ipcm® n. 53 - September/October 2018 by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

ISSN 2280-6083

ipcm digital on In this issue :

www.myipcm.com

SPECIAL ALUMINIUM 2018

INTERNATIONAL PAINT&COATING MAGAZINE

9th Year - Bimonthly N° 53 - SEPTEMBER/OCTOBER

MACCHINE, IMPIANTI, ATTREZZATURE PER LA LAVORAZIONE DI LAMIERE, TUBI, PROFILATI, FILI E CARPENTERIA METALLICA. STAMPI. SALDATURA. TRATTAMENTI E FINITURA. SUBFORNITURA. ROBOT, AUTOMAZIONE E TECNOLOGIE ABILITANTI. MACHINES AND EQUIPMENT FOR THE MACHINING OF SHEET METAL, PIPES, SECTIONS, WIRE AND METAL STRUCTURAL WORK.

1 5 - 1 8 /0 5 / 2 0 1 9

DIES. WELDING. TREATMENTS AND FINISHING. SUBCONTRACTING. ROBOTS, AUTOMATION AND ENABLING TECHNOLOGIES.

LA FORMA DELLE IDEE THE SHAPE OF IDEAS

Promossa da Promoted by

UCIMU-SISTEMI PER PRODURRE

Media Partner

065/2017 LMRX17R

soil

metals

snow

water

space

precious

flora

born iconic

A look ahead into the future of the Architectural Coatings Industry. Top Quality Collection J 20.20 includes 35 iconic colours carefully selected for their timeless appeal. The collection is divided into 7 Elements, representing the same number of facets of taste. Each Element consists of 5 easily matching colours. Available in pastel colours, textured ďŹ nishes and metallic effects for the broadest range of applications.

CONTENTS SEPTEMBER/OCTOBER 2018

SP EC IA L A L U M INIU M

SP ECIAL ALUMIN IUM

FOCUS ON TECHNOLOGY

From a Compact Vertical System to the Most Advanced Technology in the Aluminium Profile Coating Field: The History of AluK GB

FOCUS ON TECHNOLOGY

Muskita Aluminium Industries: Quality from the Starting Point

SP EC IA L A L U MINIU M

S P ECIAL ALUMIN IUM

FOCUS ON TECHNOLOGY

78 05 06 14 16

FOCUS ON TECHNOLOGY

ALMECO: The First Zero Liquid Discharge Water Treatment Plant in the World Installed on an Anodic Oxidation Line for Aluminium Coils

EDITOR’S LETTER

BRAND-NEW

BRAND-NEW INNOVATIONS: PRESENT&FUTURE The New Industrial Districts

FOCUS ON TECHNOLOGY

39 62

ON THE ROAD TO ipcm N. 53

SPE C IAL AL U MIN IUM

HIGHLIGHT OF THE MONTH Chemetall: Your Leading Global Supplier of Applied Surface Treatment Solutions

FOCUS ON TECHNOLOGY The Rotamat at Interseals: The Spring Board For Opening New Markets

ADAPTA: Improving your “Modus VIVENDI®”

18 24

Advanced Technology, Process Renewal, and Industrial Research on Pre-Treatment: Luxe Coat’s Strategy for Its Business Relaunch

Eliminating Process Steps, Increasing Quality. Manufacturer of SMC Housings Relies on FreiLacke’s PIMC Process

SUSTAINABILITY

HIGHLIGHT OF THE MONTH

FOCUS ON TECHNOLOGY Deep Collaboration with the Paint Supplier to Diversify Production and Ensure High Quality: The Winning Strategy of Lacoviana

Expand your architectural options with the colour shades of the new

Magnifica collection

international@ripol.com

CONTENTS SEPTEMBER/OCTOBER 2018

SP EC IA L A L U MINIU M

FOCUS ON TECHNOLOGY

INNOVATIONS: PRESENT&FUTURE

Metra Color: an Italian History of Quality and Innovation in Powder Coating to Conquer the US Market

114

Shot Blasting of Extruded Aluminium Profiles: Aesthetic Quality with Time and Cost Savings

110

S P ECIAL ALUMIN IUM

SP EC IA L A L U MINIU M

FOCUS ON TECHNOLOGY

124 74 76

BRAND-NEW

106

SUCCESS STORIES

122 136 142

FOCUS ON TECHNOLOGY

144

151 154

BRAND-NEW SUCCESS STORIES

SUSTAINABILITY

BRAND-NEW STANDARD & LEGISLATION - UCIF INFORMS Cybersecurity Act and Industrial Applications: Taking Stock of the Situation

BRAND-NEW

Electric Vehicles from Sokon Will Be Painted Using Highly Flexible Seven-Axis Robots

INNOVATIONS: PRESENT&FUTURE Qualicoat & Qualanod: latest eco-friendly developments for aluminium pre-treatment

New Technical Centre For Powder Coating Strengthens Karl Bubenhofer’s Market Position

Chromium-Free Pretreatment at ELVIAL. A Review of 18 Successful Years

SUCCESS STORIES

Framery in the Pursuit of Happiness with Teknos’ INFRALIT PE 8317-10 Powder Coating

134

All.co Group: A Wide Choice of High-Quality Finishes and Colours from a Well-Established Company

Tonon Forty Launches Its New Line of Radiators “Colors Vintage”, with Finishes Dedicated to Vintage Products and Created with Arsonsisi Powder Coatings

HIGHLIGHT OF THE MONTH

156 158

TRADE FAIRS & CONFERENCES ZOOM ON EVENTS

ARCHITECTURAL COATING SOLUTIONS

VISION 2020 PALETTE INSPIRED BY GLOBAL COLOR TRENDS LASTING PERFORMANCE TO ENDURE THE ELEMENTS EXCEPTIONAL COLORS Vision 2020 includes superior-performance architectural coating colors carefully selected by Sherwin-Williams’s color experts.

• Color palette creates a lasting impression • Excellent color consistency • Suitable to residential and monumental building design • Color trends orientated to future global development OUTSTANDING PERFORMANCE All Vision 2020 powder coatings fully comply with the criteria and standards set by the Quality Associations: GSB Master and Qualicoat Class 2

• Exceptional exterior durability • Remarkable abrasion resistance • Reduced cleaning frequency

zonamista.it

If you are interested in the Vision 2020 brochure of 48 colors, please send an e-mail to: inver@sherwin.com

Syntha Pulvin is a brand of The Sherwin-Williams Company www.synthapulvin.co.uk

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

uality is the ability of a product or service to meet customer needs, requirements, and expectations. It is not an inherent property, but rather it should be defined, applied, and controlled. What does it mean

to produce quality? It means applying well defined methods and sharing a vision. It means using quality operational tools, procedures, people, and skills. It means working with a system that balances all these elements. Quality is therefore the set of factors through which a company creates a product or service that meets effectiveness and efficiency requirements, i.e. customer requests, by optimising the resources used. Quality is a system and it should be pursued as such, through quality raw materials, staff training, and product certifications. This issue of ipcm® includes a large section devoted to the aluminium treatment and finishing fields and it will be distributed at the Aluminium 2018 fair in Düsseldorf (Germany). The interviews included present a few common threads that we would like to share here. First of all, what is the point in certifying a treatment phase and boasting that certification, if inadequate processes or materials are used at the previous or subsequent process stages? Speaking of aluminium, how much does the quality of metal or of the applied paint affects products’ compliance with certifications? In order to offer truthful outdoor resistance guarantees, would it not be more useful to certify a whole treatment cycle rather than just one phase? Secondly, simplifications should be avoided to produce quality. Speaking again of aluminium, the ban of chromium (VI) paved the way to numerous chrome-free alternative solutions that can be combined with a greater or lesser number of previous treatments. Some companies choose a pre-treatment process with acidic phases only, others opt for a combination of acidic and alkaline phases, and others prefer the oxidation flash technology. All these solutions are valid if considered individually, but the choice should be made based on the quality level of end products and not on criteria such as ease of management or investment size. Thirdly, water treatment greatly affects process quality. Purifying and recycling water is not only an eco-friendly choice. If well conceived, it enables to keep the process parameters constant and well balanced. In other words, it creates quality. You will find that all the topics outlined above are further developed in the next pages. This issue however also includes interesting and exclusive contents on the use of powder coatings, new colour collections available, low environmental impact innovations to pre-treat aluminium prior to coating and oxidation, recovery solutions for solvent-based paints, anti-friction coatings, and new resins to formulate better powders for the finishing of heat sensitive substrates. Quality should be perfected with practice and be specifically aimed at a purpose: offering a higher quality than that required is a waste of resources; offering a lower quality certainly leads to disputes.

Alessia Venturi Editor-in-chief Direttore Responsabile

As a publishing company ourselves, we share the mission of a great international publishing house called Condé Nast: Quality is our business plan.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

Opening photo: Regent Paints oﬀers a program of reusability of the batch failures, obsolete materials, gelled batches, washed solvents, mistints, customer returns, non-usable and nonsalable raw materials or paints of all type.

ANALYSIS

Hazmat Waste Put to Use. A Re-use Solution for Solvent-Based Paints and Raw Materials Huzaifa Matawala

he paint industry has entered into an

challenging for research and development

industry have changed more rapidly in the

era of continuous enhancement of

teams to create ecofriendly paints with

past decade than ever before. The process of

chemistry from various perspectives,

acceptable cost and product performance.

change results in several batches, raw materials

including customer requirements, costs,

Every year, several formulations are edited,

and stock items that need to be replaced with

environment, durability and reach. It is always

and product is enhanced. Formulations in our

newer ingredients. The more we evolve into

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

ANALYSIS

newer formulations, the more raw material and

based formulations have not reached several

• sorting, batch making and production.

stock inventory that is no longer usable to the

countries across the globe, and traditional

Solvents play an important role in recycling

industry. We leave behind failure batches and

solvent-based coating systems still provides an

paints and resins, as they determine the

obsolete raw materials.

essential coating solution worldwide.

compatibility and the recycling family “house”

The company has successfully reached

the paint or resin will go to. If we initiate a

Purpose

solutions for the reuse of latex-based paints.

manufacturing process without a proper

With industry experience with different type of

With every passing year Regent Paints is able

understanding, we risk having non-favourable

resins, pigments, additives, solvents and paints,

to convert more and more cans of latex paint

batches. Material may turn into cake-like

Regent Paints offers a program of reusability

into a new recycled product. The company has

formations, lumps, chips, harden like rock or

of the batch failures, obsolete materials, gelled

several projects for procuring the latex paint

lose viscosity. Successful recycling is based on

batches, washed solvents, mistints, customer

cans from the market, homes, industries and

the study of the molecular structure, boiling

returns, non-usable and nonsalable raw

counties. These paints are used for producing

point, dispersing ability and density of the

materials or paints of all types (ref. Opening

stucco, plasters, driveway sealers and recycled

solvent used in paint or resin.

photo). The attempt is to reduce the waste

latex-based paints. This article will also

generation from the factory process itself by

discuss the paint process, how it effects the

Solvent and Resin Compatibility

finding use for the items into Regent Paints’ line

environmental system and how the reuse of

Hansen Solubility Parameter Values

of products. Once the chemistry, ingredients,

oil paints offers both economic and ecological

Hansen solubility parameter values are based

compatibility, resin and solvent nature are

benefits.

on dispersion bonds (δD), polar bonds (δP)

ascertained, the reuse of the items can be

and hydrogen bonds (δH). These contain

ascertained.

Process

This article shares data and possibilities on

Important things to consider with solvent-based

interactions with other solvents and also with

working with oil paints and solvents. There

paints and resins include:

polymers, pigments, nanoparticles, etc. This

is an extensive use of oil paints and solvents

• solvent and resin structure, compatibility,

allows for rational formulations knowing, for

internationally. Advanced, ecofriendly, water-

information about the inter-molecular

example, that there is a good HSP match

density and boiling point;

Table 1: Comparing nonpolar, polar aprotic and polar protic molecules to determine compatibility.

Solvent

Chemical Formula δD Dispersion NONPOLAR SOLVENTS

δP Polar

δH Hydrogen Bonding

Hexane Benzene Toluene Diethyl ether Chloroform 1,4-Dioxane

CH3CH2CH2CH2CH2CH3 C6H6 C6H5-CH3 CH3CH2-O-CH2CH3 CHCI3 /-CH2-CH2-O-CH2-CH2-O-\

0.0 0.0 1.4 2.9 3.1 1.8

0.0 2.0 2.0 4.6 5.7 9.0

Ethyl acetate Tetrahydrofuran(THF) Dichloromethane Acetone Acetonitrile (MeCN) Dimethylformamide(DMF) Dimethyl sulfoxide(DMSO)

CH3-C(=O)-0-CH2-CH3 /-CH2-CH2-O-CH2-CH2-\ CH2CI1 CH3-C(=O)-CH3 CH3-C=N H-C(=O)N(CH3)2 CH3-S(=O)-CH3

5.3 5.7 7.3 10.4 18.0 13.7 16.4

7.2 8.0 7.1 7.0 6.1 11.3 10.2

Acetic acid n-Butanol Isopropanol n-Propanol Ethanol Methanol Formic acid Water

CH3-C(=O)OH CH3CH2CH2CH2OH CH3-CH(-OH)-CH3 CH3CH2CH2OH CH3CH2OH CH3OH H-C(=O)OH H-O-H

8.0 5.7 6.1 6.8 8.8 12.3 10.0 16.0

13.5 15.8 16.4 17.4 19.4 22.3 14.0 42.3

14.9 18.4 18.0 14.5 17.8 17.5

POLAR APROTIC SOLVENTS 15.8 16.8 17.0 15.5 15.3 17.4 18.4

POLAR PROTIC SOLVENTS 14.5 16.0 15.8 16.0 15.8 14.7 14.6 15.5

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

between a solvent and a polymer. Rational substitutions can also be made for “good”

Table 2: The boiling points of various solvents.

solvents (effective at dissolving the solute)

Solvent

Boiling point (°C)

or “bad” solvents (expensive or hazardous

ethylene dichloride

83.48

to health or the environment). Table 1

pyridine

115.25

shows that the intuitions from nonpolar,

methyl isobutyl ketone

116.5

polar aprotic and polar protic molecules

methylene chloride

39.75

are put numerically – the polar molecules

isooctane

99.24

have higher levels of δP and the protic

carbon disulfide

46.3

solvents have higher levels of δH. Because

carbon tetrachloride

76.75

numerical values are used, comparisons can

o-xylene

144.42

be made rationally by comparing numbers. For example, acetonitrile is much more polar than acetone, but exhibits slightly less hydrogen bonding. When studying the detailed characteristic properties of the solvent bond with resin, pigment metals and fillers, we can ascertain the use and breaking of such bonds into newer or similar products for use. For example, toluene and benzene are more compatible with xylene than mineral spirits. However, xylene is compatible with mineral spirits as well. Certain solvents are soluble with each other, some are soluble only to an extent and some are non-soluble. When reacted with resins and pigments, solvents change the loyalty towards their “house,”

Sorting, Batch Makings and Productions

The intention is to have a final brand of such products in the market from local facilities. The use of these coatings is minimal in developed countries, but can serve as a major help in the economies that need infrastructural development. The infrastructural zones of developing countries can be served with these durable, eco-friendly products that are created from solvents and oil paints.”

becoming more compatible most of the time.

compatibles together, we sort the materials on the basis of sheen, color, density and gloss. Depending on the inventory, the products with common sheens, colors and densities are mixed together into batch sizes as an intermediate pulp. This is an important ingredient mix check stage, where pulp is created from the oil paint, resin, solvent, pigment or waste/scrap/lots. These pulps are usually made keeping in mind the usability for the final product. We again check the pulp batches on the final gloss and resin/solvent/ pigment/filler ratio on the basis of density, hardness, gloss, weight and viscosity.

The use of additives, extenders and fillers plays an important role.

Once we have classified the groups of

We finally craft final product batches of Density

floor paints, primer paints, stucco items,

Most organic solvents have a

texture coatings, topcoats, bitumen paints,

Boiling Point

lower density than water, which means

etc. All the formulations, blends, processes

The boiling point is an important

they are lighter than and will form a layer

and other ingredients remain an important

property because it determines the

on top of water. Important exceptions

part of chemistry. These various products

speed of evaporation. Small amounts

are most of the halogenated solvents

are served in several brands and markets.

of low-boiling-point solvents like diethyl

like dichloromethane or chloroform, which will

Regent Paints is able to serve the markets

ether, dichloromethane or acetone will

sink to the bottom of a container, leaving water

with a final recycled product that saved

evaporate in seconds at room temperature,

as the top layer. This is crucial to remember

many important ingredients from land

while high-boiling-point solvents like

when partitioning compounds between

burial or fuel blending. These products

water or dimethyl sulfoxide need higher

solvents and water in a separator funnel during

are also created without the extraction of

temperatures, an air flow or the application

chemical syntheses.

resources, resulting in energy savings, which

of vacuum for fast evaporation (Table 21).

Often, specific gravity is cited in place of density.

is environmentally beneficial.

• Low boilers: boiling point below 100 °C

Specific gravity is defined as the density of the solvent divided by the density of water at the

Scope

• Medium boilers: between 100 °C and 150 °C

same temperature. As such, specific gravity is a

The scope of recycling is based on the

• High boilers: above 150 °C.

unitless value. It readily communicates whether

requirements of paint reuse projects,

a water-insoluble solvent will float (SG < 1.0) or

cost/financial benefits, and research

sink (SG > 1.0) when mixed with water.

and development.

(boiling point of water)

Solvent Properties – Boiling Point Archived 14 June 2011 at the Wayback Machine. Xydatasource.com. Retrieved on 2013-01-26.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

ÂŠ Regent Paints

ANALYSIS

Figure 1: Programs that receive latex paint.

Recycling and Utilization of Latex-Based Paints Compared to Oil-Based Paints Figures 1-4 show the opportunity to fill the gap between collection and reutilization. A project can be created for savings in the cost of disposal and the cost of manufacturing oil paints. This data was obtained from results of a DNR/DATCP survey, conducted summer 2015 (Wisconsin State). Costs and Benefits of Reusing Oil Paints Table 32 gives an example of the approximate cost of disposal of paintrelated items. In all calculations the cost of disposal of the products is included. As an environmental lifecycle calculation, the cost of solventbased paint on extraction is about twice the cost of disposal. https://admin.ks.gov/docs/default-source/ofpm/procurement-contracts---adds/tradebe-treatment-recycling.pdf?sfvrsn=2

ÂŠ Regent Paints

2 1

Figure 2: Disposal methods for latex paint.

3 1

4 1

Figure 3: Bulk waste streams.

Figure 4: Disposal methods for oil-based paint.

The process and cost of making paint

Patent Products, Research and Processes

The intention is to have a final brand of such

from scratch is saved when paint is

Regent Paints has performed detailed

products in the market from local facilities. The

reused.

scientific studies over several years. It

use of these coatings is minimal in developed

For example, when making paint,

has been working in the industry for

countries, but can serve as a major help

resins are cooked in a reactor with

five decades, and now has presence in

in the economies that need infrastructural

amines, natural agricultural oils,

recycling, paint manufacturing and raw

development. The infrastructural zones of

phallic anahydrides, penta, maelic

materials on multiple continents. The

developing countries can be served with

and monomers. The process utilizes

company was able to patent with the United

these durable, eco-friendly products that are

energy, resources, power and rare

States Patent and Trademark Office with oil

created from solvents and oil paints. There are

blends of nature. If we are able to reuse the paint, we save the ingredients and the energy that

BULK WASTE STREAMS

would have been spent creating

Type 1 Bulk Halogenated 2 Bulk Non-Halogenated* 3 Paint Waste 4 Ink Waste 5 Lab Wastes 6 Bulk Corrosive Liquids 7 Filter Waste 8 Mud Pit Wastes 9 Bulk Solids or Liquids (HAZ)

those raw materials. Additionally, when we fuel blend these items in fire, we are unable to save them. The cycle of generation of newer resins, solvents, metallic driers, pigments, additives, etc. has to take place. We have to extract more gums from more trees, erode more mountains

markets who use these items as

Table 3: Bulk waste streams.

economical coatings to protect items. Quantity 55 gal 55 gal 55 gal 55 gal 55 gal 55 gal 55 gal 55 gal 55 gal

9.1 Bulk Solids or Liquids (nonhaz) 55 gal

Cost $129.38 $74.52 $108.68 $98.33 $175.95 $175.95 $155.25 $112.82 $263.93 $87.98

for minerals, and extract the oils from the sea to create specialty

* Bulk Non- Halogenated: >5000 BTU’s and <5% Chloride

Disposal Fuel Blend Fuel Blend Fuel Blend Fuel Blend Treatment Treatment Recycle Treatment Stabilization/ Landfill Stabilization/ Landfill

Regent Paints produces bitumen paints and several coatings that use lower-end resins and solvents in the formulations. Such primers serve as an undercoat. The company has also formulated several primers for wood and metals. It has listed technical data sheets with the ministry of Kuwait with the element of alkyds and its CAS details as a part of the new formulation. These products have been tested in the market.

monomers and hydrocarbons to attain solvent-based paints. Such

paint recycling and Regent Recycling dollar

Fuel blending may be appropriate with other

savings offers much more in value and

concept of free paint against recycling, with

petrochemicals, oils or flammable items.

utility than the fuel blending properties

a vision to initiate a process of oil paint

Solvent-based paints like alkyd enamels,

a paint can provide. Also, in most cases

reuse and recycling. The patents cover a

stains, ink products, primers, paint thinners,

certain grades of paint do not help the

total program of recreating a product form

tank washing solvents, alkyd resins, epoxies,

burning process, and in fact hamper

solvent-based items at the same cost of

hardeners, etc., can be reutilized, saving costs,

the fuel blending costs.

latex recycling.

ingredients and the environment.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

SUSTAINABILITY

Sustainability of Interpon Powder Coatings Confirmed by EPD Renewal

environmental performance of a product

The EPD system looks at all ingredients

supplier of powder coatings to have

throughout its lifecycle, enabling customers

and process steps in the manufacturing

the quality of its products verified by

to better understand a productâ&#x20AC;&#x2122;s sustainable

of a product, and measures the impact on

an Environmental Product Declaration (EPD).

qualities and ultimately make more informed

the environment. For example, if a wax is

The international EPD reveals the

product selections.

made in Thailand and exported to Sweden

ÂŠ AkzoNobel

kzoNobel is the only major global

Figure 1: EPD certifications are increasingly requested in the construction industry, as architects and building owners want their projects to be recognized as environmentally-friendly.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

SUSTAINABILITY

it scores less than a wax made locally in Sweden, as a result of the CO2 generated by its transport. Similarly, if a material contains a

high amount of solvent, its impact on the ozone layer will be higher than a solvent-free product. Having first undertaken the complex process in 2015, AkzoNobel was the first global powder coatings supplier to obtain the declaration. The renewed EPD for its Interpon D range of architectural powder coatings (D1000, D2000 and D3000) lasts until 2023. The results show an improvement on the previous score and highlight various factors that are contributing to lower environmental impact, including a reduction in both waste and energy usage. “In retail markets nowadays, it’s almost unthinkable that a product would not have its origin and ingredients printed on the packaging” said powders’ Architectural Segment Manager, Jean-Paul Moonen, “yet in industrial goods it is still a new concept to ask about the origin of the ingredients. Environmental Product Declarations (EPD) are a first step on the way to change this.” Among a plethora of green and eco-labels which are not independently controlled, EPDs stand out as a trusted benchmark. The factors to be included, and how to measure them, are controlled by an international ISO standard, and so are comparable from country to country, region to region and between different suppliers. Third-party verified EPDs are the gold standard, as they prevent manufacturers from making false claims. There are several recognition schemes, with LEED being among the leading ones. Using products with an EPD gives LEED credits, and more credits lead to higher LEED ratings (from Bronze to Platinum). “EPDs are increasingly requested in the construction industry, as architects and building owners want their projects to be recognized as environmentally-friendly” continued Moonen. “Powder is an inherently sustainable product, as it does not contain VOCs, but this is another step in offering our customers sustainable coatings solutions, so I’m very proud of this EPD certification for our Interpon D series.” AkzoNobel supplies powder coatings to more than 30,000 customers worldwide, covering several market segments. The company’s products are used on buildings and landmarks around the world, including La Sagrada Família (Barcelona, Spain); the Shard (London, UK); and the Water Cube (Beijing, China). For further information: www.interpon.com

BRAND-NEW

Arsonsisi’s New e-commerce Website is Online. Innovation at Hand! otally revamped in its graphics

Customers ordering Arsonsisi coatings benefit from the

and navigation

paths, Arsonsisi’s new

same advantages as

e-commerce website

when they use the

has been designed and

main e-commerce

developed to improve

sites for private

the user’s experience

purchases: cheaper

and make online

prices and reserved

order acquisition and

promotions, access

management easier.

to their customer

4 years after its launch,

accounts to check

Arsonsisi presents a

their order and

more modern and

invoice history,

functional version for

simple and fast

the e-commerce of its

order processing,

powder coatings, capable

easy access when

of enhancing the user’s

using mobile devices

shopping experience.

and safe payments.

“Arsonsisi first introduced

Arsonsisi’s

the powder online

e-commerce website

purchasing service in

is also a support tool

Italy in 2014. It was a

for customers’ daily

courageous choice,

activities, since, on

motivated by the

each product page,

subcontractors’ request for more flexibility and autonomy in order management”, states

they can immediately

find the information on the preparation

Figure 1: Home page of the new e-commerce of Arsonsisi.

and application of the coating and can

Cristoforo Brendas, Powder Coatings Business Manager Italy.

explains Luca Troiani, Powder Coatings

download the technical sheets of all the

The new e-commerce website has

Area Manager Italy and Project Leader

codes on the online catalogue at any

been realised by Overweb, an IT and

for Arsonsisi’s new e-commerce

time.

web services company from Milan, with

website. “Apart from the graphics

The service is currently available to

Magento, one of the best and most widely

and design, the improvements

purchase only powder coatings in Italy,

used open source CMS that offers many

affect mainly the navigation path,

but Arsonsisi is planning to extend it also

functions for the development of online

order management process and

abroad and to the sale of other industrial

purchasing platforms.

optimisation of internal search with

painting lines.

“The digital world is constantly evolving

clearer and more intuitive filters for

and it is important to keep up to date with

colour, price, finishing effect and

For further information:

the times if you want to be competitive”,

chemical nature.”

www.arsonsisisi.com

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

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HIGHLIGHT OF THE MONTH

ADAPTA: Improving your “Modus VIVENDI®” David Pellicer Adapta Color SL, Peñíscola, Spain

adaptacolor@adaptacolor.com

he VIVENDI® collections of

the capacity of self-ignition under the

In relation to rail transport, the VIVENDI®

Adapta® comprise a wide range

effects of high temperatures, as well

collections have obtained the classifications

of colours and finishes which

as its subsequent behaviour regarding

R1HL3 and R7HL3 according to the European

combustion or flame.

standard UNI-EN 45545-2:2013+A1:2016

are at the forefront of powder coatings

• Smoke emission and opacity:

for architectural purposes. Developed

“Railway applications. Fire protection on

with new innovative materials and

assessment of the amount and size of

railway vehicles.” Its purpose is to reduce the

manufactured with state-of-the-

solid particles in suspension generated

risk of generating a fire, control its spread and

by the combustion of materials.

its extinguishing, as well as minimising the

art technologies, they imbue a high

• Falling droplets or particles: estimate of

performance to products that makes

damage that products generated during the

them ideal for use in the most demanding

the amount of inflamed droplets that can

fire (heat, smoke and toxic gases) cause on

applications and situations.

contribute to the spread of the fire.

passengers and crewmembers.

Its high light reflective capabilities and

The classification of VIVENDI products is

In its pursuit to increase maritime safety

the impressive chromatic effects make

as follows: A2, very limited contribution to

and prevent pollution, the European

these powder coatings an excellent tool

fire; s1, low smoke production and d0, no

Union requires that equipment installed

in the design of emblematic projects that

inflamed drops/particles are produced.

on board comply with certain safety

standards in terms of design, construction

require differing finishes together with

high quality standards. Its functional characteristics along with the different approvals from

and performance. Hence, the International Maritime Organization (IMO) and

accredited laboratories allow the

international and European

VIVENDI® collections to transcend

standards organisations have

just the architectural scope; enabling

developed detailed performance

use in other sectors such as maritime

and testing standards for some

and rail transport. In addition, it

types of marine equipment

contributes substantially to greater

included in European Directive

safety in transport, comfort and

2014/60/EU of July 23, 2014. For

sustainability, in short, improving our

compliance with this directive,

“modus VIVENDI®”.

VIVENDI® products have been

European Directive 89/106/CEE of

tested in accordance with IMO

December 21, 1988 for construction

Resolution MSC.307 (88)-(PEF

products establishes the regulatory

Code 2010) and comply with

framework for European standard

the requirements set out in

UNI-EN 13501-1: 07 + A1:2010 rating

section MED/3.18b of Annex 1

construction products and building

Part 5 of executive regulation

elements in accordance with their behaviour against fire (EUROCLASS). The products are rated in relation to three indicators: • Contribution to fire: defined as

EU 2018/773 dated May 15, 1

Figure 1: Its functional characteristics allow the VIVENDI® collections to transcend just the architectural scope, enabling use in other sectors such as maritime and rail transport.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

2018 where design, construction and performance requirements and test standards for marine equipment are developed.

HIGHLIGHT OF THE MONTH

exposed to an extremely high number of substances in very low concentrations, mainly due to the high proliferation of

Figure 3: When it comes to maritime safety and pollution prevention, VIVENDI® products are compliant with European Directive 2014/60/ EU of July 23, 2014.

In interior spaces, we can find ourselves

new materials in recent times. This wide group of substances, together with specific temperature and moisture conditions, usually make it difficult to predict whether they will be perceived as hazardous or rarefied, that is, of low quality. Adapta has proceeded to test the products of its VIVENDI® collections for architectural use according to

3 1

ISO 16000-9:2006 for the related to the environmental

Adapta Bonding System® technology

of volatile organic compounds

behaviour of the product based

that enables and ensures a

from construction products and

on its Life Cycle Analysis (LCA).

homogeneous optical effect, essential

furniture. According to the results,

The information is structured in

for use in emblematic projects or those

the company has received the A+

different impact categories (global

that require high quality standards.

distinction (very low emissions) for

warming, depletion of the ozone layer,

ADAPTA® can develop customized

the wall, ceiling, window and door

acidification, etc.) along with other

colours upon request.

decoration.

additional information such

The VIVENDI® collections have the

as produced emissions,

Environmental Product Declaration

generated waste, etc.

(EPD). The EPD collects in a

All the colours of the

transparent way, and verified by an

VIVENDI® collections

independent third party, information

incorporate the new

determination of the emission

2 1

Figure 2: In relation to rail transport, the VIVENDI® collections have obtained the classifications R1HL3 and R7HL3 according to the European standard UNE-EN 45545-2:2013+A1:2016.

BRAND-NEW

Touch the Colour With spectro2guide – Next Generation Colour Measurement by BYK-Gardner © BYK-Gardner

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

control of colour, appearance and physical properties - is introducing the new spectro2guide, the revolution in colour measurement. Like its predecessor, the new spectro2guide combines colour and gloss measurement in one instrument. Completely new, is the measurement of fluorescence to predict colour stability. Like a fluorimeter the fluorescent light can be detected using monochromatic illumination and for the first time ever an ΔEzero can be calculated to predict how the colour will change when fluorescence has degraded. This combination of a spectrophotometer with a fluorimeter opens up completely new perspectives to not only control colour harmony, but also to analyse the colour stability with measurement of fluorescence.

Figure 1: The new spectro2guide by BYK-Gardner combines colour and gloss measurement in one instrument.

Beside the combination of innovative measurement methods, the

operation and handling. Because of

calibration function. Thereby, the white

spectro2guide uses innovative,

its balanced and upfront design, the

calibration standard is always protected

high performance LED technology as

3.5” colour touchscreen is always in

and a reliable calibration is guaranteed.

light sources. Due to the outstanding

the right position and easy-to-read.

In addition, data transfer has never

performance of these LEDs, the

A perfect premise for the icon-based

been easier or more flexible. The

short-term, long-term and temperature

menu, which allows an intuitive smart

spectro2guide offers three possibilities:

stability as well as a homogeneous

phone like operation and the integrated

Via docking station or directly connected

illumination spot are unsurpassed in

camera, that shows a live preview

with USB cable or wireless with a Wi-Fi

the industry. As a result, a superior

of the measurement area to ensure

function.

accuracy and excellent inter-instrument

precise positioning and to prevent false

Raise your expectations and get ready

agreement allow the use of digital

readings on imperfections or scratches.

for the future!

standards.

As the first spectrophotometer on

This new high technology is

the market, the spectro2guide offers

For further information:

complimented by its easy-to-use

auto diagnosis and an automatic

www.byk.com/instruments

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

BRAND-NEW

A New Futuristic Headquarters for the Portuguese Plant Designer Solintellysys

Figure 1: The project of the new headquarters of Solintellysys, in the Parque Empresarial Do Casarão of Borralha.

ortugal 2020 is the partnership agreement

an indoor garden, a swimming pool, and a gym for

undertaken between Portugal and the European

employees.

Commission, which brings together the five

“We work constantly under pressure, because the

Structural and Investment European Funds (ERDF,

surface treatment market is demanding and it requires

Cohesion Fund, ESF, EAFRD, and EMFF) setting the

very tight delivery times. Our target market is also

programming principles that enshrine the economic,

vast, since we supply plants and machines throughout

social, and territorial development policy to be

Europe, Central and South America, and Africa: that

advanced in Portugal between 2014 and 2020. These

is why the physical and psychological well-being of

programming principles are aligned with the Smart,

Solintellysys’ team is crucial to our success,” says João

Sustainable and Inclusive Growth goals of the Europe

Figueiredo, the founder, owner, and general manager of

2020 Strategy. Under this program, Portugal is set to

the company. “Precisely the know-how and harmony of

receive 25 billion Euro until 2020 to stimulate growth

our team have enabled our company to develop to such

and job creation.1

an extent in just ten years, and my goal is to protect it

The impressive investment recently made by

and offer it the best.”

Solintellysys, a plant engineering company (Águeda

By 2020, Solintellysys intends to increase not only its

de Cima, Portugal) established in 2008 for the design

turnover but also the number of its employees, as well

and manufacture of highly efficient and advanced

as becoming among the ten leading European plant

technological surface treatment solutions, falls within the

designers. “The new headquarters will also include a

scope of Portugal 2020. Thanks to an investment of 11

large area dedicated to the industrial training of recent

million Euros, financed for about a third by the European

graduates in scientific and technical subjects,” states

Community, Solintellysys’ brand new headquarters

Figueiredo. “We have created a cluster with Bosch,

(Fig. 1) located in the Parque Empresarial Do Casarão

Siemens, and the Universities of Lisbon, Coimbra, and

in Borralha, a few kilometres from Águeda, will cover

Porto to create training events helping young people

an area of around 15,000 m2. It will feature a large

understand the industrial world and face the world of

production area equipped with the latest production

work with greater preparation.”

technologies (laser cutting, bending, welding, etc.),

Solintellysys’ new premises will be inaugurated by the

a large technical and design office, meeting rooms,

end of 2018 to celebrate the company’s ten-year history.

training areas for employees and customers, and even For further information: 1

https://www.portugal2020.pt/Portal2020/o-que-e-o-portugal2020

www.solintellysys.com

BRAND-NEW

ÂŠ AGTOS

Shot Blasting Power Also For Large Steel Beams

Figure 1: The AGTOS roller conveyor shot blast plant RT 15 for processing steel profiles and metal sheets.

he quality of surfaces is

the exhibition booth at the Euroblech

becoming more and more

2018.

Functioning of the roller conveyor shot blast plant

important. Users are paying

The passage width is 1.500 mm. Thus, the

The work pieces will be supplied to the

more attention to economical

shot blast plant can treat steel beams up

machine via a roller conveyor. They pass

concepts and the aspect of time

to a width of 1.100 mm and a height of 420

a switching threshold installed in front of

when it comes to shot blasting.

mm. Rust and scale will be removed reliably.

the inlet sluice. This threshold releases

Large steel beams are used more

Furthermore, this machine type is also

the automatic supply of abrasive to the

and more often. Depending on the

suitable for the treatment of metal sheets.

running high performance turbines. By

condition of the beams, the shot

The max. sheet width is 1.500 mm.

means of this measure, it is made sure

blasting process is very complex. In

In case smaller parts shall be processed,

that the blasting only takes place when

order to solve this task, AGTOS is

appropriate wire baskets are available.

there are work pieces in the blasting

offering a powerful roller conveyor

The machine shown at the exhibition is

area. This limits the wear and tear of the

shot blast plant (Fig. 1). This

part of a product series which is offered in

machine and saves energy and abrasive

machine type will be exhibited at

different sizes.

media.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

Una nuova generazione di prodotti bucciati! La nuova formulazione offre prodotti in grado di coprire con facilità i difetti del substrato metallico, grazie a una buccia più uniforme, un utilizzo industriale più versatile e un maggior risparmio energetico. La temperatura di reticolazione di 150° C ha permesso di diminuire il tempo di cottura dei pezzi e migliorato la produttività dei nostri clienti. • Bucciatura uniforme in tutte le tinte • Migliore copertura dei difetti, spigoli e punti di taglio • Versatilità d’impiego (diverse geometrie e dimensioni) • Temperatura di reticolazione rapida (150° C) • 50 nuovi colori • Ridotto impatto ambientale

marketing.italia@akzonobel.com www.interpon.it

I prodotti Interpon di AkzoNobel sono amici dell’ambiente

Le ﬁniture a polvere sono prodotti chimici vernicianti privi di solventi, di VOC (Composti Organici Volatili) e di metalli pesanti tossici, come cromo o piombo. Questi sono da considerarsi come requisiti standard per tutti i prodotti Interpon di AkzoNobel che sono formulati per rispettare l’ambiente e la salute dei loro utilizzatori. Inoltre sono riciclabili, poiché l’over-spray può essere recuperato ﬁno al 99%, e la maggior parte dei prodotti Interpon di AkzoNobel richiede un minor impiego energetico in fase di applicazione rispetto ad altri sistemi vernicianti.

marketing.italia@akzonobel.com www.interpon.it

BRAND-NEW

The inlet sluice is sealed with easily replaceable and wearresistant rubber curtains in the upper part. They avoid the escape of abrasive and dust. The lower part is sealed by means of adjustable rubber lamellas which adapt to the contour of the respective work pieces. While passing the blasting chamber itself, the work pieces are blasted evenly and accurately. Four AGTOS high performance turbines with up to 22 kW have been provided for this task. They are distinguished by their high performance and long life times of the wear parts. In case of maintenance, they can be changed relatively quickly and easily. After having passed the blasting area, the work pieces reach the combined brush and blower unit. Here, the abrasive cleaned from the surfaces of the work pieces is returned to the abrasive circuit. In order to do this, the abrasive is collected in the hopper below the machine, forwarded by means of a screw conveyor and transported to the upper part of the machine by means of a bucket elevator. There, bigger particles are filtered out and small grain and dust are removed from the abrasive. The purified abrasive is led from the abrasive silo back to the high performance turbines by means of the abrasive control unit. The dust separation of the shot blast plant is realised by means of a cartridge filter. The filter has a fan which creates a negative pressure. A deflecting separator and filter cartridges with an appropriate medium clean the aspirated air. It is clean when it returns back into the factory hall. An additional filter provides double security.

Further topics at AGTOS exhibition booth AGTOS exhibition team will be happy to inform you about the different versions of the high performance turbines - the most important component of a shot blast machine - as well as their maintenance options. They reach a long service life also when using aggressive abrasive media. Examples of already produced machines will be shown and the best solutions for processing work pieces by means of shot blasting will be demonstrated.

The AGTOS booth at the EUROBLECH 2018 AGTOS will be at EUROBLECH exhibition, 23 - 26 October 2018, Hannover, hall 13, booth B141 For further information: www.agtos.de

BRAND-NEW

Encore nLighten LED Kit from Nordson – for continuous Quality Control during the Coating Process

he new Encore nLighten LED Kit

every operator the power to both spray and

projects a powerful LED beam from

inspect, reducing the need for post-coating

the manual spray gun onto the surface

quality checks. • Improve safety

being coated. Even in darkened working

Using un-rated potential ignition sources

environments, it facilitates uniform coating © Nordson

and enables the operator to reliably monitor surface quality already during application (Fig. 1). With 42% of customers surveyed claiming light paint coverage as their biggest cause for rejects and rework (Fig. 2). Especially under poor visibility conditions, even experienced coating

in airborne dust cloud environments is a Figure 1: Bringing light into the darkness – the Encore nLighten LED kit was developed for high quality assurance.

dangerous combination. Rated for use in all powder coating environments, you can trust the Encore nLighten LED kit to provide safe, reliable illumination in hazardous areas.

Easy to retrofit on all Encore manual spray guns

operators often fail to coat their workpieces uniformly. This usually results in rework and

simple LED unit effectively highlights deep

The nLighten LED kit mounts on the Nordson

raises reject rates.

recesses and cavities. Any imperfections

Encore manual spray gun in just five simple

The new Encore nLighten LED mounts easily

or missed areas are quickly identified and

steps.

to any Encore manual spray gun. It turns on

addressed by the operator on the fly.

Nordson’s Encore spray gun range is already

automatically with the start of the spraying

• Reduced material waste

the best performing and most respected in

operation and remains on for an additional

In dark or dusty working environments,

the powder coating world, with many operator

15 seconds after spraying stops, becoming

many operators ‘spray and pray’ due to poor

benefits. With the addition of the Encore

brighter for even more precise quality control

visibility. Optimum light levels enable precisely

nLighten LED Kit, users can add powerful, safe,

(Fig. 3).

targeted powder application to reduce waste

lightweight, and controllable illumination to its

and save on material costs.

impressive list of capabilities.

Using the Encoe nLighten LED Kit, powder

• Increased efficiency

coaters benefit from: • Reduced or eliminated rejects or rework

For further information:

application and inspection tool, that gives

www.nordsoncoating.com/nlighten

Figure 2: Encore nLighten LED kit – light oﬀ. A typical working environment without lighting.

Encore nLighten LED is an all-in-one

The powerful light beam projected from the

2 1

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

3 1

Figure 3: Focused light beam for easy inspection during and after spraying.

BRAND-NEW

BASF Invests in a State-Of-The-Art Surface Treatment Site for its Chemetall Brand in Pinghu, China

he Surface Treatment global

solutions customers have come to expect

our customer support and supply chain to

business unit of the Coatings

from Chemetall. The site is ideally located

China. It will contribute to the expansion

division of BASF, operating under

at the Dushan Port Economic Development

of a broad global portfolio across multiple

the Chemetall brand, invests in a state-

Zone of Pinghu, which provides excellent

segments, with quality and environmentally-

of-the-art surface treatment site in the

infrastructure to this project.

friendly products and system solutions

Dushan Port Economic Development Zone

Asia Pacific is the largest surface treatment

for diverse market segments. These

of Pinghu, Zhejiang province, China.

market. “For Chemetall, a strong local

include automotive, auto components, coil,

The site – which is planned to be

presence in China is key to servicing our

general industry, cold forming, aerospace,

completed by 2021 – will house

customers and delivering on the ‘expect

aluminium finishing and glass,” adds Mike

production, warehousing, a state-of-the-art

more’ brand commitment to deliver the best

Watson, Vice President, Surface Treatment

laboratory and administrative offices in

customized solutions in the surface treatment

Asia Pacific.

an ideal environment for manufacturing

industry,” states Martin Jung, Senior Vice

BASF’s Coatings division has frequently

development. This investment will

President, Surface Treatment.

invested in China, especially in Shanghai, to

strengthen Chemetall’s position in China to

“This investment will create Chemetall’s most

further enhance its proximity to customers

deliver the high level of service and quality

comprehensive site globally and enhance

in the fastest growing region for automotive coatings solutions. Examples

are the first regional Automotive Application Centre in Asia Pacific at the BASF Innovation Campus Shanghai as well as a world-scale production facility which supports the growing Chinese automotive industry. The latest investment positions BASF as an even more complete solution provider for coatings by adding the surface treatment business operating under the Chemetall brand. “We are looking forward to serving our customers in China with outstanding products and services from a state-of-the-art surface treatment site in the Dushan Port Economic Development Zone of Pinghu,” says Jin Hui, General

Manager Chemetall China.

Figure 1: Martin Jung (left), Senior Vice President Surface Treatment, BASF and Fu Guoquan, Party Secretary and Director of Dushan Port Economic Development Zone, sign the agreement to invest in a state-of-the-art surface treatment site in Pinghu, Zhejiang province, China.

For further information: www.basf.com

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

INNOVATIONS: PRESENT&FUTURE

The New Industrial Districts Adriano Antonelli IBIX S.r.l - DIVISIONE TECNO SUPPLY, Santa Maria in Fabriago (RA), Italy

adriano.antonelli@tecnosupply.com

ately, there has been much debate

District of Belluno, and the Pharmaceutical

Just think that, in order to maintain its sales

about international competition:

District of the Lazio region. But how has

levels, the goods produced by an Italian

how can the market affect the

the District concept changed in the last few

company have to travel an average of

domestic production process? How

years of economic challenges? Production

400 km more than just ten years ago. The

can we face the new challenges that

Districts have certainly transformed. The

answer, therefore, are no longer districts,

await us? Economic recovery seemed

skills needed to sell goods globally are

but rather expansion. The supply chain that

sustained, but it is currently weakening

increasingly complex and challenging. It

brings products beyond the borders can

also due to political choices that hinder

may even happen that the ones required

now be distributed throughout the national

the free movement of goods. So, how

are not available in oneâ&#x20AC;&#x2122;s own jealously

territory, in various specialised industrial

can we face the new international

guarded stronghold of knowledge, which

areas. This system creates a network of

economic policies and unilateral choices,

until a few decades ago was one of the

companies that are able to maintain high

such as those concerning the heavy

most precious assets for a small business.

quality standards and low prices. ÂŠ HangOn

duties imposed by the USA on Europe? Whereas Germany has a fabric of

The coating of mechanical parts and components is certainly an important

stable companies in terms of

part of the Italian

both finance and production,

productive fabric, as well

Italy has always been the

as an important process

country of small businesses.

in terms of both product

Of course, we are not

protection and packaging.

referring to micro or nano

Coating is now a key

companies, which nowadays

factor also for highly

tend to have more and

technological products.

more problems because

For any firm needing to

of their difficulty to adapt

coat in a short time and

to the now unavoidable

on workpieces subject

insourcing trend. Here, we

to unilateral changes in

are talking about the small

terms of shape and size,

but reliable companies that

being always prepared

have managed to cope with

can be complicated and

the challenges of the global

expensive. Increasing

market despite not having

production density should

the structure and size of

be the primary goal.

many of their European

The pictures presented

competitors.

can help understand

Traditionally, in Italy, the

how a few changes in

creation of Production

the hanging method

Districts was the answer. We all know, for example, the Ceramic District of Modena, the Eyewear

Figure 1: Optimising the hanging phase can bring huge benefits in terms of time and cost savings.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

used can ensure great benefits in terms of time and cost savings (Fig. 1). Switching from individual

INNOVATIONS: PRESENT&FUTURE

hooks to structured and flexible frames (in order to avoid an exponential increase in the number of frames required) can immediately bring significant improvements. The devices described below, such as HQL, HQC, and HQS, have costs comparable to those of individual hooks, but ensure an advantage in terms of hanging speed, production density, and unloading operations. The following innovations by HangOn can help make the right decision about the best coating method. A recently presented innovative solution are the ready-made hanging bars HQC, an evolution of HQL bars. The harmonic steel hooks are already inserted on the bar

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

and ready to use. The bar is then located on

Spare Parts for Industrial Plants

2 1

Figure 2: The HQC hanging system, featuring a bar holder with a silicone protection.

The coating of mechanical parts and components is certainly an important part of the Italian productive fabric, as well as an important process in terms of both product protection and packaging. Coating is now a key factor also for highly technological products. For any firm needing to coat in a short time and on workpieces subject to unilateral changes in terms of shape and size, being always prepared can be complicated and expensive. Increasing production density should be the primary goal.”

ANTARES S.r.l. 3 1

Figure 3: The HQS hanging system (left) compared with an individual hanging solution.

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

HQL, HQC and HQS have costs comparable to those of individual hooks, but ensure an advantage in terms of hanging speed, production density, and unloading operations.” a BH R58 bar holder, welded on a 10 mm hook (Fig. 2). The silicone protection ensures free conductivity. The bar has been designed to be produced entirely automatically and it can be used for a large quantity of parts, thus proving extremely

HQS features metal sheets enabling to hang individual parts, up to profiles. The 4 or 5 mm central hook ensures a total frame capacity up to 100 kg. HQS has been recently launched on the market with various types of hooks, enabling each customer to create the most suitable configuration for its specific needs.”

economic. Its cost is around 2 Euros per bar. Moreover, it is possible to insert a series of hooks in the

The HQL bar, finally, has been in the

bar holder to hang medium-sized

catalogue for some years now (Fig. 4).

workpieces, since the central hook

It can be integrated on the universal

has a 10 mm diameter.

frames. The 1 mm hook leaves only a

Another tree frame manufactured

slight mark on the coated part. Also

automatically and therefore costing

for this bar range, Ibix has launched

less than 2 Euros/bar is called HQS

a triple V-shaped bar preventing the

(Fig. 3). It features metal sheets

workpieces to unhook during pre-

enabling to hang individual parts, up

cleaning.

to profiles. The 4 or 5 mm central hook ensures a total frame capacity up to 100 kg. HQS has been recently launched on the market with various

4 1

Figure 4: The HQL hanging system.

types of hooks, enabling each the most suitable configuration for

simple workpieces need to be hung. Sometimes, it is necessary to hang and mask the parts at the same time. And the only hanging point available can be, for example, a pivot.

customer to create

As we all know, however, not only

For these cases, HangOn has created

its specific needs.

the GHA accessory,

The tree can be

compatible with

up to 2400 mm in

the HCL BHL bar

length, while the

that can house it

sheets are 1.0 mm

internally (Fig. 5).

thick and 18 mm

This enables to mask

high. It is possible

and hang parts

to create different

with one simple

configurations:

operation. The cap

sheets on one side

features grooves

only (i.e. sheared), zigzag-shaped, or bent from 0 to 180°.

5 1

Figure 5: The special GHA Style, masking and hanging system.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

that do not hinder the conductivity of metal.

IGP-DURA®face 5807 Surface-robust powder coating system for facade and metal construction

Surface-robust powder coating system for facade and metal construction. We lend all shades of powder coatings more scratch and abrasion-resistance, making transportation and handling more secure and protecting the value of your output. – More abrasion resistant – More scratch resistant – Easier to clean – Optimized flow

Learn more about IGP-DURA®face 5807 at: www.igp-powder.com

ST SU RF

IGP Pulvertechnik AG 9500 Wil, Switzerland Phone +41 71 9298111 www.igp-powder.com info@igp-powder.com A member of the DOLD GROUP

Opening photo: Mitras Composites GmbH manufactures housings using a sheet moulding compound (SMC), i.e. plate-shaped, dough-like moulding materials made from thermosetting reaction resins and glass fibres, to produce the individual components.

FOCUS ON TECHNOLOGY

Eliminating Process Steps, Increasing Quality. Manufacturer of SMC Housings Relies on FreiLacke’s PIMC Process John-David Mäbert, Mitras Composites GmbH Peter Lobendank, Emil Frei GmbH & Co. KG

he grey junction and distribution boxes

Those who take a closer look can detect the

Mitras Composites GmbH from Radeburg,

that can be found on pavements,

weathering of the top coats of older models,

near Dresden, manufactures these types of

in front yards or the edges of

as well as the corrosion of the resin layer on

housings. The company uses a sheet moulding

properties largely go unnoticed. Only

the surface, which allows the fibres of the

compound (SMC), i.e. plate-shaped, dough-like

children sometimes use them when they

housing to become visible. The result is that

moulding materials made from thermosetting

play hide-and-seek or as pommel horses.

not only their optics suffer but, to a small

reaction resins and glass fibres, to produce the

Their housings are exposed to the elements

extent, also their mechanical properties and

individual components (ref. Opening photo).

every single day – sometimes for decades.

fire-resistance.

The flat fibres guarantee very good mechanical

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

properties. â&#x20AC;&#x153;The SMC is moulded in

Titze explained. â&#x20AC;&#x153;Frankly, the effort was

important for outdoor uses (Fig. 1). The

150Â°C steel pressing tools and, thanks

enormous and very expensiveâ&#x20AC;?.

team built a manual sampling plant in-

to the pressure and high temperature,

With regard to the increased surface quality,

house. The initial manual coating attempts

is distributed evenly within them. The

â&#x20AC;&#x153;the customer particularly wanted maximum

were very promising, Titze said. However,

polymerisation being used ensures a

weather and scratch resistance, but also a

the process engineers realised right away

crosslinking of the material and cures it

high anti-graffiti protection as well as a very

that only an automated solution could be

when it has reached its final formâ&#x20AC;?, explains

high resistance against aggressive cleaning

used for series production. Later in the

Sebastian Titze, a Research & Development

agents and corrosive solutions that are used

same year, Mitras built one â&#x20AC;&#x201C; once again

project manager at Mitras.

for removing any smearingâ&#x20AC;?, the project

in-house. It included a robot, an extraction

manager explained.

system and a powder plant.

A customer for whom Mitras also produces

PIMC testing

cable distribution cabinets demanded an

That is why the Powder In-Mould Coating

Fine tuning the powder coating

increased surface quality. Until recently,

(PIMC) process was tested at Mitras in early

In FreiLacke, Mitras found a reliable

the production of the components had

2015. In a single-step process, electrostatically

coating supplier for the process: â&#x20AC;&#x153;we

been a very logistically complex process

charged powder coatings that are based on

received a lot of support during the

for the Radeburg-based company. The

UP resins are applied onto the hot mould.

application process. When the process

components were wet-coated at an

During the hot-pressing process the coating

was introduced, FreiLacke employees

external job coater but then brought back

creates a chemical compound with the

were literally available to us around

to Radeburg for shipping. â&#x20AC;&#x153;Overall, nine

material. This compound is scratch-resistant,

the clock. Time and time again, short-

separate process steps were required until

and also very resistant against chemicals,

term adjustments to the powder were

the component was ready to be shippedâ&#x20AC;?,

graffiti and UV radiation, which is particularly

possibleâ&#x20AC;?, the engineer said.

Complex logistics

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solvents, hazardous substances or carcinogenic raw materials. “PIMC is fire-retardant in accordance with EN45545, HL3, R1 and, thanks to its good properties, can be used for many applications. Its high weather resistance makes it perfect for use outdoors. In the facade standard area, our PIMC coatings achieved a residual gloss of more than 50% in tests of 300 hours according to QUV-B”, explained Peter Lobendank. Thanks to its barrier properties, PIMC is also suitable as a primer for the automotive industry.

One process, many factors Sebastian Titze called the transition to PIMC

a “core learning process”. It was very complex Figure 1: The Powder In-Mould Coating (PIMC) is a single-step process, where electrostatically charged powder coatings that are based on UP resins are applied onto the hot mould. During the hot-pressing process the coating creates a very resistant chemical compound with the material.

and demanding, because some new tools had to be built and brought up to standard for series production. In addition, the process involved many factors – the powder coating

In its laboratory in Döggingen, in the Black

Extreme weather resistance

Forest, FreiLacke has a state-of-the-art

PIMC offers a wide range of colours since

and the moulds. “All of these parameters are

laboratory press with cooling unit that

nearly all RAL colours can be used. However,

subject to variations – each of which affect the

meets all of the requirements to create

the cable distribution cabinets receive a plain

process”, Titze said. Thanks to continuously

samples for viewing or inspections. “We

grey coat at Mitras. In rare cases, orders call

pursued experimental designs, an optimisation

used it to perform experiments on the

for green or orange – the latter particularly

as well as an improvement of the development

original substrate with different time,

for municipalities. In addition, PIMC can

process could be achieved on all levels.

temperature and pressure settings”, Peter

also be used for special applications, such

Lobendank, System Coordinator Industries

as high-gloss, multiple colours and metallic

Elimination of process steps

at FreiLacke, explained. In addition, many

granite effects. The material is free from

Mitras has now been using the process for

were conducted in the laboratory until the correct

six months. However, not

surface and cause analyses

as well as the SMC material, the temperature

only the surface quality has benefited from the

parameters were found.

transition to PIMC in

The FreiLacke team also

Radeburg. The handling

assisted the company

of the components

from Saxony with the

has also become more

implementation of the

efficient. The transition

process, the improvement

permitted the elimination

of the application efficiency,

of several process steps

the plant design and much

– the integration of the

more. “We were also very

external service provider

satisfied with regard to the

and the complex logistics

development work”, said

are no longer needed

Sebastian Titze. Therefore,

(Fig. 2). The components

it is no surprise that the two companies have launched the next joint project in the meantime.

2 1

Figure 2: The transition to PIMC permitted the elimination of several process steps, simplifying logistics.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

remain in-house until they are completed and can then be shipped immediately.

P O W E R F U L

I N

V E R T I C A L

T L E S S

I N

H O R I Z O N T A L

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

I T A LY

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

S P A I N

C A T A R I N A

F L O R I D A

U S A

B R A Z I L

Â© Interseals

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The Rotamat at Interseals: The Spring Board For Opening New Markets Dieter Adamkiewicz, Interseals Srl Frank Siegel, Walther Trowal GmbH

hen it comes to placing an

demanding anti-friction coatings to facilitate

technical aspects but was also influenced

anti-friction coating on small

the separation of the parts. Of course,

by the “German business outlook” of the

parts, Interseals early on was

reducing the coefficient of friction of the

Italian-German management team: In all its

betting on the Rotamat coater from Walther

coatings along with demands for higher

capital investments Interseals has always

Trowal. The first machine, installed in 2009,

cleanliness in automatic assembly lines were

been guided by its desire to buy from the

became the foundation for a brand-new

also key factors for changing the coating

renowned market leaders to take advantage

business division. In the meantime, the

material.

of their decades old know-how and, in the © Interseals

Italian company is operating seven Rotamat coaters at two locations and has become

end, achieve optimum process stability with, at the same time, low “costs of

the Trowal customer with the

ownership”.

largest number of Rotamat

Walther Trowal established

coaters used within a single

its leading role as a reliable

group of companies.

supplier in the field of

At its Capriolo plant in

mass finishing – deburring/

Lombardy (in the province of

radiusing grinding and

Brescia) Interseals produces

polishing of all kinds of work

O-rings, and special moulded

pieces. This reputation and

parts (ref. Opening photo).

the brand name associated

In addition to coating its own

with it, along with the

work pieces the company

excellent performance of

also provides coating services to other manufacturers of similar products. About 65% of the Interseals production volume is sold to automobile

the Rotamat, were decisive

factors in the investment

Figure 1: In its Capriolo plant, Interseals operates four Rotamat coaters; at Pol-Technology another three.

decision. No doubt, it also helped that the excellent name of Walther Trowal in the industry and with

manufacturers and their suppliers.

Since 2009 the trend towards the use of anti-

auditors can be very helpful in marketing

Interseals has established an excellent

friction coatings has dramatically accelerated.

and with audits.

reputation for coating with multi-component

Interseals recognized this significant shift in

lacquers and continues to be market leader

customer requirements early on and reacted

in this field.

by planning to expand its “coating” operations

Seven Rotamat coaters within the same group of companies

Before switching to these multi-component

and investing in new equipment. In its search

Positive processing trials with parts from

coating materials, the company, founded

for qualified suppliers the company also

the Capriolo plant in the test lab at Walther

in 1995, was mainly using lubricants like

contacted Walther Trowal.

Trowal in Haan (Germany) convinced

Molykote , silicone oil, talcum and graphite.

The decision for the Walther Trowal

Interseals to purchase its first R 90 Rotamat

However, the customers were increasingly

equipment was not only based on purely

coater in 2009.

Opening photo: Among other products, Interseals produces and coats O-rings made from diﬀerent elastomers.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

Conclusion The decision to expand the company’s product and service portfolio with the Rotamat coater has proven to be a full success. While initially only intended for the in-house production, Interseals very quickly received enquiries from other companies. That is how the Rotamat coaters were forming the foundation for a new, continuously growing business field. The machines produce excellent surface finishes, are very sturdy and require a surprisingly low degree of maintenance. The first machine, delivered nearly 10 years ago, still runs at full capacity. A big help was

2 1

that the process parameters are

Figure 2: The automatic spray gun evenly applies the coating material onto the gently tumbling mass-produced small parts.

stored in the PC in Italian and Polish language.

New parts require extensive testing

The fact that Interseals had no prior

three R 90 Rotamat systems (usable volume

to determine the optimum process

knowledge whatsoever about coating

up to 50 L) and one R 90 C (usable volume

parameters like air volume &

of mass-produced small parts was no

up to 75 L). The drum diameter in these

temperature as well as the rotary speed

doubt a challenge. The process was

machines amounts to 800 mm providing an

and inclination angle of the drum. After

completely new to the employees,

average capacity of about 50 kg and 50 L.

approval by the customer the process

and no specialists were to be found

At the subsidiary plant Pol-Technology, near

parameters are stored and locked in the

in the Lombardy region.

Katowice (Poland), established in 2016,

integrated recipe administration.

initially two Rotamat coaters were installed

With any new purchase orders for

with a third one going into operation in

the same articles the parameters

2017 (Fig. 1). All machines are in line with

are called up from the internal

the standard Walther Trowal technical

recipe administration. The

specifications. No technical modifications

process itself is automatically

were required which greatly facilitates spare

controlled and monitored by

parts supply and maintenance.

an industrial PC with touch

Basis for the successful coating with multi-

panel, which is integrated into

component lacquers is the perfectly timed

the control panel (Fig. 3). Even

coordination of the pre-treatment and

the spraying rate and spraying

coating operations: to achieve optimum

pattern are controlled by the

coating results the parts must be coated

program, ensuring a high

within a few hours after the pre-treatment

process stability with absolutely

step (Fig. 2). For this reason, Interseals is

repeatable coating results.

operating two in-house plasma systems.

With the integrated report

On average each Rotamat coater processes

administration module all coating

nearly 40 million parts per year with water-

processes run in the past can be

based lacquers, of which 30% are destined

easily recalled allowing review of

for the company’s own production in Italy

the process parameters of every

and 70% as service for external customers.

single batch ever run.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

Today Interseals in Capriolo works with

3 1

Figure 3: The entire coating process is controlled and monitored by an industrial PC with touch panel integrated into the control panel.

FOCUS ON TECHNOLOGY

That is why in the beginning the experts from Haan intensively supported Interseals. But for several years now the colleagues in Italy and Poland have been adapting the coating process to new customer work pieces. But, of course, the experts from Haan still help Interseals with special questions and customer demands. It no doubt helps that the Walther Trowal technicians and engineers have been working with Interseals

GANCI | HOOKS

know the company’s requirements inside out.

for many years and

The future Recently a new trend has developed: The products of many Interseals customers

TELAI | RACKS

are becoming more compact, but must provide the same high performance. This means that the seals are

4 1

Figure 4: The new Rotamat R 60 coater is ideal for processing work piece batches with volumes of up to 15 L.

also becoming smaller. For example, the volume of 50,000 O-rings with an

plans to purchase a new R 60 Rotamat coater with

internal diameter of 3 mm and a cord width of

a nominal usable volume of only 15 L (Fig. 4), but

1 mm only amounts to 0.5 L!

with the performance characteristics of its “bigger

However, since a certain, minimum batch size is

siblings”. This machine is intended for smaller

always required, Rotamat coaters with smaller

batches as well as the sample processing of larger

drums are needed. For this reason, Interseals

work pieces.

The coating of mass-produced small parts in a Rotamat coater is a high temperature process, whereby the small parts are coated in a rotating, enclosed spray chamber. The process can be applied on parts made from different plastic materials like elastomers, ABS, PC, PS, etc., as well as parts made from metal and wood. The Rotamat systems allow processing of water based as well as solvent based coating materials. The parts do no longer have to be placed individually on special racks but are simply loaded in bulk into the rotary drum of the Rotamat system. One or – even better - two automatic spray guns are evenly applying the coating material, while the small parts are gently tumbling over each other.

To induce the required process temperature into the parts, warm air is injected into the coating drum with an absolute minimum of turbulence. The work piece temperature is directly measured with an IR sensor. Depending on the work piece temperature a PID controller regulates the temperature of the inlet air always taking into account the actual air volume. Due to its outstanding efficiency the Rotamat coaters require only a few kW’s of installed electrical power. Once the coating process is completed, the work pieces are discharged by simply tilting the drum downwards with a gear motor. A post process drying step, for example, in an oven, is no longer required. The parts coming from the drum can be immediately used for the next production step.

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

www.emptmeyer.it

ON THE ROAD TO ipcm

n. 53

ipcm® editors in Cyprus enjoying the last days of summers with our dear guest Andreas Marcou (Muskita Alumnium Industries) and with Loris Rossi (ALIT Technologies) and his wonderful family

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

SPECIAL ALUMINIUM

FOCUS ON TECHNOLOGY Muskita Aluminium Industries: Quality from the Starting Point

FOCUS ON TECHNOLOGY From a Compact Vertical System to the Most Advanced Technology in the Aluminium Profile Coating Field: The History of AluK GB

HIGHLIGHT OF THE MONTH Chemetall: Your Leading Global Supplier of Applied Surface Treatment Solutions

FOCUS ON TECHNOLOGY Deep Collaboration with the Paint Supplier to Diversify Production and Ensure High Quality: The Winning Strategy of Lacoviana

74 76

BRAND NEW SUCCESS STORIES Tonon Forty Launches Its New Line of Radiators “Colors Vintage”, with Finishes Dedicated to Vintage Products and Created with Arsonsisi Powder Coatings

FOCUS ON TECHNOLOGY ALMECO: The First Zero Liquid Discharge Water Treatment Plant in the World Installed on an Anodic Oxidation Line for Aluminium Coils

SUCCESS STORIES Framery in the Pursuit of Happiness with Teknos’ INFRALIT PE 8317-10 Powder Coating

INNOVATIONS: PRESENT&FUTURE Qualicoat & Qualanod: latest eco-friendly developments for aluminium pre-treatment

FOCUS ON TECHNOLOGY Advanced Technology, Process Renewal, and Industrial Research on Pre-Treatment: Luxe Coat’s Strategy for Its Business Relaunch

106

FOCUS ON TECHNOLOGY Chromium-Free Pretreatment at ELVIAL. A Review of 18 Successful Years

110

INNOVATIONS: PRESENT&FUTURE Shot Blasting of Extruded Aluminium Profiles: Aesthetic Quality with Time and Cost Savings

114

FOCUS ON TECHNOLOGY Metra Color: an Italian History of Quality and Innovation in Powder Coating to Conquer the US Market

BRAND NEW FOCUS ON TECHNOLOGY All.co Group: A Wide Choice of High-Quality Finishes and Colours from a Well-Established Company

122 124

ÂŠ Muskita

Opening photo: Muskita Aluminum Industries, a Cyprus-based company that has recently celebrated 60 years of activity, has been at the forefront of the global aluminium extrusion and finishing market for years, with systems for architecture designed by itself or developed based on customer projects.

FOCUS ON TECHNOLOGY

S P E C I A L ALU MINIU M

Muskita Aluminium Industries: Quality from the Starting Point Alessia Venturi ipcmÂŽ

uskita, a Cyprus-based

and processes, which made it one of the

high solar radiation, high humidity and

manufacturer of aluminium profiles

few, if not the only company that has never

salinity, large amounts of dust settling on

and accessories, has a history of

had any complaint about the durability of its

structures at night, and continuous dilations

success. The history of a firm that has turned

finishes or the filiform corrosion of its profiles

and contractions of substrates due to

its technology investments into a weapon

in the last fifteen years, i.e. since it adopted a

temperature changes. This is a lethal mix for

to conquer the global market starting from

chrome-free pre-treatment process.

the durability, colour retention, and corrosion

a little corner of Europe. The history of an

The weather conditions of Cyprus are

resistance of finishes.

obsession with the quality of raw materials

among the most challenging for aluminium:

Thanks to its technological and process

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

heat and uses it to warm the diathermic

choices, Muskita has been at the forefront of the global aluminium market for years, with systems for architecture designed by itself or developed based on customer projects (ref. Opening photo). Its quality-oriented approach did not change even following the serious financial crisis that hit Cyprus in 2013, causing numerous companies to collapse. This firm’s entrepreneurial ability, passion for aluminium, and great technical expertise have enabled it to go back to producing, although below its capacity, exporting all over the world, and investing in technology. In the last two years, Muskita has invested in energy efficiency, installing an

oil that feeds a steam generator, which, in turn, heats the two fixing tanks of the anodic oxidation line. The company has also invested in production and it will soon add a fourth 20,000-ampere oxide tank to the three 16,000-ampere ones already present on the anodic oxidation line, bringing the total capacity of the plant to 68,000 amperes (Fig. 1). Finally, Muskita has invested in an accessory phase of the coating process, greatly affecting productivity, energy efficiency, and operational safety: it has installed a paint stripping system to treat its profile hanging hooks, choosing the technological evolution of the Fastrip ISP machine produced by Alit Technologies © ipcm ®

economiser that recovers the extrusion

Muskita, a Cyprus-based manufacturer of aluminium profiles and accessories, has a history of success. The history of a firm that has turned its technology investments into a weapon to conquer the global market starting from a little corner of Europe. The history of an obsession with the quality of raw materials and processes, which made it one of the few, if not the only company that has never had any complaint about the durability of its finishes or the filiform corrosion of its profiles in the last fifteen years, i.e. since it adopted a chrome-free pre-treatment process.”

Figure 1: Overview of the anodic oxidation line.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

SP ECIAL ALUMIN IUM

(San Bonifacio,

completed the

Verona, Italy – Fig.

process with

2). The system

the addition of

will help increase

thermal cutting

the speed of its

and assembly

coating line and

machines, long

it will enable

before the issue

the company

of European

to significantly

regulations on

reduce energy

energy efficiency,”

consumption and

states Demos

process costs.

Mouskis. “The

This is crucial for

in-house extrusion

a company like

also started the

Muskita, bearing

era of aluminium

much higher costs

exports: our

for energy supply

production

than in the rest of

Sixty years of success

capacity exceeded

2 1

Europe.

domestic demand.

Figure 2: The paint stripping system to treat its profile hanging hooks, technological evolution of the Fastrip ISP machine produced by Alit Technologies, is Muskita’s latest investment.

Besides Cyprus, our target market is now northern Europe

Muskita Aluminium Industries, which recently celebrated

existing ones to local climate and needs

– especially island countries, such as Great

sixty years in the aluminium industry, is

but above all to the new material.

Britain, Ireland and so on, which have the

currently led by Demos G. Mouskis, one

Muskita implemented its first anodic

same logistic and supply difficulties as Cyprus

of founder George Mouskis’ sons. “At

oxidation plant in 1965. “In 1985, the

and where we can even out our competitors’

the beginning of the 1960s, Muskita was

company installed its first extrusion

advantages on the mainland.”

among the first industrial companies

plant and, one year later, powder coating

The firm was listed on the stock exchange in

in Europe to introduce aluminium. My

with a horizontal plant. In 1990, the firm

the past, but for some years now it has gone

aluminium for the first

back to being an entirely

late father George saw

private capital company.

time at a fair in Switzerland

“In 2004, we took a

in 1963 and he had the

big step: after twenty

brilliant idea of bringing

years of continuous

back some samples of

expansion, we needed

metal to promote that

to rationalise our spaces

light but highly ductile and

and production flows.

resistant material with

We have reorganised

architects. It was difficult

our production, created

to move them away from

an automatic profile

the conventional wood

warehouse (Fig. 4),

and steel materials, but he

replaced our anodic

succeeded,” says Demos

oxidation line, and

Mouskis (Fig. 3).

installed a vertical

George Mouskis threw himself headlong into the design of new systems for architecture, adapting

3 1

Figure 3: Demos G. Mouskis, Executive Chairman, with his daughter Anna, Marketing Manager.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

powder coating system (Fig. 5),” says Demos Mouskis. “Muskita offers products that have never

FOCUS ON TECHNOLOGY

Quality as a mission

had any filiform corrosion problem even in the harshest environments. There are two reasons for this success: the exclusive use of primary aluminium for extrusion and the collaboration with highly skilled partners, with which there is a continuous exchange of knowledge and experience.” In 2013, Muskita suffered the Cypriot financial crisis: due to the failure of national banks, the economy was at a standstill and a turnover reduced by 60%. “That period tested all of us and shook Muskita from the ground up. However, today we are back to working well, although far below our potential and with slower exports. On the other hand, these moments of slow production are often the most creative ones: we have diversified our range and we have developed new products and services. And here we are, once again at the forefront of the global aluminium market”.

Muskita has invested in an accessory phase of the coating process, greatly affecting productivity, energy efficiency, and operational safety: it has installed a paint stripping system to treat its profile hanging hooks, choosing the technological evolution of the Fastrip ISP machine produced by Alit Technologies (San Bonifacio, Verona, Italy). The system will help increase the speed of its coating line and it will enable the company to significantly reduce energy consumption and process costs. This is crucial for a company like Muskita, bearing much higher costs for energy supply than in the rest of Europe.”

“The choice of primary aluminium for extrusion largely affects our products’ performance. However, quality can only be achieved through a production process that is quality-oriented in all its phases,” says plant manager Andreas Marcou. “It makes no sense to certify the pre-treatment phase, if the substrate is of poor quality or if non-compliant raw materials are used in other process steps. Quality is a system, and it should be treated as such. We only use primary aluminium for extrusion because we do not want to contaminate our warehouse with extruded parts that are not of high quality, but also because its advantages in terms of higher

SP ECIAL ALUMIN IUM

Figure 4: The large automatic profile warehouse.

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Figure 5: Overview of the vertical powder coating system by SAT.

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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

Â®

SP ECIAL ALUMIN IUM

anodic oxidation products and we chose Alufinish.” “Our collaboration with Muskita started about ten years ago, when they decided to implement a chrome-free pre-treatment process,” says Loris Rossi, representing Alufinish. “We currently supply 75% of their anodising products. Over the years, there has been a continuous exchange of experience and technical knowledge between Muskita and us. This has enabled us to develop highly stable anodising products, which allow them to work in complete autonomy. Muskita’s oxidation process is perfectly fine-tuned, so much so that their grey range is one of the most beautiful on the market. For their

6 1

pre-treatment phase prior to coating,

Figure 6: Athens Olympic Stadium, one of the prestigious projects in which Muskita was the protagonist.

we provide them with our chrome-free conversion product Alficoat 748/3, an easy-to-use product that ensures excellent corrosion resistance and is GSB and

but stable and easy-to-use products.

Qualicoat approved. We also supply them

oxidation and painting quality, less use of

We cannot afford to request daily

with all chemicals used upstream of the

chemicals, and above all lack of complaints

technical assistance, because we are

conversion process: also in this case,

from customers compensate for its greater

on an island and the response time

Muskita chose a high quality solution by

purchase cost,” explains Marcou.

of our suppliers is clearly longer. That

implementing a both acid and alkaline

“Quality also entails the selection of reliable

is why we have decided to rely on

pre-treatment process to obtain maximum

partners, with technologically advanced

one provider of pre-treatment and

resistance performance.”

extrusion speed, less waste, better

Muskita implemented its first anodic oxidation plant in 1965. In 1985, the company installed its first extrusion plant and, one year later, powder coating with a horizontal plant. In 1990, the firm completed the process with the addition of thermal cutting and assembly machines, long before the issue of European regulations on energy efficiency. The inhouse extrusion also started the era of aluminium exports: its production capacity exceeded domestic demand.”

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Figure 7: The anodic oxidation tanks.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Alufinish collaboration with Muskita started about ten years ago, when they decided to implement a chrome-free pre-treatment process. Alufinish currently supplies 75% of their anodising products. Over the years, there has been a continuous exchange of experience and technical knowledge between Muskita and Alufinish. This has enabled Alufinish to develop highly stable anodising products, which allow them to work in complete autonomy.”

FATI

srl

CATENE PER TRASPORTATORI CUSCINETTI A SFERA

CATENE AD ALTE PRESTAZIONI HIGH PERFORMANCE CHAINS LEISTUNGSFÄHIGE KETTEN

NOVITÀ NEW NEUHEIT

HPCOAT

The production process: a global quality system Muskita is a plant engineering company: it designs and produces in-house architectural profiles based on its own systems or tailored to customer needs, offering design support and technical advice. An example of this was the

Particolare dei cuscinetti con HPCOAT Detail of bearing with HPCOAT Ausschnitt der Lager mit HPCOAT

coverage of the Athens Olympic Stadium (Fig. 6), designed by Santiago Calatrava, for which Muskita supplied 250 tonnes of powder-coated extrusions. says Andreas Marcou. “Since we are located on an island, we must maintain a very large stock in order to always offer a quick and punctual delivery service. Our automatic raw material warehouse has 1,300 slots and it can store up to 2,000 tonnes of profiles. When orders arrive from

con | with | mit HPCOAT

customers, the planning department determines the profiles to be picked up and sent to the oxidation (Fig. 7) or coating station. Once assembled through thermal cutting, the end products are sent to our four warehouses located in the main cities of the Country: Pafos, Larnaca, Limassol, but we can oxidise or paint parts up to 7.2 metres in length upon request. We can also supply raw profiles up to 9 metres.” Muskita’s coating station is a vertical plant provided by SAT and equipped with a cascade pre-treatment station and two SAT booths featuring 20 GEMA guns each with a traditional Venturi system (Fig. 8). The pre-treatment process includes four active stages: acid attack, alkaline attack, acid neutralisation, and chromefree conversion. Each stage includes three rinses with mains water, except the last one, which is performed with demineralised water. “Our pre-treatment process is Qualicoat Seaside certified. We preferred a cascade system

and Nicosia. The standard size of our profiles is 6.5 metres,

A tt dopo Aspetto d 2 200 ore in nebbia salina Surface after 200 hours of salt spray test senza | without | ohne Aussehen nach 200 Stunden in Salzsprühtest HPCOAT

Coefficiente Resistenza alla d’attrito corrosione Friction factor Corrosion protection Reibwert Korrosionsfestigkeit Costi di Durata alle alte manutenzione temperature Maintenance costs Life-time at high Wartungskosten temperatures Corrosione Beständigkeit gegen Corrosion hohen Temperaturen Korrosion Autolubrifcazione Abrasione alle Self lubrification alte temperature Selbstschmierung Wear at high Produttività temperatures Productivity Abrieb bei hohen Produktivität Temperaturen

LESS

“We have two extrusion lines, 2,200- and 2,800-ton presses,”

FATI srl Via C. Porta, 14 | 23861 Cesana B.za (LC) | Italy t. +39 031 655688 | f. +39 031 656772 info@fatisrl.com | www.fatisrl.com

SP ECIAL ALUMIN IUM

8 1

Muskita’s coating station is a vertical plant provided by SAT and equipped with a cascade pre-treatment station and two SAT booths featuring 20 GEMA guns each with a traditional Venturi system. The pre-treatment process includes four active stages: acid attack, alkaline attack, acid neutralisation, and chrome-free conversion. Each stage includes three rinses with mains water, except the last one, which is performed with demineralised water.”

Figure 8: Detail of Gema guns with traditional Venturi system.

9 1

Figure 9: Using hooks that are perfectly suited to each coating process is fundamental in a quality system: it is the only way to ensure perfect electrostatic conductivity. That is why properly paint stripping all hooks between one cycle and another is crucial.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The Fastrip ISP system installed at Muskita’s premises is a 6-metre long chemical stripping tank, with a capacity of 2 tonnes of product and with a hook immersion depth of 30 cm. It is the first tank of this type to have a wall heating system with diathermic oil. The stainless steel tank is jacketed and it contains a circuit fed with electrically heated diathermic oil, which guarantees very low operating costs and optimal temperature maintenance.” because, although spraying ensures more uniformity on the outside of the workpieces, the cascade process allows to pre-treat also the inside of profiles,” explains Marcou. “For us, guaranteeing a Seaside quality level means to use first-choice metal, correct pre-treatment processes, and Qualicoat Class 2 coatings. That is the secret for not receiving any complaints for corroded or chalking profiles. Also the choice to use only Class 2 paints stems from our quality policy: we do so also for our wood-effect finishes obtained by sublimation, where we use films of the same quality.” For Muskita, colour is crucial, too. “Our main supplier, accounting for about 70%, is Sherwin Williams with the brand Syntha Pulvin. We also use colours from Akzo Nobel’s Futura and Structura ranges. Together with GI Color, finally, we have developed a 12-tint collection called “Colours of Earth” as well as all wood-effect finishes obtained by sublimation. In total, we manage about 100 colours, plus the ones that we have formulated by our partners on request,” says Andreas Marcou.

Fastrip ISP: paint stripping contributes to quality Using hooks that are perfectly suited to each coating process is fundamental in a quality system: it is the only way to ensure perfect electrostatic conductivity. That is why properly paint stripping all hooks between one cycle and another is crucial, too (Fig. 9). “Before installing Alit’s machine, we used an induction system that did not guarantee perfect cleaning results and above all modified our hooks’ metal structure, thus

+49 89 13928723

SP ECIAL ALUMIN IUM

causing their embrittlement and therefore hanging safety issues,” states Marcou. “Alit’s system was

a slightly higher cost,” says Andreas Marcou. “This tank can withstand a speed of 2 m/min:

convincing in terms of productivity,

we now operate up to 1.75-

but also of efficiency and

1.80 m/min, but we are ready

environmental impact.”

for any possible increase in

The Fastrip ISP system installed at

productivity in future. After the

Muskita’s premises is a 6-metre

first few weeks, we are pleased

long chemical stripping tank, with

with both the machines’ ease

a capacity of 2 tonnes of product

of management and its deep

and with a hook immersion depth

cleaning results. The unloading

of 30 cm. It is the first tank of this

operators no longer have to

type to have a wall heating system

tear off the hooks from their

with diathermic oil (Fig. 10). “The

housings due to an increase in

stainless steel tank is jacketed

size caused by badly removed

and it contains a circuit fed with

paint.”

electrically heated diathermic operating costs and optimal

A never-ending success against all odds

temperature maintenance,”

“Muskita never stops investing.

says Alit Technologies CEO Loris

Always being a step forward

Rossi (Fig. 11). “The tank can be

and offering impeccable quality

completed with a water rinse

and service are our weapons

module to remove the residual

to convince customers that

oil, which guarantees very low

paint stripping oil and with an infrared lamp module for drying. The active paint stripping solution should never be changed, because

10 1

Figure 10: The stripping tank is 6 meters long.

we can provide high precision engineering products even from the South Eastern frontier of Europe. We are a small company, © ipcm ®

the system is designed to be in balance: two

but with huge expertise in terms

products are used, one

of aluminium and

for the tank and one for

its processing” ends

feeding. Management

Demos Mouskis.

is simple: the sludge is

“Despite facing higher

filtered by a filter press

energy costs than our

that produces a dry

competitors, scarcity

residue to be disposed

of water, strict

of.”

discharge regulations

“The length of the

and considerable

machine is determined

non-current assets

by the maximum chain

related to raw

speed. A 5-metre

material, we do not

tank would have been

stop, we do not cease

enough for us, but

to invest, and above

we chose to install a

all we do not give up

6.3-metre tank because it will enable us to increase the speed of the vertical plant with

11 1

Figure 11: From the left Andreas Marcou, plant manager of Muskita, Alessia Venturi of ipcm® and Loris Rossi, CEO of Alit Technologies.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

offering the superior quality level and competitiveness that distinguishes us.”

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FASTRIP, for the easy, effective and rapid paint stripping of metals.

ALIT Technologies, the chemical paint stripping specialist. Products, machines, processes and consultancy.

www.alit-tech.com San Bonifacio â&#x20AC;&#x201C; Verona - ITALY

Opening photo: The showroom of AluK GB in Chepstow, South Wales.

FOCUS ON TECHNOLOGY

S P E C I A L ALU MINIU M

From a Compact Vertical System to the Most Advanced Technology in the Aluminium Profile Coating Field: The History of AluK GB Alessia Venturi ipcm®

coating (ref. Opening photo).

the Cube system of SAT (Verona, Italy), a firm

built over the years with frame manufacturers,

The Welsh company made its debut in the

specialising in aluminium processing plants

installers, architects, and contractors across the

world of powder coating only three years ago,

and technologies. After three years, now with

UK and beyond. It has adopted this approach

when it decided to insource this phase, crucial

the expertise needed to master the painting

luK GB’s mantra is “Collaboration is King”.

also for the selection of its suppliers, especially

to the quality of its products, by installing a

This company based in Chepstow, South

those involved in a key production process:

compact coating system. The choice fell on

Wales, is very proud of the partnership

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

first time that we use flash oxidation as a

process, AluK GB has chosen another SAT technology to make a quality leap in

AluK GB has chosen a SAT technology to make a quality leap in terms of finishes and offer an even higher-level product. The choice has fallen on a technology called FOX, which integrates a pre-treatment stage with a flash oxidation process into a vertical coating line, in order to ensure maximum resistance to filiform corrosion.”

terms of finishes and offer an even higherlevel product. This time, the choice has fallen on a technology called FOX, which integrates a pre-treatment stage with a flash oxidation process into a vertical coating line, in order to ensure maximum resistance to filiform corrosion (Fig. 1).

About AluK GB AluK GB was established in Newport (Wales) as a family-run company specialising in the distribution of coated

requires full mastery of the process,” explains AluK GB plant manager Michael Burke (Fig. 4). “Three years ago, we bought our first powder coating plant and we chose Cube because it was perfect to learn the ropes of powder coating and acquire the right skills to offer a quality product. When the company’s owners resolved to move to Chepstow, we also decided to turn the powder coating stage into one of the key points of our growth

on the European market and it was first

ensures a very high quality level, but it

on the market. Therefore, it deserved an

aluminium for residential and commercial buildings. The company grew very fast

pre-treatment method. This technology

acquired by Blyweert Aluminium (Belgium) and then by the AluK Group. AluK GB now designs and builds aluminium systems for buildings and it offers a complete range of windows, doors, and curtain walls in the United Kingdom as well as all over the world. AluK’s systems are suitable for both commercial and residential buildings and they combine high performance and functionality with modern design and lasting finishes (Fig. 2). In 2017, AluK GB has moved to a new and larger facility in Chepstow, in the Monmouthshire, to implement an ambitious expansion plan following three years of intense growth in the British market. The new plant has increased the production capacity of the company, allowing for the integration of technological innovations

Figure 1: The loading area of the new vertical line supplied by SAT.

investment proportional to its role. We

manufacturing phases, while providing

The new coating plant featuring the FOX technology

the necessary space for warehouses,

The new line was started in June, less than

install another, much more technologically

offices, and showrooms. “The decision

a year after the order, and it is already

advanced SAT line. It includes a pre-

to transfer the company to a larger

fully operational (Fig. 3). The company

treatment stage with the flash oxidation

site, here in Chepstow, was essential

is performing a series of tests to ensure

technology, which creates an oxide layer

to continue growth,” said AluK general

that the products’ quality is in line with

with a 3 to 8 micron thickness to protect

manager Russell Yates. “In the last

its standards. “We want to make sure

aluminium against filiform corrosion

three years, we had completely

that we have thoroughly understood the

(Fig. 5)”.

saturated the Newport plant. Now,

process and we fully control it: although

“The UK aluminium market is divided into

we can finally invest in cutting edge

we have powder coated with the Cube

two sectors: commercial and residential.

technology and create new jobs.”

system for three years now, this is the

The residential market accounts for 92%

in both the product design and

decided to divest the Cube system and

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

SP ECIAL ALUMIN IUM

2 1

3 1

Figure 2: Section of a profile coated by AluK GB.

Figure 3: Overview of the new coating line.

of our production. We own a few specific

we have 400 tonnes of raw aluminium in

and training support. SAT turned out to

systems for the residential construction

stock. After coating, this is transferred to

be a partner with which we could grow,

field and our flagship products, accounting

the finished product warehouse, waiting for

a company that shared and adopted our

for about 40% of the total, are sliding and

assembly and shipping,” explains Michael

vision, and above all a plant engineering

folding doors. Our investment in the new

Burke. “AluK GB has always considered the

firm able to provide us with the ideal

premises, and above all in the new powder

finishing of its products a commercial lever:

product to achieve our market objectives © ipcm ®

coating plant, was motivated by the will to

from time to time.” “This strategy meant

conquer the commercial

choosing Cube as our

market. We are now

first plant because it

developing our systems

guaranteed maximum

to adapt them to the

flexibility with our

needs of this market and

numerous colour change

we have already won two

operations, as well as

significant projects. Our

being a “training ground”

goal is to expand our

for our operators. In this

portfolio of solutions.

way, we have acquired

Thanks to the new plant

the necessary skills

with the FOX technology,

to meet the market

we are now able to compete at a higher level of the market.”

The reasons for the choice

demands in terms of

4 1

coating. At that point,

Figure 4: From left to right: Michael Burke, Plant Manager of AluK GB, Alberto Formenti, Sales Engineer of SAT and Leon Hoog, UK Business Unit Manager of GEMA.

we started planning to further grow and we decided to make a big investment in a new

AluK GB receives extrusions from various

since 1992, when the company opened up,

line that was not only perfect for the

European suppliers. The incoming

we have focused on the finishing process by

requirements of that moment, but also

aluminium is then stored in the raw

entrusting it to expert contractors. However,

ready to meet future ones. We also knew

material warehouse waiting to be coated,

a leap in quality would have been possible

that pre-treatment is a critical part of the

assembled with a thermal cutting process,

only by insourcing this operation (Fig. 6).

painting process in order to ensure high

and packaged for shipping. “Currently,

That is why we needed adequate technical

quality. That is why we opted for the FOX

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

5 1

Figure 5: The FOX system.

system. Our process was already Qualicoat Seaside certified, but the new line even exceeds the requirements.” “The transition from Cube to the new line was perfect and smooth, since the technology is practically the same, except for the FOX system,” states Burke. “The plant is very easy to use: the control PLC works like a Windows system: it is possible to “browse” through the various process phases. SAT’s engineers are highly skilled and they deeply know their technologies. Their support was essential to adapt to the use of such a large treatment line. Even the installation phase was smooth: it took three days to start and test the electrical and mechanical parts, and the system had been already started while we were still in Newport.”

Two pre-treatment technologies in one line The peculiarity of AluK GB’s new coating line is the integration of two different pre-treatment systems: a conventional chemical cycle, with a double active stage (acid and alkaline) and a chrome-free conversion

AluK GB designs and builds aluminium systems for buildings and it offers a complete range of windows, doors, and curtain walls in the United Kingdom as well as all over the world. AluK’s systems are suitable for both commercial and residential buildings and they combine high performance and functionality with modern design and lasting finishes.”

SP ECIAL ALUMIN IUM

stage, and a

to the inner

flash oxidation

ring of the FOX

process. “The

system, without

chemical spray

reducing the

pre-treatment

overall speed

cycle includes as

of the line.”

follows: alkaline

“AluK GB works

etching, rinsing

constantly at

with mains water,

1.5 m/min.

acid degreasing,

When the

double rinsing

system control

with mains water,

software

rinsing with

matches a

demineralised

load bar with

water, and

a treatment

chrome-

program that

free surface

includes the

conversion

flash oxidation

with Chemetall

phase, the

products,”

profiles are

explains Michael Burke (Fig. 7). “SAT’s technology comes into play

removed

6 1

from the main ring of the

Figure 6: Finished profiles.

line through a 4-switch

after the rinses

system and they are transferred to the FOX’s

following the acid degreasing stage: here,

internal conveyor,” says Formenti (Fig. 10).

based on the quality requirements of the aluminium profiles to be treated, we can decide whether to divert the parts toward the oxidation tank for a flash treatment aimed at improving their corrosion resistance or to complete the conventional cycle (Fig. 8).” The latest version of the FOX system was implemented. “Originally, the FOX system was based on two separate tanks, one for the flash oxidation process and one for rinsing the profiles. The speed of the main conveyor was limited by the number of profiles that could be processed by the tanks, thus limiting productivity accordingly,” says SAT sales engineer Alberto Formenti. “In the latest version of this system, however, the oxidation tank is wider in order to immerse several profiles at the same time (Fig. 9), whereas the rinse with demineralised water occurs vertically in a spray tunnel module. In this way, the main conveyor of the coating line can transfer a greater number of profiles

AluK GB has always considered the finishing of its products a commercial lever: since 1992, when the company opened up, they have focused on the finishing process by entrusting it to expert contractors. However, a leap in quality would have been possible only by insourcing this operation. That is why they needed adequate technical and training support and SAT turned out to be a partner with which they could grow and above all a plant engineering firm able to provide the ideal product to achieve market objectives from time to time.”

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

“Otherwise, the profiles proceed on their path toward the chrome-free passivation station. The winning aspect of this plant is its flexibility in terms of final quality. The company can offer a standard and more affordable product using the chrome-free pre-treatment as well as a premium quality, more expensive product using the flash oxidation technology, thus meeting the requirements of the most diverse aluminium markets.” “The anodising process lasts 3.51 minutes. We recover part of the sulphuric acid in the solution from the dripping of the profiles and we recirculate it into the system,” states Michael Burke. “Moreover, we converted the rinse with mains water included in the original project into a rinse with demineralised water, thus obtaining great benefits: the anodising process is always critical and strict parameter control is required.”

SP ECIAL ALUMIN IUM

capacity and flexibility,” states Burke. “On average, we perform twenty-five

AluK GB knew that pre-treatment is a critical part of the painting process in order to ensure high quality. That is why they opted for the FOX system.”

colour change operations a day. In the most intense months, we can handle 22 tonnes of aluminium per day, but we even performed forty-two colour changes with only 16 tonnes of aluminium treated. For AluK GB, flexibility is of the essence, as well as quality. We use © ipcm ®

almost exclusively Qualicoat 2 polyester powders provided by AkzoNobel, our main supplier with which we collaborate in terms of both colour and paint performance development. Also with AkzoNobel, we have established a partnership of mutual growth, in which the support of their engineers is crucial. For us, finishing is a “quality system” and not a series of production phases

7 1

disconnected from each other.”

Figure 7: On the right the pre-treatment tunnel.

Technology as a primary selling argument “We are confident that we have installed

Finishing: a quality system

the most advanced technology available on the market today,” Michael Burke

After pre-treatment, the profiles are dried in 110° C, depending on the room temperature. Then, they reach the application area equipped with two V-shaped booths and Gema’s feeding and AP01 dense phase powder spraying in-line technology (Fig. 11).

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the oven at a temperature between 95 and

Figure 8: The conveyor can divert the parts towards the pre-treatment tunnel or toward the FOX system.

“In terms of application, dense phase is the first choice for coating aluminium profiles, although it requires a greater investment than the Venturi injector technology,” states Leon Hoog, the UK Business Unit Manager of GEMA. “However, it is the best technology available today as for transfer efficiency, extrusion penetration, paint yield, and standard thickness deviation (Fig. 12).” The two coating booths work simultaneously: during loading, the software matches each bar with a treatment program and with its assigned booth’s number (Fig. 13). “One of the greatest benefits of the plant technology supplied by SAT is that no empty spaces are needed on the chain: this has considerably increased our production

SAT’s technology comes into play after the rinses following the acid degreasing stage: here, based on the quality requirements of the aluminium profiles to be treated, they can decide whether to divert the parts toward the oxidation tank for a flash treatment aimed at improving their corrosion resistance or to complete the conventional cycle.”

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

9 1

Figure 9: Top view of the FOX tank.

FOCUS ON TECHNOLOGY

The winning aspect of this plant is its flexibility in terms of final quality. The company can offer a standard and more affordable product using the chromefree pre-treatment as well as a premium quality, more expensive product using the flash oxidation technology, thus meeting the requirements of the most diverse aluminium markets.” Figure 10: The descender of the FOX system.

10 1

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SP ECIAL ALUMIN IUM

11 1

12 1

proudly says. “We can now start thinking

Figure 12: The GEMA nozzles that work with dense phase powder technology.

Figure 11: One of the coating booths supplied by SAT/equipped with GEMA system.

is actually not very wide. SAT’s

about a possible development of the pre-

vertical technology can favour

treatment process with the introduction of a

the opposite approach, that is,

polymer technology for surface conversion,

high volume/high variation. I

or assess the possibility to integrate a

believe this possible change is

brushing machine in the SAT line, since our

exciting for the English market.

goal is to manipulate our profiles as less as

Pre-treatment will become an

possible. However, we are more than pleased

increasingly critical aspect, when

with our current equipment. In the United

chrome VI will be permanently

Kingdom, the powder coating technology

banned in Europe and the United

level is quite low and few investments are

Kingdom. Companies must now

made in new plants, especially the vertical

equip themselves to understand

ones. The horizontal lines based on a low

the alternative chrome-free

volume/high variation approach account for

processes, otherwise quality

90% of the aluminium coating market, which

problems will be certainly an issue.” “The FOX system is undoubtedly our USP on the

AluK GB uses almost exclusively Qualicoat 2 polyester powders provided by AkzoNobel, the main supplier with which they collaborate in terms of both colour and paint performance development.”

market,” says Burke. “There is only one other UK contractor offering profiles pre-treated with the flash oxidation technology. However, we are 13 1

Figure 13: Entry and exit of the polimerization oven.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

the only ones to have installed this system in-house and in-line on a vertical system.”

HIGHLIGHT OF THE MONTH

S P E C I A L ALU MINIU M

Chemetall: Your Leading Global Supplier of Applied Surface Treatment Solutions From an interview with Martin Jung, Senior Vice President Surface Treatment of Chemetall

n December 2016 BASF’s Coatings

and in Clermont-Ferrand, France. Jung

Ipcm: Which kind of synergies will you

division acquired Chemetall, a leading

received his PhD in Polymer Chemistry from

have with BASF after the acquisition?

global surface treatment supplier.

the Eindhoven University of Technology,

MJ: Being part of BASF’s Coatings division

Being well-known within the industry for

Netherlands. He joined BASF in 2000 and

creates opportunities to offer the combined

its high-quality products and solutions,

held different management positions within

expertise of BASF within the coatings industry

Chemetall now operate as a brand of the

the group in Germany and overseas.

and Chemetall to increase customer benefits © Chemetall

Surface Treatment global business unit of BASF’s Coatings division.

with improved products and services. Obviously, we are looking in the first

Chemetall develops and

place at top performing,

manufactures customized

aligned pretreatment

technology and systems

and e-coat systems to

solutions for applied surface

reduce consumption and

treatment. The products

at the same time enhance

protect metals from

performance. We are

corrosion, facilitate forming

tapping into the huge R&D

and machining, allow parts

pool of BASF, especially in

to be optimally prepared

the surfactant and polymer

for the painting process

area, to develop new

and ensure proper coating

cleaner systems or

adhesion. These products

high-performing sealants.

are used in a wide range of

We are really excited about

industries and end-markets,

the new opportunities and

such as automotive, aerospace, aluminium

Figure 1: Chemetall is the Surface Treatment global business unit of the Coatings division of BASF.

our customers will benefit from systems and solutions across the value chain.

finishing, and metal forming. In occasion of this special issue on

Ipcm: Can you trace the evolution of the

aluminium finishing distributed at the

company in the last 10 years?

Ipcm: Which is Chemetall’s current

upcoming international exhibition

MJ: Chemetall enjoys a great history of global

strategy on the market?

Aluminium 2018 in Düsseldorf, ipcm®

recognition for providing its customers with

MJ: Chemetall’s strength is to enable our

interviewed Martin Jung, Senior Vice

high-performance products and individual

customers to run their metal treatment

President Surface Treatment of

solutions for the metal industry. Over the

processes successfully. Our offering

Chemetall.

past ten years, our sales have grown by

comprises tailor-made products as well as

Before assuming his current role, Martin

more than 70 percent. The growth is built on

tailor-made service models. That is the basis

Jung headed the Automotive OEM

impressive team performance and organic

for further growth with our customers in

Coatings Solutions Europe business

growth with our customers as well as on

the automotive, components, aerospace,

unit of BASF’s Coatings division. He

the continuous expansion of our business

cold-forming, general industry, aluminum

studied chemistry and mathematics at

by acquisitions, e.g. in the glass industry or

finishing or glass industry – to name the most

the University of Heidelberg, Germany,

aluminum finishing businesses.

important ones.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

We build on our strong local presence globally to deliver fast service and a smooth supply chain. On the other hand, we trust in globalized R&D networks to deliver top notch products. Going forward, we will also expand in adjacent segments where we can build on our strengths. Furthermore, we will leverage the synergies 2 1

Figure 2: Martin Jung, Senior Vice President Surface Treatment.

with neighboring BASF businesses.b Ipcm: Which are the most important

industrial markets (segments and countries) for Chemetall’s business? MJ: Chemetall focuses on markets where metalworking processes are used – in a variety of industries and end markets, such as Automotive, Aerospace, Aluminum Finishing, and Metal Forming. Our growth plan is built on Chemetall’s good market positions in all regions of the world. In Pinghu, China, BASF has invested in a new state-of-the-art surface treatment site for the Chemetall brand with state-of-the-art laboratories, production and warehousing. We are also expanding our production site in Langelsheim/Germany for our NADCAP-certified aircraft sealant technologies. We expect continued profitable growth in Europe & South America as well as in North America. We will further increase our efforts in emerging markets in Asia Pacific, including Vietnam, Indonesia, Bangladesh, or Pakistan.

Chemetall develops and manufactures customized technology and systems solutions for applied surface treatment. The products protect metals from corrosion, facilitate forming and machining, allow parts to be optimally prepared for the painting process and ensure proper coating adhesion. These products are used in a wide range of industries and end-markets, such as automotive, aerospace, aluminum finishing, and metal forming.”

SP ECIAL ALUMIN IUM

3 1

Figure 3: Aluminium pretreatment and anodizing with Chemetall products generate desired surfaces.

Ipcm: What is the focus of

Ipcm: How is the situation of the

countries, as is CR III. At the same time, this

Chemetall’s R&D activities?

market regarding chrome free

project gets of higher importance for global

MJ: Chemetall is focused on multiple

processes?

quality label organizations such as Qualicoat,

R&D activities: We are working on

MJ: The market demands for chrome-free

Qualisteelcoat or GSB, who are discussing

improving the environmentally friendly

technologies for galvanized material and for

this trend. This is another confirmation that

thin film technology Oxsilan for the

aluminium are constantly rising over the past

chrome-free technologies are on the rise

automotive industry and developing

years – that is what we notice worldwide.

and will be more and more in the spotlight in

a new generation of our Naftoseal®

The fact is that CR VI is under attack in many

the next time.

aircraft sealants for the aerospace

Chemetall at the ALUMINIUM 2018

industry, allowing wider application windows and faster curing. We also focus on the introduction of functional cleaners to optimize Chemetall’s surface treatment solutions for key industries, such as Automotive OEM. And we develop more environmentally-friendly chromium-free surface treatment solutions for Automotive, Coil and General Industry.

Chemetall will be exhibiting and presenting

Being part of BASF’s Coatings division creates opportunities to offer the combined expertise of BASF within the coatings industry and Chemetall to increase customer benefits with improved products and services.”

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

at the ALUMINIUM 2018 in Düsseldorf, Germany from October 9th to 11th. The Surface Treatment global business unit of the Coatings division of BASF will be present at booth 12G12 and highlight its complete portfolio for all types of aluminium finishing applications as well as anodizing processes.

powder coatings Paint Engineering

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

Anticorrosive systems

Coil Coating Superdurable Superdurable coatings for sublimation effect Metallic bonding

www.titanpowdercoatings.com

Opening photo: The range of wood-eﬀect finishes included in the wide colour collection created in collaboration with Titan.

FOCUS ON TECHNOLOGY

S P E C I A L ALU MINIU M

Deep Collaboration with the Paint Supplier to Diversify Production and Ensure High Quality: The Winning Strategy of Lacoviana Barbara Pennati ipcm®

s “quality” the result of a teamwork or of

every product, plant, or service used

Experience, quality and satisfaction:

one company’s efforts to monitor every

must be of high quality, too.

these are the three pillars of the

production and service parameter?

That is why any company should

corporate philosophy of Lacoviana

The first option is obviously right. Having

create a network of suppliers suited to

(Viana do Castelo, Portugal), a company

a quality system in place is not enough:

its quality needs.

specialising in the finishing of aluminium.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

In the last thirty years,

FOCUS ON TECHNOLOGY

by collaborating

this approach has

closely with Lacoviana

enabled it to become

to develop new

the partner of choice

tailor-made finishes

for the production

and technologies

of aluminium in

for its customers.

architectural projects

The wood-effect

all over the world.

one obtained with a

Established in 1988,

powder-on-powder

the company started

technology is the

with a modest plant for

best example of this.

treating and coating

It is now one of the

aluminium profiles. It

flagships and what

now coversbanbareabof

distinguishes the

approximately 12,000

Portuguese company

m2, of which 7,000

from others (Fig. 2).

m2 are devoted to a horizontal coating plant with 2 booths and an anodising line, 1,000 m2 with 2 lines devoted

Lacoviana’s

production structure

Figure 1: From right to left, Lacoviana CEO Luís Cambão and production manager Diogo Barreto.

to the standing seam of thermal cutting profiles, and 4,000 m2

includes as follows: a totally automated anodising line among the most modern

in Europe, featuring an installed power of

are reserved for one vertical coating plant

36,000 amperes (Fig. 3) and using chemicals

installed at the end of 2017.

by Alsan (Valencia, Spain); a horizontal coating

“Our production is mainly intended for the

line with 2 booths; and a vertical coating line,

architecture sector, followed by the industrial

the most recent one, for which the Cube

one,” says CEO Luís Cambão (Fig. 1). “In

system provided by SAT (Verona, Italy) was

the last few years, we have worked hard

chosen (Fig. 4). Chemicals by Chemetall are

to diversify our production and conquer

used for the coating lines. The production

the international markets. We currently

capacity installed exceeds 6 million square

operate not only in Portugal but also in most

metres per year (±4 million coated products

European countries, with particular reference

and ±2 million anodised products).

to Spain, France, Holland, Belgium, United

The flexibility guaranteed by its aluminium

Kingdom - and in non-European countries

coating and treatment systems, its

such as the United States, Angola, and

collaboration with Titan, and the great

Mozambique. This exponential growth was

attention paid to the quality certifications

made possible by the investments made in

of its production (Qualicoat, Qualideco and

new technologies and the close partnerships

Qualanod) have enabled Lacoviana to widen

with our customers, while we are always

its range of products and finishes over time,

supported by our suppliers, honest and

thus becoming one of the services providers

reliable collaborators.”

in Europe in the treatment of aluminium for

The partnership with Industrias Titan for

architecture and industry.

the supply of powder coatings is just one

Optimising products and services

example. This partnership has lasted for more than twenty years and it has actively contributed to creating the current company image on the market, not only by providing high quality and reliable products, but also

Lacoviana pursues quality also through

2 1

careful selection of paints: the polyesters

Figure 2: A stand with diﬀerent wood-eﬀect finishes.

for architecture provided by Industrias Titan represent absignificant percentage of these.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

SP ECIAL ALUMIN IUM

worked with Titan to expand our colour and finish range,” states Cambão. “By enhancing our brand and modernising our company, we have created a pretty wide colour catalogue. It includes not only matt and gloss standard RAL colours but also a selection of textured and metallised shades and the wood-effect finishes (ref. Opening photo). These polyesters are always available from stock to guarantee fast deliveries within the established deadlines. The anodised shades’ catalogue follows the same philosophy with a wide range of coloursbfrom natural satin effect to stainless steel, champagne, bronze and black effects, through the gold, blue and ash grey colours. The range is completed with the mechanical treatments of brushing, polishing and repolishing.

3 1

“Such diversification in coated products

Figure 3: The fully automated anodising line, with an installed power of 36,000 amperes.

was possible thanks to the joint efforts of Lacoviana and Titan, with which we have also developed a powder-on-powder

technology for our wood-effect finishes,

of trust with Titan,” says Luís Cambão. “Only

with excellent realism and resistance

in the last year, we have been required to

properties (Fig. 5). By using coatings

use 500 different colours. Taking account

provided by one supplier and perfectly

of these coatings differences, as well as

suited to our needs, we maintain optimal

replacing our old coating booths with two

compatibility between different layers of

new last generation machines by Gema with

paint, which ensures quality consistency,

a very quick colour change system, we have

reliability, and durability,” says Cambão.

Experience, quality and satisfaction: these are the three pillars of the corporate philosophy of Lacoviana (Viana do Castelo, Portugal), a company specialising in the finishing of aluminium. In the last thirty years, this approach has enabled it to become the partner of choice for the production of aluminium in architectural projects all over the world. Established in 1988, the company started with a modest plant for treating and coating aluminium profiles. It now covers an area of approximately 12,000 m2, of which 7,000 m2 are devoted to a horizontal coating plant with 2 booths and an anodising line, 1,000 m2 with 2 lines devoted to the standing seam of thermal cutting profiles, and 4,000 m2 are reserved for one vertical coating plant installed at the end of 2017.”

“We have established an excellent relationship

4 1

Figure 4: The Cube system provided by SAT (Verona) was chosen for the vertical coating line.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

5 1

Figure 5: An aluminium frame treated by Lacoviana with a wood-eﬀect finish.

The partnership with Industrias Titan for the supply of powder coatings is just one example. This partnership has lasted for more than twenty years and it has actively contributed to creating the current company image on the market, not only by providing high quality and reliable products, but also by collaborating closely with Lacoviana to develop new tailor-made finishes and technologies for its customers. The wood-effect one obtained with a powder-on-powder technology is the best example of this. It is now one of the flagships and what distinguishes the Portuguese company from others.”

SP ECIAL ALUMIN IUM

The vertical coating plant: compactness and versatility

“SAT’s Cube system is the best solution for our needs. It ensures the end quality to which our clients

The new Cube vertical coating plant

havebbecome accustomed, while

is fully operational from January

having a compact structure: this was

2018. The pre-treatment process

crucial for us due to the expansion

includes an alkaline phase followed

of the existing line” says Lacoviana

by an acid phase to improve

production manager Diogo Barreto.

corrosion resistance and it uses

“Moreover, we already knew SAT’s

Chemetall products.

products and their corporate

The coating stage in the vertical

philosophy similar to ours, focussing

plant is performed in a quick colour

on customer trust and on the ability to

change booth (Fig. 6), equipped

react quickly and efficiently in case of

with GEMA application technology

any problems.”

with Venturi injectors (Fig. 7). “The

“Gema’s last generation system,

growth of Lacoviana has required

changing colour in about 5-6 minutes,

the need to increase production

have enabled us to perform up to

that led us to add a compact and

twenty colour change operations a

versatile vertical coating plant to our already-existing horizontal system (Fig. 8). This gives us greater flexibility and production speed,”

Figure 6: One of the two vertical booths, with a GEMA quick colour change system.

explains Luís Cambão.

6 1

7 1

Figure 7: Each booth features 18 Gema dispensers with a Venturi system.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

day (Fig. 9). This has also allowed us to effectively distribute the workload between the two lines, depending on the needs and features of each production,” states Barreto.

FOCUS ON TECHNOLOGY

8 1

Lacoviana’s production structure includes as follows: a totally automated anodising line among the most modern in Europe, featuring an installed power of 36,000 amperes and using chemicals by Alsan (Valencia, Spain); a horizontal coating line with 2 booths; and a vertical coating line, the most recent one, for which the Cube system provided by SAT (Verona, Italy) was chosen. Chemicals by Chemetall are used for the coating lines. The production capacity installed exceeds 6 million square metres per year (±4 million coated products and ±2 million anodised products).”

by the certification processes, such as the

“Lacoviana made all its

immersing a part in a solution for 48 hours,

investment choices with the

but we also carry out salt spray tests. Every

aim of ensuring quality of

workpiece treated is checked, regardless

the end product, flexibility of

of its intended use. We are among the first

the response, and customer

companies in Portugal to perform this service

satisfaction. This led us to

in-house, without outsourcing it (Fig. 11).”

certify our products according

“Thanks to the type of pre-treatment and

to the Qualicoat with A1 and

the quality of the coatings used, we can

A2 Seaside-class (coated

get a salt spray resistance value up to

products), Qualideco

3000 hours. Today it is not possible to

(wood-effect coated products),

offer a product that only has an excellent

and Qualanod (anodised

look: it is also necessary to guarantee

products) standards. We are

the materials durability by increasing the

also ISO 9001 certified; our

product’s life. If the object’s substrate is

next goal is to get the ISO

not treated optimally, the coating does

14001 certification,” explains

not adhere well; at the same time, if the

Diogo Barreto. “In order to

coating is not of excellent quality, the

check the actual quality of its

final quality and corrosion resistance

products, Lacoviana relies on

levels are compromised. That is why

an internal laboratory that

both the pre-treatment with Seaside-

employs the latest technologies

class and salt spray test stages come as

in terms of analysis and testing

a standard in all our processes, without

(Fig. 10). Here, not only do we

additional costs for the customers,” says

conduct the tests required

Barreto.

Machu test, an accelerated corrosion test required by Qualicoat and performed by

Figure 8: Coated profiles exiting the horizontal plant.

Certified quality and maximum production versatility

9 1

Figure 9: Gema’s OptiCenter powder management units allow for very quick colour change operations.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

SP ECIAL ALUMIN IUM

10 1

Figure 10: Lacoviana relies on an internal laboratory for testing and analysis.

the most suitable coatings for our needs. The increase in our production capacity

The new Cube vertical coating plant is fully operational from January 2018. The pre-treatment process includes an alkaline phase followed by an acid phase to improve corrosion resistance and it uses Chemetall products. The coating stage in the vertical plant is performed in the quick colour change booth, equipped with GEMA application technology with Venturi injectors.”

allowed by the new vertical line has enabled us to optimise workloads. The vertical system is now devoted to large-size batches, while the horizontal one is used for special projects, thus allowing us to meet fast delivery requests within just 24 hours,” explains Luís Cambão. “The technologies and products used have made our production flow more flexible and agile in order to meet the needs of different markets, whose specifications often change depending on the target country. We can offer the same optimal qualitative yield for both big and small projects, whether destined for the US, English, or French market. “We are laying the foundations for our

A common path in the pursuit of quality

future in order to become a company able to work for large firms but also to meet

“Some of the great advantages of

even the smallest businesses’ requests.

Lacoviana include its wide 30-year

This is our reason for pride and it would

experience in the coating field and its

11 1

quality offered by our suppliers,” says

long-standing collaboration with Titan, which has allowed us to learn a lot about

not be possible without the trust and high

Figure 11: The salt spray chamber.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

Cambão.

BRAND-NEW

S P E C I A L ALU MINIU M

Adapta Color Launches the New ANODIC Collection for Architectural Design

he new ANODIC collection

The products available feature a

All the colours in the collection boast the

launched by ADAPTA® is part

meticulous colorimetric adjustment

cutting-edge Adapta Bonding System®

of the VIVENDI® SDS range

and are intended as an option for all

technology, which provides and

for design and planning in the field of

those who appreciate the benefits this

guarantees a homogeneous visual

architecture. These products have been

kind of coating brings to their goods,

effect, essential for use in emblematic

designed in extra-durable, premium

including:

projects or where the highest standards

polyester to ensure the maximum

• A product life-cycle with less impact on

of quality are required. At the request

standards of quality with regard to shine and colour fastness to light, and always in compliance with the applicable international quality specifications. The collection bears an environmental product declaration (EPD) and has been

the environment. • Greater uniformity of colour between manufacturing batches. metal substrates. • Greater chemical resistance.

awarded an

to standard ISO having been A+ rating for extremely low emissions in indoor environments. The colours on offer cover a wide range of the most popular anodized finishes on the market.

Figure 1: The new ANODIC collection is part of the VIVENDI® SDS range and the products have been designed in extra-durable, premium polyester.

colour not featured in the ANODIC collection.

• The same appearance on different

certified pursuant 16000-9:2006,

of the client ADAPTA® will develop any

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

Fur further information: www.adaptacolor.com

BRAND-NEW

S P E C I A L ALU MINIU M

Clariant To Debut New Striking Shade for Transforming Applications at Aluminium 2018

lariant, a world leader in specialty

capabilities offered by its complete portfolio of

consumer experiences, we are pleased to draw

chemicals, invites aluminium

Swiss-made colorants, process chemicals and

on our long history of supporting the anodizing

anodizers, product designers

special printing inks for sub-eloxal printing.

industry worldwide and introduce

and engineers visiting Aluminium 2018 to

Clariant supports the industry with a wide range

easy-to-use vibrant, eye-catching colours that

heighten their creativity with the latest

of products, such as dyes based on heavy

extend designers’ creativity and increase

high-durability, sustainable colour solutions

metal-free structures (Sanodye ),

end-user value perceptions.”

for aluminium finishing.

borax-free degreasers/cleaners, and

Centre stage at Booth G13 Hall 12 will be a

nickel-free sealing solutions, for improving the

Aluminium 2018 will be held at the

new magenta shade with a unique level of

sustainability profile of finishing processes or

Messe Düsseldorf, Germany,

light and weather fastness that is perfect for

products.

rom October 9-11, 2018.

adding long-lasting vibrancy to indoor and

Thomas Heber, Technical Marketing Aluminium

outdoor applications. Adding to its

Europe, Business Unit Pigments at Clariant

For further information:

appeal, the single dye formulation has a

comments: “Aluminium lends an extra touch of

www.clariant.com/aluminumfinishing

heavy metal-free structure, non-bleeding

quality to a wide range of

and easy to handle. It shows good dye

applications. As segments

bath stability and enables a stable dyeing

such as electronics,

process.

cosmetics packaging,

Clariant will be joined by Omya (Schweiz)

appliances, automotive

AG, the exclusive distribution partner

and transportation,

for its aluminium finishing portfolio in

sports goods and also

Europe, North Africa and the Middle East,

architecture focus on

to demonstrate the product enhancing

creating enhanced

Competence in Shot Blast Technology We offer new and second-hand wheel blast machines including conveyor and filter systems. Our range of products and services include: • Wear and Spare Parts • Repair and (remote) maintenance • Services … for wheel blast machines of other makes as well. stand on me to our co se a le P CH, EUROBLE , 2018, Oct. 23-26 r, e v o n Han 1 tand B 14 Hall 13, S

Figure 1: Clariant’s colourful anodized aluminium dyes lend an extra touch of quality to a wide range of applications.

AGTOS Gesellschaft für technische Oberflächensysteme mbH Gutenbergstraße 14 D-48282 Emsdetten Tel. +49(0)2572 96026-0 info@agtos.de

www.agtos.com

253-09/18-4c-GB

SUCCESS STORIES

S P E C I A L ALU MINIU M

Tonon Forty Launches Its New Line of Radiators “Colors Vintage”, with Finishes Dedicated to Vintage Products and Created with Arsonsisi Powder Coatings selected finishes dedicated to vintage products, the Colors radiators give a touch of style to any environment, focussing on materials to recreate the sensations for which the Italian design is appreciated in the world. Simple materials such as copper, aluminium, stone, and soil have inspired the finishes chosen for this new line: mixed together, they create unique and surprising shades reminding of the

different elements in all their nuances.

Figure 1: The new “Colors Vintage” radiator range, designed by Tonon Forty and coated with Arsonsisi powders.

onon Forty is an Italian leader

including different thicknesses and

in the design, production, and

dimensions and it fits perfectly in

sale of heating appliances and

any room, embellishing it with its

systems. In collaboration with Arsonsisi,

unmistakable style.

a well-established Italian leader in

Tonon Forty and Arsonsisi have

the industrial coating market, it has

been collaborating for years to

revamped its well-known foil radiators

ensure maximum results and

from the Colors range. Colors is

the high quality that is typical of

Tonon Forty’s flagship product, which

Italian-made products of excellence.

established itself on the market in 1967

This collaboration also led to the

thanks to its reliability and versatility. It

creation of the new “Colors Vintage”

is available in a wide range of options

range (Fig. 1). With their carefully

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

2 1

SUCCESS STORIES © Arsonsisi

S P E C I A L ALU MINIU M

That is how the Vintage Corten finish

industrial products (Figs. 2 and 3). However,

was conceived. “Our design department

quoting the Colore Sicuro project of

worked closely with the sales department

Assovernici (the Italian association of paint

of Arsonsisi,” states Tonon Forty

producers), “there is value beyond colour”.

Marketing Manager Arianna Giuseppin.

Arsonsisi has joined Colore Sicuro to support

“Arsonsisi’s expertise and technical

the values of respect for its paints’ users,

assistance helped us a lot in this project

society, and the environment.

and they were decisive for the success of

The peculiarity of these two well-established

our Vintage collection.”

Italian companies lies precisely in their values.

The Copper, Aluminium, and Stone

Tonon Forty’s collaboration with Arsonsisi

finishes are based on coloured epoxy-

once again confirms its attention to quality,

polyester coatings, whereas the Vintage

safety, and the environment through the

Land and Vintage Corten ones are

choice of eco-friendly technologies and the

obtained through a particular treatment

protection of its operators, collaborators,

on raw radiators followed by the

and customers’ health – with maximum

application of transparent polyester

transparency.

Figure 2 and 3: Tonon Forty’s radiators during powder coating.

3 1

Touch the color with our new spectro2guide: There it is in black and white: The new spectro2guide has arrived. The revolution in color management. Upfront design. Color touchscreen. Camera preview. Auto calibration. Gloss. Fluorescence. Digital standard… www.touchthecolor.com

For further information: www.arsonsisi.com

Opening photo: Bandoxaldecor™ is the widest range of anodised aluminium on the market, with 21 diﬀerent finishes, 60 colours, and 8 thicknesses available.

FOCUS ON TECHNOLOGY

S P E C I A L ALU MINIU M

ALMECO: The First Zero Liquid Discharge Water Treatment Plant in the World Installed on an Anodic Oxidation Line for Aluminium Coils Alessia Venturi ipcm®

he zero liquid discharge (ZLD)

sectors such as the aluminium one where

is even more complicated: the amount of

technology is already commonly

the liquids present high concentrations of

surface treated per hour is far lower than

chosen to purify coating waste

this metal in the solution and where both

the surface coated by a plant with the

water, i.e. active baths and rinsing water

acid and alkaline pickling is often used. In

same production potential; on the other

from the pre-treatment phase, even in

the anodic oxidation field, this operation

hand, the concentration of pollutants

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

(acids, soda, and aluminium) found in

the first system of this kind in the world to be

active baths is up to 20 times higher. The

implemented on a coil line.

anodising process removes in fact higher

“The fact that the alkaline bath accounts

ALMECO GROUP: an ideal partner at every stage of the industrial process

amounts of aluminium from surfaces,

for 90% of the aluminium removed further

The unique expertise gained in over

although these can vary depending on the

complicates the subsequent water treatment.

fifty years of activity in aluminium

required finish.

Whereas CIE’s PUR-ALL technology already

production. An international

enabled to achieve a 50% abatement with the

organisation with units specialised

“A medium-sized aluminium coating

proper chemical-physical treatment, a much

in the different stages of the entire

plant has a painting potential of 1 ton/h,

more specific and complex technology was

industrial process. A widespread

equivalent to a surface of 300 m2/h; this

needed to treat alkaline water and reach a

presence on the global market through

material is treated with baths with a

zero liquid discharge value of 95% or more.

an extensive commercial network, and

maximum concentration of 1 to 2% (i.e.

Now, CIE owns a technology that, combined

distribution centres and services for

10-20 gr/l). An anodic oxidation line with

with its proven PUR-ALL system, allows to

strategic areas. These are the strengths

a potential of 30,000 amperes can treat

reach the total zero discharge goal even on a

that make the ALMECO GROUP one of

about 150 m /h, but the concentration

continuous flow anodic oxidation line.”

the world leaders in the production of

components and sheet

is 20%. Water pollution in an

materials for the lighting

anodising line is therefore

of soda and acids in its baths

engineering, solar, and

20 times greater than that

decorative industries

of a coating line, but with a

(Fig. 2). Thanks to its

productivity equal to half, if not

in-depth knowledge

a third of the latter. On average,

of the mechanical and

the anodising baths present

optical characteristics

concentrations of sulphuric

of aluminium and of

acid equal to 200 gr/l and of

surface treatment

aluminium equal to 15 gr/l.

processes, as well as to

Indeed, the surface removal

constant investments in

rate (e.g. the one necessary to

plants and equipment,

produce a completely opaque

ALMECO currently has

anodic oxide) can reach 70 gr/m2,

a production capacity

with the alkaline bath accounting

of over 20 thousand

for 60 gr/m and the acid

tonnes of aluminium

bath accounting for 10 gr/m2.

and more than 3 million

Consequently, coating processes

reflectors per year.

allow for cleaning operations

Lighting has always been

with a flow rate of 10 l /m , 2

whereas oxidation processes call for a 200 l/m2 flow rate,” explains

its core business, from

the production of high reflectance anodised

Figure 1: CIE Srl general manager Franco Falcone.

CIE general manager Franco

aluminium to the design

Falcone (Fig. 1). CIE Srl designs

and construction of reflecting optics and

and builds ZLD water treatment systems, specialising precisely in the aluminium sector. It has recently installed the first ZLD water treatment plant in Europe on an anodic oxidation line for aluminium coils at the premises of ALMECO (San Giuliano Milanese, Italy), which is also

CIE Srl designs and builds ZLD water treatment systems, specialising precisely in the aluminium sector. It has recently installed the first ZLD water treatment plant in Europe on an anodic oxidation line for aluminium coils at the premises of ALMECO (San Giuliano Milanese, Italy), which is also the first system of this kind in the world to be implemented on a coil line.”

reflectors (Fig. 3). Once achieved a leading position, the Group has progressively developed more specialised skills that have led it to win a leading role in both the renewable energy market,

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

SP ECIAL ALUMIN IUM

Thanks to its in-depth knowledge of the mechanical and optical characteristics of aluminium and of surface treatment processes, as well as to constant investments in plants and equipment, ALMECO currently has a production capacity of over 20 thousand tonnes of aluminium and more than 3 million reflectors per year. Lighting has always been its core business, from the production of high reflectance anodised aluminium to the design and construction of reflecting optics and reflectors.” ALMECO’s production organisation consists of four different units, each structured to manage the specialised process of aluminium manufacturing, depending on the treatment to which it is subjected and the application sector for which it is intended. The Italian plant in San Giuliano Milanese is the Group’s headquarters: in addition to the production of anodised aluminium for the lighting and decorative industry, it focuses on the design and production of reflectors for lighting fixtures.

Figure 2: Solar concentrators made with ALMECO ultra-bright aluminium.

for which it produces reflective and selective metal surfaces for concentrated

2 1

solar power plants and solar flat plate collectors, and the decorative market. In order to meet the use requirements of aluminium in the decorative field, the Group has developed Bandoxaldecor™ (ref. Opening photo), the widest range of anodised aluminium on the market with 21 different finishes, 60 colours, and 8 different thicknesses. It can be supplied on request with two different types of adhesive, a special treatment that makes it suitable for outdoor use, or a specific primer.

Figure 3: Another application of ultra-bright aluminium are lighting reflectors.

3 1

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

4 1

Figure 4: Giovanni Castelli, the operations director of the ALMECO GROUP.

Light and colour to surfaces with the anodising treatment Aluminium is subjected to a continuous anodising process to improve its reflection and gloss characteristics and protect its surface from corrosion and deterioration. Similar to an extrusion anodising process, the cycle includes brightening, anodising, colouring, and fixing phases. Brightening is the electrochemical process in which aluminium strips are immersed in a tank containing a concentrated mixture of high temperature acids and they are subjected to the action of electric current to smooth their surface in a controlled way and improve their gloss and reflection properties. During anodising, through the

The Group has developed Bandoxaldecor™, the widest range of anodised aluminium on the market with 21 different finishes, 60 colours, and 8 different thicknesses. It can be supplied on request with two different types of adhesive, a special treatment that makes it suitable for outdoor use, or a specific primer.”

SP ECIAL ALUMIN IUM

“ALMECO already had two anodic oxidation lines

ALMECO already had two anodic oxidation lines devoted to thin coils, in its San Giuliano Milanese plant. Recently, it has installed a new line able to process aluminium strips up to 3 mm thick and up to 2 metres wide with a continuous flow. This system has been devoted to the new range BandoxalproTM, designed for outdoor architectural applications. This line is highly advanced and, above all, unique.”

devoted to thin coils, in its San Giuliano Milanese plant,” says Giovanni Castelli, the operations director of the ALMECO GROUP (Fig. 4).

“Recently, it has installed a new line able to process aluminium strips up to 3 mm thick and up to 2 metres wide with a continuous flow. This system has been devoted to our new range BandoxalproTM, designed for outdoor architectural applications. This line is highly advanced and, above all, unique.” “ALMECO has always focussed on environmental awareness and respect for the local community,” states Giovanni Castelli. “That is why it has decided to further invest in eco-friendliness by installing this unique water treatment plant: a zero liquid discharge system for all its process water (rinsing liquids and concentrates) that eliminates any form of discharge into sewer and external disposal of both acid and alkaline

5 1

concentrates. In addition to

Figure 5: A bird’s eye view of the ZLD water treatment system installed by CIE to guarantee total recycling of process water.

reducing its environmental impact, this system enables ALMECO not to exploit community resources such as

electrochemical process of anodic

of the product unchanged over time.

the city purifier.”

oxide deposition, brightened aluminium

Thanks to its porosity, this layer is also

“The installed system (Fig. 5) guarantees

is covered with a thin film perfectly

particularly receptive: it can be subjected

total recycling of process water as well

adherent to metal. Accurate parameter

to a colouring process by immersion

as maximum flow flexibility of recycled

adjustment ensures perfect control

in special organic baths, thus obtaining

water and conductivity constancy,” says

and consistency of the deposited

metallic shades of great aesthetic effect.

CIE general manager Franco Falcone. “CIE

oxide thickness, improving reflection

The anodising cycle ends with a high

had already supplied the Group with a few

and minimising iridescence. This

temperature fixing phase, during which

services and assistance on old systems,

transparent and very resistant layer

the pores of the anodic oxide layer

and it was chosen again by ALMECO for

protects the surface from deterioration,

close perfectly, thus ensuring maximum

its expertise. We are the most qualified

keeping the optical characteristics

compactness and corrosion resistance.

company in the aluminium sector, as well

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

ALMECO’s line operates with

as the one that has built the highest number of ZLD plants in this field, which are entirely made by us without resorting to any external supplier of auxiliary units (demineralised water, UF, RO, or evaporation systems). CIE has also developed the PUR-ALL technology, ®

ensuring the almost total elimination not only of metals but also of acids such as sulphates, fluorides, and phosphates in order to recirculate water without expensive technologies such as ultrafiltration, reverse osmosis, and sometimes even evaporation,”

a continuous flow and with frequent speed changes. Therefore, the water treatment system must be as flexible as the production line, particularly as regards rinses. Indeed, although this is a ZLD system, a variation of even 10 times the flow rate of the rinses is ensured, while guaranteeing the same quality level and without affecting the ZLD process.

states Falcone.

ALMECO’s line operates with a continuous flow and with frequent speed changes. Therefore, the water treatment system must be as flexible as the production line, particularly as regards rinses. Indeed, although this is a ZLD system, a variation of even 10 times the flow rate of the rinses is ensured, while guaranteeing the same quality level and without affecting the ZLD process.”

6 1

Figure 6: The multi-exchange resin plant that treats all the rinsing water from the new oxidation line.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

S P E C I A L A L UM I NI UM

CIE has developed this water treatment process for a continuous flow anodic oxidation line by implementing a technology that exploits special multi-exchange resins to recycle rinsing water and a chemical-physical purification phase for concentrates that uses the PUR-ALL® ZERO ZERO technology. This guarantees total elimination of pollutants and minimisation of the resulting liquid, which is sent to a special evaporator with half the energy consumption.”

A unique water treatment plant in the world “We have developed this water treatment process for a continuous flow anodic oxidation line by implementing a technology that exploits special multi-exchange resins to recycle rinsing water (Fig. 6) and a chemical-physical purification phase for concentrates that uses the PUR-ALL® ZERO ZERO technology. This guarantees total elimination of pollutants and minimisation of the resulting liquid, which is sent to a special evaporator (Fig. 7) with half the energy consumption,” says Franco Falcone from CIE. “The plant allows to renew the rinsing liquids with a very high flow rate, ensuring maximum water quality and a conductivity value of less than 100 microsiemens. The water leaving the chemical-physical unit is conveyed into an evaporator: the distillate generated by evaporation is recovered and used as rinsing liquid, whereas the residue (less than 2%), exclusively made of neutral sodium salts, is disposed of by an external company.” “This is an innovative system because it is the first example of total zero liquid discharge on an anodic oxidation line. CIE already had plenty of experience in the installation of plants ensuring a 50% water recovery rate (e.g. the one installed by TALEX in Abu Dhabi1) and featuring our PUR-ALL® 1

ipcm® Vol. IX, n. 47, September-October 2017, pages 44-58

FOCUS ON TECHNOLOGY

technology (based on a chemical system exclusively owned by our subsidiary MST Chemicals). In ALMECO’s plant, PUR-ALL® was used, but it is not the only technology implemented: it only deals with the purification of acid water. For alkaline water, we have added a complementary technology whose effectiveness is such as to guarantee total recycling of all process waters, thus eliminating any form of discharge or disposal,” explains Falcone. “The plant we have installed for ALMECO is exceptional: we recycle 100% of rinsing water, an outstanding result considering that the quality of coils and therefore of the treatment water must be very high. It is very difficult to deposit anodic oxide and brighten aluminium coils with such a high aesthetic homogeneity, and ALMECO’s qualitative requirements for rinses were very strict. With our technology, we have allowed the company to achieve excellent treatment results without the need for any environmental authorization in terms of water. We are now finishing the commissioning phase and the company has already expressed satisfaction with its choice.” “Since the tanks of a continuous anodic oxidation line are very large, about 25-30 m3, ALMECO should have discharged at least 20 m3/h of liquid: with our plant, they do not discharge anything,” states Franco Falcone. “The main advantages are a reduction of at least 18-19 m3/h in water

In ALMECO’s plant, PUR-ALL® was used, but it is not the only technology implemented: it only deals with the purification of acid water. For alkaline water, CIE has added a complementary technology whose effectiveness is such as to guarantee total recycling of all process waters, thus eliminating any form of discharge or disposal.”

HIGH

PERFORMANCE POWDER COATINGS

SP ECIAL ALUMIN IUM

7 1

Figure 7: The evaporator for the resulting liquid of the chemical-physical treatment for final distillation.

consumption, significant management

improvement of production

both inside and outside its various

and operational cost savings, and an

processes enable the Group to

production buildings, where sensitive

ethical and environmental return in line

operate in total harmony with the

parameters and emissions are

with the company’s philosophy.”

environment. Since the 1960s,

constantly monitored. Now, thanks

the ALMECO GROUP has in fact

to the cutting-edge water treatment

initiated the search for “green”

system designed by CIE, the ALMECO

Commitment to the environment is

technologies and it has invested

GROUP is among the first and few

a fundamental value of the ALMECO

in water purification as well as

companies in the world to boast a

GROUP business philosophy. Respect

fume extraction and abatement to

total zero liquid discharge plant on

for current standards and continuous

minimise environmental impact,

an anodic oxidation line.

ALMECO: A green company

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

Every surface has its own individual structure!

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

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

$OXĂ&#x20AC;QLVK Â˛ WKH SDUWQHU \RX FDQ UHO\ RQ É&#x201C; &RDWLQJV IRU DOXPLQLXP VWHHO DQG ]LQF É&#x201C; $QRGLVLQJ No matter which pre-treatment process is the ideal one for \RXU QHHGV SHUVRQDO FRQVXOWDQF\ DQG LGHQWLĂ&#x20AC;FDWLRQ ZLWK \RXU WDVN LQ KDQG DUH ZKDW FRXQW DW $OXĂ&#x20AC;QLVK 2XU KLJKO\ FRPSHWHQW VWDII DUH WKHUH WR DWWHQG WR \RXU VSHFLĂ&#x20AC;F UHTXLUHPHQWV ZLWK DQ RSHQ HDU IRU \RXU ZLVKHV DQG NHHSLQJ DQ H\H RQ WKH HVVHQWLDOV ,QQRYDWLYH HQYLURQPHQWDOO\ VDIH VROXWLRQV WKDW PHHW WKH KLJKHVW demands of your customers are vital to us.

Alufinish GmbH & Co. KG 2WWR :ROII 6WUDÂ&#x2030;H Â&#x2021; ' $QGHUQDFK 7HO

We build on trust!

E-Mail: info@alufinish.de Â&#x2021; www.alufinish.de

SUCCESS STORIES

S P E C I A L ALU MINIU M

Framery in the Pursuit of Happiness with Teknos’ INFRALIT PE 8317-10 Powder Coating firm relied on Teknos, another Finnish company specialising in the production of powder coatings. “We have never disappointed our customers’ expectations, and this was no exception,” says Teknos Sales Engineer Tero Lahti (Fig. 2). It was certainly love at first sight for the “Framerians”, who immediately found the right coating during one very brief meeting with Tero Lahti: INFRALIT PE 8317-10.

INFRALIT PE 8317-10 It is a matte powder coating based on a Soft Touch polyester resin, available in 16 different colours and suitable for finishing metal objects that require a certain weathering resistance and the

Figure 1: Framery phonebooths and meeting pods are mainly required in open-space oﬃces.

heat or ultraviolet light. The powder is polymerised at high temperatures and it

According to a study done by the

forms a protective film with good

are quickly spreading. Framery, a

University of Sydney, more than 50% of

anti-corrosion properties.

Finnish leader in the production and

people sharing their workspace claimed

that doubled its turnover in 2017, is an

that background

excellent example of creativity, innovation,

noises, the lack of

and courage. Its functional products boast

privacy, and the

attractive design as well as metal surfaces

consequent reduction

protected and enhanced by high-tech

in efficiency are the

powder coatings. For years, open space

main problems.

offices have been considered a trend

Framery’s founders

conceived to offer a break during working

have had the same

days spent in small individual offices,

experience: that

improve relations between colleagues,

is how the idea

stimulate the sharing of ideas and

of designing a

teamwork, and optimise spaces; however,

soundproof pods

they now start showing their negative

was born (Fig. 1).

aspects.

For its finishes, the

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

oundproofing solutions for offices

development of soundproofing solutions

ability not to yellow due to exposure to

2 1

Figure 2: Teknos Sales Engineer Tero Lahti.

SUCCESS STORIES © Framery

S P E C I A L ALU MINIU M

ensures higher profits. Being happy at work, therefore, is not just a personal, but also corporate and financial matter. That is why Framery, which has always based its company policy on employee welfare, claims that “the production of soundproof booths and meeting pods is just one of many possible ways we have available to spread happiness in the workplace. By finding the right solution for us, Teknos has become part of one of today’s most exciting success stories.” For further information:

3 1

Figure 3 and 4: Framery’s functional products boast attractive design as well as metal surfaces protected and enhanced by the matte Soft Touch INFRALIT powder coating.

www.teknos.com

The metal surfaces of the soundproof booths designed by Framery have therefore been coated and protected by this advanced powder, thus combining functionality with attractive and modern design (Figs. 3 and 4).

Happiness and work: a possible combination Nowadays, more and more companies consider their employees’ happiness a priority. Work can certainly help to make workers happy, but at the same time happiness affects productivity and

4 1

End-to-end solutions – from body shop to coating and final assembly. www.eisenmann.com

INNOVATIONS: PRESENT&FUTURE

S P E C I A L ALU MINIU M

Qualicoat & Qualanod: latest eco-friendly developments for aluminium pre-treatment Dr. Alberto Abad, Alvarez Schaer S.A. Paterna – Valencia (Span)

alsan@alsan.es

s with most metals, precise preparation

metal surface. Among these solutions, we

of the aluminium surface is essential

can find ECORINSE LD, a product for the

Qualicoat A-127. Anodic pre-treatment with guarantees

to ensure the adherence of the

improvement of the adhesion of the organic

It is well known that hexavalent

coatings applied subsequently, as well as their

coatings on the anodic layer and MEDSEAL®

chromium compounds are being under

durability and optimum protection against

and FRIOFIX®ECOLINE innovative and green

observation for years. Currently the

corrosion.

sealing products free of toxic metals.

European Commission is still deciding © Alsan

Anodizing, like all industrial surface treatment processes,

on CTAC (Chromium Trioxide Authorization

involves a series of stages to

Consortium) Application

ensure its technical features and

for authorization which

finishes quality and these stages

includes the aluminium

depend on the final purpose

coating sector.

of the anodic layer. Anodic

Chrome use is

layers of 10-25 μm are usually

maintained by means of

employed as a decorative finish

prorogations requested

for aluminium which provides

by various sectors under

excellent wear and corrosion

the fear of whether

resistance.

or not, “alternative

In order for the porous anodic

products to Chromium

film to be perfectly protected against corrosion, it is necessary to seal the anodic layer. In this way, the metal loses its absorbing power, and remains protected

Figure 1: Filiform corrosion results obtained in the project BRITE-EURAM at the Italian site (Venice) at diﬀerent exposition times, with diﬀerent pre-treatments and using polyester powder as coatings.

(VI)” are able to protect aluminium in the most hostile environments and prevent corrosion, especially filiform

from aggressive exposure

corrosion.

environments.

However, previous

Besides, thin anodic layers of 3-8 μm can also be used as a superior pre-treatment for organic coatings which improves corrosion protection, especially against filiform corrosion. Alsan offers a wide catalogue of products that allows covering each and every one of the pretreatment stages guaranteeing an excellent preparation of the

ECORINSE LD is a non-toxic product, which allows preparing the anodic layer for the application of organic coating (liquid and powder coatings). ECORINSE LD works at room temperature in only a few seconds, getting rid of the standard hot rinse and reducing energy costs while guarantees dry and wet adhesion. The use of Ecorinse LD as final rinse for PREOX, provides under the QUALICOAT guidelines, a solution to the problem of the wet adhesion of powder coating with PREOX.”

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

studies have shown that both, alternative products and Chromium Trioxide, are not effective enough to prevent filiform corrosion when various factors combine, such as an industrial climate or marine environment that is strongly aggressive to aluminium.

INNOVATIONS: PRESENT&FUTURE

The results of the

test correctly. Nevertheless, in

European project

the light of the corrosion results,

BRITE-EURAM II: CRAF 1004-91:

both, the acetic salt spray and

“Development of new systems

the filiform corrosion tests, really

to prevent filiform corrosion”

presented acceptable outcomes.

have already shown that only

Knowing this problem,

profiles coated with anodic base

ALSAN’s R&D department

as pre-treatment, were effective

decided to develop a simple

to give a very good resistance to

solution, following its philosophy

corrosion, even at low anodizing

of providing sustainable and

thickness, when compared with

environmentally friendly

other pre-treated material even

products and processes. This is

with Cr (VI) and with different alternative systems (Fig. 1). Due to these reasons, since 2014 a new boost has been given to the “anodic pre-treatment or PREOX” within the QUALICOAT

how the ECORINSE LD product

2 1

emerged. ECORINSE LD is a

Figure 2: Percentage of tested powder paints that show satisfactory results according to the rinsing temperature used. Anodizing conditions: 22 ºC; 1.5 A / dm2; 10 minutes, 5 μm. Alloy 6063. (Source: AluminiunSan nr. 12).

the application of organic coating (liquid and powder coatings).

“WG Preanodizing”

preparing the anodic layer for

ECORINSE LD works at room

quality label, resulting in the working group

non-toxic product, which allows

temperature in only a few seconds, getting

within the technical

rid of the standard hot

committee. The

rinse and reducing

matter is again, to

energy costs while

determine the most

guarantees dry and

effective way to

wet adhesion. The

perform this “PREOX”

use of Ecorinse LD as

process to guarantee

final rinse for PREOX,

all Qualicoat test

provides under the

requirements when

QUALICOAT guidelines,

anodizing is applied

a solution to the

as pre-treatment

problem of the wet

before powder

adhesion of powder

coating. In particular,

coating with PREOX.

the Guidelines

Since March 2017,

must be updated,

Ecorinse LD, with

clearly defining the application conditions to ensure final quality. In view of these

3 1

Figure 3: Approval certificate of Ecorinse LD.

studies and the

the quality label No

4 1

A-127 (Fig. 3),

Figure 4: Pre-treatment cycle used in the homologation process.

is the first and only product used as final rinse for

compilation of technical information, carried

the acid residues from the pores and prepare

PREOX approved by Qualicoat. Figure 4

out by the WG, it has been noted that more

the samples to pass the crosshatch test

shows the pre-treatment cycle used in the

than 50% of the powder paints did not pass

satisfactorily after 2 h in boiling water (Fig. 2).

homologation process.

the wet adhesion test. This occurs when the

Many proposals have been made on the most

Table 1 and 2 show the results obtained

washing step was carried out after the PREOX,

suitable temperature and the appropriate

with Ecorinse LD in acetic acid salt spray

as stated in the Guidelines, under 60ºC.

rinsing times to pass the wet adhesion test

and filiform corrosion tests during the

Moreover, only temperatures around 90 ºC

with the PREOX, due to the enormous difficulty

approval process. As it can be seen in these

in the subsequent rinse are able to remove

that this system presents to comply with this

tables, besides excellent wet adhesion the

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

SP ECIAL ALUMIN IUM

Table 1. Acetic acid salt spray results of the approval process of Ecorinse LD. TEST: Acetic Acid Salt Spray Resistance UNE-EN ISO 9227:2012 PROCEDURE: Acetic Acid Salt Spray Resistance UNE-EN ISO 9227:2012 Codification

AVERAGE WEIGHT (μm)

DEVIATION (μm)

316-16-25

110

316-16-26 316-16-27

EVALUATION DATA CORROSION FACTOR

MAX. LENGTH (mm)

0,00

107

0,00

316-16-28

110

0,00

316-16-29

105

0,00

316-16-30

117

0,00

Table 2. Filiform results of the approval process of Ecorinse LD. TEST: Filiform Corrosion Resistance. Qualicoat Specifications (Ed. 14)+ Resolution Nº. 10/TC 5.11.14 PROCEDURE: DCT-PE-223 (Ed. 2)

FORMAT: RDCT-PE-323_01 (Ed. 0) HORIZONTAL

DEV. (μm)

316-16-49

316-16-50

0,0

316-16-51

113

0,0

316-16-52

0,0

316-16-53

0,0

316-16-54

112

0,0

VERTICAL AVERAGE WEIGHT (μm)

implemented

Codification

RIGHT

LEFT

RIGHT

LEFT

F/10 cm

0,0

5 1

Figure 5: Lay-out of the FOX pre-treatment line using Ecorinse LD.

ECORINSE LD, in

Sustainable alternatives to classic sealings

one vertical powder

Hot Sealing and Impregnation Sealing with

coating line with Flash

Nickel salts, also known as cold sealing, have

Anodizing in Poland.

been for decades the most frequently used

Ecorinse LD was used

sealing processes in sulfuric acid anodizing

as final rinse, after the

(type II). However, none of the above can be

flash anodizing and

considered Ecofriendly due to the high-energy

rinsing steps (Fig. 5).

consumption in the case of hot sealing, or to

During the first days of

the use of toxic nickel salts in cold sealing.

implementation over 40

For this reason, Alsan has been developing

different coatings were

new and sustainable sealing processes as the

tested in dry and wet

green alternative to classical sealing.

adhesion. All the results

MEDSEAL® 08 (QND-007) has been

were satisfactory.

successfully implemented for over a decade.

In conclusion, with the

It can be considered as catalyzed hot sealing.

combination of PREOX

MEDSEAL® 08 includes light metals and

combination of PREOX and Ecorinse LD

pre-treatment and ECORINSE LD, ALSAN brings

organic additives that allow a reduction

gives perfect results in the corrosion tests

to the market the first approved and definitive

of the temperature or the sealing time

(no corrosion was observed in both tests).

solution to solve the problem of filiform

in comparison to the classic hot sealing

Last August ALSAN has successfully

corrosion.

process.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

HAI UN IMPIANTO DI MOVIMENTAZIONE A CATENA? TRAS-MEC è la prima azienda che mette in sicurezza il tuo impianto e ti garantisce da contratto una produzione senza fermi improvvisi Non dovrai più lavorare accontentandoti HM YRE WSPY^MSRI GLI RSR XM WSHHMWǻ Progettazione: Mandaci il tuo progetto e studieremo il tuo trasportatore così che risponda alle caratteristiche che rendono il tuo ciclo produttivo unico.

6 1

Non avrai più dubbi sulla produzione del tuo materiale

Figure 6: Evolution of weight loss and times at 85 and 95 ºC, with and without MEDSEAL® 08.

Produzione: Costruiremo il tuo trasportatore secondo metodi standardizzati sviluppati nel tempo per farti avere un impianto performante.

Figure 6 shows that working with MEDSEAL® 08 can decrease the temperature of hot sealing to 85 ºC and get good sealing quality in only 2 minutes/micron. If we do not add MEDSEAL® 08 we would need about 5 minutes per micron to get good sealing quality at 85 ºC. At 95

Non dovrai più preoccuparti del montaggio del convogliatore

degrees, we obtain optimum results in only 1 minute per micron, but three minutes per micron are needed in the absence of MEDSEAL® 08.

Installazione: Con quest’opzione, avrai il tuo convogliatore chiavi in mano montato da un team di tecnici montatori esperti.

Therefore, in both scenarios, sealing is three times faster when we add MEDSEAL® 08. Thus, with MEDSEAL® 08 we can choose between reducing time or temperature. In both cases, we save energy, reduce costs and extend

Non avrai più blocchi di produzione

the sealing bath life, since MEDSEAL 08 sealing is less sensitive to

Servizio di manutenzione: Con il nostro servizio di manutenzione avrai un’assistenza periodica e continuativa che ti eviterà fermi non programmati, perdite di produzione impreviste.

pollutants. Besides, by decreasing the temperature, we also reduce the amount of vapor, which can cause problems with the automatic crane. On the other hand, if we shorten the time, we can reduce the size of the sealing bath or the number of sealing positions, saving costs in

maintenance. We can also keep the same number of sealing positions

TRAS-MEC è la prima azienda che ha integrato tutti i processi in un unico sistema industriale, per farti lavorare nel modo più performante senza più fermi di produzione che non sono stati programmati. Se vuoi avere più informazioni sul tuo trasportatore scrivi a customercare@tras-mec.it Riceverai in regalo il report “I 5 errori da evitare per mettere in sicurezza il tuo impianto nto ed eliminare per sempre il rischio dei fermi improvvisi” vvisi”

7 1

Figure 7: Energy consumption in the sealing process working with and without MEDSEAL® 08.

REPORT IIN N RE REGALO! REGALO EGALO! LO

SP ECIAL ALUMIN IUM

Electron Microscopy, with and without MEDSEAL® 08 at 85 ºC (Fig. 8). With MEDSEAL® 08 the pore widening is very fast: after only 5 minutes the pore size has increased from 12 to 14 nm. On the other hand, in the absence of MEDSEAL® 08, pore widening is extremely slow, especially at the beginning. It takes 45 minutes to increase the pore size to 14 nm. If we compare the necessary time to get from 12 to 14 nm, it takes only five minutes with MEDSEAL® 08 and 45 minutes without MEDSEAL® 08. Therefore, by adding the catalyst we speed the process up about ten times in the initial stage. However, if we consider the complete process, the catalyzed sealing is only 3-4 times faster overall. Hence, the catalyst plays a very important role in the initial dissolution of the alumina. More and more frequently, aluminum anodized and sealed with

8 1

nickel salts is not accepted, especially in certain countries and

Figure 8: Morphology of the anodic layer at diﬀerent times during the sealing process working and without MEDSEAL® 08.

sectors, due to the presence of nickel in the anodic coating or because of the typically greenish appearance that it presents. The use of MEDSEAL® 08 in anodizing lines that are currently using

and increase production.

cold sealing sometimes involves

However, the most evident advantage

changes to adapt the anodizing

of adding a catalyst is to save energy. The energy consumption of hot sealing mainly depends on the surface and the temperature of the bath. Figure 7 shows the overall energy consumption during the process. When the temperature is reduced to 85 ºC, about 25 % of the energy can be also saved. But by working at 95 ºC with MEDSEAL 08, we can ®

also decrease the sealing time to 1

Alsan has been developing new and sustainable sealing processes as the green alternative to classical sealing. MEDSEAL® 08 (QND-007) has been successfully implemented for over a decade. It can be considered as catalyzed hot sealing. MEDSEAL® 08 includes light metals and organic additives that allow a reduction of the temperature or the sealing time in comparison to the classic hot sealing process.”

line to the new sealing process. In response to this problem, Alsan has developed FRIOFIX® ECOLINE, a new nickel-free cold sealing process. Since last June, FRIOFIX® ECOLINE (QND-011) is the first and only free of nickel cold-sealing product approved by the quality label QUALANOD. This process ensures very similar working conditions to those used with the

a reduction in the number of sealing

classic nickel salts, but without

positions. This way, the consumption is 50 % lower compared to the classic hot sealing, and

minute per micron and this leads to

28 % lower than working at 85 ºC and 3 minutes per micron. According to the literature, the mechanism of hot sealing is mainly divided into two different stages: in the first one, the pore walls dissolve and that explains pore widening, while in the second stage the aluminium from alumina dissolution precipitates as hydrated alumina. The volume of hydrated alumina is higher than the volume of anhydrous alumina and pores get blocked. In order to find out how MEDSEAL® 08 accelerates the sealing process, Alsan studied the morphology of the anodic layer at different times during the sealing process by Scanning

9 1

Figure 9: Appearance of hot sealed specimens (above) and sealed with FRIOFIX® ECOLINE (QND-011) (below) after 1000 hours in acetic salt spray.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

Table 3. Comparative results with the reference hot sealing / hydration obtained during the approval process from the product FRIOFIX® ECOLINE (QND-011).

In order to find out how MEDSEAL® 08 accelerates the sealing process, Alsan studied the morphology of the anodic layer at different times during the sealing process by Scanning Electron Microscopy, with and without MEDSEAL® 08 at 85 ºC. With MEDSEAL® 08 the pore widening is very fast: after only 5 minutes the pore size has increased from 12 to 14 nm.”

CLARK TEST (M)

LOSS WEIGHT (mg/dm²)

DYE DROP

ADMITTANCE (μS)

Hydration Ecoline

15 μm-Bronze-1

0,7

0,8

8,6

7,9

---

17,1

7,7

15 μm-Bronze-2

0,4

0,6

8,9

7,7

---

25,7

8,1

15 μm-Bronze-3

0,6

0,4

9,4

7,8

---

37,9

8,6

20 μm-Bronze-1

1,3

0,3

9,1

8,9

---

24,4

11,9

20 μm-Bronze-2

1,8

0,2

8,1

9,9

---

45,3

11,8

20 μm-Bronze-3

0,5

0,8

8,7

9,9

---

36,3

9,2

15 μm-Natural-1

0,9

0,5

8,4

10,6

0-1

16,3

15 μm-Natural-2

0,4

0,6

8,9

9,2

23,2

6,6

15 μm-Natural-3

0,7

10,1

10,4

14,5

6,4

20 μm-Natural-1

0,3

0,6

11,4

10,4

0-1

14,2

7,1

20 μm-Natural-2

0,9

0,6

10,9

11,8

34,5

7,8

the disadvantages created by their toxicity.

20 μm-Natural-3

0,5

1,1

10,3

10,8

16,6

7,7

Therefore, it is now possible to replace nickel

Average

0,8

0,6

9,4

9,6

---

25,5

8,3

salts with a new process free of toxicity, without needing to make changes in your current anodizing line.

Once Alsan received the approval

range of finishes: polishing, brushing,

The results of the homologation process,

from QUALANOD, the industrial

electrolytic colouring, organic colouring,

where FRIOFIX® Ecoline was compared with a

implementation process started.

and chemical brightening. Tecanal

reference hot sealing product, are shown in

Last December, the process was

used to work with two baths of cold

Table 3. As we can see, the weight loss values

successfully incorporated in the

sealing with nickel; one of them with a

obtained were very low in both cases, below

Spanish company TECANAL, mainly

large amount of additive to avoid the

10 mg / dm on average. Regarding the dye

dedicated to decorative anodizing

typical appearance of nickel salts. In

drop test, by using FRIOFIX® Ecoline product,

and which is working with a wide

this sealing bath, the nickel salts were

the absorption power loss is greater than that shown with the reference hot sealing.

At the Clark’s abrasion test, thickness losses from anodic coating were on average lower with FRIOFIX® ECOLINE, probably because the hydration sealing at higher temperatures has a little negative effect on the abrasion resistance of the anodic coating. Regarding the admittance test, and opposite to what happens with the sealing by impregnation with nickel salts, the conductivity of the anodic layers sealed with FRIOFIX® ECOLINE is extremely low, and clearly below the values measured in the reference hot sealing. Finally, at the accelerated corrosion test, the presence of corrosion pits after 1000 hours of exposure was not observed in any case, only iridescences and small spots of similar size and extension appeared in both types of sealing (Fig. 9).

10 1

Figure 10: Scheme of the pre-treatment baths after the anodizing bath in Tecanal’s line using FRIOFIX® ECOLINE.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

SP ECIAL ALUMIN IUM

11 1

12 1

Figure 11: Scheme of the pre-treatment baths after the anodizing bath in Anodicolor´s line using FRIOFIX® ECOLINE.

Figure 12: Evolution of loss weight with production in diﬀerent colors using FRIOFIX® ECOLINE in Anodicolor.

replaced by FRIOFIX® ECOLINE

fields such as the cosmetic or

(Fig. 10). The behavior of the nickel-free sealing was excellent for all the aforementioned finishes, with no influence of the sealing on the final appearance of the material. It is worth mentioning that the touch in the sealed material, which is especially important in the decorative sector, cosmetic and pharmaceutical anodizing, turned out to be smoother in the material sealed with FRIOFIX

FRIOFIX® ECOLINE (QND-011) is the first and only free of nickel cold-sealing product approved by the quality label QUALANOD. This process ensures very similar working conditions to those used with the classic nickel salts, but without the disadvantages created by their toxicity. Therefore, it is now possible to replace nickel salts with a new process free of toxicity, without needing to make changes in your current anodizing line.”

pharmaceutical market where the pressure to avoid nickel salts is even higher. More recently, in April Alsan has introduced FRIOFIX® ECOLINE at the Spanish company ANODICOLOR, mainly dedicated to architectural anodizing (Fig. 11). ANODICOLOR has QUALANOD quality label and works with ageing at 60-65 ºC after the cold sealing process. As it can be seen in Figure 12, the

ECOLINE.

The sealing quality was checked continuously

sealing quality remained excellent as the bath

by means of the dye

was ageing. Besides, the

drop test, following the

final appearance of the

QUALANOD guidelines.

material was very good

Although the material was

(Fig. 13), in all finishes,

not aged in hot water, the

as long as a good

results of dye drop and

temperature control

weight loss, 24 hours after

and immersion times

the sealing process, were

were carried out.

satisfactory.

FRIOFIX® ECOLINE

The results obtained at

(QND-011), approved

the industrial test carried

by the quality label

out in TECANAL show the

QUALANOD and with

great potential of this new

proven results at

process for the sealing of anodic layer not only in the industrial or building sector, but also in other

13 1

Figure 13: Pictures of aluminium profiles sealed with FRIOFIX® ECOLINE in Anodicolor.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

industrial level, brings to the market the first and only free of nickel cold-sealing product.

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

Opening photo: One of the stadium of Russia 2018 FIFA World Cup was built using prepainted aluminium by Luxe Coat.

FOCUS ON TECHNOLOGY

S P E C I A L ALU MINIU M

Advanced Technology, Process Renewal, and Industrial Research on Pre-Treatment: Luxe Coat’s Strategy for Its Business Relaunch Barbara Pennati ipcm®

n continuous coating processes, e.g. coil

to competitiveness. Luxe Coat Srl (Bazzano,

found in Italy, and especially in L’Aquila, the

coating operations, it is crucial to keep

L’Aquila, Italy) specialises in the continuous

ideal solution to increase production capacity

quality constant and ensure that the plant

coating of aluminium alloys. The company was

and expand into the European market.

is versatile enough to meet the market’s needs

founded by Luxe Perfil, a Valencian company

“Luxe Coat’s current corporate structure

without sacrificing high productivity, crucial

operating in the aluminium market, which

was created in March 2016, but many of

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Innovative pre-treatment

its employees have over twenty years of experience and know-how,” explains Alfredo Calvano, the Technical and Plant Manager of Luxe Coat (Fig. 1). “Luxe Perfil’s interest has enabled the reactivation of two coil coating lines and to approach an ever-booming market thanks to targeted investments. This has allowed Luxe Coat to become one of the major players in the aluminium coil coating sector (ref. Opening photo) in relatively little time.” The first step for this business relaunch was the revamping of the coating systems, with the aim of making them as flexible as possible and increasing their production capacity. Two painting systems in L’Aquila (Abruzzo) have been acquired. Both lines had been stopped during the financial crisis and a turnover of different companies. Through a targeted intervention, not only have they been put back into operation, but also modernised and modified to meet the commercial and production goals set by Luxe Perfil,” says

In continuous coating processes, e.g. coil coating operations, it is crucial to keep quality constant and ensure that the plant is versatile enough to meet the market’s needs without sacrificing high productivity, crucial to competitiveness. Luxe Coat Srl (Bazzano, L’Aquila, Italy) specialises in the continuous coating of aluminium alloys. The company was founded by Luxe Perfil, a Valencian company operating in the aluminium market, which found in Italy, and especially in L’Aquila, the ideal solution to increase production capacity and expand into the European market.”

The pre-treatment stage employs chromefree acids and it is the same on both plants. “The chrome-free products used are Qualicoat approved. In the first phases of the process, the product is applied by spray and the interlocking tanks have a capacity of 10 m3,” explains DN Chemicals Sales Manager André Bernasconi. “The decision to adopt an acid product instead of an alkaline one was based on the technical experience of Luxe Coat, which found acid products ensured greater cleaning efficiency and better paint adhesion.” Thanks to the arrangement of the system, which includes 7 tanks devoted to pre-treatment, Luxe Coat and DN Chemicals were able to experiment and test different types of products without slowing down the coating process (Fig. 4). “Over the year, we have conducted a series of industrial tests to analyse and select the best products and © ipcm ®

Calvano. “Luxe Coat now has two continuous flow coating

application methods for an optimal preparation of coils

plants. The first one applies

without compromising their

liquid products and it is able

mechanical properties. After

to treat metal strips from 0.25

the application of various

up to 1.5 mm in thickness (Fig.

products on different alloys

2). The second one is the old

and at different speeds, and

machine: it was one of the first

after the performance of

continuous powder coating

mechanical tests such as

systems, dating back to 1989;

multiple bending and impact

we transformed into a unique

tests, data were collected

hybrid plant, able to coat coils

and analysed to see if it

up to 3.05 mm in thickness

was possible to apply the

with both powder and liquid

final conversion product

products or with countless combinations of them (Fig. 3).” The investment also involved updating the pre-treatment

by nebulisation rather than

by sprinkling, as it is done

Figure 1: From left to right: DN Chemicals Sales Manager André Bernasconi and Luxe Coat Technical and Plant Manager Alfredo Calvano.

phase. This was performed by

today,” says Bernasconi. “We then installed prototypes of spraying bars on both

DN Chemicals, a Milan-based

new application method that could ensure

company specialising in chemical products

greater treatment uniformity and, therefore,

fine-tuning to proceed to the final installation

for the treatment of metal surfaces. “We have

improved paint adhesion.” Together with DN

(Fig. 5).”

collaborated with DN Chemicals to identify

Chemicals, Luxe Coat conducted a series of

“These tests have ensured several benefits,

the pre-treatment process that best suited

industrial tests to assess the effectiveness of

especially in terms of quality consistency.

our needs and the different configuration

spraying bars, until then never implemented

The coil surface is in fact converted in a

of our systems,” explains Alfredo Calvano.

on a coil coating system, for the application

uniform way and the conversion layer was

“Above all, however, we aimed at developing a

of the no-rinse conversion product.

homogeneous regardless of speed (Fig. 6).

systems, which we are now

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

SP ECIAL ALUMIN IUM

2 1

3 1

Figure 2: The liquid coating system, able to treat metal strips from 0.25 up to 1.5 mm in thickness.

Figure 3: The hybrid plant can coat coils up to 3.05 mm in thickness with both powder and liquid products.

The only difference recorded was

competitive delivery times.”

meeting the most diverse specifications,”

determined by the type of aluminium

“With our expansion on foreign markets,

says Calvano. “Finally, we aim at helping

alloy, as different alloys have different

such the US, Canadian, and German

medium-small producers grow, since they

reactivity values and, therefore, different

ones, this need has increasingly become

are more receptive to market innovations

final conversion weights,” states Bernasconi.

stringent. In Germany, for example, the

and, therefore, they need a supplier

“Another advantage ensured by the

motorway barrier specifications require

that is equally capable of renewing

spraying bars was the substantial reduction

an aluminium thickness of not less than

itself to keep up with technological

of a problem arising in any process that

3.02 mm. This is one of the reasons that

developments.”

applies chrome-free products, that is,

led us to rethink our plants with the aim of

All these reasons led to a renewal of the production process to include

the nebulised product is always fresh, thus

two coating plants equipped with

sensitivity to dragged pollutants. Indeed, eliminating pollution. Finally, nebulisation

accumulators at both the entrance and

significantly reduces costs, because it

exit, which allow to continuously coat

uses much less product than spraying

without ever stopping the system, not

processes. At least 40% of the cost of the

even during the colour change or metal

conversion product is saved each year.”

cutting phase at the end of the process

In July, the last test was concluded to

(Fig. 7). “The liquid coating system, which

check the functionality of the system to

handles thicknesses between 0.25

be implemented with the final installation

and 1.5 mm, can treat 500/600 metres

stage.

of aluminium at a time. The hybrid system, on the other hand, was

Rethinking the production process

upgraded to treat coils up to 3.05 mm in thickness and can continuously apply

“Luxe Coat’s customers belong mainly to

both liquids and powders. This allows us

three categories: distributors, installers

to obtain various coating combinations

in the architecture sector, and panel

by simply activating or deactivating the

installation experts (e.g. honeycombs for

booths and ovens. Another peculiarity

the naval sector),” says Calvano. “This variety

of these plants, finally, is the ability to

allows us to be present in various industrial fields but, at the same time, it forces us to offer maximum production flexibility and

100

4 1

Figure 4: The pre-treatment tunnel.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

simultaneously apply more than one layer of paint on each side in one coat,” explains Calvano.

Top Quality Coil coatings Since 1978 coil coatings for building, industry, and packaging for

Aluminium closures

for for

TAB stock

Indoor

for for

Valve caps

Food containers

for

Pharma caps

• Antiﬁnger for stainless steel • High gloss PE coating • Laminated system

for

Outdoor • Anti-skid coating • Copper imitation • PE coating • PUR/PA cycle • PVdF cycle • Wood effect • Wrinkled coating

Innovative coil coatings Worldwide market presence High performance paints and inks Salchi Metalcoat Srl Viale dell’Industria 3/A-3/B - 20875 Burago di Molgora (MB) ITALY Ph. +39 039 6251824 Fax +39 039 6251829 E mail: info@salchirh.it - www.salchimetalcoat.com

The hybrid system is vertical and it includes liquid application booths and

SP ECIAL ALUMIN IUM

two powder coating booths (Fig. 11). All the booths and their related ovens can be activated according to production needs: in this way, Luxe Coat has the ability to apply double layers and mixed powder + liquid systems. “This type of system is very versatile – and versatility is one of Luxe Coat’s distinguishing features,” states Alfredo Calvano. “However, this process can hide pitfalls. Therefore, it requires special measures and process control options. Continuous

powder coating is a very difficult process

5 1

7 1

Figure 5: Prototypes of spraying bars have been installed on the final part of the pre-treatment tunnel.

Figure 7: Accumulators at both the entrance and exit allow to continuously coat without ever stopping the system.

The coating lines

thanks to the air blades. This also enables

The liquid coating system performs

to control thicknesses and to avoid any

a wet-on-wet application with the

quality problems during press-bending of

first coating head, which applies

painted aluminium (Fig. 12).”

the product simultaneously on two metre long oven with an air drying

A sustainable, 4.0-oriented future

segment and a cooling segment that

“Experience has taught us that the

uses demineralised water to bring the

control of the production process

metal to a temperature of 30 degrees.

affects the final quality of workpieces.

sides (Fig. 8). This is followed by a 15

Coming out of the cooling tunnel, the coil goes back into the same booth, where the second coating head applies the coloured or special effect layer, e.g. copper-like or wood-like,

6 1

Figure 6: A coated coil exiting the curing oven and passing through the quality control area.

through photoengraved rolls (Fig. 9).

DN Chemicals turned out to be a partner that shares this approach and is therefore able to develop solutions to meet such need, thus enabling us to give more guarantees to our customers. We have had the chance to

The plant also features a second

to control, as the guns’ mechanical

test different pre-treatment chemicals,

booth equipped with a coating head

movement and overspray can cause

but DN Chemicals’ technology offered

able to apply 20 to 25 microns per

pollution on the uncoated side.

the soundest solutions, in addition

side. After curing, the coil undergoes

Luxe Coat solved this problem by

to a fast and professional assistance

a final check to identify any surface

installing air blades to prevent excess

service. They were able to offer us

defects. The accumulator at the exit

powder from falling on the coil’s

a versatile, advanced, and unique

of the system allows to keep the plant

underside and by applying a liquid back

process, which will help improve

working even when cutting the metal

coat on surfaces that are clean and free

Luxe Coat’s product quality even

strip (Fig. 10).

from any powder residues precisely

further,” says Alfredo Calvano.

102

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

* patent pending

FOCUS ON TECHNOLOGY

8 1

Figure 8: A coating head with liquid products.

The pre-treatment stage employs chrome-free acids and it is the same on both plants. The chrome-free products used are Qualicoat approved. In the first phases of the process, the product is applied by spray and the interlocking tanks have a capacity of 10 m3. The decision to adopt an acid product instead of an alkaline one was based on the technical experience of Luxe Coat, which found acid products ensured greater cleaning efficiency and better paint adhesion.”

Light on rejects Light on waste Bright on application The must-have accessory for the Encore manual spray gun range

The Encore® nLighten™ LED Kit* Reduce or eliminate rejects or rework Effectively highlight and ﬁx light powder areas on surfaces, deep recesses and cavities – on the ﬂy. Reduce material waste Optimum light levels enable precisely targeted powder

application, to reduce waste and save on material costs. Increase efﬁciency This all-in-one application and inspection tool gives every operator the power to both spray and inspect at the same time. Improve safety Rated for use in all powder coating environments. For more information please visit www.nordsoncoating.com/nlighten ics.eu@nordson.com | www.nordson.com/powder 9 1

Figure 9: Coils painted with diﬀerent eﬀects: from the copper-like finish to the oxidised-like and matte ones.

Performance by design

SP ECIAL ALUMIN IUM

10 1

11 1

Figure 10: The final part of the plant, with a coil rewind system.

“Investments and innovations in the last few years have allowed us to grow a lot and give a second life to our old plants. The number of hires has increased exponentially and we have expanded by acquiring different neighbouring buildings and warehouses,” says Calvano. “We did not expect this success. Initially, the goal was ensuring greater production capacity for Luxe Perfil. However, our will to grow and

Figure 11: One of the two powder coating application booths.

will be presented at the

DN Chemicals has conducted a series of industrial tests to analyse and select the best products and application methods for an optimal preparation of coils without compromising their mechanical properties. After the application of various products on different alloys and at different speeds, and after the performance of mechanical tests such as multiple bending and impact tests, data were collected and analysed to see if it was possible to apply the final conversion product by nebulisation rather than by sprinkling, as it is done today. Then prototypes of spraying bars have been installed on both systems, which DN Chemicals is now fine-tuning to proceed to the final installation.

Aluminium 2018 fair in Düsseldorf on October,” states Calvano. “In future, we aim at further expanding our portfolio and at implementing an automatic process control that allows remote monitoring of all phases and process parameters, thus making intervention in case of any problems easier and more timely. Together with DN Chemicals, we are also developing a

old skilled and experienced

water recovery system.

start again together with our employees has enabled us to

This is a critical issue in

meet Luxe Perfil’s objective as

the Abruzzo region, which

well as to establish ourselves

entails significant costs for

on the national and foreign

our type of production.

markets with our own identity,

With a view to sustainability

in just two years.”

and respect for the

“The revamping of our

environment, therefore,

systems has ensured

we would like to adopt as

excellent quality consistency

soon as possible a system

while allowing us to expand

that allows us to exploit less

our range of products

and less drinking water by

and be flexible enough to experiment and develop new ones. Some of these

104

12 1

Figure 12: Powder dispensers.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

purifying and recirculating our process water,” says Alfredo Calvano.

Zaniolo CdA - 1.18

ESTETICA AESTHETICS DURATA ED

ESTETICA SEMPRE

EVIDENZA

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Opening picture: The vertical plant in operation.

FOCUS ON TECHNOLOGY

S P E C I A L ALU MINIU M

Chromium-Free Pretreatment at ELVIAL. A Review of 18 Successful Years Thomas Sondermann Aluﬁnish GmbH & Co. Kg, Andernach (Germany)

thomas.sondermann@aluﬁnish.de

ven as early as the 1990s, Alufinish

in Europe was at the ELVIAL company in

success story started in 1990 as a

developed the first chromium-free

Kilkis, Greece in 2000. ELVIAL is one of the

manufacturer of profiles for the industrial

ENVIROX pretreatment systems

leading aluminium extruders and finishers

sector. Production is now carried out on

which were successfully approved by the

in Greece who develop, manufacture

three aluminium presses with an annual

GSB International and Qualicoat quality

and market coated systems for a wide

capacity of more than 25,000 tonnes.

communities.

variety of architectural requirements as

Thanks to continuous advancement,

One of the earliest practical applications

also industrial purposes. The company’s

plant modernisation and automation with

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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

From the start in 2000, excellent coating results were achieved with this process. At the same time, Alufinish had the opportunity to gather valuable experience in dealing with the still new chromium-free technology. Based on their successful achievements with Alficoat 748/3, it was hardly surprising that ELVIAL again relied on this technology when building their new production location in 2005 (Fig. 1). The facilities that have since been built on the almost 40-acre site owned by the company include modern, vertical pre-treatment plant with surge technology in addition to robot-controlled transportation engineering and a large profile warehouse. The vertical line is made completely of 316 stainless steel. It is designed in tunnel form, has 12 process stages (Fig. 2) and is

capable of pretreating around 15 tonnes of Figure 1: The new production site of ELVIAL, built in 2005 in Kilkis (Greece).

aluminium profiles per shift.

robotic systems, the company is today able to fulfil even the most individual wishes of their customers. Besides extrusion lines, ELVIAL currently operate two coating lines (one horizontal and one vertical unit), both Qualicoat-Seaside class certified. The first chromium-free application using Alufinish products was implemented in a horizontal spray unit at the former production site in Kilkis. The Alufinish products used at the time were a simple combination of alkaline pickling and degreasing solution (Alfinal 273 – Alfisid 12), acidic pickling bath (Alfideox 74), and chromium-free pretreatment (Alficoat 748/3) (Table 1). This plant is still in operation.

Process

Products

Alkaline cleaning and pickling + rinsing

Alfinal 273 – Alfisid 12 + circular spraying nozzle, process water

Rinsing

Process water

Acidic pickling + rinsing

Alfideox 74 + circular spraying nozzle, process water

Rinsing

Demineralised water

Chromium-free pre-treatment, no-rinse

Alficoat 748/3 (ENVIROX NR process)

Draining and drying Table 1 - The first chromium-free application using Alufinish products, implemented in a horizontal spray unit at the former production site of ELVIAL.

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SP ECIAL ALUMIN IUM

conducted at the coastal location of Hoek van

The pretreated goods leave the long tunnel after the chromium-free pretreatment and are then dried in the retained water drier. This vertical installation is designed to allow maximum flexibility and currently has three acidic process stages. Cleaning and pickling are carried out simultaneously in zone 1 using Alfideox 74 and Alfisid 14. In zone 4, the same Alfideox product is used again for acidic post-pickling. The two-component product consists of Alfideox 74 – a pickling component with fluoride content – and the cleaning intensifier Alfisid 14. This method is particularly interesting whenever it is necessary to remove thicker oxide layers. Instead of having to implement the requirement in a single zone,

After 13 years of operation, the chromium-free ENVIROX NR process (Alficoat 748/3) is fully established in the vertical line at ELVIAL and provides the consistently high level of surface quality demanded by customers. More than 80,000 tonnes of aluminium have been treated in this installation to date. So, in the case of ELVIAL, one could definitely speak of a chromium-free model for success.”

Holland. Alficoat 748/3 generates colourless corrosion protection layers with titanium content which can be established, both on a quantitative as well as a qualitative level, by means of photometric layer determination and rapid test (staining). At ELVIAL, the product functions in a concentration range of just 4 – 6 g/l and is consequently very economical. Besides this, the continuous partial replacement of the bath solution also warrants consistent processing conditions and a guaranteed pre-treatment quality. In the vertical line (rif. Opening picture), the goods are treated by the surge method. In this case, pumps deliver the relevant process solution upwards into a surge box from which it

entailing a high consumption of chemicals, the necessary removal of the oxide layer has

ELVIAL are currently operating the line solely

flows down over the goods in a constant liquid

been divided between the two zones. In the

with acidic processing stages and achieve the

film (surge), thus performing the pretreatment.

event that the cleaning efficiency in the first

required surface qualities in this way.

The surge boxes are variable and can be

processing step is inadequate, the option is

The chromium-free ENVIROX NR implemented

adapted to the relevant profile sizes.

provided to intensify the cleaning performance

here is a single-component no-rinse system

Now, after 13 years of operation, the

in zone 4 by the addition of Alfisid 14.

that requires no downstream rinsing steps

However, this variant is usually only needed for material which has been contaminated with oil

(Alficoat 748/3) is fully established in the vertical line at ELVIAL and provides the

and is not generally necessary.

consistently high level of surface

Further to that, in order to have

quality demanded by customers.

the ability to speed up the line

More than 80,000 tonnes of

without losing the etching rate

aluminium have been treated in

the system provides another

this installation to date.

acidic process stage in zone 8 in

So, in the case of ELVIAL, one

ambient temperature this time.

could definitely speak of a

In theory, the entire line could

chromium-free model for success.

also be operated with an alkaline pickling and degreasing step in zone 1 and one or two acidic pickling steps in zone 4 and/ or 8. At least two rinsing stages

Thanks to flexible plant

2 1

technology, established from the

Figure 2: Schematic diagram of vertical line with surge pre-treatment (Zones 1 – 12 are actually located in a linear tunnel).

very beginning, the company is also well equipped for the future and follows the new trends. A further anodizing process for

between the processing steps were planned by the plant manufacturer,

at all. Despite this, the option is provided to

pre-anodization and chromium-free methods

ensuring sufficient rinsing efficiency, even in

perform posttreatment by means of a water

is under construction. The innovative method

different operating modes. The combined

spray unit. The product used is Alficoat 748/3

from ELVIAL, allows to pretreat the profiles with

alkaline pickling and degreasing (Alfinal 276

which has attained all the necessary approvals

a flash oxide layer (between 3 and 8 microns)

and Alfisid 12, for instance, would be

of the Qualicoat and GSB International quality

ensuring that the aluminium and the coated

conceivable) and acidic pickling pretreatment

communities and has also been certified since

layer are excellently protected from corrosion.

(Alfideox) enable optimum cleaning and

the beginning of the millennium. The product

A fully automated and technology advanced

pickling as they remove residues that are

has also passed the GSB International 10-year

process that performs all the steps on the

soluble in both alkaline and acidic solutions.

outdoor weathering test which was successfully

same line.

108

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

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Opening photo: The mechanical pre-treatment of extruded aluminium profiles significantly reduces the pickling time while creating a pleasant, uniform satin eﬀect.

INNOVATIONS: PRESENT&FUTURE

S P E C I A L ALU MINIU M

Shot Blasting of Extruded Aluminium Profiles: Aesthetic Quality with Time and Cost Savings Enzo Dell’Orto OMSG – Oﬀicine Meccaniche San Giorgio Spa, Villa Cortese (MI), Italy

management@omsg.it

he most common surface treatment

make it difficult to employ alternative methods.

of precious material that must be recovered

used for finishing extruded aluminium

On the other hand, the use of caustic

with further processes.

profiles has always been chemical

soda-based chemicals entails a large number of

In a global context where the demand for

pickling in a basic bath. The profiles’ complex

disadvantages due to the need to handle toxic

aluminium products is constantly growing, all

shapes, their sensitivity, and the aesthetic

solutions and properly dispose of their related

of this calls for a change of paradigm in order

perfection required raise several issues that

waste water, as well as to the significant erosion

to increase productivity and reduce costs, of

110

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

course without affecting quality. A solution

ÂŠ OMSG

INNOVATIONS: PRESENT&FUTURE

that has been successfully tested by major manufacturers of extruded aluminium profiles is a pre-treatment phase with a mechanical shot blasting process performed in an automatic turbine system, followed by a quick immersion in an alkaline bath to complete the finishing treatment. Shot blasting quickly eliminates most of the surface defects generated by extrusion and handling operations, while creating a pleasant, uniform satin effect (ref. Opening photo). The subsequent pickling phase, therefore, has a mere finishing function, thus being much more delicate. Some product characteristics, however, make it difficult to get optimal results. First of all, profiles have complex shapes and, therefore, they require careful positioning of the

Figure 1: OMSGâ&#x20AC;&#x2122;s LAUCO 80/30 shot blasting machine eďŹ&#x20AC;ectively treats numerous types of extruded aluminium parts.

turbines in order to obtain a uniform finish. Secondly, the parts are generally very thin

of abrasive per minute. The turbines are

its dispersion with the dusty air flow, thus

and thus susceptible to shot peening-induced

mounted on the central body of the shot

minimising waste.

deformation when subjected to mechanical

blasting machine and they are specially

At the exit of the machine, the workpieces are

stresses. Finally, in order to preserve their

arranged and inclined so that the whole

automatically transferred sideways on a special

aesthetics, any contact of the profiles with the

workpiece is perfectly treated.

hydraulic lifting system parallel to the exit roller

machineâ&#x20AC;&#x2122;s metal elements should be avoided.

A special conveyor made of rubber rollers

conveyor. This device tilts them to remove all

In order to meet all these requirements,

(Fig. 2) moves the workpieces through the

the abrasives stuck in their internal grooves and

OMSG â&#x20AC;&#x201C; Officine Meccaniche San Giorgio Spa

shot blasting chamber. Two pressure rollers

channels (Fig. 3); the stainless steel abrasive

(Villa Cortese, Milan, Italy) has developed a

block them from above, maintaining their

is then automatically returned to the shot

special range of shot blasting systems called

position, alignment, and distance. If needed, a

blasting machine. The choice to move the parts

LAUCO 80/30 (Fig. 1), able to effectively treat

third pressure roller can be added to enable

sideways maximises the productivity of the

any type of extruded aluminium part. As

the treatment of particularly short profiles,

plant, quickly freeing up the exit roller conveyor

always, the core of the shot blasting plants are

up to a minimum of 2 metres. Due to the

and concealing the time required for the tilting

four high-performance centrifugal turbines

need to use a fine, stainless steel abrasive

of pallets and the removal of abrasives. In this

patented by OMSG, each with an installed

composed of very small-sized spherical grains,

way, the pitch between batches can be limited

power of 15 kW, projecting more than 900 kg

the suction system is suitably sized to avoid

to a few seconds.

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9LVLWD LO VLWR

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ÄŻÄşĹ ÄĄÄśĹ? Ĺ&#x152;Ĺ&#x152;Ĺ&#x152; Ĺ&#x2030;ÄşÄ¸Ĺ&#x192;Ĺ&#x201E;Ĺ&#x2C6;Ĺ&#x160;Ĺ&#x2026;Ĺ&#x2026;Ĺ Ĺ&#x17D; Ä¸Ĺ&#x201E;Ĺ&#x201A; ÄžĹ&#x192;ÄťĹ&#x201E;#Ĺ&#x2030;ÄşÄ¸Ĺ&#x192;Ĺ&#x201E;Ĺ&#x2C6;Ĺ&#x160;Ĺ&#x2026;Ĺ&#x2026;Ĺ Ĺ&#x17D; Ä¸Ĺ&#x201E;Ĺ&#x201A;

#0%+ g 664'<<#674# g #5%*'4#674# g 2'55+/'64+ g 7.+5%+ #6'0#

SP ECIAL ALUMIN IUM

reduces the pickling time. Although this can

Mechanical pre-treatment significantly reduces the pickling time. Although this can vary greatly depending on the type of finish required, it is decreased by about 80%. In other words, if a chemical-only treatment takes 20 minutes, the finishing pickling process after shot blasting may last only 4 minutes.”

vary greatly depending on the type of finish required, it is decreased by about 80%. In other words, if a chemical-only treatment takes 20 minutes, the finishing pickling process after shot blasting may last only 4 minutes. This evidently ensures three benefits: - limited size of the plant and production area; - reduced total processing time; - reduced dispersion related to the material corrosion. This increases productivity and overall efficiency. In particular, it is possible to obtain

2 1

As per OMSG’s tradition,

a production increase of over 15%, while a

normally very fine and with a high percentage

recurring cost reduction of around 20% (for

of aluminium, the most effective safety systems

the same tonnage produced) can be expected.

have been adopted to avoid explosion.

Besides these economic advantages, another

An effective two-stage argon fire extinguishing

significant advantage of this solution is its

system can be added to also avoid fire.

much lower environmental impact, as it greatly

Now, what are the real advantages of

reduces the amount of sludge to be disposed

the combined cycle compared with the

of. The combined treatment proves therefore

conventional, chemical-only treatment? This is

to be a simple, modern, and feasible way to

the main question asked by customers before

innovate and make the treatment of extruded

deciding to purchase this turbine shot blasting

aluminium profiles more competitive while

machine. Mechanical pre-treatment significantly

saving and avoiding giving up quality.

Figure 2: A special conveyor made of rubber rollers moves the workpieces through the shot blasting chamber.

Given the characteristics of the particulate,

this shot blasting system is extremely robust, built with the highest quality materials, and advanced in terms of engineering solutions. It is equipped with a PLC that accurately sequences the work phases, sophisticated sensors for positioning control, and effective field diagnostics based on a PROFINET interface. A practical and user-friendly touchscreen interface enables the operator to manage the system effectively, check its performance, and watch synoptic graphics about the system status. Particular attention was paid to the dust extraction system.

112

3 1

Figure 3: At the exit of the machine, a special hydraulic lifting system tilts the parts to remove all the abrasives, which are automatically returned to the shot blasting machine.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

G R

Opening photo: The new BNL headquarters in Rome with curtain walls supplied by the Metra group.

FOCUS ON TECHNOLOGY

S P E C I A L ALU MINIU M

Metra Color: an Italian History of Quality and Innovation in Powder Coating to Conquer the US Market Ilaria Paolomelo and Alessia Venturi ipcm®

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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

n some aluminium

In order to help these

markets, such as the US

(few) applicators

one, powder coating is

tenaciously using

still uncommon, whereas

powders compliant

liquid and especially PVDF

with AAMA2605 , some

coatings are preferred

systems are being

thanks to their excellent

developed to optimise

outdoor and colour retention

the application

characteristics. However, the

process and avoid

trend is now being reversed,

significant investments

with an increasing number

for complete plant

of architectural projects

updates. An example

requiring powder-coated

of this is Eurosider’s

profiles for curtain walls (ref.

POLIFLUID® device

opening photo).

(Fig. 1), recently

In most cases, the suppliers of

installed by Metra

these profiles are European

Color in Rodengo

an, in particular, Italian,

Saiano.

since the local market lacks the necessary in-depth

Metra Holding has

knowledge of the powder

focused on innovation

coating process. However,

to achieve maximum

these projects’ specifications

quality levels since its

continue to call for

establishment in 1962.

compliance with the AAM2605

The Group has always

certification, requiring

specialised in the

powders with the same

aluminium extrusion

resistance properties of PVDF

and finishing field,

liquid paints, that is at least 10

quickly becoming an

years of outdoor resistance

industry leader both

in Florida Test. These powder

in Italy and abroad.

coatings compliant with AAMA2605 and that could be certified Qualicoat Classe 3 without this being a necessary

Currently, the Group

has three production

Figure 1: The control panel of one of the three machines featuring POLIFLUID®, a technology patented by Eurosider.

condition – are also called

plants located in Italy, including its subsidiary company

“hyper durable” and have been

Metra Color (Rodengo Saiano, BS),

available on the European market

which performs the whole finishing

for some time now. Nonetheless, such powders have a few critical issues in terms of formulation and application. These limit their colour range to a few shades and require a very high-quality application process, as well as its continuous monitoring and the protection of the workpieces against contamination with powders of different chemical nature.

process of aluminium profiles with an

Metra Holding has focused on innovation to achieve maximum quality levels since its establishment in 1962. The Group has always specialised in the aluminium extrusion and finishing field, quickly becoming an industry leader both in Italy and abroad.”

anodic oxidation line and a vertical powder coating plant (Fig. 2). In line with the Group’s philosophy, last year the latter was integrated with a new advanced technology offered by Eurosider, which enabled the company to solve a few quality issues and to achieve excellent aesthetic performance by modifying the powder application phase.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

115

SP ECIAL ALUMIN IUM

2 1

Figure 2: The unloading area of the vertical coating plant.

The innovative pre-treatment and coating cycle In Metra Color, extruded aluminium from the other factories of the Group enters the spray pre-treatment tunnel that performs the following stages: • degreasing with an acid solution • double rinsing with demineralised water • pickling with an alkaline solution • double rinsing with demineralised water • neutralization with an acid solution • double rinsing with specific demineralised water • surface conversion based on chrome-free zirconium-titanium • double rinsing with specific demineralised water.

116

“We chose to add an alkaline stage in order to achieve excellent performance

Last year Metra Color decided to integrate the coating line with a new advanced technology offered by Eurosider, which enabled the company to solve a few quality issues and to achieve excellent aesthetic performance by modifying the powder application phase. ”

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

and quality results. Thanks to this acidalkaline-acid pre-treatment cycle, all our aluminium products have obtained the Qualicoat Seaside certification: in this way, our profiles can be installed anywhere in the world, even in the marine areas most subject to corrosion (Fig. 3),” says Metra Color technical manager Biagio Scopel (Fig. 4). After pre-treatment, the aluminium bars are dried and sent to the application station, composed of three vertical coating booths provided by Euroimpianti. “The first one of the three booth is devoted to the

FOCUS ON TECHNOLOGY

3 1

Figure 3: The “Dollar Bay” towern in London’s Ciry.

The reason behind the choice to add an alkaline stage is to achieve excellent performance and quality results. Thanks to this acid-alkaline-acid pre-treatment cycle, the aluminium profiles manage to obtain the Qualicoat Seaside certification: in this way, they can be installed anywhere in the world, even in the marine areas most subject to corrosion.”

application of hyper-durable coatings as well as metallic colours and special products (Fig. 5); the second one of light shades, and the third of powders with conventional RAL colours (Fig. 6). The choice to devote each booth to a particular type of powder prevents any problems of contamination among different colours and chemical natures, as happened in the past. Also this choice is aimed at high quality and it avoids disputes over our products. In June, we decided to further improve the coating quality of our profiles by installing Eurosider’s POLIFLUID® system on all three coating booths.”

POLIFLUID®: Powder coating with nitrogen POLIFLUID® is a powder coating technology patented by Eurosider that exploits the nitrogen contained in compressed air through the selective permeation principle and uses it as a carrier in all application stages. The use of 96% pure nitrogen instead of

4 1

Figure 4: The touch screen panel managing the POLIFLUID® devices.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

117

S P E C I A L A L UM I NI UM

5 1

Figure 5: Close up of the powder coating application in typical vertical coating booth.

compressed air enables this generator to prevent powder from accumulating in the gun and from producing lumps that could compromise surface uniformity. “Thanks to the installation of these generators, precisely a POLIFLUID® 150 and two POLIFLUID® 200 systems, we have solved the aesthetic problems that we encountered in the past, especially in terms of coating distension. Hyper-durable powders are very difficult to spread compared with other powders on the market and

Each one of the three vertical coating booths, provided by Euroimpianti, is devoted to the application of a different powder coating, in particular: the first of hyper-durable coatings as well as metallic colours and special products; the second of light shades; the third of dark shades and conventional RAL colours. The choice to devote each booth to a particular type of powder prevents any problems of contamination among different colours and chemical natures.”

FOCUS ON TECHNOLOGY

POLIFLUID® is a powder coating technology patented by Eurosider that exploits the nitrogen contained in compressed air through the selective permeation principle and uses it as a carrier in all application stages. The use of 96% pure nitrogen instead of compressed air enables this generator to prevent powder from accumulating in the gun and from producing lumps that could compromise surface uniformity.” they created orange peel issues; moreover, they are difficult to control during application and they require more than uniform thicknesses,” says Scopel. “POLIFLUID® ensures numerous advantages: more uniform thicknesses on profiles, better distension and therefore reduced orange peel effect, better yield, greater coverage with lower thicknesses, and about a 10% saving on coating products (Fig. 7). POLIFLUID® has allowed us to solve all our application issues without having to change the whole application system of our coating plant: with a small investment, we have been able to continue to use the equipment already present on our line without replacing it.” “Eurosider technicians have worked in close cooperation with the Italian customer: we were very willing to find the best solutions for them and solve any problem found” Ottavio Milli (Fig. 6), CEO of Eurosider in Grosseto, Italy, explains. “During the first month, we would

POLIFLUID® ensures numerous advantages: more uniform thicknesses on profiles, better distension and therefore reduced orange peel effect, better yield, greater coverage with lower thicknesses, and at least a 10% saving on coating products.”

SP ECIAL ALUMIN IUM

Figure 6: Ottavio Milli, CEO of Eurosider (Grosseto, Italy).

receive from the customer a weekly report with application parameters

6 1

and production data (Fig. 7), which made us realise that they had reduced their powder consumption. Given the high cost of hyper durable coatings, which they use on a stable basis, this also translates into significant economic savings.”

Metra Color’s choice “Investing in an unusual pre-treatment cycle, in new advanced technologies, and in more expensive but better performing powder coatings has proved to be a winning choice. It has enabled us to provide our customers with excellent-quality aluminium profiles and to become the supplier of choice on the US market,” says Scopel.

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7 1

Figure 7: Process parameters of POLIFLUID® equipment.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

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S P E C I A L ALU MINIU M

Micro-Gloss Robotic: Automatic Online Gloss Control

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The long-term stable LED light source

mounting track for fast calibration

the field of measuring colour

of the micro-gloss provides not only

on a regular basis. The intelligent

and appearance and testing

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auto diagnosis of the micro-gloss

physical properties of plastic, coatings and

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notifies when the standard is

cosmetics is introducing a new member

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reliable measurement at any time.

The new micro-gloss 60° robotic enables

to advanced temperature control, the

Power supply occurs via the USB

automatic measurement of surface gloss

micro-gloss assures highest stability

interface, as well as control of all

(Fig. 1). Matte, satin-finished or glossy

of the gloss values. A high-tech,

measurement functions. The smart

- uniform appearance stands for high

automated calibration procedure

data communication allows direct

quality. A stable running process is the

on a complete range of gloss tiles as

and fast data transfer to the smart-

key for uniform and consistent quality.

final step in the meter’s production

chart software.

Therefore, gloss needs to be measured on

process guarantees outstanding

a routine basis in the production process

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For further information:

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repeatability, inter-instrument

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documented for clear communication.

agreement and temperature stability.

The new micro-gloss robotic allows

The reference tile for calibration

automated gloss control to increase the

is supplied in a special

measuring cell, on a xy-table or similar set-ups. Thus, readings are always taken on the same sample area, which ensures repeatable positioning and reliable results. The lightweight of the unit and the fast data collection allow measuring a high number of parts. This provides complete and representative data for statistical process control enabling proactive reaction to process changes.

122

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

Figure 1: The new micro-gloss 60° robotic enables automatic measurement of surface gloss.

BRAND-NEW

S P E C I A L ALU MINIU M

New High-Performance Turbines for Aluminum Components he increasing processing of aluminum

requires new developments in surface technology. What is needed are economical concepts for deburring, cleaning and finishing the aluminum workpieces. Aluminum workpieces are increasingly being processed with aluminum abrasive. For this application, AGTOS engineers and technicians have developed new highperformance turbines (Fig. 1). One turbine can be seen as an exhibit at the AGTOS booth of the ALUMINUM fair in hall 12, booth 12I20. In addition to the blasting processing, the gentle handling of the workpieces is important. Only if both is matched to the aluminum workpieces the quality of the surfaces can meet the

requirements. The AGTOS exhibition team is happy to inform the visitors

Figure 1: The new high-performance turbine from AGTOS

about shot blasting machines specially

blasting machines. These are

Trade fair ALUMINIUM, 09. – 11.

designed for the processing of

as well delivered in a technically

Oktober 2018 Düsseldorf, Hall 12,

aluminum workpieces.

perfect condition, modernized and

Booth 12I20.

Generally, AGTOS offers many

tailored to customer requirements.

different types of new blasting

An extensive service program

For further information:

machines and deals with used

completes the range of services.

www.agtos.de

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

123

Opening photo: All.co Group, an industrial group founded in Pisa (Italy) in 1973, has established itself among the most successful companies in the sector of aluminium extrusion and processing.

FOCUS ON TECHNOLOGY

S P E C I A L ALU MINIU M

All.co Group: A Wide Choice of High-Quality Finishes and Colours from a Well-Established Company Barbara Pennati ipcm®

pcm® has already presented several

right strategy to remain operational and

All.co Group is an industrial group established

examples of Italian companies that have

relaunch their products. The solutions

in Pisa (Italy) in 1973 by the Vecoli family

had (and been able to) innovate in order

adopted up to now have involved plant

(Fig. 1). It has managed to consolidate its

to overcome the economic crisis that hit the

investments, close collaborations with

presence on the Italian and foreign markets,

Country in 2008. In the last few years, there

suppliers, widening of the product ranges,

establishing itself among the most successful

has been a slow recovery, but some markets

and export to foreign markets. Very often,

companies in the sector of aluminium

are still struggling to get back on track and

the winning strategy is just a combination of

extrusion and processing and achieving a

numerous company still have to look for the

all these practices.

turnover of 162 million Euros in 2017.

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FOCUS ON TECHNOLOGY

our production more versatile, we have

The success of this company is due to several factors, including its ability to present itself as a specialised aluminium extrusion centre. Its production cycle starts with the purchase of raw material and it continues with melting, extrusion, coating, and distribution operations – a process involving seven production plants and thirteen distribution centres located in Italy and abroad (ref. Opening photo). Besides presenting itself as a singlesource supplier, over the years All.co has been able to cope with market fluctuations by adapting its production to the current demand and thus ensuring constant growth and affirming itself on the international markets. “All.co designs and manufactures aluminium extrusions for the industrial and construction sectors, handling all phases in-house,” says Luigi Vecoli, the coating manager of the All.co Group. “In 1991, we even insourced the coating process to offer an extra service to our customers. We mainly paint material for the construction sector. This has enabled us to meet the needs of the market in terms of finishing, which, especially in recent years, has

All.co Group is an industrial group established in Pisa (Italy) in 1973 by the Vecoli family. It has managed to consolidate its presence on the Italian and foreign markets, establishing itself among the most successful companies in the sector of aluminium extrusion and processing and achieving a turnover of 162 million Euros in 2017. The success of this company is due to several factors, including its ability to present itself as a specialised aluminium extrusion centre. Its production cycle starts with the purchase of raw material and it continues with melting, extrusion, coating, and distribution operations – a process involving seven production plants and thirteen distribution centres located in Italy and abroad.”

become increasingly important for the

on foreign markets, which have become our main target, as the Italian aluminium market is still slow,” states Vecoli. All.co has been actively collaborating for more than ten years with Inver, a manufacturer of industrial coatings belonging to the Sherwin-Williams Group, as well as the main supplier of the Syntha Pulvin® branded polyester powders used by All.co. For even greater production flexibility, also the vertical coating plant designed by Trasmetal (Milan, Italy) underwent a revamping in the 2014, with the installation of a new coating booth equipped with two OFB disks, able to treat profiles up to 6 metres and with an overall capacity of 40 tonnes per day.

Combining production versatility and quality consistency “Our collaboration with Inver began in 2004. The first few years have been a trial stage for both parties: since we previously had other suppliers, Inver had to analyse our colours and adapt its products to our needs,” explains Luigi Vecoli. “Much of the material painted in our Pisa plant is sent to © All.co

construction field and

also succeeded in establishing ourselves

therefore for us too.

our other factories and distribution

In the past, the most

centres. This

used colours were

allows us to be

white and ivory and

more competitive

the most common

on the market

finish was the glossy

and ensure fast

one; nowadays, in the

delivery times to

world of aluminium

our customers.”

and in particular of

The powders

window and door

applied on all All.

frames, there is

co products are

the possibility to

Syntha Pulvin®

experiment with

polyesters

many shades,

specifically

whose demand

designed for the

varies according to the destination market. By making

Figure 1: The Vecoli family, which founded the All.co Group.

architectural sector, which are Qualicoat and

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

125

SP ECIAL ALUMIN IUM

Figure 2: Inver is the main supplier of polyester powders of the All.co Group.

In Germany and France, for example, greys are in high demand, whereas in Italy the palette is much wider, from white and ivory to green and gothic brown (Fig. 4).” “All.co performs 4 to 6 colour change operations per day. With such special and varied requests, for us it was crucial to find the right powder supplier, able to guarantee extreme versatility without compromising quality standards. Inver showed

2 1

perseverance and expertise in meeting all our needs and it proved

GSB-INTERNATIONAL approved (Fig. 2).

Marco Canola (Fig. 3). “Now, not only

to be the perfect technological

Thanks to the joint efforts of Inver and All.co,

quality must be high, but suppliers

partner for All.co,” says Vecoli. “When

the company is able to offer different

must also be able to cope with the most

we replaced our coating booth in

finishes and effects while maintaining a

diverse requests in terms of colours

2014, they were also able to modify

high quality standard. These skills have

and finishes. Matte finishes prevail

their formulations to perfectly

helped establishing the firm on both

everywhere, while the colours requested

adapt them to our new application

the building and industrial market as

vary depending on the Country.

parameters.”

application sectors of its products – which currently

well as expanding the

include road, naval, and air transport. “Today’s market requires attention to detail and very high quality levels, even in industries where a lot less attention used to be paid to possible defects and imperfections, such as the building one,” explains Sherwin-Williams architectural sales representative

Figure 3: From left to right, Marco Canola from Sherwin-Williams and Luigi Vecoli from All.co.

126

3 1

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FOCUS ON TECHNOLOGY

The coating process The coating plant was designed by Trasmetal and it integrates into the fully computerised production flow of All.co (Fig. 5). “The plant has two loading areas: one for packaged materials that must be handled by an automatic unwrapping machine, the other devoted to the baskets containing ready-to-be-coated profiles,” explains Luigi Vecoli. “Our production system is completely computerised. The operators use barcode reading guns to manage the whole cycle: in this way, not only have we eliminated paper, which is an advantage in terms of both eco-friendliness and

4 1

Figure 4: Some colours and finishes produced by All.co.

SP ECIAL ALUMIN IUM

Figure 5: The vertical coating plant.

5 1

Figure 6: The profile loading area and the entrance to the 10-stage pre-treatment tunnel.

128

6 1

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

cost efficiency, but we have also minimised the possibility of any order management errors. Moreover, all information related to profiles is linked to the coating parameters, so that the operators have a complete overview of production and All.co can analyse the various data to improve its painting process. Monitoring every process phase has also resulted in a substantial reduction in

PAINTING ROBOTS & SYSTEM INTEGRATOR We are able to provide the full range of articulated and cartesian robots for every painting need!

production waste, as we are able to intervene promptly to solve any problems and prevent them from happening again.” Coating starts with a 10-stage pre-treatment

All.co has been actively collaborating for more than ten years with Inver, a manufacturer of industrial coatings belonging to the Sherwin-Williams Group, as well as the main supplier of the Syntha Pulvin® branded polyester powders used by All.co. For even greater production flexibility, also the vertical coating plant underwent a revamping in the 2014, with the installation of a new coating booth equipped with two OFB disks, able to treat profiles up to 6 metres and with an overall capacity of 40 tonnes per day.”

LeBot MV A5-A6: 5 and 6 axis articulated robot with self-learning, point to point and 3D offline programming, also available in chariot, carriage and carousel configuration with 3D Lesta shape acquisition system.

process (Fig. 6). The chemicals are applied through spray nozzles. After drying, the profiles enter the new coating booth (Fig. 7) installed by Trasmetal in 2014 and featuring two

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

OFB disks. “The OFB technology is the most suitable for our type of production flow, which involves processing large quantities of material, and it enables us to perfectly coat all our profiles, as they loop around the disk to obtain uniform

LeBot IA6: articulated 6-axis industrial robots with jointed-arm kinematics for all point-to-point and continuous-path tasks, controlled by our LeCRob K-Manager software. LeBot IA6 robots can work with 3D Lesta shape system. aacquisition ac qu tem.

application over their entire surface. In the past, only visible parts had to be painted, but now we prefer to coat our products on all sides,” says Vecoli. “After coating,

the profiles reach an IR gelling oven (Fig. 8), again provided by

WWW.LESTA.IT

Trasmetal. It is located before the polymerisation oven to ensure greater control over colour and reduce contamination among different process phases.” “The profiles then reach the polymerisation oven (Fig. 9), operating at a temperature of 180-190°C. A storage buffer allows for effective cooling before unloading (Figs. 10 and 11). During the revamping process of 2014, we also lengthened the unloading bench (Figs. 12 and 13),” states Vecoli. “In the past,

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SP ECIAL ALUMIN IUM

the material was unhooked, gathered, and loaded on forklifts for weighing. This much longer unloading station allows us to manage orders according to our current needs, postponing or anticipating operations without ever stopping production or slowing down the weighing and packaging procedures, which are performed automatically to minimise the possibility of damaging the material.”

A high-performance future “Although coating is not the core business of All.co, our company is very attentive to the quality of its products and it strives to offer a reliable and complete service to its customers,” explains Vecoli. “Our activity is certified according to the international quality

standard ISO 9001 and the environmental standard ISO 14001,

7 1

Figure 7: Trasmetal’s coating booth paints the profiles with two OFB disks.

The powders applied on all All.co products are Syntha Pulvin® polyesters specifically designed for the architectural sector, which are Qualicoat and GSB-INTERNATIONAL approved. Thanks to the joint efforts of Inver and All.co, the company is able to offer different finishes and effects while maintaining a high quality standard. These skills have helped establishing the firm on both the building and industrial market as well as expanding the application sectors of its products – which currently include road, naval, and air transport.”

130

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8 1

Figure 8: The IR gelling oven installed before the polymerisation oven for greater control over colour and contamination.

FOCUS ON TECHNOLOGY Figure 9: Profiles entering the polymerisation oven.

and our pre-treatment phase is Qualicoat Seaside certified. During production, we take samples of each colour at the beginning, in the middle, and at the end of the coating cycle. We then perform the tests required by the certification – scratch, impact, tear-off, and bending tests – as well as a salt spray test to ensure a 1000-hour resistance value.” “Before working with Inver, we already had our own tints, which Inver has managed to reproduce and adapt to its products,” says Vecoli. “This may seem a secondary factor, but finding the right colour is never easy and quality can be affected if the formulation is not correct. For instance, door and window profiles are often coupled and even a minimal

9 1

shade difference is not tolerated. Inver was able to faithfully

10 1

Figures 10 and 11: The storage buﬀer for cooling the profiles and the unloading area.

Coating starts with a 10-stage pre-treatment process. The chemicals are applied through spray nozzles. After drying, the profiles enter the new coating booth installed by Trasmetal in 2014 and featuring two OFB disks. The OFB technology is the most suitable for All.Co’s type of production flow, which involves processing large quantities of material, and it enables them to perfectly coat all the profiles, as they loop around the disk to obtain uniform application over their entire surface. In the past, only visible parts had to be painted, but now they prefer to coat the products on all sides. After coating, the profiles reach an IR gelling oven. It is located before the polymerisation oven to ensure greater control over colour and reduce contamination among different process phases.”

11 1

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

131

SP ECIAL ALUMIN IUM

12 1

reproduce the colour chart developed

Figures 12 and 13: The storage buﬀer for cooling the profiles and the unloading area.

over the years by All.co and to further enrich it, guaranteeing at the same time the quality level required by the certifications that distinguish our group’s production.” “The Italian market still prefers Class 1 powders. However, as increasing attention is paid to quality, the request for Qualicoat Class 2 certified products is raising,” states Marco Canola. “In future, we plan to further strengthen our collaboration with All. co and offer to the Italian market an added value for conventional products, that is, better performing powders (as proved by our accelerated tests), already widespread in Germany and England.”

132

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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

ÂŠ Karl Bubenhofer AG

Opening photo: Karl Bubenhofer AG has invested in a new high-tech powder coating plant supplied by Wagner.

HIGHLIGHT OF THE MONTH

New Technical Centre For Powder Coating Strengthens Karl Bubenhoferâ&#x20AC;&#x2122;s Market Position Michael Loretan, Karl Bubenhofer AG Gossau SG, Switzerland

pulver@kabe-farben.ch

he family-owned company Karl

curing options, the company can carry

reason, the family-owned company invested

Bubenhofer AG has upgraded its

out practical coating tests, evaluate newly

in a modern powder coating system at its

technical centre for powder coating

developed products and provide

site in Gossau (ref. Opening photo). The

in Gossau and invested in a new high-tech

high-quality training.

new powder coating plant is designed and

powder coating plant, which is the only one

At the former powder coating plant

developed for their specific requirements and is

of its kind in the industry. With state-of-

of Karl Bubenhofer AG real tests of

equipped for all types of automatic and manual

the-art application equipment and flexible

coating processes were limited. For this

powder coating application processes.

134

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

High-tech solution

Special equipment for coating heat-sensitive substrates

the engineers can carry out practical

The new plant, which was supplied by the application system manufacturer

The markets for alternative and heat-

products and in-depth evaluations

J. WAGNER GmbH, meets all of the

sensitive materials are becoming

of the behaviour of powder coatings

company’s needs. The spacious

increasingly important for Karl Bubenhofer

in automated systems in order to

plastic spray booth is fitted with the

AG. These include plastics and, in particular,

improve their quality even further.

latest type of recovery system. Three

wood. The new coating plant is fitted with

At the same time, existing and

automatic spray guns on reciprocators

counter-electrodes and a software system

potential customers can benefit from

are arranged vertically on each side

that allows high-quality coating tests to be

high-quality training using the latest

of the booth. If necessary, this can be

carried out on components made from

application technology. The amount

increased to five guns on each side. A

MDF, which is used in furniture production

of preparation and cleaning involved

light curtain detects the size of the parts

for example, and other types of materials.

has been significantly reduced, which

to be coated and adjusts the movements

The curing oven has been specially

allows more tests to be completed

of the guns accordingly. The application

designed to specifications drawn up by

in a short time and leads to higher

system, conveyor and batch oven can

the engineers at Karl Bubenhofer AG.

quality results.

be controlled from a central location by

The coated parts are transported directly

The newly modernised powder

touch screens.

from the booth to the batch oven, where

coating technical centre at Karl

The powder is supplied by a semi-

the powder coating is cross-linked using

Bubenhofer AG is unique. The family-

automated powder centre with an

medium-wave infrared emitters.

owned company has made a major

integrated control system and an

The heaters can be replaced with long-wave

investment in its future success and a

ultrasonic sieve which all the new and

infrared emitters or UV lamps, if necessary.

clear commitment to the production

recycled powder passes through. The

In addition, the oven can operate in air

site in Arnegg (Switzerland).

interior of the powder centre is made

recirculation mode or

from chrome steel and this ensures that

in combined mode. An

the frequent cleaning processes needed

integrated infrared camera

in the technical centre can be carried out

analyses and documents

quickly and without leaving any powder

the cross-linking process.

residues. The closed circuit system

The flexibility of the plant

allows the experts at Karl Bubenhofer

allows the development

AG to obtain reliable information about

engineers to control the

the behaviour of standard products and

cross-link procedure and

of high-tech bonded metallic powder

test all types of powder

Leader group in wastewater treatment for metal ﬁnishing line and ZLD is looking

coatings.

coatings including the result

for new addiction to our winning team located in the south of Milan.

As well as being equipped with the latest

logging.

application and control systems, the A cleverly designed exhaust air ducting

Investing in a successful future

system and a cyclone with an optimised

The newly installed

air flow allow the use of a compact

plant in the technical

extraction filter with very low energy

centre belonging to Karl

consumption.

Bubenhofer AG functions

The plant is ideally suited for practical

both as a practical training

user training. From the central control

facility and as a test lab

module, the course participants

for the development of

can follow the settings made by the

new products. The plant’s

engineers in the lab in real time and

modern technology allows

evaluate their impact on the final coating,

powder coating systems

which makes the learning process more

to be cross-linked under

effective.

ideal conditions. As a result,

new plant is also highly energy efficient.

tests of their newly developed

JOB OFFER

Open positions for CIE: 1 CHEMICAL OR MECHANICAL ENGINEER (or comparable preparation) 1 DESIGNER AUTOCAD 2D/3D, 3D SOLIDWORK 1 QUALITY, SAFETY AND MANUAL OFFICERS 1 SOFTWARE TECHNICIAN, AUTOMATION (Siemens, Allen Bradley) Open positions for MST CHEMICALS: 1 TECHNICAL - SALES MANAGER CHEMICAL SPECIALTIES for wastewater treatment

What you need to succeed: - Aged preferably under 35; - Good knowledge of MS Office and order management systems; - Written and spoken english (min. level required: B2); - Availability to travel abroad for medium-term periods; - Candidates coming from Metal Finishing sector appreciated.

Please send detailed CV to silvia.tamburini@cieeng.com www.cieeng.com

BRAND-NEW

Gardner-scrub ECE 43 – Scrub Abrasion Tester Designed to Comply with Economic Commission for Europe Regulation on Safety Glazing

YK-Gardner - worldwide partner of

liquid containers, and pre-cut wiper

The tester has a compact size to save on

the automotive, paint and plastic

blades. The Abrasion Tester simulates

counter space. The instrument comes

industries for quality control

on-road abrasive conditions.

with a two-year warranty and supported

of colour, appearance and physical

Dry condition testing is also possible.

by BYK-Gardner’s worldwide offices and

properties - is introducing the Gardner-

Gardner-scrub ECE 43 has a touch-screen

distributor channels.

scrub ECE 43.

display for easy operation. Cycle speed

Safety glass for use in cars and other

and time are user selectable. Proven

For further information:

motorized vehicles has to withstand

drive mechanism for long-term usage.

www.byk.com

different conditions than conventional glass products. In order to ensure the quality of vehicle glass the United Nations Economic Commission for Europe (ECE) has issued regulation R43 that specifies standards for safety car glass. The new Gardner-scrub ECE 43 allows for a quick and reliable determination of scratch resistance according to this regulation. To determine the scratch resistance of glass or plastic © BYK-Gardner

materials and coatings used for motorized vehicle windshields, a windshield wiper blade under a specific force and cycle time scrubs the sample. A standardized abrasive liquid solution accelerates the test results. The Gardner-scrub ECE 43 runs two samples simultaneously. The abrasion tester comes with two blade holders, sample holders,

136

Figure 1: The new Gardner-scrub ECE 43 allows for a quick and reliable determination of scratch resistance.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

BRAND-NEW

ÂŠ Chemtec

Chemtec Improves Customer Service With the Acquisition of a New Building hemtec has bought the building

adjacent to its already-existing one in Corbetta (Milan, Italy). With this acquisition, it will have more than 1,000 m2 available to devote to commercial and administrative offices, an R&D laboratory, a warehouse, and a production unit for water-based products. The aim was giving the

Figure 1: Chemtecâ&#x20AC;&#x2122;s premises in Corbetta (Milan, Italy).

company the chance to continue the growth path that is leading

allow the firm to meet the needs

it to acquire ever larger market shares in

of end customers requiring more

Italy, France (where its subsidiary company

and more specific and customised

Aertech SAS is based), other European

products.

countries, and North and South America

Thanks to this acquisition, by 2019

(where the Chemtec North & Latin

Chemtec will be able to rapidly

America branches are located).

produce medium/small and medium/

Thanks to the new logistics structure,

large-sized batches of its products

Chemtec will improve customer service

for metal surface pre-treatment and

by shortening delivery times and thus

waste water treatment. It will also be

meeting the increasingly demanding

able to ship them more quickly. For

requests of end customers, distributors,

the company, production and logistics

and retailers. The new production unit,

efficiency is in fact a key to constant

on the other hand, will enable Chemtec

growth in the short, medium, and

to insource an important part of its

long-term future.

processes with the aim of shortening lead-time and increasing flexibility and

For further information:

production efficiency. This, in turn, will

www.chemtecitalia.it

BRAND-NEW

Industry Leading Performance With AGM’s Genable® 3000 Series, Graphene Based, Active Non-Metallic, Anticorrosion Additives

arlier in 2018 Applied Graphene

on another extensive test programme

Genable® 3000 series dispersions are

Materials (AGM) launched their

looking at the performance of a higher

available initially in epoxy resins but with a

latest, ground-breaking, dispersion

build primer system. The thickness of this

range of solvent and water based dispersions

range – the Genable 3000 series. Genable

high build primer is around 110 microns,

under near-term development. All AGM’s

3000 dispersions are graphene based,

and is therefore typically thinner than many

Genable® dispersions are formulated

active non-metallic, anti-corrosion additives,

comparative industry standard systems in

for long term stability and engineered

which are proven capable of delivering

the C4/C5 category (ISO12944).

to aid easy incorporation into existing

leading performance through numerous

The properties of the Genable® 3000

manufacturing processes. The new range

extensive test programmes. Like all Genable

series make it an ideal tool-box additive

follows on the heels of the recent launches

dispersions, they are formulated to enable

for formulators seeking to significantly

of the Genable® 1000 series (for enhancing

the full benefit of graphene materials to be

enhance coating performance in a range

existing anti-corrosive additive performance)

accessed by coating industry formulators

of environments. As an additive capable of

and the Genable® 2000 series (specifically

seeking a step change anti-corrosion

offering metal free systems with extended

for corrosion inhibition on aluminium

performance.

durability it is anticipated that the

substrates).

AGM is now reporting results from further

Genable® 3000 should find multiple

testing, which not only underlines the

applications in industrial areas subject to

Prohesion Testing

potential for significant anticorrosion

high humidity and aggressive atmosphere,

Over 5 times extension to the primer coating

performance gains but also the products

including inshore areas of medium to high

lifetime under cyclic salt spray (ASTM G-85-94

commercial attractiveness – particularly under

salinity. Extended durability and thinner

Prohesion) with the use of Genable® 3000,

harsher C4/C5 corrosive environments.

flexible coatings are directly equitable

AGM’s formulation ready active corrosion

Incorporated into the formulation of an

to significant cost savings in both initial

inhibitor, in place of Zinc Phosphate.

industry standard C3 epoxy primer system,

coating system application, as well as

and tested under representative cyclical salt

maintenance and repair for commercial

Fur further information:

spray testing (ASTM G-85-94 Prohesion),

end users.

www.appliedgraphenematerials.com

Genable 3000 series materials have been ®

shown to deliver a 5- fold extension in coating lifetime, based on a single 60 micron dry film thickness (Fig. 1). These exciting results are supported by a detailed mechanical dataset and studies incorporating combination with a PU topcoat exploring intercoat adhesion and overcoating intervals. All results confirm the products attractiveness for development into commercial anti-corrosion systems. Further investigating Genable® 3000 series potential for applications in harsher C4/C5 environments, AGM has embarked

138

Figure 1: Genable® 3000 series materials have been shown to deliver a 5-fold extension in coating lifetime, based on a single 60 micron dry film thickness.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

BRAND-NEW

ÂŠ Cabycal

Cabycal Provided an Infrared Oven to Istobal he Spanish multinational choose Cabycal

reader located before the gelling zone. Depending

to improve the powder

on the information

paint line of its factory in

collected by these

Valencia.

measurement

Cabycal has designed,

barriers, the

manufactured and

IR carriage

assembled an infrared (IR)

automatically

gas oven, also known as

approach or

gelling zone, forbIstobal,

move away from

a leading company in the

the frame with

design and manufacture

anbaccuracy of

of solutions for the

5 millimetres.

automotive sector. This IR

In addition, the

oven has beenbadapted

automation of this

to the existing convection

system also allows

ovenbby combining a

the activation of

mixed system by intelligent control. This IR short wave heating area aims tobimprove the powder coating

only the infrared

plates of the area

Figures 1 and 2: The new IR oven installed by Cabycal at the Valencia production site of Istobal.

application linebthat

of the frame in which parts have been detected (upper zone or

Cabycal installed in the Istobal

lower zone), which gives

plantbin 2009. Among the

anbimportant saving of energy

advantages of the new system

for the client.

is the increase in speed of

Istobal is the leading Spanish

the production, the rise of the

company in the design,

temperature of pieces with high

manufacture and marketing of

thickness and the elimination

automotive washing solutions.

of the contamination of colours

They export their products to

in the polymerized oven. In

more than 75 countries, have

addition,bthe space occupied has

seven subsidiaries and two

been minimizedbsince the system

assembly plants in Europe and

has been installed between the

two other subsidiaries and

paint booth and the entrance to

assembly plants in the US and

the existing polymerization oven.

Brazil.

thebrecognition of the dimensions of the framebthanks to a parts

2 1

ÂŠ Cabycal

The new system allows For further information: www.cabycal.com

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

139

BRAND-NEW

ithin three months

Groundbreaking Expand!™ Coatings Pigment From Colors & Effects® Portfolio Off To Strong Start With Customers of its official launch, the eXpand!™ Red

EH 3427 stir-in pigment for automotive coatings from the Colors & Effects® pigment portfolio has received its first commercial sales order from a major automotive coatings manufacturer. “This is our fastest introduction of any new pigment in automotive applications and demonstrates that we are well prepared to meet customer demand quickly and successfully,” said Paul Verhoeven, eXpand!™ business leader. “This technology underwent an intensive customer testing phase and we are very glad about the

early demand.” The eXpand!™ Red pigment is the first in the eXpand!™ line and is the result of

Figure 1: The eXpand!™ Red pigment is the first in the eXpand!™ line and is the result of the strategic partnership stablished in 2017 between BASF and Landa Labs.

the strategic partnership stablished in 2017 between BASF and

“A very close collaboration between the

researching and developing more pioneering

Landa Labs. The blue-red shade stir-

technical units of the Colors & Effects®

pigments.

in pigment is compatible with modern

team and our customer underscored the

In addition, Morcillo Ruiz will be at the 2018

automotive coating systems and offers

innovation and benefits that eXpand!™ Red

Pigment Color & Science Forum at the Marriott

intense shades, colour depth and

offers,” said Javier Morcillo Ruiz, technical

Copley Place in Boston, Massachusetts, on

sparkle thanks to its high transparency,

director of eXpand!™ at BASF. “We were able

October 4, presenting “On the Road to New

low scattering and tinting strength. It is

to demonstrate its outstanding coloristic

Dimensions in the Golden to Red Color Space”

the first of its kind suitable for outdoor

properties as well as its efficient stir-in

at 3 p.m. during the Advancements in Pigment

applications and is easily dispersible,

characteristics within a very short timeframe.”

Technology session.

cutting the time involved in the production

Looking ahead, the eXpand!™ team currently

process compared to traditional milling and

has more than 20 projects running with

For further information:

dispersion methods.

automotive coatings suppliers globally and is

www.colors-effects.basf.com

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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

SUCCESS STORIES

Electric Vehicles from Sokon Will Be Painted Using Highly Flexible Seven-Axis Robots

ürr acting as general contractor for

investment and maintenance costs in the

for the sealing stations. The seam sealing

the construction of complete paint

spray booth and also enables a better

and insulation materials will be applied to

shop in Chongqing (Fig. 1).

view of the booths.

the bodies by 20 robots from the EcoRSi

In total, 60 Ecopaint robots from the

series (Fig. 3).

Electric cars will be manufactured using

state-of-the-art technology in the Chongqing Sokon Industry Group,

Lower investment and maintenance costs

within the next weeks. It is the first

Dürr’s third generation of robots

time that the extremely mobile,

is modular in structure. This

seven-axis painting robot EcoRP

means that the EcoRP E/L033i

E043i from Dürr’s new generation of

and EcoRP E/L133i models

robots will be used in China (Fig. 2).

with their 6-axis kinematics

It can paint differently sized bodies

can be used both for painting

of the fully electric SUVs flexibly and

and for opening the hoods.

without the previously required

The modular concept has been

displacement rail. The complete

applied throughout the 6-axis

new electric vehicle plant of the

paint shop with Dürr as the general contractor also includes an Ecopure air purification system with heat recovery. The new plant will therefore also set standards when it

and 7-axis kinematics. The

only difference between the

Figure 1: Dürr is constructing the entire paint shop for Sokon as general contractor.

comes to air pollution control.

variants is the additional axis of rotation in the main arm. The otherwise universally identical components simplify spare

latest generation are being used in the

parts management, save storage costs, and

development of electric mobility with its new

primer, top coat, and clear coat lines for

make maintenance work easier. The control

plant at the company’s site in Chongqing.

interior and exterior painting at Sokon.

technology of the robots for applying paint

The production technology itself is also

As well as the 36 EcoRP

pioneering. It will be the first time that a

E043i painting robots,

third-generation painting robot from Dürr will

16 SCARA door openers

be used in a Chinese car factory. The EcoRP

and the six-axis models

E043i has seven rotary axes, making it much

as a hood opener are

more mobile than previous painting robots

being sent to China.

with six axes. The additional joint extends

In addition, Dürr is

the robot’s working area. As a result, it

supplying the robots and

reaches even hard-to-access areas with ease

application technology

Sokon is dynamically promoting the

when painting the interiors of the bodies. Up to now, painting robots often moved on horizontal rails. The EcoRP E043i no longer needs these thanks to the high mobility of its 7-axis kinematics. This greatly reduces the

142

Figure 2: Ready to go: Dürr’s latest robot generation will soon be painting electric SUVs in China.

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

2 1

SUCCESS STORIES Figure 3: The seam sealing and insulation materials will be applied to the bodies by 20 robots from the EcoRSi series.

the building structure, saves space, and enables intelligent material flow control, making it a key part of Dürr’s Eco+Layout. Among other things, the technical scope of services includes the RoDip rotational dip process in pre-treatment and electrocoating, all robots and applications

3 1

Further milestones

for the sealing and painting processes, and

towards the

the EcoDryScrubber dry separation system

digitization of

(Fig. 4). This binds the paint overspray in

the plant are

a process involving no water or chemicals,

reached with the

and can therefore be operated with up to

MES software

90% recirculated air. The result is an energy

and high-viscosity material is also universal.

for production control developed by Dürr.

The modular design of the control cabinets

Monitoring, tracking, and individually

enables the optimal configuration for the

configurable reporting are important elements

respective application process of a painting or

in efficient process control and optimization.

Energy-eﬃcient exhaust air purification

sealing station at the customer.

This solution is the basis for further advances

When it comes to emission protection,

With EcoScreen 3D-OnSite 4, a universal

in the area of Industry 4.0.

Sokon will comprehensively meet all legal

software package is available for

saving of up to 60% in the spray booth.

requirements and also realize maximum

Dürr’s painting and sealing robots. In

One-stop shop for a complete paint shop

addition, all relevant process data can be

The mechanical and plant engineering

zones will be purified by a combination of

parameterized. The software supports the

company Dürr is constructing the entire paint

the adsorptive process of the Ecopure®

programming, simulating, and optimizing

and is compatible with the previous

solvent emissions from the application

KPR VOC concentration

new generation of robot controllers

energy efficiency. The large volume of

system and the Ecopure® RTO

version. It can be connected online

regenerative thermal oxidation

to multiple robot controllers directly

system. The gaseous pollutants

via the network. As a result, changes

in the exhaust air from the

to teach programs and process data

booth first undergo adsorptive

can be transferred to the production

concentration before being

process in the shortest possible time.

disposed of in the downstream oxidation system with minimal

Fit for Industry 4.0

energy consumption.

The new coating and sealing robots

The latest generation of the

are prepared for the intelligent

Ecopure® TAR recuperative

factory of the future. Sensors detect temperature, operating hours, and the degree of wear of the components, among other things. The also newly developed EcoRCMP2

thermal air purification system

4 1

is used to purify the hot

Figure 4: EcoDryScrubber: dry paint separation without using water and chemicals.

process and motion controller

exhaust air flows from the various paint drying processes. This process purifies the exhaust air and at the same

transfers the information to the higher-level

shop for Sokon and, as general contractor, is

time makes all the heat available for

maintenance and control system. Thanks to

also responsible for the construction of the

heating the oven.

this technology, the data from multiple spray

building and for three high-bay warehouses.

booths or even complete paint shops can be

These high-bay warehouses mean that various

For further information:

combined and evaluated.

surface storage is not needed. This simplifies

www.durr.com

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

143

Â© RoyalbDSM

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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

SUSTAINABILITY

Uralac® Ultra Technology: A Better Solution for Coating Heat-Sensitive Substrates Sjoerd de Jong DSM Coating Resins, Waalwijk, The Netherlands

uralac.ultra@dsm.com

oyalbDSM is a globalbscience-

performance, environmentally friendly

based company active in health,

alternative to traditional solvent-borne paints.

The evolution of powder coatings for heat-sensitive substrates

nutrition and materials with

These attributes, together with the unique

From the first commercial attempts in the

solutions that nourish, protect and

aesthetic options that are available with

early 1990s until only a few years ago, powder

improve performance in a wide range of

powder, have made it the preferred coating

coatings available for heat-sensitive substrates

end markets. Fortune Magazine recently

have provided a viable solution to drive a shift

ranked DSM number two in its 2017

away from liquid coatings. However, the new

‘Change the World’ list of 50 companies that are making an important social or environmental impact through their profit-making strategy and operations. Additionally, DSM has consistently been recognized by the Dow Jones Sustainability World Index for integrating sustainability into its business, having been named among the global leaders in each of the last 13 years, and holding the number one position in the sector seven times. One of its business units in particular, DSM Coating Resins, has made a significant contribution to the transformation to sustainable technologies in the field of paints and

technology came with a significant degree of uncertainty about the results that this shift For metalwould yield. based products, powder In terms of thermally-cured technologies, coating is well established as a several factors hindered the widespread high-performance, environmentally adoption of powder coatings; most friendly alternative to traditional prominently, limitations associated with solvent-borne paints. These attributes, together with the unique aesthetic options cure temperature/duration imposed by the poor chemical storage stability that are available with powder, have of catalyzed systems. With regard to made it the preferred coating technology UV-cured powders, the inability to cure for many products. With the launch of complex shapes, difficulty curing some Uralac® Ultra technology by DSM, the colors, limitations on coating thickness benefits of powder coating are now (including poor intercoat adhesion when available for products made with applied in multiple coating layers), have heat-sensitive materials such made the technology unsuitable for many as engineered and natural applications. Aesthetic properties also imposed woods as well.”

coatings. Specifically, the business has

limits, as the available technologies struggled

promoted the shift away from traditional

to achieve the smoothness and gloss versatility

solvent-based coating technologies by

technology for many products. With the launch

requirements of several market spaces.

providing the propositions necessary

of Uralac® Ultra technology by DSM, the

In addition to the limitations imposed by the

for the segment to evolve towards a

benefits of powder coating are now available

available material technologies, advancements

sustainable future.

for products made with heat-sensitive materials

in application and curing process technologies

For metal-based products, powder

such as engineered and natural woods as well

were necessary for powder coatings to gain

coating is well established as a high-

(Fig. 1).

extensive acceptance. The electrostatic

Figure 1: With the launch of Uralac® Ultra technology by DSM, the benefits of powder coating are now available

for products made with heat-sensitive materials.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

145

SUSTAINABILITY

????????? ???????

2 1

Figure 2: Uralac® Ultra oﬀers superior aesthetic qualities in many colors, gloss levels, textures and finishes, even on unusual shapes, edges, hollows and contours, allowing imaginative new substrate designs and semi-assemblies that could not easily be finished with liquid coatings.

variables associated with non-metal substrates made it difficult to control film thickness, and conventional ovens lacked a mechanism to direct and control heat with adequate precision.

The revolution of powder coatings for heat-sensitive substrates Thanks to recent advances in application

Powder coatings based on Uralac® Ultra technology create competitive advantage: - Tougher - Greener - Safer - Greater production efficiency - More design flexibility - Technical support, from start to finish

that hindered the advancement of powder coatings in non-metal applications in the past have been overcome. The technology has advanced to such a degree that, for those who have taken a close look at the possibilities, converting to powder coatings is no longer a questionable proposition. Rather, as those who have made the conversion in recent years will attest, converting to powder coating for heat-

and curing equipment technologies,

sensitive substrates is steadily developing into

together with the recent introduction of

a competitive necessity.

the Uralac Ultra binder chemistry (based

development of regulated counter electrodes

on unsaturated polyester, which imparted

provided an important step forward. Oven

The commercial launch of

flexibility, and urethane, which improved

technology, with the advent of catalytic

Uralac® Ultra in 2014 further established the

durability), powder coating technology has

infrared curing systems, now provides an

viability and added value of powder coatings

bridged the technology gap and become

efficient and reliable way to cure powder on

for heat-sensitive substrates, offering a

a reliable proposition for heat-sensitive

heat-sensitive substrates. Finally, with the

competitive advantage to manufacturers by

substrates.

commercial launch of Uralac® Ultra based

improving both their operational solutions

In the field of application technology, the

powder coatings in 2014, the obstacles

and the final product.

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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

SUSTAINABILITY The revolutionary process of coating by powder The powder production process involves mixing, extrusion, milling and sieving steps, after which the powder is typically applied electrostatically, followed by curing under heat to allow it to flow and ultimately harden. The powder coating formulation consists of a binder (resin and crosslinker), pigments and additives. Powder coatings are mainly used for the coating of metals, such as household appliances, aluminium extrusions and automobile and bicycle parts due to the high temperature that is required

significant efforts towards reducing the curing temperature: this has been the driving force to further reducing the required energy of an already ecological, low-footprint process. This creates an increased demand for low-temperature curing powder coatings without adverse effect on the curing times, which are also important for lowering manufacturing costs. DSM has been a pioneer in developing polyester resins since the 1960s, and, through its ongoing commitment to resin quality, consistency and sustainable growth, has become the world’s leading

to harden the coating, which is typically

160-170°C. For years, there have been

Thanks to recent advances in application and curing equipment technologies, together with the recent introduction of the Uralac® Ultra binder chemistry (based on unsaturated polyester, which imparted flexibility, and urethane, which improved durability), powder coating technology has bridged the technology gap and become a reliable proposition for heat-sensitive substrates.”

3 1

Figure 3: Uralac® Ultra reduces the environmental footprint and guarantees a higher chemical and physical resistance than traditional coating solutions, enabling a reduction in the cost and fuel consumption involved in transportation and storage.

148

N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

SUSTAINABILITY

MDF was intended for. Next, low-temperature

imaginative new substrate designs and semi-

UV-curable powder coatings were often

assemblies that could not easily be finished

proposed for coating heat-sensitive substrates.

with liquid coatings (Fig. 2).

However, UV technologies also have a

The coated surfaces also possess impressive

number of drawbacks, including an inability

resistance against abrasion and moisture,

to produce thick or matte coatings, shade

broadening the scope of market opportunities.

specificity, higher material costs and higher

For example, IKEA noted in their 2016 Annual

capital equipment requirements. The powder

Report that, as more of their customers are

coatings using Uralac® Ultra system enables

now living in humid climates, the powder

fully powder coated MDF objects, without

coating technique has helped improved the

exposing the MDF to excessive heat loads

humidity resistance of the HEMNES bathroom

and it provides an opportunity to differentiate

series. The versatility of Uralac® Ultra also

finished products by offering superior

allows for a greater design freedom, being

aesthetic qualities in many colors, gloss levels,

able to be applied on real wood, MDF, HDF

textures and finishes that are still challenging

and alternative substrates, offering opaque,

for other powder coating technologies for

transparent or glazed surfaces for every design

heat-sensitive substrates.

material.

Superior aesthetic oﬀering

Robust, eﬃcient processing

As products made from heat-sensitive

Uralac® Ultra not only allows manufacturers

supplier of high-quality, consistent powder

substrates such as MDF gain a bigger

to broaden their market reach, and raise the

coating polyester resins. These high-quality

and bigger market share, both in interior

performance standards of their products,

resins, such as Uralac® Ultra, are combined

architecture and furniture manufacturing, the

it also enables significant cost savings in

In line with the market demand for “mass customization”, Uralac® Ultra provides an opportunity to differentiate finished products by offering superior aesthetic qualities in many colors, gloss levels, textures and finishes, including hammer tones, veins and speckles. What’s more, it does so even on unusual shapes, edges, hollows and contours, allowing imaginative new substrate designs and semi-assemblies that could not easily be finished with liquid coatings.”

with Uralac Ultra crosslinkers, pigments

design possibilities and color choice of powder

the manufacturing process compared to

and other additives, to determine the

coatings become increasingly important

incumbent coating technologies. The powder

specific properties of the powder coating,

properties. In line with the market demand for

coating process offers many advantages

and then applied by electrostatic spray to a

“mass customization”, Uralac® Ultra provides an

compared to the application process of a

pre-heated substrate. The coating is cured

opportunity to differentiate finished products

liquid finish, requiring fewer operational steps

in a specialized catalytic infrared curing

by offering superior aesthetic qualities in many

and enabling a higher line density. Depending

chamber at a high temperature.

colors, gloss levels, textures and finishes,

on the substrate, the powder coating

For Uralac Ultra, this curing process takes

including hammer tones, veins and speckles.

processing can take place up to ten times

place at 130°C (265°F) for three minutes.

What’s more, it does so even on unusual

faster than liquid coating, and cost savings can

Once the powder coating has been

shapes, edges, hollows and contours, allowing

reach 45%.b

In particular, the fully automated one-step

successfully cured, the finished product is taken off the racks. MDF is an excellent example of a heat-sensitive substrate that can be coated using the described technology. Different powder coating technologies can be used to coat MDF, including hybrid technology, epoxy powders or UV powder coatings. However, when exposed to temperatures above 140°C, temperatures needed to harden for hybrid systems, for a relatively short time MDF shows warping and cracks. This is clearly unacceptable for any decorative or structural application the

It’s possible to use just three minutes of oven time with powder, rather than the 30 minutes with liquid paint. Powder coatings are also faster to process because there is no priming and less sanding involved. But make no mistake, this increased speed does not impact at all on quality.” – Paul Maeyninckx, company owner.

application of powder coatings based on Uralac® Ultra technology results in reduced rework and minimized sanding. Color changes on the production line can be implemented in a quick and efficient way, without the requirement of additional floor space. From start to finish, the process can be completed in 20 to 30 minutes, with all surfaces covered in just one step. What’s more, as the overspray is in solid form, it is easy to collect and re-use, resulting in material utilization of over 90%, and also proves to be less toxic to operators handling the product.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53

149

SUSTAINABILITY A greener, more sustainable coating solution With increasing environmental awareness, and air pollution standards becoming more stringent, the demand for environmentally friendly coatings is also increasing. A conversion to powder coatings based on Uralac® Ultra allows manufacturers

With increasing environmental awareness, and air pollution standards becoming more stringent, the demand for environmentally friendly coatings is also increasing. A conversion to powder coatings based on Uralac® Ultra allows manufacturers significant environmental advantages, as their environmental footprint will be reduced by integrating a low-temperature bake and a nowater process. The powder coating process also prevents harmful chemicals from damaging the environment, as it involves no VOCs. ”

On-hand technical product support DSM provides comprehensive technical support to manufacturers in adopting the Uralac® Ultra powder coating technology at every stage. This ranges from fine-tuning the best coating and curing process for your applications in laboratory testing, to equipment selection, coating line configuration and general project management.

significant environmental advantages, as their environmental footprint

Blue Wool Scale (discoloration tests) and

With five manufacturing centers in the

will be reduced by integrating a low-

hinge hole benchmarking (known as swelling

Netherlands, Spain, the United States and

temperature bake and a no-water process.

test or the Ledro test). These tests confirmed

Greater China, as well as marketing and sales

The powder coating process also prevents

the solution’s excellent humidity, UV light

hubs on three continents, DSM can provide

harmful chemicals from damaging the

and chemical resistance, and its other

technical support to coating manufacturers

environment, as it involves no VOCs. In addition,

high-performance qualities. Furthermore,

across the world, and for a broad range of

powder coatings based on Uralac® Ultra

the Uralac® Ultra architectural range comes

industrial sectors.

have higher chemical and physical resistance

withbEnvironmental Product Declarationsbthat

than traditional coating solutions, enabling a

contribute towards LEED credits.

reduction in the cost and fuel consumption

Uralac® Ultra also enables manufacturers

The right time to convert to powder coating

involved in transportation and storage (Fig. 3).

to meet increasingly stringent workplace

The operational, environmental and

A comprehensive Life Cycle Assessment for

regulatory standards. Since this technology

performance benefits of Uralac® Ultra powder

Uralac Ultra measures a carbon footprint that

is solvent-free, it reduces fire and application

coating technology make it a better choice

is five times lower than solvent-borne coatings.

risks, and offers a better disposal of waste.

than the incumbent coating technologies for a

The eco-footprint for Uralac Ultra, which

It also reduces the health risks for operators, as

wide range of applications, including children’s

indicates the impact on resource depletion and

any powder can easily be washed off and there

furniture, bathroom furniture, office furniture,

climate change, is equally reduced.b

are fewer hazardous materials.

outdoor furniture, and kitchen furniture.

As manufacturers across the world try to

By converting to Uralac® Ultra powder coating

implement safer operational practices,

technology, manufacturers can lower operational

Meeting higher regulatory standards

Uralac Ultra technology provides an

costs, increase end-product value and provide a

The eco-friendliness of powder coatings

SHE-compliant solution for a wide variety of

mechanism for meaningful differentiation.

based on Uralac Ultra also enables

markets.

In fact, given the considerable advantages of

compliance with tighter and tighter industry

this coating technology, converting to powder

restrictions. Since 2005, the coating industry

coating for heat-sensitive substrates such as

in Europe has been subject to the strict environmental guidelines of the Kyoto protocol of 1997, and in recent years these industry guidelines have become even stricter. In light of this, Uralac Ultra-treated products offer a high ®

level of compliance with all major regulatory requirements, and have been submitted to key industry standard tests, such as

We made the switch to the one-layer coating quickly and efficiently. Moreover, since adopting the new coating technology, our supplier has continued to work closely with us and has developed a wide range of colors and effects specially for us.” – Walter Schweiger, company owner.

NEN-EN 12720 (resistance to cold liquids),

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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine

Uralac® Ultra is quickly becoming a competitive necessity. With the adoption of Uralac® Ultra technology by leading manufacturers in both North America and Europe already well on its way, few coating companies can afford the late integration of this superior powder coating solution. For further information: www.dsm.com

BRAND-NEW

BYK-Gardner Seminar – the Complete Solution for Paints Control

earn how to test objectively the physical

Day 1: Physical Properties 101

The seminar content applies to all

properties of wet to dry coatings. Then,

- Viscosity Measurement in CQ

industries and is appropriate for users at

experience how practical colour and gloss

- Wet film preparation

all levels and for those who want to expand

measurements will improve product quality and

- Temperature control of production ovens

their knowledge.

communication along the supply chain.

- Hardness, Abrasion and Flexibility control - Film Thickness measurement on different

Prices

When: November 07-08, 2018 Where: CDH Hotel Parma & Congressi, Parma, Italy

Day 2: Color and Gloss in practice

Both days: 795,00 € per person

During both seminar days, the subject will cover

- Visual and instrumental gloss evaluation

Prices include certificate, lunch and training

theoretical basis and advices of international

- Fundamentals of gloss measurement and its

materials.

standards. The presentations will be integrated

substrates

Day 1: 495,00 € per person Day 2: 495,00 € per person

limitations

with interactive workshops and all the

- Fundamentals of color measurement

attendees will have the chance to operate with

- Which geometry is suitable for my application?

For further information:

the instruments.

- Color system and color tolerancing

www.byk.com

Aluminium Wheel Painting

Excellence in surface finishing For the painting of aluminum wheels, Dürr delivers powerful technologies along the whole process, starting with wheel surface cleaning and chemical conversion for effective corrosion protection, painting and curing, to the purification of air exhaust. Dürr offers their own application technology with specially patented features that fit best with the requirements of quality-oriented aluminum wheel surface painting. www.verind.it

BRAND-NEW

Automation Made Easy

he new SprayPackE control unit from

system. This also sets it apart from other

guns. The powder supply is switched off

WAGNER facilitates the changeover

solutions on the market. For example, the

in the gaps. In addition, the innovative

from manual to automated powder

powder quantity can be easily determined

height control system, which previously

coating (Fig. 1). Due to its great user-

via a central touch screen (Fig. 2) - for

only existed for larger WAGNER systems,

friendliness, the operators can efficiently

all guns, in groups or individually. With

is now optionally available for the

achieve a high coating quality. Existing powder

comparable devices, the guns must be set

entry-level model. Michael Topp

coating systems can also be brought up to

individually via the corresponding control

explains: “The height control optimizes

date.

modules. This costs time - and money, as

the coating of parts of different heights

Full order books quickly push companies

an example shows:

by switching off guns that would spray

While an operator

past the workpiece. This works via a

the limits of their capacities. One

needs around ten

continuous light bar at the entrance

seconds to change

to the powder booth. Spaces in the

the parameters

workpiece, for example in window frames,

with conventional

are also omitted in this way.” This creates

controls, new

maximum efficiency and minimizes

solution is to switch to automated applications. In addition to the

that do manual powder coating to

powder booth, powder preparation, motion systems and guns, this includes an intelligent control

settings can be made

powder consumption.

system that is easy to install and

with the SprayPackE

The guided colour change process

operate. This saves time and

in just two seconds.

makes operation even easier. An easyto-understand step-by-step guide helps

guarantees a high coating quality. With the new SprayPackE automatic

Figure 1: SprayPackE automatic control unit, the CPE module for controlling the power supply and safety interlocking of the motion technology, the MCE module with intuitive menu navigation for easysystem control.

control unit, WAGNER has brought a solution onto the market that meets all these requirements. It controls up to 20 automatic guns and the motion systems in the powder booth. “Thanks to its integrated design and high user-friendliness, the SprayPackE offers an ideal introduction to automatic powder coating. Even outdated plants can be

to avoid errors and, as a result, timeconsuming reworking or downtimes. Furthermore, a maintenance counter records the operating hours per component and thus enables an optimal maintenance routine for a long service life of the control unit.

Entry into automated powder coating or upgrade of obsolete systems

easily modernised,” explains Michael Topp,

With an average of four setting changes

The new automatic control unit is suitable

Global Senior Product Portfolio Manager at

per hour, extrapolated on the basis of a

for all industries. Be it for users who

WAGNER.

conventional eight-hour day, this results in

switch to automatic coating, but also for

an efficiency gain of several thousand euros

upgrading outdated coating systems.

per year.

“Controls in older powder coating systems

Sophisticated user guidance saves time and money

can be easily replaced by the SprayPackE,”

its predecessor model, this new product

Material savings through intelligent gap and height control

scores above all through its simple operation.