ipcm® n. 50 - March/April 2018 by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

ISSN 2280-6083

ipcm digital on In this issue:

Special Issue

www.myipcm.com

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

& INTERNATIONAL PAINT&COATING MAGAZINE

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

2018

9th Year - Bimonthly N° 50 - MARCH/APRIL

l UV you

UV coatings In how many ways can the love for beauty and colour be expressed? Arsonsisi does it through a line of state-of-the-art UVcuring coatings, thanks also to the experience and know-how of Tecnocolor, a specialized company that is part of our group. Arsonsisi UVcolor range includes solvent-based, water-based or 100% dry residue coatings, suitable for various types of applications among which high vacuum metallization, Sputtering or PVD, and hybrid â&#x20AC;&#x153;Dual Cureâ&#x20AC;? coatings with mixed heat/UV curing for complex 3D objects. Italian colour technology at the service of all industries.

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CONTENTS MARCH/APRIL 2018

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

The Trend Towards Ever-Greater Colour Customisation In The Aluminium Industry: The Response Of ALUKON

The Cube’s Flexibility

FOCUS ON TECHNOLOGY

HIGHLIGHT OF THE MONTH

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

48 05 06 10 14

FOCUS ON TECHNOLOGY

Impol: the Supplier of High Quality PVDF Pre-Painted Aluminium for the Infrastructure of the 2018 World Cup in Russia

EDITOR’S LETTER ANALYSIS

25 26

Lean Production: How to Reduce the Production Time and Cost of Special and Customised Mask

HIGHLIGHT OF THE MONTH

CMA Robotics Celebrates 25 Years of History at the Forefront of Technology in the Automatic Coating Sector

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

FOCUS ON TECHNOLOGY Alumero: An Investment in the Coating Quality of Aluminium Profiles

BRAND-NEW HIGHLIGHT OF THE MONTH

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

SUCCESS STORIES Asif Khan Reveals Super-Dark Vantablack Pavilion for Winter Olympics 2018

86 89 102

BRAND-NEW INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

FOCUS ON TECHNOLOGY When the Proper Design of a Two-Rail Conveyor Improves the Versatility and Productivity of a Coating Company: The Success Story of Franchini Snc

Paint Expo 2018 17 - 20 April Visit us at:

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CONTENTS MARCH/APRIL 2018

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

FOCUS ON TECHNOLOGY

INNOVATIONS: PRESENT&FUTURE

Ready for “Industry 4.0” and The Smart Factory with Nordson Dense Phase Technology

DKcomposing © Fotolia

110

Arneg Italia’s New Coating Line: an Industry 4.0-Oriented Management System in Compliance with the Most Advanced Environmental Protection Requirements © Cabycal

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

170 130

FOCUS ON TECHNOLOGY

A New Automatic Coating Line to Increase the Production Capacity of a Glass Objects’ Manufacturer: the Positive Result of the Industry Teaming Up with Craftsmanship

FOCUS ON TECHNOLOGY Shot Blasting 4.0 for a Flexible and Highly Efficient Pre-Treatment Process Prior to Coating

154

Energy Efficiency in Italy: the Implementation Decree on the National Fund Has Been Published

160 BRAND-NEW 164 INNOVATIONS:

184

NitroBoxSpray® Revolutionises the Nitrogen Coating Concept: Better Performance at Low Costs Both In-House and On Site

174

BRAND-NEW

STANDARD & LEGISLATION What Changes with the ISO 9001:2015 Quality Certification?

PRESENT&FUTURE

INNOVATIONS: PRESENT&FUTURE Dense Phase, Low Pressure (DPLP) Powder Application: Reduced Consumption and High Performance with the New Transport System NEA 415

188

STANDARD & LEGISLATION - UCIF Informs

190 TRADE FAIRS & CONFERENCES

192

ZOOM ON EVENTS

PAINTING ROBOTS & SYSTEM INTEGRATOR Articulated and cartesian robots for every painting need! LeBot C5: 5 axis cartesian robot with shape acquisition scanner system.

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LeCrob Production Manager STD RFID WEB: production management software with RFID tags and antennas for automatic recognition of production queue

LeBot IA6: articulated 6-axis industrial robots for point-to-point applications, controlled by our LeCRob K-Manager software.

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EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

From Product Customisation to Individualisation

Alessia Venturi Editor-in-chief Direttore Responsabile

e are living in the era of mass customisation, a very strong trend facilitated by the logics of the fourth industrial revolution. However, a new era is already on the horizon, that of “market of one”. Although the two terms are often used as synonyms, there is a profound difference between “customisation” and “individualisation”, at least in the framework of industrial production. Mass customisation uses modularisation to increase product variety and at the same time maintain the logics (and benefits) of mass production. In this paradigm, consumers can choose the personalised configuration of their product within a series of options pre-set by its manufacturer and designer. Mass customisation, therefore, does not allow to create exclusive, unique, and individualised products. In order to do so, consumers must co-design and cocreate the product they are going to buy. In the spectrum of individualisation, the manufacturers of hard goods are at the lowest point, whereas at the highest point there are the producers of soft goods that can be configured and provided electronically, such as service companies1. At the industrial level, single-product batches are already a reality. What is new is the idea of creating unique products with the same logics of mass production. The Industry 4.0 will offer new forms of personalisation. Companies will be able to manufacture exclusive products in shorter cycle times, with efficiencies and costs normally associated with standardisation. Finishes are the “skin” of products and one of the parameters that influence purchase behaviour. That is why they are one of the most used elements for customisation. In future, companies performing coating tasks will have to be able to offer products with unique and exclusive finishes for each consumer, without sacrificing productivity and efficiency but at the same time implementing a just-in-time approach. If I have to find the common thread of the numerous articles included in this issue of ipcm® – which is a special edition for the PaintExpo 2018 trade fair, which in a few years has become the unmissable event for the world of industrial coating – it is precisely this: how companies are gradually transforming their production structure to meet the “market of one” needs and produce single-product batches, and how digital innovation is helping them. This transformation involves the whole value chain of coating processes: from paint suppliers, which must offer always new and customisable finishes and colours but also be able to produce them in very small lots and in a short time, to plant builders, whose management software must automate production to the point where it is possible to coat in sequence single-products batches with different colours and effects without sacrificing productivity, up to manufacturers of hooks and masks, which are gearing up to reduce their sampling times in the name of efficiency. Most case studies included in this issue portray Industry 4.0-ready factories with high levels of human-machine interaction and an optimal system integration to reduce production downtimes (e.g. colour change operations) and waste. These are factories ready to mass-produce highly customised products. These are factories of the future. 1

Wang, Y., Ma, HS., Yang, JH. et al. Adv. Manuf. (2017) 5: 311. https://doi.org/10.1007/s40436-017-0204-7

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

Opening photo: Masks, hooks and hanging systems are just a small part of industrial coating processes, but they have a greater impact on results than one might think.

ANALYSIS

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

adriano.antonelli@tecnosupply.com

istory cannot be seen as a mere

the Republics that dominated the so far crucial

The economic and financial balance has

sequence of facts and dates. It is

trade routes. What fears and perplexities did

certainly changed, as have the behaviour of

always interesting to study it by

those communities perceive in such complex

consumers, who no longer buy things in a

delving into the people’s lives, the society

historical periods? What solutions did they

“cold” way, but prefer products with a high

of their time, and the mysteries behind the

conceive to counter the new events?

added value; the rules of communication and

continuous “cause and effect” cycle. Many

In a sense, history is now repeating itself.

marketing; and the production world – that

historians, for example, are intrigued by the

The recent crisis was not a part of a classic

is under everyone’s eyes. Planning methods

feelings, the enthusiasm and the motives of

economic-financial cycle. A negative economic

and even the just-in-time approach are

the first European explorers in the New World.

cycle has not just ended to be replaced by a

obsolete. The markets’ frenzy calls for quality

New lands to explore, new opportunities, and

new growth one. It is now clear that we are

at competitive prices, technology and skills.

new populations and cultures to deal with in

living in a New Economic Era. The world has

Market penetration can no longer be left to

seemingly infinite countries. All this changed the

profoundly changed in a way that we do not

chance. The value chain has become crucial:

equilibrium in the Old Continent, too, with the

fully understand, yet. One can feel lost and

we need to understand it and analyse it in its

loss of centrality of the Mare Nostrum and of

doubtful like the explorers of the New World.

specific aspects; such systematic study can

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

ANALYSIS

Figure 1: HQS tree frames can be made up of diﬀerent metal sheet shapes: 8 versions and diﬀerent length.

and flexible hanging equipment is needed, which can be used with workpieces with similar shapes. This should always be not only available, but also analysed and tested in a short time, which is sometimes not reasonable for a technical and productive department.

protect companies from new problems such as

In this New Economic World, production stocks

fiscal and social dumping. Whole productions

and buffers are minimised and only exactly

with their satellite activities can disappear or be

what the market is currently asking for is

moved without any warning and in anomalous

produced. All efforts are directed at hanging

ways. A key concept has become crucial to

components in a smoother and faster way,

compete globally: productivity. In this article, we

while reworking and touching up operations

would like to apply it to the coating sector. In our field, “productivity” could be translated into the increase of workpiece hanging density while maintaining the same finishing quality. The greater the number of parts that can be hung onto the line, the higher the productivity of the plant, with countless advantages (ref. Opening photo). Some of them are immediate, such as less operation hours for the same number of hung parts and less waste of paint, energy, pre-treatment solutions, and so on. For this purpose, efficient

2 1

Figure 2: HQL bars are ready for use and feature already inserted 1 mm hooks; they can be integrated on HCF universal frames.

The economic and financial balance has certainly changed, as have the behaviour of consumers, who no longer buy things in a “cold” way, but prefer products with a high added value.”

operations with a minimum contact point. They can be integrated on HCF universal frames,

A HQS shaft can reach a 2400 mm length, while the distance between two hooks is adjustable according to production needs. In this way, the hanging point is minimised and the part is stable.”

3 1

which offer the great advantage of being able to implement all the three bar types of the HangOn range (Fig. 3). As well as HQL bars, H11B bars can also be integrated (Fig. 4): these enable to always protect the contact point, since the hooks are inserted in cavities. Flexibility and robustness are their two main characteristics. It is also possible to insert a second identical hook to make the hook stable as if it were soldered. HCL bars feature hook-holders (“socket”) welded on a wire with a diameter of 6 or 8 mm. “Each ‘socket’ is covered by a silicone cap to ensure maximum electrostatic force even if it is not used (Fig. 5). It can accommodate springs, sheet-cut hooks, and arrows. Countless arrangements can be created by using one bar

Figure 3: HangOn’s HCF universal frame is designed to flexibly accommodate diﬀerent types of bars, depending on the hanging and coating requirements.

and changing only its accessory. The reduced cleaning needs of bars and frames are another important advantage.

are not acceptable. It is therefore important

Other interesting new hanging solutions will be

to avoid any disputes due to the presence

soon launched, especially suitable for coating

of corrosion or other surface defects caused

small parts: flexible frames that can be adapted

by improper pre-treatment or coating.

to various needs, standardised, economical, and

Tecno Supply, division of Ibix, and its partner

ready for use as always.

HangOn are offering hanging and masking © Hang On

solutions aimed at facilitating the work of coating line operators while meeting the growing demands for lean manufacturing processes. HQS tree frames (Fig. 1), for instance, feature 1.5 mm thick plates with different arrangements to be selected depending on the workpiece; 8 versions are currently available. There can be a 4 or 5 mm central hook. The frame is very durable and it can bear 30 kg per hanging point and 100 kg overall. The plates can be arranged with a

4 1

Figure 4: Suspension system (H11B, HB, H2B, H25B, H3B) bars are flexible and robust; they are punched to protect the contact points, since the hooks are inserted in cavities.

zigzag pattern, on one side only, or in parallel bends. This frame has been the subject of

to production needs. In this way, the hanging

an in-depth study to be produced at a cost

point is minimised and the part is stable.

equivalent to that of a box of hooks; on

Another particularly economical and efficient

the other hand, despite costing like a hook

hanging system for small components are

box, it ensures a 3 times higher hanging

HQL bars (Fig. 2). They are ready for use

and unloading speed. A HQS shaft can

and feature already inserted 1 mm hooks

reach a 2400 mm length, while the distance

in harmonic steel. These automatically

between two hooks is adjustable according

produced bars allow for fast hanging

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

5 1

Figure 5: HCL bars feature “sockets” covered by a silicone cap to ensure maximum electrostatic force even if they are not used.

Â®

SPECIAL

BRAND-NEW

Ready2spray Painting Solutions for General Industry: Dürr Introduces Robot System At Paint Expo In Karlsruhe

this new combination at the Paint Expo

for customers in general industry.

the ready2spray paint robot EcoRP

Karlsruhe in hall 3 at booth 3218.

The robot lines into the new concept

10 R1100 (Fig. 1) contains fully

Dr. Hans Schumacher, CEO of Dürr

of ready2spray and ready2integrate

compatible, tried-and-tested components

Systems AG, says: “General industry has

sets which are a true innovation in this

and offers a unique combination in

seen a growing need for fully automated

market segment.”

the market. It is perfectly suited for the

paint application of the highest quality. The

The automated painting robot system

requirements of general industry. Areas of

new painting robot system offers a perfect

consists of a small six-axis robot

application include the painting of wood,

complement to Dürr’s product portfolio

equipped with state-of-the-art paint

plastics, glass and metal. Dürr presents

in the form of a compact painting robot

application technology. This technology

re-installed and ready-to-spray,

Figure 1: Equipped with application technology, ready to spray: While the robot comes from Kuka, Dürr provides the paint application technology.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

SPECIAL

BRAND-NEW

receive all components from a single source. These include the four product categories of pump and fluid-handling equipment, conventional application technology (spray guns), two-component systems as well as solutions for electrostatic application. The EcoBell high-speed rotating atomizers are ideally suited to industry, thanks to their variable spray jet. Therefore, Dürr offers perfectly coordinate solutions as ready2spray or ready2integrate solutions. The ready2spray systems are preinstalled, manual or automated solutions to be put directly into operation by the customer himself. The ready2integrate sets are automatic painting sets or paint supply sets, ready to be integrated into existing customer facilities. Dürr offers global support for the ready2spray and ready2integrate systems with assistance for all components and an international 24/7 hotline. For further information: www.durr.com

2 1

Figure 2: The new painting system is fully Industry 4.0-ready.

is available in different configurations, tailored to each individual customer project. The system, with all its different components, is completed and pre-commissioned at Dürr. It is thus ready to use (“ready2spray”), can be quickly installed at the customer’s site, and ensures efficient processes and a consistently high-quality paint finish. The ready2spray robot enables the application of solvent- and waterbased one- and two-component paints. It can be equipped with matching dosing pumps, paint pressure regulators and color changers. Depending on the requirements, it comes with automated spray guns (air-atomizing or airless) from the EcoGun range or with electrostatic high-speed rotating atomizers from the EcoBell range, both by Dürr. The compact industrial robot is an innovation in industrial painting. Its integrated concept also includes the motion control of the robot and the process control for the applications, housed together in one control cabinet. Furthermore, the new painting system is fully Industry 4.0-ready (Fig. 2). Dürr is the world leader in automotive painting and car body sealing through its painting and sealing robots as well as its application technology. As in the automotive industry, Dürr also covers the entire spectrum of paint application in the industrial sector. Customers

VACUDEST vacuum evaporator. An effective treatment of industrial wastewater. Thanks to innovative VACUDEST technology you get high quality rinsing water, resulting

in excellent results in your surface technology processes. Are you interested?

Visit us at the international trade fairs: PaintExpo: 17th to 20th March 2018, Karlsruhe IFAT: 14th to 18th May 2018, Munich H2O GmbH | info@h2o-de.com | www.h2o-de.com

SPECIAL

BRAND-NEW

H2O Gmbh Presents the Answer to Higher Coating Requirements at Paintexpo

Figure 1: H2O at PaintExpo in Hall 1, booth 1611.

and reducing the disposal costs enormously.

ustomers are placing higher and

the world’s leading trade fair for coating

higher demands on consistent

technology, will take place from 17 to 20 of

Companies that produce a wastewater volume

cleanliness and low costs for part

April 2018 in Karlsruhe.

of 180 to 30,000 cubic metres per year stand

cleaning – processes need to be ever cleaner,

VACUDEST systems boast patented,

to enjoy the greatest savings. Wastewater

better and more cost-efficient. To respond to

innovative technology that sets high

can be treated coming from various different

these demands, H2O GmbH, which is based

standards in rinsing water treatment. For

manufacturing processes, such as paint pre-

in Steinen, Germany, has developed efficient

example, Clearcat technology produces

treatment, degreasing, electroplating, stainless

solutions that simultaneously improve rinsing

crystal clear, oil-free distillate that allows

steel pickling and many more.

water quality and reduce costs. H2O GmbH

surface technology processes to achieve

will demonstrate how it works at PaintExpo

excellent cleaning results. Thus it is ideally

For further information:

in Hall 1, booth 1611 (Fig.1). PaintExpo,

suitable for recycling in the rinsing process

www.h2o-de.com

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

Opening photo: The new flat cutting machine purchased by Euromask.

HIGHLIGHT OF THE MONTH

Lean Production: How to Reduce the Production Time and Cost of Special and Customised Mask Francesco Stucchi ipcm®

the creation of samples and prototypes,

A flat cutting machine for the production of masks in hard materials

labour and waste: substantially, this

two activities with a strong impact on the

Finishing Group Srl (Solaro, Milan, Italy)

means to reduce the flow time of a

delivery times of companies offering tailor-

operates in the coating market with the well-

product along a manufacturing line. An

made products.

established brand Euromask for the production

he industrial philosophy of lean

exemplary lean production measure is

production focuses on creating

the reduction of the time required for

value with as little as possible

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

Finishing Group Srl (Solaro, Milan, Italy) operates in the coating market with the well-established brand Euromask for the production of masks and hanging hooks.” of masks and hanging hooks. In the last three years, all its investments have been aimed at achieving greater flexibility and versatility and reducing process times, in line with the lean production philosophy. The most recent investment was a flat cutting machine (ref. Opening photo) enabling to cut harder materials with rather high thicknesses for manufacturing special and customised masks. “Our new machine can cut silicone, EPDM, foams with different densities, adhesives, and coupled materials with a thickness ranging from 2 to, currently, 15 mm,” says Simeone Maitan, the owner of this Group now operating worldwide with distributors in the main European countries and a branch in Mexico. “We have installed the new system to reduce almost completely the flow time of our normal production process, from sampling to manufacturing through prototyping.” “For conventional machines, we need two weeks to produce samples and at least three weeks to create the final production mould. Our new system, a sort of a flat plotter, enables us to switch from sampling to manufacturing in one day with similar or lower costs, since the moulds’ amortisation cost is eliminated,” states Maitan. This investment has made Euromask’s production not only very fast but also flexible and versatile also in terms of quantities. “The machine has no production quantity limits: it can range from 200 to 500,000 workpieces. Of course, for large-volume productions, we will require an economic assessment to determine if this machine is preferable to conventional systems,” says Maitan. From a technical point of view, the system has a well-defined flat surface of 100x60 cm. “It is possible to display different outlines on this surface (Fig. 1),” states Luca Bonin, the new machine’s manager at Euromask. “New outlines can be

Euromask has installed the new system to reduce almost completely the flow time of the normal production process, from sampling to manufacturing through prototyping.” international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

Besides the already-mentioned advantages in terms of lean production, this new flat cutting machine, particularly appreciated in the leather and shoe sectors, enables Euromask to produce special masks even in peculiar materials such as foams.”

Applications

are more flexible and adaptable

Besides the already-mentioned

to complex shapes, thanks to

advantages in terms of lean

their lower density and hardness

production, this new flat

properties compared with

cutting machine, particularly

silicone,” says Simeone Maitan.

appreciated in the leather and

“With this new machine, we can

shoe sectors, enables Euromask

also produce masks in silicone

to produce special masks even

foam, which is high-performing like

in peculiar materials such as

silicone because it resists up to

foams. “Liquid coating does

300 °C, but less hard.”

not call for high temperature

resistant masks, but it requires

Figure 1: Examples of masks with special shapes that can be produced with the new machine.

large components or with very large holes to be protected. Foams are therefore the most suitable material, because they

program or, if they are particularly complex, with a 3D CAD drawing program. In this

drawn directly with the system’s 2D drawing

case, the drawings are then transferred to the machine and converted into its software language. The machine projects the realsize shapes on the worktable, showing different arrangement options to optimise production. Once the drawing is correctly positioned on the work surface, the machine’s pump creates vacuum to lock the material in its cutting position and a rotating spindle equipped with different types of blades cuts the shapes (Fig. 2).”

This investment has made Euromask’s production not only very fast but also flexible and versatile also in terms of quantities.”

2 1

Figure 2: A technical detail of the flat plotter.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

Opening photo: Saturated and unsaturated edrizzi® paint mist separators. They are assembled in the modular system to an optional size of separation area.

HIGHLIGHT OF THE MONTH

The Cube’s Flexibility Andrea Zanier Azett Kommunikation, Lienz, Austria

andrea@azett-kommunikation.com

years ago, Michael Eder revolutionized

first to entirely avoid filter mats extracted from

ergonomic finishing in numerous international

the surface processing industry with

mineral oil.

painting companies. Through the conversion

a cardboard box. In long time development he

In 2003 Brainflash, Eder’s company, launched

from wet to dry absorption, chemicals

pursued his vision of changing the varnishing

the trend-setting invention: paint mist

are eliminated in the separation process

process in an economical and sustainable

separators in the form of cubes, made from

and energy costs are lowered accordingly.

way: to eliminate chemicals in the separation

100% recycled paper. The major stroke lies

Saturated edrizzi® dry scrubbers are practically

process by the alteration from wet to dry

secretly within the inconspicuous boxes:

disposed of just like ordinary domestic waste,

separation. From the very first of his processing

complex, smart labyrinth systems made

and thus reduce the amount of harmful paint

Eder focused on physics, technology and 100%

of corrugated paper. Those can, with the

scrap, which is a cost-intensive special waste.

recycled paper. He never considered the mere

help of the centrifugal force, hold up to 100

The flexibility of the edrizzi® system is another

enlargement of filter surface – which doesn’t

kg overspray/m² and more and provide

benefit for plant operators, regardless of

even exist in the edrizzi® system and he was the

economical, environmentally friendly and

which industry or factory size.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

The modular system enables an individual

HIGHLIGHT OF THE MONTH

to absorb all of the overspray.

application in any

Figure 2 shows

kind of surface

a plant in the

processing.

automotive

The manageable

industry with

cubes are

the edrizzi®

assembled in the

system in air

modular system

circulation

to an optionally

mode and thus

large separation

with several

area – no matter if used horizontally, vertically, or a combination of the

secondary

Figure 1: In spray gun facilities of every dimension the edrizzi® system may reach perennial service life. Since 2003, the system was further developed twice and adjusted for every application of surface treatment.

filters: the

to retrofit existing systems or install new

and ergonomic replacement. In consideration of

systems in a shortage of space - adaptions in

the designated air flow slow down zone, the first

measurements are possible in special-purpose

secondary filter is installed behind the edrizzi dry

solutions. Eight different types of edrizzi® dry

scrubber system. Pocket filters can be found in

scrubbers and five types of complementing

the exhaust air area as the next set of secondary

filters. Recirculated air flows

secondary filtrations cover all areas of

through the recuperator and

industry. All modules within the

incoming air vent fitted with

edrizzi® system can be changed

Viledon® filter mats, into the

separately and economically when

paint shop.

saturated.

edrizzi® became synonymous

Due to the flexibility of the system,

for dry separation with a

edrizzi® is effectively applied in

“cardboard box” and has

a variety of surface processing companies. From the smallest spray gun facilities with multi-year service life to ambitious automated

application in the surface processing

since encouraged several

PaintExpo 17. - 20. April 2018 Halle 2, Stand 2512

replications. In consideration of environmental aspects, the trend towards dry absorption is to

within the plant determines

be welcomed. Due

the modular assembly of

to the existing patent

the edrizzi system: the

protection of edrizzi®,

paint mist separator level

guarantee the best solutions for our customers around the globe.

manufacturers to produce

The individual situation

Especially in air circulation

Worldwide leading and innovative technologies

vertically in the subsurface area, which allows for a quick

several follow-up filtrations.

… and always close to you

are built in

photo). Different sized modules make it easier

can be complemented by

worldwide

edrizzi® cubes

two (ref. Opening

paint shops (Fig. 1).

Paint stripping

replicas lack important Figure 2: The edrizzi® system is implemented in international paint shops.

features of the original. Manufacturers of replications use filter

mode and top paint shops, those secondary

mats as alternative to the patented edrizzi®

filters are essential and important with regard

corrugated paper labyrinth, which leads to

to the development of emission control laws

restrictions in function and in disposal.

and environmental protection. There are indeed

Due to the sales cooperation with Freudenberg

facilities which run without secondary filtration

Filtration Technologies, edrizzi is being

though, because edrizzi® dry scrubbers are able

distributed globally since 2016.

SPECIAL

BRAND-NEW

TMC Develops Special Self-Lubricating, High Temperature Resistant Bearings for the Chains of Coating Systems

MC, based in Cesana Brianza (LC, Italy) and established in 1964, specialises in

the production of high precision mechanical components for automation and coating systems. It has recently designed and developed special self-lubricating bearings able © TMC

to withstand high temperatures up to 250 °C. “Through our research activity on new materials and processes, we have tried to increasingly diversify our production in order to meet

the demands of the market and the different technical needs of each industry and type of users,” explains

Figures 1 and 2: An overhead conveyor chain featuring bearings treated with TMCoat.

TMC owner Lorenzo Mauri. “For the industrial coating sector, we have developed special bearings that can withstand high operating temperatures, compared to the conventional ones that are used at room temperature or in refrigerated environments.” TMC’s bearings are

especially employed in conveyor chains (Figs. 1 and 2). They meet the standard requirements for corrosion resistance and they are characterised by excellent lubrication, which can triple the service life of the chains themselves.

2 1

“In TMC, we firmly believe

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

A NEW DIMENSION IN EFFECT POWDER COATINGS • • • • • • • •

Liquid paint-like 3D effects in one-coat Brilliant and bright effects Visible from all angles of observation New design effects for architects For multi-coater projects Easy-to-apply: minimal equipment inﬂuence Considerable reduction of rework Very good batch consistency

www.tiger-coatings.com

TIGER Drylac®

3D Metallics

TIGER Drylac® 3D Metallics Until now, one-coat powder coatings could not match the visual performance provided by liquid effect paints. However, TIGER is now opening completely new spheres with its TIGER Drylac® 3D Metallic products: the coating features a breathtaking, wet paint-like 3D effect with stunning depth, spatial clarity and unsurpassed brightness – still visible at a considerable distance and from different perspectives. With TIGER Drylac® 3D Metallics, many areas of industrial surface ﬁnishing may now draw on the “green” technology of powder coating and move away from solvent-based wet paints. TIGER Drylac® 3D Metallics are subject to the strict quality and test regulations of GSB International and QUALICOAT and available in Series 68 superdurable quality.

For more information or color cards please contact your TIGER representative or visit our website:

©mariana_designer - stock.adobe.com

www.tiger-coatings.com TIGER Drylac Italia s.r.l. 24122 Bergamo via F.lli Calvi 2/g Italy Phone: +39.035.413 35 80 E-Mail: 3DM@tiger-coatings.com

Experience TIGER Drylac® 3D Metallics live at

PaintExpo | Karlsruhe | Germany April 17 to 20, 2018 Hall 1 |Booth 1641

SPECIAL

BRAND-NEW

in the quality and reliability of our

materials and treatments that could

“The strength of this new product

product over time. Our experience

ensure greater resistance to wear and

is its versatility and adaptability to

has shown that the major problems

corrosion. This has resulted in the

all types of system and intended

of conveyor systems are often related

development of a special material that

use. It combines corrosion

to their bearings’ lubrication, which

we are considering patenting, able to

resistance and functionality

in turn affects the durability of their

self-lubricate and extend the life of

without affecting the chain

chains,” states Lorenzo Mauri. “We have

a chain up to three times compared

range and the plant efficiency,

focused on the choice of construction

with standard bearings (Fig. 3).”

while significantly reducing maintenance costs,” says Mauri. This new technology and the TMC product range will be

presented during the PaintExpo exhibition, Hall 1, booth 1412 to be held in Karlsruhe from April 17 to 20. For further information: www.tmc-italia.com

3 1

TMCOAT

WITHOUT TMCOAT

Figure 3: Bearing rings compared after a 200-hour salt spray test.

CALDAN conveyor solutions - simply perfect.

Visit us here:

Hall 1, Stand #1530

SPECIAL

BRAND-NEW

Under the Slogan “Your Efficiency Our Innovations”, the Wagner Group Will Present Innovative Products and Solutions for Increasing Efficiency

n addition to the latest products for powder and liquid coating, adhesive and © Wagner Group

marking solutions, Wagner will present

the following highlights at PaintExpo 2018, the leading trade fair for industrial coating technology: Automation concepts for highly efficient liquid coating will be showcased, such as the new TOPFINISH Bell 1S highrotation atomizer for reciprocators and linear axes, which is available in many variants, for example with integrated 2- or 4-colour change discs or 2-component It ensures

mixers. It complements the TOPFINISH

flawless, sharp-

RobotBell 1 for robot applications, which has been on the market since 2017. All models of the product family have adjustable shroud airs and can be used with different bell

Figure 2: Layer Check LC 1000.

edged markings 2 1

in OK/NOK component marking, alphanumeric labelling

plate combinations. Fast rinsing processes

and in the metalworking industry.

and short colour change times support fast

For powder coating, Wagner will present

cycle times for coating workpieces. Walther

innovative system solutions which can

Pilot, a subsidiary of the Wagner Group, will

considerably increase the productivity of

demonstrate the PILOT GA 9010 Marking

coating systems. In addition, Wagner’s

(Fig. 1), a fully automatic

Industry 4.0 solutions create transparency

spray gun for single

with regard to productivity, maintenance and

and multi-coloured

quality information - on the PC, smartphone

spot and line

or tablet. In this way, industrial customers

marking.

can identify unused potential in production at a glance. The trade visitors’ interest is also likely to be attracted by the Layer

Check LC 1000 (Fig. 2) for layer thickness measurement, which can be used to measure the layer thickness of powder and liquid paint before curing or drying without

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

Figure 1: PILOT GA 9010 Marking, a fully automatic spray gun for single and multi-coloured spot and line marking.

contact and with micrometer accuracy. For further information: www.wagner-group.com

Meet the world’s most experienced rookie.

Say hello to a remarkable business partner: We combine decades of expertise with the enthusiasm and dedication of a start-up. With the united powers of Silica products, TEGO® additives, and specialty additives of former Air Products, we oﬀer innovative and tailor-made solutions that deliver real value for your coating formulations.

Coating Additives of Evonik. Home of ACEMATT®, AEROSIL®, SURFYNOL®, and TEGO®. And much more.

ALUMINIUM 2018 12th World Trade Fair & Conference

9 – 11 October 2018 Messe Düsseldorf, Germany www.aluminium-messe.com

Organised by

Partners

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

FOCUS ON TECHNOLOGY Alumero: An Investment in the Coating Quality of Aluminium Profiles

FOCUS ON TECHNOLOGY The Trend Towards Ever-Greater Colour Customisation In The Aluminium Industry: The Response Of ALUKON

SUCCESS STORIES Asif Khan Reveals Super-Dark Vantablack Pavilion for Winter Olympics 2018

FOCUS ON TECHNOLOGY Impol Sevalcon: the Supplier of High Quality PVDF Pre-Painted Aluminium for the Infrastructure of the 2018 World Cup in Russia

56 58

BRAND NEW

FOCUS ON TECHNOLOGY How Cutting-Edge Technologies and Targeted Interventions Have Made Sepal One of the Most Advanced and Flexible Aluminium Processing Companies in Europe

64 70

BRAND NEW

HIGHLIGHT OF THE MONTH CMA Robotics Celebrates 25 Years of History at the Forefront of Technology in the Automatic Coating Sector BRAND NEW

FOCUS ON TECHNOLOGY Extrusiones Metálicas: Loyalising a Powder Coating Supplier to Consistently Meet the Quality Requirements of Very Different Markets

BRAND NEW

VTT Studio © Fotolia

74 76

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

FOCUS ON TECHNOLOGY

Alumero: An Investment in the Coating Quality of Aluminium Profiles

Alessia Venturi ipcm® he biggest

specialises in the design

problem that many

and construction of

manufacturers

customised aluminium

from different sectors

structures. “Such

face when it comes

problems were due

to finishing, if it is

partly to the big

outsourced, is related

changes occurred in

to quality consistency

the formulations of

and to the possibility to

chemical products

obtain different quality

and powder

levels for products with

coatings to meet

different intended uses.

the more restrictive

This is especially true in

environmental

industries where surface

regulations, and partly

treatment products and

to our difficulties in

technologies evolve so rapidly that contractors do not always manage to keep pace with innovations and their

maintaining constant

and timely control

Figure 1: The new powder coating plant installed by Euroimpianti Srl of Valeggio sul Mincio (Verona, Italy).

on the work of our providers. That is why in 2017 we decided to insource all our coating

related investments.

activities, installing a technologically advanced

Let us consider the aluminium profile

“In the last five years, we had found an

sector. With the banning of Chromium VI,

increasing number of quality issues in our

horizontal line,” says Šlamberger (Fig. 1).

the introduction of the REACH chemical

suppliers’ coated parts,” states Boris Šlamberger,

“Alumero’s coating quality level is too

substance monitoring register, and the

the plant manager of Alumero d.o.o.

important to accept even the slightest defects.

increase in performance requirements, which

This company, based in Bistrica (Slovenia) and

We paint both profiles and sheets for doors,

more and more often must comply with the

belonging to the Austrian Group ALUMERO,

curtain walls, fences, and so on. Coating

Qualicoat 2 specifications

aluminium sheet

for architecture, keeping

components, especially if intended for private

control over the quality of coated profiles is a challenge for the manufacturers that chose to entrust their finishing treatments to third parties (ref. Opening photo).

With the banning of Chromium VI, the introduction of the REACH chemical substance monitoring register, and the increase in performance requirements, which more and more often must comply with the Qualicoat 2 specifications for architecture, keeping control over the quality of coated profiles is a challenge for the manufacturers that chose to entrust their finishing treatments to third parties.”

homes, is even more difficult than treating profiles: they require the highest aesthetic quality level possible. For all these reasons, we decided to install

Opening photo: Application of powder coatings on profiles at Alumero d.o.o of Bistrica (Slovenia).

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

2 1

Figure 2: In the wide range of Alumero’s products, indoor and outdoor doors are very important.

Alumero paints both profiles and sheets for doors, curtain walls, fences, and so on. Coating aluminium sheet components, especially if intended for private homes, is even more difficult than treating profiles: they require the highest aesthetic quality level possible. For all these reasons, Alumero decided to install a coating line able to ensure maximum quality, chosing Euroimpianti, to support them in this insourcing project.”

a coating line able to ensure maximum

compromise that could jeopardise quality.

had the plant certified by a German

quality: Euroimpianti, the Italian company

This was one of the most difficult plant

body and our line reached the maximum

we have chosen to support us in this

design projects handled by Euroimpianti

values in all the parameters tested:

insourcing project, did not make any

in the last few years. The final solution was

polymerisation, pre-treatment, powder

compromise during the design phase.

the result of a precise joint work between

coating, colour change flexibility and

We can now safely state that the installed

the customer and the supplier. Alumero

speed, and workpiece handling.”

production needs,” says Boris Šlamberger. “The analysis, design and creation process

line was the best solution for our quality and

of the final layout of Alumero’s plant was very long and complex,” states Dean Bassi, the East Europe sales manager of Euroimpianti. “We revised the initial project over twenty times, precisely because we were required to avoid any technical

Alumero d.o.o, based in Bistrica (Slovenia) and belonging to the Austrian Group ALUMERO, specialises in the design and construction of customised aluminium structures.”

3 1

Figure 3: The 7-stage pre-treatment tunnel.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The Alumero Group The Alumero Group is a complete partner for the design, development and production of aluminium structures: curtain walls and components, windows, outdoor doors, roofing systems, sunblinds, fences, and even profiles for furnishings and kitchens, for solar panels, and for the industry (Fig. 2). Established in 1992 by Manfred Rosenstatter in Seeham (Austria) the Group now includes a branch in Poland, an extrusion company in Helmond (Netherlands), and the branch of Bistrica

The Alumero Group is a complete partner for the design, development and production of aluminium structures: curtain walls and components, windows, indoor and outdoor doors, roofing systems, sunblinds, fences, and even profiles for furnishings and kitchens, for solar panels, and for the industry.”

(Slovenia), which has recently inaugurated the Group’s first in-house coating line. Alumero specialises in the machining of precision profiles with thicknesses down to 0.4 mm, cross sections up to 500 mm and lengths up to 15 m. In its four sites, it vertically integrates the whole profile production process: extrusion,

Faster and Stronger Coat twice - bake once

machining, and coating, as

Powder-in-Powder solutions from FreiLacke

well as the processing and

www.powder-in-powder.com www.freilacke.com

painting of aluminium sheets intended for curtain wall doors and panels. “The Bistrica plant coats the entire Group production,” says Andreja Kurež, the

general manager assistant. “We receive extruded profiles from different suppliers and we machine them with 3, 4 and 5-axis CNC centres, weld them with various technologies, and assemble them. Assembly occurs after coating. Our customers are architects, construction companies, and final consumers.”

Improving quality: an imperative for Alumero The primary reason that lead Alumero to install a horizontal profile coating line was the need to improve its products’ finishing quality and resistance levels. “After a careful assessment, we concluded that we had to invest in quality in order to grow on the European profile market,” says Boris Šlamberger. “At the same time, we noticed that our contractors had not invested in new technologies for years: this prevented them from improving the quality of their surface treatments. Therefore, the only possible solution was insourcing our coating stage. The Slovenian plant was chosen to accommodate this new process phase.”

Visit us for more system coatings und applicationsolutions from one source!

Hall 1; booth 1420

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

Inaugurated on October 19, 2017, the horizontal powder coating plant for aluminium profiles and sheets required an investment of almost 2 million Euros, aimed at enhancing the added value of the firm’s products and completing its manufacturing process.”

Whereas the first requirement of the new plant was a high treatment quality level, the second one was flexibility: Alumero coats profiles with very different sizes and thicknesses, as well as plates and fences requiring different technical choices than profiles.”

Inaugurated on October 19,

Plant features

2017, this horizontal powder

Whereas the first

coating plant for aluminium

requirement of the new

profiles and sheets required an

plant was a high treatment

investment of almost 2 million

quality level, the second

Euros, aimed at enhancing

one was flexibility:

the added value of the firm’s

Alumero coats profiles

products and completing its

with very different sizes

manufacturing process. “Buying

and thicknesses, as well as

a coating plant is not like buying

plates and fences requiring

a car: you must speak the

different technical choices

same language as the supplier,

than profiles. “The spray

carefully assess all the machines all finding a partner that listens

pre-treatment tunnel was

4 1

included in the line, and above

designed to easily achieve

Figure 4: Entry of the pre-treatment tunnel.

the Qualicoat 3 and GSB 3

to your needs. Euroimpianti

certification levels.

ticked all the boxes,” states Boris

It currently includes 7

Šlamberger. “We required a

stages, but it is ready for the

tailor-made plant and wanted to actively contribute to its design, especially to verify that our requirements were always met and our goals always considered. The design phase lasted over a year: not many companies are willing to invest so much time on a potential customer.” “Once the goals were established accurately, Euroimpianti showed Alumero the way to reach them,” says Dean Bassi, “providing them with all the

introduction of a further stage in future to

Alumero required a tailor-made plant and wanted to actively contribute to its design, especially to verify that the requirements were always met and the goals always considered. The design phase lasted over a year.”

support possible.”

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

increase the line productivity (Fig. 3),” says Dean Bassi from Euroimpianti to describe the constructive characteristics of the plant. “The cycle uses chemicals provided by Alufinish GmbH and it includes the following stages (Fig. 4): acid attack, pre-cleaning, a rinse with mains water, two rinses with demineralised water, nebulisation of a chrome-free no-rinse passivating product, and nebulisation of demineralised water. The pre-treatment

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

5 1

Figure 5: The power&free conveyor supplied by Futura Convogliatori Aerei of Robecco Pavese (Pavia, Italy).

plant also includes a demineralisation unit and

to strategically create several storage

The colour change operation has an

a chemical-physical water treatment system for

buffers, used for optimising the colour

impact of 10 to 20 minutes on productivity,

continuous discharge; this ensures constant

change times and, above all, ensuring

compensated for by two storage buffers

concentration and pollution levels

– one after the drying tunnel,

in the baths during plant operation,

also used for cooling the parts,

without changing the quality of the

and the other after the coating

pre-treatment results.” The pre-treatment tunnel is followed by a blow-off station and a drying oven. As for logistics, Alumero had initially chosen a one-rail conveyor. It then

The spray pre-treatment tunnel was designed to easily achieve the Qualicoat 3 and GSB 3 certification levels. It currently includes 7 stages, but it is ready for the introduction of a further stage in future to increase the line productivity.”

booth (Figs. 6 and 7). Another storage buffer is located inside the polymerisation oven to compensate for the different curing times of products (due to different sizes and thicknesses – Fig 8).

opted for a power&free one that could provide the line with greater productivity, flexibility and treatment

maximum treatment quality for every

The coating booth is the machine with the

accuracy. Futura Convogliatori Aerei

workpiece during both pre-treatment and

highest colour change automation offered

developed this power&free conveyor in order

polymerisation (Fig. 5).

by Gema, featuring a conventional Venturi

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

to enter the oven is also the first to leave it: this ensures uniformity of the polymerisation time for the whole length of each profile. “With a conventional U-shaped oven, on 6-7 metre long profiles there may be a polymerisation time difference of up to 1 minute,” says Bassi. “The Z-shaped oven we installed in Alumero eliminates this problem. This is the only possible choice for a company seeking the highest level of finishing quality, since, as is well known, an excessive polymerisation time causes colour issues whereas too

6 1

short a time creates film resistance problems.”

Figure 6: The storage buﬀer before the coating booth.

A storage buffer located after the polymerisation oven is used to cool the parts and to

application system and 10 automatic guns (Fig. 9). It is also equipped with two double preand post-retouching stations to ensure perfect coverage of workpieces with any shape (Fig. 10). The automatic guns are adjusted by the system

Futura Convogliatori Aerei developed a power&free conveyor in order to strategically create several storage buffers, used for optimising the colour change times and, above all, ensuring maximum treatment quality for every workpiece during both pretreatment and polymerisation.”

completely empty the oven at the end of the work shift; once again, this ensures that the cycle meets the minimum or maximum polymerisation time requirements of each workpiece type.

which changes the coating parameters depending on the input received during loading

management software,

without any operator intervention. In theory, every load bar on the chain could be automatically coated with different parameters. The polymerisation oven located afterwards features a powder gelling pre-chamber. “Instead of an oven dedicated solely to gelling, with consumption values sometimes almost equal to those of polymerisation ovens themselves, we chose to create a pre-chamber exploiting the energy recovered from the oven to gel the powder. Only one load bar at a time stays in this pre-chamber, in order to avoid any colour contamination between parts,” explains Dean Bassi from Euroimpianti. “This design choice ensures minimum energy consumption for gelling the coating at almost zero cost.” Alumero’s production flow is based on the FIFO (First InFirst Out) principle; therefore, the first part of a workpiece

7 1

Figure 7: A storage buﬀer is positioned after the powder application booth and before the polymerization oven.

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

8 1

Figure 8: A storage buﬀer is located inside the polymerization oven.

Fully automatic management

A green field project

The plant is completely digitalised.

The new coating plant installed by Alumero’s

During loading, the operator selects

Slovenian branch belonged to a green

the complete treatment sequence for

field project: the company expanded its

each hung part, choosing the type of

production site by building a new plant

pre-treatment, the colour of the coating

devoted only to coating. “The numerous

The coating booth is the machine with the highest colour change automation offered by Gema, featuring a conventional Venturi application system and 10 automatic guns. It is also equipped with two double pre- and postretouching stations to ensure perfect coverage of workpieces with any shape. The automatic guns are adjusted by the system management software, which changes the coating parameters depending on the input received during loading without any operator intervention.”

of the guns, and the polymerisation times (Fig. 11). In case a colour change

to be applied, the operating parameters

is needed, the system management software commands the spray booth to stop the chain. After cleaning, the operator can restart production with the new colour. Thanks to the buffer created inside the polymerisation oven, the system ensures that there is no over- or under-polymerisation, even with parts requiring different process times. Again in order to achieve maximum treatment quality, the plant prevents any load bar to remain inside the pre-treatment tunnel at the end of a shift or in case of any sudden production interruptions. In the same way, the management system prevents any coating process to start on a load bar if there is not enough time for to complete at least the pre-treatment and drying stages.

9 1

Figure 9: The fast colour change coating booth, with the powder centre on the left, is equipped with 10 automatic guns, all supplied by Gema.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

10 1

Figure 10: The booth is equipped with two double pre- and postretouching stations.

Instead of an oven dedicated solely to gelling, with consumption values sometimes almost equal to those of polymerisation ovens themselves, Alumero chose to create a pre-chamber exploiting the energy recovered from the oven to gel the powder. Only one load bar at a time stays in this prechamber, in order to avoid any colour contamination between parts. This design choice ensures minimum energy consumption for gelling the coating at almost zero cost.”

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

requirements and it is efficient in terms

systems described were located in a space perfectly designed for this purpose,” states Dean Bassi. “Since this was in a new building, involving further costs for the company in addition to the technology investments, the challenge was to minimise the space needed to accommodate each machine, including the water treatment plant, the demineralisation unit, the compressors, and the quality control

The plant is completely digitalised. During loading, the operator selects the complete treatment sequence for each hung part, choosing the type of pre-treatment, the colour of the coating to be applied, the operating parameters of the guns, and the polymerisation times.”

of environmental impact. In Slovenia, we have one of the most stringent legislations in Europe and controls are constant and frequent.” “Compliance with Slovenian regulations was a true “stress test” for this plant, but we are proud to say that we have passed it,” states Dean Bassi, “especially because this is not a zero liquid discharge system: its water discharge is perfectly in line with the legal requirements.”

laboratory, as well as spaces for the

“Euroimpianti supported us not only

internal and external logistics.” “I

in terms of design, but also of plant The system has been in operation for

management and operation,” says Boris

plant to have the exactly necessary

a few months now. “Currently, we are

Šlamberger. “Their experience in terms of

dimensions, no more and no less,”

using about 20% of the plant’s production

operating costs enabled us to make a very

states Boris Šlamberger, “also due to

capacity, because we are still in the

accurate comparison between different

quality reasons: the less the space

learning phase,” says Šlamberger. “We are

solutions and understand how different

dispersion, the less the external

very pleased with the work of Euroimpianti.

technological choices would have affected

contamination.”

The plant meets all our quality

our investment and management costs.”

wanted the new building hosting this

11 1

Figure 11: The loading area with the storage buﬀer before the pre-treatment tunnel.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

Opening photo: Alukon KG is one of the leading suppliers in Central Europe in the sectors of shutters, window screens, sun protection systems, and garage doors

FOCUS ON TECHNOLOGY

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

The Trend Towards Ever-Greater Colour Customisation In The Aluminium Industry: The Response Of ALUKON Francesco Stucchi ipcm®

roduct customisation is one of the

lifestyle and consumption behaviour leads

also in the building sector, for example for

mega trends of our time. We have

to the demand for increasingly customised

window and door frames and awnings.

already dealt with it on this magazine1,

products. The quickest way to customise

This mega trend forces manufacturers to

analysing how the will to distinguish through

a product? Requiring an exclusive

be increasingly flexible in terms of coating

the originality and individualisation of one’s own

colour and finish. This is already a well-

to stay competitive, while pushing paint

established practice in the car market, but

suppliers to focus on R&D to meet individual

it is becoming more and more common

non-standard requests.

ipcm®_International Paint&Coating Magazine, Vol. No. 39, May/June 2016, page 03

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Established as a distributor of aluminium shutters,

products, this company is still growing. With its new

Alukon KG is now one of the leading suppliers in Central

development project, Alukon expanded the space at

Europe in the sectors of shutters, window screens, sun

its headquarters in Konradsreuth, near Nuremberg

protection systems, and garage doors (ref. Opening

(Germany), by 50% (Fig. 2). The implementation

photo). It is currently expanding its plant by over

of a vertical warehouse (Fig. 3) and an advanced

12,000 m ;

coating plant

by 2019, it will be updated to the

that will come into operation in

latest construction

2019 will enable

and technology

it to optimise

standards (Fig. 1).

its production

Alukon is in fact

flow and reduce

constantly striving

delivery times.

for progress and

“Our focus for

improvement,

the future is to

as proven by its

confirm ourselves

evolution in its fortyyear history. A lot has happened since its establishment in 1974: it went

as reliable

suppliers for

Figure 1: Aerial view of the factory of Konradsreuth, near Nuremberg (Germany).

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

an increasing number of customers while

keeping innovating our products,” says Alexander

expanded its product range up to the production

Winkler, the Head of Product Management and

and sale of textile materials for sun protection

Marketing at Alukon (Fig. 4). “As a supplier of

systems and rolling shutter boxes. Belonging to

both components and complete systems, Alukon

the Hörmann Group since 2013 and characterised

provides its customers with great flexibility, as

by a layered production and sale structure

they can decide if and what to produce or buy

including both individual components and end

depending on their order volume. We aim at

from 3 to about 400 employees and it gradually

ANTARES S.r.l. 2 1

Figure 2: The entrance of Alukon AG in Konradsreuth.

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

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

coatings ensure the highest durability and resistance performance, and therefore they are the best option to colour our aluminium products. Colour has become increasingly important in the last few years. Up to ten years ago, one would use five shades at most: requests for different, customised, metallic, and special effect colours have now increased enormously (Fig. 5).” Alukon has a standard colour catalogue with three different finishes: gloss, matte, and textured. However, it offers its customers – not only architecture firms, but also end users – almost any tint they may require. They perform more than 20 colour change operations per day. “Currently, we use two coating systems: one is large-sized and it treats the biggest batches and the other is small-sized and it performs up to

3 1

25 colour change operations per day. Our new coating line, which will © ipcm ®

Figure 3: The brand new vertical warehouse.

be certified according to the GSB standard, will handle the production volumes of both plants, which will be divested,

reacting to the market’s and our

and it will perform a colour

partners’ requests in the most

change in less than 5 minutes,”

versatile way possible in order to

states Alexander Winkler.

develop tailor-made solutions.” In the last two years, Alukon has launched a large number of new

Figure 4: from left to right, David Seim and Alexander Winkler (Alukon) with Alessia Venturi (ipcm) and Oliver Ott and Gilberto Vercesi (RIPOL).

products and innovations, such as the frame-mounted shutters AK-Flex and the last generation systems ZipTex.

4 1 © Alukon

of its textile sun protection

In 2018, one of the most important changes will be the startup of the new coating line. Advanced and extremely flexible, it is currently being installed and it is expected to come into operation by the end of this year. After its completion, Alukon will continue to rely on its proven partners for painting products, including RIPOL (Santo Stefano Ticino, Milan, Italy). “Alukon has been collaborating for many years with RIPOL, which we consider a really trustworthy partner,” says Alexander Winkler. “They provide us quickly and reliably with high quality products characterised by excellent quality consistency among batches. Moreover, they strive to support us in the development of both standard and customised colours.”

Alukon’s production cycle Powder coating is a strategic phase for Alukon. “Powders are the best finishing solution for our products, which, being intended for outdoor use, must withstand a variety of weather conditions,” says Alexander Winkler. “Only powder

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

Established as a distributor of aluminium shutters, Alukon KG is now one of the leading suppliers in Central Europe in the sectors of shutters, window screens, sun protection systems, and garage doors. It is currently expanding its plant by over 12,000 m2; by 2019, it will be updated to the latest construction and technology standards.”

5 1

Figure 5: The application of thermosetting powders.

FOCUS ON TECHNOLOGY

6 1

Figure 6: A part of the colour catalogue available to Alukon’s customers.

Of course you can paint 400 horses. Surface coating expertise on many levels – that‘s where Rippert has been making a name for itself for over ﬁve decades. We conceived a surface coating plant for the CLAAS Group for the ﬁnishing of chassis. We are delighted to accompany a successful company with our ideas and technologies. We make brands shine. Find out more at www.rippert.de

In 2018, one of the most important changes will be the start-up of the new coating line. Advanced and extremely flexible, it is currently being installed and it is expected to come into operation by the end of this year. After its completion, Alukon will continue to rely on its proven partners for painting products, including RIPOL (Santo Stefano Ticino, Milan, Italy).”

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

any shade of grey,” Alexander Winkler

high and above all consistent among batches,

says ironically. “Historically, the most

as are their colours,” says Alexander Winkler.

used colours in our production have

“That is why we have never really needed

always been white and brown: even

RIPOL’s technical assistance service. In any

nowadays, these two tints account for

case, their engineers know our coating line

50% of our volume. However, there

very well and they know how to change their

is a growing trend towards grey,

formulations if any surface defects occur.”

especially in its metallic shades, © ipcm ®

which now accounts for about 40% of our production volume. Customised and non-standard colours, such as the yellow and pink tints used on profiles for schools or kindergartens, account for the remaining 10% (Fig. 6).” For a company like Alukon, aiming at extreme service flexibility and at colour and finish customisation, it is crucial to rely on a trustworthy and efficient partner for the supply of coating products. “Their commercial relationship with

7 1

RIPOL began at the turn of 2010

Figure 7: Traditional and innovative solutions in Alukon’s products.

and 2011,” says Oliver Ott, the Business Development Manager of RIPOL GmbH, the commercial

“With the new coating technology that will

branch of the Italian company, located

be available to us by the end of 2018, we

near Stuttgart. “We started with a few

will be extremely flexible. At the moment,

colours, but we now supply a significant

with our old line, we are not: we are forced

share of the outdoor polyester coatings

to organise our production flow based on

they use. We developed a colour of their

the colours to be applied in order not to

catalogue, Alukon White (similar to RAL

lose productivity. In future, we will be able

9016) with a matte finish, exclusively

to adopt a just-in-time approach, coating

for them. Then, we started providing

according to the orders received. We also

another standard tint, Alukon Brown,

aim at increasing our coating capacity, but

with a semi-matte finish. We are now

our main focus is definitely on flexibility, as

working on another custom colour (Figs.

Growing requests for customised colours

we produce components that are then cut,

7 and 8).” “Matte finishes are definitely

“In response to the growing demand for

processed, and assembled by customers,

another trend in the industry,” states

colour innovation in the architectural

finished products on request, and profiles

David Seim, from the purchasing office of

powder coating market, RIPOL invested in

requiring any intermediate processing

Alukon. “Until a few years ago, the most

a new manufacturing unit to produce new

operation.”

requested finish in Germany was smooth

colours, shades and effects from few boxes

and glossy; then, a trend towards matte

up to 200 kg”, states RIPOL Sales Manager

finishes started in Austria and continued

Gilberto Vercesi. “If we need to create

on other Central European markets, such

a custom match, we will do it in 7 – 10

Although Alukon can use any colour shade,

as the Polish one.”

business days, quicker if we can.

the market trend goes towards grey finishes,

“We are very pleased with our supply

I am sure that our cooperation with Alukon

both metallised and matte. “As we like to

relationship with RIPOL, because the

will be strengthened by our flexibility in

put it, the current colour trend is towards

quality of their products is always very

manufacturing also small batches”.

Colour trends: Alukon’s strategy in partnership with RIPOL

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

8 1

Figure 8: Alukon is a leading supplier in Central Europe also of sunblinds.

Visit us at PaintExpo 2018

Hall 3, booth 3417

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

SUCCESS STORIES

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

Asif Khan Reveals Super-Dark Vantablack Pavilion for Winter Olympics 2018

Figure 1: The 10-metre-high pavilion for the Winter Olympics 2018, spray-painted by architect Asif Khan with Vantablack VBx2.

sif Khan has unveiled a pavilion at

absorbs over 99% of light. Vantablack

all four sides of the pavilion, giving the

the Pyeongchang Winter Olympic

VBx2, is a sprayable version of Vantablack

impression of stars suspended against

Games in South Korea, described as

pigment, which British artist Anish Kapoor

the darkness of space.

the “darkest building on earth” (Fig. 1).

controversially acquired exclusive rights for

Speaking to Dezeen, Khan – who

The British architect spray-painted the

in 2016.

describes himself as a “closet astronaut” –

10-metre-high temporary structure

Rods tipped with tiny white lights protrude

said he “wanted to create the impression

Vantablack VBx2, a substance that

from the “super-black” parabolic curves of

of a window cut into space”.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

SUCCESS STORIES

Asif Khan, a British architect, spray-painted the 10-metre-high temporary structure Vantablack VBx2, a substance that absorbs over 99% of light. Vantablack VBx2, is a sprayable version of Vantablack pigment, which British artist Anish Kapoor controversially acquired exclusive rights for in 2016.” “It’s a preoccupation of mine, trying to create experiences to better understand where we are now as humans, placing ourselves in the big picture,” said Khan. “I’m interested in that feeling of the sublime when you pull back the curtain of reality. It’s a different way of

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experiencing architecture.” The sprayable Vantablack VBx2, is so black that it is almost impossible for the human eye to perceive the shape of an object it coats. “It changes as you approach it. From far away you see it as a surface of blackness, it just looks like a void,” said Khan. “As you approach you pick out the stars, and as you get closer the stars begin to move in parallax,

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which means they appear as a three-dimensional body. As you walk past it they’re almost globular in their clustering.” The light-absorbing power of Vantablack VBx2 and the optical illusions created by the lights against the curved walls is almost too difficult for humans to comprehend, according to the architect. “There’s a tension between wanting to know what form something is and actually accepting that it could be formless – you’re looking at infinity,” he said. Khan had been in contact with the scientists behind the original Vantablack, since 2013, after reading a paper on the subject while researching how to create a building that could be as black as space.

The sprayable Vantablack VBx2, is so black that it is almost impossible for the human eye to perceive the shape of an object it coats.”

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SUCCESS STORIES

rights over uses microscopic stems to

Park you don’t have much of a time frame to

absorb light, VBx2 has a sponge-like

get anything wrong,” said Khan.

structure at micro level.

When it opened on 9 February 2018, visitors

To build the PyeongChang Winter

will be able to enter the pavilion through a

Olympics pavilion, the steel substructure

dark corridor that opens into a bright white

was bolted together on site and then

space lined with solid-surface material Corian.

clad to create the curved surfaces.

Channels have been carved into its surface

A scaffold was then erected around

as part of a multi-sensory hydrophobic water

the pavilion and tented, creating

installation also designed by Khan. Walking across a pathway, visitors

The Vantablack used for Khan’s building is structurally different to the original pigment. Whereas the black Kapoor has rights over uses microscopic stems to absorb light, VBx2 has a sponge-like structure at micro level.”

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

interact with sensors causing 25,000 water droplets a minute to whizz along the channels, colliding and splitting before pooling into a lake. The 35-metre by 35-metre

“They were quite taken aback that

building was commissioned

someone would think to try and

by Hyundai Motor as part of

apply their materials in the built

its global art initiative, with the

environment,” he said. “They’re

pavilion’s space theme aligning

a bunch of very skilled scientists

with the car manufacturer’s latest

who are working a lot of the time

technology: a Hydrogen Fuel Cell

in a laboratory. They are working

vehicle.

at nanoscale and the idea of

The “stars” on the outside (Fig. 2)

making something that’s millions

represent the chemical element

of times bigger than that hadn’t

on a cosmic level – gaseous balls

really come into their minds.”

shining due to the thermonuclear

Khan and the scientists first

fusion of hydrogen into helium at

collaborated on a proposal using

their core.

the material for the UK Pavilion

Inside the pavilion, the liquid

at Milan Expo 2015, which was

embodies hydrogen at a more

eventually shortlisted.

human scale, as two atoms of

In the meantime, the

hydrogen bond with one oxygen

manufacturers devised Vantablack

atom to form water.

VBx2, a more versatile material

The building also references

better suited to architectural pigmented coating is suspended in a carrier solution that allows it

its location in South Korea.

2 1

application. The light-absorbing

The curved wall of the building

Figure 2: A detail of the “stars” on the outside of the pavilion.

makes it star-shaped in plan, yet rectangular in elevation, while the shape formed by the intersection

to be sprayed onto larger areas. “This was the real challenge, actually going

conditions suitable for spray painting.

of the curved walls echoes the swooping roofs

from the lab to full scale manufacturing,

During construction the team had to

of traditional temple architecture.

which they pulled off. It’s amazing,” said

contend with the mountain climate and

Khan.

temperatures between -15°C and -25°C.

The Vantablack used for Khan’s building

“It’s a challenging climate to work in,

is structurally different to the original

because of the temperature, because of

For further information:

pigment. Whereas the black Kapoor has

the extreme high winds. On an Olympic

www.dezeen.com

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

Author: © India Block for Dezeen

Innovate today. Inspire tomorrow. IGP. FOR SURE.

IGP Pulvertechnik AG CH-9500 Wil Phone +41 (0)71 929 81 11 www.igp-powder.com info@igp-powder.com A member of the DOLD GROUP

PaintExpo 2018 Visit us at booth 2517 in Hall 2 17. â&#x20AC;&#x201C; 20. April 2018, Karlsruhe

www.igp-future.com

Opening photo: The Luzhniki Stadium, built in 1956 and recently renovated in view of the upcoming FIFA World Cup, coated with the Olympic Gold colour.

FOCUS ON TECHNOLOGY

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

Impol: the Supplier of High Quality PVDF Pre-Painted Aluminium for the Infrastructure of the 2018 World Cup in Russia Alessia Venturi ipcm®

leven cities and twelve stadiums will host the 64 matches of

The Luzhniki Stadium, built in 1956, has hosted a myriad of sporting

the 2018 FIFA World Cup in Russia. About 15 billion Euros were

and non-sporting events, including the 1980 Olympics. This wonderful

invested in setting up the tournament, to build and renovate the

building has 80,000 seats and it will host the opening match on June 14,

infrastructures of the selected locations. These will be Moscow, with two

which will see the home team face Saudi Arabia, and of course the final,

facilities, Saint Petersburg, Kaliningrad, Nizhny Novgorod, Kazan, Samara,

scheduled for July 15.

Saransk, Volgograd, Rostov-on-Don, Sochi, and Ekaterinburg. The two

The complete renovation of this stadium has required an investment of

semi-finals will be played in Saint Petersburg and Moscow, while the final

over EUR 350 million and it has included the creation of an upper band

will be hosted by Moscow’s Luzhniki Stadium.

in pre-painted aluminium, for which PVDF coatings were used to ensure

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The complete renovation of this stadium has required an investment of over EUR 350 million and it has included the creation of an upper band in pre-painted aluminium, for which PVDF coatings were used to ensure that the exterior appearance of the building will remain intact for decades. The Olympic Gold-coloured pre-painted aluminium used for the Luzhniki Stadium was produced by Impol Seval, a company based in Sevojno, Serbia, which is a division of IMPOL group with the head office in Slovenska Bistrica, Slovenia.â&#x20AC;? that the exterior appearance of the building will

onion dome coated with a wrinkled product

remain intact for decades. The Olympic Gold-

featuring a gold/iridescent pigment; the new

coloured pre-painted aluminium used for the

terminal of the Perm international airport

Luzhniki Stadium (ref. Opening photo) was

(Fig. 2) for which the Dubai Gold colour was

produced by Impol Seval, a company based in

used (Fig. 3); VTB Arena, located in the heart

Sevojno, Serbia, which is a division of IMPOL

of Moscow, for which a sea foam-inspired

group with the head office in Slovenska Bistrica,

white pearl finish was used; and Zaryadye

Slovenia.

Park (Fig. 4), the new green lung of the city of Moscow a few steps from the Red Square, characterised by a metallic finish called Silver

many projects, which Impol Seval has completed

Charge. Thanks to its 35-year experience in the

in Russia in the last few years, with its products

coil coating technology for aluminium and long

branded Sevalcon, using high quality PVDF

term cooperation with SALCHI Metalcoat, high

coatings. Among others, they were used for the

performance coatings with special effects were

Rossosh monastery, with the beautiful golden

developed.

ÂŠ Sevalcon

The Luzhniki Stadium (Fig. 1), is just one of the

Figure 1: Detail of the Luzhniki Stadium, painted with PVDF products supplied by Salchi Metalcoat.

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

2 1

Figure 2: The new and futuristic terminal of the Perm international airport, where Impol and Sevalcon have applied the Dubai Gold finish.

In 2013, Impol started a new coating line that enabled it to dramatically change its product portfolio, positioning itself in a very high-end market segment. From the beginning, Impol focussed on special products for architecture and infrastructure. In these sectors, quality is everything. Thanks to the new advanced coil coating line, they can finally offer structural aluminium for iconic buildings with special aesthetic effects and very high aging resistance performance. At the same time, Impol can ensure quality consistency also with very high volumes, which is the most critical issue when it comes to producing special finishes.”

Impol: focus on quality in coil coating

Europe, especially Germany, Holland, Italy

In 2013, Impol started a new coating line

even the most specific needs, we have now

that enabled it to dramatically change

greatly increased our market share in Russia,

its product portfolio, positioning itself

thus becoming suppliers of many exclusive

in a very high-end market segment.

projects such as the new infrastructure for

“From the beginning, Impol focussed on

the 2018 World Cup.”

special products for architecture and

Impol is highly flexible, equipped with casting

uniform coating thicknesses and perfect

infrastructure. In these sectors, quality is

ovens, hot and cold rolling mills, coil coating

film spreading along the whole coil surface.

everything. Thanks to our new advanced

line and hot-lamination section. Over the

In order to achieve this quality result, the

coil coating line, we can finally offer

years it has used more than 1000 different

Serbian coil coater cooperates closely with its

structural aluminium for iconic buildings

coatings. Its coil coating line operates at a

paint suppliers in terms of both development

with special aesthetic effects and very high

speed of 60 metres/minute and ensures

of the coating and regulation of the line based

and Poland. Thanks to our ability to meet

on the characteristics

time, we can ensure quality consistency

of the product to be

also with very high volumes, which is

aging resistance performance. At the same

applied. Therefore

the most critical issue when it comes to

Impol Seval insists

producing special finishes”, states Impol

with its paint suppliers

Seval’s Senior Sales Officer Nemanja Rosić.

on fast and efficient

“There are two key elements to succeed in

technical service and

the field of exclusive architectural projects:

collaboration in matching

high quality customised coatings made

the coatings to the needs

with high-performance raw materials and

and requirements of

a plant able to apply them – these paints

the coil coating line in

usually present some application problems

Sevojno, emphasizing a

from the beginning to the end of metal

high level of satisfaction

coils,” says Ljubomir Jevtić, Impol’s Coil Coating Line Manager. “Until today, we have sold 99% of our pre-painted metal in

3 1

Figure 3: The Dubai Gold shade.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

with the cooperation with the supplier SALCHI Metalcoat.

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

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

Customisation, performance, and special eﬀects: the three pillars of Impol’s success

short time (Fig. 5). The choice to rely on an Italian partner also stems from Italy’s reputation in terms

Impol works in close

of aesthetics and

contact with clients

design.”

and architectural firms.

“As for performance,

“Before approving a

PVDF products

certain coating product,

account for 90% of

we supply many

the coatings used

different samples, all

for our projects in

with customised colours.

Russia. They are the

This is our strength,”

only coatings that can

says Milos Popovic,

ensure exceptional

who manages the

aging resistance,

relationships between Impol and its Russian clients. “Very often, the choice falls on colours and

colour retention,

4 1

and no need for

Figure 4: Zaryadye Park is the largest green area in the city of Moscow, featuring modern high-tech infrastructure.

maintenance over very long periods of time. Our paint

effects that combine several different

speed of its deliveries: our paint development

suppliers must therefore also be expert in

samples. Architect always require specific

partners must be equally timely,” states

the use of PVDF raw materials in special

coatings for their projects: that is why it is

Popovic. “For example, for the cladding

effect products,” says Milos Popovic.

important that the paint supplier selected

of Moscow’s VTB Arena, we developed a

“Furthermore, they must be able to solve

is able to offer customised products.

complete ocean-inspired collection in a very

any colour matching problems that may occur between pre-painted

not have months or years to develop a

aluminium and aluminium

coating that meets the architects’ needs.

Moreover, time is of the essence: we do

profiles, which are traditionally powder coated. Providing a

Impol is well known on the market for the

customised product exactly in line with the architects’ ideas is not enough: such coating

Besides the Luzhniki Stadium, which exceeded the expectations of both investors and Football Federation officials, Impol has worked on several international airports in the Russian cities of Rostov, Saransk, Volgograd, and Perm. Russia is in fact making huge investments in its infrastructure, not only for the FIFA World Cup but also as a part of a larger country development project.”

must also harmonise with the paint products made by other suppliers for different components of the structure. Finally, a crucial requirement for Impol is the fire resistance certificate: it enables our aluminium to be used in airports, commercial and financial buildings, hospitals, schools, stadiums, and all types of infrastructure that provide 5 1

Figure 5: The ocean-inspired colour range developed by Impol Seval in collaboration with the coating supplier Salchi Metalcoat.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

access to the public. I think that Impol is the only pre-painted aluminium producer to have this certificate in Russia.”

FOCUS ON TECHNOLOGY

Russia: great excitement in architecture

Russian capital, which turned 870 years

“It should also be noted that Salchi’s

old, Zaryadye Park is the largest green

coatings are customised not only

Besides the Luzhniki Stadium, which

area created in the city in the last fifty

in terms of colours, effects, and

exceeded the expectations of both

years. Here, modern high-tech structures

performance, but also based on the

investors and Football Federation

can be admired, such as the “suspension

characteristics of our application line,

officials, Impol has worked on several

bridge” on the Moskva River, an

which its engineers know very well,”

international airports in the Russian

underground glacier, and the honeycomb

says Ljubomir Jevtić from Impol. “Each

cities of Rostov, Saransk, Volgograd,

roof of the Philharmonic Hall,” says Milos

coating line has its own influence on

and Perm. Russia is in fact making

Popovic. “A very metallic finish that we

the application process, which can

huge investments in its infrastructure,

called Silver Charge has been chosen to

affect the finishing results. However,

not only for the FIFA World Cup but

enhance the modernity of this structure.

our projects require uniformly

also as a part of a larger country

“We collaborated with Salchi also for

perfect surfaces from the beginning

development project (Fig. 6). “We

this project because it is a coil coating

to the end of coils. That is why we

participated in the realisation of

manufacturer particularly inclined to

have fully automated our coating

one of the most important projects

produce specialty coatings – exactly what

process, which is adjusted from time

implemented in Moscow in the last

we are looking for. On the other hand,

to time depending on the type of

few years, Zaryadye Park, rising on

Impol has a great expertise in the coating

coating product to be applied, and

the ashes of the colossal 7000-room

of aluminium coils: they are able to

we monitor the thickness of both the

Rossiya Hotel, demolished in 2008.

perfectly coat very thick aluminium strips

tape to be painted and of the coating

Inaugurated on September 9, 2017

with an impressive final quality, even with

layers applied with three different

on the occasion of the birthday of the

“difficult” products such as PVDF.”

measurement and control devices.”

Your efficiency, our innovations.

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Coating. Bonding. Sealing. Eﬃciency and highest quality.

Characteristics of the coating system

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

From a technical point of view, the Kynar 500®-based PVDF coatings used by Impol Seval guarantee a minimum outdoor service life of 20 years. Impol generally applies two or three-coat systems, depending on customer requests. “In some special cases, metallic/iridescent effects may call for the application of an intermediate layer and a topcoat,” explains Jevtić. “Normally, the former gives the surfaces corrosion and ageing resistance characteristics, while the latter creates the special effect. At other times, the special effect is already present in the

6 1

Figure 6: Moscow’s Crocus City Oceanarium, another impressive and futuristic structure built by Impol Seval

intermediate layer and the topcoat as the preferred building material,

significantly lengthen the maintenance

treatment cycle is the same for all our

especially thanks to its durability,

intervals of structures, reducing their

products.”

design versatility, lightness, and

management and maintenance costs.

aesthetic characteristics. Preserving

They please the eye, preserve cities

the beauty of a building for a long

from the ugliness of decadence,

time goes far beyond aesthetics.

and allow to pass the heritage of

Modern times have seen the rise of

Maintenance-free materials,

contemporary society on to future

metal, and in particular of aluminium,

such as PVDF coatings, enable to

generations.

Aluminium: a protagonist of modern times

Salchi – Arkema: a winning partnership since 1963 Established in 1963, Glidden-Salchi (fig. A) was the first licensee of the Kynar material. In that same year, Pennwalt (Cleveland, Ohio, USA) decided to start a licensing program to ensure high quality for the end users of PVDF coatings formulated with Kynar resin. When, in 1976-77, the industrial Group led by the Brenni family acquired Glidden-Salchi and turned it into Salchi Spa, the license formally passed to the new legal entity. Since then, Salchi and Arkema (the current manufacturer of PVDF Kynar 500®) have been partners in the formulation of surface materials aimed at enhancing the aesthetics, decoration, protection, and durability of building skins. Over the past fifty years, Arkema has conducted several studies on the

improves and protects it. The pre-

of their coating products, with positive effects along the entire value chain up to architects, who can be 100% sure of the durability of their creations’ look for fifty years. As a licensee, Salchi has always followed the guidelines provided by these studies and it is therefore able to offer solid guarantees to all Figure A: The inauguration of the Glidden-Salchi plant in 1963. its customers. The fun fact about the PVDF Kynar 500® program is that aging of coatings, testing different combinations of pigments and additives some samples have been exposed in PVDF Kynar 500®-based formulations. in Florida for the last fifty years, and This makes the technology licensees we have absolutely no idea if one day 100% sure about the aging behaviour they will start to deteriorate.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

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BRAND-NEW

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

Adapta Color Presents Metal Vivendi Collection for Architectural Design

Figure 1: Vivendi SDS METAL Collection samples.

f something distinguishes Adapta

The new outstanding Metal Vivendi

finishes and other special effects

Color in the powder coatings

Collection is based on the proven Adapta

when they are applied to aluminium.

industry is its positioning in the

Vivendi technology for architecture,

Table 2 shows the mechanical and

market of metallic finishes. The new

which holds the Environmental Products

chemical properties of this product,

metallic colours of the Vivendi METAL

Declaration (EPD) and has been tested

obtained applying on 0.8 mm AA1050

range offer innovative developments

according to ISO 16000-9:2006 getting an

aluminium panels with the right

with excellent resistance to weathering

A+ for indoor emissions.

pre-treatment process and correctly baked, following the individual product

and maximum light fastness, always complying with international quality

Vivendi SDS METAL Collection products

data sheet instructions in order to get

specifications.

(Fig. 1) are based on ultra-durable

a right cross-linking reaction.

Coatings within Adapta’s Vivendi

polyester resins, hardeners without TGIC,

range have given an excellent exterior

pigments and additives (Table 1). They

Vivendi SDS METAL Collection

durability during more than 20 years

are semi-transparent pigmented clear

products meet or exceed the highest

with very good gloss retention and

coats to imitate noble metals (such as

international quality specifications for

colour stability.

copper, rose gold, brass…), anodised

powder coatings and can be used for

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

BRAND-NEW

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

external architectural applications. These are available in smooth satin gloss finish with a gloss range from 30 to 80. They offer 70% gloss retention after 1000 hours of QUV313B test. Vivendi products have been designed mainly to be used on aluminium surfaces as: - expanded and perforated aluminium panels - raised and flattened aluminium meshes - aluminium rain screens and sun protection parts - aluminium cassettes for faรงades. The substrate to be coated must be

Table 1: Powder characteristics and cure-stoving conditions of the product.

cleaned, degreased and pre-treated with the most suitable process (chrome-free or pre-anodizing). Vivendi SDS METAL Collection can bel electrostatically sprayed with all commercial Corona Guns. At the end of 1997, ADAPTA COLOR began to manufacture powder coatings. Since then, the company has been deeply committed to providing high quality solutions for all the requirements of the market, foreseeing the emergence of such needs to the greatest extent possible. With wholly Spanish capital, ADAPTA COLOR today represents the integration of experience and youth in the manufacture of powder coatings in Europe. A team of professionals with a long history of development in the industry and enterprising management have managed to place this company in an outstanding position in the market of powder coatings in a short period of time. For further information: www.adaptacolor.com

Table 2: Mechanical and chemical properties of the new Metal Vivendi products.

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

FOCUS ON TECHNOLOGY

How Cutting-Edge Technologies and Targeted Interventions Have Made Sepal One of the Most Advanced and Flexible Aluminium Processing Companies in Europe Barbara Pennati ipcm®

or a company performing coating

were both supplied by SAT Spa (Verona, Italy),

Qualicoat Seaside standard without any

tasks, a high finishing quality level

specialising in the design of vertical coating and

surface conversion process. Today, as then,

is just as important as a good

surface finishing plants for extruded aluminium

Sepal is driven by a will to renew and search

productivity rate. Production volumes

profiles.

for the best quality possible. That is why it has

should not be sacrificed in order to reach

ipcm visited Sepal’s premises in 2015 to report

recently made further important investments

the best quality possible for a given

the installation of the first plant in Europe, in

that led it to consolidate its presence on

markets. Another critical parameter to be competitive nowadays is

international markets. Once again, it chose SAT as its technological

flexibility, in terms not only of types

partner.

of component treated but also of

“Before the latest plant

compliance with specifications.

modifications, Sepal always

These can vary a lot among different

performed a flash oxidation pre-

markets, not so much for the

treatment process with the FOX®

requirements as for the processes

technology patented by SAT, that

needed to comply with them.

is, a very rapid anodic oxidation

Sepal Spa (Lograto, Brescia, Italy) is

phase able to improve corrosion

a well-established company in the

resistance. However, a few

sector of aluminium extrusion, which

markets, especially the French one,

has managed to distinguish itself in through the installation of some of the most advanced technologies available on the market. The aim was

have very strict specifications in

the field of aluminium profile coating

terms of chrome-free conversion,”

Figure 1: The brushes scratch the profiles’ first layer of aluminium to significantly reduce the possibility that surface defects appear after coating.

achieving higher quality and finishing

explains Andrea Trevisan, the CEO of SAT. “Therefore, we decided to modify their already-existing plant by integrating an acid attack

levels for their products, combined with

terms of both dimensions and production

and chrome-free conversion phase, which

high flexibility to meet the demands

cycle integration, to have industrialised the

enables Sepal to perform both the FOX® and

of different markets as well as high

flash oxidation pre-treatment technology ,

conventional pre-treatments on the same

productivity. Established in 1973, in 2014

which ensures salt spray resistance values of

line.” In the framework of this important

Sepal insourced its finishing operations

about 3000 hours and compliance with the

investment, other crucial changes were made

through the implementation of a modern coating plant with an in-line flash oxidation system and an anodising plant. These

1 “The first coating plant in Italy for aluminium profiles with an in-line flash oxidation pre-treatment process” ipcm®_International Paint&Coating Magazine Vol. VI, No. 31 January-February, pages 46-55

for quality purposes, but also to ensure constant productivity and greater versatility of the line.

Opening photo: The in-line brushing system added between the loading of profiles and the start of the pre-treatment cycle.

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

2 1

Figure 2: The coating booths feature 18 guns each.

In-line brushing machines for optimal surface preparation One of the main innovations was the addition of an in-line double brushing machine between the loading of profiles and the start of the pre-treatment cycle (ref. Opening photo). “Another important change to the plant was the integration of a brushing system to scratch all four sides of the profiles and remove any residues and surface defects created by the extrusion process,” says Trevisan. “Normally, with a part of Sepal’s production for which a very high surface quality is required, the brushing operation takes place before loading. However, performing this process offline entails high costs in terms of labour and time, and therefore a loss of productivity. That is why, based on Sepal’s automation-oriented approach and thanks to our patented system, we installed these in-line brushing machines.” This system is the second one installed by SAT and the first one in Italy, which confirms Sepal’s inclination towards technological experimentation. “By scratching the profiles’ first layer of aluminium, the brushes eliminate ‘stubborn’ chips and residues that

Sepal Spa (Lograto, Brescia, Italy) is a well-established company in the sector of aluminium extrusion, which has managed to distinguish itself in the field of aluminium profile coating through the installation of some of the most advanced technologies available on the market. The aim was achieving higher quality and finishing levels for their products, combined with high flexibility to meet the demands of different markets as well as high productivity.”

FOCUS ON TECHNOLOGY

chemical pre-treatment alone can hardly remove. It is an expensive process, but it significantly reduces the possibility that surface defects appear after coating, resulting in waste or expensive rework (Fig. 1),” says Trevisan. “The in-line integration of the brushing process also gives an advantage in terms of productivity: once the profiles are loaded, the whole finishing process is performed fully automatically. The same operation carried out offline, moreover, would require the use of one or more machines depending on the volumes to be treated.” “What makes our in-line brushing machines unique and innovative is their patented system to stop the profiles only in the brushing area, thus ensuring a safer, simpler and more consistent process. At the same time, the stop of the workpieces does not affect the speed of the line, because this patented system allows to compensate for the time required with an increase in the movement speed from one station to another,” explains Andrea Trevisan. “This is the second brushing system we have installed after the one of Cortizo, a Spanish manufacturer of aluminium profiles.”

The revamping of the coating booths The third plant modification involved the coating booths and it was aimed at increasing their productivity and quality levels. “Sepal’s plant includes two powder coating booths: the one dating back to 2014 is equipped with Venturi injectors, whereas the one added in 2015 features Gema dense phase pumps, a dispensing technology that ensures significant paint saving and better adhesion,” states © ipcm ®

Trevisan. “In order to further improve their performance, we increased the number of guns from 12 to 18 in the second booth, so that they both have the same number of guns (Fig. 2), and we retrofitted the first booth’s multiple controls to simplify its operation. Moreover, the oldest booth was replaced with a new V-shaped one, patented by SAT (Fig. 3). Originally, the line had been conceived to rotate the profiles; now, with these two

3 1

Figure 3: One of the two V-shaped booths, patented by SAT.

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

4 1

Figure 4: Sepal can manage both the booth and the guns with one control panel.

due to excessive

Performance and aesthetics 4.0

exposure.

“In 2015, Sepal was the first factory in

However,

Italy to employ the FOX® pre-treatment

it ensures

on all its products; their line could work

extremely

at a speed of 1-1.2 m per minute. With

durable and

the implementation of a chrome-free

resistant

pre-treatment process, the line can

products and

now work at a higher speed, up to

it has allowed

1.8 m per minute. Combined with the

Sepal to improve

two coating booths featuring 18 guns

the productivity

each, the modified unloading system

of its line, as

that automatically wraps the profiles

well as meeting

in packages, and the hook stripping

the quality

system that has allowed to insource

requirements

this operation, this has given Sepal

of international

extreme versatility and production

markets,” states

speed,” states Andrea Trevisan.

Trevisan.

“Finally, the reproducibility of process phases through the automation and

new generation booths, this is no longer

In-line hook stripping process

necessary,” says Trevisan. “Finally, we installed

Performing all the coating phases in-line

has contributed to ensure very high

a software for the vision system, able to

is a significant advantage: it enables to

production and quality standards.”

interact with the Gema powder management

reduce handling and labour and it increases

“The example of Sepal proves that

unit and in particular with the control system

economic efficiency. That is why SAT also

remarkable advantages in terms of

OptiControl CM22. This enables Sepal to

equipped Sepal’s plant with a hook stripper

both aesthetics and finishing quality

manage both the booth and the guns with one

supplied by Alit (San Bonifacio, Verona),

can be obtained through targeted

control panel (Fig. 4).”

which eliminates the need to remove the

interventions and small investments

hooks from the conveyor and send them to

on the already existing plants,

A 25-micron oxidation tank

interconnection of the production flow

modified quickly and without stopping

consists of a tank for the paint stripping

production by taking advantage of

treatment, which has given Sepal greater

product positioned between the unloading

summer breaks and holidays,” says

versatility, we also improved their anodic

and loading stations. On their way from

Andrea Trevisan.

oxidation system,” says Trevisan. “This

one station

plant is completely automatic and able to

to another,

handle profiles up to 8 metres. The initial

the hooks are

project provided for the installation of three

immersed in the

16,000-amperes tanks to obtain thicknesses

stripping tank

between 10 and 16 microns with a standard

while still hanging

oxidation process. However, we also created

on the chain.

the space for another tank, which we

After about 3

equipped with a 20,000-ampere rectifier in

minutes, they

December 2017, when the revamping project

are cleaned

started. This provides 25-micron oxide layers,

from any paint

as requested in particular in the United

accumulation

Kingdom.”

that can affect

“This type of oxidation is very difficult to obtain

electrostatic

because it requires the right balance between

generation during

the time spent in the tank and the acidity

application.

degree, so that the surface is not damaged

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

a stripping contractor (Fig. 5). The system

“Besides implementing a chrome-free pre-

5 1

Figure 5: Alit’s hook stripper.

Paint Engineering

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

Anticorrosive systems

Coil Coating Superdurable Superdurable coatings for sublimation effect Metallic bonding

www.titanpowdercoatings.com

BRAND-NEW

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

ondoroil Launches Condorcoat EC 930, a New

Condoroil Launches Condorcoat EC 930, a New Nanotechnology Conversion Product Nanotechnology Conversion

Product Condorcoat EC 930 is the new frontier of pre-treatment: a nano ceramic process, more commonly known as “nanotechnology process”, for the surface conversion of iron, galvanised metal and aluminium (Fig. 1). The nanotechnology product Condorcoat EC 930 creates a very compact inorganic layer, although much thinner than that achieved with iron phosphating. The protection obtained is of higher quality and with lower operating costs. Condorcoat EC 930 is free from phosphates, heavy metals such as zinc, manganese, nickel, etc., COD, and VOC; it is therefore highly eco-

Figure 1: Condorcoat EC 930 is the new nanotechnology product developed by Condoroil.

friendly. The economic-applicative advantages

with surfactants ensuring the

to perform application tests in its

of nanotechnology are manifold,

perfect removal of processing oils

technological laboratories, where

since it is possible to operate at

and greases, commonly found on

the effectiveness of the proposed

room temperature thus reducing the

iron and galvanised parts.

solutions can be assessed by

conversion bath management costs.

Condorcoat EC 930 is preferably

exposing the treated samples in

Sludge production is reduced, calling

used in demineralised water

accelerated corrosion chambers

for smaller doses of Condorcoat EC

solutions, with both spraying

before the in-line application.

930 and thus increasing the duration

and immersion techniques, from

Specialised engineers are also

of the bath itself. This generates

room temperature up to 50 °C, in

available to support the customers in

further savings, thanks to the

AISI 304 or 316 L stainless steel

the application phase.

reduced consumption of water due

systems. The workpiece treatment

to the lower replacement frequency

is followed by a rinse with

For further information:

of the bath.

demineralised water.

www.condoroil.it

Condorcoat EC 930 can also be

The pre-treatment process with

used in a single degreasing/surface

Condorcoat EC 930 is compatible

conversion stage (nanotechnology

with all coating processes.

degreasing), because it is enriched

Condoroil offers the possibility

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

SPECIAL

BRAND-NEW

APSA, the Spanish producer of aluminium

The painting line, being

wheels based in Orkoyen, near Pamplona, and

told as the fastest for

affiliate to Mondragon Group, has awarded

aluminium wheels in Europe, running at 8 m/min, will

to Dürr the realization of the entire new painting line for

be a real challenge for Dürr technicians, both for rims

aluminium wheels on a turnkey basis.

handling and conveyor synchronization as for paint

MAPSA will exploit the advantages of the extended

application and multiple rims baking and cooling.

product portfolio of Dürr Group for aluminium wheels

The new line will allow MAPSA to prosecute its

that includes layouting, complete process line, conveyors,

plan of capacity expansion with a high quality and

handling robots, complete automatic liquid paint

productivity plant, fully automated, from robotic

application system with electrostatic EcoBell 2 (Fig. 1), demi and waste water plant, VOC abatement systems – that in case of regenerative thermal oxidisers are specially tailored to handle wheel paints exhaust – and a dedicated software for the management of the entire system.

Figure 1: MAPSA’s new painting line will feature a complete automatic liquid paint application system with electrostatic EcoBell 2.

Dürr Will Realise the New Aluminium Wheels Painting Line for MAPSA

loading to final inspection, provided with innovative solutions including the state of the art liquid paint application systems. For further information: www.olpidurr.it

EcoGun AUTO

Automatic spray gun for wood working industry Compact and light automatic spray gun for air-assisted, air-less and airspray application. Can be used for paint application in the machining and wood working industry. All EcoGun automatic spray guns offer a wide range of spraynozzels and additional equipment.

www.verind.it

SPECIAL

BRAND-NEW

he second test plant, primarily focusing on the coating of temperature-sensitive substrates

IGP Pulvertechnik AG: Test Plant for Temperature-Sensitive Substrates Enters Operation such as MDF and plastics, became operational in February 2018 in addition to the existing metal coating technical centre located at the headquarters in Switzerland. The new test centre enables IGP to simulate the coating of temperature-sensitive substrates under real production conditions and to experiment with application methods (Fig. 1). This will create the foundation for shorter product launch times as well as robust volume production processes at the customer premises. Furthermore, the plant also functions as a research and training centre. In doing so, IGP is consolidating its position as a premium provider of powder coatings and ensures its ability to provide a suitable solution for all customer requirements. “With the new technical centre, we are further expanding the strategically important field of powder coating for temperature-sensitive substrates. In doing so, we are creating a further condition for consolidating our leading role in terms of innovations and design in addition to competitiveness,” explained Savvas Legidis, Head of Technology. “The ultra-modern technical centre is an important component of this. One particularly noteworthy special feature of the new technical centre is the variable speed control in the furnace, which permits a simulation of various furnace lengths (Fig. 2).”

Figure 1: The new test centre enables IGP to simulate the coating of temperature-sensitive substrates and to experiment with application methods.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

SPECIAL

BRAND-NEW

Special features of the technical centre: – Furnace with 56 individually controllable radiator elements constantly in a halo arrangement – Pre-heating furnace with 8 individually controllable radiator elements constantly in a halo arrangement – Fully electric furnaces with medium-wave infrared radiators – Conveying system with 3 power lines for pre-heating furnace, coating and stoving oven – Plastic coating cabin with 6 guns respectively on each side in a short-stroke arrangement – Gun arrangement can be variably adjusted (short-stroke/long-stroke) – One counter-electrode on each coating side – Stoving oven with variable radiator distance, individually adjustable on each side. IGP Pulvertechnik AG will be at PaintExpo 2018, booth 2517, Hall 2. For further information: www.igp-powder.com

2 1

Figure 2: The technical centre features a variable speed control in the furnace, which permits a simulation of various furnace lengths.

SPECIAL

BRAND-NEW

ST Powder Coatings Received the “Le Fonti Innovation Awards®” Nomination he company was among the finalists in the special category Excellence of the Year / Innovation & Leadership.

The nomination came after various prizes and certifications obtained by the company both nationally and internationally, including the recent admission to the Elite project of the

The eighth edition of the “Le Fonti Innovation

London Stock Exchange Group. A pleasant

Awards ” (Fig. 1), a prestigious international

surprise, therefore, but also a strong confirm

award dedicated to entrepreneurial excellence, took place on March 9 in th

Milan, at the famous headquarters of the Italian Stock Exchange placed in Palazzo The event was organized by the Milanese editorial group Le Fonti

for ST Powder Coatings and for its constant effort in terms of innovation, quality and customer service. The selection was developed by the Centro Studi Le Fonti in

Mezzanotte (Fig. 2).

Figure 1: ST Powder Coatings was nominated at “Le Fonti Innovation Awards”, an international award dedicated to entrepreneurial excellence.

concert with the editors of the magazines World Excellence, Le

with the patronage

Fonti Legal and

of the European

the newspaper

Commission and, in

Finanza & Diritto.

previous editions,

The choice was

had winners such

also made on the

as Basf, Bosch,

basis of a survey

Sanofi, Dainese,

carried out by over

Fujitsu, Epson,

40,000 qualified

Porsche, Bmw,

contacts from the

Panasonic, Ibm and

world of industry

Vodafone.

and professionals.

Business results,

Le Fonti Awards’

industry leadership,

gala, which was

strategic development, internationalization, quality of service, sustainability,

preceded by a

2 1

World Financial

Figure 2: The event took place at the headquarters of the Italian Stock Exchange placed in Palazzo Mezzanotte.

Summit, has been live broadcasted and widely distributed on

innovation and training are the criteria by which the

by the editorial staff and readers of the

the main national media like Il Sole 24 Ore,

competitors are rewarded.

magazine World Excellence, is motivated

La Repubblica - Affari e Finanza, Il Corriere

ST Powder Coatings has been selected

by the fact that the company constitutes

della Sera, La Stampa, L’Impresa and Harvard

as finalist along with 14 other companies

“a growing Italian excellence, a leader and

Business Review.

rated “excellent” in the special category

a milestone in the chemical sector of the

of Excellence of the Year / Innovation &

production of powder coatings for innovation

For further information:

Leadership. The nomination, promoted

and quality.”

www.stpowdercoatings.com

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

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

ÂŠ CMA Robotics

Opening photo: For 25 years, CMA Robotics has been passionately dedicated to the production of high-tech coating robots with a distinctive green colour.

HIGHLIGHT OF THE MONTH

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

CMA Robotics Celebrates 25 Years of History at the Forefront of Technology in the Automatic Coating Sector Alessia Venturi ipcmÂŽ

rom a small warehouse for rent in the

These two sentences summarise the

electronic controls and automatic machines,

early 1990s to a well-established company

extraordinary and emblematic story of CMA

they decided to apply the expertise gained in

present in 60 countries across the world.

Robotics, made possible by the talent, passion,

the electronic field to the robotics world. On

From a passion-driven local start up to one of

and vision of its three founding members: Paolo

Friday, March 2, Sergio and Marco celebrated

the top ten companies in the world with the

Piano, Sergio Della Mea, and Marco Zanor.

the 25 years of activity of CMA Robotics

highest technological level in the automatic

In 1993, when they were just thirty years old

and the inauguration of its new, futuristic

coating sector (ref. Opening photo).

and worked together in a company producing

headquarters in Pavia di Udine (Fig. 2) with a

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

Figure 1: The event organised on March 2 to celebrate the 25 years of activity of the Friulian company.

big party (Fig. 1) also dedicated to the memory of Paolo,

automatic execution. Thanks to a self-learning

who died prematurely in 1997.

programming system, the control computer saves

CMA currently designs, builds and installs the widest

the operator’s movements and repeats them at the

range of coating robots and systems now available on

desired speed. The coating operator plays a different

the market. It provides complete solutions, from design

role: he is no longer in contact with chemicals, but

to the integration in complex plants: besides supplying

he manages the machine and controls its quality and

individual robots and machines, CMA Robotics handles

operational efficiency.

the integration of such systems in their intended lines

With the self-generation of programs, CMA Robotics

in collaboration with the customers.

has then taken a further step forward: thanks to

Its first of coating robot prototype dates back to 1994.

artificial vision systems, the robot recognises the

advanced technology and it was designed for painting chairs: the aim

It featured a particularly

was to meet the growing needs for automation of local companies. In 1997, a renowned Brazilian company chose CMA for the construction of 14 customised plastic-coating robots. It was a turning point for the Friulian company, as well as its chance to take full advantage of the enormous potential of the product it had created. Coating robots combine human intelligence and

2 1

Figure 2: The entrance of the new futuristic headquarters in Pavia di Udine, Italy.

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

“The health of operators and the environment is at the core of our idea of automation: the application of coatings through robots reduces paint consumption up to 40% and it enables the operators to be no longer in direct contact with chemicals and emissions.” CMA Robotics also focusses on customer service, offering turnkey solutions complete with hardware, software, control, and assistance and, above all, ensuring high quality levels and speed of execution.

The insourcing phase CMA’s expansion began in 2003 with the establishment of a German branch, CMA Roboter. In 2005, the company underwent a complete makeover, modernising its image

3 1

and logo and giving its robots a green colour for greater recognisability on the market – since then, no other company

Figure 3: The cutting of the ribbon for the inauguration of the new headquarters.

established through a strategic joint venture with Efort, the largest Chinese robot manufacturer. With this, CMA improved its commercial power and design scope. In 2018, now known all over the world, the company has finally inaugurated its new prestigious, advanced headquarters

4 1

(Fig. 3).

Figure 4: Sergio Della Mea (left) and Marco Zanor (right), two of the three founding members of CMA Robotics, with Alessia Venturi from ipcm®.

shape, size and characteristics of the parts to be treated and it generates the best coating program in real time. Robots are therefore able to acquire skills and apply them to processes. “Our robotics is humanfriendly: machines evolve the work functions of man, improve their conditions, and perfect their final results,” says Sergio Della Mea. “CMA’s robots can self-program by recognising the characteristics of the product to be treated, thus enabling manufacturers to save time, money, and resources. Figure 5: On the stage of the event, employees, customers, and representatives of authorities, business associations, and local financial institutions.

2015, CMA China was

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

“We work in 60 countries worldwide, but we

Coating robots combine human intelligence and automatic execution. Thanks to a self-learning programming system, the control computer saves the operator’s movements and repeats them at the desired speed.”

in the robotics industry has used it for its products. In

5 1

HIGHLIGHT OF THE MONTH

are still a small business compared

CMA’s expansion began in 2003 with the establishment of a German branch, CMA Roboter. In 2005, the company underwent a complete makeover, modernising its image and logo and giving its robots a green colour for greater recognisability on the market – since then, no other company in the robotics industry has used it for its products. In 2015, CMA China was established through a strategic joint venture with Efort, the largest Chinese robot manufacturer. ”

Della Mea and Marco Zanor (Fig. 4)

right size to ensure flexibility, quality,

thanked and welcomed on the stage

high performance, and continuous

their first collaborators, some of the first

innovation,” states Marco Zanor on the

customers who trusted the company, and

sidelines of the event. “We now have

the representatives of authorities, business

an international team to implement

associations, and local financial institutions,

numerous experimentation and

as well as Paolo Piano’s daughter in

innovation projects. We also collaborate

memory of her father (Fig. 5). The evening

with several universities at the national

culminated in a fascinating display of the

level, especially the Udine and Trieste

capabilities of some robots that, instructed

ones, but also at the international

by CMA’s engineers, “danced” on the notes

level, including the National Robotics

of two pieces of music, as well as in a dinner

Engineering Center of Pittsburgh and the

with Friulian specialities and wines.

Wuhu Hit Robot Technology Research Institute. This enables us to be futureoriented and focus on the development of systems in which the robots will be able to share their experiences with other robots.”

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During this touching celebration, Sergio

with multinational giants: this is the

SPECIAL

BRAND-NEW

Unconventional © Shutterstock

Superdurable Powder Coatings for Architectural Applications he trend towards architectural powder coatings

is becoming unavoidable regarding the high demands on coating solutions in the modern construction landscape. Architectural products are known for having some of the most challenging coating performance requirements in the industry. Coatings for building products need the right properties to withstand rain, humidity, salt air and UV exposure from sunlight while

maintaining their original appearance during years of serving. Over time, the long-term performance

Figure 1: Ecopolifix’ powder coatings have proven to provide long-term appearance and excellent weather and corrosion resistance.

of suitably pretreated and powder-coated aluminum has

laboratories, these solutions are

are specifically designed to meet

established a solid track record in

optimized in close cooperation with

these requirements. Thus, they are

terms of performance. Ecopolifix

the customer and tested to perform

the ideal coating solution for outdoor

powders are specially formulated

perfectly in practice.

architectural applications. Ecopolifix

for the architectural needs.

To ensure the quality of the products

offers over 480 Qualicoat-approved,

Known as Superdurables, Ecopolifix’

for architecture, the company

customized and environmentally

powder coatings have proven to

provides Qualicoat-certified powder

friendly products in stock. Additionally,

provide long-term appearance and

coatings, that hold the specification for

Ecopolifix Qualicoat Class 2 product

excellent weather and corrosion

architectural requirements. Ecopolifix,

solutions can be designed in all RAL

resistance (Fig. 1).

will present its Qualicoat-certified,

colours on customer’s demand.

Powder coating systems of Ecopolifix

high-performance class 1 and 2

open up completely new perspectives

powder coatings for aluminum profiles

For further information:

for functional coatings of the future.

at PaintExpo 2018 in Karlsruhe, Hall

www.ecopolifix.it

The development engineers create

2, booth 2128. The Superdurable

system solutions with properties

polyester-based powder coatings with

tailored specifically to customer

their excellent weather resistance,

demands. In Ecopolifix’ in-house R&D

flexibility and adhesion properties,

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

Visit us at: April 2018 KARLSRUHE - hall 1 | Stand 1330

Opening photo: The Valladolid’s plant of Extrusiones Metálicas covers a 55,000 m area. 2

FOCUS ON TECHNOLOGY

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

Extrusiones Metálicas: Loyalising a Powder Coating Supplier to Consistently Meet the Quality Requirements of Very Different Markets Alessia Venturi ipcm®

xtrusiones Metálicas was established thirty-seven years ago

one thousand employees. It sells products on the US, Latin American,

in Mexico and it has always been dedicated to becoming an

Caribbean, and European markets, and it participates as a supplier in the

excellence in the world of aluminium. It now owns four production

largest Mexican architectural projects.

plants in Mexico (Texcoco, Guanajuato, Vallejo, and Veracruz) and one

The acquisition of the Valladolid plant, one of the most advanced in

in Europe, in Valladolid (Spain) (ref. Opening photo), and it has over

Europe, is part of a company expansion plan on the industrial and

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

automotive markets, as well as the

and employing different

metal architecture one. The facility

technologies and skills.

covers a 55,000 m2 area and it is

A solution to ensure

equipped with 7, 8, and 10-inches

quality consistency is

extrusion presses (Fig. 1),

choosing partners able

machining centres, an automatic

to supply all the factories

warehouse for profiles and one

of the Group with the

for dies, a vertical and a horizontal

same products, adjusted

coating plant, a sublimation

according to the technical

machine for wood-effect

needs of each plant and

decorations, and thermal bridge

to the requirements of all

assembly, packaging, and delivery

markets, with very different

departments.

environmental regulations

Extrusiones Metálicas is

and quality standards from

synonymous with operational

each other.

excellence, commitment to service,

For Extrusiones Metálicas,

high quality, and attention to detail

one of these partners is

in every process. That is why all

Industrias TITAN S.A.U.,

production phases are completely

one of the most well-

integrated in its factories, from

established and innovative

foundry to delivery. In order to

Spanish companies in

do so, in addition to its internal

the field of industrial and

warehouses, it has a large network

decorative coatings. It

of distributors throughout the

supplies both the Spanish

whole Mexican Republic.

and the Mexican plants of

“We want to be much more than

the Group with powder

suppliers: we want to be a partner

coatings for aluminium.

for our customers. Therefore,

“Extrusiones Metálicas is

we have a technical department support our clients in terms of design, material specifications,

Qualicoat, Qualideco and

with architectural experts who

AAMA (for the American

Figure 1: The plant is equipped with 7, 8 and 10 inches extrusion presses.

powders complying with

explains Antonio Sanz, the

both these standards,” says Fernando

production manager of Extrusiones thirty-five years of activity, our Group has become a leader in the field of extrusion, anodising, coating, and decoration of aluminium profiles. This result has been achieved also thanks to our deep relationships with our operators, customers, and suppliers, which have created one strong value chain.” Establishing a relationship of trust and continuity with suppliers is a strategic factor for a company that has plants located in distant geographical areas

they require high and very high-quality polyester

development, and consultancy,”

Metálicas Europea, in Valladolid. “In over

market) certified. Therefore,

Extrusiones Metálicas was established thirtyseven years ago in Mexico and it has always been dedicated to becoming an excellence in the world of aluminium. It now owns four production plants in Mexico (Texcoco, Guanajuato, Vallejo, and Veracruz) and one in Europe, in Valladolid (Spain), and it has over one thousand employees.”

Blas, Titan’s supervisor for the Mexican Group. “Moreover, let us not forget that TGIC powders are still used in the North and South American markets, while they have been banned here in Europe. Their Valladolid plant, however, also produces architectural profiles intended for those markets. Our R&D department, therefore, strives to meet the colour requests of their Mexican customers, which send samples formulated with TGIC, by creating TGICfree products with the same tint and effect that can be used in Europe.”

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

2 1

Figure 2: The coating plant can treat profiles with a length up to 7.4 metres.

A highly automated production process

profiles up to 7 metres reach the loading

tunnel, which performs 4 active stages:

area directly from the automatic vertical

degreasing, acid stage, alkaline stage, and

Extrusiones Metálicas Europea

warehouse, an imposing 28-level structure

chrome-free conversion. We work with the

implements a highly automated

with 1792 slots and a capacity of about

Qualicoat Seaside certification for all our products: it requires a

production process that

minimum attack of 2

provides for minimal manipulation of the profiles along the various phases, from extrusion to packaging. “In our Valladolid plant, all movements of material from one department to another

One of the partners of Extrusiones Metálicas is Industrias TITAN S.A.U., one of the most wellestablished and innovative Spanish companies in the field of industrial and decorative coatings. It supplies both the Spanish and the Mexican plants of the Group with powder coatings for aluminium.”

gr/m2, but our process average is higher, about 3,5 gr/m2. “Then, the material enters the drying oven and it reaches

are automated through

the coating station,

bridge cranes,” states Julio

equipped with

Nogal, the coating manager. “Also the

500 kg per container (Fig. 3); only the

two automatic vertical booths with a

feeding of the coating plant, which can

profiles exceeding this length are taken to

conventional Venturi application system,

treat profiles with a length up to 7.4

the coating plant manually. After loading,

supplied by Gema (Fig. 4). Each booth

metres, is mainly automatic (Fig. 2). The

the profiles enter the pre-treatment

features 22 guns (Fig. 5). The colour

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

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

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

change time is about 5 minutes. One booth is devoted to light colours, the other to the dark ones. Before curing, the profiles go through an IR oven for the gelation of the film, in order to avoid colour contamination. The average productivity is 12 tonnes per shift with, on average, 8 colour change operations per day.” “Titan is our main supplier of powder coatings,” says Julio Nogal, “accounting for more than 60% only of the paints used in the Valladolid plant. However, it also supplies all the Mexican branches of our Group.” “We provide Extrusiones Metálicas with all the types of products they use: sublimation bases as well as textured, matte, metallic, satin, and glossy coatings, all complying with the Qualicoat or Qualideco quality levels for the wood effect (Fig. 6),” states Fernando Blas from Titan. “Most products are in Class 1 for the European branch, whereas in Mexico we mainly supply Class 2 coatings. Currently, we have not received any request for Class 3 products, yet.”

Loyalising a supplier to ensure quality consistency “We have loyalised Industrias Titan as our main powder supplies especially because they have very good products. We have never encountered any quality problem and they have always met our expectations,” states Antonio Sanz. “Moreover, Titan’s products have a very high yield, thus increasing our coating productivity. We have established a true partnership, a mutual collaboration aimed at the maintenance of a high quality level at competitive costs. Together, we also carry out

3 1

projects for the development of

Figure 3: The automatic vertical warehouse, with 28 levels and 1792 slots.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

new and customised products.”

FOCUS ON TECHNOLOGY

The feeding of the coating plant, which can treat profiles with a length up to 7.4 metres, is mainly automatic. The profiles up to 7 metres reach the loading area directly from the automatic vertical warehouse, an imposing 28-level structure with 1792 slots and a capacity of about 500 kg per container.”

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.

Non avrai più dubbi sulla produzione del tuo materiale Produzione: Costruiremo il tuo trasportatore secondo metodi standardizzati sviluppati nel tempo per farti avere un impianto performante.

Non dovrai più preoccuparti del montaggio del convogliatore Installazione: Con quest’opzione, avrai il tuo convogliatore chiavi in mano montato da un team di tecnici montatori esperti.

Non avrai più blocchi di produzione 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.

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”

4 1

Figure 4: One of the two automatic vertical booths with a conventional Venturi application system, supplied by Gema.

REPORT IIN N RE REGALO! REGALO EGALO! LO

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

The coating station is equipped with two automatic vertical booths with a conventional Venturi application system, supplied by Gema. Each booth features 22 guns. The colour change time is about 5 minutes. One booth is devoted to light colours, the other to the dark ones.”

“We have developed the colours included in Extrusiones Metálicas’ European catalogue as well as all wood-effect (Fig. 7) sublimation bases for profiles mainly intended for the Mexican market,” says Fernando Blas. “Titan has chosen to establish an exclusive partnership with a sublimation film producer, the Miroglio Group. This enables us to give full guarantees on the sublimation process, with no attempt to waive liability by the paint or film supplier in case of any quality problems.”

A complete service for a global market Extrusiones Metálicas Europea’s main target market is the European one. “Besides the domestic market, we have an export share of around 40% to France, Belgium, the Netherlands, and the United Kingdom. The rest of our production is intended for customers in the United States and Latin America through our Mexican Group. Here in Valladolid, thanks to our cutting-edge plant equipment, we can extrude profiles that cannot be produced in the Mexican factories. Moreover,

5 1

Figure 5: Each booth features 22 guns.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Central Europe

6 1

Figure 6: Some profiles coated with wood-eﬀect sublimation bases.

Industrias TITAN S.A.U. provides Extrusiones Metálicas with all the types of products they use: sublimation bases as well as textured, matte, metallic, satin, and glossy coatings, all complying with the Qualicoat or Qualideco quality levels for the wood effect.” i n f o @ w a t e r e n e r g y. i t w w w.w a t e r e n e r g y. i t

visit us at hall 2 - booth 2369

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

INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE

Figure 7: The wood-eﬀect range available by Extrusiones Metálicas was developed by Titan.

our Group is constantly engaged in reducing the carbon footprint of its activities and it is equipped with a water treatment plant (Fig. 8). Moreover, the use of recycled aluminium for our productions makes us one of the most sustainable companies in the extrusion industry, with LEED and “Industria Limpia de Mexico”

7 1

certifications.”

the high automation of our plant enables us to offer customised packaging and shipping services based on our customers’ needs and location,” says Antonio

Extrusiones Metálicas Europea’s main target market is the European one. Besides the domestic market, they have an export share of around 40% to France, Belgium, the Netherlands, and the United Kingdom. The rest of the production is intended for customers in the United States and Latin America through the Mexican Group.” © ipcm ®

Sanz. “For instance, we can make a type A package, i.e. a stretch-wrapped Euro-pallet, a type B one, which is boxed and palletised, and a type C one, with profiles arranged in wooden boxes. In many cases, we prepare the profiles in advance, dividing them according to sales orders. “Our mission is to offer a service that goes beyond the mere production of a finished profile. Another important part of this mission are respect for the environment and commitment to our planet. Every factory of

8 1

Figure 8: The water treatment plant.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

SPECIAL

BRAND-NEW

he third generation of Interpon

shades even matter (8-12 gloss)! And

Stock Range is now available in

there are many other exciting finishes

Europe and it offers a wider range

for every kind of projects.

of product technologies, shades and

Those interested in discovering the

finishes.

whole range of 1500 products can

AkzoNobel’s experts reviewed it every year

contact Customer Service.

to embrace markets’ needs with a more

The products are every day available

dedicated offer of products and services

in AkzoNobel’s storehouses all over

based on sector peculiarities.

Europe, ready to be shipped to the

Powder Coatings Interpon Stock Range

clients (Fig. 2)!

now includes also Interpon EC (Anti-Grafiti)

Detailed product information and newly

in 10 new RAL colours (Fig. 1) – suitable for

added collections can be found on

public transportation, street furniture etc.

AkzoNobel’s digital tools. To download

Some ranges have been enlarged to

AkzoNobel’s app on i-Pad, visit the

include new shades aligned with recent

following link: https://itunes.apple.com/

color trends. Interpon D2525 Structura,

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Figure 1: Powder Coatings Interpon Stock Range includes Interpon EC (Anti-Grafiti) in 10 new RAL colours.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

Interpon European Stock Range Gets Bigger!

Figure 2: Interpon Stock Range counts 1500 products, directly available at AkzoNobel’s storehouses all over Europe.

SPECIAL

BRAND-NEW

he entrepreneurial

Since 1962 Manufacturers of Premium Quality Overhead Conveyor Chains path of Nazzareno Roda, the President

of TSPGROUP, belonging to Trafilerie San Paolo, is the emblem of that of an entire generation. In the mid-1960s, Nazzareno Roda crossed destinies with Trafilerie San Paolo, a company established in 1966 by three partners and specialising in drawing stainless steel tubes. Nazzareno Roda made their business take off, importing the cold plastic deformation technique to Italy. This important innovation gradually turned Trafilerie San Paolo’s customers from

turners (with 60% waste and non-constant quality levels) to moulders.

Figure 1: Orbita, established in 1962, is specialized in the manufacturing of overhead conveyor chains.

In addition to the parent company Trafilerie San Paolo, the

of conveyor systems and our chains

got the upper hand. It now produces

Group includes two other drawing

are basically the ‘core’ of the whole

tens of thousands of meters of chain per

mills, Gerosa and Meal, each with a

mechanism,” say Andrea and Massimo

year.”

different specialisation; Raptor, for the

Roda. “By observing these plants, my

Today, the company’s activity is carried

development of application software;

father realised that the chains used

out in a modern plant of about 2,000

Tramev; EME, with its tools intended

were extremely heavy, thus adding a

square meters. Its highly qualified staff

for the main drawing machines; and

further burden to those structures.

uses sophisticated automatic machines,

Orbita. The latter is located in Cesana

Thanks to his experience with the

as well as assembly robots able to

Brianza (Lecco, Italy) and it is the pride

highest quality steels, he invented a

complete the production process of an

of the Roda family (Fig. 1).

much lighter chain combined with

entire component autonomously and

“The company was established in 1962

a new full-complement bearing also

in absolute safety. Technical skills and

to manufacture overhead conveyor

invented by him, which featured no ring

innovation are still the forte and the

chains: this is a small niche in which

nuts to withstand high temperatures.

distinctive feature of the entire Group.

we are the European leader with

It was not easy to fight against the

our products of excellence. We work

‘battleships’ of the great British and US

For further information:

for the world’s major manufacturers

manufacturers, but in the end Orbita

www.orbita.it

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

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

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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

FOCUS ON TECHNOLOGY Arneg Italia’s New Coating Line: an Industry 4.0-Oriented Management System in Compliance with the Most Advanced Environmental Protection Requirements

102

FOCUS ON TECHNOLOGY When the Proper Design of a Two-Rail Conveyor Improves the Versatility and Productivity of a Coating Company: The Success Story of Franchini Snc

110

INNOVATIONS: PRESENT&FUTURE Ready for “Industry 4.0” and The Smart Factory with Nordson Dense Phase Technology

116

FOCUS ON TECHNOLOGY CNH Industrial: A new Smart Factory in Pune, India. Industry 4.0-Oriented, High Technology Innovation in Coating

126

SUCCESS STORIES Looking Inside the Microcosm of Car Painting - With The Viledon® filterCair Module “Basic + Dirt In Paint”, Freudenberg Brings the Cause of the Tiniest Paint Defects Into the Light of Day

130

FOCUS ON TECHNOLOGY Shot Blasting 4.0 for a Flexible and Highly Efficient Pre-Treatment Process Prior to Coating

138 140

BRAND NEW FOCUS ON TECHNOLOGY Collaboration Between Specialists for the Versatile, Integrated, and 4.0-Oriented Coating of Light Carpentry Components: Tecnolaser’s Success Story FOCUS ON TECHNOLOGY Metalcolor: a New Coating Plant with a Low Environmental Impact for Greater Production Versatility

Wisky © Fotolia

148

Opening photo: Arneg Group produces refrigerated cabinets, refrigeration systems, furniture & heavy duty, check-out counters, cold rooms and doors.

FOCUS ON TECHNOLOGY

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

Arneg Italia’s New Coating Line: an Industry 4.0-Oriented Management System in Compliance with the Most Advanced Environmental Protection Requirements Monica Fumagalli ipcm®

rneg is a world leader in the design, production and

“We produce refrigerated furniture and refrigeration systems that

installation of complete equipment for the retail sector.

are our core business, but also shelves for display cabinets in the

Established half a century ago in Marsango (Padua, Italy) by

food and non-food sectors, sales counters, cold rooms, and doors

Luigi Finco and Roberto Marzaro, it is now an international Group

(ref. Opening photo).”

consisting of 36 companies throughout the world. “The Arneg

This is a constantly growing sector, now faced with one of the

Group’s products are all intended for the small and large retail

most critical current issues: the environmental impact not only of

industry, mainly but not only in the food sector,” says Federico

its companies’ production activities, but also of the refrigeration

Pandolfo, the Industrial Engineering Manager of Arneg (Fig. 1).

systems installed at supermarket chains and other commercial

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

for both specialised

businesses. “We have always stood out for our policy

Arneg’s goal is to enhance and continuously improve production processes: the recent project of the new paintshop, whose installation was the result of the synergy between different suppliers, was born in the framework of this development plan. The powder coating plant was built by Imel, the overhead conveyor by Futura Convogliatori Aerei, the three coating booths by Gema, and the water treatment plant by KMU Loft”

sensitive to the major issues of environmental protection, energy saving, and respect for people,” states Pandolfo. “This is reflected in our effort to provide our customers not only with equipment, but also with assistance in terms

and non-specialised stores to conventional and customised sales counters. “At the international level, we have 20 production plants and 16 representative companies. This gives us a global vision of

their stores, in an integrated

our customers’ needs,

production system

enabling us to meet

developed to ensure that all

of energy management of

all their requirements

manufacturing processes

through a daily exchange

and supply relationships

of ideas that is crucial

with third parties comply

to develop innovative solutions for the market.

with the current regulations on quality, safety, energy

The high collaboration

saving, and eco-friendliness.

and coordination

Our goal is to enhance

capacity of our different

and continuously improve

production sites also

production processes: the

confirms the validity of

recent project of our new

our Group’s management

paintshop, whose installation

system.”

was the result of the synergy

Arneg’s procurement logistics

between different suppliers, was born in the framework of this development plan. The powder coating plant was built by Imel (Codroipo,

Figure 1: From left to right Katia Cattelan, Federico Pandolfo with Luca Zaramella.

Udine, Italy), the overhead

Arneg Italia produces raw and coated sheets that are used

conveyor by Futura

The Group is present in Italy with four

Convogliatori Aerei (Robecco Pavese, Pavia,

subsidiaries, each specialising in the

of its refrigeration systems’ bodies. It

Italy), the three coating booths by Gema,

manufacture of specific products:

buys already machined but uncoated

and the water treatment plant by KMU Loft.

- Arneg, the leading company, designs,

sheets from both its subsidiaries and

for the construction

Arneg acted as the prime contractor and

manufactures, and installs complete and

other suppliers. In this second case,

coordinated the whole project.”

advanced equipment for the retail sector;

for the finishing of their semi-finished

An international Group with an Italian heart One of the Group’s strengths is its ability to offer complete equipment solutions to furnish every department of a supermarket. “Our company structure translates into

- Oscartielle is among the main European

products, such suppliers can use the

producers of refrigerated counters with

coating plant installed by Arneg, which

built-in units and custom plug-in counters;

in this way also provides a contracting

- Incold specialises in the production of

coating service. Different procurement

commercial and industrial cold rooms and

and treatment methods are used in

of a complete range of doors;

Arneg’s plant: some raw sheets are

- Intrac operates in the furnishing sector

both machined and coated in-house,

flexibility and customisation capacity

for the small, medium and large retail

whereas sometimes semi-finished

levels that have no equal on the market,”

industries with a wide and diversified

products are bought and then coated in

states Katia Cattelan, the Marketing &

range of products, from commercial

the company’s paintshop.

Communication Specialist of Arneg.

shelving for any product category and

The production activity mainly focusses on

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

2 1

Figure 2: The manual loading area devoted to sheet metal.

Arneg Italia produces raw and coated sheets that are used for the construction of its refrigeration systems’ bodies. It buys already machined but uncoated sheets from both its subsidiaries and other suppliers. In this second case, for the finishing of their semi-finished products, such suppliers can use the coating plant installed by Arneg, which in this way also provides a contracting coating service.” the refrigerated counters’ insulated bodies, made of sheets and high-density polyurethane supporting structures. A base, lower supports, refrigerating elements, lighting and the electrical system are then added during assembly to create

complete refrigeration systems, which are finally packaged and

3 1

Figure 3: A detail of a load bar that can carry up to 300 kg.

FOCUS ON TECHNOLOGY

stored. “Our corporate strategy fully embodies the just-in-time philosophy,” says Pandolfo. “We build our equipment on order: we start the raw or semi-finished material procurement process and any required machining operation only after receiving an order. Since we do not produce any standard product, but only tailor-made systems, there are no stocks in our warehouse and our material delivery flow is lean and flexible.”

Quality finishes for high aesthetics and functionality levels “The materials used for the construction of Arneg’s systems,” says Pandolfo, “range from aluminium to iron and from galvanised and black sheet to plastics. The coating results on the refrigerator bodies’ external elements must ensure a high aesthetic quality level and they must be repeatable for all the substrates treated because, as well as defining the quality of our products, they must consistently reproduce the colours of each

supermarket brand. As for the internal components, we apply

4 1

Figure 4: A detail of the conveyor supplied by Futura Convogliatori Aerei.

a protective coating against corrosion and rust – which are caused by wear and the chemical products used by stores for their cleaning operations – that must also achieve the hygiene level needed for direct contact with food.” In the Marsango plant, every component is sent to the paintshop regardless of its origin (the firm’s machining department or a supplier’s plant). “We have diversified both our machining operations and our suppliers,” says Katia Cattelan. “If an unexpected event occurs in the supply chain, we can rely on another partner or directly produce in-house the parts required. The production flow continuity is thus ensured.”

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

design team and to integrate their equipment with the others’.” The line concept was based on the innovative technologies of the Industry 4.0, aimed at effective human-machine interaction, optimal integration of all internal and external management systems (especially in the framework of supplier relationships), and energy waste reduction for a more sustainable environmental impact. The system is entirely PLC-managed and it features 2 manual loading operations (Fig. 2). The 4 m long load bars can carry up to 300 kg (Fig. 3). Once loaded on the conveyor frames (Fig. 4), the parts are taken to the storage buffer of the 60 m

5 1

long 6-stage multi metal cleaning tunnel (Figs. 5 and 6). Drying after

Figure 5: A bird’s eye view of the 60 m long pre-treatment tunnel.

time, with a downtime of

The new coating line developed by Imel

on Imel for this project

came into operation in April 2017, after

because we already knew

about a year of project development

the efficiency of its systems.

coordinated by Arneg’s technical staff and

This previous experience

based on the experience gained with the

played a fundamental role

firm’s previous plant. “Our previous line

in the selection of the plant

was built in 1986: after thirty years, it could

engineering company, as

still ensure a good performance level, but

well as their ability to interact

it included obsolete machines. Composed

with the other suppliers that

of two plants, it was replaced in a short

formed the new paintshop

only three weeks. We relied

The line concept was based on the innovative technologies of the Industry 4.0, aimed at effective human-machine interaction, optimal integration of all internal and external management systems (especially in the framework of supplier relationships), and energy waste reduction for a more sustainable environmental impact. The system is entirely PLC-managed and it features 2 manual loading operations. The 4 m long load bars can carry up to 300 kg. Once loaded on the conveyor frames, the parts are taken to the storage buffer of the 60 m long 6-stage multi metal cleaning tunnel.”

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

A new coating plant for high production flexibility

pre-treatment occurs in a bell oven with

6 1

Figure 6: Components entering the cleaning tunnel.

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

7 1

we perform is non-aggressive, but, on

an outgoing gas heat recovery

the other hand, it represents a guarantee

station, which heats the renewal

of greater surface protection against

air of the oven itself. A second

corrosion (Fig. 7).”

buffer accommodates the

The components are sorted from the

workpieces after drying, which

post-drying buffer to three different

concludes the first treatment

storage buffers connected to the three

phase. This buffer allows to

coating booths (two automatic and

empty the cleaning tunnel at

a manual one where powder is not

the end of the day, in order

recovered) operating simultaneously

to ensure that all material

(Figs. 8 and 9). The correct destination

is perfectly dry, avoid the

of each batch to be painted is set at the

formation of rust, and improve

beginning of processing through the

the application and functional

software program, depending on the

quality level of the subsequent

number of parts loaded onto the bars

coating phase.

and their shape. The manual spray booth

“The materials we treat do not

(Fig. 10) is most suitable for small-sized

present any heavily polluted

batches requiring a specific colour, for

surfaces: galvanised sheets,

parts with particular undercuts or cavities,

accounting for 99% of the

and in the case of a colour change

material used both for the

requested by the client at the last minute.

external and internal parts of

“The system was designed to ensure

our refrigerated counters, do not

maximum loading flexibility, without

have any oil residues or welds.

constraints deriving from the need to

Therefore, the cleaning process

pool workpieces requiring the same tint

Figure 7: The inside of the cleaning tunnel.

an air vein burner connected to

Figure 8: Parts taken to the application area.

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N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Figure 9: The coating application area.

9 1

but belonging to different batches. Again, this choice was aimed at creating a high-level just-in-time production. Since we produce on order, we can happen to load a part to be coated with red, followed by a part requiring the yellow colour and by a second one requiring red. In this case, for example, it is more convenient to send the load bar to be treated with yellow to the manual booth, in order not to decrease the line productivity by performing a colour change on an automatic booth. In any moment of the day, however, one of the booths is always non-operative.” “Thanks to the power&free conveyor layout designed by Futura, we can easily manage the line speeds of the different surface treatment stages (from the 5 m/min of the pre-treatment tunnel to the 3 m/min of the application booths). This ensures a constant average speed of 4.5 m/min. The buffers compensate for both the colour change times and the different loading speeds of parts, with highly variable shapes and dimensions,” states Pandolfo. After coating, a “traffic light” system brings together the workpieces coming from all booths and sends them to the polymerisation oven.

The system was designed to ensure maximum loading flexibility, without constraints deriving from the need to pool workpieces requiring the same tint but belonging to different batches. This choice was aimed at creating a high-level just-in-time production.”

10 1

Figure 10: The coating application carried out in the manual booth.

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

Application consistency and quick colour change operations thanks to the dense phase technology

Arneg performs 40 to 60 colour change operations per day: having 3 booths alternating during the two work shifts so that the application operations are never interrupted was decisive for the production flow. Moreover, the powder transport and spraying technology with dense phase pumps instead of conventional Venturi injectors guarantees the quality consistency typical of Arneg’s products.”

The line flexibility characteristics requested by Arneg to Imel were further reflected in the powder application system chosen, which implements the Optispray dense phase technology developed by Gema. “We perform 40 to 60 colour change operations per day: having 3 booths alternating during the two work shifts so that the application operations are never interrupted was decisive for our production flow (Fig. 11). Moreover, the powder transport and spraying technology with dense phase pumps (Fig. 12) instead of conventional Venturi injectors guarantees the quality consistency typical of Arneg’s products. The supermarket brand colours must be identical even if applied on different elements and regardless of their material. We must ensure that the coating results can be reproduced over time,” says Federico Pandolfo.

11 1

Figure 11: The coating application carried out in an automatic booth

After application, the conveyor sends the parts coated by the three booths to the

polymerisation oven – also a bell oven but with no air vein in order not to pollute the drying air with the burner’s exhaust gases. Curing occurs at a controlled and constant temperature. Although load bars with parts coated in different tints enter the oven one after the other, there is no risk of colour contamination during drying thanks to the zone controlled ventilation system. The first zone was designed for powder gelling: it is not ventilated and has a temperature of 120150 °C. It is followed by a segment with hot air at 180 °C. The workpieces then reach the cooling buffer (Fig. 13) and finally

12 1

the two unloading areas (Fig. 14)

Figure 12: A detail of the dense phase application pumps supplied by Gema Europe.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

where the coating cycle ends.

FOCUS ON TECHNOLOGY

GANCI | HOOKS

TELAI | RACKS

13 1

Figure 13: A detail of the conveyor taking the coated workpieces to the unloading station.

From production to installation: Arneg’s green soul

Federico Pandolfo. “Special attention was paid

During the design phase of the new paintshop,

air vein drying oven, operating at 120-130 kWt

the team coordinated by Arneg never lost

and recovering heat through inverter motors,

sight of one of the main requirements of the

and to the thermal energy consumed by the

company: the commitment to reducing energy

polymerisation oven, which operates at

consumption that has always characterised it.

220-250 kWt and which does not implement

“The new plant was designed to optimise

the air vein technology not to pollute the paint

electricity and heat consumption,” states

film, although it still allows to recover the

to the ventilation of the post-pre-treatment

The new plant was designed to optimise electricity and heat consumption. Special attention was paid to the ventilation of the post-pre-treatment air vein drying oven, operating at 120-130 kWt and recovering heat through inverter motors, and to the thermal energy consumed by the polymerisation oven, which operates at 220-250 kWt and which does not implement the air vein technology not to pollute the paint film, although it still allows to recover the renewal air thanks to its bell structure.”

MASCHERATURE | MASKING

Visit us! 17. - 20.04.2018 Hall 2, Booth 2320

www.emptmeyer.it

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

renewal air thanks to

consultant for

its bell structure.

the energy

“Moreover, the pre-

consumption

treatment tunnel

management of

is equipped with

our customers’

inverter-managed

commercial

cleaning pumps

activities.”

that switch off automatically if there

Conclusions

is no part on the line.

“We are really

This system also

pleased with

enables the operators

the team that

to adjust the cleaning

was created

product spraying

during the

capacity depending

design phase

on the workpieces’

of our new

dimensions. On

plant, which

average, the cleaning

maximum installed

a year,” states Pandolfo. “It

Figure 14: The collection buﬀer of the unloading area.

power of 70 kW. The whole cleaning department is

has not always been easy

kW compared with its

lasted about

14 1

tunnel consumes 20

to coordinate all our suppliers’

activities, but in the end, thanks to

connected to other plant areas,

their know-how, it was possible to

which leads to a significant saving

resolve every critical issue – such

in gas consumption.” Waste

as, for example, the software

water is treated in two tanks

setting based on the security

equipped with an evaporator

requirements of applicable laws.

supplied by KMU Loft, which

Of course, each supplier could

separates the eluate from water

guarantee that all the safety

and recirculates the latter. This

parameters of its equipment were

closed-loop system with zero

met, but, thanks to the technical

liquid discharge minimises mains

skills and professionalism of

water consumption.

their staffs, we have managed to

“These results are extremely

create a digital system capable

good and have even exceeded

of signalling any anomalies or

the expectations of our suppliers.

dangers on the entire line. IT

Our attention to our production

systems have proved crucial also

activities’ environmental impact

in terms of safety and health,

is not limited to our in-house

management of production

processes, but it is also reflected

processes and suppliers, and

on the performance of our

efficiency of all energy saving

refrigeration systems. Thanks to

resources: each of these elements

the studies conducted by our

is essential, in order to be a true

R&D centre, we reduced the

“Smart Factory”.

consumption of a refrigerated counter by 50% and we can act as a reliable partner and

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Figure 15: The water treatment plant installed by KMU Loft.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

Our new coating department is the most obvious and significant example of this.”

OptiStarÂŽ 4.0 Gun Control The benchmark for the efficient gun control OptiStar 4.0 gun control ensures an optimized application with an exceptional coating result. The new generation of OptiStar presents the proven DVC- and PCCTechnologies and the new Electrostatic App, delivering an intelligent control to provide a seamless link to Smart Factory Automation. With the new Electrostatic App, essential application data and parameters can be retrieved at any time, with crucial coating information and statistics available via your mobile device. This opens up new possibilities for process control.

www.gemapowdercoating.com

GEMA EUROPE SRL Via Carlo Goldoni 29 | 20090 Trezzano Sul Naviglio (MI) | ITALY T. +39 02 48 400 486 | F. +39 02 48 400 874

Opening photo: Franchini has been working in the sector of surface treatments for light and heavy carpentry structures for over thirty years.

FOCUS ON TECHNOLOGY

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

When the Proper Design of a Two-Rail Conveyor Improves the Versatility and Productivity of a Coating Company: The Success Story of Franchini Snc Francesco Stucchi ipcm®

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FOCUS ON TECHNOLOGY

n 1970, a small individual company

for the building sector. However, since

carpentry components (Fig. 2),”

specialising in car bodyworks was

this activity provided little chance of

states Federico Franchini. “It is a very

established in Villimpenta (Mantua, Italy)

development in the winter months, in

demanding industry, in which we have

by Giuliano Guerrino Franchini. Franchini

2002 we expanded our business with

to face the most diverse requirements

Snc is now a well-known company in the

new headquarters of about 10,000 m2, of

because the products will be installed

sector of contracting sandblasting and

which 3,000 are covered, and we started

all over the world. For example, our

coating of small, medium and large-sized

focusing on the contracting sandblasting

corrosion protection processes

metal carpentry components. During these

and coating of light and heavy carpentry

must meet very strict specifications

almost fifty years, the firm has grown in

structures (ref. Opening photo).” In

complying almost exclusively with ISO

terms of both business and size: currently,

2007, a decisive increase in orders led

12944 C4 and C5 classes.”

it has an about 21,000 m production site,

the Franchini family to plan a further

“Over the years, however, we have

24 employees, and customers from the

expansion of their headquarters. In 2009,

understood that the key to our

most diverse industrial sectors (Fig. 1).

they inaugurated a new facility in an area

success is diversifying our services

“In the 1990’s, with the entry into the

of 11,000 m2, of which about 6,000 are

as much as possible, in order to

company of me and my brother Cristian

covered, devoted to the treatment of small

meet any kind of need. We have to

and due to the increasing requests from

and medium parts.

be able to treat both small and big

parts even for the same customers,

the building industry, our bodywork activity “We serve various sectors (furniture, exhibit

without limiting ourselves but rather

abandoned,” says Federico Franchini,

spaces, pneumatic cylinders, mechanical

offering a complete service,” says

one of the founder’s sons. “The current

carpentry), but our core business are

Cristian Franchini. “While gradually

company was established as a coater

amusement rides, with their large-sized

abandoning the building sector,

was gradually diminished and finally

Figure 1: The Franchini headquarters in Villimpenta (MN) are located on an area of 21,000 m2.

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

we have therefore focussed on our production site expansion and on the plant development of our treatment line for small and medium carpentry parts through the implementation of a completely versatile system.”

Treatment lines Franchini’s activity is divided into two large categories: heavy carpentry, with workpieces up to 18 metres, and light carpentry, with parts up to 3.5 metres in length and weighing up to 400 kg. “In order to treat large-sized components,” says Cristian Franchini, “we have a dedicated line consisting of a 18x5x5 m manual free jet sandblasting tunnel using garnet and three static coating plants, of which two with a size of 20x10 m (Fig. 3) and a modular one. The parts are handled through overhead cranes with a maximum capacity of 10 tonnes.” Garnet is a natural mineral abrasive, therefore free from any harmful substances, which ensures maximum film adhesion on aluminium, steel, stainless steel, and special steels. These large workpieces are never subjected to any chemical pre-treatment. The subsequent coating phase is performed with a continuous monitoring of environmental conditions and always indoor, so as to ensure continuity of the production flow regardless of the weather conditions. All three static coating booths are heated and ventilated; one of them,

2 1

buffered and closed, can also act as

Figure 2: A liquid coated heavy carpentry workpiece.

an oven booth for the drying of parts, which otherwise are air-dried. “Coating is performed exclusively with liquid products,” explains Federico Franchini. “50% with a

In 1970, a small individual company specialising in car bodyworks was established in Villimpenta (Mantua, Italy) by Giuliano Guerrino Franchini. Franchini Snc is now a well-known company in the sector of contracting sandblasting and coating of small, medium and large-sized metal carpentry components. During these almost fifty years, the firm has grown in terms of both business and size: currently, it has an about 21,000 m2 production site, 24 employees, and customers from the most diverse industrial sectors.”

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N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

one-coat cycle and 50% with the application of a surface tolerant primer and a twocomponent epoxy, polyurethane, or acrylic topcoat.” The second treatment line is devoted to the finishing of light carpentry workpieces, with maximum dimensions of 3,5x1x2 m. It is an actual 80-metre long in-line plant equipped with a two-rail overhead conveyor (Fig. 4).

FOCUS ON TECHNOLOGY

Franchini’s activity is divided into two large categories: heavy carpentry, with workpieces up to 18 metres, and light carpentry, with parts up to 3.5 metres in length and weighing up to 400 kg. In order to treat large-sized components, Franchini has a dedicated line consisting of a 18x5x5 m manual free jet sandblasting tunnel using garnet and three static coating plants, of which two with a size of 20x10 m and a modular one.”

3 1

Figure 3: One of the three static coating systems for large-sized parts.

PAINT SHOP 4.0 DIGITAL ∙ SMART ∙ EFFICIENT

www.eisenmann.com

Visit us at

PaintExp o Apr

il 17 to 2 0, 2018 in Karlsru he hall 1, b ooth 122 0

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

Figure 4: A bird’s eye view of the plant devoted to light carpentry components.

4 1

Figure 5: The continuous shotblasting machine: the first phase of the coating process.

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FOCUS ON TECHNOLOGY

The overhead conveyor: the core of the in-line coating plant

of this project lies therefore in the presence

The coating process

and management capacity of several

The first phase is pre-treatment. The line is

storage buffers.” From the technical point

equipped with a continuous shotblasting

“This system was built in 2008, but we

of view, there was a need to manage the

machine (Fig. 5) and a 4-stage cleaning

started using it at full capacity in 2010.

plant used only if the parts are not perfectly

It was the result of a close collaboration

prepared after shotblasting. “The requests for

with Tras-Mec (Casalromano, Mantua),

shotblasting from our customers account for

which designed the two-rail overhead conveyor as the core of the whole plant,” says Cristian Franchini. “We decided to rely on Tras-Mec based on the excellent references we had always received about them. This plant was entirely designed by our father Giuliano, Tras-Mec owner Silvio Zanelli, passed away in 2014, and TrasMec’s engineers; we now consider it the

This system was built in 2008, but they started using it at full capacity in 2010. It was the result of a close collaboration with Tras-Mec (Casalromano, Mantua), which designed the two-rail overhead conveyor as the core of the whole plant.”

99% of the total; chemical pre-treatment is a plus that we can provide if necessary in order to be fully versatile,” says Cristian Franchini. “A SA 3 preparation degree is generally required.” At the exit of the shotblasting system, there is a first buffer where the workpieces accumulate before the following stations: - 5 stations for accessory work (grouting, sealing, protection, masking);

flagship line of our company.”

- basecoat and liquid primer application booth;

“The conveyor plays a crucial role in this plant because the large and heavy

parts accumulating at the entrance of the

- flash-off booth;

iron parts it treats cannot be unloaded

shotblasting machine and at the exit of the

- topcoat application booth;

after each phase,” explains Claudia

ovens, since the cooling time of large-sized

- flash-off booth;

Zanelli from Tras-Mec. “The peculiarity

workpieces is considerable.

- drying and flash-off ovens (Fig. 6).

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

The last storage buffer

The conveyor is also equipped with a

is devoted to finished

motor-powered bar rotating system with a

parts, which are then

manual control panel, in order to place the

sent to one of the two

workpieces in the most suitable position to

warehouses and finally

optimally coat them on every side.” Finally,

unloaded.

the plant features an efficient software package providing for PLC control as well as

“The overhead system we have designed for 45 mm double speed

Complete versatility: the key to success

biplanar chain conveyor

“We work on order and with a long-term

with a total length of 515

order portfolio. The versatility of our

metres, of which 189 are

systems enables us to meet the most

devoted to shotblasting

diverse needs, always ensuring workflow

and 326 to coating,” says

efficiency and continuity,” states Federico

Claudia Zanelli. “The load

Franchini. “We look to the future with

bars have a maximum

even more ambition. Just consider

capacity of 400 kg, for a

that, when we designed this plant in

total allowable load of

2009, despite the economic crisis we

27,000 kg (Fig. 7).

had already planned extra spaces to

The loading and

implement robotic coating systems in

unloading operations are

future.” Indeed, Franchini’s vision has

performed on a straight

resulted in excellent achievements, which

stretch in which the

over the last four years have translated

bars are stopped with

into a successful turnover and high

special locking stations.

customer loyalty.

Franchini is a two-rail,

6 1

Figure 6: The storage buﬀer near the flash-oﬀ booth.

remote assistance.

The loading and unloading operations are performed on a straight stretch in which the bars are stopped with special locking stations. The conveyor is also equipped with a motor-powered bar rotating system with a manual control panel, in order to place the workpieces in the most suitable position to optimally coat them on every side. Finally, the plant features an efficient software package providing for PLC control as well as remote assistance.”

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7 1

Figure 7: The 515 metre long two-rail overhead conveyor designed by Tras-mec.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

WASHING

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Opening photo: Advanced nozzle technology enables Encore HD guns to achieve first transfer eﬃciency and consistent film build.

INNOVATIONS: PRESENT&FUTURE

Ready for “Industry 4.0” and The Smart Factory with Nordson Dense Phase Technology Corinna Hellwig Nordson Industrial Coatings Systems

ics.eu@nordson.com

“I

ndustry 4.0” develops solutions that use proven mass

coating operations. With its HDLV pumps, Nordson’s highly efficient

production methods to manufacture customized products

dense phase technology is available from manual application to fully

– in extreme cases with a batch size of 1. In that context,

automated, robot-controlled coating systems: a perfect example of

personal color selection is playing an increasingly important role

pioneering coating technology that combines maximum productivity

in many markets – and also posing new challenges for powder

and flexibility with optimum profitability.

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INNOVATIONS: PRESENT&FUTURE

In the 1910s, when a journalist timidly

“Industry 4.0” is characterized by sensory-perceptive and intelligent machines (“artificial intelligence”) arranged together and with others in a continuous exchange of data (“Internet of Things”). Their objective is to achieve “individually customized mass production” (“mass customization”), i.e. to apply the beneficial effects of mass production (economies of scale, learning curve advantages) toward the manufacture of extremely individual products.”

asked why the Model T only came in one color, Henry Ford replied with the now famous phrase: “Every customer can have his car painted any color they want

Customization in its ultimate form: Batch size = 1 The more product individuality a manufacturer accords its customers, the greater the resulting

as long as it’s black.”

complexity costs.

The journalist purportedly let it go at that,

configurations), and there is a Maserati

And those costs were precisely what Henry

and for the millions of people who bought

Quattroporte with over 4 million variants

Ford so successfully fought against.

the first large-scale production automobile

– to say nothing of the variation that can

That’s the way things were – till now.

manufactured in mass quantities, the

be achieved through combinations. “All

The smart factory or “Industry 4.0” – the great

importance accorded individual color

together, the number of different ways we

transformation that has already taken hold

comparison with the high practical benefit

of production and

selection also paled in

work processes and is attracting the

provided at a low

attention of about

price: When the last

half of all German

“Tin Lizzie” rolled off

companies – has

the production line in

become a top priority,

1926, black remained

above all in the

the only color option.

manufacturing sector.

Since the days of

It aims to maximize

“Industry 2.0” – just

production flexibility

like after what

by seamlessly

eventually came to be

networking people,

known as the age of

machines, systems

mass production that

and services. “Industry

Henry Ford helped

4.0” is characterized

launch – the demands

by sensory-perceptive

of customers have

and intelligent

changed dramatically. Today it goes without saying that they configure even the most complex

machines (“artificial 1

intelligence”)

Figure 1: Powder coating application with PowderPilot HD advanced control system and integrated network interface for production data acquisition, system status monitoring and remote diagnosis.

technical devices to

arranged together and with others in a continuous exchange of data (“Internet

match their strictly

of Things”). Their

personal preferences. Cars are still a good

can combine components is 10 raised to

objective is to achieve “individually customized

example: At the height of the current wave of

the 20th power,” according to the Head of

mass production” (“mass customization”), i.e. to

automation driven by platforms and modules

Complexity Management at Audi, Klaus

apply the beneficial effects of mass production

(Industry 3.0), the VW Group offers 156

Alders, who was quoted at the time.

(economies of scale, learning curve advantages)

different steering wheels, an Opel Astra can

And the Variant Manager at BMW, Franz

toward the manufacture of extremely individual

be ordered in 360 different combinations

Decker, even estimates the number of

products. Ideally, even the customer is

of engines and optional equipment (while

options available to him as “10 raised to

integrated into this network, selecting their

a 3-Series BMW is available in 453 different

the 32nd power.”

configuration online to control the machinery

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

111

2 1

Figure 2: Nordson HDLV pumps are virtually maintenance-free, which means they also enhance quality, flexibility and production benefits over the long term.

that then produces their desired product right before their eyes. This enables the manufacturer to produce a previously unimaginable range of products without having to maintain uneconomically large component inventories. And ultimately, why not “Batch size 1” – i.e. a product produced only once for a single customer?

More economical coating as a step toward mass customization With many articles of everyday life, a personally selected color expresses the individual taste of the owner. In the case of supplied parts and technical

112

components, painting is indicative

Since demands for the customizability of products are rising right along with more intense competition and cost pressures, the costeffectiveness and flexibility of coating systems are playing an increasingly decisive role. The solution lies in the streamlining of processes (“lean manufacturing”) and the minimization of downtimes, while effective material usage also helps reduce production costs and raise profit margins.”

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

of origin (manufacturer’s color) and underscores the intended quality appeal (ref. Opening photo). Since demands for the customizability of products are rising right along with more intense competition and cost pressures, the cost-effectiveness and flexibility of coating systems are playing an increasingly decisive role. The solution lies in the streamlining of processes (“lean manufacturing”) and the minimization of downtimes, while effective material usage also helps reduce production costs and raise profit margins.

INNOVATIONS: PRESENT&FUTURE

This also places high demands on an equipment system, because the investment in a state-of-the-art powder coating system is amortized by - fast coating processes and high output - uniformly high coating quality and film thickness without rework - a high degree of automation requiring minimal intervention by operating personnel - economical operation that consumes a minimum of resources - careful application of materials - the ability to change colors rapidly – even more than once during a shift - fast and thorough cleaning of the equipment - easy maintenance, and - extremely durable components. In order to take full advantage of flexibility and economic potentials, it is important not only to optimize individual components, but also to fully integrate and harmonize entire powder coating systems. That means powder materials, lines, pumps, guns, extraction technology and booths (Fig. 1).

Nordson dense phase technology: Integrated, eﬃcient, flexible The key to Nordson’s high-efficiency powder coating is dense phase technology with its characteristic HDLV (High Density Low Velocity) pumps (Fig. 2), which has dramatically improved both processes and results. Enabling powder material savings of up to 45%, this technology operates at much lower air pressure, gives users accurate control over the quantity of powder coating supplied and allows them to work with even greater precision. Instead of a conventional Venturi pump, it uses a

The key to Nordson’s high-efficiency powder coating is dense phase technology with its characteristic HDLV (High Density Low Velocity) pumps, which has dramatically improved both processes and results. Enabling powder material savings of up to 45%, this technology operates at much lower air pressure, gives users accurate control over the quantity of powder coating supplied and allows them to work with even greater precision.”

air-operated pinch valves open

two-chamber pump in which four

so no mechanical adjustments are required.

and close in pairs. As soon as an

The technology is ideally suited

inlet value opens, the discharge

for fully automated production

valve closes, powder is drawn in

and helps achieve even the most

and stored. In the next work cycle,

ambitious lean manufacturing

the powder is forced out of the

objectives.

first chamber while the second

ensuring high application efficiency

Intelligent control, essentially independent of operator qualifications

with low powder consumption –

Equipped with many sensors, a

and maintains that performance

modern powder coating application

for extended periods under an

system determines all relevant

extremely wide range of settings,

control parameters for material

even when processing thin film

supply, application and booth, and

powders.

continuously provides production

Nordson’s HDLV pumps are virtually

and system status data to a central

maintenance-free, which means

control system. Integrated network

they also boost quality, flexibility and

interfaces make it possible to

production benefits over the long

monitor the powder application and

term. The only components subject

greatly facilitate remote diagnosis.

to wear are the pinch valves, which

An industrial touchscreen enables

are designed for a service life up

control of all coating process

to 4,000 hours. They regularly last

parameter, such as supply and

well beyond that figure, however,

atomizer air settings, electrostatics,

thereby minimizing expensive

and gun stroke and triggering, as

maintenance and downtime.

well as color change sequences.

chamber is being filled. This results in constant, linear powder delivery,

When used in combination with powder guns (Fig. 3), HDLV pumps offer even greater benefits. These include reduced color

Preset and widely adaptable

3 1

the specially developed Nordson

programs make it easy to optimize

Figure 3: The soft spray at low velocity improves transfer eﬃciency in the initial coating operation.

contamination, more uniform

also especially fast and the selfcleaning feature keeps them troublefree. Hoses with a diameter of just 6 millimeters supply the guns and produce soft spray pattern. This adheres better, thereby raising application efficiency, facilitating the coating of complex geometries, minimizing the amount of work required, increasing the production rate and reducing powder consumption. The powder application rate is easily regulated by means of the control system,

114

range of products and powder materials. Last but not least, such a highly automated system lowers

coating thickness and better coating of Faraday cages. Color changes are

performance for an extremely wide

the qualifications required of the equipment

Nordson’s HDLV pumps are virtually maintenancefree, which means they also boost quality, flexibility and production benefits over the long term. The only components subject to wear are the pinch valves, which are designed for a service life up to 4,000 hours. They regularly last well beyond that figure, however, thereby minimizing expensive maintenance and downtime.”

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

operators. Whether manual, automatic or fully robotcontrolled, Nordson’s perfectly harmonized dense phase components provide powder coaters with the right technology to coat even the smallest batch sizes flexibly and economically and to take full advantage of the opportunities that “Industry 4.0” offers. At this year’s PaintExpo, from April 17-20, 2018, (Messe Karlsruhe, Hall 2, Booth 2440) Nordson will show the appropriate coating solutions with a variety of dense phase applications and end user products.

s.r.l.

CHAINS FOR CONVEYORS

Visit Us at

PaintExpo 2018 Hall 1 Booth 1332

Leader in Europe since 1962

M A D E

w .

I N

I T A L Y

Opening photo: CNH Industrial is a global leader in the design, production and selling of agricultural and construction equipment, trucks, commercial vehicles, buses and specialty vehicles, in addition to a broad portfolio of powertrain applications.

FOCUS ON TECHNOLOGY

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

CNH Industrial: A new Smart Factory in Pune, India. Industry 4.0-Oriented, High Technology Innovation in Coating Alessia Venturi ipcm®

“C

NHi’s objective is to make its machines recognisable on the

Group, to summarise his company’s attitude towards finishing (Fig. 1).

market not just for their brand but also and above all for the

CNH Industrial is a global leader in the capital goods sector, operating on

quality of their finishes,” says Massimiliano Rosoldi, the APAC

international markets with commercial and financial activities of design,

Region ME and Operation Process and Methods manager of the CNH

116

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

production and distribution. It is present in 180 countries, with nearly

FOCUS ON TECHNOLOGY

63,000 employees in 64 manufacturing facilities

headquarters â&#x20AC;&#x201C; and the Italian company Verind

product waste; monitoring of the

and 49 research and development centres.

Spa, belonging to the international DĂźrr Group,

Key Performance Indicators (KPI) of

CNH Industrial designs, builds and markets

for the coating process. Verind was already a

application systems; monitoring of

â&#x20AC;&#x153;work machinesâ&#x20AC;? and has 12 brands of vehicles

partner of the CNHi Group for the supply of

the KPI of operators with a numerical

for the agriculture and industry sectors: tractors

painting systems and equipment, including

assessment of the line personnelâ&#x20AC;&#x2122;s

(ref. Opening photo), combined harvesters,

some special solutions for the direct-to-metal

abilities; and collection of the systemsâ&#x20AC;&#x2122;

lorries, buses, propulsion and transmission

(DTM) technology1.

operating, consuming and performance ÂŠ ipcm ÂŽ

systems for trucks and road and off-road commercial vehicles,

data. â&#x20AC;&#x153;We asked our industrial

engines for marine applications,

partners for solutions

and so on.

that could minimise

CNH Industrial is also present

the problems arising

in India with the brands Case

from manual coating,

IH, a leader in the field of

which is necessarily

sugarcane harvesters, and

required in our industry,â&#x20AC;?

New Holland, with its new

says Massimiliano

harvesters assembled in the

Rosoldi. â&#x20AC;&#x153;Unfortunately,

production and R&D centre

it is always assumed

of Pune. CNHiâ&#x20AC;&#x2122;s plant in Pune

that colour change

is a complete manufacturing

inefficiencies are normal,

facility performing laser cutting,

that a system can only

subgroup welding, coating and assembly operations on such agricultural machines. In 2017, the plant has been

be either manual or

automatic, and that the

Figure 1: Massimiliano Rosoldi (centre) with Alessandro Soba on the left and Ivan De Angelis from Verind on the right.

involved in a highly innovative plant engineering investment.

issues arising from any functional aspects or from the poor capacity of an operator are

unsolvable. Our project has proved

an Industry 4.0-oriented factory has been

Innovative and digital solutions for common issues

created through the implementation of

The aim of the investment in Pune was to

all our needs with the development

advanced digital systems specially developed

find a technologically advanced and possibly

of special solutions that have resulted

to meet CNHiâ&#x20AC;&#x2122;s ambitious goals. The industrial

digital solution to a few thorny problems of

in the creation of Pune Painting, an

partners chosen for this project were the

the whole coating industry, such as: colour

Industry 4.0-oriented factory.â&#x20AC;? It is worth

German company DĂźrr Systems AG for the

change management in terms of time and

adding that all CNHiâ&#x20AC;&#x2122;s requests included

The coating stage has been improved and

plant engineering aspects â&#x20AC;&#x201C; the project has been entirely developed by DĂźrr Indiaâ&#x20AC;&#x2122;s

that this attitude is wrong and has met

technical proposals and solutions that

Ref. IPCM no. 42 November-December, Vol. VII, year 2016, pages 96-104.

were then developed by the designers.

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international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

117

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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

The future of the industry and a new coating concept

and finishing results, whereas the

“Verind translated

data and any deviations from the

the engineering

pre-set standards are monitored and

and plant ideas

made available on a specific interface

of Massimiliano

of the Line Master to enable corrective

Rosoldi and his

actions.

team into an 2 1

Figure 2: EcoDose 2K is an evolved electronic system for the stoichiometric dosing and mixing of 2K/3K coatings.

management of the 2K coating products and the process digitisation are entrusted to a special integrated automation feature. The production

- Developing an electronic device,

industrial project,”

EcoDose 2K, suitable for handling

states Ivan De

different series of two-component

Angelis, Verind’s

epoxy and polyurethane coatings.

Site Manager. “Pune Painting

- Continuous monitoring of the application parameters and KPIs.

is a paintshop

118

“The coating process is complex due to

to this project, is now semi-automated in

its high number of variables, especially

terms of automation management and

with manual application operations,”

performance. System engineering, know-how

says Alessandro Soba, the APT Industry

and innovation were the winning factors

Sales Manager of Verind. “A joint

that enabled Verind to meet CNHi Group’s

and coordinated work enabled the

challenging industrialisation demands.”

development of innovative and industrially

The main objectives were as follows:

sustainable market-oriented solutions:

- Creating a coating line with several manual

- Eco-friendliness and safety of the work

operators, but managed according to a

environment;

new concept with integrated control and

- Lower production costs;

automation features that make it unique

- High surface quality;

on the market. The booth operators’ team

- Industry 4.0 and digitisation of the

is required to get the best application © Verinid

CNH Industrial is a global leader in the capital goods sector, operating on international markets with commercial and financial activities of design, production and distribution. It is present in 180 countries, with nearly 63,000 employees in 64 manufacturing facilities and 49 research and development centres. CNH Industrial designs, builds and markets “work machines” and has 12 brands of vehicles for the agriculture and industry sectors: tractors, combine harvesters, lorries, buses, propulsion and transmission systems for trucks and road and off-road commercial vehicles, engines for marine applications, and so on.”

designed for manual operations that, thanks

3 1

Figure 3: A partial view of the large coating plant.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

coating process.”

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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

• Advanced management of the pot life

“Innovation enables us to remain technologically competitive. We strive to ensure that all our new products/solutions contribute to lower the costs per unit produced while increasing efficiency,” states Soba. “That is why we built a flexible and modular system combining an electrostatic application device with an automatic 2K coating dosing and mixing system based on the Coriolis technology. EcoDose 2K (Fig. 2) is an advanced electronic system for the stoichiometric dosing and mixing of 2K/3K solvent-based, water-based, and HS coatings, also suitable for DTM processes.” “The main technical benefits of the Coriolis technology are as follows: • Function control with an industrial PLC and an operator panel; • 1:1 to 30:1 stoichiometric catalysis ratio;

The coating stage has been improved and an Industry 4.0-oriented factory has been created through the implementation of advanced digital systems specially developed to meet CNHi’s ambitious goals. The industrial partners chosen for this project were the German company Dürr Systems AG for the plant engineering aspects – the project has been entirely developed by Dürr India’s headquarters – and the Italian company Verind Spa, belonging to the international Dürr Group, for the coating process.”

• Possibility to store over 1024 treatment

parameter; • “Push out” function in the automatic colour change operation to optimise consumption; • Closed loop flow control; • Local and remote function control; • Connection to a Line Master for the automatic colour change management based on the conveyor’s FIFO information; • Advanced management of the consumption measurement for each application station; • Consumption statistics based on models/ colours used in the whole production flow; • Predictive maintenance service on all components.”

Solutions for 100% eﬃcient colour changes and for the control of all KPIs The solutions provided by Verind have had a major impact on the plant’s colour change management and have enabled © Verinid

programs; • Dosing tolerance less than 1%; • Direct Injection

the monitoring of numerous operational parameters. To this day, in conventional

Technology (DIT)

manual coating

dosing with two

booths with two

channels (A and B);

or more stations,

• Separate cleaning

the colour change

circuits for the A and

process has always

B components;

be performed as

• Measurement of

follows: the operator

the coating and

stops the line at the

cleaning product

end of a job requiring

consumption;

the application of

• Modular automatic

a given colour, he

colour change system for paints and catalysts; • Display of the actual flow and partial

carries out the colour change operations, he

4 1

restarts the line and he begins coating

Figure 4: The inside of the pre-treatment tunnel.

the following batch.

consumption rates

In plants devoted to

for each program; • Display of alarms with extensive diagnostics and of VOC levels; • Data transmission to a supervisory

off-road vehicles, this • Measurement of the density and

can happen four or five times a day for each

temperature values for the A and B

manual workstation.

channels and their alarm thresholds;

Massimiliano Rosoldi says: “When talking

system for the analysis and printing of

• High reliability and stability;

about colour change with Verind, we asked

current and/or past events;

• No stress on coatings;

ourselves, why work in this way if it is possible

120

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

to implement an application tracking

before the arrival of a new batch.

in progress and to use the residual paint in

system on our conveyor? We realised that

â&#x20AC;&#x153;The second issue related to colour change

the gun supply circuit (through a separate

this would have enabled us to generate

processes is the product waste that results

circuit) without requiring further product.

only one empty place on the conveyor,

from the emptying, washing and re-loading

Of course, we previously compared the

automatically positioning in front of the

of the dosing device. Since we use two-

workload to the amount of paint remaining

different coating stations.â&#x20AC;? Such empty

component coatings, moreover, these

in the pipes, and we determined that this

space represents only â&#x20AC;&#x153;oneâ&#x20AC;? loss of

operations are required on two circuits,

was more than sufficient to saturate the

productivity due to the colour change

that of the painting product and that of

last component of any job. Just to be sure,

operation, instead of the many losses of a

the catalyst. The product wasted during a

however, we excluded from this feature

conventional system.

colour change operation, however, is still in

the last workstation, so that it can perform

â&#x20AC;&#x153;In Pune, we implemented a â&#x20AC;&#x153;semi-

good conditions and can be safely reused.

any operation that might not have been

automaticâ&#x20AC;? system by connecting our

Thanks to the tracking function integrated

completed by the previous ones.â&#x20AC;?

conveyor with the application system

into the conveyor, we have found a way

â&#x20AC;&#x153;Pune Painting currently uses a

â&#x20AC;&#x201C; which is common when working with

to use the product left in the circuit

management system that we call â&#x20AC;&#x153;pushing

robots, but innovative in a manual process,â&#x20AC;?

before the start of a new coating job to

outâ&#x20AC;?. It allows to spray the residual coating

says Rosoldi. â&#x20AC;&#x153;We managed to do this

paint the last component of the previous

in the circuit to treat the last component

together with Verind. Our system now

one: in our case, it equals to about 2

of a batch, thus reducing the colour

generates only one empty place on the

minutes and a half spraying. CNHi can

change times, since the pipeline is already

conveyor; the operator no longer has to

now efficiently manage the end of tasks:

empty, as well as the paint waste and the

stop the line because he has enough space

the tracking system enables the plant to

environmental impact of the process,â&#x20AC;?

to perform the colour change operation

recognise the last component of the job

states Rosoldi.

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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

The conveyor’s application tracking

an impressive amount of operating data is

to generate the outputs needed to plan

feature also opens up to countless KPI

available. In addition to standard parameters,

preventive maintenance processes,

monitoring functions. “It makes the

such as running time, total downtime and the

assess the plant’s performance, control

system very flexible and enables us to

data normally generated by simple “clock”

its environmental sustainability, identify

monitor the operators’ performance

counters, values like water, gas and electricity

areas requiring predictive maintenance

EcoDose 2K machines control the amount of paint used on

operations, and handle all

with numeric parameters. The

process variables that are now monitored offline and manually.

all operating stations from the beginning to the end of the

compares the theoretical coating

The main features of the coating plant

consumption (expected based

The new coating plant

on the component’s design

was designed by Dürr and

application phase and they generate a KPI that immediately

and surface area) with the real between the two consumption

installed by its local branch.

5 1

consumption level. The gap

Although it looks like a standard system, it is highly

Figure 5: Workpieces exiting the drying oven.

values is a performance indicator

technological and has a

that allows us to understand

much more sophisticated

if the operator is skilled, if we

structure than normally

are using the correct time and process parameters, and the paint consumption habit of each operator,” says Rosoldi. “We were then excited to generate other indicators, such as the VOC quantity. The Coriolis flowmeters allow us to monitor the total

required by the agriculture

The coating booth is 24 metres long, of which 20 are usable and can be equipped with five application station. As well as equipping the manual coating stations with EcoDose 2K systems, Verind also set up some non-in-line coating units, installed on skids with pumps and paint and catalyst circuits. They are used for the application of special colours.”

First of all, the 6-stage pre-treatment cycle is highly innovative since, for the first time, it includes a neutral pickling process as the first stage instead © Verinid

amount of paint delivered every

sector (Fig. 3).

hour compared to the known volumes of air in the booth and

of the conventional acid degreasing one (Fig. 4). “In Pune, we laser cut

therefore to calculate the amount

our sheets generating

of VOCs released in the booth

oxidation on their

itself and in the ovens. This will

edges; moreover, the

enable us to generate a further

subgroups supplied by

set of indicators automatically in

our contractors often

future.”

have oxidation and rust traces on their surfaces,”

A future Industry 4.0 The main characteristic of an Industry 4.0-oriented department

says Massimiliano Rosoldi.

6 1

“Chemetall developed a

Figure 6: The coating booth.

neutral pickling product, therefore free of

is the availability of system

hydrochloric acid, able to

inputs. However, an authentic Factory 4.0 needs, above all, a software

consumption of each point of use, coating

significantly reduce surface oxidation.

package analysing the data collected

consumption, VOC emission, alarm times, and

It has a pH of 7, it is not labelled as

and providing operational indications.

operating times are available in digital form.

hazardous, and it can completely

CNHi’s Pune Painting paintshop is

These Big Data, however, can only be exploited

remove oxidation and light rust from

Industry 4.0-oriented precisely because

at best if they are collected in a database able

metal sheets and components with a

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FOCUS ON TECHNOLOGY

spray application process with those of a cataphoretic basecoat for the yellow and red machines and of a one-layer coating for the grey ones (Fig. 9). “The coating system is still one of this project’s variables,” states Massimiliano Rosoldi. “We currently use a standard system including a primer and a “bake-on-bake” enamel (Fig. 10), but the project of this painting system was born with the aim of using cataphoresis. That is why we did not add any booth exclusively devoted to primer: it would

7 1

have soon remained unused. On the other hand, we opted for one semi-

Figure 7: The curing oven on the left and the coating booth on the right.

automatic coating booth with six stations for the two-coat application of both the primer and the enamel. maximum concentration of 10% and in

a code stored in the EcoDose 2K system:

This is possible thanks to a carefully

1 minute and 20 seconds, with better

when a special colour is needed, the skid

designed use of in-line buffers. The

results than the conventional process.

code is inserted and the system proceeds

buffers at the exit of both the pre-

We performed numerous laboratory

automatically.”

treatment area and the coating

tests before using it on our line. I can

The oven’s design is typical of the automotive

booth are long enough to free the

now state that such a pre-treatment

sector, with smooth walls, inspectable man-

two processes. Therefore, through

process, combined with the use of a

height pedestrian walkways, and a top and

the continuous conveyor’s software

surface tolerant epoxy primer ensuring

bottom area entirely cleanable from the

program, we manage to work on a

good adhesion even on imperfect

inside through access doors (Fig. 7).

mission basis. The pre-treatment and

substrates, certainly helps us control our

The system is ready for the possible

the primer and enamel application

quality levels.”

installation of a second drying oven to tackle

missions are stand-alone: they are

The pre-treatment cycle also includes a

any future increase in productivity, as well as

released at a specific time and based on

second degreasing stage, two rinses, an

of a cataphoresis tank (Fig. 8). In fact, CNHi

a precise sequence.” The system is very

Oxsilan nano-ceramic conversion stage,

Pune intends to replace its expensive primer

flexible and can manage one-layer,

water (Fig.5). The coating booth is 24 metres long, of which 20 are usable and can be

and a final rinse with demineralised

equipped with five application stations (Fig. 6). As well as equipping the manual coating stations with EcoDose 2K systems, Verind also set up some non-in-line coating units, installed on skids with pumps and paint and catalyst circuits. They are used for the application of special colours. “After entering the booth, these wheeled skids connect to the coating station and to the EcoDose 2K equipment feeding two opposing electrostatic coating guns,” says Ivan De Angelis. “Each skid has

8 1

Figure 8: The raised area of the plant.

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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

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Figure 9: The coating management unit.

two-layer and, for higher quality standards, even three-layer (cataphoretic basecoat + primer + enamel) systems. Another advantage in the integrated communication between the conveyor and the process is that, thanks to the inverters installed on all motors and pumps and following the phase sequence (pre-treatment, primer

Besides the introduction of management software for the Big Data coming from the coating plant and the application equipment, which will turn CNHi Pune into an all-round Factory 4.0, another goal of CNHi is the implementation of a grey-coloured one-layer system.”

application and enamel application), it is

Goals of productivity increase Besides the introduction of management software for the Big Data coming from the coating plant and the application equipment, which will turn CNHi Pune into an all-round Factory 4.0, another goal of CNHi is the implementation of a grey-coloured one-layer system. “For yellow and red, © Verinid

possible to adjust the consumption of gas and electricity according to three modes of operation:

we will continue to apply a primer + topcoat system, where the primer will be replaced

Warming, Stand-by, and Running.

by a cataphoretic coating,

If, for example, the pre-treatment

whereas the grey components

station is in a waiting phase

will be coated with a one-layer

between one mission and another,

product. In this way, when

the software program automatically

the cataphoresis plant will be

starts the Stand-by mode; the

operating, the coating booth will

inverters drive the pumps at lower

apply only one coating layer for

frequencies (15-20 Hz) or those

both yellow and grey. This will

that are not needed are turned off, with great benefits in terms of sustainability.

124

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Figure 10: A yellow workpiece exiting the curing oven.

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increase the modular capacity of the plant with significantly reduced costs.”

SPECIAL

SUCCESS STORIES

Looking Inside the Microcosm of Car Painting - With The Viledon® filterCair Module “Basic + Dirt In Paint”, Freudenberg Brings the Cause of the Tiniest Paint Defects Into the Light of Day

or cars packed with innovative technologies such as BMW, nothing should dull the driving pleasure

and futuristic design (Fig. 1). Not even the smallest surface defects in plastic components, which are barely visible to the human eye. But what is the source of these ever recurring faults in the coating of plastic parts? A wetting defect?

Under the name Viledon® filterCair, Freudenberg Filtration Technologies combines its flexible, individually tailored complete service package, aimed at the qualitative and economic optimization of coating processes.”

The experts at Freudenberg Filtration able to assist in solving and clarifying this question. Under the name Viledon® filterCair (Fig. 2), the company combines its flexible, individually tailored

Back to the specific case at BMW. As the BMW Group already relies on Viledon® filters for the purity of its painting processes at its plant in Lower Bavaria, the two Viledon® Site Engineers, Pascal Brodhun and Stephan Wassermann, were already familiar with the local situation. A status analysis of the paint zone is usually the first step in seeking to identify the cause, since the causes can be as diverse

Technologies should be

First step: status analysis of the painting zone

as the paint defects themselves. Potential sources include fiber or dirt inclusions, paint overspray, pollen, wetting defects caused by

complete service package,

application technology,

aimed at the qualitative

contaminated

and economic optimization

compressed air, silicone-

of coating processes.

containing lubricants

For many years, Viledon®

and oils, dirt carried in

filterCair has symbolized

by employees as well as

the holistic understanding of the filtration experts at Freudenberg: offering customers not just filters, but consistently high air

on their clothes or tools.

“Due to the large number

Figure 1: For cars packed with innovative technologies such as BMW, nothing should dull the driving pleasure and futuristic design.

of possible sources of contamination, it is necessary to look at the process holistically and

quality; acting not only

has also been providing this expertise on a

as product suppliers but as consultants

demand-driven basis outside fixed service

to examine it onsite. No two cases are alike”,

and problem-solvers too. Since 2017,

contracts, including for the BMW Group’s

explained Christian Westenburger, Contract

Freudenberg Filtration Technologies

plant.

Manager Viledon® filterCair.

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SPECIAL

SUCCESS STORIES

Since 2017, Freudenberg Filtration Technologies has also been providing their expertise on a demand-driven basis outside fixed service contracts, including for the BMW Group’s plant in Lower Bavaria.” Figure 2: Viledon® filterCair modules: customized service packages to meet your precise needs.

2 1

A thorough filter analysis and evaluation, meaningful particle,

“Our aim is to systematically rule out possible sources of error step

temperature, humidity and volume flow measurements and determining

by step”, commented Michael Steuer, Regional Manager Viledon®

the sinking speed in the paint line - these are the key components of the

filterCair, describing the procedure. “One element of this is the process

Viledon® filterCair module “Basic”. However, they did not reveal anything

or root cause analysis on site. At the same time, we began detailed

unusual at the BMW Group plant. The painting process was flawless: the

paint damage analysis for BMW in our laboratories”, he explained.

work processes were stable, all systems were set up correctly and the air

This second approach with the Viledon® filterCair module “Basic + Dirt

balance in the spray booth was perfectly in order.

in Paint” was the successful one in this specific case.

Welcome to the

Visioneering

Group

Best surface quality by heating up the car body from the inside Best process times with up to 30 % shorter heat-up Best curing technology for EVs EcoInCure: Innovative car body curing from the inside www.durr-paint.com

SPECIAL

SUCCESS STORIES

Any color that exhibits the circular to oval inclusions below the defect represents a chemical element that makes up this particle. In this specific case, that meant silicon and oxygen in particular, but also phosphorus, aluminum and a little potassium.”

Second step: problem-specific analysis under high performance microscopes

electron microscopic (SEM/EDX) analysis

Freudenberg then examined the granulate

into play. In this case, the faulty spot is

from which the car catchers were sprayed.

precisely cross-sectioned and inspected in

“From samples, we produced wafer-thin

During this process, Freudenberg experts

cross-section to find out which elements

films with a melting temperature of 280°C”,

immerse themselves in the microcosm of

are causing the flaw (Fig. 4). What may look

explained Frank Hofmann, Contract

the plastic paint. To begin with, they use

to the layman like a variety of differently

Manager Viledon® filterCair. This granulate

incident light microscopy. “This showed us

colored images set the Freudenberg

analysis showed that the quartz particles

an inhomogeneous surface. In some places,

experts immediately on the right track.

found were a constituent of the raw

there was no basecoat at all (Fig. 3). At the

Any color that exhibits the circular to oval

material. In places where they were too

same time, however, since the entire defect

inclusions below the defect represents

coarsely grained, painting errors emerged.

was covered with clear lacquer, we were able

a chemical element that makes up this

Problem solved. This fulfilled the most

to exclude a wetting defect caused by silicone

particle. In this specific case, that meant

important goal: a satisfied customer.

or similar”, explained Michael Steuer.

silicon and oxygen in particular, but

The problem thus had to lie deeper, in the

also phosphorus, aluminum and a little

For further information:

true sense of the word. This brought an

potassium.

www. freudenberg-filter.com

4 1

A thorough filter analysis and evaluation, meaningful particle, temperature, humidity and volume flow measurements and determining the sinking speed in the paint line - these are the key components of the Viledon® filterCair module “Basic”.”

128

Figure 4: Observation of the faulty spot in cross section by means of scanning electron microscopic SEM/EDX analysis.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

Figure 3: Incident light microscopy of the defect in the paint.

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

Â© Tosca

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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

FOCUS ON TECHNOLOGY

Shot Blasting 4.0 for a Flexible and Highly Efficient Pre-Treatment Process Prior to Coating Francesco Stucchi ipcm®

perating based on the Industry 4.0

into the firm; our next goal is to become a

on its clients’ parts, when requested or

principles, with highly automated

company 4.0.” Co.An.Auto is no longer a simple

authorised, is shot blasting. This is followed

and interconnected production

coating contractor, but it is a true enterprise.

by cataphoresis coating with a chemical pre-

processes and rationalised and optimised

By operating in the most diverse industries

treatment phase and/or powder coating for

costs, is now crucial for companies in the

(motorcycles, cars, tractors and earth-moving

combined systems; if only a powder coating

industrial sector. A firm based in the Italian

machines, toys, lighting), it has increasingly

process is required, this is carried out with an

Brianza area has turned its generational

Oxsilan “green technology” nanotechnology

change into a starting point towards

pre-treatment.”

innovation 4.0: Co.An.Auto Componenti S.r.L.,

“Based on our company philosophy, we have

established in Arcore (MB, Italy) in 1997.

always refused to include any acid pickling

“When it was established twenty years ago, Co.An.Auto Componenti S.r.L. was a cataphoresis coating contractor,” explains Bruno Maggioni, one of the owners and founding partners, “but we immediately started widening our horizons. Our service range now includes shot blasting as well as cataphoresis, powder and combined-system coating for both steel and aluminium parts. The latter is currently our most requested treatment besides processes requiring masking. Initially, we dealt almost exclusively

When it was established twenty years ago, Co.An. Auto Componenti S.r.L. was a cataphoresis coating contractor but they immediately started widening their horizons. The service range now includes shot blasting as well as cataphoresis, powder and combined-system coating for both steel and aluminium parts. The latter is currently the most requested treatment besides processes requiring masking. ”

stage in our chemical pre-treatment,” states Maggioni. “First of all, it is a little controllable chemical process and it decreases the corrosion resistance performance of substrates. Secondly, it has a negative environmental impact, which is totally unacceptable for us. The only alternative to acid pickling that is equally effective for preparing surfaces is shot blasting: if performed properly according to the metal treated, it offers an incomparable level of surface cleanliness and paint adhesion. That is why we opted for a largesized, highly automated advanced shot blasting

with auto parts, hence our name; now, we

system, enabling us to be competitive also in

can treat workpieces from the most varied

terms of costs.”

industrial sectors.” “In the last seven years, we have started a

focused on surface preparation processes

The new shot blasting plant

generational change,” says Maggioni, “with my

through shot blasting, besides coating (with a

“Our turning point towards innovation 4.0 was

son Alberto, a management engineer who

cataphoresis and a powder plant).

precisely the purchase of this new shot blasting

is now our technical-commercial manager

machine (ref. Opening photo) in December

founding member, Matteo Teruzzi, currently

The importance of shot blasting for Co.An.Auto

our production manager and an advocate of

Whether a cataphoresis or powder coating

over fifty years’ experience in the industry, a

process industrialisation. Our entrepreneurial

or a combined system is required, the

team composed of young and proactive people

vocation was strengthened with their entry

first process performed by Co.An.Auto

with which we have worked in perfect harmony

as well as a partner, and the son of another

2017,” states Maggioni. “As a supplier, we chose Tosca Srl (Canegrate, MI, Italy), a company with

Opening photo: The tailor - made shot blasting system supplied to Co.An.Auto by Tosca Srl.

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

Figure 1: A detail of the ring-shaped onerail conveyor, which enables to load and unload parts on diﬀerent hooks outside the chamber while another one is being subjected to shot blasting.

The plant installed at the premises of Co.An.Auto is a cluster shot blasting system equipped with a one-rail conveyor and several hooks; its ring layout enables to load and unload parts on different hooks outside the chamber while another one is being subjected to shot blasting (Fig. 1). During this phase, the hooks are rotated and simultaneously perform a “coming

and going” movement, in order to ensure that the media launched by the turbines in terms of electronics – to facilitate their

hit the parts’ surfaces with different

know-how for our needs.”

digital integration with already automated

angles and therefore optimally.

“The peculiarity of our company,” states

customer lines, which is very important in

The plant is equipped with four 7.5

Tosca srl’s team, “is that over the years

the framework of the Industry 4.0 – as well

kW turbines managed by separate

our customers have led us to develop a

as easy to maintain and definitely durable.

inverters, which allow to select the

definite kind of machines. We build shot

Our “standard” are tailor made shot blasting

abrasive throw speed depending on the

blasting machines that are very solid in

systems and not “basic models”: this is what

type of workpiece to be treated (Fig. 2).

terms of mechanics and very well equipped

differentiates us from our competitors.”

These are matched to servo controls

right from the design phase, and the ideal

Whether a cataphoresis or powder coating or a combined system is required, the first process performed by Co.An.Auto on its clients’ parts, when requested or authorised, is shot blasting. This is followed by cataphoresis coating with a chemical pre-treatment phase and/ or powder coating for combined systems; if only a powder coating process is required, this is carried out with an Oxsilan “green technology” nanotechnology pre-treatment. ”

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Figure 2: Electric circuits equipped with an inverter to allow the selection of the abrasive throw speed.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

Figure 3: The recovery and reconditioning system.

that regulate the quantity of abrasive based on the rotation speed of the turbines, thus optimising their operation. The abrasives used are small conditioned steel cut wire; by being able to set out their throw speed, users can define in advance the surface roughness value they want to obtain for each hook. A recovery and reconditioning system ensures the total elimination of waste, burrs and powders (Fig. 3). Since aluminium parts are also shot blasted, in order to comply with the regulations concerning the risk of detonation due to the concentration of aluminium powders, which explode at lower concentrations than the iron ones, Tosca srl opted to install an Atexcompliant filter, not ‘self-certified’, but supplied by one of the world’s leading companies in the sector. A PLC programmable via the operator panel allows to control all system functions and create customised sequences with different pace, turbine rotation speed, and media flow values (Fig. 4). Tosca created a series of HUB connections so that all solenoid valves and sensors can be managed via PROFINET through the PLC and remotely with a modem and an Internet connection (Fig. 5). When properly developed, in future this system will enable to monitor the systems’

3 1

status even from a smartphone.

The plant installed at the premises of Co.An.Auto is a cluster shot blasting system equipped with a one-rail conveyor and several hooks; its ring layout enables to load and unload parts on different hooks outside the chamber while another one is being subjected to shot blasting. During this phase, the hooks are rotated and simultaneously perform a “coming and going” movement, in order to ensure that the media launched by the turbines hit the parts’ surfaces with different angles and therefore optimally. ”

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Figure 4: The touch screen operator panel for setting all the shot blasting machine’s functions.

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FOCUS ON TECHNOLOGY

5 1

Figure 5: HUB connections of all the solenoid valves and sensors of the system.

A PLC programmable via the operator panel allows to control all system functions and create customised sequences with different pace, turbine rotation speed, and media flow values. Tosca created a series of HUB connections so that all solenoid valves and sensors can be managed via PROFINET through the PLC and remotely with a modem and an Internet connection. When properly developed, in future this system will enable to monitor the systems’ status even from a smartphone. ”

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

“Tosca’s shot blasting machines can adapt their characteristics and working parameters to the products treated and the finishes required. Before starting a cycle, the operator selects the proper sequence through a touch screen panel,” states Tosca’s team. “However, this stage will soon be completely automated and managed remotely through pre-set barcodes for each type of product, again in compliance with the Industry 4.0 principles.” As for the plant’s construction, the shot blasting chamber is made with steel and manganese steel sheets featuring reinforcement profiles and an anti-wear lining as follows: - interchangeable 10 mm thick manganese steel plates at the centre - interchangeable 6 mm thick manganese steel plates at both sides - special anti-abrasive rubber sheets on the interior walls of the automatic doors (Fig. 6). Another characteristic of all the machines produced by Tosca, besides extreme durability, it is their ease of maintenance. For instance, the interchangeable plates are fixed outside the plant, so that it is always possible to replace them quickly and easily, thus reducing costs and downtimes.

Industry 4.0: goal achieved “Relying on Tosca was the right choice,” states Maggioni. “Their shot blasting machines are highly technological and effective. All our requirements have been met quickly and concretely. The Tosca team has always been available and above all flexible, paying attention to the smallest details and enabling us to get the most out of their expertise.” In terms

6 1

of both process and finishes obtained, the

Figure 6: The shot blasting machine is equipped with two automatic doors operated by pneumatic cylinders.

results are definitely satisfactory. “Since we installed the system two months ago,” says Maggioni, “we are still at the ‘break-in’ stage, but we are already working on implementing a management interface between the Tosca

Another characteristic of all the machines produced by Tosca, besides extreme durability, it is their ease of maintenance. For instance, the interchangeable plates are fixed outside the plant, so that it is always possible to replace them quickly and easily, thus reducing costs and downtimes.”

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machine and Co.An.Auto’s already existing software. This will enable us to manage the over 5,000 part numbers we deal with, each with different shot blasting needs, much more efficiently.”

SPECIAL

BRAND-NEW

Sames Kremlin Announces the Launch of Our Brand New Manual Fpro Airspray Spray Gun Pressure Range

ames Kremlin announces the

FPro - effortless and perfect spraying:

launch of the FPro Airspray

- a painter must feel comfortable and at ease with his spray gun to be efficient and

spray gun bringing professional

finishing for all (Fig. 1).

productive. With the new generation of

«For all» means easy to

super light hoses, lightweight gun body and

use for all. The FPro

ergonomic handling, the FPro spray gun

spray gun is perfectly

applies the coating with ease and less effort

balanced; therefore,

(Fig. 2).

delivering the perfect finish In 1925 Sames Kremlin industrialized the first

«For all» means the largest range

airspray gun in Europe and reinvents the way

of pressure guns and accessories for

to atomize paint with patented innovations

all applications in all the high finishing

with the New FPro airspray spray gun. Sames

markets.

Kremlin understands the customers’ needs

FPro is the new standard in airspray:

2 1

Thanks to innovative patent pending technologies inside the gun, the painter has complete control with the paint

Figure 1: The new FPro Airspray gun.

for any type of painter.

due to decades of knowledge and customer application experience. For further information: www.sames-kremlin.com

atomization with very high transfer efficiency (up to 78% in HVLP). FPro delivers performance at your fingertips: - the FPro delivers a rich experience at your fingertip with a perfectly balanced gun body and a high level of sensation on the trigger for perfect applications.

Figure 2: FPro Airspray guarantees a perfect and easy application thanks to its lightweight and ergonomic handling.

138

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BRAND-NEW

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

Feltani Reti: High Quality Coating Hooks Since 1975 AISI304 stainless steel wire can be produced

Snc, based in Campodarsego (Pd),

upon request.

was established in 1975 by the

The characteristics of each product are collected

©Feltani Reti

he Italian company Feltani Reti

Feltani family, which has dedicated itself to metal wire processing for almost forty

in a technical file containing information on each type of hook, in accordance with the UNI EN

years now. Initially, it was a handicraft

standards:

manufacturer of bed and sofa bed nets,

- indications of use;

but over the years and with the advent of

- identification of the coil used for each batch,

automation it has constantly expanded

complete with the certification of the steel mill

its plant equipment, thus improving its

(Fig. 3);

product range and focussing on the production of coating hooks, which is still its core business (Fig. 1).

- maximum hook capacity; Figure 1: Coating hooks manufactured by Feltani Reti.

from mechanical

Written on the initiative of Isabella Feltani, our marketing and communication manager, this

©Feltani Reti

The switch

- load test results.

manual is a plus for users in terms of both safety and process optimisation.

control to

Its forty-year experience, advanced technology

advanced

and extreme processing precision have led

numerical

Figure 2: Technologically advanced numerical control machines ensure maximum production flexibility.

control machines (Fig. 2) has enabled Feltani Reti to produce hooks in the

2 1

Feltani Reti to collaborate with the leading companies of the coating, furniture, and automotive sectors, as well as becoming well known on the market for its professionalism, flexibility, quality, and delivery speed. For further information: www.feltanireti.it

sizes, types and materials (normal metal, galvanised, or stainless steel wire), ensuring high flexibility in meeting customer requests with the right mix of technique and creativity. Indeed, this company’s strength is its ability to produce hooks based on its customers’ designs, in addition to having a large stock availability with very fast delivery times. Feltani’s production is divided into two large categories, standard bend and round bend coating hooks. They are available with various diameters: - hooks in FE360 with a diameter from 2.00 mm to 15.00 mm - hooks in SM phosphated steel with a diameter from 1.50 mm to 8.00 mm.

Figure 3: Metal wire coils labelled and identified by the producing steel mill.

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139

Opening photo: Tecnolaser is a company specialised in the processing of sheet metal for machine tools, textile machines, earth moving machines, and accessories for the industry

FOCUS ON TECHNOLOGY

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

Collaboration Between Specialists for the Versatile, Integrated, and 4.0-Oriented Coating of Light Carpentry Components: Tecnolaser’s Success Story Barbara Pennati ipcm®

ecnolaser, based in Curtarolo (PD, Italy) and specialising in the

The advent of automatic machines, which have facilitated some mechanical

processing of sheet metal, was established in 1986 as a production

processes and reduced production times, then led Tecnolaser to expand

department of Officine Facco & C. Spa, a manufacturer of plant

its production capacity and acquire new customers. That is why it moved

engineering solutions for the poultry farming and breeding industry.

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N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

to a new larger site, suitable for hosting its new work cycles (Fig. 1).

FOCUS ON TECHNOLOGY

“The intensification of our activities and the increase in our turnover forced

The first coating plant Thanks to the implementation of

us to change our logistics. In the late

a pre-treatment nanotechnology,

Nineties, we decided to move our

Tecnolaser could make a

company headquarters and build a first

qualitative leap in terms of finishing

plant devoted to machining, assembly,

performance. However, the ever-

and welding. Coating was entrusted to

increasing workload and the small

contractors,” explains Gian Maria Tonin,

size of its coating system limited the

Tecnolaser’s quality system manager

versatility and quality of its service.

(Fig. 2). “However, we experienced

“We performed over 70 colour

various quality problems with the

change operations per month but,

finishing of our products, not so much

since we had a one-rail conveyor, the

due to the coating process itself as

plant downtime negatively affected

related to transport. Light carpentry components, made of carbon steel, coil

our production rate and forced

Figure 1: Tecnolaser’s plant in Curtarolo (PD, Italy).

galvanised or electro galvanised steel, and structural steel (Fig. 3), are easily

us to double the shifts,” says Gian Maria Tonin. “Moreover, although the strength that distinguishes

damaged if not carefully handled, and we often found damaged workpieces that resulted in an increase in waste and production times (ref. Opening photo).” “Besides these quality issues, we also needed to support our customers during the whole sheet metal treatment process, from our co-design service in the components’ development to the supply of end products,” says Tonin. “We installed our first powder coating plant in 2009, which enabled us to meet our clients’ needs in terms of quality and delivery times.” “When one of our important customers

Tecnolaser, based in Curtarolo (PD, Italy) and specialising in the processing of sheet metal, was established in 1986 as a production department of Officine Facco & C. Spa, a manufacturer of plant engineering solutions for the poultry farming and breeding industry. The advent of automatic machines, which have facilitated some mechanical processes and reduced production times, then led Tecnolaser to expand its production capacity and acquire new customers. That is why it moved to a new larger site, suitable for hosting its new work cycles.”

us on the market is our ability to handle medium-low volume production batches, our reduced space, the impossibility to integrate a second spray paint booth, and the increase in the number of orders led us to make a second important investment. We built a new adjacent building of about 4500 m2, where we installed a new coating plant that could finally meet all our needs, ensuring also we had the possibility and the space for any future implementations.”

The new coating plant

Padua, a part of its processes

“In order to design the

closed its production plant near was entrusted to Tecnolaser.

new system, we set up a

However, the finishing quality

roundtable with Dollmar,

requirements, i.e. 500-hour salt

as the sole supplier of

spray resistance, where higher

pre-treatment products;

than those met by our coating

Costabeber, as the plant

plant,” states Gian Maria Tonin.

engineering company; Gema

“While searching for the best

Europe, for the installation

suited passivation system, we

of the new coating booth;

came into contact with Dollmar

and Futura Convogliatori

(Caleppio di Settala, Italy). The

Aerei, for the installation of

tests performed with them led us to integrate a multi-metal pretreatment process with the final nebulisation of a nanotechnology passivation product,” he says.

the conveyor and of the 4.0 2 1

management software,” states

Figure 2: From left to right, Tecnolaser plant manager Filippo Tonello, Tecnolaser quality system manager Gian Maria Tonin, and Alessia Venturi from ipcm.

Tonin. The new coating line, in operation since December 2017, includes a multi-metal

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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

3 1

4 1

Figure 3: Tecnolaser treats parts in carbon steel, coil galvanised or electro galvanised steel, and structural steel.

Figure 4: The pre-treatment tunnel

no rinse pre-treatment process performed as

“Aware that one of the main process variables is

their process versatility and quality level,”

follows: acid phosphodegreasing with products

the substrate quality of sheets, which cannot be

explains Gherardo Minotti, Dollmar’s

from the Dollphos range; 3 rinses with mains

controlled, we relied on Tecnolaser’s previous

Products Division Business Development

water; 1 semi-osmotic rinse; a pure flash of

experience to solve the old plant’s critical issues

specialist. “The current tunnel (Fig. 4) is

osmotic water; a nanotechnology passivation

and fully meet their needs. That is why we

62 metres long, of which 9 are devoted

through nebulisation; and a hot air drying stage.

implemented technologies that could improve

to the first phosphodegreasing stage. Its

Thanks to the implementation of a pre-treatment nanotechnology, Tecnolaser could make a qualitative leap in terms of finishing performance. However, the ever-increasing workload and the small size of its coating system limited the versatility and quality of its service.”

142

dimensions are based on the longest workpieces treated by Tecnolaser, which are 5 metres long. The cleaning tanks are equipped with pH and conductivity control probes, integrated into the level control system and featuring a dedicated interface to constantly monitor the process and avoid any lowering of cycle performance.” “The Soft Level system, besides optimising water consumption, can 5A 1

5B 1

Figures 5A and 5B: The new Gema MagicCylinder coating booth with a quick colour change system.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

communicate with Soft Rain Advanced. This system enables to apply an osmotic water flash,

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

Tecnolaser’s customers generally choose the

other the light ones, in order to avoid any

coatings. They can be epoxy, polyester or

contamination. They both have pre and

epoxy-polyester products. Their application is

post-retouching stations, used only if the

carried out in two booths. “For cost efficiency

workpieces’ shape requires it (Fig. 8).

reasons, we decided to keep the first plant’s

“Thanks to the new plant layout, including

booth and add a new MagicCylinder booth

a Futura power and free overhead

(Figs. 5a and 5b) with the new OptiCenter

conveyor (Figs. 9a and 9b), we can now

system (Fig. 6) featuring OptiSpray dense

also perform two-coat processes. In

phase application pumps (Fig. 7),” says

this case, we lower the polymerisation

Tecnolaser plant manager Filippo Tonello.

oven temperature in order to avoid

“One booth applies the dark colours and the

return the parts to the booth selected for the application of the second layer through a priority route.” “We carry

6 1

out around 5

Figure 6: The new Gema OptiCenter.

colour change operations per day. Thanks

therefore free of the pollutants present in the tank due to dragging, which ensures optimal product preparation

to the storage

7 1

buffers (Fig. 10) strategically

Figure 7: Gema OptiSpray dense phase pumps.

stage. This is carried out with Dollcoat SA 115, already used in the first plant. The Dollcoat SA product range is based on synthetic oligomers containing organically functionalised silanes, able to enhance the properties of the silanes themselves and ensuring excellent paint adhesion and corrosion protection. The nebulisation action ensures that a fresh product is always applied on parts for maximum treatment quality, avoiding any contamination due to dragging or to the presence of reaction by-products,” states Minotti. “At the moment, we have opted for an acid phosphodegreasing stage because it ensures excellent results on both carbon and galvanised steel, the two most treated types of metal by Tecnolaser. However, the plant is ready to switch to an alkaline degreasing process in future.”

144

In order to design the new system, Tecnolaser set up a roundtable with Dollmar, as the sole supplier of pretreatment products; Costabeber, as the plant engineering company; Gema Europe, for the installation of the new coating booth; and Futura Convogliatori Aerei, for the installation of the conveyor and of the 4.0 management software.”

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8 1

Figure 8: Both booths are equipped with pre and post-retouching stations.

FOCUS ON TECHNOLOGY

9A 1

9B 1

Figures 9A and 9B: Futura Convogliatori’s power & free conveyor.

positioned along the two-rail conveyor (in front of the pretreatment tunnel, after the drying oven, and in the two unloading areas, as well as some 3-bar mini buffers at the booths’ entrance and exit), plant downtimes have decreased and our production and delivery processes are no longer slowed down,” states Filippo Tonello.

A software package 4.0 for the integrated management of the plant The new coating plant is totally managed by a software developed by Futura Convogliatori Aerei and integrated with Tecnolaser’s factory management system (Fig. 11). “The whole production flow is organised in “colour chains”, identified by a unique code that is applied to all load bars with parts requiring the same coating process. During processing, the system collects plant data – times of entry and exit from the various stages, pH parameters, oven temperatures, unloading times, and so on. The data are then stored and, once a “colour chain” is ended, they are automatically integrated into the internal database to update the production data related to coating,” explains Gian Maria Tonin. “The automation of the whole

G RT

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

states Tonin. “Our active collaboration with Dollmar, Futura, Costabeber, and Gema, as well as the technical suggestions received, have allowed us not only to improve the quality level of our production, but also to solve the handling and delivery problems that we encountered with the old plant layout. The new line offers us optimal flexibility thanks to the strategic positioning of storage buffers and the creation of priority routes for materials to be delivered urgently, made possible by the two-rail conveyor, but also thanks to the two spray paint booths that enabled us to perform a two-coat cycle and make improvements in terms of overspray and consumption. For

10 1

Figure 10: Several butters of the power & free conveyor by Futura.

the future, we are considering the integration of a third coating booth, working simultaneously to the two

process and its integration with our internal

Conclusions

system enables us to carry out activities such

“Since we are required increasingly

the plant to another transport line that

as updating production orders with no human

different types of coatings and effects,

takes the workpieces directly to the

intervention. Moreover, since the system and

it has been crucial to equip ourselves

subsequent assembly phases, thus

the software communicate with each other,

with a plant enabling us to efficiently

achieving a complete and 4.0-oriented

we can trace the different colour batches and

meet the needs of the market in terms

automation of production,” says

intervene promptly in case of any problems.”

of both quality and delivery times,”

Gian Maria Tonin.

146

Thanks to the storage buffers strategically positioned along the two-rail conveyor (in front of the pre-treatment tunnel, after the drying oven, and in the two unloading areas, as well as some 3-bar mini buffers at the booths’ entrance and exit), plant downtimes have decreased and the production and delivery processes are no longer slowed down.”

already in use, and the connection of

11 1

Figure 11: The new coating system is managed by integrated software 4.0.

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

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148

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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

FOCUS ON TECHNOLOGY

Metalcolor: a New Coating Plant with a Low Environmental Impact for Greater Production Versatility Barbara Pennati ipcm®

n each issue of ipcm®, we bring examples

this purpose, Metalcolor collaborated

whereas for the pre-treatment phase we

of companies that, regardless of their

with SAVIM Europe, a company that

adopted Chemtec’s one-stage process

size, employee number, turnover, and

designs and produces both manual and

Toran 3®: an innovative technology with a

production capacity, have recognised the

automatic complete coating systems.

low environmental impact that uses organic

importance of making targeted investments

In 2016, faced with an increasing

polymers.”

to establish themselves in their target

demand and aiming at opening up to

sectors and stand out in an increasingly

new sectors, Metalcolor turned again to

fast and competitive market through very

SAVIM Europe to install a second coating

The new painting line for light carpentry components

high quality standards. An ever-changing

system. “In order to expand our service

“The layout of the first plant installed by

market, however, entails an evolution of the

range without slowing down our heavy

demand itself. This, in turn, means that companies must cope with the most diverse needs, thus always

application booths, one automatic and one manual, an oven booth to apply liquid coatings

taking new challenges

on parts up to 14 m,

and looking for the right

and a static oven for

investment and the most

polymerising powder

suitable technological

coatings. The pre-

partner.

treatment is performed

This is the case of

with an automatic

Metalcolor (Caprazzino di

shotblasting system or, in

Sassocorvaro, PU, Italy),

the presence of complex

belonging to the Epta

shapes, with a manual

Group and specialising in the treatment and coating of metal. In 2015, it implemented an important

sandblasting operation,”

says Davide Dini.

Figure 1: The new coating system designed by SAVIM Europe.

site expansion project (also

“Treating light carpentry workpieces in such a large system, however,

reported by ipcm®1) by moving to a 3500 m2

carpentry production rate, we installed

was uneconomical and not very productive.

facility equipped with cutting-edge systems,

a new automatic powder coating line

A new automatic line was therefore started in

with the aim of specialising in particular

devoted exclusively to the processing of

November 2016 (Fig. 1), equipped with a one-

in the treatment of large-sized parts. For

small components such as sheets and

stage pre-treatment tunnel, a drying oven, a

carters (ref. Opening photo),” explains

Wagner SuperCenter booth featuring a quick

Metalcolor production manager Davide

colour change system and 10 guns (Fig. 2),

Dini. “We relied again on SAVIM Europe,

and a bell curing oven (Fig. 3).”

1 “A coating line designed specifically for the heavy carpentry sector and to ensure maximum energy savings” ipcm®_International Paint&Coating Magazine Vol. VI, No. 35 September-October, pages 104-108

Opening photo: in order to expand its service range, Metalcolor (Caprazzino di Sassocorvaro, PU, Italy) installed a new automatic powder coating line devoted to light carpentry parts.

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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

2 1

Figure 2: The Wagner SuperCenter automatic coating booth with a quick colour change system.

“On average, we perform two colour change

managed to design a functional but compact

operations a day, working in two shifts. In

system: a simple solution, but able to meet our

order to make our production flow more

needs and required standards,” states Dini.

Toran 3®: a one-stage pre-treatment process based on organic fluids

flexible, besides the automatic booth we

“Moreover, Metalcolor pays great attention

The pre-treatment tunnel of the new plant

added a small manual unit built by us. This is

to environmental sustainability and it has

is about 10 m long and equipped with a

devoted to the coating of batches

containment tank with a capacity of

requiring different colours than

about 2,000 litres. It uses Chemtec’s

the one applied on the automatic

Toran 3® technology, a VOC free

line,” says Dini. “The polymerisation oven is about 3 m long and, like the drying oven, it is equipped with a modulating air vein burner that, compared with a conventional burner, ensures lower pollutant emissions and higher energy saving

The pre-treatment tunnel of the new plant is about 10 m long and equipped with a containment tank with a capacity of about 2,000 litres. It uses Chemtec’s Toran 3® technology, a VOC free process based on organic fluids and developed to clean, degrease, and protect metal surfaces.”

thanks to its high combustion

process based on organic fluids and developed to clean, degrease, and protect metal surfaces (Fig. 4). “Metalcolor treats several different materials for different industrial sectors. Our customers are mainly manufacturers of machines for marble, glass, and wood processing,

efficiency.”

always been committed to reduce pollutants.

whose components are usually treated by our

The new plant features a 124 m long one-rail

This is also reflected in the choice of both

plant devoted to heavy carpentry parts. Carters,

overhead conveyor and it was designed

the coatings used, which are free of solvents,

doors, and sheets in general, on the other hand,

to fit the available space. “One of the main

chromium and lead, and the plant installed,

are processed in the new dedicated system.

issues of this project was the relatively small

with a low environmental impact and ensuring

The materials used are also different: carbon

space available in our factory. SAVIM Europe

considerable energy saving.”

steel, cold galvanised steel, iron, and aluminium.

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FOCUS ON TECHNOLOGY

3 1

Figure 3: The hot air bell oven for the polymerisation of coatings.

4 1

Figure 4: The containment tank for Chemtec’s Toran 3® process.

5 1

6 1

Figures 5 and 6: A SEM image of a steel Q-Panel degreased without Toran 3® (left) and treated with Toran 3® (right).

INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

7 1

Figure 7: A metal sheet with Toran 3®+ 2% of laminating oil: the oil is incorporated into the polymer in “nanobubbles”.

That is why we needed a versatile multi-metal

The organic polymer that covers the

Conclusions

pre-treatment process able to handle different

components absorbs oils and organic

“Metalcolor was established in 2005 and

types of workpieces while maintaining a high

contaminants up to about 1.5 g of oil

initially it was equipped with a small coating

quality standard,” says Davide Dini. “We had the

per square metre treated (Fig. 7). The

plant. Our immediate strong growth led

opportunity to verify the effectiveness of Toran

process, therefore, traps oils and grease

us to install a larger system designed by

3® first-hand in a few plants in France and we

in the three-dimensional structure of the

SAVIM Europe, which enabled us to cope

decided to adopt it, too.”

polymer created on the metal. It does not

with the growing demand from our area,”

The process operates at room temperature in

generate any waste, but it rather converts

says Davide Dini. “Then, in order to be even

one stage including treatment, dripping, and

contaminants into an active part of the

more competitive and grow in terms of

drying at a maximum temperature of

production, we realised that we

140 °C. Toran 3® consists of polymers

had to invest again in coating.

and special additives dissolved in a particular mixture of organic fluids. When the product dries, cross-linking of polymers occurs; they coat the surfaces with a very thin continuous three-dimensional conversion film, which is about 1 micron thick and able to increase adhesion of the coating (epoxy, polyester, or mixed), provide oxidation protection, and improve

The organic polymer that covers the components absorbs oils and organic contaminants up to about 1.5 g of oil per square metre treated. The process, therefore, traps oils and grease in the three-dimensional structure of the polymer created on the metal. It does not generate any waste, but it rather converts contaminants into an active part of the treatment.”

That is why we relied on the expertise of SAVIM, which once again met our needs with a compact, functional, advanced, and eco-friendly system, the latter characteristic being very important for us.” “The integration of our previously implemented mechanical pretreatment with the Toran 3®

corrosion resistance (Figs. 5 and 6).

organic fluid-based one provided

“We performed some tests with

by Chemtec allowed us to solve

Chemtec’s cleaning process and, with one

treatment. “We were particularly impressed

the problems we encountered in the

powder coat, we managed to achieve a salt

by the presence of a microprimer that, as

cleaning of some parts. We immediately

spray resistance value of 500 hours,” says

well as degreasing the material, incorporates

obtained excellent results that enabled us to

Davide Dini. “Before installing the new system,

dirt and contaminants. This translates into a

successfully meet even the most particular

we only implemented a mechanical pre-

lower environmental impact because there

customer requests and specifications,”

treatment that, however, could not ensure

is no emission or creation of solid waste to

says Davide Dini. “The whole plant

perfect paint adhesion on some types of

be disposed of. This is perfectly in line with

can be managed by one control panel.

parts. With this new pre-treatment process,

our corporate philosophy of respect for the

This facilitates the timely resolution of any

we have managed to get excellent results

environment, including the working one,

problems and the maintenance operations.

in terms of both adhesion and corrosion

which in this way is cleaner and safer,” states

Two years after the installation, we cannot

resistance.”

Dini.

but be very pleased,” he states.

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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING

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INNOVATIONS: PRESENT&FUTURE

Dense Phase, Low Pressure (DPLP) Powder Application: Reduced Consumption and High Performance with the New Transport System NEA 415 Carlo Perillo Verne Technology, Milan, Italy

c.perillo@vernetechnology.it

NEA 415 hardware for the DPLP powder transport management

for Venturi or other systems. In future,

Verne Technology (ref. Opening photo).

Verne Technology designed a touch

systems managed by one portable

It represents an evolution of the NEA 430

screen control unit that, together with the

touch screen device, operating in Wi-Fi

system, launched on the market last year

NEA 415 software specifically designed

mode and, therefore, requiring no

and already described on this magazine*.

for the coating industry’s needs, forms a

cables.

This innovative DPLP transport system

complete digital control system for the

integrates perfectly with the existing

management of the powder delivery

EA 415 is the new dense phase, low pressure (DPLP) powder transport system developed by

this will be evolved into customisable modules with up to 32 NEA 415

The evolution of NEA 415

plants and application devices in the

Initially, NEA 430 was designed to

industrial coating sector. It ensures optimal management of all powder treatment stages, from recovery to feeding. The main features of the NEA 415 system are as follows: - 4-stroke operating cycle; - transport up to 600 pulsations/min; - powder collection up to 3 m; - powder transport from 10 to 35 m; - constant adjustment of the powder transport capacity from 0 to 400 g/min;

meet the needs for DPLP powder transport in the chemical and

NEA 415 is the new dense phase, low pressure (DPLP) powder transport system developed by Verne Technology. It represents an evolution of the NEA 430 system, launched on the market last year.”

pharmaceutical sectors: based on a pneumatic-mechanical operating principle, it operates without electricity. Its development, however, enabled Verne Technology’s staff to apply it also to the surface treatment industry, thanks to its cyclone’s powder recovery, its dust collector filter’s emptying, and its

- constant adjustment of the powder

powder management unit’s feeding

transport pressure from 0 to 5 bar;

characteristics. The NEA 415 system

- constant regulation of the feeding flow;

and recovery process (Fig. 1). The

was designed based on the results of

- no additional auxiliary air in the feeding unit;

hardware can be supplied separately to

NEA 430: it is completely electronic

- integrated powder flow inversion system;

provide electrostatic application system

and able to ensure consistent feeding

- product change in less than 30 sec.

manufacturers and plant engineers with

thanks to its 4-stroke operation,

the possibility to install NEA 415 and

powder transport up to 600

manage it with an already existing PLC or

pulsations/min, and constant control

circuit board, integrated or modified in

of the powder collection/ transport

the rack control module, be they designed

processes.

* C. Perillo, “NEA 430: an innovative pneumatic system for the low pressure, high density precision feeding of powders”, ipcm® International Paint&Coating Magazine no. 45 (May-June 2017), pages 68-71.

Opening photo: The new generation powder transport pump NEA 415.

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155

Powder collection and transport

The dense phase powder coating systems

Verne Technology’s software enables to

currently on the market normally operate

set and control the amount of powder

with 2-stage cycles. However, this concept

to be collected, its condensation, its

often causes critical issues due to feeding

transport within the tube, and the

discontinuity: the powder reaches the

type of application flow (Fig. 2). The

dispensing nozzle with an inconsistent

NEA 415 system uses tubes with an

flow. That is why these systems are often

internal diameter of 6 mm and it is

integrated with a “diffusor” near the gun to

able to collect powder up to 3 m and

pump continuous compressed air. Although

transport it for a length of 10 to 35

this partially helps stabilise the feeding flow,

m. Conventional Venturi systems, on

such solution inevitably causes the loss of most of the benefits of a real DPLP transport system. A 4-stroke system, on the other hand,

The NEA 415 system was designed based on the results of NEA 430: it is completely electronic and able to ensure consistent feeding thanks to its 4-stroke operation, powder transport up to 600 pulsations/ min, and constant control of the powder collection/ transport processes.”

The eﬀectiveness of the 4-stroke cycle

and application processes of automatic application devices, where the high flow rate and

ensures the feeding consistency

air pressure used considerably

needed for uniform and homogeneous

increase the feeding flow

application. The 4 chambers of the

speed, with a consequent

pump body significantly reduce the

overspray risk.

powder collection and transport time

NEA 415 only exploits the low

(pulsation) compared with conventional

pressure pulsations within

2-stroke systems with the same

the transport tubes without

transport capacity/min, given the larger

the need for any auxiliary air

volume of the chamber to be filled.

supply. It can consistently

Moreover, thanks to the number of

feed minimum quantities

pulsations it can achieve (up to 600/

of powders thanks to the

min, almost twice as much as the dense

management of its parameters

phase devices now available), the NEA

with a decimal precision.

415 system stabilises the powder flow

At a distance of 20 m, the new

without the transport tube length

NEA 415 can feed up to

changing its performance. In fact,

400 gr/min, whereas a

transport tubes with variable lengths

conventional Venturi system

from 10 to 35 meters can be used.

delivers an inconsistent amount of powder. The advantages of DPLP application can therefore be

Verne Technology designed a touch screen control unit that, together with the NEA 415 software specifically designed for the coating industry’s needs, forms a complete digital control system for the management of the powder delivery and recovery process.”

156

summarised as follows:

Figure 1: The touch screen control unit designed by Verne Technology for the management of the powder delivery and recovery process.

- lower powder consumption; - shorter application time; - better quality results and more uniform coating

the other hand, require a continuous compressed air supply and, therefore,

application.

they use transport tubes with an

Flow management

internal diameter of at least 10 mm.

Besides managing the amounts of

Moreover, their limitations in terms

powder to be collected and applied,

of powder capacity and transport

the device enables to calibrate also

distance influence the management

the transport flow pressure, from 0 to

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INNOVATIONS: PRESENT&FUTURE

powder remains in

5 bar, with the same decimal precision. Verne Technology performed some tests by removing the gun’s delivery body, since the nozzle’s indentations could create friction during spraying (Fig. 3). The results showed that it is possible to reach an output of 400 gr/min

the delivery tube.

NEA 415 only exploits the low pressure pulsations within the transport tubes without the need for any auxiliary air supply. It can consistently feed minimum quantities of powders thanks to the management of its parameters with a decimal precision. At a distance of 20 m, the new NEA 415 can feed up to 400 gr/ min, whereas a conventional Venturi system delivers an inconsistent amount of powder.”

The most common solution is an empty feeding operation performed until the gun is completely clean. Verne, however, conceived a powder flow inversion system controlled with one key and able to return the powder

with a pressure of only 0.4 bar. With the integration of the dispenser, the

to its management unit or container, thus enabling to recover most of

pressure reaches the

it. This is a further

value of 1.1 bar.

contribution to

NEA 415 allows

reducing coating

therefore to maintain

costs for applicators.

the same transport

and reach a capacity

Quick colour change operations thanks to the cleaning process with a cyclonic valve

of 400 g/min, in order

The cyclonic valve,

to meet application

already integrated

needs that normally

into the NEA 430

call for a capacity 250

system, is based

g/min at most.

on a fluid-dynamic

pressure by modifying, when required, only the quantity of product to be fed. Indeed, it can deliver very small quantities of product

operating

The integrated powder flow inversion system For the recovery of powders, Verne Technology’s engineers have integrated a

principle. In the NEA 415 device, it was made even more efficient

2 1

with the reduction

Figure 2: A detail of the transport pump unit.

of the passage holes from 12 mm (NEA 430)

transport application widespread in the pharmaceutical and food

to 6 mm (NEA 415). This considerably increases

sectors. All current systems have a collection

the speed of the compressed air jet, allowing to

point A and an exit point B. If the powder

completely clean a NEA 415 system in less than

supply must be interrupted at the end of a

30 seconds, both in the pump body and in the

shift, it can occur that a certain amount of

transport tubes.

ÂŠ Verne Technology

3 1

Figure 3: The spray gun.

In conclusion, both the NEA 430 and NEA 415 systems can be integrated into new or existing application plants for the efficient management of the transport and delivery of powder coatings. They ensure the high flow transport of virgin coatings to and from the powder management unit,

Verne Technology operates in the field

Both the NEA 430 and NEA 415 systems can be integrated into new or existing application plants for the efficient management of the transport and delivery of powder coatings.â&#x20AC;?

of high density, low pressure transport of powders, granules and polymers. It designs and manufactures high-tech transport systems ensuring remarkably higher performance levels compared with the other similar products currently available on the market. The company

the cyclone powder recovery unit, and

is the exclusive owner of international

the dust collector emptying device,

patent applications (PCT) currently not

as well as the smooth feeding and

yet public and therefore not accessible to

application of powder through the

third parties.

coating guns. As mentioned, they both use the dense phase, low pressure (DPLP) technology.

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SPECIAL

BRAND-NEW

new mass finishing system completely

thus, the overall efficiency, fuel consumption

eliminates manual operations.

and noise emissions.

For the efficient surface finishing of

To date the surface finishing of blisks was done manually with grinding disks and

and land-based turbines, Walther Trowal

other manually operated tools. Due to

has redesigned its “CM” vibratory system.

the “human factor” the quality of the final

It ensures that the work pieces receive a

finish could greatly vary between work

uniform, homogeneous high quality finish with

pieces. Frequently, it could even happen

absolutely repeatable results.

that certain surface areas were not

The surface finish of blisks (“Blade Integrated

finished at all.

Disks”) in airplane and other turbines affects to

For the consistent and high quality

a large extent the airflow characteristics and,

finishing of circular high value components

high value work pieces like blisks for airplane

Surface Finishing of Components for the Aerospace Industry: Walther Trowal Cuts Processing Times for Finishing of Blisks From Several Days to A Few Hours

2 1

Figure 2: In the “CM” rotary vibrator work pieces with a diameter of up to 980 mm can be processed. During the finishing process itself the work bowl is covered with a noise absorbing lid.

Walther Trowal redesigned the rotary vibrator “CM” in close cooperation with leading turbine manufacturers to make it more suitable for treating all kinds of turbine components (Fig. 1). The “CM” system allows deburring and general surface improvement of components with diameters of up to 980 mm (Fig. 2). Single work pieces are mounted to the

inner dome of the processing bowl.

Figure 1: The work bowl of the “CM” rotary vibrator. The shown work piece is a dummy.

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The height of the inner dome itself has

SPECIAL

BRAND-NEW

3 1

Figure 3: With a diameter of just 1,450 mm the compact rotary vibrator easily fits into any manufacturing environment.

been drastically shortened (Fig. 3). After grinding media has been filled into the bowl, a vibratory motor causes the complete work bowl to vibrate. This causes a constant “rubbing” of the media against the fixed work piece. Since the “rubbing” action is highly homogeneous, a uniform, even finish on all surface areas of the disk and blades is achieved. After completion of the process the surface roughness readings amount to Ra = 0.2 to 0.4 μm. Starting with an initial surface roughness of Ra = 4 to 5 μm, the desired finishing results are achieved within about five to six hours. Compared to this innovative method the manual finishing of blisks can take several days. Christoph Cruse, sales manager at Walther Trowal, is commenting on the special conditions prevailing in the aerospace industry: “Especially for the production of turbine components any manual manufacturing operations must be viewed with great skepticism, because the quality of the work will vary greatly. With our new finishing machine, we have completely eliminated the vagaries of the human factor. And, we can reduce the finishing times for blisks from several days to just a few hours”. For finishing of blisks Walther Trowal is recommending the special finishing media, type V 2030. This media produces very smooth surface finishes on materials and shapes, which are typical for blisks. Of course, the V 2030 media is globally approved for the aerospace industry. For further information: www.walther-trowal.com

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SPECIAL

BRAND-NEW

Flexible High-Performance Coating Plant for Aluminium Wheels

uperAlloy Manufaktur GmbH

is automatically adapted to suit the

wheels from the pre-treatment line and

in Lossburg has put one of the

downstream process. Pre-heating

supplies them directly to the individual

most flexible coating plants in the

temperatures and cooling sections are

coating areas. The plant concept still

wheel industry into operation (Fig. 1).

also individually adaptable. Thanks to the

has further potential for future coating

The wheel-coating plant makes a

high level of automation, SuperAlloy can

variants, coating patterns and special

large number of coating processes

track the wheels precisely and thus carry

coatings.

possible and is thus equipped not only

out detailed quality assurance checks.

for the present-day requirements of

A special distribution conveyor ensures

For further information:

the market, but also for those of the

the plantâ&#x20AC;&#x2122;s high flexibility. It fetches the

www.rippert.de

forged aluminium wheels coated at SuperAlloy

ÂŠ Rippert

future, too. The

Manufaktur GmbH are destined for exclusive car manufacturers in Europe. The goal of achieving maximum flexibility through a high level of automation of the conveying equipment and robots was implemented perfectly. The flexibility of the wheel plant necessitates the exact definition and planning of the flow of material in order to achieve an optimum mode of operation. To this end, SuperAlloy creates a coating plan each day. The pre-treatment

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Figure 1: SuperAlloy Manufaktur GmbH in Lossburg has put one of the most flexible coating plants in the wheel industry into operation.

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SPECIAL

BRAND-NEW

FREOPUR Polyurea Gel Coats in Series Production he new FreiLacke gel coat based on an aliphatic polyurea system allows a reduction of the coating thickness

in comparison to conventional polyester gel coats. A further advantage is its exceptional UV resistance. The advantages are obvious and they are now being implemented in series production at Liebherr/Lienz (Fig. 1) and Aquaproduction

SAS in France (Fig. 2), amongst others. Due to the very short curing time, very short cycle times can also be achieved during component manufacturing. The application of such materials takes place using 2C highpressure coating lines and special moulds. An investment in production processes, coating line technology and mould construction is therefore required. However, by applying the coating system as a liquid component, additional interesting possibilities can be implemented. In both

Figure 2: Polyurea gel coats for the production of shower trays at Aquaproduction SAS in France.

cases, the process is implemented specifically

2 1

due to its versatility with regard to design, the profitability of the production process as well as the variety of colour shades. The combinations and possibilities of composites are endless and, due to their outstanding properties, their range of application is enormous. Thanks to FreiLacke’s many years of experience in the area of Durelastic, the results can be used during the development of new application solutions. Many other interesting applications are possible and are pursued intensively in the Sales and Development departments. More system coatings and application-solutions from on source: PaintExpo hall 1, booth 1420.

Figure 1: Use for freezers at Liebherr/Lienz.

For further information: www.freilacke.com

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INNOVATIONS: PRESENT&FUTURE

NitroBoxSpray® Revolutionises the Nitrogen Coating Concept: Better Performance at Low Costs Both In-House and On Site Ottavio Milli Eurosider, Grosseto, Italy

info@eurosider.com

urosider, an Italian company

amount of nitrogen necessary for the

Benefits of NitroBoxSpray®

based in Grosseto, designs

consumption required by spray guns.

- Overspray reduction;

and builds coating systems

This helps eliminate any pressure

- better spreading of the film applied;

using nitrogen as the paint carrier

drops due to the disparity in the

- improved performance and,

instead of compressed air. This

production of nitrogen compared

therefore, coating results;

ensures greater effectiveness

with the actual application needs.

and better application yield for

Thanks to a Eurosider patent,

- reduction of the spray paint booth’s maintenance and cleaning times;

any type of coating system. For

- reduction of investment

several years now, Eurosider has

costs;

been providing the market with its devices NitroThermSpray® (Fig. 1), internationally patented and suitable for feeding liquid coatings, and Polifluid®, designed for thermosetting powder coatings (Fig. 2) and already described on the ipcm® magazine. The latest innovation developed by Eurosider is the NitroBoxSpray

system (ref. Opening photo), which represents the technological evolution of NitroThermSpray®. This compact and economical nitrogen production machine is

- reduction of coating

Eurosider, an Italian company based in Grosseto, designs and builds coating systems using nitrogen as the paint carrier instead of compressed air. This ensures greater effectiveness and better application yield for any type of coating system. For several years now, Eurosider has been providing the market with its devices NitroThermSpray®, internationally patented and suitable for feeding liquid coatings, and Polifluid®, designed for thermosetting powder coatings.”

consumption by 20 to 50%.

Overspray reduction At any given pressure, compressed air moves at a velocity of nitrogen of 7.2 m per second, while nitrogen at 13.7 m per second, i.e. almost double. This results in a lower pushing pressure, so much so that the pressure values are halved in the atomisation phase. This,

installed between the compressor

in turn, greatly reduces

and the coating application point and it can be integrated directly

the absence of tanks simplifies

overspray and, therefore, any risk

into the spray paint booth or

the management, control, and

of contamination of the coated

placed in its vicinity, depending

maintenance of this system, thus

surface due to paint rebound

on the space available. One of the

making it particularly suitable for

and of any coating emission. It

most innovative characteristics of

robotised coating lines such as, for

also facilitates the maintenance

this new system is the absence of

example, cupboard door coating flat

and cleaning operations of the

tanks, since it produces the exact

lines.

booths.

Opening photo: The new NitroBoxSpray® system designed by Eurosider.

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165

Thanks to a Eurosider patent, the absence of tanks simplifies the management, control, and maintenance of this system, thus making it particularly suitable for robotised coating lines such as, for example, cupboard door coating flat lines.”

Better spreading of the film applied Used to transport paint, compressed air can create charges within the coating layer that can compromise its spreading quality and uniformity. Used as a carrier, nitrogen prevents this from happening. An additional advantage is the elimination of micro bubbles formed on surfaces due to the impact of the air with the relative humidity present on the substrate. With varying temperatures, this can cause spreading problems that, on the other hand, are eliminated by nitrogen, which ensures better adhesion and greater durability of coatings. NitroBoxSpray® also enables to adjust the temperature of nitrogen and, therefore, of the coating itself, thus increasing or decreasing its density. Nitrogen is kept at a constant temperature and it ensures that also the paint maintains consistent thermal conditions, regardless of the external temperature. With automatic coating systems, keeping the viscosity parameter constant also ensures consistent and uniform film thicknesses.

166

Figure 1: The NitroThermSpray® device, suitable for the application of liquid coatings.

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INNOVATIONS: PRESENT&FUTURE

The evolution of the membrane technology NitroThermSpray® is based on the membrane separation technology: it exploits the selective permeability of membranes made of hollow fibre polymers to separate gaseous nitrogen from air. In order to design the new NitroBoxSpray® system, the R&D centre has developed a membrane project that is now one of the numerous Eurosider patents: the new device is equipped with membranes able to guarantee a fibre service life of 20 years. The second significant advantage of the new system is an airnitrogen ratio equal to 2 (i.e. 2 m3 of air needed to produce 1 Nm3 of nitrogen), compared with the previous device with a ratio of 4. This evolution is the result of the greater efficiency of membranes, which separate a higher quantity of nitrogen in relation to the guns’ consumption and therefore do not require any tank.

Further advantages of NitroBoxSpray® Eurosider has also considered the outdoor application needs of construction sites, shipyards, refineries, pipeline maintenance specialists, and so on. That is why it has equipped NitroBoxSpray® with wheels for moving a fully-equipped machine in any place, making the application operations easier even in the most severe and harsh conditions. Another benefit is the possibility of working with hot nitrogen, which reduces the coating drying time by 50%. If high thicknesses are applied, it also reduces

NitroBoxSpray® enables to adjust the temperature of nitrogen and, therefore, of the coating itself, thus increasing or decreasing its density. Nitrogen is kept at a constant temperature and it ensures that also the paint maintains consistent thermal conditions, regardless of the external temperature. With automatic coating systems, keeping the viscosity parameter constant also ensures consistent and uniform film thicknesses.”

Eurosider has also considered the outdoor application needs of construction sites, shipyards, refineries, pipeline maintenance specialists, and so on. That is why it has equipped NitroBoxSpray® with wheels for moving a fully-equipped machine in any place, making the application operations easier even in the most severe and harsh conditions.”

Reduction of investment costs As mentioned, NitroBoxSpray® represents the evolution of the nitrogen production plant concept originally developed with NitroThermSpray®. Compared to the latter, the former is smaller, it is set up to produce the exact amount of nitrogen required by one or two spray guns, and it is much more economical. It has been designed for installation in medium and small companies

2 1

that cannot make large investments,

Figure 2: Polifluid by Eurosider optimizes powder feeding during application with the use of nitrogen.

operating in the most diverse sectors: automotive, general industry, aerospace, nautical, architecture, interior design, etc. – that is, wherever there is a need for coating operations.

dripping and the orange peel effect, thus

coating gun or robot. The peculiarities

becoming ideal for coating the walls of

of thermo-conditioned tubes ensure

ships and bridges.

constant temperatures and therefore

Safety regulations

The NitroBoxSpray device can be

consistent paint viscosity when the

Eurosider produces in compliance

connected to hoses with a maximum

environmental temperature varies. This

with all safety regulations and their

length of 30 m, patented for the transport

system is Atex certified and patented in

evolution, in particular those related to

of ionised nitrogen from the plant to the

Europe.

the ISO 13849-1 standard.

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+2.222%

Opening photo: Diseños Y Decorados Ceramicos SL (Navalcarnero, Spain) specialises in the artistic decoration of ceramic and glass objects.

FOCUS ON TECHNOLOGY

A New Automatic Coating Line to Increase the Production Capacity of a Glass Objects’ Manufacturer: the Positive Result of the Industry Teaming Up with Craftsmanship Barbara Pennati ipcm®

some companies have chosen to employ technologically advanced

“Much of Diseños Y Decorados Ceramicos’ work is still done manually,

processes while maintaining an essentially artisanal approach. These

including loading and unloading. We believe in the importance of our

include Diseños Y Decorados Ceramicos SL (Navalcarnero, Spain),

operators’ control of all production phases,” explains general manager

n most industrial sectors, the general trend of the last few years has

established in 1946. Now managed by the third generation of the

been to automate processes as much as possible by implementing

Nogales family, the company has 62 employees and specialises in the

increasingly Industry 4.0-oriented advanced technologies. However,

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artistic decoration of ceramic and glass objects (ref. Opening photo).

FOCUS ON TECHNOLOGY

Figure 1: Diseños Y Decorados Ceramicos’ products require mostly manual and artisanal operations.

higher production rates. It became necessary to install a second automatic coating line, which now operates together with the first one,

installed eight years ago and also supplied

Cristina Nogales. Although the company philosophy and the peculiarities of Diseños Y

by Cabycal,” says Cristina. The new coating line is

Decorados Ceramicos’ products call for mostly

7.5 m long and it is equipped with a 45 m

manual operations, especially due to

Diseños Y Decorados Ceramicos deals, above all, with the artistic decoration of porcelain and glass products for the hotel, cosmetic, and promotional sectors. Precisely their intention to conquer the latter led the company to install a new coating line that could increase the productivity. That is why they turned to Cabycal, a Valencia-based company specialising in the construction of industrial coating systems.”

the artistic meticulousness required, the firm equipped itself with a new coating

“The second line is symmetrical to

plant that combines high-performance

the first one. The only change made

technology with craftsmanship (Fig. 1).

was the replacement of the old line’s

“We deal above all with the artistic

conveyor with the type used for the

decoration of porcelain and glass

new one, in order to achieve the same

products for the hotel, cosmetic, and

production level and the same timing

promotional sectors. Precisely our

on both plants,” states Cabycal’s

intention to conquer the latter led

project engineer Sergio Mateo. “The

us to install a new coating line that could increase our productivity,” states Cristina. “That is why we turned to Cabycal, a Valencia-based company

system is equipped with two coating

2 1

booths featuring only Atex-certified

Figure 2: Glasses are decorated by silk-screen printing or automatic liquid coating.

components; the first one has three guns and the second one two (Fig. 4). They are followed by a polymerisation

specialising in the construction of industrial coating systems with which we had

long SPINDLE type conveyor featuring 392

oven with a natural gas supply and an air-vein

already collaborated.”

pinion spindles and with a motorised rotator

burner that maintains a temperature of 200 °C

to ensure that all

“At the beginning, we mainly decorated

surfaces are covered.

ceramics for the contract sector. Over time, we

The chamber’s

have expanded to other industries, such as the

pre-filtration system

cosmetic and promotional (product branding)

ensures that the

ones, and we started decorating also glass

coating application

by silk-screen printing or automatic liquid

takes place in the best

coating (Fig. 2),” states Cristina from Diseños

cleanliness conditions

Y Decorados Ceramicos SL. “This choice has

(Fig. 3).

The new coating line

in the chamber

enabled us not only to offer both standard and customised decoration options, but also to establish ourselves in the European and Eastern markets, for example in India.” “However, the promotional sector required

Figure 3: Cabycal’s new coating line with a SPINDLE type conveyor.

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171

4 1

Figure 4: The automatic application of liquid coatings provided by Pinturas Benicarlò (Grupo Ferro SL).

The coatings applied

Conclusions

are water-based two-

“Glass requires a lot of attention during

component products

application, mainly due to adhesion issues.

specifically formulated for

It is always necessary to make a correct

glass. “Our cycle includes

assessment of the quantity of product to be

a curing stage at 200 °C

applied and of the right curing temperature.

for about 20 minutes. We

A more limited range of colours can be used

use coatings supplied by

on glass than on porcelain, and some of

Pinturas Benicarlò (Grupo

them, such as gold and silver, require a very

Ferro SL). Although they are

precise manual decorative process,” explains

more difficult to apply than

Cristina. “Although glass is a difficult-to-treat

the solvent-based ones, we

material requiring artisanal skills, the adoption

chose to use water-based

of a flexible and robust advanced system

paints for environmental

that can work uninterruptedly and integrates

reasons and for better

perfectly with our manual processes proved

waste management,” states

to be the optimal solution for us.”

for 20 minutes. Dry filtration systems with

Cristina. “We also ran some tests, which showed

“We relied on Cabycal because we already

the Edrizzi technology have been installed

that the products treated with these coatings

knew their know-how and product quality

in the booths for overspray collection and

and polymerised with the cycle chosen by us can

level. In terms of capacity at the exit of the

environmental protection purposes (Fig. 5).”

withstand up to 500 washes.”

ovens, the new line, which is managed by

Diseños Y Decorados Ceramicos can therefore

“We use organic colours available in different

one operator, enables us to decorate and

count on four decoration lines, of which two

shades. We usually apply more than one layer,

coat around 80,000 products a day.

devoted to the automatic coating of glass

depending on the required effect. For one of

This investment has allowed us not only

products, one for porcelain, and a manual

our treatments, for instance, we coat the inside

to increase production and establish

silk-screen printing one, and on four ovens, of

of a glass with an aluminium-effect coating and

ourselves in the promotional sector, which

which three for glass and one for porcelain.

the outside with more evocative colours, such as

was our goal, but also to spread Diseños

The glass processing performed requires a

pink or light blue; if you look inside it, it feels like

Y Decorados Ceramicos’ craftsmanship to

pre-treatment stage that is usually entrusted to

you are drinking from an aluminium object, but it

a variety of sectors and markets,” states

manufacturers. “We receive already treated and

is actually glass,” says Cristina.

cleaned parts. Only in some cases, when we notice that the paint has not adhered perfectly, we perform a glass annealing process from 450 to 600 °C, depending on the product,” says Cristina.

The new coating line is 7.5 m long and it is equipped with a 45 m long SPINDLE type conveyor featuring 392 pinion spindles and with a motorised rotator in the chamber to ensure that all surfaces are covered. The chamber’s prefiltration system ensures that the coating application takes place in the best cleanliness conditions.”

172

5 1

Figure 5: The line is equipped with dry filtration systems with the Edrizzi® technology.

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SPECIAL

BRAND-NEW

PG is introducing the MeasureColor Mobile™ tool, an innovative and accurate colour

customers the freedom to work with experienced PPG representatives to compare colour standards and choose

platform that combines a colour-

the best colours for their specific job.

matching app with a handheld scanning

The mobile tool reflects PPG’s long-

device to immediately identify colour

standing commitment to customer

matches (Fig. 1). Within seconds, the

service and underscores its pledge

technology links customers to more

to provide customers with innovative

than 2,500 commonly specified colours

coatings solutions that meet specific

in PPG’s industrial powder coatings

customer needs.

colour library within ΔE 0.5.

Through MeasureColor Mobile, PPG’s

The easy-to-use device is about the

customers now have a fast and accurate

same size as a flashlight battery.

way to keep their colour-matching

Customers can place it on nearly any

projects moving ahead.

surface to begin the colour-matching process, including metal, plastic, wood

and even soft surfaces (Fig. 2). Within seconds, the device interprets

Figure 1: PPG is introducing the MeasureColor Mobile™ tool, a colour platform that combines a colour-matching app with a handheld scanning device to identify colour matches.

the colour data, calculates any colour differences and then, through the PPG MeasureColor Mobile app, sends an smartphone or tablet. This technology is cloud-based, eliminating costly and time-intensive

accurate PPG colour match to the user’s

lab work. But the device does more than match colours. It also provides customers with important ordering information, such as the colour name, product code, gloss range, resin chemistry, and if the product is made to stock based on the customer’s location. As a result, customers can order the PPG powder coatings they need right on the spot, saving them time and money. In addition, the search results give PPG

Figure 2: Customers can place it on nearly any surface to begin the colour-matching process, including metal, plastic, wood and even soft surfaces.

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MeasureColor Mobile and the MeasureColor Logo are trademarks of Colorware USA, Inc.

For further information: www.ppg.com www.measurecolormobile.com

SPECIAL

BRAND-NEW

Two Further Shareholders: IIoT Platform ADAMOS is Growing

he joint venture for the open digital

way, we are advancing with our customers in

providing the interface with the machinery

IIoT platform ADAMOS (ADAptive

the digital world with great momentum.”

operators are developed using ADAMOS as a

Manufacturing Open Solutions) has

With sales revenues of EUR 1.36 billion,

basis (Fig. 1).

Engel Austria is one of the leading plastics

Austria GmbH and the KARL MAYER Group.

processing machine manufacturers and

The Dürr Group offers two digital marketplaces

This strategic alliance for the Industrial

the global market leader in injection-mold

LOXEO (for Dürr and Schenk customers) and

Internet of Things (IIoT) was established by

equipment. KARL MAYER is an innovative

tapio (for HOMAG customers). Using LOXEO

Dürr, DMG MORI, Software AG, ZEISS and ASM

market leader in textile machine building

and tapio, plant operators can evaluate data,

PT and is available around the world with 200

and offers solutions for warp knitting and

map their production activities digitally and

experts.

warp preparation for weaving as well as for

purchase digital services and apps, e.g. for

Ralf W. Dieter, CEO of Dürr AG: “With the

technical textiles.

predictive maintenance, adaptive production

accession of these two new mechanical

All seven companies are contributing

planning or the management of operating

engineering companies, we are making further

extensive industry knowledge and innovative

materials. This helps to optimize production

progress in our efforts to establish ADAMOS

IT expertise to ADAMOS. The IIoT platform

and maintenance.

as an industry standard. Together, we have

is comparable to the operating system of

an installed base of several hundreds of

a computer and collects large volumes

For further information:

thousands of machines and systems. In this

of production data. Digital marketplaces

www.durr.com

gained two additional shareholders: Engel

Figure 1: The structure of ADAMOS platform.

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SPECIAL

BRAND-NEW

New Coating Solutions: Standard Frames

ssuming that it is possible to

This new hanging system features a

dimensions, such as handle height,

improve a company’s operations

central supporting pole, called “column”,

hanging height, and hook distance and

through smart hanging and

number.

called “comb” (Fig. 1). There are two

The columns are combined with

working in the sector since 1990, has

types of columns, very similar to each

standard crossbeams, already in

always been committed to providing

other but differing in their robustness:

stock or customisable on request.

coating users with innovative and

the light version P20 is suitable for use

Any type of comb can be integrated,

versatile solutions. At the PaintExpo 2018

in small plants (up to 2 metres in height),

from simple rods with welded slings to

exhibition (Hall 2, booth 2520), the firm

whereas the P25 version is ideal when the

sheet bars with clips, or even complex

will present a preview of its new range

coating height exceeds 2 metres and the

hanging systems for special structures.

of modular frames, a solution conceived,

size and volume of parts call for a robust

All components used have been

field-tested, and improved over the years.

frame. Both versions can have custom

standardised. This ensures significantly

and a horizontal bar with welded hooks,

masking operations, Rostirolla S.r.l,

Figure 1: The hanging system features a central supporting pole, called “column”, and a horizontal bar with welded hooks, called “comb”.

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SPECIAL

shorter delivery times and streamlines the design and

ÂŠ Rostirolla

BRAND-NEW

difficult to store on pallets. However, columns and combs

sampling phases. Moreover,

can be disassembled, placed

since the components are

in small baskets, and stored on

already in stock, the costs for

shelves (Fig. 3). Stripping costs

small quantities are also greatly

are also significantly reduced

reduced (Fig. 2).

because it is possible to strip

The joint between the comb

the comb only, whereas the

and the column has been

column can be used for many

specially designed so that each

more coating cycles (a few

part remains clean despite the

users have gone beyond 100

numerous layers of paint that

cycles). Also in this case, the

accumulate cycle after cycle. The

reduced storage volumes help

system has already been tested

lower transport costs when

by numerous coaters and coating

paint stripping is entrusted to

contractors. The number of cycles

external companies. Since it

guaranteed before the parts are

has built special moulds and it

glued depends on many factors,

produces all components in-

first of all the customersâ&#x20AC;&#x2122; needs,

house, Rostirolla has managed

but in some cases several tens

to reduce its production costs,

of processing cycles have been

thus making these frames

achieved. A further advantage of this hanging system is perceived during storage. Welded frames

economical product.

Figure 2: All components have been standardised to ensure significantly shorter delivery times and streamlines the design and sampling phases.

For further information: www.rostirolla.it ÂŠ Rostirolla

are notoriously voluminous and

a versatile, universal and 2 1

3 1

Figure 3: Stripped and stored combs.

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177

SPECIAL

BRAND-NEW

Paintexpo: Eisenmann Presents Innovative Solutions for the Paint Shop of the Future

Efficient atomizer technology, innovative paint

mm, which enable precise adaptation to the

in Karlsruhe, Germany, the painting

supply solutions and modular high-pressure

workpiece, are also retained. The VarioBell v.3 is

system specialist Eisenmann will be

pumps for the supply of materials are shown

supplemented by an integrated mixer.

presented under the motto “Paint Shop

by Eisenmann, as well as the possibility of

This reduces the curing distance and simplifies

4.0. Digital – smart – efficient”. The focus is

achieving improved quality management in

the rinsing process.

on developments for application and plant

the coating process by means of a thermal

At PaintExpo, Eisenmann presents itself as

technology for surface treatment in various

imaging camera. In addition to the well-

an experienced system supplier offering

industries.

established VarioBell v.2 high-rotation

comprehensive solutions and services in all

In hall 1, booth 1220, Eisenmann presents

atomizer, which can be used for all component

areas of surface treatment. The portfolio ranges

its “Smart & Digital Solutions” for the Paint

requirements – from complex cavities and

far beyond high-quality coating and painting

Shop of the future. One of the highlights

undercuts to wide surface coatings - due

systems: from reliable and flexible conveyor

is the new era of the E-MES production

to its compact design, the newly developed

technology such as Moveable Hoist and

management system, which allows for

VarioBell v.3 opens up further possibilities

heavy-duty Power & Free, to the uncomplicated

consistent plant transparency and forward-

(Fig. 1). Combined with the dosing and

paint separation system E-Cube, to

looking intelligence in the paint shop. In

potential separation system VarioCharger,

comprehensive service and operator models.

addition, the spotlight will also be on “Smart

it enables the application of 2-component

Eisenmann at PaintExpo 2018 in Karlsruhe,

Engineering & Service Solutions”, such as

water-based varnish under high voltage.

Germany: Hall 1, Booth 1220.

the E-PASS VCI, which enables virtual plant

Direct charging at the atomizer tip leads to

commissioning on the Digital Twin. Remote

significantly higher application efficiency.

For further information:

support solutions will also be discussed.

The variable spray jet widths from 50 to 350

www.eisenmann.com

rom April 17 to 20 at PaintExpo 2018

Figure 1: VarioBell v.3 from Eisenmann enables the application of 2-component water-based coatings under high voltage.

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SPECIAL

BRAND-NEW

he German manufacturer Jürgen Emptmeyer GmbH, expert for

Emptmeyer Launches New Products and Presents its Custom Made Solutions hanging and masking solutions for

industrial coating, presents its custom made solutions to the public during the PaintExpo (Fig. 1). Reliable hanging solutions, broad expertise and quick developments are of top priority when Jürgen Emptmeyer GmbH is involved in any project. Thereby the company makes sure to offer its customers the most efficient solution for each individual requirements. For further information: www.emptmeyer.de

Figure 1: Jürgen Emptmeyer GmbH will present its custom made solutions at PaintExpo.

New Back-Pressure Regulator

he new 3:1 back-pressure regulator “TimECO” (Fig. 1) was developed for the paint industry. Since the consumption rates of the paint spray guns are not constant in time, undesired pressure

fluctuations in the ring circuit system are possible. Back-pressure regulators (BPR) are intended to solve this problem. © Timmer GmbH

This is achieved through automatic control of the flow cross-section by the pneumatic BPR. Strong shear stresses in conventional BPRs that can damage the paint are well known. In the new BPR, the fluid is guided in a straight line so that dangerous shear stresses are hardly possible. To this effect, an innovative double diaphragm system was developed. The maximum flow defined by the manufacturer is 40 l/min, whereby the fluid pressure must not exceed 25 bar.

For further information: www.timmer-pumps.com

Figure 1: Back-pressure regulator from Timmer GmbH.

international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

179

SPECIAL

BRAND-NEW

Deurotech Group Acquires Majority Stake in Exhaust Air Specialist Airprotech Srl

its market position in the field of exhaust

Wessel-Umwelttechnik, striving to

2018, Deurotech Group

air purification (Fig. 1) and decisively

promote the strategic expansion of the

acquires a majority stake in the

expands its portfolio in the field of

product sector exhaust air purification -

Italian exhaust air specialist Airprotech

environmental technologies.

in particular the biological and thermal

Srl, located in Magenta, Italy. The founding

The investment in Airprotech

exhaust air purification processes. In

Family Gatti remains with a minority stake.

complements the already existing

addition to innovative technologies and

With this decision, the group strengthens

product program of their subsidiary

qualified personnel, positive synergies

ÂŠ Airprotech

ith effect from February 8th,

Figure 1: A plant by Airprotech.

180

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

SPECIAL

BRAND-NEW

in procurement, R & D as well as in

Wessel-Umwelttechnik offer coordinated

Wessel-Umwelttechnik is a

customer service are expected.

process technology in surface converting

professional partner in all questions

Airprotech and Wessel-Umwelttechnik

from a single source: impregnation

of exhaust air purification and heat

have a high level of know-how

and coating lines, systems for resin

recovery. The company provides

and innovation potential, which

preparation as well as exhaust air

turn-key installations for various

offer opportunities with regard to

purification and energy recovery.

environmental tasks. An extensive product range allows tailor-made system

diversification and global growth. In the light of these market opportunities,

Airprotech is a leading company

technology. In addition to cost-effective

the acquisition of Airprotech is a first

specialized in designing, manufacturing

delivery and installation, the companyÂ´s

step for a further significant expansion

in its own facilities and supplying

main focus is on optimal economic

of the business unit environmental

turn-key plants for the purification

operation of the system.

technologies.

of polluted gas emissions, based on

AirprotechÂ´s proven management team

reliable and modern technologies,

For further information:

as well as the location remain the same.

deriving from more than 25 years of

www.airprotech.eu

experience applied to different product Deurotech Group is a group of

sectors. International customers

businesses specializing in the wood-

from the chemical, pharmaceutical,

based panels and paper industry.

petrochemical, print, paint industry and

The machinery and plant engineers

many other fields are supplied with

Vits Technology, IFA Technology and

custom-designed turn-key solutions.

9 - 13/10/2018 Macchine utensili a asportazione e deformazione, robot, automazione, digital manufacturing, tecnologie ausiliarie, tecnologie abilitanti. Metal cutting and metal forming machines, robots, automation, digital manufacturing, auxiliary technologies, enabling technologies.

THE DIGITAL ERA OF MACHINE TOOLS bimu.it

UCIMU-SISTEMI PER PRODURRE

BRAND-NEW

The Combination of a Self-Healing Polymer and Graphene Oxide Could Be the Future of Scratch Resistant Coatings combines a soft, self-healing polymer with a tough layer of

graphene oxide could one day form the

Figure 1: A bio-inspired material that combines a selfhealing polymer with a layer of graphene oxide could form the basis of scratch resistant coatings.

bio-inspired material that

basis of new, ultra-tough scratch resistant coatings (Fig. 1). The researchers who developed the material say it combines the best properties of skin – which can heal itself from the inside out – with tooth enamel, which is hard but cannot self-repair (Fig. 2). ‘For a material to self-heal, it generally needs to be a highly dynamic polymer

network,’ says Ming Yang from Harbin Institute of Technology in China. ‘Unfortunately, this also means self-

When tested in isolation, neither layer on its

to initiate the healing process. This may be

healing coatings are typically made of soft

own was able to fully recover after scratching.

acceptable for indoor use but is unwanted

materials.’

But when the soft polymer and graphene

for outdoor applications or for electronic

Their material does feature a soft self-

oxide sheets were integrated correctly, the

devices,’ Yang explains. He adds that the

healing layer, a mixture of tannic acid

resulting skin-like hybrid could self-heal.

group are also working on versions of the

and polyvinylalcohol (PVA) which form

Yang suggests the material could be

coating that self-heal in response to light or

a dynamic hydrogen-bonded network.

used to make anti-scratch coatings or

heat.

But this is reinforced by an outer PVA

even coatings for medical devices, as the

Wayne Hayes, a polymer chemist at the

layer containing nanosheets of graphene

components are biocompatible. But there

University of Reading in the UK, says the

oxide – a tough material that gives greater

are still hurdles to overcome. ‘The current

use of relatively low-cost components such

scratch resistance. This is similar, Yang

coating system uses water as a stimulus

as PVA is ‘very impressive’. ‘It’s the way this material is processed, the

where hardened outer cells protect the

careful layer-by-layer assembly

soft, living tissue beneath, which can repair damage. ‘The more dynamic sublayer provides additional polymers to the top layer, while

says, to the structure of the skin epidermis,

approach,’ he says. ‘What will be interesting to see is how well they can actually use this method to produce very precise structures. I think that

the top hard layer behaves like a barrier to trap these diffusing polymers,’ he says. ‘Graphene oxide is, however, much harder than the plate-like cells in skin, so we get the hard surface.’

182

2 1

Figure 2: Scanning electron microscopy images of the hierarchical coating (right) shows that it mimics the structure of human skin (left).

N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine

will be the next challenge.’ For further information: www.chemistryworld.com

BRAND-NEW

Cabycal Provides Gestamp with an Automated Passivation Plant for Aluminium Parts

abycal has designed, built and

inside a recirculating convection oven

installed a passivation system

heated with a gas burner. The parts are

for aluminium components for

handled by three automatic bridge cranes,

Gestamp’s plant of Newton Aycliffe (UK –

a Power & Free conveyor, and two transfer

Fig. 1). The installation started at the end of

systems that move the workpieces from the

2017 and the plant will become operational

conveyor to a bridge crane and vice versa.

in the coming weeks.

Cabycal had already supplied Gestamp with

The workpiece pre-treatment is carried out

three cataphoresis plants for its production

in nine tanks with the following process:

sites in Zaragoza (Spain), Wroclaw (Poland),

degreasing, rinsing with industrial water, acid

and Chattanooga (USA).

bath for the passivation phase, and rinsing with demineralised water. After immersion

For further information:

in the tanks, automatic drying takes place

www.cabycal.com

Figure 1: The passivation system for aluminium components built by Cabycal for Gestamp’s plant of Newton Aycliﬀe (UK).

300 scenari per superfici perfette. SurfaceTechnology GERMANY 5 – 7 giugno 2018 Stoccarda ▪ Germania surface-technology-germany.com

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STANDARD & LEGISLATION

What Changes with the ISO 9001:2015 Quality Certification? Fulvio and Marco Zocco Zeta Due Quality, Vimercate (Monza e Brianza) - Italy

fulvio.zocco@zetaduequality.it - marco.zocco@zetaduequality.it

nyone who has heard of quality

Therefore, all the previously certified

management system of an organisation is

certifications, whether because their

companies as well as those currently getting

based. A company should base its activities

company is certified or because

certified will have to update their systems.

on an organisational model in order to

they have worked with companies that

Here below, you will find the main changes

identify goals and possible risks. The

are, wonders if investing in them is really

in the standard.

elements that can positively or negatively

useful or just a cost incurred due to market

affect such objectives should be assessed.

processes. The legislation has recently

Context analysis and risk-based thinking

changed: the ISO 9001:2015 certification

Context analysis is a crucial aspect of the

response to the choices related to the

can be obtained by September 2018.

new standard, on which the whole quality

structure selected. Based on ISO 9001:2015,

impositions, resulting in rigid business

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Context analysis involves the assessment of “organisational” risks: it represents a

STANDARD & LEGISLATION

Defining the context in which a company operates

The legislation has recently changed: the ISO 9001:2015 certification can be obtained by September 2018. Therefore, all the previously certified companies as well as those currently getting certified will have to update their systems.”

risks are a part of a process-based approach and they result in the

This issue can be understood better through a few definitions:

need for preventive actions. Risk-based thinking is the key principle of the whole standard: a company should plan its processes on the basis of its risk identification and assessment. What are these risks? The elements, factors, and situations that can

Risks

The effects of uncertainty on the company’s objectives

Risk management

Coordinated activities to lead and monitor an organisation with regard to risk

Context identification

Identification of the external and internal parameters to be taken into consideration with regard to risk management and to the determination of its scope of application and risk criteria

have a more or less important impact on the achievement of the defined objectives. A company should assess the severity of these risks and their effect with analyses supported by data; it should also implement appropriate actions to minimise the likelihood of them occurring and the damage they could cause to the organisation. To better clarify the concept of risk, let us take the example of an Italian company operating in the luxury good sector: it buys

According to the definition of the ISO 31000:2010 standard, the risk

its machines abroad to save money, but it does not analyse the

management reference structure it is the set of elements that provide

maintenance-related risks deriving from the fact that its supplier

the fundamental bases and the organisational aspects needed to

offers no technical assistance in Italy, and it must intervene from

plan, implement, review and continuously monitor risk management

abroad with significant costs and times. In order to minimise risk,

throughout a company. Understanding the organisation and its context

the company should consider these factors during the purchase

is the first step in the design of a quality system.

phase and analyse the actual downtime risk, the possibility to perform an ordinary maintenance intervention in-house, the

The external context

chance that the supplier will soon have a technical assistance

The external context is the external environment in which the company

office in Italy, etc.

operates. This includes the stakeholders’ objectives and concerns. What

This approach does not mean to remove all potential dangers from

are these stakeholders? They are people or organisations that have the

sight or have a cumbersome decision-making process: it should

ability to influence, be influenced, or perceive any company activity or

help the management analyse all the risks present in its operational,

decision as an influencing factor (Table 1).

commercial, strategic, etc. activities. Sich risk analysis and assessment enables to determine in what circumstances and ways damage can occur to the company and to identify the methods for coping with it. The FMEA technique has always been used in the quality management field. It is based on the analysis of the modalities and effects of possible failures – in other words, risk analysis. This technique can be applied to products, services and processes and requires the calculation of a risk index based on the probability of an event occurring in relation to its gravity. If the resulting detectability value exceeds a defined level, a corrective action should be planned and regular checks on its results should be performed. Risk management is required based on the following requirements: • Quality management systems and processes; • Customer focus; • After-sales activities.

The FMEA technique has always been used in the quality management field. It is based on the analysis of the modalities and effects of possible failures – in other words, risk analysis. This technique can be applied to products, services and processes and requires the calculation of a risk index based on the probability of an event occurring in relation to its gravity. If the resulting detectability value exceeds a defined level, a corrective action should be planned and regular checks on its results should be performed.” international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50

185

Table 1: Examples of main stakeholders.

MAIN STAKEHOLDERS

REQUIREMENTS

Company’s owners

• profit generation • economic-financial sustainability • compliance with applicable laws • operational continuity

Customers/clients (public administrations, private companies, private citizens)

• low prices • compliance with product delivery times • products made as per specifications • compliance with environmental and safety laws

Professionals appointed by the clients (designers, construction managers)

• products made as per specifications • compliance with the project • use of suitable materials • compliance with environmental and safety laws

Citizens of the area • no atmospheric and water pollution affected by the company’s • no waste or polluting substances activities released • minimised noise Company’s staff

“Critical” suppliers (subcontractors, maintenance workshops, technical-environmental consultants)

• adequate remuneration • compliance with the employment contract • supply of safe and good-quality clothing, PPE and equipment • good work organisation • possibility of dialogue with the management • regular payments • clear instructions about the services requested • continuity in orders

The processes and activities carried out by a company and the risks it faces depend on the context in which it operates. The Paragraph 4.1 of the standard involves understanding an organisation and its context and requires the company itself to identify the internal and external factors that are relevant for its purposes and strategy because they can influence the ability of its quality management system to achieve the desired results. The standard does not define a method of analysis, but every action should be documented.” The credibility, trust and value of an organisation are continuously influenced by its lack of recognition of opportunities to achieve its strategic, planning and business objectives. The analysis of the internal context should take into account at least as follows: • the set of rules (laws, regulations, etc.) governing the management of the company; • the organisational structure, roles and responsibilities; • policies and objectives as well as the strategies implemented to achieve them; • capacity and agreements in terms of resources and knowledge; • relations with the internal stakeholders; • the company culture; • systems, information flows and decision-making processes; • rules, guidelines and models adopted by the organisation; • the nature and extent of contractual relations.

Risks arising from customers In its risk analysis, a company should consider the context related to the

Let us consider customer-defined acceptance criteria, which are often

whole organisation and assess, in particular, the requirements arising

neglected or examined very superficially by both parties. Precise

from the stakeholders’ perception and from any other aspect concerning

customers will identify all defects and limits of acceptability, whereas

the management of a risk.

others will neglect this aspect and, in case of any problems, they will try to

The internal context The internal context is the internal environment in which the company operates trying to achieve its objectives. Anything that can influence the way it handles risk should be considered as a part of its internal context.

prove they are right (and not to pay) in every way. This leads us to some conclusions: • with precise customers, who clearly define what they want, the risk of making mistakes is low; • with more superficial customers, the risk not to meet their requirements is high. This is a risk analysis – not very detailed, but still a risk analysis! In this

As mentioned in the standard, it should be considered that:

case, without any risk analysis, a production process could turn out to be

• risk management takes place in the context of the organisation’s

ineffective due to the lack of well-defined requirements; such inefficiency

objectives; • the objectives and criteria of a specific project, process or activity should

would not depend on the process itself, but rather on the customer. For some clients, a risk analysis should be performed to understand how

be considered with respect to the objectives of the organisation as a

to minimise error: ultimately, this is one of the suggestions of the ISO

whole.

9001:2015 standard.

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www.feitintas.com.br @/feitintas

Paints, Varnishes and

/feitintasbrasil