 m of which are covered. Two factories are located in Italy (in San Prospero and San Secondo, in the province of Parma), on a total area of 45,000 m2, and the third one is in Belgrade, Serbia, on a 30,000 m2 wide area. Its production range includes hydraulic oil, fuel, compressed air, oil and diesel, and water tanks. These have been approved by TÜV Bayern, the Italian Ministry of Infrastructure and 1 Transport, ASME USA, Bureau Veritas ICEPI and RINA. The Figure 1: Standard hydraulic oil tanks manufactured by SMA. company offers a wide range of standard tanks available in stock as well as all tank components. nautical sector ones can reach 1600 litres and the ones intended for industrial vehicles “Our tanks for fuel and hydraulic oil (Fig. 1) of 50 to 1000 litres. Our customers include are produced in three materials: steel, Iveco for its trucks, Volvo for its bulldozers, stainless steel or aluminium,” says Umberto Manitou, Azimut - Benetti Group and Ferrovie Maria Bertolucci, the Production Manager dello Stato.” SMA Serbatoi also deals with of SMA Tanks. “Our compressed air tanks all the accessories that, depending on the

agreements with the customer, are often supplied already assembled to the tanks, such as fixing systems, plugs, filters, floats and level indicators. “The manufacturing of our products starts with a stamped sheet that is folded to create the shell,” states Bertolucci. “Then, we build the side walls and bulkheads, perform a longitudinal welding and assembly bottoms and lids to close the tank. We check the seal of all our products and we follow all the regulations concerning their approval.” The production of the different SMA Serbatoi plants is diversified. “In San Prospero, we only produce tanks for fuel and oil, while in San Secondo, as well as manufacturing tanks for compressed air, we have located our Italian coating and logistics departments. Since we paint all our products – in special cases, due to the clients’ aesthetic needs, even the stainless steel ones – also the components manufactured in the first plant are sent to San Secondo,” says Bertolucci. Currently, the pretreatment system used in San Secondo includes as follows: an alkaline degreasing stage; two rinses; a heavy iron phosphating stage; and two further rinses, one with recirculated demineralised water and one with pure demineralised water, used only once and then disposed of. With aluminium workpieces, an organic passivation stage is added. Subsequently, after the drying oven, there are two liquid coating application booths, which use acrylic and epoxy paints supplied by Inver-Valspar, and a polymerisation oven. The tanks are then sent to the warehouse for mounting the accessories. © SMA

major manufacturers at the European level. It has recently installed a new coating plant at its factory in Belgrade, Serbia, working with Dollmar Spa (Caleppio Settala, Milan, Italy) for the integration of a pre-treatment process that includes the PROMETEUS nanotechnology conversion module.

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The pre-treatment process is fundamental for us, we need our parts to achieve an optimal cleanliness degree before coating, since any contaminant would compromise the finishing results. In some cases, when the tanks are installed in visible parts of the vehicles and not within the chassis, our customers demand that the coating reaches the same aesthetic quality level required in the automotive industry, the pre-treatment process is important because we have to give our products excellent corrosion resistance and paint adhesion properties in an effective and efficient way.”

“The pre-treatment process is fundamental for us,” Bertolucci states. “We need our parts to achieve an optimal cleanliness degree before coating, since any contaminant would compromise the finishing results. In some cases, when the tanks are installed in visible parts of the vehicles and not within the chassis, our customers demand that the

coating reaches the same aesthetic quality level required in the automotive industry; under these circumstances, we also perform scrupulous visual controls. Moreover, the pre-treatment process is important because we have to give our products excellent corrosion resistance and paint adhesion properties in an effective and efficient way.” With a view to the implementation of this crucial process in its Belgrade factory, SMA

performed some tests with the solutions offered by Dollmar Spa in Parma. Based on the results achieved, the company decided to adopt a system including the PROMETEUS nanotechnology conversion module and the Dollcoat SA 115 chemical. “The laboratory tests, especially the salt spray one – for which our customers’ specifications have always been increasing in the last few years – have shown excellent results, the same ones that we are now achieving with the plant running,” states Bertolucci. In order to cope with the flexibility requirements arising from the different shapes of their workpieces and from their different machining times, SMA has opted for a “mixed” solution for the handling of its

With the goal of making the Serbian factory completely independent, SMA doo Vrs˘ac, opened in Belgrade in 2010 for the production of carbon steel tanks for oil and fuel, was equipped towards the end of 2016 with a new coating line, whose concept, however, had taken its first steps in San Secondo.

Figure 2: The pre-treatment tunnel installed at the premises of SMA doo Vrsˆac.

SMA doo Vrs˘ac: maximum ﬂexibility and quality

3 Figure 3: Tanks waiting to enter the pre-treatment tunnel.

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FOCUS ON TECHNOLOGY

installed at the premises of SMA doo Vrs˘ac is PROMETEUS nano, a module designed for the production, control and application of the nanotechnology solution only. The solution is prepared and controlled in its central unit even if wastewater is re-used. The modules are provided with stainless steel nozzle ramps that can be installed within the tunnel and, if necessary, with an automatic counter-current system

tanks in the Serbian plant. The components are hung to a chain in the loading area, within manual handling trolleys for a quicker loading operation. Then, they are transferred to a storage buffer and they are finally hung to an automatic two-rail conveyor that takes them into the pre-treatment tunnel (Fig. 2 and 3). The spray pre-treatment process includes a phospho-degreasing stage with chemicals supplied by Dollmar Spa followed by two rinses, one with recirculated demineralised water and one with a ramp with demineralised water coming directly from the osmosis plant (Fig. 4). At the end of these phases, the parts reach the PROMETEUS nebulisation module for the nanotechnology conversion process (Fig. 5). “PROMETEUS is the name of a range of nebulisation modules created by Dollmar SpA and Dollmar Meccanica to optimise and simplify the application of nanotechnology conversion products after pre-treatment. These systems are characterised by their reduced footprint, their use of high pressure pumps, and their simplified dosing and mixing of the nanotechnology product through the installation of two different tanks for the demineralised water and the nanotechnology solution,” says Fabio Cecchetto, Dollmar Spa’s Technical Sales Specialist. “The PROMETEUS range offers three different solutions1. The one 1 “PROMETEUS: a nebulisation technology that breaks the mould”, ipcm®_International Paint&Coating Magazine no. 35, Vol. VI, 2015

4 Figure 4: Tanks inside the pre-treatment tunnel.

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The adoption of this solution has enabled us to make the most of the available space, thanks to its compact size. It has also enabled us to avoid implementing a phosphating stage, resulting in considerable saving not only in terms of plant but also of water and sludge disposal. Since of the Dollcoat SA line products can also operate at the room temperature, finally, it is not necessary to heat large amounts of water, thus saving energy as well”

for the recovery and recycling of the rinsing water according to the process parameters set.” “The adoption of this solution has enabled us to make the most of the available space, thanks to its compact size,” Bertolucci explains. “It has also enabled us to avoid implementing a phosphating stage, resulting in considerable saving not only in terms of plant but also of water and sludge disposal. Since of the Dollcoat SA line products can also operate at the room temperature, finally, it is not necessary to heat large amounts of water, thus saving energy as well.”

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With a view to continuous improvement and based on the results obtained so far, in future we will consider the possibility to implement this pre-treatment cycle and the PROMETEUS nanotechnology conversion module also in our San Secondo factory.”

to be used in case the latter is full. Finally, the components are manually carried to the unloading and accessory assembly area.

Conclusions “Our sector demands the highest quality level in terms of both functions and aesthetics,” says Bertolucci. “We are pleased with the results we have achieved so far in terms of efficiency and effectiveness of the pre-treatment process and we will continue to monitor them. The stresses to which the tanks are subjected and our customers’ specifications always lead us to search for the best solutions. With a view to continuous improvement and based on the results obtained so far, in future we will consider the possibility to implement this pretreatment cycle and the PROMETEUS nanotechnology conversion module also in our San Secondo factory.” © ipcm ®

Other critical issues arisen in the Serbian plant were the final cleanliness degree required and the difficulties posed by the different shapes of the parts. “We pay close attention to the internal cleaning of our products, especially the hydraulic oil tanks. To ensure that the pre-treatment process is carried out correctly, it is necessary to act on the components’ design and to send them into the tunnel with all connections (for sleeves, pipes, filters, etc.) open. Then, an operator takes care of the dripping and drainage of the parts before they enter the drying oven. After the coating process, performed only on the outside of the tanks, their interior is oiled with a protective, antioxidant product.” At the exit of the drying oven, the workpieces are transferred to another storage buffer where they are manually handled again. The tanks needing it are 5 subjected to masking, blow-off (to remove water from any interstice) and other Figure 5: The PROMETEUS nebulisation module for the operations, whereas the others are directly nanotechnology conversion process. sent to the manual powder coating booth (Fig. 6). “We opted for a powder coating plant to meet the needs of our industry, which prefers this kind of finishes. We apply epoxy or polyurethane coatings depending on the clients’ specifications. Although we currently do not have to perform many colour change operations, we are ready to meet every need,” says Bertolucci. After the coating station, there is another storage 6 buffer in front of the polymerisation oven, Figure 6: The manual powder coating booth.

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SPECIAL ECS 2017

PRODUCT INNOVATION

1 Figure 1: At the last European Coatings Show, ipcm® investigated a little bit deeper the main trends in the paint and coating industry with Evonik.

Innovations and Highlights 2017 by Evonik Resource Efficiency Alessia Venturi ipcm®

he Coating Additives business line of Evonik combines decades of expertise with the enthusiasm and dedication of a start-up. With the united power of Silica products, TEGO additives, and specialty additives of former Air Products, Evonik offers innovative and tailor-made solutions that deliver real value for your coating formulations. Over 500 products, approximately 450 employees, and 30 production and research sites across the globe make up Evonik’s new business line. Its diverse product portfolio contains additives,

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co-binders, matting agents, rheology control additives, specialty resins and nanoresins. Coating Additives is a leading market provider of additives for water based paints, and the business line is continuously expanding its position in the area of solvent-based paints as well. At the last European Coatings Show, which was held in Nuremberg 4 to 6 April 2017 (Fig. 1), we interviewed Dr. Claus Rettig (Fig. 2), Chairman of the Board of Management, Dr. Stefan Silber (Fig. 3), Senior Vice President Innovation

SPECIAL ECS 2017

Management Coating Additives, and Ingrid K. Meier (Fig. 4), Director Product Development, Coating Additives of Evonik to investigate a little bit deeper the main trends in the paint and coating industry. ipcm: “Resource efficiency is one of the main trends within different industrial fields. Which kind of trends can you describe for Evonik activities?” Stefan Silber: “We clearly recognize an ongoing trend towards what is more environmentally friendly. This trend is strengthening within the industry and within our base of clients. Overall, we clearly recognize a demand for higher performing coating solutions, in particular for coatings that are more durable. The regulatory changes are more and more complex around the globe and for us it’s mandatory to stay very close to our clients and their clients to anticipate all these changes in the right way. They have to feel that they can rely on our innovation effort. We see these regulatory changes, which translate into stricter legislations and compliances, more as an opportunity for our specialty additives than as a risk. Another important trend is functional coatings, also known as smart coatings. To meet this need of the market, we have recently founded a new research center named Smart Surface Solutions which deals with the formulation of functional coatings and the development of specific additives to enhance antimicrobial, anti-icing, easy-to-clean, antifouling, as well as anticorrosion properties of coatings”. Claus Rettig: “With our additives business, we want to address the feeling of lack of innovation that is spreading within the industry. The market desires something significantly new. Innovation is something that takes quite a lot of money and is something that you cannot expect in a short period of time. Our new research center will play a key role in innovation in the years to come. Industry is looking for something unexpected, and Evonik Resource Efficiency will contribute to satisfy this quest”. ipcm: “Do you think that waterborne technology is being used in Europe?” Claus Rettig: “From our point of view, this environmental changeover is more determined by waterborne systems than high solid formulations. We have some stakes in high solids and UV curable coating systems, but the new gravity center is definitely waterborne. What people demand for environmentally friendly coating systems is similar performance levels like the one they are used to with

SPECIAL ECS 2017

2 Figure 2: Dr. Claus Rettig, Evonik.

conventional systems. The changing towards waterborne systems is a stepby-step process. The trend is somehow driven by the end user, who more and more makes choices in this direction. Regulations play an important role in this changeover, too. In a lot of Asian countries, for example, we are recognizing a dramatic, positive turnaround in environmental legislations, and they clearly benefit from it”. ipcm: “Let’s talk about nanotechnologies. What does it mean for Evonik?” Stefan Silber: “Nanotechnology plays a role in our Silica business. We have been producing and using nano-sized particles of silica for many decades. They have specific properties and are used in many everyday essentials. We produce matting agents, rheological modifiers or silica that improves scratch resistance and triggers customized functions in the surface. Nanotechnologies deliver particular performances through the particle structure. All have a different impact on the final properties of the coatings and can deliver a wide range of surface modifications”.

Claus Rettig: “It is particularly important to understand that only nano-structured material can provide this range of effects. We handle nano particles in a very responsible way: They do not cause any risk to the consumer or to the environment. The end consumer does not have any concept of these nano-particles when using a product containing them because they are always embedded in a coating system. This is what makes the difference in the end”.

determines the speed of innovation with his or her choices”. ipcm:” Do you find cooperation from both sides, customer and end-user?” Claus Rettig: “It depends very much on the project, I would say. Most of the time, the hint regarding innovation comes from our direct clients, but there are some fields, like food application for example, where we get involved by the end user”. ipcm: “Which kind of relationship does Evonik have with the end user?” Stefan Silber: “They are setting the standards for the whole industry which is why it is important to have a continuous talk with them to anticipate their requirements, to direct our innovation to the right side. They are the one who have the purchasing power so they are setting the demand for the overall industry. I think it is important for them to receive updated information about what raw materials can do inside a coating system”.

ipcm: “How do the paint and coating manufacturers react to your most advanced innovations?” Claus Rettig: “We have to go through a lot of approval cycles before our customers can really use our innovative products. One of the very prominent examples is that we are the leader in additives for waterborne systems and have been for a very long time: now the trend is accelerating, but we developed it many years ago. Work in this industry takes more time, but in the end, is a success story ipcm: “Is there if your innovation any specific is really interesting, project you want 3 under many different to share with points of view, for the our readers?” Figure 3: Dr. Stefan Silber, Evonik. customer and end Stefan user”. Silber: “We would like to drive your attention to Stefan Silber: “I totally agree with our recent highly automated system Claus. In addition, most of these for testing coating formulations: in this multiple innovations are developed way, Evonik can accelerate the search in close collaboration with leading for optimal formulations. The highmarket players. At the end, that’s a little throughput equipment plant enables bit driven again by the end user who the company to systematically test more

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PRODUCT INNOVATION

SPECIAL ECS 2017

formulations over the same period of time than before. For Evonik’s customers, this means they can optimize and develop their coating formulations quicker, saving valuable time when launching new products into the market. Within 24 hours, an average of 120 samples can be formulated in the plant. It’s the result of a joint cooperation with the Swiss manufacturer Chemspeed and is a benchmark in the coating industry”.

Ingrid K. Meier: “From the products side, we are going on with the integration of Air Products with Evonik Coating Additives. We are targeting food contact compliance with an oil-based defoamer, the AIRASE® 4655, which is compliant to FDA and European regulations. It’s a formulation that goes in all regions and is a very good example of the ongoing integration process. We are also launching a new range of 4 TEGO® Glide products with Figure 4: Ingrid K. Meier, Evonik. excellent antiblocking and scratch resistance properties, triggering customized functions of surfaces. We are going to launch a new structure-modified hydrophilic AEROSIL® (VP4200) that improves anti-fouling performance in cuprous oxide based coatings. Last but not least, we are launching some easy-to-disperse silica AEROSIL® products that will allow our clients to reduce processing times, equipment demand, and capital expenditure”.

Claus Rettig: “This system is enabling us to do many more experiments in a shorter period of time, to speed up the development process, and to find the optimal formulation much faster and with less cost.”

SPECIAL ECS 2017

PRODUCT INNOVATION

Fascinating red

intensity and brilliance of Tigris Blue. Used alone or in combination with other pigments, the red crystalline pigments of Xirallic® NXT Cougar Red (Fig. 5) give coatings a mysterious magic with an intense sparkle in a broad spectrum of possible shades. They impart even more depth to black automotive coatings. The European Coatings Show provided a first look at Meoxal® Victoria Red, which will be available in late 2017. It is the fourth effect pigment in the Meoxal® series, featuring excellent color intensity and extraordinary brilliance while evoking the world’s deserts. Meoxal® Victoria Red is inspired by the color strength and intensity of Australia’s Great Victoria Desert. The simultaneously color-intense and vibrant effect pigment enables stylings both in pure red and in bluish nuances.

The fascination with red is unwavering: Figure 1: The eye catching Rolls-Royce was one of Two new pigments from Merck make the main attraction of Merck’s booth at ECS 2017. innovative red effects possible – Xirallic® NXT Cougar Red (Fig. 3) and Meoxal® Victoria Red (Fig. 4). Merck launched Xirallic® NXT Cougar Red at the European Coatings Show. It is the fourth product in the Xirallic® NXT series, modeled on the beauty and fascination of big cats. It creates a spectacularly neutral to bluish red and lively sparkle - following the metallic shimmer of Panthera Silver, the interplay between color and 2 extraordinary sparkle of Leonis Gold, and the special Figure 2: A Harley-Davidson featuring Merck’s premium pearlescent pigments.

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erck, a leading science and technology company, presented novel products and innovative concepts for the paint and coatings industry at the European Coatings Show 2017. From April 4 to 6, industry experts were introduced to many samples and demo tools at Merck’s impressively designed exhibition stand in Nuremberg, Germany. Multimedia displays were also used to show the potential and possibilities of the innovations from Merck. Underscoring the “Bold & Vibrant” theme, a Rolls-Royce (Fig. 1) and a Harley-Davidson featuring Merck premium effect pigments attracted attention (Fig. 2).

“Bold & Vibrant”: Merck Innovations Presented at the European Coatings Show 2017

For simply brilliant surfaces Tivida® fluorosurfactants make perfect, flawless, and scratch-free coatings possible. Its special branched molecular design enables maximum performance at minimum application concentrations without the environmental issues associated with conventional fluorosurfactant chemicals.

SPECIAL ECS 2017

PRODUCT INNOVATION

Writing and designing with light © Merck

Merck presented Tivida® FL 3000 at the European Coatings Show. It is the first non-ionic fluorosurfactant from the Tivida® series and is excellently suited for aqueous and non-aqueous coating formulations. Thanks to its high chemical stability, it also works very well in applications with either acidic or alkaline pH values. Pigments from the Iriotec® 7000 series dissipate electrostatic charge where it develops: on the surface of printed packaging and painted or coated surfaces. The new product Iriotec® 7340 has an even lightercolored mass tone - with the proven conductivity of the Iriotec® 7000 range, it is particularly suited for light-colored or colored coatings and floor coatings as well as for conductive primers for electrostatic application (ESTA).

Figure 3: The Xirallic® NXT Cougar Red range.

The functional pigments from the Iriotec® 8000 series convert laser light to durable, wear-resistant markings that remain in the material. So far, this series has made a name for itself above all for indestructible markings in all types and colors of plastic. Now there’s Iriotec® 8850: This innovative pigment reacts so quickly and sensitively to laser light that only a very thin layer is sufficient for a permanent marking. Light and colored powder-coated surfaces can now be labeled with razor-sharp expiration dates, bar codes, or trademarks. And much more – the pigment’s fast reaction time uses a process

international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

SPECIAL ECS 2017

PRODUCT INNOVATION

House of Truth, and Data Bridge. These trends were also visible in the Merck Innovative Concept Car (“the car of tomorrow”). Visitors were able to view this type of car “live” in virtual reality with smartglasses. The car meets future automotive trends, requirements, and usage patterns with materials from Merck. These materials included colors for car body paints that virtual users could create themselves using novel effect pigments, as well as autonomous driving, online communication, adaptive headlights, various design options for interiors and exteriors, and innovatively shaped displays (Fig. 6). Last but not least, Merck illustrated the innovative power of its products through the materials used in its own exhibition stand. The floor shimmered with a strikingmuted effect provided by Miraval® Cosmic Silver. Façade panels showed the possibility

future and interpreted them with ideas for innovative paints for car bodies. The tool describes five trends in-depth: 1001 Nations, Crossroads, Park,

developed by LPKF Laser & Electronics AG for an extremely innovative purpose: With laser light and this pigment, a large number of light-colored plastics and powder coatings can be metallized as the basis for the development of 3D circuit carriers. These circuit boards are applied directly to the component, creating totally new design possibilities for designers and product developers.

Figure 4: The Meoxal® Victoria Red range.

Inspiring concepts and application examples Visitors to the European Coatings Show have seen what the innovative products and pigments from Merck are suited for and what they actually look like. That’s because Merck’s trend researchers have developed the Global Mobility Color Inspirations (GMCI) tool. They have pooled their individual experiences, observations, and analyses from around the world about how people live and what they like. From this they have derived color, material, and social trends for the

6 Figure 6: Merck innovative concept car.

5 Figure 5: Xirallic® NXT Cougar Red is the fourth product in the Xirallic® NXT series inspired by big cats.

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of effect pigments with coil coatings and powder coatings, for example with Xirallic® NXT Leonis Gold. Liquid crystal window modules created privacy by partitioning the meeting nooks. An eye-catching Rolls-Royce in a fascinating red was one of the main attractions of the stand itself, while a HarleyDavidson featuring premium pearlescent pigments at the hall’s east entrance invited visitors to stop by Merck’s stand.

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

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A new horizon for sustainable coatings. Decovery® technology from DSM Alessia Venturi ipcm®

Ipcm: Can you explain the thinking behind the development of more sustainable resins? “At DSM we want to address the big, defining societal problems - hence our company strapline, Bright Science, Brighter Living. In the case of resins, sustainability is about two things. The first is tackling resource scarcity so that instead of using our dwindling reserves of fossilbased materials to make resins we are now using raw materials that originate from plants and seeds. By creating products that

are less carbon-intensive we can reduce the carbon footprint for our customers and other partners in the value chain, all the way to consumers. And plant-based resins also limit the exposure to VOCs versus

moving away from solvents towards more sustainable technologies like powder, waterborne and UV-curing coatings – which all have a significant lesser carbon footprint and VOC demand”.

SM Coating Resins is a global leader in sustainable coating resin solutions with a strong focus on innovation. Today, a new generation of resins made from renewable raw materials like sugars, starches, natural oils and agricultural waste is helping manufacturers reduce the carbon footprint of their products, while making them safer for human consumption – good for people, planet, and increasingly, profit. Products like DSM’s plant-based Decovery® technology for paint applications are now able to match or exceed the high performance of fossil-based alternatives (Fig. 1). At the last European Coatings Show (Fig. 2), held in Nuremberg April 4 to 6, 2017 we interviewed Patrick Niels (Fig. 3), President, DSM Resins & Functional Materials, who addressed the main trends of DSM’s research in the field of waterborne and powder coating resins.

Ipcm: Precisely what impact can these sustainable resins have in reducing carbon footprint? “As you can see here at the booth, we have now introduced plant-based industrial coatings for interior wood and for decorative coatings, based on our Decovery® technology. In the coatings industry you have monomers manufacturers, resins manufacturers, paint manufacturers and applicators: The largest part of the carbon intensity is in the choice of the resin technology, so we have a major opportunity to reduce carbon footprint. To give you an idea, every 1kg of Decovery® resin used, saves 0.5kg – 1kg of carbon dioxide. That’s a significant contribution to reducing greenhouse gases. 1

Ipcm: How do plant-based resins like Decovery® perform compared to conventional resins? The performance versus existing fossil based paint has significantly improved. The Decovery® resins enable our customers to make the highest quality paints. It’s highly

Figure 1: The Decovery® technology has been displayed at the DSM’s booth during the European Coating Show 2017.

traditional solventborne products. If you look at the coatings industry, today 21% of all non-methane VOCs come from paints and coatings. We want to address that by

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example, awareness in China is rising and the government regulation is really aiding the growing use of more sustainable paint. Personally I would like our industry to be a little bit more visionary. In general, there is some reluctance to commit to sustainable solutions because they are more expensive – but the bigger picture is all about the overall value they provide. In this regard there are some great example of visionary companies, like the Italian ICA Group (case study below), who are getting excellent benefits from introducing plant-based paints.”

Figure 2: The DSM’s booth at the ECS 2017.

resilient and resistant to chemicals and thus ideally suited to intensive industrial processing cycles. Today we have an R&D team of some 50 people focused on how to further improve that performance, as well as how to continue replacing fossil-based content with renewable materials. Today, some 50% of all paint used is still solvent-based and this will not radically change in the next 5 years. The transformation of our own portfolio is an ongoing process, not just in sustainability and performance but also safety by continuing to eliminate CMR raw materials and focusing on amine and co-solvent demand reduction.” Ipcm: What demand are you seeing from manufacturers and consumers for more sustainable resins? “Educating the consumer is extremely important – and difficult. The retail channel provides the information about plant-based paints used to finish specific products but sometimes this information is not really understood by customers. Furthermore, there’s no doubt we have work to do in making fossil-based products less attractive to purchase. In terms of the industry as a whole, we are seeing positive developments; for

Ipcm: In terms of finding an alternative to solvent-borne products do you think the industry is moving more towards powder coatings or waterborne coatings? “Besides our plant-based technology, we have powder, water based and UV technologies. Ultimately, the end-user will decide which is the best solution, based on their own unique needs. Our R&D powder group, for example, is putting a lot of effort into reducing curing temperature of powders to allow them to be applied on wood. Our UV group is working hard to ensure that UV can be applied to all kinds of woods - even in © DSM

3 Figure 3: Patrick Niels, President of DSM Resins & Functional Materials.

SPECIAL ECS 2017

the result of an extensive collaboration between DSM and ICA Group. The Iridea Bio paint line provides for coatings that are more resilient, resistant to chemicals and lightfast than existing alkyd resins. In addition, Iridea Bio mono-component and bi-component coatings are easier to sand and more resistant when subsequent coats are applied, meaning they can be used in intensive industrial processing cycles.

of colors, as well as with a transparent finish, and offer superior colorfastness, even over extended periods. The finishing of the coatings can be “warm” or “cold”, according to the desired effect sought by the designer. “As an architect and designer, I was very impressed by the aesthetic nature of this product,” says Daniele Della Porta. “It reflects light in a very attractive way, and can be easily integrated into my designs.” “I was asked to design a small sculpture that will be exhibited at different roadshows and fairs to showcase the aesthetic properties of this new plantbased coating. I designed a sculpture based on the Chinese game Mikado (Fig. 4), where different colored pieces of wood form a self-sustaining structure. This object proves the excellent lightreflecting properties of Iridea Bio across different colors.” Daniele Della Porta is now designing a new line of furnishings that use Iridea Bio, which will be manufactured by the Naples-based company Falegnameria Rubinacci. They will be available on the market in early 2018. Stile Libero has been integrating wood coatings manufactured by ICA Group

Based in Italy, Daniele Della Porta is a well-established architect and designer, whose practice has won important prizes, such as the Young & 4 Design award at the Salone del Mobile di Milano. Many of Figure 4: The Mikado sculpture coated with Iridea Bio Della Porta’s designs, such as products, based on Decovery® technology. door frames, stairs, furniture and skirtings, incorporate wood as its primary material, both dark colours, which is the challenge for UV because of its aesthetic qualities and based coatings; and our waterborne group environmental friendliness. is focused on improving the chemical “Sustainability is becoming an resistance of waterborne coatings. In increasingly important issue in short we are committed to our customers’ the worlds of architecture and success rather than any single technology. design,” says Daniele Della Porta. “In our own designs, we Case study: Decovery® technology for want to use materials that do Iridea Bio paint by ICA Group not have a negative impact on DSM and Italian paint manufacturer ICA the environment or on human Group have jointly developed a new, health. We were very happy sustainable paint called Iridea Bio. It to discover the plant-based contains one of DSM’s Decovery® plantIridea Bio paint to protect and based resins and has been on display color the wood in our designs, at the European Coatings Show in since it not only fits with our Nuremberg, Germany, through the work of sustainability philosophy, but it two Italian design studios, Stile Libero and 5 also performs very well”. Daniele Della Porta. The Iridea Bio products are This newly developed paint for Figure 5: The Möbius band sculpture, designed by Stile available in a very wide range industrial interior wood applications is Libero with Iridea Bio paints.

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into their design projects for almost 30 years. On a visit to ICA’s manufacturing plant in November 2016, Stile Libero’s director Salvatore Cozzolino was introduced to the sustainable plant-based coating line Iridea Bio. ICA’s technical experts explained these coatings have been made with materials whose renewable nature is derived from innovative processes aimed at refining plant matter that is not competing with human food supplies. “Wood furnishing coatings that are sustainable and do not harm the environment have been around for 20 years, and are not really a new thing,” says Salvatore Cozzolino, founder of Stile Libero. “However,

up until now, these coatings have been very inferior in quality compared to oil-based coatings. It was simply not possible to achieve the same results and long-lasting finishes with products derived from renewable sources. Iridea Bio has changed that”. “From a sustainability point of view, this is a great product, and it comes at the right time,” says Salvatore Cozzolino. “Sustainability is no longer an additional extra – something that is nice to have but not crucial – it is essential. It should be the basis for all creative projects and processes, and all designs should take into account both human health and the environment’s health”. “To show how Iridea Bio reflects light and how pleasant it is to touch, I was

asked to design a sculpture to exhibit at tradeshows and industry fairs. At Stile Libero, we designed a Möbius band sculpture (Fig. 5), which is a surface with only one side and one boundary. This sculpture has the advantage of being non-orientable, which means you can see its coating reflect light from any angle” says Salvatore Cozzolino. After a successful testing stage, Stile Libero is now looking to incorporate Iridea Bio into its new range of furnishing, which will be produced by the Naples-based company Falegnameria Rubinacci.

Color. Protection. Function.

Our solutions

for infrastructure!

Coating. Bonding. Sealing. Eﬃciency and highest quality.

www.wagner-group.com

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1 © BASF

Figure 1: Nano pigments will allow BASF to formulate easy dispersible ultra-high transparency pigments.

BASF Presented Ground Breaking New Pigments Technology at ECS 2017 BASF and Landa partner to create revolutionary pigments for automotive coatings BASF and Landa Labs announced their strategic long-term partnership on April 4 at the European Coatings Show (ECS) in Nuremberg, Germany. Under this exclusive agreement, BASF will employ Landa’s revolutionary nanopigment technology in a new portfolio of easy dispersible ultra-high transparency pigments marketed under the Colors & Effects brand (Fig. 1). This groundbreaking development

will offer unprecedented color depth while significantly simplifying the production of automotive coatings. “We are very excited to partner with Landa in this cutting-edge venture,” said Alexander Haunschild (Fig. 2), Senior Vice President, pigments, BASF. “We see the remarkable impact that Benny Landa and his company are having in the printing industry and are proud to bring this amazing technology to our customers in the automotive coatings market. This long-term collaboration

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demonstrates our commitment to differentiate our customers’ business by bringing new technology to demanding markets.” The Landa nano-pigment technology – originally developed for the printing industry – allows BASF to introduce a new generation of Colors & Effects pigments with the highest quality consistency for the final automotive coating. The smaller size and narrower particle distribution leads to a thinner, higher chroma coating.

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“The benefits to our customers with this Sicopal Red pigment are numerous, as it provides expanded design options along with excellent opacity, remarkable stability, plus a durability that exceeds lead chromates,” said Jenny Reuber, Industry Management, Industrial Coatings, Pigments, BASF.

“We are proud to establish this global partnership with BASF and its Colors & Effects team,” said Benny Landa (Fig. 3), Chairman of the Landa Group. “By combining our technologies and expertise, we can provide fantastic new products to the automotive coatings market. This synergistic alliance has the potential to disrupt the market.” “This is an industry first,” said Stefan Sütterlin (Fig. 4), Vice President of Global Business Management, pigments, BASF. “For decades, our customers have been looking for an advancement like this in the industry. Using this technology will allow us to create new products for automotive coatings (Fig. 5)”.

BASF’s Colors & Effects Brand Offers Another Dimension of Red with New Sicopal® Pigment BASF’s Colors & Effects brand previewed their latest innovation, Sicopal® Red EH 2370 (L 3050). The high performance, inorganic red pigment has a new Colour Index, Pigment Red 290 (Fig. 6). Ideal for coating applications including architectural and industrial applications, the new pigment is significantly more chromatic than iron oxides and offers much more reddish tones compared to inorganic orange pigments.

Rust effects for durable ﬁnishes The Firemist® Velvet pigments shown at ECS include a range of effect pigments for industrial and architectural applications. Firemist® Velvet offers elegant and unobtrusive shines of metal effects with 5 shades: pearl (white), bronze, copper, gold and russet. In architectural coatings, the Firemist Velvet product family offers unique and warm design options with an aged patina appearance and velvety haptic effects. The ideal solution for high-quality applications: Painters can apply coatings designed with Firemist Velvets onto plasters, concrete, wallpaper, and wooden surfaces. In powder coatings, with the addition of Firemist Velvet pigments, the highly fashionable weathering steel can be mimicked © BASF

Figure 2: Alexander Haunschild.

“We continue to expand our product lines working closely and flexibly with our customers while assessing market potentials.”

3 Figure 3: Benny Landa.

“Introducing the new Colour Index, Pigment Red 290, brings a true innovation to the coatings market.” Due to its robustness, the new pigment is ideal for use in applications such as exterior facades, roofing, powder coatings, coil coated facades, signal colors on bridges, cranes and oil platforms, and more.

Enhancing styling options for red effect shades Under the Colors & Effects brand, BASF presents Firemist® Velvet pigments for architectural and powder coatings and Paliogen® Red L 3990 for automotive and high end industrial applications (Fig. 7). The coatings market requires durable advancements that still provide new styling options,” said Rose Qin, global business director, pigments for coatings, BASF.

4 Figure 4: Stefan Sütterlin.

(Fig. 8). The BASF team developed a new application technique when applying powder coatings to create this rusty steel effect for architectural applications. The solution results in significantly lower weight in comparison to steel and prevents staining of the façade with rusty run-offs.

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BASF presented further pigment innovations at ECS. The broad range of products offered by BASF includes dispersions, resins, formulation additives, light stabilizers, antioxidants, pigments, hardeners, cross-linking agents, reactive diluents and solvents.

Figure 5: Comparison between traditional pigments dispersion (on the left) and nanopigment dispersion.

Environmentally compatible corrosion protection for industrial metal coatings

Highly efﬁcient defoamer for water-based systems Foam formation is a common problem occurring during production and processing of paints and coatings. To avoid such problems, BASF has added a new defoamer to its range of formulation additives that is based on organo-modified polysiloxanes – the FoamStar® SI 2240. Apart from its strong defoaming effect, FoamStar SI 2240 shows broad compatibility with different binder systems and excellent long-term

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Within the BASF pigments portfolio, the Paliogen® perylenes are high performance organic pigments with high The new water-based Acronal® PRO chroma and transparency that provide 7600 acrylic dispersion provides light to medium corrosion protection outstanding weathering fastness and good flocculation stability, which (categories C2 to C3) for industrial promote their use in automotive and metal coatings. The binder offers an high end industrial applications. environmentally compatible drop-in solution that does not contain APEO and The Colors & Effects brand now adds replaces Acronal® PRO 760, the current a new member: Paliogen Red L 3990. 6 market standard. Acronal PRO 7600 can The new development is an extremely be used for all current applications such Figure 6: The high performance, inorganic red pigment saturated blue shade perylene red Sicopal® Red EH 2370. as airless, brush, roll or dip. pigment that simultaneously delivers perfect brilliance, good transparency and high tint strength. stability and efficiency. Paliogen Red L 3990 FoamStar SI 2240 is enhances styling options registered worldwide especially for red and can, among effect shades. This is other applications, be made possible through used in water-based very narrow particle architectural coatings, size distribution in an industrial coatings and optimized process. The paints as well as in product is suitable for pigment concentrates. both solventborne and In addition, FoamStar waterborne applications SI 2240 complies without compromising with specific FDA and technical properties like EU requirements for bleeding and dispersibility. 7 8 food contact and is The resulting performance therefore suited for makes Paliogen Red L 3990 Figure 8: Patina effects with the addition Figure 7: New red shades for automotive printing and packaging the next step in organic of Firemist Velvet pigments to powder and high-end applications with applications. pigment innovation. coatings. Paliogen® Red L 3990.

PRODUCT INNOVATION

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The activity of SAVIM EUROPE starts from the planning up to the delivery turn key of INDUSTRIAL PAINTING PLANTS. The production includes spray booths and ovens, complete powder coating and liquid coating plants, automatic and manual treatment and washing plants.

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L’attività di SAVIM EUROPE parte dalla progettazione ﬁno alla consegna chiavi in mano di IMPIANTI INDUSTRIALI DI VERNICIATURA. La produzione comprende cabine e forni di verniciatura, impianti completi di verniciatura sia a liquido che a polveri, impianti automatici e manuali di pre trattamento e lavaggio.

YOUR TECHNOLOGICAL PARTNER La nostra linea di produzione segue scrupolosamente le norme vigenti, prestando particolare attenzione alle norme in materia di Prevenzione e Sicurezza sul Lavoro con le certiﬁcazioni più importanti del settore. Our production line strictly follows current laws, paying particular attention to rules and standards on Accident Prevention and Safety in the Workplace, as proven by the leading sector certiﬁcations.

SAVIM EUROPE s.r.l. Via Venezia, 2 - 37024 Arbizzano - Verona - Italy Tel. 0039 045 7514099 - 7514188 Fax 0039 045 7514205 E-mail: info@savim-europe.com www.savim-europe.com

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1 © NuernbergMesse / Thomas Geiger

Figure 1: The Audi Q2 was the highlight of the Covestro booth at the European Coatings Show.

Pushing the Boundaries of Possibility with Innovative Coating Raw Material Developments

ovestro, formerly Bayer MaterialScience, appeared at the European Coatings Show under its new name for the first time. The company had a large booth at the trade fair in Nuremberg (Fig. 1). The focus was on innovative and sustainable coating raw material developments and their use in near-series projects. More than just examples of concrete applications, they also document the great interest of key industrial segments. “For 80 years innovations have been the engine of progress for our company,” said Board Member for Innovation and Chief Commercial Officer Dr. Markus Steilemann while speaking to journalists. “We

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don’t rely solely on our own research efforts here, but also collaborate intensively with partners along the value chains. This enables us to push existing boundaries and offer added value for our customers.”

Sustainability targets met “But all of our developments must also meet our sustainability goals,” said Steilemann. “They should drive energy efficiency and improve people’s lives, but also reduce our own use of fossil raw materials. At the European Coatings Show we used concrete projects to illustrate how they can also meet the sustainability goals of our customers.”

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Covestro therefore wanted to bring more biobased products to the market, provided that they are cost-effective, have a small ecological footprint and their technical properties are at least as good as, if not better than, those of existing petrochemical-based products.

Renewable coating raw materials trending The use of biobased coating raw materials is becoming increasingly important. One of the driving forces here is growing market interest in sustainable products. Covestro is committed to raw materials from biomass and has now expanded its portfolio once again. The latest product is the hardener Bayhydur® eco 7190. It is the first polyurethane hardener for waterborne, two-component polyurethane coatings and is very well suited for coating furniture more sustainably, for example. The raw material is the perfect complement to the hardener Desmodur® eco N 7300 and the dispersion Impranil® eco. All three products are made from up to 70% biomass and do not compete with food production. Covestro presented a number of visionary, and in some cases near-series, applications with these products at the European Coatings Show. “They are the results of close collaboration with partners along the entire value chain,” said Daniel Meyer, head of the Coatings, Adhesives, Specialties segment. “That underscores the strong industry interest in these developments.”

First automotive coating with biobased hardener The highlight of the Covestro booth was an Audi Q2 (Fig. 1). It is one of a number of test bodies to which a clearcoat containing a biobased hardener was applied for the first time under realistic production conditions. The two-component coating was developed by BASF’s Coatings division. It contains the coating hardener Desmodur® eco N 7300, which helps to improve the customer’s eco-balance without

compromising product quality. “The three partners were very pleased with the results obtained when coating the test bodies on existing equipment at Audi,” said Daniel Meyer.

eco-balance over the entire life cycle of coated textiles while also helping to conserve water. Covestro is thus helping brand owners and textiles manufacturers to achieve their sustainability goals.

Debut in rail vehicle coating

Unique design with DirectCoating

The biobased hardener also recently made its debut in the coating of commercial vehicles. Polish rail vehicle manufacturer Newag SA used a coating formulated with Desmodur® eco N to coat two diesel locomotives. Lankwitzer Lackfabrik of Berlin developed the coating in close collaboration with Covestro. The coating meets the specifications of the rail vehicle industry and offers 70 percent better gloss stability and abrasion resistance than standard coatings.

Coating furniture under extreme conditions Milan-based furniture specialist RiFRA, coatings manufacturer Sirca and Covestro conducted a feasibility study to demonstrate that waterborne furniture coatings could be formulated even more sustainably by reducing the content of fossil resources. They succeeded in doing just that with the new biobased hardener Bayhydur® eco 7190, which can reduce the carbon footprint of coatings formulated with it by roughly 30 percent. RiFRA tested the first biobased, waterborne, 2K polyurethane coating under extraordinary conditions. It exhibited very good mechanical and chemical resistance even in damp kitchen and bath environments. The company presented a line of designer furniture featuring the coating at the Salone del Mobile in Milan, Italy.

Unique designs at competitive costs – this is Covestro’s aspiration for its DirectCoating technology. Carmakers want to meet customer demand for greater interior customization options even as they strive to increase productivity. With the help of DirectCoating, coated plastic components can be produced in a single production step rather than the total of five forming and coating steps required by the conventional process. DirectCoating can also reduce costs by up to 40 percent and energy consumption by as much as 75 percent. Covestro offers a complete package of coatings and plastics expertise.

New dimension of design freedom A successful joint project with Votteler Lackfabrik suggests that a breakthrough is imminent for DirectCoating technology. It can be used to create parts with new and attractive designs combining different shades, surface structures and haptic properties even on a single component. Covestro also presented innovative and sustainable developments from six different industrial segments at the European Coatings Show.

The biobased, waterborne polyurethane dispersion Impranil® eco opens up a new dimension in the sustainable coating of textiles. The newest product in Covestro’s INSQIN® lineup, it offers an improved

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Opening Photo: Clariant’s Hostatint™ A 100-ST pigment preparations used for a OptiWhite plate glass with alternating black and gold special effect pigments in the strips.

Clariant Unveils Ground-Breaking Additives at European Coatings Show 2017 Alessia Venturi ipcm®

lariant, a world leader in specialty chemicals, presented several new products developed by its Additives and Pigments Business Unit at the European Coatings Show 2017, which took place in Nuremberg, Germany, last April 4-6, under the motto: Painted love; It’s innovation. It’s passion. It’s love.

During the Press Event held on April 5, Clariant specialists provided first-hand information on the Company’s latest advances. What all these new products have in common is sustainability, protection, and enhanced anti-scratch and aesthetics properties.

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Exolit® AP 435 & Exolit 855 (TP) Exolit® AP 435 (Fig. 1) is a ground-breaking new halogen-free flame retardant that prolongs the shelf-life of water-based intumescent coatings without affecting fire protection properties. Coatings containing Exolit AP 435 have a low and stable viscosity, even in cold environments and after long

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and construction materials like steel beams and columns” comments Achim Hennemann, Segment Manager Coatings at Clariant. “It significantly extends the lifetime of the product, stabilizes the viscosity, it’s very easy to use and it smoothens the surface on the Intumescent Coating – everything the consumer asks for. The second solution is specific for Intumescent Coatings for transparent wood application coating, again a halogen-free flame retardant as we only look for sustainable solutions. This product is very innovative for the wood sector: it is different because it’s absolutely clear, easy to use and handle, lifetime extending”.

AddWorks® IBC 251 It is a “tribo enhancing” additive for electrostatic powder coatings, providing an all-in-one solution for cost-effective

formulations. It features a high electrostatic charge loading capability, together with protection against heat and light. AddWorks IBC 251 is suitable for a broad range of resins, including polyesters and polyester/epoxy binders, among others. It is non-staining, so discoloration is reduced under gasfading conditions in open-flame baking processes. “Tribo Spray Powder coatings get their electrostatic charge by frictional contact with the inside of the gun barrel and not by a high voltage discharge. The benefits of tribo spray powder coatings are many, among them better flow, uniform coating practically without any orange peel effect and of course no need of high voltage” Dr. Mouhcine Kanouni, Technical Marketing Manager Coatings at Clariant said. “The use of a tribo enhancing additive at a dosage around 1.0% is © Clariant

storage, offering customers increased flexibility on the construction site. This fineparticle ammonium polyphosphate has the same high quality and performance level as Clariant’s well-known Exolit AP 422. Exolit 855 (TP) is a fire protection ingredient for transparent intumescent coatings on wood and is a completely clear, almost colourless solution (Fig. 2), enabling it to be used even on light-coloured woods. It is suitable for application on surfaces subject to very strict regulations – in public buildings for example. As a liquid partial phosphoric acid ester, it can be used in combination with acid curing resins for coating solid and engineered woods (e.g. chipboards, medium density fiber boards (MDF), oriented strand boards (OSB), plywood and veneered wood). “The first product is being used mainly in water-based Intumescent Coatings; it’s a fire protection solution for building

Figure 1: Exolit® AP 435 keeps intumescent coatings ﬂuid and workable even after long storage.

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required when the powder coating resin is not already pre-additivized. AddWorks® IBC 251 is an innovative additive as it not only enhances the electrostatic charge of the powder coating, but also acts as a very efficient heat stabilizer for processing, baking and over baking (in direct and indirect flame gas oven). In addition, it improves the light-stability of the end product”.

Hostatint™ A 100-ST

the entire colour circle to solvent-based paint systems. Very fine pigment particles, excellent dispersion and long-term stabilization are the prerequisites to enhance effects with colour intensity similar to dyes but with very high light and weather fastness, and no migration or bleeding. In addition to its performance benefits, Hostatint A 100-ST helps the coatings industry to open up manufacturers’ creativity options. For electronics OEMs, the halogen-free Hostavin®1 TB-03 pigment molecules support the formulation of This is a synergistic combination of a high bright green colour shades that meet industry performance UV absorber and a hindered restrictions on halogen content. amine light stabilizer (HALS). It meets the Industrial coatings with the super most demanding requirements transparency of for high performance Hostatint A 100-ST coatings. can be used to add Hostavin TB-03 is mainly a quality appeal characterized by its to applications by broad compatibilities in emphasizing the both solvent-borne and visibility of a substrate water-borne coatings such as glass, wood (all-in-one solutions). It or metal. Super is recommended for all transparent coloured kinds of highly durable coatings, virtually clear and pigmented invisible over a black coatings and for substrate, are also numerous applications, particularly effective including automotive in highlighting black/ clear coats, plastic colour contrast. coatings, coil coatings, Hostatint A 100-ST and high-end wood pigment preparations coatings. 2 are easy and safe ® to use. They have Licocare RBW is a new Figure 2: Exolit® 855 (TP) is a new ﬁre protection ingredient for transparent wood coatings. low viscosity, are family of hard waxes widely compatible based on renewable with solvent-based paint systems, and a feedstock. Their diverse properties make has come up with products that not only very high flashpoint results in safer storage, them suitable for a wide range of applications enable colouring, but made metallic and even transportation and handling. The stability of including coatings and inks, polish and care, color travel effects easy-to-formulate and the colorants contributes to a long shelf life. economically accessible to specialized areas agricultural coatings and plastics processing. Bernhard Stengel-Rutkowski further They show excellent matting, slip and scratch such as lifestyle objects, artwork and consumer commented: “From cellphones to bikes goods, e.g. sports gear.” so Bernhard Stengelresistance properties in coating applications, and cars, metallic and mineral effect shades Rutkowski, Senior Global Technical Marketing and excellent rub resistance in printing inks. are becoming increasingly important for Manager at Clariant when presenting the new Licocare RBW 102 TP and Licocare industrial applications. There’s also growing Hostatint A 100-ST range. RBW 106 TP are medium to high polarity interest in using high transparency to It features nine ready-to-use, highlywax types; Licocare RBW 300 TP is a enhance glass or wood surface properties. transparent pigment preparations that offer partially saponified wax. © Clariant

This is a range of super-transparent preparations based on non-halogenated pigments to support the eye-catching metallic and mineral effects as well as new shades for surface and contour enhancements so desired for today’s lifestyle products (ref. Opening photo). “In the past coatings for high value consumer goods such as cell phones performed mostly a protective function, what was missing was the aesthetic component. Since most of these products were made of metal very often they would highlight them with mineral or metallic shades. With our new range, Clariant

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SPECIAL ECS 2017

PRODUCT INNOVATION

3 Figure 3: Clariant’s Hostatint™ UV pigment preparations are an excellent choice for the coloration of industrial wood ﬁnishes.

As a full range of pigment preparations, new Hostatint A 100-ST enables the fast and flexible formulation of a wide range of colour shades for transparent applications. In addition, they are providing a cost-efficient way for manufacturers to address new coating trends in the market segments.”

Hostatint™ UV UV curing is gaining in popularity as coatings producers recognize its advantages in creating coatings with enhanced scratch, chemical and abrasion resistance, using less energy and resources. The technology offers opportunities for fast curing at low temperatures, increasing line speed to improve productivity, thus offering

environmental and surface performance benefits (Fig. 3). “Wood is an extremely important substrate for both internal and external applications but there is an increasing demand for colour performance coatings to increase durability. In addition, manufacturers of furniture really like to reduce their costs, improve their processes and be sustainable: UV curing systems offer great environmental advantages as you can cure the film with significantly lower energy” stated Thomas Metz during Clariant’s press conference. The new Hostatint UV pigment preparation range supports the trend for coloured UV systems and the industry focus on improving sustainability and product performance.

Clariant’s new Hostatint UV liquid pigment preparations go the next step in supporting easy formulation of low VOC high performance coatings. The ready-touse tinters are suitable for both interior and exterior coatings and cover the full colour spectrum in opaque and transparent applications for dual and 100% UV systems. “So far it has been difficult to add colour into UV systems but now Clariant has a range of preparations that will allow manufacturers of coatings to give colour to these types of UV coatings. They now have all the advantages of high performance solutions and they can meet the aesthetic trends with a very satisfying sustainability” ended Thomas Metz.

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Opening photo: Renato Nisi Srl’s New Milano product. An insertion mechanism with a two-fold opening system. A high-resistance furniture tube frame treated with an epoxy coating.

FOCUS ON TECHNOLOGY

Automation and Industry 4.0 for a Cutting-edge Coating Process in a “Made in Italy” Project Luca Antolini ipcm®

he Italian artisan tradition, characterised by high manual skills, quality of raw materials and creativity, has evolved over time thanks to new technologies and innovative solutions, always grasping such opportunities without forgetting the importance of quality and materials. Following this philosophy, Renato Nisi Srl, a company specialising in the production of mechanisms for sofa beds, has recently installed in its coating plant a robotic system provided by Lesta Srl for the pre-retouching of components. It is able to recognise and paint the workpieces autonomously, while collecting useful data on component

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types, quantities and processing times. The implementation of this solution and the synergy between the supplier and the producer have created an all-Italian virtuous circle for the benefit of the process efficiency and quality as well as of the firm’s end customers.

Renato Nisi Srl Headquartered in Forlì (Italy), Renato Nisi Srl was established in 1972 as a handicraft company. It soon became one of the Italian leaders of its sector thanks to the quality of its products, specialising in the contracting production, finishing and assembly of folding and insertion mechanisms

FOCUS ON TECHNOLOGY

called “progressive dies” and fed by numerically controlled decoilers. The welding step is performed automatically through robots. Afterwards, the mechanisms are assembled and taken to the pre-treatment station by a Futura Convogliatori Aerei overhead conveyor. The pre-treatment plant includes a phospho-degreasing, a rinsing, and a drying stage (Fig. 1).

Pre-retouching: uniformity, automation and safety 4.0

coating plant a robotic system provided by Lesta Srl for the pre-retouching of components. It is able to recognise and paint the workpieces autonomously, while collecting useful data on component types, quantities and processing times.”

A critical issue of the coating process is the need to completely cover the sofa bed mechanisms, often characterised by folds, bends and difficult-to-reach areas, as well as by wrappings that make the electrostatic application of paint with the use of reciprocators more difficult due to the Faraday cage effect. “In 2016, due to an increase in our production volumes, we installed a Gema booth with a quick colour change system. We mainly use it to apply a grey colour coating, while our second booth, supplied by Zeus Electrostatic System, applies a bronze colour,” Nisi explains (Fig. 2). “We only use the best epoxy coatings available on the market, provided by manufacturers such as Arsonsisi and Europolveri.” The plant has a productivity

The mechanisms’ manufacturing process starts with the design of the product, carried out in-house in collaboration with the customer, and continues with the cutting stage, in which last generation numerically controlled cutoff machines ensure millimetre precision in metal machining. Stamping is done by means of mechanical presses that use 3 special dies for each component, Figure 3: The Lesta robot for the pre-retouching operations. © ipcm ®

for sofa beds. Over the years, the company has modernised its production facilities by expanding its premises in various stages and installing advanced machinery to ensure maximum precision in its products’ processing. The company deals with every phase, from design to production and delivery. The raw material used has all the international certifications and it is treated with processes 1 constantly undergoing quality controls. Figure 1: The mechanisms’ loading area. “Our main customers include the largest producers of Italian sofas, from the major furniture manufacturers of Renato Nisi Srl, has Veneto and the Pesaro area to one of the most relevant company at national level, of which we recently installed in its

2 Figure 2: The Gema spray paint booth is equipped with two opposing reciprocators.

are the main supplier,” says Cristian Nisi from Renato Nisi Srl. “Although we mainly work for Italian firms, however, in recent years we have expanded to reach the Spanish and Eastern European markets.”

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4 Figure 4: Gema’s gun installed on the wrist of Lesta’s robot.

of hundreds of bed bases per day in two shifts. The powder coating system’s speed is 3 metres per minute. Another critical aspect is the great variety of components to be coated. “Our product range is very wide and the shape of our mechanisms requires us to perform a pre-retouching stage to ensure uniform application of the paint on the whole workpieces,” says Nisi. “In order to carry out this process safely, reliably and efficiently while keeping the pace with the line’s speed, we need a cuttingedge technology that eliminates any manual operation by automating each step.” In order to overcome these challenges, Renato Nisi Srl has turned to Lesta Srl, a company based in Dairago (Milan, Italy) specialising in the design, manufacture and marketing of industrial coating robots, which has installed a robot devoted to the automatic pre-retouching stage, located at the entrance of Gema’s spray paint booth (Fig. 3 and 4). Lesta’s Lebot A6 is a six-axis robot equipped with optimally balanced carbon fibre arms and with the LeCrob management software; this enables to

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manage up to 12 axes at the same time through program,” Nisi explains. a control panel featuring an LCD touch screen In order to run the different coating monitor. The robot can be installed on the sequences, Lesta’s robot is programmed with ground or on a cart and it has a wrist capacity a self-learning system (Fig. 5). The optical of 4 kg, with a maximum working area of 2257 mm. It weighs 270 kg and it is explosion proof. The robot adapts to the conveyor speed according to the speed changes detected by the line encoder. As a result, the software adapts the duration of the program in real time. “The solution adopted has enabled us not only to overcome the problems related to the uniform and complete application of paint, but also to increase the efficiency, reliability 5 and safety of such operation. The pre-retouching system Figure 5: The touch screen control panel of the robot. is equipped with an optical scanner able to recognise the incoming product type. After taking a picture, the software compares it with scanner located in front of the booth is also able to recognise any component that must preloaded images in its database and, once it not be subjected to pre-retouching, thus has found a match, it loads the right coating interrupting the robot’s operations (Fig. 6). There have also been significant improvements in terms of safety. “Previously, we used another type of robot with a pointto-point learning control, but it proved non suitable for painting because of the complexity of its programming method – we needed to manually set the coating sequence for each type of mechanism – and of its lack of precision,” states Nisi. “Moreover, the arm of that robot was equipped with an engine, a potential spark risk factor in an electrostatic coating environment, which must comply with the Atex directive. Lesta’s robot, on the other hand, has no engine on its arm, since the engines are all located in an under-pressure airtight chamber and the arm movements are operated by chains. An anti-collision system automatically stops the robot arm in case the 6 gun hits a workpiece (Fig. 7 and 8).” The pre-retouching system has made this Figure 6: The optical scanner located before firm’s coating phase fully automated and it the spray paint booth.

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Conclusions

has almost completely eliminated any need for post-retouching operations, which are carried out outside the line during the final assembly stages only in a few cases, for very special products. The optical scanner system has also enabled them to integrate another aspect of the Industry 4.0 concept: the automatic counting of production. “The 7 software log enables us to be constantly Figure 7: The Lesta robot’s electrical cabinet. informed on the amount of bed bases and mechanisms produced in a given time interval, even dividing it by product types,” says Nisi. “It is therefore a great solution for monitoring our production and obtaining useful data.”

“We are very pleased with the solution we have installed for our pre-retouching operations,” states Nisi. “We had assessed also other suppliers, but the choice had soon fell on Lesta for the specificity and quality of their technology. The new robot enables us to keep pursuing the highest quality and efficiency while continuing to grow and to serve all our 8 important clients. We will soon start building Figure 8: A close-up of the robot. another 7,000 m2 wide plant for the production of our mechanisms: together with our already existing production site, it will house our whole manufacturing process.”

SUCCESS STORIES

Opening picture: Nordson installation at Secal Ltd. with Andrew Simpox.

Achieve Production Confidence with Nordson Dense-Phase Technology Corinna Hellwig Nordson Deutschland GmbH, Erkrath, Germany

ics.eu@nordson.com

ean processes continue to be a focus for many manufacturers – operate with the minimum of raw materials, reduce rework and waste, use automation to increase production and reduce downtime and running costs. In a powder coating environment, colour change time, finished product quality, plant reliability and maintenance costs are essential factors in

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order to run a lean and profitable operation. In 2015 Salop Powder Coating Ltd. in the United Kingdom considered how to diversify from the automotive industry they had served for 60 years. They decided to invest in a powder coating line to acquire new customers in new markets and re-shape how the company does business. Important

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to them to be competitive in the market was to invest in technology that provided process control, the maximum production uptime and the highest application efficiency. “The technical aspects of the Nordson ColorMax3 spray booth and the Spectrum HD Powder Feed Centre are, for us, exactly what we need to be more efficient. The powder hopper cleaning process is automated,

SUCCESS STORIES

From manual powder coating to an automated coating system

don’t suffer from fatigue! They can do a 12 hour shift and just keep going!”

Maintenance Free Operations

Secal Ltd. in Telford, Karolina Szwugier, Quality Engineer from Secal United Kingdom, offer Ltd (Fig. 2), declared “in 23 months since our a precision sheet installation the system has never missed a metal service that beat, with no maintenance time required and includes: CAD/CAM, no replacement pump parts such as pinch CNC laser cutting, CNC valves necessary. Altogether, the Nordson punching and folding, HDLV equipment saves us money, makes full welding facilities, us more productive and gives us complete powder coating; production confidence”. 1 final assembly, warehousing, With over 800 global Figure 1: Andrew Emmerson (Salop Powder Coating Ltd.) displays the installations, Nordson packaging and ﬁrst Nordson HD pump pinch valve they installed after coating for over Dense-Phase Technology has logistics. The 4,000 hours. proven beneﬁts company employs - A constant powder pump output over time over 120 people and delivers consistent quality and powder requires no extra hoppers, and all internal operate from a 36,000 sq ft facility. surfaces are clearly visible after the colour distribution on the finished product through “Our paint system, comprising of a Nordson change, giving us a high degree of confidence process control. ColorMax3 fast colour change booth, Spectrum - Self cleaning pump technology reduces in the quality. In terms of the operation, HD Powder Management System and Encore operator skill dependency, for sustainable having all the controls on one simple touchHD dense phase automatic spray guns was and reliable results and reduced rework. screen interface is a really clever touch, and installed in 2015. The system makes it a joy - Up to 4,000 hours of maintenance free it means the operator’s learning curve is to walk in the door in the morning, it makes pump operation, Nordson customers enjoy shorter – there’s less room to make a mistake” the whole process a lot more efficient, it is production confidence, lower costs and less Christopher Greenough, a Director of Salop, easier for the lads to operate and the finish is explained. “The core element of the installation downtime. of a higher quality and more uniform” states is the Nordson HDLV pump that provides Andrew Simpox, Supervisor consistent powder output over time, is selfof the paint plant at Secal cleaning, and is almost maintenance free in its Ltd (ref. Opening picture). Furthermore Andrew operation”. Andrew Emmerson from Salop (Fig. 1) explains added “we’ve gone from manual powder coating further “the Nordson HDLV gun pumps operate at our powder line 10 hours per day, 5 days to an automated coating system that is accurate to per week, and since 2015 we have only had ten microns across each to maintain one pinch valve in one of the coated product. We are HDLV pumps. That’s over 4,000 hours of using less powder material, maintenance free operation!” have increased production “All customers that come to us for powder and are providing our coating stay with us. A lot of our order book customers with a superior is repeat business, which reflects on our lean 2 product at the end of it. Of operation and quality. We know working with course, one of the reasons Nordson makes us more efficient. We also Figure 2: Karolina Szwugier (Secal Ltd.) with a Nordson HDLV we are able to get more know that efficiency and that quality will win us pump pinch valve – a spare part they still haven’t used after done is because the robots further work.” 23 months of production.

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Opening photo: The entrance of the Tiberina Pomigliano‘s headquarters.

FOCUS ON TECHNOLOGY

“ediVer” Electrodialysis Membranes: Technological Solutions for Electrophoresis Plants Renato Saruggeri Verind S.p.A., Verind S.p.A. Ultraﬁltration and Waste Water Treatments, Milan, Italy

ubular electrodialysis cells for electrophoresis (anaphoresis and cataphoresis) plants were first used in Italy in December 1993, with the first important industrial installation (Fig. 1) carried out by Verind, a company belonging to the Dürr A.G. Group that has been operating in the surface finishing, fluid handling, ultrafiltration, and water treatment markets for sixty years. In the following years, there was a growing interest in this type of cells thanks to their ease of installation, higher yields per square metre of

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Renato.Saruggeri@verind.it

painted surface, better penetration in generally difficult-to-reach areas, and higher homogeneity of the deposited coated film. The ediVer cell (Fig. 2) now supplied and installed by Verind is the result of a technical evolution that has led to the development of a product enabling to replace only the worn membrane film without having to change the whole structure. The experience gained with more than 5,000 cells installed in at least 300 plants since 1993 enables Verind to provide the users with innovative

FOCUS ON TECHNOLOGY

supply service, which included solutions ensuring, as well as mounting, was completed with good technical results, also the addition of a flow control economic efficiencies that allow device for each cell. The existing for a return on investment in a anolyte feeding circuit was short time. reused (Fig. 4). In order to validate this One month after the launch important process choice, we of the new tubular cells, the report some data by courtesy of customer was able to make Tiberina Pomigliano, a company an energy saving forecast: of the Tiberina Group, an Italian as expected, it has been multinational with over 22 able to lower the current factories located throughout the intensity and the voltage country, in Europe and in South 1 used, while achieving the America (ref. Opening photo). desired thicknesses on both Its reference markets are the Figure 1: A detail of the cataphoresis tank with tubular cells installed in 1993. the exposed surfaces of the automotive and the off-highway workpieces and within the sectors; through moulding, Tubular electrodialysis boxed components. This automatic sheet metal working forecast has been widely confirmed in the and coating processes, it produces cells for electrophoresis following months; after one business year, subgroups for commercial and passenger (anaphoresis and cataphoresis) the energy saving was about 7,000.00 Euro transport vehicles worldwide. In 2013, it plants were first used in Italy for the same amount of coated square was awarded as FCA’s Best Supplier of in December 1993, with the metres. the Year and, in 2015, it was rewarded for first important industrial In addition to such energy saving, the achieving the “Bronze Level” certification installation carried out by customer has also achieved lower annual in the World Class Manufacturing (WCM) Verind, a company belonging costs for: programme at its premises of Tiberina to the Dürr A.G. Group that has • Non-conforming products: about 10,000.00 € Sangro. been operating in the surface • Maintenance: about 9,600.00 € In August 2015, Tiberina installed finishing, fluid handling, • Coating consumption: about 48,000.00 €. ediVer-type tubular electrodialysis cells ultrafiltration, and water This has enabled the client to recover the to replace the old ones of a cataphoresis treatment markets for sixty investment costs in a short time and to benefit line of its Pomigliano plant (Fig. 3). This years. ” WCM project was developed by the technologist Oreste Pugliese and the One month after tenant of the method Giuseppe Ceruso. The client had decided to replace its old the launch of the new cells due to significant limitations such tubular cells, the as: non-performing cells that caused customer was able out-of-tolerance pH values in the paint to make an energy with a non-homogeneous electric field saving forecast: as and an insufficient ion exchange; too expected, it has been much anolyte drainage; paint infiltration able to lower the in the anolyte circuit; difficulties and high current intensity and costs for maintenance; non-conforming the voltage used, while thicknesses; and poor penetration on achieving the desired boxed components. thicknesses on both These problems were solved by installing the exposed surfaces 20 ediVer tubular cells, able to coat, on of the workpieces 2 average, a cathode surface equal to 40 and within the boxed Figure 2: An ediVer tubular cell. m2 with an immersion (wet) process. The components.” international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

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ÂŠ Verind

Figure 3: Tubular cells in the cataphoresis tank of the Tiberina Pomigliano plant.

ÂŠ Verind

the possibility to replace anodes and/or membranes with very simple operations and without any need to replace the whole structure (Table 1). Standard anodes are made in SS 1.4404 (AISI 316L) or SS 1.4571 (AISI 316Ti) stainless steel. It is possible to have special titanium anodes coated with iridium oxide (IrO2) for greater durability and a longer service life (Table 2).

4 Figure 4: The anolyte dispenser in the cataphoresis tank of the Tiberina Pomigliano plant.

even more in the following years, since it no longer had to offset such expenses. Eighteen months after installation, these process data have proved to be constant, with the full satisfaction of the Tiberina Group. Verind has provided an excellent global service in terms of engineering, products and technical solutions integrated into an already existing plant/process.

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ediVer tubular electrodialysis cells Electrodialysis cells are used in electrodeposition coating systems performing both cataphoresis and anaphoresis: cells are needed to create an electric field for the electrodeposition process. Tubular cells can be used for new plants as well as joining/ replacing other types of cells in existing plants. The great advantage they offer is

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5 Figure 5: Immersed dialysis cell.

FOCUS ON TECHNOLOGY

Vertical dialysis cell

Table 1: Technical data and benefits of tubular cells FUNCTIONS Dialysis cells perform two basic functions: - providing the electric field needed for the deposition of the paint; - removing the free acid released in the process. In the cataphoresis process, the cells work as anodes.

BENEFITS Reduced maintenance due to the interchangeability of anodes and membranes. Electrode rotation (tubular cells). Saving in the cell’s service life costs. Possibility to avoid emptying the tank for maintenance and replacement operations. Saving on spare parts. Reduction in unprogrammed maintenance resulting from the improvement of the system. Possibility of masking or excluding a part of the electrodes during commissioning or during normal operation.

TECHNICAL FEATURES Available for anaphoresis and cataphoresis applications. Possibility of customising the cells. No contact between the internal grille and the electrode. Improvement in the anolyte circulation. Prevention of the shading effect or small oxidation zones on the electrode. Reduced number of spare parts compared with conventional PVC systems. Easy replacement of anodes and membranes. 0.18 m²/m anode surface.

Table 2: Components and materials - Anode - Membrane - Main frame - Internal grille - External grille - Crossbeam - Seals - Bolts

SS 1.4404/1.4571 IONAC or MEGA Polypropylene (PP) Polypropylene (PP) Polypropylene (PP) Polypropylene (PP) Rubber (EPDM) Stainless steel

PROCESSI PER IL TRATTAMENTO DELLE EMISSIONI GASSOSE ED EFFICIENZA ENERGETICA

The main advantages of using this cell are as follows: - closed-loop operation with a back pressure system - high flexibility - the best solution for vertical immersion applications - adaptable to different tank sizes.

Immersed dialysis cell The main advantages of using this cell (Fig. 5) are as follows: - versions available for installation on the surface or on bottom of the tank - possibility of transverse or longitudinal installation in the electrodeposition tank - better coating application on the under-floor and the roof of the bodies - reduction of the absorbed power on peripheral cells.

Trattamento efficiente ed economico delle emissioni gassose industriali. Le soluzioni Dürr soddisfano i requisiti richiesti per le emissioni e inoltre ottimizzano il consumo energetico.

www.durr-cleantechnology.com

Opening photo: The manual coating application on different sized parts on which the maskings used can be clearly seen.

FOCUS ON TECHNOLOGY

Shorter Takt Times thanks to Special Maskings for Different Workpieces Monica Fumagalli ipcm®

xcellent finishing quality, high flexibility, speed of delivery and focus on innovation are common concepts in the contracting coating sector. Especially for SMEs, such features may be crucial for acquiring new customers and thus represent a distinguishing element from competitors. However, investments made by small and mediumsized coating contractors to keep focus on these elements often require big sacrifices. That of Verniciatura Braglia (Zola Pedrosa, Bologna, Italy) is the story of a winning business idea born in the Sixties, which, over the years, has enabled a small handicraft company to establish itself in a highly

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competitive market, that of the motomotive industry’s satellite activities. “In our plant, we treat any kind of coatable metal component,” says Carla Braglia, the owner of the company together with her sister Patrizia (Fig. 1). “Our customers come from very different fields, such as medical, motorcycle, footwear, and household and commercial furnishings (ref. Opening photo). However, given the area in which we are located, the motorcycle industry is the one that has accounted and still accounts for the greatest part of our activity. We work with leading industry brands, such as Ducati, BMW, Triumph and Yamaha; we coat their mechanical parts, in particular fork stabilisers, carters and suspensions.

FOCUS ON TECHNOLOGY

The development of Verniciatura Braglia suffered a setback when one of its most important customers, a manufacturer of suspension for motorcycles, significantly reduced its demand for coated workpieces due to internal business issues. “It was one of our most difficult times,” states Braglia. “However, any contractor knows that working mainly for only one customer is always a great risk. Anyway, that experience also brought two positive aspects. First, 1 we started to diversify our production, although, as is Figure 1: Carla Braglia, Verniciatura Braglia’s sales manager, during our understandable, the more the interview. clients, the more the problems to be solved; however, this has never scared us. On the growth, the firm soon moved from Casalecchio other hand, due to the special coating needs of to its current plant in Zola Pedrosa. After this suspension producer, we have met Tecno my father’s passing in 1993, my sister and I Supply (Santa Maria in Fabriago, Ravenna, Competition in our market is pressing, but, decided to take his place in the management despite being a small firm, we have been able Italy), a division of Ibix Srl specialising in of this business, established on values such as to ensure our customers’ loyalty thanks to high masking and hanging systems for industrial a strong bond with the territory and a push for coating processes. A collaboration started that quality products and a service aimed at the innovation aimed at keeping the quality of our customer’s satisfaction.” continues and will hopefully continue for a very surface treatments as the main focus of any long time.” entrepreneurial initiative.”

We work with leading industry brands, such as Ducati, BMW, Triumph and Yamaha; we coat their mechanical parts, in particular fork stabilisers, carters and suspensions. Competition in our market is pressing, but, despite being a small firm, we have been able to ensure our customers’ loyalty thanks to high quality products and a service aimed at the customer’s satisfaction.”

Verniciatura Braglia was established in 1972 by Renzo Braglia, formerly responsible for the coating department of Ducati. “The first “headquarters” of our company were a basement,” Carla Braglia adds. “In the Sixties and Seventies, when my dad decided to open his own business, the working conditions were very different from today’s ones: the chances of “doing business” were almost unlimited. With its

A description of the paintshop

Verniciatura Braglia: a winning combination of tradition and innovation

2 Figure 2: Some parts intended for the motomotive industry and coated by Verniciatura Braglia.

Dealing every day the strict specifications of highly demanding sectors such as the automotive and motomotive ones can turn into an incentive for growth for small firms focusing on their finishes’ quality to stand out (Fig. 2). “Our relationship with the major OEMs has enabled us to improve and achieve optimal finishing results”, Braglia adds. “We have a very flexible coating department, able to deliver the same quality level with both solvent-based

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4 3

Figure 4: A component waiting to be coated. 5

Figure 3: The entry into the pre-treatment tunnel.

Our relationship with the major OEMs has enabled us to improve and achieve optimal finishing results. We have a very flexible coating department, able to deliver the same quality level with both solvent-based and waterbased one, two-component products and thermosetting powders.”

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and water-based one and two-component products and thermosetting powders. The plant has undergone several improvements and implementations over the years. The most significant one was the one relating to the pre-treatment system. We needed to meet a customer’s need to treat magnesium components intended for mountain bikes and we realised that the 3-stage pre-treatment we had performed until that moment would not have been appropriate, as it did not ensure long-lasting paint adhesion.

That is why, together with Condoroil (Casale Litta, Varese, Italy), our chemical supplier, we developed a solution that enables us to treat the most diverse materials with one multi-metal system.” The pre-treatment plant, therefore, has been renewed by adding to the already existing phosphating process an alkaline cleaning stage at 60°C, two rinses with fresh water, a cleaning stage with demineralised water and

6 Figure 6: Manual coating application.

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Figure 5: Other types of workpieces to be painted.

a no-rinse passivation stage with zirconium salts (Fig. 3). The new pre-treatment process enables to achieve a salt spray resistance value up to 1500 hours for die-castings and aluminium alloys and up to 750 hours for magnesium alloys.

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7 Figure 7: Protections developed by Tecno Supply applied to a fork stabiliser.

Coating is performed with the inline plant for both small and large batches and with non-inline pressurised booths for special finishes also on plastic materials. “The coating plant,” says Braglia, “consists of two booths linked by a flash-off station, one for the application of the basecoat and the other for the topcoat: here, if needed, powders can also be applied (Figs. 4, 5 and 6). The following oven polymerises both liquid and powder coatings, ranging from a minimum of 80°C for low temperature paints up to 240°C.”

Masking: an operation that should not be undervalued In order to maintain the high quality of its coatings, Verniciatura Braglia pays special attention to its masking operations. “Protections play a key role for us: sometimes, the search for the right masking tool is more problematic than the coating operation itself,” Braglia states. “That is why it is important to have a partner able to support us and find the solutions that best suits our clients’ requests. We contacted Tecno Supply for the first time for the masking of the suspensions that we coated for our main customer. Our requests were really diversified – special-shaped, round and adhesive maskings on which no traces of glue should

Protections play a key role for us: sometimes, the search for the right masking tool is more problematic than the coating operation itself, that is why it is important to have a partner able to support us and find the solutions that best suits our clients’ requests.”

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the protection was to be applied to Ibix’ partner Hang On (Hillerstorp, Sweden) to have it custom-built.” “Our collaboration with Tecno Supply also works thanks to their operational flexibility,” Braglia says. “Generally, we provide them 8 with the design of the component that Figure 8: A masked part before coating’s application. must be protected. Their staff analyses have remained, among the others. With the it and develops the best solution possible, reduction of orders by this customer, we sometimes even assembling different 9 started needing Tecno Supply’s help less products from their catalogue, as in the case frequently; however, we continue to use mentioned. We always demand for maskings Figure 9: An adequate hanging system their products because they have always met that are quick to apply and remove at the end optimises the coating operations. our demands, even a very particular one for of the process (Fig. 8).” a catalogue arranged by codes that makes it A further help for a coating easier to choose and order products.” “Verniciatura Braglia uses HSQ frames contractor: the hanging system “It is generally thought that coating provided by our Swedish partner Hang protections are standardised products,” In addition to maskings, Tecno Supply On. These are universal frames designed provides Verniciatura Braglia with a few says Adriano Antonelli, Ibix’ sales manager. to make the most of the available space hanging systems. “In terms of workpiece “Actually, our range is highly diversified: we and speed up the coating operations. need to find the right customised solution protection,” says Braglia, “the hanging With the proper protection and hanging system can help a lot: in some cases, for every client’s task. One of the most systems, it is possible to reduce or it is constructed in such a way that no particular protections we have developed for eliminate any retouching operation Verniciatura Braglia, for instance, is intended masking at all is needed, which for a fork stabiliser (Fig. 7): it is a special enables a small plug made with cut and assembled silicone firm like ours to bearings, featuring robustness and softness save a lot of time at the same time to ensure perfect masking seal. In this case, we sent the part to which and space (Fig. 9). We use the hanging systems supplied by Tecno Supply In terms of workpiece for the numerous small components protection, the hanging we treat, such as system can help a lot: in some for example cast cases, it is constructed in iron gas valves, such a way that no masking at 10 components for all is needed, which enables lifts and hooks for a small firm like ours to save Figure 10: The cross cut adhesion test performed on a motorcycle curtains.” a lot of time and space” component.

FOCUS ON TECHNOLOGY

needed after the surface treatments and thus reduce the costs of discarded material,” states Antonelli.

Conclusions

11 Figure 11: The exterior of the coating plant: some painted workpieces are being carefully checked.

“For a small company like ours, even the smallest detail can contribute to greater productive efficiency,” Carla Braglia says. “Also for this reason, we are mindful of any operational phase we perform. All that can lead to a reduction in our production times is crucial. Verniciatura Braglia is a well-established firm in our area. We are committed to further improve the tools we use to increase the value for money of our products and, whenever necessary, we will always be ready to invest in innovation. Currently, we are particularly focusing on our finishing results, with further tests and trials to ensure that our components meet all the specifications (Figs. 10 and 11).”

Opening picture: The new paintshop at Nordautomation Oy.

FOCUS ON TECHNOLOGY

A Record-large Production Hall Got Pekotek’s Surface Treatment System Marko Karttunen Pekotek Oy, Reijola, Finland

he forestry and sawmill technology 10,800 square meters. The new hybrid hall services, and thereby to increase the turnover. company Nordautomation Oy has made doubles the surface treatment facilities of After the investment, the production facilities the largest investment in its history in Nordautomation, which features the blasting increased from 7,500 square meters to the production facilities located rooms and three painting rooms. in Alajärvi. This production The new production facilities hall is one of the largest in enable the surface treatment of the Nordic countries. Pekotek long and wide objects (Fig. 1). supplied it with custom-made The inside height of the new surface treatment systems and hybrid hall reaches up to 16 equipment (ref. Opening picture). meters, the width is 55 meters, Tenho Saarimaa, the production and the length is 66 meters. The manager of Nordautomation Oy, length of the painting chambers is pleased with the new modern is no less than 30 meters. production hall in Alajärvi, which In the new hall, the machine was completed in March 2017. shop is located directly next The aim was to make the surface to the painting chambers. On treatment more environmentally the first floor, there are office 1 friendly, to increase energy spaces for designers. In front efficiency, to decrease the of all these facilities, there is a Figure 1: Tenho Saarimaa, on the left, of Nordautomation with Petri production lead time of surface cold storage room, where the Rautiainen, Manager Development and Service of Pekotek Oy, in front of treatment, to increase the components wait for the surface the long and heavy components for the forestry and sawmill technology painted by the Finnish company. capacity of the engineering shop treatment.

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FOCUS ON TECHNOLOGY

2 Figure 2: The new production hall which contains the paintshop.

“We can now move the log handling equipment quickly from the machine shop to the painting chamber and from the painting chamber to the assembly room,” says Saarimaa.

Environmental friendliness improves Nordautomation chose Pekotek as a partner to install the surface treatment systems and equipment in the new production hall (Fig. 2). The cooperation had already been discussed since the beginning of the millennium, when the idea of this major investment emerged for the first time. Saarimaa appreciates the environmental friendliness in Pekotek’s surface treatment system, since Nordautomation utilises a blasting room which uses recyclable steel grit (Fig. 3). The aim is to reduce the environmentally damaging emissions from the grit being reprocessed. “The surface treatment started to become an obstacle, which can now be solved thanks to the investment; and this will make an increase in revenue possible. The blasting room is nearly emissionfree,” explains Saarimaa. A recyclable steel grit will now be recovered with the help of the floor hoppers, therefore eliminating the cleaning time, and the blasting visibility remains clear thanks to dust removal. Only one fan is required for the transfer of the blasting material for the blasting room, the blasting chamber ventilation, dust removal, and waste transfer.

Production lead time is shortened The ventilation equipment of the Pekotek system also reduces the time needed for the painting and at the same time the total production lead time. The modern painting chambers got Pekotek’s heat recovery, which increases energy efficiency by recovering at least 70 percent of the exhaust air energy.

The industrial internet is seen in the condition supervision

Flexible installation

In the painting chambers, there are also air installations and filters for solvent-based and water-based paints. The equipment in the painting chambers follows the conditions in real time, i.e., the ventilation starts up automatically when the gas sensors “smell” the solvent content. “Energy is saved because the automatic gas control ensures clean and safe working conditions as well as adjusts the exhaust air to the actual needs and enables air recycling,” says Petri Rautiainen, who is the manager responsible for the maintenance and spare parts in Pekotek. “The repayment time for the heat recovery system is about two-three years, which means that the operating costs of the plant will reach the modern level with a short repayment period,” says Rautiainen.

The procuring of the existing production facilities and the construction of the new hall with all the equipment cost a total of four million euros. The customers of 3 Nordautomation Oy or forest Figure 3: The grit blasting chamber. industry companies in “In March 2017, we set out to install the Finland and abroad will benefit from the new world’s longest and most modern log sorting surface treatment system. Nordautomation Oy provides technical solutions for log plant for the Keitele Group. The length of the facility is 500 meters, and it has 126 log processing which combine world-class compartments. Thanks to the large-scale performance with operational reliability and durability. references and the above-mentioned improved production facilities, we can meet the increasingly demanding challenges of our customers.” © Pekka Rajakangas

The Industrial Internet is seen in the painting chamber condition system (Fig. 4): Pekotek’s system monitors, among other things, the vibration of the fan motors, the differential pressure of the filters, the temperature, the About Nordautomation Oy humidity, and the dew point. - A leading log handling If necessary, the system supplier and expanding into gives a dew point alarm. new markets in collaboration The condition information is with multinational clients automatically transferred from and technology partners the system to the painting serving the forest industry record. If necessary, the system can be accessed from - Proper machinery ensures that timber is converted the remote control point. Error by mechanical or chemical messages will go directly processing into products of from the painting chamber 4 the best value and optimal equipment to the control properties application. Figure 4: Rautiainen and Saarimaa in front of the monitoring system of the “This investment enables Located in paintshop. Kristiinankaupunki, and the us to better meet the pulp ”The installation of Pekotek’s surface production is in Alajärvi and industry’s stringent requirements for surface treatment system was a project that went employs sixty professionals. treatment. The surface treatment of the pulp smoothly and quickly. The cooperation has - Founded 1991 industry’s equipment takes twice as much been based on trust. The work that was as the sawmill industry’s equipment,” says - Turnover 15 MEUR (2016) agreed upon has been done,” Saarimaa says. Saarimaa. - Employs totally 80 professionals.

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BUSINESS TRAINING

Customer Satisfaction Analysis & Management – Part 2 Felice Ambrosino consultant

simeida@tin.it

Levels of customer satisfaction In a nutshell, the degree of customer satisfaction can be defined as the difference between the value of its expectations and the perceived value of the goods purchased. If the perceived value is lower (gap) / equal / higher (delta) than its expectations, the

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customer is dissatisfied / satisfied / oversatisfied with the purchase (Richard F. Gerson, Measuring customer satisfaction, Crisp Publications). This simple paradigm is normally completed with the concept of Quality Function Deployment, i.e. the difference between the supplier’s assessment of the customer

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expectations and the value transferred through the products sold. This gives a wider perspective on the Customer Satisfaction issue, while helping identify the guidelines to achieve it. The following diagram taken from a DataBank publication (Customer Intelligence, 1992) applies as an example:

BUSINESS TRAINING

Gap or Delta of satisfaction

Value of expectations

Customer Satisfaction

Interpretation gap

Interpretation of the value of expectations

Perceived value of purchased goods

Communication gap

Quality Function Deployment

Value transferred by the products

Realisation gap

In order to achieve customer satisfaction, therefore, the perceived value of the purchased products must be equal to or greater than the value of the expectations, provided that the supplier has properly interpreted these expectations (no interpretation gap), it has transferred a value in line with the correct interpretation (no realisation gap) and it has communicated effectively with the customer to foster a perception of the transferred value that is as accurate as possible (no communication gap). Before closing this paragraph, it may be worth answering another question: Why are we talking about customer satisfaction as it was something new? After all, did not traditional marketing consider customer satisfaction as its core issue? Why talk about “new competitiveness” and “new marketing”, then? The question is very pertinent and deserves a whole essay. For brevity, however, we will just state as follows: • Traditional marketing dealt with the satisfaction of market needs: the Customer Satisfaction concept is geared towards the “overall satisfaction” of the client;

• For the traditional marketing, the centrality of the customer was more a slogan than a behaviour: Phrases like “the customer is king”, “customers first”, etc. were merely the result of formal attitudes, whereas attention was (and unfortunately still is) actually focussed on selling as many products as possible. The Customer Satisfaction Management is not based on this attitude. Its ultimate goal is customer satisfaction: the client is an end, not a means to increase sales. In order to please customers, the Customer Satisfaction Management approach makes a firm even willing to make sacrifices in terms of revenue and profit, because it knows that its true chances of growth lie in its customers’ satisfaction and that the sacrifices made to achieve it will be paid off (VV.AA., Customer Satisfaction Management, Il Sole 24 Ore); • Compared with the conventional one, the “new marketing” is faced with the scarcity of customers and the critical importance of their satisfaction (Leoni e Raimondi, Un metodo per la misurazione della Customer Satisfaction, published on

Customer Satisfaction, ISEDI). Customer Satisfaction has become a priority within the Total Management framework and it is no longer a matter only concerning the sales area. The Customer Satisfaction Management is not an activity or a business function, but rather a culture, a philosophy. It is a way to get into the market that is more appropriate to the modern industrial environment, characterised by increasingly more

The new marketing approach, therefore, focusses on the customer’s centrality and the Customer Intelligence concept. This does not only include the awareness of its needs, but also the overall knowledge of the customer, its business, its environment, its strengths and weaknesses, its strategic positioning, and its correspondence to the expectations of its clients – a much deeper knowledge, as the word “intelligence” suggests.” international PAINT&COATING magazine - MAY/JUNE 2017 - N. 45

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similar products that become obsolete and difficult to promote very rapidly. As stated by the specialised literature (Leoni e Raimondi, op. cit.), the satisfaction of a business’ customers has even become the main criterion to assign several quality awards, such as the coveted Malcolm Baldrige Award in the US and the European Quality Award given for the first time in 1992. The new marketing approach, therefore, focusses on the customer’s centrality and the Customer Intelligence concept. This does not only include the awareness of its needs, but also the overall knowledge of the customer, its business, its environment, its strengths and weaknesses, its strategic positioning, and its correspondence to the expectations of its clients – a much deeper knowledge, as the word “intelligence” suggests.

The pros of satisfaction and the cons of dissatisfaction In addition to Fidelity, which, as mentioned, is the basis of Retention, a good level of customer satisfaction also brings benefits for the development of a business, which fully validate the role of Customer Satisfaction as an alternative path of growth: • Increased sales thanks to cross-selling: A satisfied customer is certainly willing to consider purchasing other products from the same supplier;

In addition to Fidelity, which, as mentioned, is the basis of Retention, a good level of customer satisfaction also brings benefits for the development of a business, which fully validate the role of Customer Satisfaction as an alternative path of growth.”

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• Increased willingness to pay a premium price: A satisfied customer is also willing to pay a reasonably higher price for the purchased product, certain that it will recover the difference with the need for less control on the quality provided. Normally, satisfied customers are also more willing to accept price increases; • Increased sales thanks to positive word of mouth: a satisfied customer is willing to advise other people to contact its supplier. A good level of satisfaction also results in economic benefits: • Compliance with payment terms; • Availability to anticipate orders; • Willingness to cooperate on more levels (market surveys, acceptance of price increases, exchange of information and know-how, clarity in relationships, etc.); • Contribution to a good business climate: Customer Satisfaction motivates the supplier’s employees, who are encouraged to further improve; • Reduction in the costs for the acquisition of new customers thanks to positive word of mouth, but also to the improvement in the supplier’s image brought by the satisfaction of its customers. As can be seen, Customer Satisfaction ensures many significant advantages, whose effects often exceed the brightest expectations. On the other hand, one may also want to consider their opposite, that is, the disadvantages of dissatisfaction. Indeed, an unsatisfied customer: • behaves in a hostile way (no crossselling, price fight, no cooperation, attempts to delay payments even without any justification, etc.); • requires discounts and gifts to settle disputes; • starts negative word of mouth: It has been calculated that each unsatisfied customer produces at least ten negative contacts on the market;

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The gap between the advantages of having satisfied customers and the disadvantages of having unsatisfied customers is clearly huge and certainly explains the great popularity that the Customer Satisfaction Management techniques have been gaining.”

• Creates a litigious and unhelpful business climate; • Generally, does not openly declare its dissatisfaction, thus becoming a “loose cannon”, an unmanageable risk for the supplier. According to a recent study conducted in the USA, the percentage of unsatisfied people who do not openly complain is very high – between 65 to 96% depending on the market; • Finally, it harms the supplier in terms of missed opportunities for development, which on the contrary are created by satisfied customers. The gap between the advantages of having satisfied customers and the disadvantages of having unsatisfied customers is clearly huge and certainly explains the great popularity that the Customer Satisfaction Management techniques have been gaining. (to be continued on the next issue of ipcm®)

STANDARD & LEGISLATION - UCIF Informs

Noise Pollution: Harmonisation of National Legislation Marcello Zinno info@ucif.net

UCIF-Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

wo legislative decrees on noise pollution (no. 41 of February 17th, 2017 and no. 42 February 17th, 2017) were published in the Official Gazette of the Italian Republic no. 79 of April 4th, 2017. This was done to implement the mandate to the Government for the reorganisation of the regulatory measures regarding the protection of outdoor and indoor environments against the noise pollution produced by fixed and mobile sound sources according to the EC legislation. The legislative decree no. 41/2017 ‘Provisions for the harmonisation of national legislation on noise pollution with the directive 2000/14/EC and with the regulation (CE) no. 765/2008, in compliance with the article 19, paragraph 2, letters i), l) e m) of the law of October 30th, 2014, no. 161’ includes changes to the legislative decree no. 262 of September 4th, 2002 ‘Implementation of the directive 2000/14/EC concerning the environmental noise emission of machinery and equipment intended for outdoor operation’. These changes include as follows: - The clarification that, if the manufacturer is not based in the European Union and has not identified any agent, the obligations set out in the legislative decree no. 262/2002 fall on anyone, a natural or legal person, who markets

or puts into service its machines and equipment on the national territory; - A clarification on the activities of Certification Bodies; - A clarification of sanctions. On the other hand, the legislative decree no. 42/2017 ‘Provisions for the harmonisation of national legislation on noise pollution in compliance with the article 19, paragraph 2, letters a), b), c), d), e), f) and h) of the law of October 30th, 2014, no. 161’ includes the following changes: - Changes to the legislative decree no. 194 of August 19th, 2005 ‘Implementation of the directive 2002/49/EC relating to

the assessment and management of environmental noise’ (republished on October 13th, 2005); - Changes to the law no. 447 of October 26th, 1995 ‘Framework law on noise pollution’; - The legislative decree no. 42/2017 requires the establishment of a Commission for the Protection against Noise Pollution at the Ministry of the Environment and the Protection of the Territory and the Sea, with technical-scientific support tasks; - The decree also sets out general criteria for the exercise of the profession of acoustic technician. Both decrees entered into force on April 19th, 2017.

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TRADE FAIRS & CONFERENCES

JUNE 2017 INDUSMACH KENYA Nairobi, Kenya June 02-04, 2017 www.expogr.com/kenyaind/

FASTENER FAIR MEXICO

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GLOBAL AUTOMOTIVE COMPONENTS AND SUPPLIERS EXPO

METALLURGY LITMASH Moscow, Russia June 05-08, 2017 www.metallurgy-tube-russia.com

Stuttgart, Germany June 20-22, 2017 www.globalautomotivecomponentsandsuppliersexpo.com/english/

SUBCON

LACS - LATIN AMERICA COATINGS SHOW

Birmingham, UK June 06-08, 2017 www.subconshow.co.uk

Mexico City, Mexico June 20-22, 2017 www.lacsmexico.mx/sitio/principal/?se=50&id=2

SUBCONTRATACIÓN Bilbao, Spain June 06-08, 2017 subcontratacion.bilbaoexhibitioncentre.com/en

ALUMINIUM TWO THOUSAND

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Verona, Italy June 20-24, 2017 www.aluminium2000.com

FERROFORMA

FEIMAFE

Bilbao, Spain June 06-08, 2017 ferroforma.bilbaoexhibitioncentre.com/en

São Paulo, Brazil June 20-24, 2017 www.feimafe.com.br

BELAGRO

M-TECH

Minsk, Belarus June 06-10, 2017 belagro.minskexpo.com/english

Tokyo, Japan June 21-23, 2017 www.mtech-tokyo.jp/en/

ECCA’S 50TH ANNUAL CONGRESS AND CONFERENCE Amsterdam, The Netherlands June 07-09, 2017 www.prepaintedmetal.eu

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Verona, Italy June 21-24, 2017 www.metef.com

KENYA PLAST

SURFACE & COATINGS

Nairobi, Kenya June 08-10, 2017 www.kenyaplast.in

Bangkok, Thailand June 21-24, 2017 www.surfaceandcoatings.com

EAST AFRICAN COATINGS CONGRESS

MANUFACTURING EXPO

Nairobi, Kenya June 13-14, 2017 www.coatings-group.com

Bangkok, Thailand June 21-24, 2017 www.manufacturing-expo.com

METAL + METALLURGY CHINA

ESTAD

Shanghai, China June 13-16, 2017 www.mm-china.com/En/

Vienna, Austria June 26-29, 2017 www.estad2017.org

Mexico City, Mexico June 14-16, 2017 paace-automechanika-mexico.us.messefrankfurt.com/mexicocity/en

SIAE - SALON INTERNATIONAL DE L’AÉRONAUTIQUE ET DE L’ESPACE Paris, France June 19-25, 2017 www.siae.fr

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METEF-ALUMOTIVE

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PAACE AUTOMECHANIKA MEXICO

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Mexico City, Mexico June 20-21, 2017 www.fastenerfair.com/mexico/english/

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SURCAR Cannes, France June 29-30, 2017 cannes.surcarcongress.com

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JULY 2017 MTA VIETNAM Ho Chi Minh City, Vietnam July 04-07, 2017 mtavietnam.com

BIAME - BEIJING INTERNATIONAL AUTOMOTIVE MANUFACTURING EXPO Beijing, China July 19-21, 2017 www.ciame-show.com

ALUMINIUM CHINA

MANUFACTURING SURABAYA

Shanghai, China July 19-21, 2017 www.aluminiumchina.com/en

Surabaya, Indonesia July 19-22, 2017 manufacturingsurabaya.com

AUGUST 2017 BUILDEXPO AFRICA

INDUSMACH AFRICA

Dar-es-Salaam, Tanzania August 10-12, 2017 expogr.com/tanzania/buildexpo/

Dar-es-Salaam, Tanzania August 22-24, 2017 www.expogr.com/tanzania/indexpo/

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AUTOEXPO AFRICA Dar-es-Salaam, Tanzania August 16-18, 2017 www.expogr.com/tanzania/autoexpo/index.php

SEPTEMBER 2017 ALUMINIUM INDIA

COMPOSITES EUROPE

Mumbai, India September 07-09, 2017 www.aluminium-india.com

Stuttgart, Germany September 19-21, 2017 www.composites-europe.com

ICSP 13

CMTS

Montreal, Canada September 11-14, 2017 www.shotpeening.org

Mississauga, Canada September 25-28, 2017 cmts.ca/

CONSTRUCTION INDONESIA

POWDER COATING & CURING PROCESSES SEMINAR

Jakarta, Indonesia September 13-16, 2017 constructionindo.com

Atlanta - GA, USA September 26-27, 2017 www.ccaiweb.com/events/EventDetails.aspx?id=886647&group=

ASIA PACIFIC COATINGS SHOW

POWTECH

Jakarta, Indonesia September 13-15, 2017 www.coatings-group.com

Nuremberg, Germany September 26-28, 2017 www.powtech.de/en

IAA CARS

ALTECNOLOGIE

Frankfurt, Germany September 14-24, 2017 www.iaa.de

Erba (Como), Italy September 28-30, 2017 www.altecnologie.it

EMO HANNOVER Hanover, Germany September 18-23, 2017 www.emo-hannover.de

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ZOOM ON EVENTS

xalta Coating Systems, one of the world’s leading manufacturers of liquid and powder coatings, is attending some of the itinerant training workshops organised by the publishing house Action Group. Their aim is analysing the most current issues in the fields of architecture and design (Fig. 1). In 2016, there were sixty-nine meetings in 36 locations throughout Italy. For 2017, Action Group has scheduled over one hundred training events accredited by the National Council of Landscape Architects, Planners and Conservationists, the National Council of Engineers and the National Council of Geometers and Graduated Geometers. This year, meetings will be held in several new cities, such as Caserta, Ferrara, Parma, Pesaro, Pordenone, Potenza, Siena and Taranto. The event of May 11, held at the Hotel Ramada Naples, belonged to a series of meetings on “The future of the building industry: Renovation, technologies, innovations, smart building, materials and sustainability”, addressed to professionals in the fields of architecture and design (Fig. 2). The conference speakers, coordinated by the moderator Domenico Lattanza, discussed the future prospects of sustainable design and renovation projects. The architect Armando Bruno, the CEO of the architecture firm Marco Piva, opened the conference with a speech titled “Projects and their players”. The first technical roundtable saw the participation of four speakers:

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A Series of Itinerant Meetings on the Future of the Construction Industry with the Participation of Axalta Coating Systems

1 Figure 1: Cristian Palmieri, Axalta Coating Systems’ Sales Manager Italy, during the conference “The future of the building industry” held in Naples.

- Marina Sedani from Sapa Building Systems, “Door and window frames as a design element” - Anna D’Ammando from Neolith, “Introduction to sintered stone” - Sergio Rizza from Arpa Industriale, “A case history on innovative materials for interior design” - Francesco Bigoni from Scrigno, “From a constructive solution to a design concept”. The second technical roundtable dealt with the following issues: - “Ever, design for all made in Italy”,

N. 45 - MAY/JUNE 2017 - international PAINT&COATING magazine

Angelo Golisano from Thermomat Srl - “Design and nature: A new way of designing surfaces”, Mario Lombardi from Favaro 1 - “Design icons to make any project come to life”, Elena Baj from Zucchetti Rubinetteria Spa - “The building industry of future. Fences 2.0”, Fabio Citterio from Nuova Defim Orsogril. The afternoon session included the following reports: - Enzo La Mura from Geosec Srl, “Seismic consolidation and improvement of

ZOOM ON EVENTS

Figure 2: An audience of architects and designers attended the event held in Naples.

properties and foundations: intervention techniques and design support” - Giuseppe Bechis from Rubinetterie Zazzeri Spa, “The shape factory” - Antonino di Giovanni from Cotto Cusimano Srl, “Cotto tiles: Restoration and bio-architecture” - Giulia Ficco from Dott. Gallina Srl, “Modular alveolar polycarbonate systems: Lightness, transparency and thermal insulation” - Joseph Smeysters from NMC Italia Srl, “Finishes for interiors, façades and terraces”. The speech titled “Building today. Energy efficiency and sustainability of sports facilities”, delivered by the architect Alessandro Lomonaco from

Studio Lomonaco, closed the afternoon session and preceded the final debate. On the occasion of the Naples conference, Axalta Coating Systems presented its new collection, ICONICA, belonging to the Alesta® Super Durable powder coating line, with forty colours intended for metal structures for building and architecture (Fig. 3). For further information: www.infoprogetto.it and www.powder.axaltacs.com

3 Figure 3: ICONICA, Axalta’s new collection, was presented to the architects and designers who attended the Naples conference on May 11, 2017.

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ZOOM ON EVENTS

1 Figure 1: The Poliefun-TST conference was held at the premises of Politecnico di Milano on May, 18.

he IV edition of TST, Trends in Surface Technology, the symposium on advanced research in the field of surface finishing and coating was held on Thursday, May 18, 2017 at the premises of the Politecnico di Milano (Fig. 1). The several speeches have focused on the sector at the international level and on the assessment of the state of the art of research applied to the surface treatment industry; the interesting scientific programme saw the prestigious contribution of prominent personalities of university and industry. This free conference was organised by Poliefun, the association that since 2000 has been working for an effective relationship between university and companies’ R&D departments through training events and the dissemination

POLIEFUN-TST 2017: the World of Surfaces at the Politecnico di Milano

of business culture (Fig. 2). The firms that have joined TST’17 were called to active participation and involved in a lively debate with the academic world through direct, effective and constructive contributions (Fig. 3). A few scientific papers were also presented, which were really appreciated by the audience (Fig. 4). The speech reports and the papers have been collected in a volume for sale at the Poliefun secretariat. For further information: segreteria@poliefun.org

Figure 2: The audience during the conference.

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The awarding of the Degree Prizes in memory of Anna da Forno, a researcher and collaborator of Poliefun who passed away prematurely, was particularly touching (Fig. 5). Emanuele Agnoli, Andrea Balzarotti, Francesco Ciaglia, Matteo Longo, and Tommaso Geri were awarded for their undergraduate thesis titled “The functionalisation of organic coatings for obtaining hydrophilic surfaces”, whereas Stefano Musso was awarded for his master thesis titled “The tribological behaviour of laser textured CrA1N PVD coatings”. TST’17 has even managed to combine science, research and technology with art, thanks to the presence and the exhibition of the Maestro Paolo Conti, whose works have made the event even more exclusive.

Oral sessions and main lectures: • Automotive (application plants, in-line control, required performances) • Evolutions in the automotive paint shops • Architecture & Design (materials and colour control) • Perception and protection properties of paints with different colour pigments • Paint applications (pre-treatments, finishing) • Surface modification and patterning of UV-cured coatings • Metal (organic special coatings) • Techniques for real time process control in thin film deposition.

Figure 4: The scientiﬁc posters.

Figure 3: The information desks of the event’s sponsors.

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5 Figure 5: The awarding of the Degree Prizes in memory of Anna da Forno.

Speakers involved and their specialisation: Alessandro Di Lucrezia / Process Engineering Manager / Geico Taikisha Nelson K. Akafuah / Professor Department of Mechanical Engineering University of Kentucky / Eurosider Johannes T. Grobe / Senior Vice President Sales& Marketing / DÜRR System AG Marie Marguerite Dugand / Physical Analysis Department Group materials labs / C.R.F. Marco Mora / Paint Manager / Fondmetal Stefano Rossi / Professor Department of Industrial Engineering / Università di Trento

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Francesca Valan / CMF Design Studio / Associazione del Colore Stefano Corrado / Account Manager Coatings Performance Materials Pigments & Functional Materials / Merck Roberta Bongiovanni / Full Professor Department of Applied Science and Technology / Politecnico di Torino Claudia Salomoni / Marketing & Communications Manager / Akzonobel Michele Fedel / Assistant professor Department of Industrial Engineering / Università di Trento

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Sebastiano Luridiana / Technical Manager / Tecno Vacuum Angelo Falzetti / Laboratory Engineer - R&D / Rösler Italiana Andrea Redaelli / Materials Engineering & Nanotecnology Sara Bagherifard / Research fellow / Politecnico di Milano. For further information: www.poliefun.org and www.smoothadv.com

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FABTECH Mexico 2017 Brought Best Innovation in Manufacturing to Monterrey, Mexico North American sales, American Welding About FABTECH Mexico Society. “Giving businesses and customers FABTECH Mexico along with the the opportunity to come together at one established AWS Weldmex, METALFORM place to learn, network, explore new Mexico and COATech is Latin America’s products and technology and make lasting largest collaboration of technology, connections is what has made this show the equipment and knowledge in the metal largest of its kind in forming, fabricating, welding and Latin America.” finishing industries. The event provides The annual show is a powerfully aligned hands-on, face-tocomprised of four face business growth experience, and is co-located shows, made possible by its five co-sponsors, FABTECH Mexico all of whom representing the varied and encompasses diverse makeup of the manufacturing metal forming and industry. They include SME, the fabricating as well American Welding Society (AWS), the as tube and pipe Fabricators & Manufacturers Association, technology, AWS International (FMA), the Precision Weldmex features Metalforming Association (PMA), and 1 welding technology, the Chemical Coaters Association METALFORM International (CCAI). Figure 1: The entrance of the FABTECH Mexico’s show. Mexico highlights For more information: metal forming www.mexico.fabtechexpo.com and tool and die technology 11,000 attendees and over 500 exhibitors and COATech focuses on during the three-day show (Fig. 1). finishing technology, where Spanning over 300,000 net square feet the ipcm’s booth was present of exhibit space, the fourteenth edition of (Fig. 2). It is sponsored FABTECH Mexico provided attendees the by SME, The Fabricators & opportunity to see live demonstrations, Manufacturers Association explore the latest manufacturing and welding (FMA), the American technologies, meet with industry experts and Welding Society (AWS), attend educational sessions. Educational the Precision Metalforming sessions covered technical topics such as Association (PMA) and the automation, cutting, forming and fabricating, Chemical Coaters Association lasers, lean management, software, finishing, International (CCAI). stamping and welding. The show rotates each year “Corporate executives and owners made 2 between Monterrey and Mexico up over 28% of the attendance and bought City. The next event will be held machinery and technology directly off the May 2-4, 2018 in Mexico City. show floor” said Joe Krall, managing director, Figure 2: The ipcm’s booth at the Coatech pavilion.

ABTECH Mexico, the leading manufacturing event in Latin America for metal forming, fabricating, welding and finishing industries, brought the latest innovations in manufacturing to Monterrey, Mexico on May 2 – 4, 2017 with close to

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For the First Time More than 30,000 Visitors: New Records Set at European Coatings Show

1 Figure 1: More than 30,000 trade visitors from far more than 100 countries visited the European Coatings Show 2017.

ore than 30,000 trade visitors from far more than 100 countries and 1,135 exhibitors from 40 countries – the European Coatings Show 2017 was bigger and more international than ever (Fig. 1). The show continues to expand its position as the leading event for the global coatings industry. In an expanded space at Exhibition Centre Nuremberg, the exhibiting companies presented innovative and new products and services for every aspect of paints, coatings and sealants production. The

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European Coatings Show Conference was just as popular: over 840 participants from about 50 countries set another record for this hub for discussion among coating researchers and developers. The next European Coatings Show will be held at the Exhibition Centre Nuremberg from 19–21 March 2019. Held every other year, the European Coatings Show reflects the entire process chain in paint production, and offers its trade visitors a comprehensive view of development and production. In addition to raw materials

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for paints, printing inks and adhesives, the exhibitors also present laboratory and production technology, as well as testing and measuring instruments.

International participation and group pavilions for countries The 2017 European Coatings Show filled seven halls and boasted a more extensive international presence than ever. In addition to one Chinese pavilion, the group pavilions of the Czech Republic and the Republic of

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previous years. More than 140 specialised presentations by internationally renowned speakers explored the production of paints, sealing compounds, construction chemical materials and adhesives. The focus was on current needs like functionality and environmental protection. The keynote speech at the Plenary Session was given by Renaud Nicolaÿ, a researcher from the École Supérieure de Physiques et de Chimie Industrielles de la Ville de Paris who studies covalent bonds and

Korea provided an overview of their particular nations. Young innovative companies from Germany appeared at a joint pavilion funded by the Federal Ministry for Economic Affairs and Energy (BMWi). Product presentations in three halls offered short talks by exhibitors with additional specialized knowledge about uses, effects and technical data (Figs. 2, 3, 4, 5 and 6).

With more than 840 participants, the European Coatings Show Conference was even more heavily attended than in

Conference impresses with specialized knowledge for current challenges

their potential applications. In his talk, “When everyday plastics become highperformance re-usable materials”, he showed how to produce high-resistance vitrimers with new properties, including ease of deformation, self-healing capability and recyclability – all while still maintaining their original characteristics. This year’s European Coatings Show Award for the best submission went to Bas Tuijtelaars from DSM Coating Resins. The jury recognized his environmentally friendly approach to making amine-free resins.

The Leading Coatings Shows

• 3–5 October 2017 ABRAFATI, São Paulo, Brazil • 8–10 March 2018 PAINTINDIA, Mumbai, India • 14–21 March 2018 European Coatings Show Reloaded/online • 10–12 April 2018 American Coatings Show, Indianapolis, USA • 19 –21 March 2019 European Coatings Show, Nuremberg, Germany. For more information: www.european-coatings-show.com

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ollowing a 2015 successful edition, the world’s leading international congress on automotive body finishing since 1964, SURCAR, will take place again this year in the heart of Cannes. Held every two years, it brings together an international audience of 300+ decision-makers and experts in automotive body painting from over 25 countries. SURCAR Cannes is your chance to examine and exchange views on the latest surface treatments and equipment technologies as well as meeting top level experts, researchers and executive from the automotive industry. The automotive industry is in constant mutation: New mobility, network connected, self-drive and more and more electric cars. The car concept must encompass a multitude of criteria not only to meet the requirements of weight reduction, shared use etc… but also to satisfy the passionate car driver in his search hunt for personalization. The Technical Committee and its international experts have elaborated a program regarding the opportunities in the ever changing

automotive industry: Developments, Changes and Results from New Technology and Market Trends, Smart Factory / Industry 4.0. and strategic issues for the Coating Industry.

SURCAR Cannes 2017, Next Edition on 29-30 June!

SURCAR Cannes offers great business 1 opportunities and networking: Figure 1: Great business opportunities and networking will be - Two days of conferences expected at SURCAR Cannes 2017 (29-30 June 2017). carefully selected by a high level International around the globe (USA, Japan, Germany, Committee France, China, The Netherlands, Italy, Portugal, - An Exhibition Area with the opportunity Sweden, Turkey, UK, Fig. 2). for companies to present their product(s)/ Many manufacturers and suppliers key players skill(s) and exchange with delegates (Fig. 1) already have confirmed their attendance such - A Gala Dinner on June 30th with the as: ABB, AUDI, ARCELORMITTAL, AUSON AB, exceptional environment of a typical Riviera AXALTA COATING SYSTEMS, BASF COATINGS, evening to continue networking BMW, BOLLIG & KEMPER, CHEMETALL, - The SURCAR Awards’ Ceremony which KLUTHE, CONSTELLIUM, DAIMLER, DURR, reward the best presentations and present EFTEC,EISENMANN, FAURECIA, FERRARI, FIAT three prizes: CHRYSLER AUTOMOBILES, GEICO, GEKATEX, The Award for HELMUT FISCHER AG, HEMMELRATH, HENKEL, Innovation, the HONDA, KANSAI PAINT, KIMBERLY CLARK, Award for Technique JAGUAR LAND ROVER, KREMLIN REXSON, and the Jury’s Award. KRUSS, MAGNA STEYR, MAHINDRA, NIPPON PAINT, NISSAN, NOF METAL COATINGS, OPEL, These 2-days of ORONTEC, PORSCHE, PPG INDUSTRIES, conferences will PROCOAT TECNOLOGIAS, PSA PEUGEOT gather high-level CITROEN, RENAULT, SAMES TECHNOLOGIES, international experts SOCOMORE, TATA STEEL, TOYOTA MOTOR to discuss and gain CORP., VERIND, VOLKSWAGEN, VOLVO CAR insight on a global CORP., ZELLER ET GMELIN GMBH & CO KG... vision at this world 2 Want to join? renowned congress For more information: http://cannes. with speakers Figure 2: 2-days conference of high level technical and prospective will surcarcongress.com coming from all take place during SURCAR Cannes 2017.

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his year Scandinavian Coating 2017 took place at Øksnehallen in Copenhagen, Denmark. Øksnehallen is a stunning building, situated in the heart of the lively old meat district in the centre of Copenhagen (Fig. 1). Scandinavian Coating had over 70 exhibiting companies and organizations and 1 328 visits over two days. The exhibitors came from countries such as Italy, France, Poland and Germany, to name but a few. There were also visitors from 12 countries, a trend that has shown an increase in recent years (Fig. 2). Scandinavian Coating is the Nordic’s foremost meeting place for the Scandinavian coating industry and is an established concept with an exhibition showcasing the latest innovations to hit the market, along with a thorough two-day programme of free

Big Success for Scandinavia’s Only Comprehensive Surface Treatment Exhibition

1 Figure 1: Øksnehallen is a stunning building in the centre of Copenhagen.

seminars providing an educational and fascinating insight into the very latest developments in the industry. In addition to the exhibition and seminars, there were also an industry get-together with dinner and an opportunity to mingle with colleagues in a relaxed atmosphere at the Carlsberg Brewery. It was a very successful event with satisfied exhibitors and visitors. In 2019 Scandinavian Coating will be back again. For more information: www.scandinaviancoating.com

Figure 2: The visitors came from 12 countries, a trend that has shown an increase in recent years.

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The Middle East Region Is on the Right Track to Becoming the Leader in the Aluminium Industry

more on recycling end-of-life aluminium scrap and bringing more attention to the circular economy. “We are looking to become one of the largest downstream aluminium facilities in the region, with our new project that allows us to recycle scrap metal into useful liquid metal and reuse for production, bringing down the costs of the overall production. Our re-melt facility will be capable of producing 120,000 metric tonnes per year of cast slab product in a sustainable yet productive way.” said Ahmed Farah, Supply Manager at GARMCO, Bahrainbased aluminium producer for sheet and coils. “To achieve a strong growth in the global market, companies need to look into a joint effort to formalize

luminium experts believe the region is on the right track to achieving its goal for expected global demand for aluminium to reach 70 million metric tonnes per year by 2020 and becoming the leader in the growing metal industry. Speaking at the Aluminium Middle East Summit, panellists discussed how the growth in demand for aluminium products and technologies has had an increasing impact on the overall industry production. In order to meet the high demand and benefit from the market, aluminium companies must diversify their downstream product portfolio to include added value products like automotive and high-grade products. In addition, companies must look into expanding their casting capabilities and upgrading their equipment to reduce metal cost by focusing

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trade barriers on aluminium import and export businesses within the GCC. By doing so, the aluminium industry can take advantage of the regional demand, boosting the overall economy, and meeting the government’s Industrial Strategy,” he added. Dubai government’s 2030 Industrial Strategy, which has aluminium and fabricated materials as one of the six sub-sectors, will help create an environment for international and local investments and help with the development of the economy while providing a platform for knowledge and innovation. As one of the leading world producers, especially in the manufacturing of upstream products, Dubai is also looking to expand and gain competitiveness in the aluminium downstream industry and becoming the preferred platform of choice for global manufacturing.

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right dialogue between world experts in order to become the world leader in the aluminium industry. The show has been able to gather international thought-leaders from around the world strengthening its position as the leading event for aluminium industry.” Launched in 2009, Aluminium Middle East brings together international industry front-runners including producers, manufacturers and processors of raw materials and end products made with aluminium components, as well as suppliers

Speaking about the event, Daniyal Qureshi, Group Exhibition Director of Reed Exhibitions Middle East, the official organizers of Aluminium Middle East said, “The region is establishing the right strategies and facilitating the

For more information: www.aluminium-middleeast.com

5 © ipcm ®

of technologies and accessories for aluminium production, processing and refinement. The biennial event is expected to take place again in 2019.

More than 150 exhibitors, and over 3,000 industry professionals, from over 73 countries attended the Aluminium Middle East, the biggest gathering for aluminium professionals, to provide strategic insights and highlight ways in which the region can reach its goals. They were various Italian company, included ipcm Magazine (Figs. from 1 to 8). The event ran in conjunction with the Middle East Aluminium Summit where international and regional industry leaders provided market insights and recommendations for the sector. Panellists speaking at the summit stressed the importance of recycling aluminium within the region, UAE alone consumes 500 million beverage cans every year and out of which only 5 per cent is recycled while the rest goes to scrap dealers or landfills.

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Global Coatings Innovation Summit Networking! Exhibition! Conference!

he Curtis & Wyss Group is pleased to invite you to the «Global Coatings Innovation Summit» scheduled on September 11-12, 2017 in Berlin, Germany. Top Experts from Leading Companies will be sharing the latest need-to-know techniques and business information to improve your company’s efficiency and productivity. This premier B2B event will enable the participants to learn about the most advanced and tools through which they can assess their portfolios and development potential along with strategies on preventing potential risks.

5 Reasons Why you should be there? - Network with VPs, Directors and Managers of Coating Technology - Understand key drivers and future opportunities for Global Coating Technology Application Market - Implement the best strategies of the Coating Technology - Learn about new technologies for Coating Technology - Interact and connect with some of the most innovative minds in the industry. Curtis & Wyss look forward to welcoming you in Berlin! For more information: www.curtiswyss.com