ipcm n. 43 Magazine – January/February 2017 – English Version by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

ISSN 2280-6083

ipcm digital on

www.myipcm.com 2017

8th Year - Bimonthly N° 43 - JANUARY/FEBRUARY

D U R ATA E D E S T E T I C A

DURABILITY & AESTHETICS

R I C E R C A E I N N O VA Z I O N E R E S E A R C H & I N N O VAT I O N

AMBIENTE

ENVIRONMENT

RISPOSTE ANSWERS

Q U A L I T À _ P R I O R I T À A S S O L U TA

Zaniolo CdA - 1.17

Q U A L I T Y_ A S

ABSOLUTE PRIORITY

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Three letters spelling Advantage:

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CONTENTS JANUARY/FEBRUARY 2017

The only appropriate approach in SOP is the individualised approach

HIGHLIGHT OF THE MONTH

WAGNER E-Line: a smart approach to powder coating

HIGHLIGHT OF THE MONTH

38 05 06

INNOVATIONS: PRESENT&FUTURE

State-of-the-art Adapta Rustproof System vs. ISO 20340:2009

EDITORIAL ANALYSIS Industry Innovation Index 2016: German Companies Richer in Ideas Than Ever Before

07 18

BRAND-NEW BRAND-NEW

FOCUS ON TECHNOLOGY

Cataphoresis: advanced solutions for maximum functional and design quality

HIGHLIGHT OF THE MONTH

MAN using the latest Dürr painting technology for its cabs

The newness in the coating industry was born in Poland

24 28

BRAND-NEW FOCUS ON TECHNOLOGY A rinse water treatment process contributes to the success of CBM, an agricultural machinery OEM

SUCCESS STORIES

SUCCESS STORIES Conserving resources during automotive production with integrated paint process

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CONTENTS JANUARY/FEBRUARY 2017

Cataphoresis and edge protection in the ACE industry

INNOVATIONS: PRESENT&FUTURE

Interpon Align “powder on powder” coating system: features and benefits

INNOVATIONS: PRESENT&FUTURE

84 50

BUSINESS TRAINING

Strategic planning: Back to the business definition

FOCUS ON TECHNOLOGY Paint more, better and cheaper: The milestone reached by Exkal with Nordson’s patented HDLV powder coating pumps, which use dense phase technology and intelligent design of the painting line

58 BRAND-NEW 64 INNOVATIONS:

PRESENTE&FUTURE TORAN 3®: An effective, simple, economic and ecological pre-treatment process

BRAND-NEW

STANDARD & LEGISLATION - UCIF Informs

Italy’s 2017 budget law: hyper-amortisation plans have come to life

88 BRAND-NEW 90 ipcm corsi 96 IPCM CONFERENCES 100 TRADE FAIRS & CONFERENCES

102 ZOOM ON EVENTS

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EDITORIAL

ipcm® welcomes you in 2017 with a brand new style

Alessia Venturi Editor-in-chief Direttore Responsabile

ur magazine has ceased to be bilingual. It will be issued in two identical versions, one in English that will circulate on the international market and one in Italian that will circulate only in Italy, our home market. A number of different reasons motivates this choice, which has also implied an important investment for the publisher. First, we wanted to emphasise the international nature of the magazine. Since its launch in 2010, ipcm® has presented itself as a worldwide mag, not only because the main language was English, but also because it was distributed to an international audience and because it presented technical content from around the world. Seven years later, these characteristics have further strengthened: currently, 84% of the readers of ipcm® are of European origin and 16 % come from non-European Countries. At the same time, we have recorded a greater and greater affection from the Italian market – our home market as well as one of the most dynamic and technologically advanced markets in the surface treatment sector. It has proven to appreciate a source of technical information free from purely commercial logics and in total rupture with the other magazines of the field. That is why it makes sense for a publisher like EOS Mkgt&Communication, always focussing on high-quality content and on a strong orientation to the reader, to invest resources in strengthening the internationality of its magazine. Another reason is content. Since we collaborate with the majority of the world’s leading manufacturers of finishing and surface treatment technologies, we receive technical articles and interesting news items every day. As a result, it had become difficult to include them all in a clear and organic way, with a bilingual magazine. Not to mention that ipcm® is the only international magazine to offer original articles with success stories from all over the world, written upon visiting the major users of surface treatment technologies from various industrial sectors. Separating the two languages will enable us to offer even more technical content, while maintaining the advertising/text ratio in favour of the latter. Nothing will change in the distribution of the magazine, which will continue to be shipped to an elite target of end users – 5000 paper and 8000 digital copies – and distributed in all the most important trade fairs for the finishing sector. Furthermore, the magazine will be available for online reading at any time on our website www.myipcm.com, while all articles will be indexed and searchable by keywords through the “ipcm®WIKI” search engine available on our site. Our 2017 has started with a great change and with a lot of enthusiasm. We are confident that these changes will inspire renewed enthusiasm for quality technical information in all of you, too!

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

ANALYSIS

Industry Innovation Index 2016: German Companies Richer in Ideas Than Ever Before Andrea Neumann info@altana.com

ALTANA AG, Wesel – Germany

ccording to top managers in German industrial companies, the biggest challenge the industry will face in the future is coping with the pressure of having to differentiate one’s company from the competition by means of products and solutions. Eighty-two percent of decisionmakers consider innovative strength a key component for a company’s success. Innovativeness has grown, as the Industry Innovation Index 2016 shows. For the study, the specialty chemicals Group ALTANA commissioned the Forsa institute for the third year in a row to survey 250 top decision-makers and 250 entrylevel employees in German industrial companies (Fig. 1).

The Industry Innovation Index, a specially developed indicator for recording the innovative ability of German companies, reached a level of 143.5 points in 2016, a fourpoint increase compared to 2015. Managers, in particular, assess their companies to be more innovative vis-à-vis the previous year. Almost every second manager – 48 percent – sees his or her company as being “very innovative”; in 2015 it was 43 percent. The benchmark group of entry-level employees has also given their employers a better evaluation: 44 percent currently perceive their companies to be very innovative (2015: 42 percent).

Background to the “Industry Innovation Index” study In the spring of 2016, the market research institute Forsa conducted 500 telephone interviews with representatives of industrial companies with at least 250 employees for a study commissioned by ALTANA. A total of 250 management board members, managing directors, and division heads were interviewed. In parallel, Forsa surveyed 250 entry-level professionals from industrial companies aged 18 to 35 with one to five years of professional experience.

Industry Innovation Index 2016

Promoting innovation culture and higher investments

1 Figure 1: Results of a survey of 250 top managers and 250 entry-level professionals from German industrial companies with at least 250 employees.

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

The increased innovative ability is largely due to the improved innovation culture in the companies. In particular, more freedom was created for innovations. Thus the share of managers who see individual employees as having creative leeway rose by 13 percentage points. This development is in line with the trend toward collaborative rather than hierarchical management styles within companies. That this freedom

ANALYSIS

is a decisive prerequisite for the development of new approaches seems to have become anchored in the companies’ management. Also in keeping is the fact that 24 percent of the managers and 16 percent of the entry-level employees see creative freedom as a key factor enabling companies to make groundbreaking innovations. However, entry-level staff members do not acknowledge the increased creative freedom as much as managers. The share of people just beginning their careers who see their company as providing great freedom increased only from 22 to 23 percent.

The willingness to take risks Companies often lack the entrepreneurial courage for innovations. Both managers and entry-level employees see potential for improvement here. Only nine percent of the managers say that a willingness to take risks is implemented in their companies – a five-percent decrease compared to the previous year. Seventeen percent of the entrylevel employees see a somewhat higher willingness to take risks; in 2015 the share was 19 percent. “To enable innovations to be made, it is decisive to continually question established procedures and in cases of doubt to get off the beaten track. To this end, it is essential that the corporate culture grants sufficient scope of action and admits mistakes,” says ALTANA’s CEO Martin Babilas. In addition to promoting innovation culture, higher investments also help boost innovations in German industry. In 2015, every third manager said that his or her company would increase its investments in innovation projects. These investments seem to be paying off, for every third company planned to increase its expenditure for innovations again in 2016.

Number of Participations in Startups Stagnating The biggest challenge currently facing german industry managers is the need to differentiate themselves. Nevertheless, the number of networks with innovative startup companies did not increase compared to 2015. In 2016, as in the previous year, eleven percent of industrial companies invested in young technology companies. Instead, the number of networks with customers promoting innovation grew vis-à-vis the prior year.

CONVEY YOUR SUCCESS

“Established industrial companies can learn a lot from startups” An important prerequisite for investing in startups is a willingness to take risks. But according to the study, business courage is less widespread in German companies than other innovation-promoting measures. Only 9 percent of the managers consider this aspect to be very strong in their company, while 38 percent considered it to be weak or not pronounced at all. Unconventional thinking and action, and targeted use of external knowledge, were the measures implemented for an innovation culture that finished in second-to-last and third-to-last place, respectively. This is another indication that cooperation between established industrial companies and innovative startups needs to be reconsidered. “The challenge is to continually reinvent yourself in order to remain innovative. In this regard, established industrial companies can learn a lot from startups. The prerequisite is a corporate culture that is open to the new and to different opinions,” says Martin Babilas, summing up.

About ALTANA ALTANA is a global leader in true specialty chemicals. The Group offers innovative, environmentally compatible solutions with the matching specialty products for coating manufacturers, paint and plastics processors, the printing and packaging industries, the cosmetics sector and the electrical and electronics industry. The product range includes additives, special coatings and adhesives, effect pigments, sealants and compounds, impregnating resins and varnishes, and testing and measuring instruments. The ALTANA Group has four divisions: BYK Additives & Instruments, ECKART Effect Pigments, ELANTAS Electrical Insulation, and ACTEGA Coatings & Sealants. All of these divisions occupy a leading position in their target markets with respect to quality, product solution expertise, innovation and service. Headquartered in Wesel/Germany, the ALTANA Group has 47 production facilities and more than 50 service and research laboratories worldwide. Throughout the Group about 6,000 people work to ensure the international success of ALTANA. In 2015, ALTANA achieved sales of more than 2 billion euros. About 6 percent of sales are invested in research and development every year. Its impressive earning power and high growth rate make ALTANA one of the most successful and innovative chemical groups worldwide.

INTERNAL HANDLING SYSTEM IMPIANTI MOVIMENTAZIONE INTERNA

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

BRAND-NEW

xalta Coating Systems, a leading global manufacturer of liquid and powder coatings, has made its Alesta® AP powder coating line of products for metal substrates available as Building Information Modelling (BIM) objects (Fig. 1).

BIM is a method of optimising the design, execution and management of building construction, and is required for use increasingly by governments around the world on public construction projects. The European Union Public Procurement Directive (EUPPD), of 15 January 2014, allowed the EU member states to make the BIM method mandatory from 1 January 2016. By using BIM, all relevant building data is digitally recorded, combined and interlinked, and the building is rendered as a three-dimensional model. This provides a base of communication for everyone concerned with the construction of the building.

Axalta adapts Alesta architectural powder coatings to Building Information Modelling (BIM) format

1 Figure 1: The Alesta AP Star, Anodic and Fine Textured Collections have been adapted to the numerical formats required for BIM - Revit, ArchiCAD, IFC.

“Powder coatings such as our Alesta line are specified by architects not only for aesthetic reasons, but also because of their functional properties,” says Mercè Berengueras, Architectural Prescription Leader for Axalta’s powder coatings business, in Europe, Middle East and Africa. “We work closely with our customers and want to make it easier for them to access detailed performance and colour information quickly

and accurately. The BIM format enables that in an intelligent, digital form.” The Alesta AP Star, Anodic and Fine Textured Collections have been adapted to the numerical formats required for BIM - Revit, ArchiCAD, IFC - and can be viewed in English, French, German, Italian and Spanish. The Star Collection is made up of sophisticated bonded metallic greys and special colours with mineral and textured finishes. The Anodic Collection

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

has targeted applications for doors, window frames, furniture and lighting that require a specific look with very low gloss. And the Fine Textured Collection offers an unbeatable range of colours that deliver premium levels of aesthetics and functional performance while hiding substrate imperfections. The powder coatings from these collections can be viewed or downloaded as BIM objects at www.axalta.bimetica.com. For further information: www.powder.axaltacs.com

BRAND-NEW

Euroimpianti opens a new plant in Spain

coating systems that are uroimpianti has able to adapt to the different opened a branch in productivity needs of its Spain, in the city of customers and to seamlessly Barcelona. integrate into any production From this year on, with the cycle. inauguration of Euroimpianti Manual and semi-automatic Instalaciones de Pintura, systems ensure flexibility for Euroimpianti will provide its small batches different from Iberian customers with an each other, whereas automatic extensive service, also thanks and horizontal plants enable to a new local just-in-time to optimise mass production warehouse stocked with spare while ensuring lower system parts and consumables management costs (Fig. 2). (Fig. 1). The range also includes Euroimpianti has been vertical systems for the building industrial powder 1 coating of profiles. coating plants since 1976. The group companies Its target markets are all Figure 1: Albert Pérez, Manager of the are: Euroimpianti Srl’s industries dealing with metal new Euroimpianti branch in Spain. headquarters in Verona (Italy); processing and finishing Euroimpianti do operations: Brasil Ltda, a manufacturers production unit of components located in Santa for the industry, Catarina (Brasil) producers and and serving distributors South America; of parts for the newly end users, established manufacturers Euroimpianti of semi-finished Instalaciones products, de Pintura s.l. coating in Barcelona contractors and (Spain); and so on. 2 a subsidiary The firm’s ability providing to serve clients Figure 2: One of the coating plants installed by Euroimpianti. labour and belonging to assembly very different services, Euroimpianti Service Srl. sectors is the result of forty years of experience For further information: gained by the Italian parent company. Indeed, www.euroimpianti.com Euroimpianti designs highly differentiated powder

BRAND-NEW

Maximum transfer efficiency for electrostatic coating © Wagner

ncreasingly strict regulations mean that companies face the task of further reducing polluting emissions during coating processes. In view of their important contribution towards this aim, electrostatic processes have become successfully established in the market in recent years, and the trend is continuing. It is accompanied by an increase in the use of automated systems, partly due to reducing investment costs for robots. To serve this growing segment, WAGNER has now developed the GA 5000 automatic electrostatic gun (Fig. 1) and associated EPG 5000 control unit (Fig. 2). “The starting point was the GM 5000 manual electrostatic gun which has been very positively received in the market,” explained Peter Neu, Senior Product Manager at WAGNER Industrial Solutions. “We have integrated tried-and-tested elements of the GA 4000 automatic gun in this product to ensure easy assembly on both lifting equipment and robots.”

2 Figure 2: EPG 5000 control unit by Wagner.

Fine atomisation for high coating quality The GA 5000’s special air system also ensures particularly fine atomisation in minimally small droplets. The homogeneous spray jet does not rebound from the workpiece, but coats curves and inaccessible places with a high quality finish. This speeds up the coating process, reducing coating times by up to 20 per cent and paving the way for significant increases in productivity. The GA 5000’s nozzles and air caps can also be replaced under pressure even during low pressure applications, which means that production processes are interrupted for just a few seconds. And maintenance is quickly taken care of, thanks to the GA 5000’s simple disassembly and assembly.

Rapid amortisation thanks to efﬁcient coating The gentle spray jet with low kinetic energy is the secret behind the GA 5000’s very high transfer efficiency. “Anyone switching from conventional coating processes to an electrostatic system with the GA 5000 can save between 30 and 50 per cent in materials. Depending on usage, this allows the associated investments to be amortised very quickly, in some cases in less than a year,” stated Peter Neu.

Extensive control features

Figure 1: GA 5000 automatic electrostatic gun by Wagner.

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

“In combination with the EPG 5000 control device, the GA 5000 EA or GA 5000 EAC offer the most extensive range of control features on the market,” emphasised Peter Neu. An external interface is used for either manual or automatic control, allowing all electrical parameters in the coating process to be set and optimised. The high voltage can be adjusted variably in real time to suit the shape of the workpiece. The VM 5020 WA automatic control unit for the AquaCoat system can be used together with the GA 5000 EAW or EACW guns for water-based paints. Even before the market launch of the GA 5000 in November 2016, feedback from dealers and customers was positive. “The high transfer efficiency combined with the new compact design and attractive price have persuaded many customers even today. We are already experiencing high demand,” said Peter Neu. For further information: www.wagner-group.com

BRAND-NEW

BASF receives the German Federal Ecodesign Award for “Cool Coatings”

ASF’s Coatings division has won the German BASF offers a complete package of temperatureFederal Ecodesign Award. The jury was management solutions for all types of vehicles. convinced by the “Cool Coatings” automotive The special formulations can be integrated into coating technology’s innovative approach and its conventional application processes without any sophisticated design, which enables a broad colour extra effort and meet the high quality standards for range. BASF’s Cool Coatings the life cycle of a finish. reflect infrared light and in so “The Cool Coatings doing, reduce the temperature technology allows a broad on the automotive surface and colour range. This way, interior (Fig. 1). This passive even complex colours can temperature management be produced – ranging from reduces heating of the car warm, intensive colours to surface by up to 20°C, which cool colour concepts”, said leads to a reduction of 4°C in the Stephan Schwarte, head interior of the vehicle. Due to the of Pigmentdispersion & savings in air conditioning, fuel Innovative Colors (Fig. 2). 1 consumption can be reduced This year marks the fifth time or the range of electric cars the German Federal Ecodesign Figure 1: One of the colours got with the can be extended. BASF uses Award has been presented by Cool Coatings formulation. the technology to the German Federal support its customers Environmental Agency in optimizing their (UBA) and the German vehicles’ fuel and Federal Environment energy efficiency. Ministry (BMUB) in “In addition to cooperation with providing an attractive the International appearance and Design Centre Berlin protecting the vehicle, (IDZ). The jury, Cool Coatings also whose members are feature additional experts in the areas of functional properties. design, ecology and 2 The technology is an economics, selected important step toward contributions from Figure 2: From left to right: Stefan Sickert (Product Management basecoats BASF), Stephan Schwarte (head modern mobility. We over 350 submissions of Pigmentdispersion & Innovative Colors BASF) and are especially happy to in the categories Barbara Hendricks (minister of the environment). receive the award, since Product, Service and it honours exactly this Young Talent. aspect,” said Mark Gutjahr, head of Automotive Color For further information: Design EMEA. www.basf-coatings.com

BRAND-NEW

Axalta Announces its Automotive Color of the Year 2017 - Gallant Gray

xalta Coating Systems (NYSE: AXTA), a leading global supplier of liquid and powder coatings, is excited to announce its Automotive Color of the Year 2017 – Gallant Gray (Fig. 1). This luxurious color is enhanced by blue and silver flakes that produce a unique sparkle effect and dark undertones that enrich the finish, adding sophistication. A year-long Color of the Year celebration will commence with a variety of events during the 2017 North American International Auto Show (NAIAS) Preview Days in Detroit, Michigan, including

a video reveal at the EyesOn Design awards program on January 10, 2017. The color will also be prominently featured at the Axaltasponsored Charity Preview on January 13, 2017 that raises funds to support services for children. Daily inspirations, coupled with extensive research, helped Axalta color designers and product experts select Gallant Gray as the Automotive Color of the Year. A high percentage of the market is interested in a neutral palette and adding slight hints of hues can add life to these colors. Gallant Gray is designed to look spectacular on any size vehicle. The complex color is dark in value with various sparkling flakes that add depth and color.

“At Axalta, we monitor automotive trends and forecast how color tastes are changing in the automotive market,” said Nancy Lockhart – Axalta Global Color Marketing Manager.

“We are pleased to partner with automakers by using our coatings to give their vehicles beauty and character, and we’re confident customers will appreciate Gallant Gray. With hints of blue and green, it exemplifies modernity and elegance. Taking everything into account, we think Gallant Gray is the new silver.” Axalta’s recently released 2016 Global Automotive Color Popularity Report, which documents vehicle color trends by geography, showed a rise in the popularity of gray shades around the world. Neutral colors have dominated the market over the last ten years. Although white and black maintained the top positions worldwide, gray is now tied with silver for third place at eleven percent. Gray leads silver in popularity in Europe (by six percent), North America (five percent), and South Korea (seven percent). Gray is most popular in Europe (17 percent), North America (16 percent), South Korea (19 percent), and India (12 percent). Axalta’s Global Automotive Color Popularity report is in its 64th consecutive edition. For more information: axalta.com/color

Figure 1: Gallant Gray has been announced as Automotive Color of the Year 2017 by Axalta Coating Systems.

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

Openinig photo: The technology centre built by SOP includes a high-tech coating line for powder coating of metal products.

HIGHLIGHT OF THE MONTH

The only appropriate approach in SOP is the individualised approach Jasna Močnik SOP - INTERNATIONAL, d.o.o. - Krško, Slovenia

info@sop-international.si

lovene company SOP – INTERNATIONAL d.o.o. has almost 60 years of tradition in manufacturing technological equipment for surface protection of metal, plastics and wood. It has its own experts with a lengthy experience and wealth of knowledge. They manage the complete process from initial customer consultancy, through design, construction, manufacture, installation, and equipment start-up, to staff training. They have their own know-how. The company SOP – INTERNATIONAL d.o.o. is the leading manufacturer of industrial painting equipment in Slovenia, and

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

respected and trustworthy business partner, well-established within, as well as outside the EU. The company provides comprehensive and individualised approach to customers, respects the agreed deadlines and meets the needs of the most demanding clients. The company’s production program encompasses supply of modern systems for surface protection, which are in accordance with high-quality and environmental standards. In the light of continuous development and provision of most modern solutions, they built their own technology centre, which includes

HIGHLIGHT OF THE MONTH

steel, aluminium and various other alloys of up to 8 m of length, up to 1.5 m of height, up to 700 mm of width, and up to 1000 kg of weight. The procedure starts with the loading of the work pieces onto the P&F conveyor by means of a hoisting device (Fig. 1). A coding system then enables setting of various operating parameters for each individual work piece during the surface protection process. Such system is easy to use for workers on the line and at the same time enables great flexibility of the line, which makes it appropriate for a wide range of work pieces. The work pieces then undergo a process of chemical pre-treatment. The latter includes cleaning and degreasing of the work pieces, as well as application of chemical conversion

coat, which represents the first and very important anti-corrosion protection. Work pieces are then thoroughly rinsed, and the liquid adhering to the surfaces of the work pieces is removed. The work pieces are then sent into a drying tunnel which prepares them for further treatment. If needed, the work pieces are then sent into a cooling tunnel, which cools the work pieces down to 30 °C. Agent used for degreasing and conversion is appropriate for a wide range of metallic materials. If it is used together with high-quality powder coatings, the protection of metallic materials can achieve up to 500 hours of salt spray resistance, whereas the aluminium alloys achieve even up to 1000 hours of salt spray resistance. In order to achieve high-quality and stable

high-tech coating line for powder coating of metal products (Ref. opening photo). The choice for such a line was made because such technology enables metal surface protection of high quality, is visually attractive, enables low production costs, and is at the same time, in comparison to other alternatives for surface protection (e.g. wet coating), far most environmentally friendly. The company SOP – INTERNATIONAL uses the line for coating of work pieces from their own production program, for provision of powder coating services for clients, as well as a technology centre for testing and educational purposes for their existing and potential clients. The line is used for coating of work pieces made of steel, galvanised

1 Figure 1: A detail of the line: the work pieces are moved by the Power&Free conveyor throughout the different steps of the process.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

Figure 2: Automated application of powder.

3 Figure 3: The accumulation area in front of the powder coating booth.

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

pre-treatment process, the replenishment of the bath is done on the basis of the cascading principle, from the baths with the water of the highest quality to the baths with reduced quality water. Water that is supplied into the process is pure demineralised water from RO purification device, which forms an integral part of the equipment. Automated dosing of the chemical agents plays an important role when it comes to the stability of the process. Such dosing is done by means of a device that measures pH value and conductivity of the agents in the baths. Finally, waste water treatment plant makes the line environmentally friendly. Powder coating is done by the automated powder booth application which enables manual touch ups for work pieces of

more complex forms (Fig. 2). The powder that does not adhere to the surface of work pieces is filtered and returned into the process. The powder recovery rate is therefore around 95 %, which makes the line extremely economical and environmentally friendly as it does not burden the environment with substantial quantities of waste colors. The color-change takes approximately 15 minutes. Collecting points in front of the powder coating application booth and the P&F conveyor ensure the line production capacity is not reduced due to the colorchange (Fig. 3). After the application of powder, the work pieces are then sent to polymerization oven, and further on into the cooling tunnel where they are cooled down to temperature appropriate for unloading of the work pieces.

The whole line is designed for energyefficient performance. The latter is ensured by adequate thermal insulation, precise regulation of the temperature of all heating elements of the devices, automated door for passage of the pieces through the heating areasâ&#x20AC;&#x2122; entry and exit points, as well as precise design of the devices according to the desired size and production capacity. Initial investment into high-tech powder coating line may be a bit high at the first glance, especially for clients new to such technology. However, a rough calculation of the costs in connection to the use of energy sources, chemistry and powder coats shows that in a long term, such highquality equipment is definitely worth the money, as it is user-friendly and enables high-quality surface protection of the work pieces.

BRAND-NEW

A16 – Adapta’s new colour collection

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

effects, as in the collections dedicated to the Zhangye Danxia National Geological Park in northeast China, the Blue Grotto in Capri, Italy, the Caño Cristales river in Colombia and the lava effects of the volcanoes of Kamchatka. Finally, pastel colours are the protagonists of the collection inspired by Ta Prohm, the Khmer temple located in Cambodia, by the Iguazu Falls, between Argentina and Brazil, and by the Eiffel Tower in Paris. The colour variations of the Adapta A16 range are endless, especially as regards neutral and metallic shades. The collections are based on the proven Adapta Vivendi technology for architecture, which has recently been tested according to ISO 16000-9:2006 getting an A+ for indoor emissions. They also include some interference colours from the Dichroic ranges as well as the textured and oxidised metal effects of the Patina collection. All the colours have been developed with the last generation Adapta Bonding System® technology, which ensures a homogeneous optical effect. This is crucial for complex designs and for projects requiring high quality standards. Many of the new colours are already available also in their superdurable versions, which in any case can be requested for all other shades. Moreover, most hues can be integrated with some of the functions listed in Adapta’s smart coating catalogue, such as insect repellency, easy removal of stickers (Stickers Proof technology), self-cleaning ability (BioNox) and the Adapta Tracker technology against the counterfeiting of paints. For further information: www.adaptacolor.com © ipcm ®

dapta has launched on the market A16, its new collection of architectural finishes. After the great success of the two previous collections, A8 and A12, this Spanish leading manufacturer of smart coatings and special powders for metal architecture has completely renewed its range to include all the trends, effects and textures that will be the most required ones in the next four years by architects and designers. Like for the A12 range, the A16 catalogue consists of 32 collections with a very broad colour spectrum, each one composed of 8 shades. Every collection is inspired by an iconic building or a famous place on the Earth, used by Adapta to develop and choose the various colour combinations. The spectrum ranges from the metallic white, grey and blue colours typical of many post-modern and contemporary buildings such as the Chrysler Building in New York, the Burj Al Arab in Dubai, the United States Air Force Academy in Colorado Springs and the Walt Disney Concert Hall in Los Angeles, to the fuchsia, pink and purple shades of the Wadden Sea, enclosed by the Dutch, Danish and German coasts, and of Mount Mayon in the Philippines. It includes the beige and warm brown colours of Mont-Saint-Michel in France and of the Chhatrapati Shivaji train station of Mumbai, India; the deep and iridescent blue hue of the Brooklyn Bridge in New York and of the Blue Mosque in Istanbul; and the golds and bronzes of the John F. Kennedy Space Center in Cape Canaveral, the Maya, archaeological site of Palenque, in Chiapas, Mexico, the Easter Island and the Giant’s Causeway in Ireland. There are also strong shades, extreme colours and pronounced textured

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HIGHLIGHT OF THE MONTH

WAGNER E-Line: a smart approach to powder coating Patrick Schumacher patrick.schumacher@wagner-group.com

J. Wagner GmbH, Markdorf, Germany

1 Figure 1: With its smart design, intelligent features and economical price, the E-Line complete concept is enjoying a positive reception from customers all over the world. Even before the sales launch, WAGNER had received numerous pre orders for the compact powder coating system.

“T

he E-Line is an ideal choice for anyone who is still working with steel booths, outdated systems or purely manual hand-coating, as well as for anyone interested in trying powder coating for the first time,” emphasised Patrick Schumacher, Product Manager at WAGNER Industrial Solutions. He and his team have integrated all the crucial features for high-quality coating in the E-Line solution, and managed to combine them with a very attractive price and low operating costs.

Smart high-quality powder coating Made possible only thanks to smart solutions, as demonstrated by the three models from the E-Line system (Fig. 1): the “E Cube” quick paint-change booth, the energy efficient recovery system and the PXE powder centre. The PVC booth features an extraction system with twin channels positioned sideways on the floor. As well as allowing easier cleaning, this also ensures high transfer efficiency. The air flow generated by the extraction has no adverse effect on the powder cloud, resulting in uniform application of powder even on the

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

bottom section of the workpiece – unlike conventional systems on the market. “This illustrates the design principle behind the E-Line solution. We have developed smart and efficient features that deliver top quality and an excellent result,” explained Patrick Schumacher.

Around corners without turbulence The recovery system with EEP incorporates another smart design detail. The acronym stands for Energy Efficient Package. And the name says it all: the system consumes up

New Anodic Collection Super durable powder coatings

New Interpon D2525 Collection Anodic III features 12 exclusive trendy colors including 6 new products: • Soft Silver • Soft Champagne • Gold Splendour • Steel Blue Platinum • Steel Bronze 1

For more information on Interpon Anodic Powder Coatings, visit www.interpon.com

• Steel Bronze 2

AkzoNobel Powder Coatings present this exclusive range of Anodic colors. These attractive matt and metallic effect ﬁnishes provide a great alternative to anodized aluminum. Collection Anodic colors are supplied in Interpon D2525 super-durable polyester technology to give long service life.

• New metallic technology for “Soft Silver” and “Soft Champagne” giving an exceptional pure metal finish • Attractive matt and metallic effects that provide an excellent alternative to anodized aluminium • Meets the demanding weathering requirements of the leading industry specifications Qualicoat Class 2, GSB Master and AAMA 2604, as well as BS EN 12206. • Third party certified Environmental Product declarartion (EPD) • Used on some of Europe’s most iconic buildings

For more information on Interpon Anodic Powder Coatings visit www.interpon.com or contact your local representative: Tel: 0039 (0)31 345 111 Email: marketing.italia@akzonobel.com

HIGHLIGHT OF THE MONTH

to 40% less energy than comparable models, as a smaller motor is sufficient to generate the same extraction volume. This increases powder recovery while reducing pressure loss and powder deposits. This is made possible thanks to pipes with square cross-sections, developed in partnership with a flow engineer. “The special crosssection geometry avoids turbulence in curves. Instead, the air flow follows the pipe routing,” said Patrick Schumacher, explaining the principle (patent applied for).

Intuitive operation The third module in the E-Line solution is the very user-friendly PXE powder centre. With a minimal footprint of 1.24 square metres, it comes complete with all key features, including control of the complete system, powder feed from the carton as well as supply for the manual or automatic guns. “The E-Line application solution is an economical entry point to professional powder coating. Simple and intuitive operation was therefore a priority for us. The aim was to ensure that even employees with no previous experience are able to quickly achieve good and reproducible results,” said Patrick Schumacher.

High number of pre-orders The E-Line complete concept appears to be enjoying a positive reception from customers. Even before the sales launch in October 2016, WAGNER had already received numerous orders from Europe, China and even Africa. The E-Line is available with different booth sizes for workpieces measuring up to 2,000 mm wide and 800 mm high. It therefore covers a wide spectrum – from smaller items to larger workpieces such as control cabinets.

Technical Data • MAX. GUNS: 12x automatic + 2x manual or 14x automatic • GUNS: PEA C4 or PEA C4 XL 1.4 • MANUAL PLATFORMS: 1x pre-coating / 1x post-coating • SIZE: Max. 2000 (H) x 800 (W) • GUN SLOTS: MAX.3 per side • VERTICAL UNIT: VU 2-1800 to UV 2-2400 • HORIZONTAL UNIT: RS1000 (manual device) or HU 1000 (electrical device) • POWDER CENTER: PXE (standard) or PXE (maximum) • TYPE OF INJECTORS: PI-F1 (80-360 g/min), PI-F1-S (80-450 g/min), HiCoatED (50-250 g/min) • CYCLONE & FILTER: 12.000 Nm3/h 18,5 kW or 16.000 Nm3/h 22 kW • CONTROL TYPE: All-in-one control • DISPLAY SIZE: 7” colour touch display. For further information: www.wagner-group.com

HIGHLIGHT OF THE MONTH

The newness in the coating industry was born in Poland Georgios Bousios Quality Painting Development Sp.z o.o - Chorzów, Poland

georgios.bousios@qpd-poland.com

for the construction of painting lines, extended to the design process based on the standards of the end customer OEM. It is based on a participatory review of the risk process and the early identification of risks and prevention at the earliest possible stage. Depending on customer’s request, the company suggests materials, assistance during work organization and selection of tools of control and measurement. Extensive knowledge and experience in the painting industry is what makes QPD a reliable partner on production process optimization - mainly by identifying the activities related to the reduction of defects, shortening the production cycle and improving the organization of maintenance activities. Because QPD realizes how important rational management of financial resources is, it offers a convenient system of calculating remuneration for its services, which is linked closely with the identified savings. Consequently, using services generate costs for the customer only in case it has measurable benefits of cooperation with the company. This way we reduce customers’ risk of unjustified expenses. QPD is for customers who need a change for the better. © QPD Quality Painting Development

lbeit Quality Painting Development Sp.z o.o is a relatively young company on the market, its resources include people with an extensive track record, who have gained experience in various fields, thus giving form to a team composed of mutually complementary specialists, who are therefore able to offer a comprehensive assistance throughout the entire process of project management. QPD is specialized mainly in the painting of plastic parts for automotive industry, where requirements are the most restrictive from all branches. In this area, the company has completed several projects for the construction of painting lines and for the execution of processes, and realized orders for the analysis of defects on painted surface. Among the aforementioned projects, we include the construction of a paint line for bumpers (PP) model Maserati and Ferrari (Fig. 1), with one spray booth, whose conveyor allows painting in one cabin from one to three layers of lacquer. Other projects include a line for painting parts of ABS, mainly the products to VW (Poland) and painting line of plastic parts for Kia & Hyundai (Slovakia). What distinguishes QPD from the competitors is a comprehensive offer

1 Figure 1: One of the paintshops engineered and installed by QPD in the automotive sector.

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

BRAND-NEW

Customized cleaning solutions for any requirement – variety made in Germany

cleans the components on a rotating parts carrier. The two-tank version of the Ocean RC features spray rinsing – another cleaning step which also rinses away cleaning agent residue.

1 Figure 1: Turntable system OceanRC with strong cleaning performance and space saving design.

leanliness plays a particularly important role in the manufacturing of machine tools and complex solutions for manufacturing and automation engineering. Only thoroughly cleaned components and workpieces can meet the high requirements for usability in the further production process. BvL Oberflächentechnik GmbH offers a comprehensive product range of cleaning systems for a variety of different requirements. The systems are designed according to the order and the customer requirements, manufactured in-house in Emsbüren in northern Germany and then installed at the customer site. All systems have a water based cleaning concept. This removes even smallest particles and film contaminations in an efficient and environmentally friendly cleaning process. At the same time, this protects the surface of the components particularly well in contrast to other cleaning processes. We are presenting a small selection of the BvL cleaning solutions from the variety of 2 possible systems.

With a cover that easily opens to the top, the turntable system Ocean RC is a universal spray cleaning system for compact and medium sized workpieces. The sturdy and space saving design goes hand in hand with strong cleaning action for new and repair parts (Fig. 1). An upright U-shaped spray nozzle frame

Figure 3: Basket washing system NiagaraMO with stationary table with cross moving for space saving cleaning of components with high cleanliness requirements.

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The pass-through system YukonDA is ideal for production processes with continuous material flow. The parts pass through the successive treatment zones in an in-line process (in cycles if required). The parts pass in front of the continuous nozzle frame with an offset nozzle arrangement. This nozzle system as well as the permitted loads and effective dimensions are individually adapted to the respective components (Fig. 2). The sequence of different wet processing zones for washing, degreasing, phosphating, rinsing and passivating as well as for drying are implemented as required.

NiagaraMO – versatile and compact Another cleaning principle is implemented in the basket washing system NiagaraMO (Fig. 3). The compact two-tank flooding/rinsing system allows all-around, thorough cleaning through the rotation of the parts baskets or parts carriers around the horizontal axis. Front loading via a roller guided holding fixture allows a direct connection to the existing production process. A supplementary stationary table with cross moving in the feed and discharge sections allows even faster processing times, even for components with complicated shapes. This system can optionally achieve particularly high cleaning results with ultrasonic cleaning. For further information: www.bvl-group.de © BvL Oberﬂächentechnik GmbH

OceanRC – small and strong

Figure 2: Pass-through system YukonDA for integration into the individual production process.

YukonDA – speedy and individual

BRAND-NEW

From the well-established Trafilerie San Paolo to the acquisition of all the Sommer group’s shares

- Tramev, specialising in the production of shears and equipment for the wire and cable industry; - Raptor, a software development company established to provide the market with a set of advanced operative solutions; - Eclo, dealing with the recovery of the exhausted sulphuric acid baths of firms that clean metals by chemical pickling. This industrial “world” was celebrated last September, on the occasion of the fiftieth anniversary of Trafilerie San Paolo, with a photo exhibition, “Steel – Life”. The photographs displayed were taken by Lucrezia Roda during the various steel processing stages carried out at the different group’s plants (Fig. 1). In 2016, the Roda family has also acquired 100% of the shares of the Sommer group’s

companies, thus becoming their sole owner. Such goal was achieved thanks to the forces fielded by Giuseppe Nazzareno Roda and his seven sons, all involved in the family business, and to the collaboration of their competent teams, capable of putting new ideas into practice. Nowadays, the Sommer group is turning its attention to the international market, thanks to its technical-commercial network in continuous evolution. Its ongoing insourcing process is going hand in hand with constant R&D activities, which have already enabled the group companies to enter some emerging markets and to consolidate their position in Europe. For further information: www.orbita.it, www.tspaolo.it and www.sommer.it

ased in Erba (Como, Italy), Trafilerie San Paolo has been producing drawn steel, scalped from one bundle to another and rolled to be cold formed, since 1966. The company celebrated its fiftieth anniversary last year. Inextricably linked to the history of the Roda family and to Orbita, a firm based in Cesana Brianza (Lecco), it has been successfully managed for half a century by the founder of the family, Giuseppe Nazzareno Roda. In fact, Roda has been the head of the company as well as of its group of subsidiaries established over time since their very foundation. The Sommer Group, created in 1992 by the will of Roda himself, who is currently its president, now consists of eight companies. They are engaged in manufacturing different industrial products, but they are united by the work culture, innovative spirit and “manic” pursuit of quality transmitted by the Italian entrepreneur. Besides Trafilerie San Paolo, the group is composed as follows: - Orbita, the company established by Roda in 1962 and now run by his sons Massimo and Andrea, specialising in the production of chains and bearings for overhead conveyors; - Trafilerie Meal, for the transformation of drawn steel in bundles for various applications in the mechanical and steel industry; - Trafilerie Gerosa, for the production of drawn and rolled raw and annealed steel; - Eme - Elettromeccanica Erbese, for the construction, maintenance and servicing of machines and plants for the steel sector, from wire drawing to the subsequent machining operations of bars and rolls in steel and non-ferrous metals;

1 Figure 1: One of the 27 shots of the “Steel – Life” exhibition.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

BRAND-NEW

he Tribo lance PEM-TL1 (Fig. 1) is a manual powder coating gun for two-handed operation with a telescopic shaft that can be extended to over 2.80 metres. This opens up a whole range of advantages for the coater. It makes it possible to coat even very large workpieces, for example transport or infrastructure components such as lorry chassis or bridge sections, safely from the floor, with no need for ladders or ATEX platforms. Two-handed operation and a lightweight construction with a carbon shaft allow coaters to work for longer, extending daily production times by 30 minutes or more.

Tribo lance PEM-TL1: efficient powder-coating for extra-large dimensions the inner wall of the powder tube. In contrast to Corona charging, there is no Faraday cage effect here, which means significantly faster coating around welds and recesses. It also allows very high layer thicknesses of up to 300 μm.

Greater corrosion protection: trend for powder-in-powder application

Higher productivity for powder coating “Half an hour increase in coating times, every day, represents an additional productivity gain of some 50,000 euros per year,” calculated Michael Topp, Senior Product Manager at WAGNER. “A further increase in productivity can be achieved when the benefits of the Tribo technology are fully exploited.” Because while the Corona process charges the powder using a high-voltage electrode, in the Tribo process this takes place by means of friction on

1 Figure 1: The Tribo lance PEM-TL1 extends coaters’ reach by 2.8 meters. This allows efﬁcient manual powder coating of large components, for example from the infrastructure and transport sectors, as well as other industries.

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Another interesting aspect is that powder-in-powder application of primer and top coat is also a trend in the area of high corrosion protection. Instead of baking and cooling after applying each coat, the primer and top coat are applied directly after each other. This eliminates two costintensive and time-consuming process steps. “Powder-inpowder coating allows low unit costs, higher productivity, energy savings as well as reduced investment and maintenance costs,” explained Michael Topp. “At the same time, the increased layer thickness and improved edge covering ensure very good corrosion protection, an important requirement, in particular, in the transportation and infrastructure sectors.” In tests, the Tribo/Tribo combination proved the best in comparison with Corona/Tribo

ÂŠ WAGNER Industrial Solutions

BRAND-NEW

Figure 2: The Sprint X manual unit is the ideal partner for the new WAGNER Tribo lance. A central rotary control on the EPG-Sprint X unit is used to enter all parameters. The powder is fed directly from the original container or optionally from a 60-litre stainless steel tank.

or Corona/Corona for this two-coat application. However, coaters need to make sure that they use a suitable powder for this process.

Different versions for an optimal coating result WAGNER offers three versions of its Tribo lance PEM-TL1: a fixed 1-meter lance or a telescopic version, starting at 1.8 metres and extending to 2.8 metres. A quick-release closure allows the length to be adjusted very quickly. The Tribo lance also has a 3D 150Â° flexible swan neck. Multi-slotted nozzles, round jet nozzles or sprinkler nozzles are also available, as well as different hose lengths. WAGNER supplies the Tribo lance PEM-TL1 together with the Sprint X manual unit (Fig. 2) for optimal manual powder coating. For more information: visit www.wagner-group.com

Â© CBM Group

Opening photo: CBM Group specialises in the production of 3-point coupling systems for tractors: in the picture, a 3-point coupling system for rear mounting.

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FOCUS ON TECHNOLOGY

A rinse water treatment process contributes to the success of CBM, an agricultural machinery OEM Monica Fumagalli ipcm®

Fendt and Claas, to name a few – it is the it has installed a water demineralisation he last 2016 issue of ipcm® perfect example of a company that has plant to optimise the final rinsing stage of and the conference we held on managed to adapt to such demands for its pre-treatment process and thus obtain December 14th were both devoted increasingly high performance coatings. perfectly clean surfaces prior to painting. In to the technological evolution of finishing Besides developing the most appropriate order to do so, CBM has cooperated with treatments in the field of Agricultural, coating process to improve its final results, Water Energy, a company based in San Pietro Construction and Earthmoving (ACE) in Casale (Bologna, Italy), specialising in waste equipment. We highlighted that, while water treatments. The aim was to improve the aesthetic quality level of the ACE the washing efficiency level and make the machinery is now comparable to that of production process smoother, eliminating the the automotive industry, the corrosion and CBM has installed a need for touch-up operations due to a nonshock resistance performance required water demineralisation suitable metal pre-treatment process. to the former is even higher than that plant to optimise the final imposed for the latter. The search for rinsing stage of its preThe company new application systems able to meet treatment process and “With nearly fifty years of experience,” CBM’s the demands of the major players in the thus obtain perfectly clean Manufacturing Manager Daniele Iaquinto says market is constant and their development surfaces prior to painting” to introduce his company, “we are among is a permanent test bed. the major OEMs in the We will deal again world for the design, with these issues manufacture and supply in this article about of hooking, towing CBM Spa Costruzioni and lifting systems Meccaniche, a wellfor implements and established company trailers connected based in Modena and/or coupled with (Italy) and specialised tractors. Established in in the agricultural the late ‘70s, this firm machinery sector. It has remained a family has been producing business. Omero Cornia, tractor hooking, towing and lifting systems its founder, is still active since 1967 and is now and present in the a leading company at company (Fig. 1).” the international level. CBM is now managed by Thanks to its relationship the second generation 1 with key stakeholders of the family, leading a in the sector – John group made up of five Figure 1: From right to left: Omero Cornia, the founder of CBM, Elisabetta Masotti, the Deere, CNH Industrial, companies with about Sales Ofﬁce Coordinator of Water Energy, and Daniele Iaquinto, the Manufacturing Manager of CBM, in the show room of the Modena headquarters. Same Deutz-Fahr, Agco 900 employees. In the

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

they are building a second plant in Dewas to meet the demand of John Deere, a major customer of CBM, for the creation of a few satellite activities in this Indian region. With this structure, the Italian group exports over 85% of its production, while 15% remains on the Italian market.

The customisation of complex components

2 Figure 2: The monorail conveyor leads the hydraulic cylinders along the pre-treatment and coating line.

The fifth company of the group is Mita India, founded in 1999 as a joint venture for the production of hydraulic lifts for the Indian and the Far East markets and located in the industrial area of New Delhi. At the moment, © ipcm ®

Modena area, there are CBM Spa, the group’s headquarters, and Te-tra Acciai, dealing with the heat treatment of alloy and special steels. In Tregnago, in the province of Verona, Mita Oleodinamica manufactures lifters and hydraulic cylinders, as well as their related control parts. In 2007, a Polish company based in Lublin, previously an important part of the Same Deutz-Fahr Group, joined the group and changed its name to CBM Polska. Initially producing the full range of agricultural machinery components, following the acquisition by CBM it has specialised in medium-heavy carpentry products, mainly featuring welded structures. “We have chosen to entrust CBM Polska with the construction of towing components. In this way, in the Modena plant we have been able to focus on our production of 3-point coupling systems for front or rear mounting, which have always been our core business, without wasting any resources in the installation of the same machines for the same processes in different plants (Ref. opening photo).”

The design of CBM products complies with the strictest regulations on size and dimensions as a function of the roadway, the position of the power take-off (PTO) system and the axle of the towing vehicle, as well as with the requests of the customers. “Only a small part of CBM’s production,” Iaquinto states, “is based on standard designs. In most cases, our products are developed and customised for each client. Every day, we process our steel bars to obtain, on average, about 24 t of flat bars, 8 t of tubular bars and 6 t of round bars to produce rolled rods. “We have two main production lines. One processes solid bars in quenched special steel, the other tubular bars in S275/2G3 steel. After cutting, we perform drilling and milling

3 Figure 3: The outside of the pre-treatment tunnel and, on the right, the water demineralisation plant.

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FOCUS ON TECHNOLOGY

4 Figure 4: On the left, the non-hazardous eluate collection silo and, on the right, the control panel for the management of the water treatment system.

operations with automated machining centres. Most components, at this point, undergo an induction bending and a heat treatment stage. The latter is a special process considered crucial to increase the material’s mechanical resistance, achieve greater surface hardness and protect the product against contact abrasion.” After the thermal process, some products, such as the lifting arms, are welded to smaller parts; other components, such as the tow bars, go directly to the coating and assembly department.

The coating of components for agricultural vehicles “In our sector, the aesthetic finishing of components has not always been considered a strategic operation: at the beginning of our collaboration with the manufacturers of agricultural vehicles, in the ’70s-’80s, our task was to provide them with a raw product. They dealt with the painting once it was mounted on the tractor’s axle. The first requests for treated surfaces were due to storage needs, with the aim of keeping the stocked parts in good conditions for long periods of time. Afterwards, such demand has grown and the required aesthetic level has become increasingly higher. Many years ago, therefore, we equipped ourselves with two coating plants, one for the application of a primer on the parts that are subsequently repainted by the customer and the other for the application of a full primer + topcoat system. We only use two-component, water-based epoxy primers and two-component polyurethane topcoats, all approved by our clients.

We only use two-component, waterbased epoxy primers and two-component polyurethane topcoats, all approved by our clients.”

reported that an appropriate substrate preparation was needed in order to achieve the parameters required by the customer. The old system was designed with a 3-stage pre-treatment process that proved inadequate for this new coating. Our current pretreatment phase, on the other hand, includes 8 stages with a nanotechnology conversion process. Because of the complexity of the treated parts, numerous tests have been performed with the supplier of chemical products, Henkel, to identify the best suited process.” The plant consists of a through-feed monorail conveyor with a 0.9 to 1.1 m per minute speed, equipped with nearly 400 hooks on which the components (with a weigh ranging from a few 5 kilograms up to 120 kg) are placed (Fig. 2). After loading, the workpieces reach the spray Figure 5: In the foreground, the two columns of the demineralisation system: one with cationic pre-treatment tunnel, which includes: resins, the other with anionic resins. - 2 alkaline degreasing stages with the same products. The first bath operates at 55 °C, the second one at 50 °C. In the first bath, We have selected two coating suppliers: Invera more intensive degreasing takes place; Valspar, a multinational industry with an Italian the passage in the second one enables branch in Bologna, and Gross & Perthun, based Our current pre-treatment to eliminate any residues that were not in Mannheim, Germany, for the Austrian and phase, includes 8 stages with removed during the previous stage. When German customers who have approved the a nanotechnology conversion the first tank is saturated and must be paints of this German manufacturer.” process.” emptied, the second one continues to The acquisition of more and more important operate, thus avoiding any interruption in orders has led the Italian company to replace the production flow; the plant devoted to the - 2 rinses with recycled primer + topcoat application osmotic water; with a new one, designed - a nanotechnology and installed three years conversion stage; ago by Airmadi Painting - 2 rinses with recycled from Castelnuovo del Garda demineralised water; (VR), and to dedicate the - 1 rinse with pure primer application machine demineralised water. to the components that do “We have also installed a not require a high degree of demineralisation plant to resistance. produce the pure water required for the last rinse of The pre-treatment cycle the pre-treatment process,” Iaquinto explains (Fig. 3). “The decision to replace “In this way, we avoid any our old plant,” Iaquinto hazing or staining problem says, “was motivated by the 6 due to salt residues addition of a new approved remaining on the surfaces coating system: the supplier Figure 6: The separator for the removal of mineral oils from the pre-treatment tanks.

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FOCUS ON TECHNOLOGY

after rinsing: our operators no longer have to intervene in order to complete the cleaning process, which results in a production process without any bottleneck.”

The demineralisation plant’s operating principles “The demineraliser installed by Water Energy,” says Elisabetta Masotti, Sales Office Coordinator at Water Energy, “operates through an ion exchange process for the removal of salt from water. It consists of two columns, a cationic and an anionic one; they are regenerated with the most appropriate products: hydrochloric acid for the former and sodium hydroxide for the latter (Fig. 4). Demineralisation occurs as water passes through the two columns filled with resins: the cationic section removes the excess ions and the anionic one holds the negative ions. The

final result is the pure water fed to the last pre-treatment stage. The eluate is conveyed into a silo and disposed of by a specialised firm as non-hazardous waste (Fig. 5). The resins are depleted over time and must be regenerated properly.

Our operators no longer have to intervene in order to complete the cleaning process, which results in a production process without any bottleneck.”

Water Energy has also installed a coalescence separator for the separation and removal of the mineral oil present in the pretreatment baths (Fig. 6). The recovered oil is

continuously drained and conveyed into a waste oil storage tank through a pipe. The de-oiled water, on the other hand, is sent to the degreasing tank.” “Over three years of use,” Iaquinto states, “we have regenerated the demineraliser’s resins four times. Such operations should have been more frequent because of the high hardness of water, but Water Energy has added a pre-treatment system composed of a softener and an osmosis unit, which removes most salt from water. As a consequence, the demineralisation plant is fed with treated water characterised by a reduced percentage of salt, which helps ensure it works optimally. “This has resulted in higher efficiency of the coating process, thanks to constant, low μS levels and to the well-adjusted, uniform quality of the treated water. We can only be pleased with the result.”

The coating line’s features

The film thicknesses required by the clients’ specifications range between 80 and 100 microns, depending on the components’ shape: the primer layer is normally ≥ 30 microns thick, the topcoat one ≥ 50 microns. The coating process occurs in two dry application 7 booths equipped with automatic Figure 7: The two booths for the dry application of primers and topcoats. electrostatic mixing and spraying system provided by Wagner Group and two semiautomatic reciprocators provided by Zeus Electrostatic System (Fig. 7). The primer application booth features Columbus paint collection filters; the topcoat application one is equipped with two kinds of filters, Columbus and Andreae. After the application of the primer, the parts stay in the drying oven for 30 minutes at 55 °C. Then, the topcoat is applied and the parts are dried for 35-40 minutes at 90-95 °C. The following steps are: cooling, unloading, packaging and assembly, if required by the component; otherwise, the part is ready for the shipment. The entire painting cycle ends in 4 hours. “For our new coating line, we have required some fundamental parameters to be respected to ensure a successful surface treatment process,” CBM’s Paint Shop Manager Maurizio Guiduzzi says. “A crucial aspect for us was the system’s automation level, according to the industrialisation philosophy applied to our entire production plant over the years. Since 8 we deal with heavy construction materials, we have always tried to lighten the work of Figure 8: Coated hydraulic cylinders.

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our operators as much as possible, with considerable advantages also in terms of human error reduction. “We have also asked the plant engineers to include an alarm system able to stop the process if the parameters set for any phase of the treatment, from cleaning and drying to paint mixing, are not respected. In this case, the system enters standby mode and it is not possible to resume work until the problem is solved. In this way, we make sure that each component undergoes the right pre-treatment and coating process (Fig. 8).”

Conclusions “In the last few years, finishes have played an increasingly important role,” Iaquinto says. “The attention paid to the coatings’ performance is comparable to that of the automotive industry. The customers take it for granted that they will receive a workpiece to be sent on their assembly lines that complies with their technical requirements and that is also aesthetically pleasing. CBM’s components are mounted on high-range tractors (from 400 to 500 horsepower) and we cannot afford to deliver a product with any defect, however slight, in the coating – even if it works perfectly. Nowadays, end users want to drive nice and eye-pleasing farm machines. That is why we are planning to replace also the second paint installation in the next few years. Given the good results obtained so far, we will turn to the same suppliers that helped us build the coating line installed three years ago.”

SUCCESS STORIES

MAN using the latest Dürr painting technology for its cabs Dürr’s scope of delivery starts with pre-cleaning. Two robots of the type EcoRS 210 remove the dust and dirt particles from the bodies using blade brushes prior to painting. The tried-and-tested brushes from the passenger car segment can adapt very flexibly to the contours of the body, and are being used for the first time for truck cabs in the Munich plant. © Durr

ürr is installing its innovative EcoDry X dry separation system in truck manufacturer MAN’s new paint shop for truck cabs in Munich now for the first time in Germany. EcoDry X is a semiautomatic system based on cardboard filter technology. Dürr’s scope of delivery includes complete system configuration, conveyor technology, pre-cleaning, sealing, and painting stations as well as the associated application technology complete with paint and PVC delivery. “With this concept, we are supplying a highly efficient system where the customers benefit from our consistent components,” says Dürr Global Customer Director for Trucks, Andrea Klein, explaining the reasons behind the company’s selection as the system supplier.

Four EcoRS 30 robots are used in the PVC line. They apply roof and underbody seams and seal welded seams inside the body. This prevents water and moisture getting into the cab. The robots are equipped with the flexible applicator EcoGun 3D, which can apply the material at three different application angles of 0, 45, and 90 degrees. Up to three nozzles for different seam thicknesses are Integrated application 1 integrated in the Dürr technology for sealing applicator in the 3D and paint application, Figure 1: EcoDry X – the intentionally simple and robust paint overspray separation system. version. identical robot “The standardized platforms for preEcoGun 3D is suitable cleaning and sealing as for all fields of application in seam sealing,” says Andrea Klein, describing well as the standardized controller technology not only reduce the variety the benefits of the applicator. “This means that it is not necessary to of spare parts, but also simplify all future maintenance tasks. Needing stock spare parts for multiple models”. just one service technician for all applications means top efficiency both The scope of delivery also includes a line for sealing the door sill. for MAN as the plant operator and for Dürr as the technology supplier. The quality standards at this station are particularly high, since “Having the same operating software for all applications also significantly incorrectly executed seams are visible when the door is opened. Suitable reduces the training costs for the plant operators,” adds Andrea Klein, fine seam nozzles are therefore used for applying these visible seams. explaining the benefits of the concept.

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

SUCCESS STORIES

The underbody, the interiors of the doors, and the exterior of the bodies are painted in the third primer booth by a total of four EcoRP robots. If necessary, the top coat can also be applied in the booths using the same robots and the application technology installed on them. The atomizers from the EcoBell3 series with external charging are used in combination with the color changer EcoMCC3 and the metering pump EcoPump9 for painting the interiors of the doors and the exterior of the body. The application technology offers impressively short color change times and low paint consumption. The atomizers can apply the water-based paint with improved efficiency and to the highest quality standards without the need for complex potential separation systems. The compact

form of the EcoBell3 Ci in particular means that it can reach all the interior surfaces of the body with ease. The spray jet can be focused, and overspray and selfcontamination are noticeably reduced. Even though state-of-the-art application technology means that the amount of overspray is constantly being reduced, an efficient separation system for the overspray is extremely important. That is why the EcoDry X, the semi-automatic variant of the dry separation system and the newest addition to the Dürr separator family, is being used at MAN – for the first time in Germany. EcoDry X is a multi-stage filter system comprising filter trolley and final filter stage. The disposable filter boxes made of cardboard can be easily replaced thanks to the filter trolley – even during

production. An additional feature being used here is the filter replacement concept based on RFID and a database for optimum utilization of the filter boxes. Like the tried-and-tested EcoDryScrubber, the EcoDry X does not use any water or chemicals either. The first cabs will be painted on the new paint line in the Munich plant from September 2017. For further information: www.durr.com

Â© bomboman-Fotolia.com

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

State-of-the-art Adapta Rustproof System® vs. ISO 20340:2009 Diego Año

adaptacolor@adaptacolor.com

he issue of corrosion poses a major problem around the globe, both in terms of the associated occupational safety issues as well as the economic losses that it causes each year. In more developed countries, the annual cost of corrosion has been estimated at 3.1% of GDP, which is why scientific institutions and communities are devoting time and resources to analysing and preventing it. In this respect, Adapta has seen an interesting avenue of research in testing its state-of-the-art 1 ROC (Rustproof One Coat) antiFigure 1: Visual representation of the cycles. corrosive powder coating systems with respect to ISO 20340: 2009, since we understand that the technical committee that drew up this regulation has incorporated a truly interesting component: the stress of the coating in the face of atmospheric and temperature changes. Regulation ISO 20340: 2009 for paints and varnishes ‘Performance requirements for protective paint systems for offshore and related structures’, anticipates a total exposure for the coating of 4,200 hours, divided into 25 cycles. Each cycle is divided into the following stages (Fig. 1): - 72 hours of UV exposure and condensation according to regulation UNE EN ISO 16474-3:2014, alternating four hours of artificial aging under UV light at 60 ± 3 °C and four hours of condensation at 50 ± 3 °C. Type 1 Lamps (UVA 340) - 72 hours of exposure to salt spray according to UNE-EN-ISO 9227:2012 - 24 hours of exposure at low temperature, at -20 ± 2 °C. At the end of 25 cycles, this adds up to the following number

of hours of exposure during each of the various stages: - 1,800 hours of QUV 340; - 1,800 hours in the Salt Spray Chamber; - 600 hours at -20 °C. Before beginning the cycles, a 50-mm incision is made in the coating with a width of 2 mm. The repeated exposure cycles are an attempt to simulate the extreme environments of offshore structures, that is, structures exposed to a marine environment and submerged in sea water or brackish water (Ref. opening photo). Offshore structures may be floating or fixed to the sea floor, with many of these being oil and gas extraction platforms. A great number of these platforms are located in the North Sea and the Norwegian Sea. Adapta has selected two types of substrates prepared according to NORSOK Standard M-501 (Surface preparation and protective coating - Edition 6, February 2012): galvanised steel (Fig. 2) and aluminium (Fig. 3). Both substrates received, prior to painting, a phosphate-free nanotechnological surface treatment. The NORSOK standards are based on internationally-recognised regulations and incorporate additional requirements that are deemed necessary in order to satisfy the extreme demands of the Norwegian oil industry. It compiles the requirements for selecting coating materials, preparing the surface, application procedures, and inspection of protective coatings that are applied during the construction and installation of offshore structures. © Adapta Color

Adapta Color SL, Peñíscola - Spain

Opening Photo: The anti-corrosive coatings systems simulate the estreme environments of offshore structures.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

Figure 3: The aluminium substrate tested by Adapta.

The anti-corrosive coating applied consists of a coating system of two powder coating layers. The first layer is made up of a primer, Adapta ROC, RB-7708, and the second is a metallic finish in super-durable quality (Adapta SDS), DX-9006-XW. The total thickness of both layers in both systems is between 140 and 180 microns, this being less than the minimum required (>225 microns) for systems based on liquid paints. This also provides a reduction in costs and procedures compared to these liquid systems.

The tests were performed in the certified laboratories of Tecnalia Research & Innovation, where tests were performed with respect to the evaluation of defects, according to UNE-EN-ISO 4628, adhesion according to UNE-EN-ISO 14624, and pull-off test for adhesion according to UNE-EN-ISO 4624. Satisfactory results were obtained from all of these tests. The anti-corrosive system Adapta Rustproof System® is, therefore, highly recommended in extremely corrosive environments, such as, for example, coastal buildings and facilities (Fig. 4).

Figure 2: The galvanised steel substrate tested by Adapta.

Figure 4: Among the most corrosive environments for which Adapta Rustproof System® to be recommended there are coastal buildings and facilities.

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

Opening photo: The components of the cataphoresis plant.

FOCUS ON TECHNOLOGY

Cataphoresis: advanced solutions for maximum functional and design quality Luca Antolini ipcm®

igh skills and proven technical know-how lead to important production results in terms of efficiency and quality. While this may seem obvious, it should not to be underestimated that the path to be taken in order to reach an excellent industrial quality level includes process and development engineering, perseverance, experience gained on the field and the selection of the professional partners.

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

This is the case of Cataforesi Srl, a cataphoretic coating contractor based in Mantello (in the province of Sondrio, Italy) and established in 2008 as a branch of a powder coating contractor with the aim of meeting, in particular, the requirements of the automotive market: just-in-time deliveries and, above all, coatings with a high aesthetic and functional quality level as well as extreme corrosion resistance. After using a

FOCUS ON TECHNOLOGY

second-hand cataphoresis Integrated cataphoresis and plant completely renovated powder coating for its needs for a few years, processes: the Cataforesi Srl has equipped prerequisite for the itself with a totally new, highest quality cutting-edge system, which Cataforesi Srl’s past and is now enabling it to make present are closely linked to the most of the skills and DAFER Srl, a Mantello-based experience gained over the powder coating contractor years to achieve even better and to INVER-PRESS Srl, results, more efficiently (Ref. a leading company for the opening photo). In order to moulded parts production in reach this goal, the firm has the automotive and appliance turned, among other partners, 1 fields, based in Valmadrera to Verind S.p.A., a company (Lecco, Italy). After years based in Rodano (Milan, Italy) Figure 1: From left to right, Jessica Valsecchi, Gianluca Marastoni and Renato of cooperative work, Rocco belonging to the German Saruggeri. Pedri and Gianpaolo Mossini, group Dürr Systems A.G. and the respective owners, decided specialising in automotive Since the clients asked to found the Cataforesi Srl industrial coating technologies. company, initially in order to get a greater Its innovative solution, including new ediVer for high quality products with autonomy for the treatment processes, by electrodialysis cells, which allow to replace excellent corrosion resistance leaving the suppliers. Then they were able to a damaged membrane without changing the properties, we subjected our seize the opportunities offered by the market entire structure, has guaranteed to Cataforesi components to cataphoretic and decided to accept also contracting jobs. Srl greater efficiency and productivity. treatments”

2 Figure 2: The pre-treatment tanks of the new cataphoresis plant.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

LONDON | UK

o t t a f n e B NEW FETTER LANE

3 Figure 3: The Power & Free conveyor was provided by Futura Convogliatori Aerei from Robecco Pavese (PV, Italy).

PERFETTA SINERGIA

* UV 30 PROTECTION

* 3 years South Florida

TIGER Drylac ITALIA s.r.l., Bergamo(BG) ofﬁce.it@tiger-coatings.com | www.tiger-coatings.com

engineered by Focchi

» INGEGNERIA ITALIANA PER FACCIATE » VERNICI IN POLVERE AUSTRIACHE

The production process of DAFER Srl was completely reorganised in 1994 with the installation of the most innovative technologies on the market. This led the firm to become a point of reference in the coating field for the most important companies operating at the national and international level. Its powder coating plants treat mediumsmall as well as large components for several industries, such as cycles and motorcycles, household products, hardware, furniture, automotive, corrosion protection, engineering, bathroom furniture and appliances. DAFER’s strength is its ability to offer customised solutions. With the use of a chromium-free nanotechnology multi-metal universal passivating product for its pre-treatment operations, the company has also improved by 20% the corrosion protection performance of its coating process, with a significant reduction of its environmental impact. In 2008, in order to meet the market needs and with the desire to offer a more complete and faster service to his customers, it was decided to insource the cataphoresis process with the ambition to take it to new heights of quality. “Initially, DAFER’s activity focused on the field of service area construction, with the coating and silk-screen printing of tanks and petrol pumps for customers such as Agip and Esso,” says Pedri, the founder of DAFER Srl and co-founder of Cataforesi Srl. “Since the clients asked for high quality products with excellent corrosion resistance properties, we subjected our components to cataphoretic treatments at the premises of our partner companies. We decided to insource this process when we started exploring other markets, especially the automotive one, where orders must be satisfied justin-time: such requirement would not have always been met, if we had continued to rely on third parties. Moreover, this sector has very high demands in terms of corrosion resistance and aesthetic finish. That is why we needed to combine to our extensive knowledge of powder coating with top-level cataphoresis know-how.”

LONDON | UK

e n o d l l e W MOOR PLACE

4 Figure 4: In the foreground, the skid with the 8-inch ultraﬁltration membranes installed.

The simultaneous increase in the number of customers requiring both treatments, cataphoresis and powder coating, has therefore convinced Pedri to insource this operation by opening a new company that deals exclusively with contracting cataphoresis, Cataforesi Srl.

The establishment and development of a business

PERFECT SYNERGY

engineered by Focchi

» ITALIAN FACADE CONSTRUCTION » AUSTRIAN SURFACE SOLUTIONS

The new company specialises in the processing of metals with black cataphoresis. Thanks to a cutting-edge coating system and the use of high-quality products, it is able to reach a very high quality level on both small and large-sized components, adapting its process to the specifications provided by each customer. Initially, the company bought a second-hand cataphoresis plant in order to take the first steps and learn more about the process. “The machine had been completely revised and integrated with the replacement of the dialysis cells,” so Renato Saruggeri, Sales Manager at Verind S.p.A., which also contributed to the renovation of the second-hand system (Fig. 1). The investment for integrating the cataphoretic coating process proved to be a success under different points of view. Afterwards, the increase in the number of customers from the automotive sector and the consequent need to increase its production capacity have led Cataforesi Srl to invest in a new cataphoresis plant. Thanks to the enormous wealth of knowledge acquired with the first system, the firm had a very clear vision of its needs and the results it wanted to achieve. For the new plant design, it has relied on an engineering company with which it has collaborated in the choice of the various components, including a new immersion pre-treatment plant (Fig. 2) and a new two-rail conveyor supplied by Futura Convogliatori Aerei (Fig. 3).

* UV 30 PROTECTION

* 3 years South Florida

TIGER Drylac ITALIA s.r.l., Bergamo(BG) ofﬁce.it@tiger-coatings.com | www.tiger-coatings.com

Figure 5: All the main parts of the cataphoresis plant are mounted on two skids.

Figure 6: The cataphoresis tank.

A new generation plant

They are new tube-shaped closed cells named ediVer (electro dialisys cells Verind), developed with the latest technology” © Verind

Thanks to the innovative know-how in the field and the positive previous collaboration, Verind S.p.A. has been chosen for the provision of some basic components of the cataphoresis plant, such as the recycling pumps and the ultrafiltration unit. The goal was to meet the most stringent requirements of the major international OEMs of the automotive sector (Fig. 4). “The cataphoresis system consists of two skids equipped to handle the entire process (Fig. 5),” Saruggeri says. “The first one includes the coating recycling pumps and their related components for the filtration of the coating bath. In fact, the content of the tank, for a total of 13 cubic metres of volume, is recycled, filtered and conditioned with a plate heat exchanger (Fig. 6); moreover, the tank is heated to maintain a constant temperature of 30.5 °C. The second skid, on the other hand, integrates the ultrafiltration unit. Two 8 inch-membranes with a disposable container have been installed; the nominal plant capacity is 1500 litres/ hour, expandable to 2250 litres/hour. This skid also hosts the cleaning system (permeate recovery and recycling) and the flushing section used for the cooling of the pumps’ mechanical components. There is also a section of the anolyte feeding and management system, which feeds all the

7 Figure 7: The new ediVer cell (electro dialysis cells Verind).

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

dialysis cells. There are 16 cells installed (diameter of the active membrane: 2-inch), supplemented by 2 exposed ones. They are new tube-shaped closed cells named ediVer (electro dialisys cells Verind), developed with the latest technology, which allows to replace only the damaged membrane without the need to change the entire structure, thus ensuring maximum efficiency and quality (Fig. 7).” The anode-cathode ratio is 1:8. Every bath enables to coat about 50 m2 of surface with high thickness paints. The two skids, the whole cataphoresis tank system and the oven are managed and controlled by an integrated supervisory system. Upstream of the cataphoresis process, the workpieces are subjected to a pre-treatment process with a Chemetall solution. “Our 14-stage pre-treatment includes an alkaline degreasing phase followed by two rinses, a pickling phase, two further rinses, an activation phase, a phosphating process with zinc salts, one rinse with fresh water, one rinse with demineralised water, a nanotechnology passivation phase and one last rinse with demineralised water,” Cataforesi Srl’s Production and Quality Manager Gianluca Marastoni says (Fig. 8). Downstream of the cataphoresis process, on the other hand, the parts enter two washing tanks with a cascade recycling

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FOCUS ON TECHNOLOGY

8 Figure 8: The loading bars are automatically transferred from the conveyor to the bridge crane used for the pre-treatment and cataphoresis tanks.

system fed by the ultrafiltration unit, and afterwards a washing ramp using pure ultrafiltrate. â&#x20AC;&#x153;Before entering the oven, the components remain in a preheating chamber for 4 to 8 minutes and then they are subjected to a blow-off operation,â&#x20AC;? Marastoni says. â&#x20AC;&#x153;The preheating is required to avoid any problems arising from the dripping, which may cause defectiveness: by pre-heating the parts at a low temperature, the water evaporation is achieved, thus avoiding a thermal shock to the subsequently applied coating. We have been able to take this precaution aimed at maximum quality and process improvement thanks to the experience gained with the previous system (Fig. 9).â&#x20AC;?

Figure 9: The end result is of the highest quality.

When the parts exit the oven, they are unloaded. At the end of the cycle, 60% of production is delivered to the customers, while the remaining part is sent to DAFER to be powder coated.

Quality: present and future The cataphoresis plant, in operation since April 2015, has far exceeded the expectations and goals set by Cataforesi Srl. â&#x20AC;&#x153;We wanted a system that would enable us to produce at full capacity for one shift with the highest coating quality,â&#x20AC;? Pedri states. â&#x20AC;&#x153;Now, thanks to strong demand, we are working on two working shifts. And the quality of our cataphoretic coatings is confirmed not only by the trust of our customers, which rely on us for both their

functional performance and their aesthetic qualities, but also by the approval we got for the whole process from some of the most important international car brands. Indeed, thanks to the quality level that we have been able to reach, 90% of our production is now intended for the automotive industry.â&#x20AC;? â&#x20AC;&#x153;We focus on a flexible service, timely deliveries, a direct and transparent relationship with our customers, and also continuous investments,â&#x20AC;? Marastoni says. â&#x20AC;&#x153;For example, a second powder coating plant is expected to come into operation in August 2017 at DAFERâ&#x20AC;&#x2122;s premisesâ&#x20AC;?.

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SUCCESS STORIES

Conserving resources during automotive production with integrated paint process

he BMW Group saves 12,000 tons of CO2 annually during automotive production at its Munich plant by eliminating one step from the paint process. This means that compared to a conventionally coated vehicle, a car coated with the shortened process can drive the first 420 kilometers with a net zero carbon footprint. In addition, the process saves as much energy as the amount needed by 250,000 Munich residents to wash one load of laundry every week.

Eco-Efﬁciency Analysis by BASF The study was based on real-life data from 2014 evaluated with the Eco-Efficiency Analysis developed by BASF. The analysis will help BASF and its customers decide which products and processes are the best choice for a defined benefit, both ecologically and economically. The study has been validated by TÜV (German technical inspection and certification organization) and NSF (National Sanitation Foundation). When it comes to sustainability in the automotive industry, the focus is directed more and more to manufacturing processes. In addition to the utilization phase, the production phase is now being examined more closely. “It is no longer just a question of whether a product is sustainable in consumption but also whether it has been manufactured sustainably,” said Nigge. “The study’s findings provide compelling evidence that the Integrated Process is one of the most eco-efficient solutions.” For further information: www.basf.com/eco-efficiency/

These are the findings of a new TÜV-certified study conducted by the BMW Group together with the mechanical and plant engineering firm Dürr and BASF’s coatings experts. They aimed to find out how the eco-efficiency of the OEM coating process can be improved allowing resources to be conserved at the same time. “The paint process is one of the most energy-intensive process steps involved in industrial automotive manufacturing,”

said Dr. Hans Schumacher, head of Dürr’s Application Technology division. “We have consolidated the expertise of three companies in order to make paint processes even more environmentally friendly in the future,” said Lars Nigge, Account Manager BMW at BASF’s Coatings division. The study specifically compared two primer-based coating processes to the integrated paint process without primer (Fig. 1). In conventional systems the primer smooths surface irregularities and protects the cathodic e-coat, the undermost paint layer, from UV radiation. BASF was able to substitute the primer by integrating its protective properties into a newly developed waterborne basecoat layer. In all categories included in the study, the “Integrated Process” proved to be the most beneficial. Compared to the current primer process, the Integrated Process reduces energy consumption and CO2 emissions by around 20 percent and saves costs.

1 Figure 1: The primer-based coating process has been compared to the integrated paint process without primer.

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

Opening photo: Some Exkal refrigeration systems installed in a supermarket.

FOCUS ON TECHNOLOGY

Paint more, better and cheaper: The milestone reached by Exkal with Nordson’s patented HDLV powder coating pumps, which use dense phase technology and intelligent design of the painting line Alessia Venturi ipcm®

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

“T

The consortium of companies that designed he sustainable path is evolution, and supplied systems and equipment change and adaptation”. With The sustainable path according to Exkal specifications included these words Exkal explains its is evolution, change and Geinsa (Fig. 1) for the painting system, Futura global brand, a company based in Marcilla adaptation.” Convogliatori Aerei for the conveyor and the (Navarra, Spain) founded in 2005 with the design of the line’s logistics, Proquimia for goal of becoming the technology leader in the To achieve this ambitious goal Exkal defined the process chemistry, while Nordson was field of industrial refrigeration (Ref. opening three approaches: the brand of the systems and application photo). Faithful to this concept, the company - Replace classic pretreatment with a equipment that offered the product is moving rapidly towards the Industry 4.0, nanotechnological process. characteristics and service best aligned with simplifying, balancing, synchronising and - Implement a power and free conveyor and Exkal’s needs with regard to application, minimising anything that does not add value a layout designed to provide maximum efficiency and quality of the coating. to the product. Exkal is evolving its production flexibility and productivity, reducing “At Exkal we paint using a lean system, order processes, from the working of sheet metal downtime on the line to zero. by order. This means that when we start to painting and all the way to logistics, - Adopt the most innovative system of powder working on an order for a new supermarket, towards flexibility, quality and the reduction coating application available today, namely for example, the furniture is painted in of delivery times, gradually increasing dense phase HDLV pumps for conveying the various stages, even months apart”, explains automation and interconnecting processes powder and Nordson Encore HD application Fernández. “So for us repeatability, uniformity through the “Internet of Things” in order to equipment for total control of the process. and reliability over time are critical. The convert the collected data into information Nordson technology with Encore HD guns and that is useful for continuous improvement. HDLV pumps guarantee such a result”. “In the 2014-2016 management plan the For Exkal repeatability, company planned investments of about 8 Zero downtime with a million euros both in facilities and personnel uniformity and reliability over superﬂexible layout and to triple production, reaching a total of 60,000 time are critical. The Nordson superautomated colour changes refrigeration appliances per year”, explains technology with Encore The layout of the new Exkal coating line is Miguel Fernández, production engineer at HD guns and HDLV pumps extremely flexible. The starting point for the Exkal. A major portion of this investment was guarantee such a result.” project were three for painting because work shifts and 40 it was a bottleneck for colour changes per us: the first line, with day. The goals were a monorail conveyor to double production and a single spray reducing downtime booth, was fully during colour change, maximised with three improve quality and shifts and had no have a robust control room for an increase over the process. in productivity. At The current line has the end of 2014 made it possible for Exkal approved the company to reach an investment in a a downtime equal to coating line that was zero during colour on the cutting edge change, reducing for pre-treatment, shifts to one and a paint application and half. Thanks to the handling of parts with Futura power & free the aim of increasing 1 conveyor system (Figs. production capacity 2 and 3), the addition and quality while Figure 1: The consortium of companies that designed and supplied systems and equipment meeting Exkal’s speciﬁcations included Geinsa for the paint system. of twin Nordson reducing costs”.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

Figure 2: The power & free conveyor system from Futura Convogliatori Aerei.

Figure 3: Detail of the power & free conveyor system from Futura Convogliatori Aerei.

ColorMax 3 booths in parallel (Fig. 4) and the strategic positioning of overflow areas The current line has made before and after the booths it is possible it possible for the company to either paint two colours at the same to reach a downtime equal to time or use one booth for painting while zero during colour change, changing colour in the other. Any colour can reducing shifts to one and a be painted at any time with total flexibility half.” (Fig. 5). Thanks to the HDLV powder coating pumps repeatability. In a few months, by using the that use dense phase powder technology, same application parameters, you can get which allows for a better control of coating the same painting result”, begins Sebastián and automatically performs many stages of González de Zárate, system cleaning, the time to change colours has been reduced to four minutes. “The HDLV pumps provide great application accuracy, perfect adjustment of the thickness, increased layer uniformity, greater penetration 4 and, above all, increased process Figure 4: The twin Nordson ColorMax 3 powder coating booths in parallel.

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Area manager of industrial coating systems at Nordson Ibérica. “This is because dense phase technology does not use Venturi but rather HDLV pumps that require only a small amount of compressed air to convey the powder at low speed. This allows greater application accuracy and total control of the process. Furthermore, it also helps to decrease colour change times because all the cleaning of the circuits, the fluidised hopper and the system is automatic”. © ipcm ®

How does dense phase work? “What sets the dense phase apart from the traditional Venturi powder coating system is how the powder is conveyed to the guns, which is done with very little compressed air. The electrostatic system loads

FOCUS ON TECHNOLOGY

just the powder to be conveyed to the piece and is therefore much more efficient”, continues González de Zárate. “Essentially the dense phase pumps are dosing the powder. While in Venturi systems the amount of powder supplied depends on the increase of compressed air, in dense phase the control of the powder intake is independent of the amount of compressed air. The HDLV pump uses a tube having an inner diameter that is only 6 mm which makes it possible to carry twice the amount of powder compared to the Venturi system. Nordson’s Spectrum HD powder centre is fed with new powder by a high-capacity HDLV pump working continuously, mixing it with recovered powder. Level sensors monitor the fluidised hopper to verify the intake of new powder as needed”. In the Nordson Spectrum HD powder centre (Fig. 6) both the new powder and

the recovered powder pass through an ultrasound sieve that ensures the quality of the finish. During colour changes the dense phase pumps execute an automatic cleaning of the powder circuit for a few seconds, first blowing out the section between pump and gun, then the section between the pump and the fluidised hopper. In the meantime two operators clean the booth. The recovered powder returns to the fluidised hopper, where it is sifted. The fluidised hopper is completely emptied by means of a valve and the powder is pumped into the container, then the HDLV pumps automatically clean the powder suction line. In this phase compressed air is injected into the fluidised hopper and suction is set at maximum power. This way the Spectrum HD powder centre is automatically cleaned, considerably reducing colour change times.

The PowderPilot HD with command touch screen (Fig. 7) shows the data on the amount of powder and air in use, making it possible to control the system’s operation at any given moment, to check online for compliance with assigned application values, to control the suction unit, the Spectrum HD colour centre and the powder level sensors, as well as activating the HDLV recovery pumps, the HDLV new powder coating pumps, the ultrasound sieve and suction. Alarm sensors alert the operator of possible malfunctions in the system or drops in set parameters. The suction system is a compact double cyclone, a Nordson design that guarantees a higher recovery efficiency. It has inspection windows and the sieve is removable so it is easier to clean. A high-capacity dense phase pump (up to 4 kg/min) carries the recovered powder to the powder centre. This way the cyclone is never saturated.

5 Figure 5: With the new layout, it is possible to paint two colours simultaneously, or apply one colour in a booth and change colour in the other. Any colour can be painted at any time with total ﬂexibility.

Line Characteristics Exkal paints galvanised sheet metal with a maximum size of 1800 mm in height and 400 mm in width and with a speed of 3 m/min. This industrial system includes, among other equipment, a surface treatment tunnel with degreasing/hot nanotechnology steps; washing with demineralised water; passivation at room temperature; demineralised water plant and oil separator. In addition, the industrial facility includes a humidity drying oven; IR gelling oven; polymerisation and painting oven; chain for overhead conveyor and electrical cabinet with general mimic panel, PLC and touch screen. The surface treatment tunnel is situated within the complex. It is a closed area - 36,500 mm long, 1,400 mm wide and 3,900 high covered with stainless steel sheets, which eliminates any possibility of formation of oxides. The structure consists in sheet metal

panels assembled using a special system of construction without welds. It has a closing system in the roof that uses brushes to prevent vapour from reaching the conveyor. At the tunnel exit there are two forced blowers directed in such a manner as to eliminate water particle from the surfaces of the pieces, with the objective of reducing the amount of deposited water present before introducing the components into the humidity drying oven. Finally, the paint system installed at Exkal is equipped with an electric control panel that includes a touch screen and mimic panel representing the entire system, depicting the

This coating line is designed to work according to the concept of Industry 4.0.”

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elements operating on the line with LEDs that start flashing if there are problems. The burners installed in the humidity drying oven are of the direct flame type, while the polymerisation oven uses indirect flame modulating burners with a refractory AISI-310 stainless steel combustion chamber. “The only way to achieve good productivity was to have two spray booths painting in parallel”, says Miguel Fernández. “On average our refrigerating machines have 4 colours, always chosen by the customer. Our philosophy is to paint to order, this means an average of 20 colour changes per shift. With the first line, the average was eight minutes to change colour, a huge amount of lost production time”. “This coating line is designed to work according to the concept of Industry 4.0”, continues Miguel Fernández. A sensor system controls the pretreatment

FOCUS ON TECHNOLOGY

6 Figure 6: The Nordson Spectrum HD powder coating centre.

automatically, adding product only if needed. Compared to the previous measurement performed manually once a day, we now have greater traceability of parts and can guarantee that there will be no quality problems. Thanks to this system and the introduction of nanotechnology, we went from 500 to 1000 hours of salt spray resistance”. Similarly to the pretreatment, the powder coating (Fig. 8) is also perfectly controlled thanks to the use of HDLV pumps. “The paint layer is 60 ± 5 microns. We lose very little powder and have a film that is uniform and well spread. Even though the system has been in operation only since January 2016, the data show a savings in powder of around 10-15% for the same coating and production volume”. “When it comes to savings in powder, Exkal is penalised by the number of colour change made during the day”, clarifies Sebastián González de Zárate of Nordson. “Furthermore, the percentage of

7 Figure 7: The PowderPilot HD with command touch screen from Nordson’s HDLV system.

8 Figure 8: Application of the coating powder using Nordson Encore HD guns.

savings varies depending on the starting point of each company. Those that replace a sheet metal booth and a Venturi system with a plastic booth and Nordson HDLV application can achieve savings of 40%”.

Conclusions “The painting line is just the first step of our investment plan”, concludes Miguel Fernández. “The next phase - even more ambitious - is an internal logistics system that allows us to direct every outgoing carrier from coating to a specific area for a predefined time, and then send it from there to the assembly line only when it is needed so that nobody touches the pieces after painting and before assembly, thereby preventing any damage. For this second phase of the

For all this modernisation of the production process we have chosen to work with suppliers that can understand our complex process and transform the ‘dream’ of Exkal from paper to reality”

investment plan, which is the core and more complex part of the project, we have again chosen to work with Futura Convogliatori Aerei. In general, for all this modernisation of the production process we have chosen to work with suppliers that can understand our complex process and transform the ‘dream’ of Exkal from paper to reality”.

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“It is not just a matter of supplying a product, but rather being part of a very large and complicated project, in which suppliers must be able to coordinate with each other at all times. Suppliers that were chosen for the added value that they can bring to the investment, not simply because they offer the best price. We chose Nordson for the quality of the dense phase system and for its assistance, the human support and advice that it is able to offer”. “Our product is a product with a high level of technological development: our suppliers were chosen based on the improvements that they have been able to make to their technologies, for their attention to detail and because they are focused on the realisation of the Industry 4.0”.

SCANDINAVIAN COATING Scandinavia’s only comprehensive surface treatment exhibition!

MARCH 15-16, 2017• ØKSNEHALLEN, COPENHAGEN

Don’t miss Scandinavia’s most important tradeshow for the surface treatment industry! After being a success in Sweden, Scandinavian Coating is now back in Denmark where everything once started. At Scandinavia’s only comprehensive surface treatment exhibition, you will have the possibility to meet professionals within the industry. Come and meet platers, buyers, decision makers, experts and other professionals at Øksnehallen, Copenhagen and see the latest coating machinery, equipment and services of all kinds, for treating timber, plastics and metal surfaces. Visit also our free-of-charge conference where many new developments and product news will be presented and the industry get-together where you will have the possibility to mingle with colleagues in a relaxed atmosphere. Curious to find out more? Have a look at www.scandinaviancoating.com Welcome to Scandinavian Coating 2017!

Scandinavian Coating is organized by:

BRAND-NEW

Xirallic® NXT Cougar Red: The mysterious colour-intense pigment innovation from Merck erck, a leading science and technology company, is presenting Effect pigments from Merck ® Merck is one of the world’s leading suppliers of effect pigments for its latest pigment development: Xirallic NXT Cougar Red (Fig. 1). It is the fourth product of the Xirallic® NXT brand under which the coatings, plastics, printing, cosmetic, food and pharmaceutical industries. Effect pigments underscore the emotional impact of color Merck, the market leader in Al203-based pigments, is establishing a new series that calls to mind the beauty and fascination of wild cats. Panthera and are an important design element when creating surfaces with a special appearance or quality. Application possibilities range from cars Silver creates a metallic shimmer, Leonis Gold an interplay of colour and to packaging and high-tech products up to building façades. extraordinary sparkle, and Tigris Blue a special intensity and brilliance. In addition to decorative Now follows Cougar Red with effect pigments, Merck offers a spectacular bluish red and lively sparkle. pigments that also have functional applications such “The mysterious appearance as heat-reflecting or antiof the cougar and its powerful elegance gave the pigment counterfeiting pigments. Merck is a leading science innovation its name,” and technology company explains Alexander Peters, Global Marketing Manager in healthcare, life science Decorative Pigments at and performance materials. ® Around 50,000 employees Merck. “Xirallic NXT Cougar Red convinces in red stylings work to further develop through its high chroma, technologies that improve attractive flop behaviour and enhance life. In 2015, and brilliant red sparkle.” Merck generated sales of The red crystalline pigments, € 12.85 billion in 66 used alone or in combination countries. ® with Colorstream Lava Founded in 1668, Merck Red and Meoxal®, impart a is the world’s oldest mysterious magic with an pharmaceutical and chemical intense sparkle to automotive, company. 1 plastic, industrial and powder The founding family remains coatings. In addition, they the majority owner of the Figure 1: Xirallic® NXT Cougar Red is suitable for interior and exterior coatings open up a broad spectrum publicly listed corporate and for creative combination with other colour and effect pigments. of possible red shades – group. Merck KGaA, from dominant-fascinating Darmstadt, Germany, holds to elegant-mysterious. The newcomer’s powerful brilliance gives even the global rights to the Merck KGaA, Darmstadt, Germany, name and brand. The only exceptions are the United States and Canada, where more depth to black automotive coatings, with a fascinating interplay of colours. the company operates as EMD Serono, MilliporeSigma and EMD ® ® Performance Materials. Like all pigments of the Xirallic NXT series, Xirallic NXT Cougar Red is For further information: suitable for interior and exterior coatings and for creative combination www.merck-performance-materials.com with other colour and effect pigments. © Merck

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BRAND-NEW

Evonik successfully completes acquisition of Air Products specialty additives business “We are well prepared to ensure a smooth vonik Industries AG has completed in the amount of € 10 to 20 million in the business transition and a successful the activities to acquire the specialty year 2017. integration. To this end, we have worked additives business (Performance The acquisition is expected to increase intensively with Air Products over the past Materials Division) of the US company Air the adjusted earnings per share (EPS) of few months to develop integration plans,” Products, Inc. for US$3.8 billion (approx. Evonik in the 2017 business year. confirmed Ralph Sven Kaufmann, Chief € 3.5 billion) by the end of the year as Since the transaction is partly structured Operating Officer and Executive Board planned. The closing took place on January as an asset deal, it will lead to tax benefits member responsible for the integration. 03, 2017 (Fig. 1). All relevant antitrust as a consequence of write-offs which authorities have are typical for approved the transactions transaction and the of this nature. integration of the These benefits acquired business amount to a is underway. The net present transaction financing value of more was completed than US$500 successfully in million, which September and can be used will consist of the on a prorated company’s own basis in the 2017 funds in the amount business year. € 1.6 billion, with the other half to be The Specialty financed by bonds & Coating with a nominal value Additives of € 1.9 billion. business of Air “The successful Products is the completion of Performance 1 the acquisition Materials paves the way for Division within Figure 1: Evonik Industries AG has completed the activities to acquire the specialty additives swiftly merging the the Materials business (Performance Materials Division) of the US company Air Products. activities of Evonik Technologies and the acquired Segment of Air units of the Air Products Performance Positive EPS in the 2017 Products and Chemicals, Inc. It has around business year Materials business,” said Klaus Engel, 1,100 employees at 11 production and Chairman of the Executive Board of Evonik The annual synergy effects in the amount of development locations and offers local Industries AG. “It puts Evonik in an excellent US$80 million can be confirmed at this time customer support in all key global regions. position for further profitable growth in the For further information: and should be fully realized by 2020 at the attractive specialty additives market.” www.evonik.com latest. Evonik expects to leverage synergies © Evonik

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BRAND-NEW

BASF to offer tailor-made product innovation at European Coatings Show

Environmentally compatible corrosion protection for industrial metal coatings

Highly efﬁcient defoamer for water-based systems Foam formation is a common problem occurring during production and processing of paints and coatings. To avoid such problems, BASF has added a new defoamer to its range of formulation additives that is based on organo-modified polysiloxanes – the FoamStar® SI 2240 (Fig. 1). Apart from its strong defoaming effect, FoamStar SI 2240 shows broad compatibility with different binder systems and excellent long-term stability and efficiency. FoamStar SI 2240 is registered worldwide and can, among other applications, be used in water-based architectural coatings, industrial coatings and paints as well as in pigment concentrates. In addition, FoamStar SI 2240 complies with specific FDA and EU requirements for food contact and is therefore suited for printing and packaging applications. © BASF

t the European Coatings Show 2017 (ECS), which is going to take place in Nuremberg from April 4 to 6, BASF experts and specialists from BTC, the distribution organization of BASF, will present new raw materials for the coatings, paint and construction industries at booth 523 in hall 7A. The broad range of products offered by BASF includes dispersions, resins, formulation additives, light stabilizers, antioxidants, pigments, hardeners, cross-linking agents, reactive diluents and solvents.

The new water-based Acronal® PRO 7600 acrylic dispersion provides light to medium corrosion protection (categories New kaolin-based product for C2 to C3) for industrial architectural paints metal coatings. The binder applications offers an environmentally compatible drop-in With the launch of kaolin-based Mattex® PRO, BASF continues solution that does not 1 contain APEO and replaces to develop new technology ® Acronal PRO 760, the with focus on sustainability. Figure 1: FoamStar® SI 2240 is the new defoamer by BASF with high defoaming current market standard. Mattex PRO enables paint efﬁciency (even at high shear rates). Acronal PRO 7600 can be formulators to eliminate flatting used for all current applications such as airless, brush, agents and crystalline silica containing minerals while simultaneously roll or dip. providing simpler formulations and the same high-performance results with less TiO2. “We look forward to using the ECS trade fair to present Environmentally compatible high-performance various innovative solutions aimed at current market challenges that will dispersion for interior paints enable our customers to improve their competitiveness,” says Christoph With the Acronal® 6292 dispersion, paint manufacturers are Hansen, head of the Dispersions & Resins Europe business unit. BASF enabled to produce sophisticated interior paints with highest wet offers the broadest global range of raw materials for the formulation of scrub resistance at competitive prices. The water-based styrenecoatings and paints in the field of architectural coatings, construction, acrylate binder is a high-quality alternative to the conventional automotive, industrial coatings, furniture and flooring as well as raw technologies and facilitates the formulation of environmentally materials for powder coating resins. compatible interior paints: Acronal 6292 is a low-odour product For further information: that neither contains ammonia nor coalescents. www.basf.com/ecs2017

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BRAND-NEW

1 Figure 1: Surface treatment for the automotive industry by Chemetall.

Chemetall develops and manufactures customized technology and system solutions for surface treatment. Their products protect metals from corrosion, facilitate forming and machining, allow parts to be optimally prepared for the painting process and ensure proper coating adhesion. These chemicals are used in a wide range of industries and end-markets, such as automotive, aerospace, aluminum finishing, and metal forming (Figs. 1 and 2). Chemetall’s sales for the full calendar year of 2015 were US$845 million. To prepare for a seamless integration, BASF has established a Global Integration Management Team, which will ensure business continuity while maintaining a clear priority on meeting customer needs. For further information: www.basf-coatings.com

ASF has completed its acquisition of Albemarle’s global surface treatment business, Chemetall. Through this acquisition, BASF’s Coatings division expands its portfolio to become a more complete solutions provider. BASF combines its know-how in chemistry and coatings applications with Chemetall’s marketleading expertise in surface treatment. The combined businesses will benefit from each other’s global infrastructure, scale and market access, driving new growth opportunities by offering an unmatched solutions competence to customers. “We are extending a warm welcome to our new colleagues. The acquisition of Chemetall allows us to significantly expand our market. By combining the expertise and innovation power of two global market leaders, we will accelerate innovation and make our customers even more successful,” said Markus Kamieth, President of BASF’s Coatings division.

BASF completes acquisition of Chemetall

2 Figure 2: Pre-treatment process at a customer’s site using Chemetall’s Oxsilan technology.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

INDUSTRIE: BUILDING TOMORROW TODAY 22 000 VISITORS 900 EXHIBITORS WWW.INDUSTRIE-EXPO.COM

Avec le soutien du

INNOVATIONS: PRESENT&FUTURE

TORAN 3ÂŽ: An effective, simple, economic and ecological pre-treatment process Carlo Guidetti Chemtec S.r.l, Corbetta, Milan

c.guidetti@chemtec.it

Conventional pre-treatment processes, although they are quite effective and employed worldwide, have seen very few innovations over the past decades. As a consequence, their effectiveness, efficiency and environmental

impact have not significantly improved with time. Moreover, their quality is directly proportional to the attention and precision that end-users devote to their daily management. CHEMTEC, a company based in Corbetta (Milan, ÂŠ Chemtec

s is well-known in many industrial sectors, most problems arising in the coating of an object are not related to the painting process in itself, but rather to the preparation of the workpiece.

1 Figure 1: The one-stage pre-treatment tunnel.

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INNOVATIONS: PRESENT&FUTURE

Italy), is launching a completely different solution, TORAN 3®, on several international markets together with its French subsidiary AERTECH and to its branches CHEMTEC NORTH and LATIN AMERICA.

As can be noted, TORAN 3® provides better corrosion resistance than a phosphodegreasing process, comparable to that ensured by nanotechnology processes or phosphating operations followed by passivation.

Description of the TORAN 3® process The TORAN 3® process does not use water and it is based on special Simplicity high-boiling organic fluids in which specifically developed polymers A traditional pre-treatment process includes at least 3 stages, and additives are dissolved. It is a one-stage process: no preliminary often 5 or even more. Its quality generally depends on the degreasing or rinsing phases are needed. The end user’s ability to manage each treatment occurs in about 60-120 seconds process phase every day, coping with at room temperature and it is followed by a problems such as the dragging of dripping (5 minutes) and an oven drying stage (8TORAN 3® can be paint and the consequent pollution 10 minutes at 130-150 °C). During the product’s of the bath, the formation of sludge recycled and reused and it is application (immersion or spray, Fig. 1), that may clog pipes and nozzles, never disposed.” the oils are dissolved in it, while the non-oil temporary oxidation, and so on. The contaminants are detached from the part’s daily analysis of the various stages surfaces by mechanical action. of the process and the frequent After dripping, the drying of the fluids in the oven causes a uniform, one maintenance operations performed on the plant are standard micron-thick organic polymeric film to crosslink on the treated surfaces procedures that require time, lower the process efficiency and (Figs. 2 and 3). This offers immediate protection against oxidation and cost a lot of money. excellent coating adhesion on ferrous and non-ferrous surfaces, with The TORAN 3® process, however, only requires topping up the tank with fresh product. both liquid and powder paints. Table 2 shows the ease-of-use of TORAN 3®. The oil contaminants dissolved in the product are captured by the three-dimensional organic polymer without interfering in the interaction Table 2: TORAN 3® process operation between the polymer itself and the coating film. In this way, instead of a waste product, such oils become a useful part of the process. The TORAN 3® CONVENTIONAL insoluble particles, on the other hand, are removed from the liquid with a PROCESS specific filtration system. Routine maintenance No maintenance At least twice a TORAN 3® can be recycled and reused and it is never disposed of. of the plant required year, it is necessary Hundreds of industrial users worldwide confirm these benefits. to empty all the

Effectiveness TORAN 3®’s advantages in terms of quality compared with a traditional phosphodegreasing process are summarised in Table 1. Analysis of the baths

Table 1: quality advantages of TORAN 3® FEATURE

TORAN 3®

Salt spray resistance Multi-metal process Quality consistency

400 - 500 hours (*) Yes Always consistent, even over the years

Immediate oxidation Temporary protection of uncoated workpieces

Non-existent Several weeks, for items stored in a warehouse

CONVENTIONAL PROCESS 200 - 300 hours (*) In some cases Linked to the control of the baths and to the frequency of the product changes in the tank. High risk Non-existent

(*) on conventional carbon steel, with a polyester powder coating

No analysis needed. Control tests are performed free of charge every three months by CHEMTEC’s central laboratory Emptying of the tanks Never Waste disposal None, the TORAN 3® process does not management create waste (bureaucracy) Management of the various chemical products

TORAN 3® requires the use of only one chemical product that is supplied ready-for-use

tanks and change them, removing limescale from all the phosphating stations and from all the nozzles. Each stage of the process, including rinsing, must be analysed at least once per work shift

At least twice a year Frequent disposal of waste with the appropriate procedure In many cases, it is necessary to use various additives to balance or correct the bath

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

Efﬁciency The use of TORAN 3® eliminates many typical costs of conventional processes, such as energy and disposal costs. Moreover, the initial investment for a one-stage system is much lower than that for a 4 or 5-stage tunnel. With this process, therefore, it is easier to obtain a loan and the return on investment is faster. Furthermore, a one-stage tunnel is half the length of a 3 or 4-stage one. The space needed for the coating operations is therefore reduced. With TORAN 3®, the only process cost is that of the chemical. Its economic benefits are summarised in Table 3.

TORAN 3®

ENERGY

Virtually non-existent

WASTE TREATMENT/ DISPOSAL

Non-existent

WATER

Non-existent

INVESTMENT ROI COST OF THE CHEMICAL PRODUCT

Low Rapid High

Figure 3: A SEM image of the polymer created by TORAN 3® with 2% oil. As can be noted, the oil drops are trapped in the polymeric coating.

The TORAN 3® process, however, only requires topping up the tank with fresh product.”

Eco-friendliness

Table 3: economic advantages of TORAN 3® COSTS

Figure 2: A SEM image of the polymer created by TORAN 3® in the absence of oil in the product.

CONVENTIONAL PROCESS High. Necessary to heat and maintain at least one stadium at 50-70 °C and to handle large quantities of liquid High. Several thousand Euros/year to treat or dispose of many m3 of waste water and spent product High for large volumes of water and to treat and manage demineralised or purified water High Slow Medium-low

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The use of TORAN 3® ensures a significant reduction in the environmental impact of industrial coating operations, as shown in Table 4. Table 4: environmental impact of TORAN 3® TORAN 3® ENERGY

Virtually no energy consumption

WATER DISPOSAL

No water consumption Non-existent

CREATION OF CO2

Almost non-existent

TOXIC-HAZARDOUS WASTE

Non-existent

CONVENTIONAL PROCESS Huge energy consumption to heat large volumes of water and handle large volumes of liquid Huge water consumption Every year tens of m3 of polluting aqueous solutions are disposed of High, to heat large quantities of water Significant amounts, in tricationic phosphating processes

INNOVATIONS: PRESENT&FUTURE

Applications The adaptability and integration flexibility of plant and process technologies in different industrial environments, especially when talking about small and medium-sized firms with limited spaces already full of machines, are critical features to deliver a truly comprehensive service to these industries. However, of course, they are not the only ones: Today, companies also require lower costs (not only as regards their investment in machinery and chemicals, but also, and above all, in maintenance operations), energy consumption to its lowest levels, ease of process management and high quality results. The TORAN 3® technology is able to satisfy all the above mentioned advantages, by delivering energy efficiency, low environmental impact, lower process costs combining them with high quality results.

Many are the companies worldwide which have already implemented the TORAN 3® technology. Among them, we can mention Canon, the Japanese multinational world leader in imaging and digital solutions for home and office, which is using the single-stage cold pretreatment technology in its USA manufacturing plant in Newport News, Virginia (see ipcm®_International Paint&Coating Magazine, n. 16, Vol. III, 2012, pags. 66-71).

maintenance-free and high efficiency thanks to the zeroing of energy and waste disposal costs. Finally, TORAN 3® reduces the environmental impact of operations: it does not pollute, it does not use water, it does not produce waste, and it requires a very small amount of energy compared with conventional pre-treatment systems.

Conclusions The TORAN 3® one-stage process is rapidly spreading in Europe (France, England and Italy) and in North and South America. The reasons for this are the advantages and benefits that TORAN 3® offers compared with conventional processes: high quality standards and consistency, but also simplicity of the process since it is

VERNICIATURA, SIGILLATURA, INCOLLAGGIO

www.verind.it

Eccellenti apparecchiature di applicazione per tutti i settori industriali, specifiche per prodotti vernicianti e prodotti ad alta viscosità ove è richiesta la protezione da corrosione, nonché la sigillatura e l’incollaggio.

BRAND-NEW

Ultrasonic Measurement System to Monitor Setting Processes

Figure 1: IP-8 system.

Easy to use – intuitive software

- Measuring of Young’s modulus - Extremely high repeat accuracy - Automatic data logging and evaluation.

The products presented include an ultrasonic measuring system designed for a precise monitoring of setting processes for all kinds of materials, especially cement, dry mortar, gypsum, construction chemicals, additives, adhesives and many other applications.

Moreover, IP-8 enables an early stage recognition of deviations by comparing current values with stored reference runs of the curve. The user can easily define admissible deviations from reference curves. These and other evaluation tools make IP-8 an optimal solution for R&D and quality assurance during production processes as well.

ltraTest, a pioneer in ultrasonic measurements, who recently celebrated its 60th anniversary, participates in the European Coatings Show 2017 for the first time.

Signiﬁcant reduction of development time and costs Ultrasonic sound wave velocity measurement is a well-engineered contemporary non-destructive test method offering a variety of advantages that result in a substantial reduction of development time and costs. The 8-channel ultrasonic measurement system IP-8 allows (Fig. 1): - Setting development visualization from mixing to 28-days in one measuring procedure

Figure 2: Three setting curves of standard mortar.

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National Instruments’ international standard software LabView ensures intuitive handling and operation of the ultrasonic measurement system IP-8. The ultrasonic test system can visualize setting processes of any material that undergoes a setting process. Fig. 2 displays three setting curves of standard mortar. 50% H2O is the standard mixing ratio. From the screen, it is easily visible that 40% H2O result in a better consistency, but is difficult to handle. 60% H2O lead to a significantly lower final strength of the mortar. In order to understand critical situations, the user can easily add further curves, e.g. derived signal curves or the temperature of the material under test. The LafargeHolcim group recently installed IP-8 systems in 20 European R&D labs and plants. The product range includes stand-alone systems that can be run in situ. European Coatings Show will be held 4 - 6 April 2017, in Nuremberg, Germany. For further information: www.ultratest.eu

BRAND-NEW

CBPE Capital Acquires Sustainable Solvent Solution Provider SAFECHEM from Dow

supportive owner of the business. With CBPE, I am confident that we have a committed and reliable partner to support our exciting growth plans for the future, such as our geographic expansion and the accelerated launch of new products. The time is right, as our customers have increasing demands for quality, service

BPE Capital LLP (CBPE) has acquired SAFECHEM Europe GmbH (SAFECHEM) from The Dow Chemical Company (Dow). The new ownership structure is effective January 1, 2017. With CBPE as new owner, SAFECHEM has an experienced partner to support its growth strategy. The value of the transaction is not being disclosed. SAFECHEM is an experienced provider of services and solutions related to the safe and sustainable use of solvents for high quality metal cleaning, dry cleaning and asphalt analytics. Committed to the principles of Responsible Care® and Product Stewardship, SAFECHEM develops innovative business models, products and services to optimize the balance between ecology, economy and social responsibility (Fig. 1). CBPE is an established, leading London-based mid-market private equity investor. It has extensive experience in the chemical sector, having invested in five chemical companies over the last 10 years, acquiring assets from Degussa AG, BP plc, Chemtura Corp. and Henkel Inc. “SAFECHEM is a very successful company with a unique business model. The combination of its sustainability mindset, quality-orientation and focus on customer requirements make it exceptional in its market segments. We are looking forward to supporting SAFECHEM’s long-term strategy, enabling the business to thrive in the future,” states Mathew Hutchinson, partner at CBPE. Manfred Holzleg, general manager of SAFECHEM, explains: “I am very pleased to announce CBPE as the new SAFECHEM owner. Dow founded SAFECHEM, establishing the unique business model, and has been a very

Figure 1: The SAFE-TAINER system.

All parties are committed to a smooth transition ensuring that SAFECHEM’s customers will receive a consistent high quality of service.

About SAFECHEM SAFECHEM Europe GmbH was founded in 1992 and is an experienced provider of services and solutions related to the safe and sustainable use of solvents in dry cleaning and surface cleaning. This includes the closed-loop SAFETAINER™ system for the safe and emission-free supply and take-back of solvents. SAFECHEM is committed to the principles of Responsible Care® and Product Stewardship and develops new business models and services like COMPLEASE™ Chemical Leasing to optimise the balance between ecology, economy and social responsibility. With offices in Düsseldorf and Shanghai, SAFECHEM serves in close cooperation with a network of responsible distributors over 5,000 customers world-wide. Expert know-how around the entire cleaning process is offered by SAFECHEM via the CHEMAWARE™ Knowledge Services. www.safechem-europe.com, www.chemaware.org.

About CBPE Capital and flexibility which we are keen to surpass.” “Dow believes that SAFECHEM has a strong and unique business model and will thrive and reach its full potential under a different ownership structure,” says Ralf Brinkmann, Business President of Dow Building and Construction. “This continues Dow’s efforts to further focus our portfolio on assets and businesses consistent with our future strategy.”

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

CBPE Capital is a leading private equity firm with nine funds raised over 32 years. It is currently investing its latest fund, CBPE IX, which had its final close in August 2016 at £459m. Investments are typically made in companies seeking growth or development capital, with an enterprise value of up to £150m. For further information visit www.cbpecapital.com

BRAND-NEW

Dymax Introduces Multi-Cure® 9451 Conformal Coating can be applied in multiple passes. It becomes immediately tack free after curing, helping to avoid handling defects such as fingerprints that may be left on the boards if they are handled too soon, or other damage caused by stacking and arranging the printing boards during processing. Moreover, this multi-cure material can be applied to a variety of substrates including glass reinforced epoxy laminates, glass and stainless steel with a good bond. In essence, the 9451 coating has been developed to cover sensitive information, yet it not will destroy the board surface if removed. This product is in full compliance with RoHS Directives 2002/95/EC and 2003/11/EC.

Dymax 9451 is yet another addition to the Dymax Conformal Coatings product line, which includes UV/Heat-Curable as well as UV/Moisture-Curable materials in a range of viscosities, all providing circuit board protection and shadow-curing capabilities. Their ability to cure in seconds enables faster processing, greater output, and lower processing costs. When cured with Dymax light-curing spot lamps, focused-beam lamps, or flood lamps, they deliver ideal speed and performance. Dymax lamps offer the ideal balance of UV and visible light for the fastest, deepest cures. For further information: www.dymax.com

ymax has announced the release of its newest conformal coating Multi-Cure® 9451. This “true” black material - a single-component, 100% solids, light and heat curable conformal coating - is designed to enhance security on PCBs. In addition to its ability to improve circuit reliability in harsh conditions, its opaque black colour is intended to cover markings, labelling, other identification as well as sensitive information on the circuit board (Fig. 1). Formulated with a secondary heat cure, 9451 can typically be applied and cured at up to 5 mils thick - in one pass - for applications where shadow areas exist. It’s easily dispensed and for thicker coating requirements the material

Figure 1: Multi-Cure® 9451 Conformal Coating.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

Opening photo: The presence of sharp edges in the components intended for the ACE sector is one of the main causes of corrosion.

INNOVATIONS: PRESENT&FUTURE

Cataphoresis and edge protection in the ACE industry Stefano Ballotta Inver Valspar Spa, Bologna, Italy

stefano.ballotta@valspar.com

his article will investigate the main cause of the formation and spread of corrosion in the ACE industry and, more specifically, whether and to what extent cataphoresis can contribute to solving this problem.

Costs of corrosion The estimated costs arising from corrosion problems in the ACE field are about $ 250,000 per year, although some sources report even

higher figures. A large part of these costs is due to the presence of sharp edges and to the lack of adequate protection of such areas (Ref. opening photo). This is a very relevant

and important issue in the ACE sector, while it is less so in other industrial segments where the issue can be approached and partially solved with solutions that go beyond the coatings and their formulation.

The cataphoretic coating is the first protective layer to be applied and it is the one giving the surface most of the anticorrosion properties required.”

Cataphoresis in the ACE industry

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

The cataphoretic coating is the first protective layer to be applied and it is the one giving the surface most of the anti-corrosion properties required. The other layers are therefore left

INNOVATIONS: PRESENT&FUTURE

clearly define the sectors with the task of meeting to be analysed. We have the requirements of look, taken into consideration four resistance to light and segments: automotive OEMs, resistance to any substance appliances, coil and pipe. The with which the painted architectural and packaging component will come in ones could be added as well: contact. Despite having to components, shapes, weighs, ensure the anti-corrosive substrates and thicknesses performance of the coating are clearly defined in these system, the cataphoretic industries. Moreover, each layer is also the thinnest one of them is characterised one: its thickness often does by sufficiently homogeneous not exceed 20-25 microns, 1 technical specifications in sufficient to ensure the desired terms of coating. All of this, performance. Figure 1: Diagram of an excavator showing the complexity and diversity of its in turn, helps to identify the The use of cataphoresis is now components. most efficient and economical expanding in the ACE sector, coating technologies and but its related volumes are systems to be used. always a fraction of the total number. In most In the ACE field, however, the issue is much cases, the cataphoretic process is employed more complicated. Figure 1 schematically in the automotive sector, which offers the but clearly illustrates one of the machines Furthermore, a best conditions for its use – large volumes, attributed to this segment: this excavator – and homogeneity of products, excellent quality comparison between the this also applies to other equipment – is not a and consistency of the substrates as well as coating specifications of all homogeneous object to be coated, but a set of of the pre-treatment processes. That is the component manufacturers dozens of individual parts. Each one of them reason why R&D in the field of cataphoresis will show huge gaps in is different in terms of mass, shape, thickness, have always been focussed on the increasingly terms of performance and substrate, and qualitative and aesthetic stricter needs of automotive OEMs. The same inhomogeneities in the requirements and therefore calls for different proven products, manufactured in large methods and in the number processes, coatings and application systems. volumes, are then also offered to other markets of tests to be conducted.” Cast iron, steel and aluminium components such as the ACE one, although they have not may be treated with sand been specifically developed blasting, phosphating or for them. If all the resources simply washing operations devoted to the car industry and and then painted with different its needs had been invested products and thicknesses in the ACE sector over the by spray, immersion or past twenty years, this would cataphoresis processes. now be characterised by very Furthermore, a comparison different products as well as a between the coating much greater use of them. specifications of all component manufacturers will show huge Market sectors and expectations gaps in terms of performance and inhomogeneities in the Each market segment has methods and in the number of its own peculiarities, which tests to be conducted. greatly influence the approach 2 In this context and for the to the problem of edges reasons listed above, the and their protection. First, Figure 2: The expectations on the cataphoretic process from the different table in Figure 2 summarises therefore, we will have to sectors. international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

the expectations of the various rolled steel, alloys and cast market segments in terms In most cases, however, the task of tackling iron. They are chosen based on of cataphoresis; the general the edge corrosion issue is delegated to the costs, workability, strength, and industry one includes all the pre-treatment and coating processes.” market availability; miscellaneous goods that cannot - Processing: there are countless processing techniques (Table 1), be added to any other sector, but that also employ cataphoretic resulting in different surface conditions prior to coating (e.g. calamine products. As can be seen, some aspects are crucial for all the generated by laser welding processes, swarf and striations); segments (overcoatability and technical assistance); the protection of sharp edges, on the other hand, is a top priority for the ACE field, Table 1: Processing techniques whereas, although required, it is not the “main one” in the other cases. Cutting Methods Forming Methods Sawing

Pressing

Edge protection: approaches

Grinding

Welding

The protection of sharp edges, or even better the solution to any corrosion problem arising from the presence of edges, can be approached with three activities: - selection of materials; - design of components; - development of a specific coating product and/or process.

Drilling

Fastener

Punching

Bonding

Shearing/Guillotine

Riveting

Laser

Bending /Clinching

Flame Plasma Water Jet

The ACE industry’s approach If we analyse the ACE sector with the same method, we find as follows: - Materials: the most used ones are hot and cold

4 Figure 4: The modiﬁcation of the rheological characteristics of products.

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

Figure 3 shows the approach of the automotive sector in these three potential areas of action. Careful selection of materials and their composition is carried out. Over the years, the design process has taken account of several aspects related to corrosion, thus transforming sharpcornered bodies and components in parts with basically no pronounced edges. Finally, the coating process (pre-treatment, paints and application systems) reached the 3 top of the performances besides the cataphoretic Figure 3: The three potential areas of action in the automotive sector. layer, three or four further layers of paint are applied with constant thicknesses and optimal envrionmental conditions.

- Masses and thicknesses: the range is wide and linked to choices made due to costs, resistance performance, damage, and process requirements; - Outsourcing: some processes are often outsourced and this may affect the quality level and the supply chain in general. The most advanced players of the field have tried to minimise these problems. Special galvanic products with ten times greater corrosion resistance than the standard ones have been selected; a pre-painting welding processes have been replaced with post-painting riveting operations; and automatic edge-breaking systems have been installed.

INNOVATIONS: PRESENT&FUTURE

Flat Surface 29,6

Average ERP

Edge

ERR

4,3

14,5%

19,8

4,1

20,7%

Vectrogard 950E

24,6 26,7 24,4

16,5 15,5 11,7

67,1% 58,1% 48,0%

57,7%

Customer

24,9 23,6

14,7 15

59,0% 63,6%

61,3%

Ecoat standard

17,6%

Figure 5: A comparison between a standard product and Valspar Vectrogard/E.

In most cases, however, the task of tackling the edge corrosion issue is delegated to the pre-treatment and coating processes.

Pre-treatment Where possible, one of the adoptable and most widely used solutions in the ACE field is sandblasting. If performed correctly, with properly hung parts and calibrated turbines, media and pressure parameters, this process eliminates calamine, swarf and striations and enables to break most edges. However, the resulting increase in the surface profile (Ra and Rt) must be taken into account because it may require, even on flat parts as in this case, products presenting a similar rheology to those used for the coverage of edges.

High edge coverage coatings for the ACE ﬁeld First of all, it should be said that a coating tends not to remain on the edges of an object due to its surface energy. The phenomenon is very complex and it is not the subject of this article. However, the idea that a component’s surface energy removes the paint from its edges can also explain why the coating manufacturers often focus on this aspect: the modification of the rheological characteristics of products. Figure 4 shows how this phenomenon is controlled. The edge retains a sufficient amount of coating as to ensure corrosion protection. Of course, there exist high edge coverage versions also for other types of paint – solvent-based, water-soluble and powder coatings.

Valspar has started from the conventional product and it has developed a special high edge protection version for the ACE field, formulated and tested together with the end users.”

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

one has been corrosion protection assessments do not determined take it into account. The risk of making the through wrong choices is therefore high. numerous However, it is also clear that end users destructive cannot systematically measure this value tests, based through destructive methods. That is why on numerous the possibility to perform a measurement formulations that does not compromise the integrity of and their related workpieces has been tested. A series of corrosion tests. panels coated both with a standard product In this case, and with Vectrogard 950E has been tested Valspar has with the Electrochemical Impedance 6 started from the Spectroscopy (EIS) technique to assess conventional the edge protection. As shown in the table Figure 6: The increase in the protection performance with Vectrogard 950E. product and it in Figure 6, Vectrogard 950E ensures an has developed a special high However, it is evident that the cataphoretic edge protection version for the ACE field, ones need this characteristic more than Where the ERR value formulated and tested together with the end others do, due to the low thicknesses applied users. was higher than 50% and to the fact that they are often the product The table in Figure 5 (Vectrogard 950E), the edge providing the whole coating system with compares a standard product with corrosion rate was definitely corrosion resistance properties. VECTROGARD/E, Valspar’s high edge lower.” protection The measurement of the edge cataphoretic coating. coverage On the basis of these The ACE industry is highly varied. Without and other results, any proper measurement method, it it can be said that often happens that, since all coating a standard product manufacturers offer high edge coverage has a ERR value paints, end users are in difficulty when ranging from 15 to choosing. In some cases, a product may even 20%, while a high prove to be inadequate. edge protection one A measurement unit must be therefore has values exceeding specified for this characteristic, which can 50%. For applications be defined with the acronym ERR (Edge requiring a 20-30 Retention Ratio). This is a percentage factor micron thickness, calculated in a simple way with following an ERR value of 20% method: is likely to be very critical in terms of edge coverage. ERR = thickness onto the edge x 100% thickness onto the flat part Measuring and therefore collecting In order to measure and calculate this this information is factor a destructive method enabling to crucial to users. The measure the coating’s thickness on the edge coverage value, cross section of the workpiece is used. The in fact, is almost 7 target ERR value that distinguishes a high never added to the edge protection product from a conventional specifications and the Figure 7: Results of the cyclic corrosion test.

INNOVATIONS: PRESENT&FUTURE

increase in the protection of edges by two orders of magnitude (from 106 to 108 ohms). The destructive and non-destructive measurements, then, have been confirmed by corrosion tests carried out on special panels, shaped and designed based on the possible critical situations that could arise in the ACE field; these have been painted with a cataphoretic product and with a cataphoretic product + a white two-component solvent-based liquid topcoat. After the cyclic corrosion test, the results shown in Figure 7 have confirmed expectations. Where the ERR value was higher than 50% (Vectrogard 950E), the edge corrosion rate was definitely lower.

Conclusions In summary, the concepts outlined in this article are as follows: - the volume of cataphoretic products used in the ACE industry is very low when compared with the total number; - the cataphoretic products are often specifically developed for the automotive sector; - the claims for corrosion in the ACE field generate costs of over $ 250 million per year; - edge corrosion is the main cause of such costs; - in the ACE industry, most specifications do not require testing of the edge protection; - the problem can be minimised through the choice of materials, design and manufacturing methods; - in the ACE sector, it is not economically sustainable to adapt the design and the production methods; - high edge protection cataphoresis is a sustainable solution for the ACE field; - Valspar offers a specific cataphoretic product for the ACE sector that meets these requirements.

AT THE CORE OF INNOVATION PAINTING MACHINES AND LINES

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Opening photo: The total costs arising from the corrosion of metal products are equal to about 1.7 billion Euros per year.

INNOVATIONS: PRESENT&FUTURE

Interpon Align “powder on powder” coating system: features and benefits Tullio Rossini Akzo Nobel Coatings, Como, Italy

tullio.rossini@akzonobel.com

ccording to a reliable estimate of global data, the total costs arising from the corrosion of metal products are equal to about 1.7 billion Euros per year. This strikingly high figure, of course, does not only refer to the structural decay of the parts subject to corrosion, but also to the

According to a reliable estimate of global data, the total costs arising from the corrosion of metal products are equal to about 1.7 billion Euros per year.”

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

continuous maintenance works needed to keep the structures in good condition, as well as to the (sometimes costly) replacement of the damaged components. It should also be noted that this problem affects every sector of the metal product market: building structures, agricultural, construction and earthmoving

(ACE) equipment, outdoor plants and facilities, pipes, tanks and engines, to name just a very few. In the face of these data and in order to improve as effectively as possible the protection of metal substrates, especially the ferrous ones, with appropriate coatings or paints, Akzo Nobel Coatings’ R&D laboratories have carefully studied the main corrosion phenomena and developed a new, innovative powder coating system. In particular, it is able to improve the corrosion protection of metal sheets while reducing the application costs and difficulties.

INNOVATIONS: PRESENT&FUTURE

0% Edge Coverage

thus leaving them totally or partially uncovered in several points. In general, a coating system is called such because it requires different treatment stages to be performed in order to ensure its effectiveness on metal substrates: cleaning or washing, chemical conversion or pre-treatment (which can also be mechanical or physical), and finally coating (with one or more layers of organic paint) and full polymerisation.

Innovation: a “powder on powder” system with one polymerisation stage

Any painting/coating system must be Protection of metal satisfactory in terms of: 1 components: a “sharp” a) protection (technical requirement) solution to the problem b) look (aesthetic requirement) Figure 1: One of the primary causes of corrosion is the poor It is easily understood and proved (by c) total cost (economic requirement). coverage of edges. practice as well as by the underlying The conventional coating systems electrochemical theories) that most normally include a chemical precorrosion phenomena on a painted product treatment process, i.e. a chemical conversion start on its edges, especially the sharpest of the surface, cleaning, drying, and primer ones (Fig. 1). By observing these trigger application with a powder coating process or points in the microscope, one can always Most corrosion an electrophoretic one (cataphoresis); this first detect a significant lack of coating thickness coating layer in then crosslinked. Afterwards, phenomena on a painted on such edges, even when the adjacent flat a powder topcoat layer is applied to give the product start on its edges, surfaces have been covered with abundant product the required aesthetic characteristics especially the sharpest ones” paint. Akzo Nobel’s experimental work has in terms of colour, look and texture. The produced a wealth metal pre-treatment of microphotographs process can also • Chemical pre-treatment with E-Coat and Topcoat that clearly show this. be mechanical, i.e. It is therefore sand blasting or shot confirmed that the blasting; also in this coating systems case, however, the directly applied operation is followed on metal, be they by the application of a • Chemical pre-treatment with Primer and Topcoat powder, solventprimer and a topcoat based or water-based (Fig. 2). systems, are generally Anyhow, if we not able to adequately compare the costs and cover the edges of the environmental/ • Mechanical pre-treatment with Primer and Topcoat workpieces. In the energy impact of industry jargon, it is powder systems 2 commonly said that a with those of liquid coating “runs away” systems, even with an Figure 2: Operating diagram of conventional coating systems. increased efficiency, from the edges,

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

the former prove Standard Energy Efficient significantly better Wet Coating Wet Coating in terms of both CO2 emissions (carbon footprint) and energy Footprint costs, also including Depuration and the waste, VOC and Waste VOS management Energy Cost (Fig. 3). Akzo Nobel’s VOC & CO2 innovative solution Capital Cost aims at a further significant increase Figure 3: Comparison between systems. in the efficiency of two-layer powder coatings in terms of costs and implementation times. This This technology, called technology, called Interpon ALIGN, eliminates a complete polymerisation cycle, thus saving Interpon ALIGN, eliminates money, energy and time. a complete polymerisation

cycle, thus saving money, energy and time.”

Interpon ALIGN © Akzo Nobel

This new system can be used with either a chemical or Chemical pre-treatment with 2C1B Primer and Topcoat a mechanical pretreatment process. It undoubtedly leads to many benefits for its applicators (Fig. 4): - Increased Mechanical pre-treatment with 2C1B Primer and Topcoat productivity = increased production on an hourly basis; - One type of primer 4 to minimise the need for colour Figure 4: The new ALIGN coating system. change operations; - Elimination of a Based on these general assumptions, the complete polymerisation cycle; two types of Interpon Align now available are - Flexible, compact and synchronised coating both able to achieve the objectives mentioned line; above. They are as follows: - Reduced investment; - Ability to meet the most demanding technical 1. “Dry-on-Dry” type, to be applied on cold requirements (e.g. OEM and ACE industries) by substrates; achieving a high protective and aesthetic level; 2. “Dry-on-Fused” type, to be applied on hot - High corrosion resistance; substrates. - Reduced carbon footprint.

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

In the case of the Dry-on-Dry system, the pre-treatment process is followed by the electrostatic application of the two layers of powder coating, immediately one after the other (i.e. without any full or partial crosslinking or curing of the first layer, Fig. 5). With the Dry-on-Fused system, on the other hand, the application of the first layer is carried out on a surface that has been pre-heated in the oven; also in this case, however, the second layer is applied immediately afterwards, with no intermediate crosslinking stage (Fig. 6). With both systems, the application of the two layers of powder is followed by an oven polymerisation phase that enables the coating system to completely crosslink in one stage (Fig. 7). It is worth mentioning that the powder coatings used with this particular application technology are specifically formulated and they must have specially developed formulation and physical-chemical characteristics (e.g. particle-size distribution). Also the application parameters and, above all, the charge polarity of the particles during the electrostatic spraying stage must be carefully adapted to the process. Especially for the Dry-on-Dry system, this plays a fundamental role in obtaining the deposition of the two layers and ensuring that all the protection and aesthetic requirements are met (Figs. 8 and 9).

Powder Coating

INNOVATIONS: PRESENT&FUTURE

Topcoat Application

Curing

Temperature

Powder Primer Application

Time

Figure 5: The Dry-on-Dry process deﬁnition.

Powder Primer Application

Powder Topcoat Application

Curing

Temperature

Drying Oven

Time

70°C

7 Figure 7: Temperature and ﬁlm formation.

85°C

Figure 6: The Dry-on-Fused process deﬁnition.

Substrate Temperature 150°C

DryOnFused

Traditional Application

In summary, the Environment 85°C main advantages ensured by the Dryon-Dry system are as follows: DryOnDry 1. Products: powder coating systems Opposite Pole compatible with Application each other and 8 easier to use; 2. Products: control Figure 8: The 2C1B process. of the rheology of the product in its melt phase, ensuring an optimal balance between protective and aesthetic functions; 3. Application: improved and satisfactory coverage of edges; 4. Application: application uniformity obtained through the correct management of the polarity during powder spraying; 5. Application: selection of the application systems based on the parts’ Traditional System 9 shape and complexity.

enables the coating system to completely crosslink in one stage”

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

1. Products: the primers used are already existing, known and used for some time, resulting in an increase of efficiency; 2. Products: already existing track records can be used; 3. Products: the highly reactive coating systems further improve the benefits obtainable; 4. Application: improved and satisfactory coverage of edges; 5. Application: conventional application methods can be used; 6. Application: the primer’s charge is dissipated (this layer is applied by melting on the preheated workpiece); 7. Application: high transfer efficiency.

Also in this case, the system can be further improved as follows: - Influence of the metal substrate’s thickness/ mass ratio on the application results; - Efficient control of the overall thickness applied, especially as regards the primer (hot application, Fig. 10).

Optimised DryOnDry System

Figure 9: The ﬁlm uniformity. However, the system can be further improved as follows: - Influence of the type of substrate, its surface preparation and its thickness/mass ratio on the application results; The application of - Proper management of the thickness the two layers of powder uniformity that can be obtained for is followed by an oven the two layers. polymerisation phase that

On the other hand, the main advantages ensured by the Dry-onFused system are as follows:

Advantages and key parameters of the system

Conclusions In view of all the parameters and aspects that we have described so far, we can state that the Interpon ALIGN system, as well as featuring an innovative technology, ensures a significant advantage in terms of energy savings thanks to the elimination of a

INNOVATIONS: PRESENT&FUTURE

Dry-On-Dry

Dry-On-Fused

Figure 10: One of the advantages of the ALIGN system is the absence of intermixing between the two layers.

11 Figure 11: A comparison of the various rheological proﬁles of a coating.

complete polymerisation stage. A second benefit is the reduction of the total time needed to coat a component, with a positive impact on the hourly productivity. The metal workpieces with a particularly large dimension, mass or thickness can especially benefit from these advantages. Referring to what we wrote at the beginning of this article, it is worth highlighting that also the coverage of edges is much increased, with a layer thickness such as to ensure excellent performance in terms corrosion protection (Fig. 11). Last but not least, the good aesthetic properties of the two layers applied with both the Dry-on-Dry and Dry-on-Fused Interpon ALIGN systems will enable any coater, be it working on its own or as a contractor, to meet the most stringent specifications of important sectors such as those of ACE or industrial vehicle OEMs.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

BUSINESS TRAINING

Strategic planning: Back to the business definition Felice Ambrosino consultant

simeida@tin.it

n our previous article (Strategic planning: The definition of the business, ipcm®_International Paint&Coating Magazine no. 13, Vol. III, 2012, pages 72-78), we insisted on the need to define a business in terms of customers’ needs and desires and not in terms of products. We presented

A product is nothing more than the application of a technology aimed at satisfying the needs and desires of certain groups of customers”

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

Abell’s three-dimensional model (customer needs, strategic customer groups, alternative technologies), where the product is not even explicitly mentioned, but conceptually included in the combination of the other parameters: a product is nothing more than the application of a technology aimed at satisfying the needs and

BUSINESS TRAINING

desires of certain groups of customers. That is why we mentioned the great work of Theodore Levitt, who placed the customer, his needs, his aspirations and his ambitions at the centre of a company’s activities. Levitt firmly believed in this assumption. In his famous Marketing Myopia, published in 1960 and later become a Harvard Business Review “classic”, he went so far as to state that a business should be seen as an economic process created to satisfy the customers, and not to produce goods. He claimed – and history proved him right – that any product is transient, since it has a life cycle that, albeit gradually, leads it to decline and then disappear, whereas needs are not. Needs endure over time, sometimes forever. Therefore, customers’ needs are the strategic key to open up new markets. As has been repeatedly said, focussing on products means to focus on a secondary aspect of a business, thus sacrificing creativity and withdrawing into a narrow view of reality. Such vision prevents a company from understanding the real needs of its groups of customers, seizing opportunities, broadening the concept of competition up to include indirect and potential competitors, and developing the strategic capabilities needed to predict trends and choose the right route to “steer the ship in calm waters”. Levitt’s warning, launched almost fifty years ago, is therefore still relevant: “Nowadays, it is all too easy to be lead to follow the economic

A business, therefore, must be defined by placing the needs and desires of customers – and, of course, the ways to meet them – at the centre of attention. This is the marketingoriented approach.” principles of mass production and invest all energies for productive purposes only, forgetting what is the true function of a company. The entrepreneur who does not dare to go against the tide will inevitably consider himself as a producer of goods and services, instead of an operator committed to meeting the needs of consumers.” A business, therefore, must be defined by placing the needs and desires of customers – and, of course, the ways to meet them – at the centre of attention. This is the marketing-oriented approach. Otherwise, a company remains linked to a production and sale cycle. This is precisely the difference between sales and marketing: the former are driven by the seller’s need to turn a product into money, while the latter requires to be “obsessed” by the need to meet the customer’s requests. For instance, a company that operates in the business of coatings for the residential and building sector should stop defining its business in terms of tempera, washable paints, breathable coatings, enamel, stucco, primers and so on and try to identify the real needs of those who go to a store or a supermarket to buy a tin full of a chemical product. It may find out that their real need is for cleanliness and perhaps hygiene, renewal, colour, status symbol, or simply for a kid to be happy with his freshly painted room. This could bring to the definition of a new market

w w w . c m s p r a y . i t

Starting from this issue, ipcm® resumes the series of articles dedicated to marketing and business management, in the section named BUSINESS TRAINING. The purpose of this section of the magazine is not lecturing, but offer some important insights, theoretical and practical references, and a conceptual frame to continue to do marketing, because marketing is the very essence of a business, large or small the task be. The author of the articles is the Dr. Felice Ambrosino, a chemist who, after three years in the research university has worked for 27 years in the paint industry for the multinationals of the caliber of Max Meyer and held various positions from research to sales to marketing. Left the employees, in 1993 he founded Studio Sigma (General Management System), a consulting group that brings together 22 business leaders, all from the chemicals sector, each specialized in their functions, from finance to manufacturing, sales marketing to research. Studio Sigma has among its clients the most prestigious national and international

segmentation, the expansion of the product range, the creation of promotional initiatives or the decision to reposition the company’s brand. A company’s activity, therefore, should not be focussed on its products, but on the satisfaction of the needs and wishes of its customers. That is the step to be taken: from the product sale to the customer satisfaction, from transitional to permanent values. In his famous Marketing Management, Kotler gives the example of horse carriage manufacturers, which disappeared from the market as soon as the first cars were launched. Perhaps, if they had redefined their business in terms of customer need, i.e. individual transport of people instead of production of carriages, they could have diversified their activity and enter the market as car manufacturers. In short, the lesson is clear: all corporate activities should be reviewed in the light of the needs to be met and not of the products to be sold. The customer is the core of this business model and the satisfaction of his needs is the

companies and operates exclusively for charitable purposes, and donate to non-profit and charitable all of its revenues. The topics of the previous series of articles, again by Dr. Ambrosino, can be tracked down in the following issues of ipcm®: - “The concept of marketing”, published in two parts in ipcm® n. 1, Vol. I, January 2010 and ipcm® n. 2, Vol. I, March 2010: birth of the market-oriented philosophy, with history in brief until its modern definition. - “Business survival: strategic marketing the importance of the mission statement”, published in ipcm® n. 3, Vol. I, May 2010: the importance for small and medium sized companies of business planning, starting right from the mission, to growth also in periods of economic crisis. - “Analysys of the sector”, published in two parts in ipcm® n. 4, Vol. I, July 2010 and ipcm® n. 6, Vol. I, November 2010: how to find its own goals and how to know the competitive background.

raison d’être of the supplier, the source of its profit. A satisfied customer is an asset for an enterprise, a guarantee for its future existence, a wealth of strategic importance; a dissatisfied customer, however, is a loose cannon ready to explode at any moment. The moral is that a company should not sell products: if it wants to win the race, it must enrich the relationship with its customers by adding value to their exchange. This means “to sell profit” instead of products, i.e. provide the customers with a profit for them, knowledge about how to improve their business, and a factual contribution to achieving this goal, as beautifully stated by Jack Malcolm in his Bottom-line selling.1 However, a generic knowledge of the market and the customers – often boasted but rarely possessed – is not enough to get to sell profit. Of course, a particularly “smart” seller 1 Jack Malcolm, Bottom-line selling, Booktrope Editions. Jack Malcolm is the President of the Falcon Performance Group, a company specialised in training professional sellers.

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

- “The strategic market planning” and the second part, “The strategic market planning: An eye for the company organization”, published in ipcm® n. 8, Vol. II, March 2011 and ipcm® n. 9, Vol. II, May 2011: the different strategies a company may start to prevail and survive on the market, and how to put them into practice. - “How to cope with the environmental change: the environmental analysis”, published in ipcm® n. 10, Vol. II, July 2011: how a business can update its arrangement when the changings of the business conditions and of the macro-environment ask for it. - “Strategic planning: business definition”, published in ipcm® n. 13, Vol. III, January 2012: how to define its own business contest in three dimensions and how to assess how much this affects the company structure. The first article of the new series catches again the threads of the previous one, by underlining how important it is for a company to focus on the Customer’s needs and wishes.

All corporate activities should be reviewed in the light of the needs to be met and not of the products to be sold.” gathers more information than others do on his customers, but the knowledge it takes to sell profit is something else. It goes beyond the limits of “normal”, up to the knowledge of the customer’s customers and their needs, and therefore of the client’s business, the position that a person occupies within the company, the approach followed by the firm to improve the business of its own clients, and so on. This is the knowledge that enables to sell profit. Modern marketing is not a stranger to this problem and it has developed many techniques to help the companies take the leap. One of these is the Customer Satisfaction Analysis & Management, another one is the abovementioned “selling profit” concept. Both of these methods will be described in future articles.

BRAND-NEW

Dörken Days 2016

1 Figure 1: Numerous representatives from the automobile industry as well as the subcontractor industry attended the Dörken Days 2016.

his year the Dörken Days took place in Münster (Germany), from 24 to 26 November 2016. Numerous representatives from the automobile industry as well as the subcontractor industry from throughout Europe and Turkey made their way to the small city of Münster. In addition, representatives of the construction industry, plant engineering firms and, of course, the whole range of Dörken coating companies came together to learn news from the company and the international automobile market as well as to discuss current technical issues and developments (Fig. 1). One of the guest papers presented on the first day was that of Scherdel GmbH. Entitled “Component testing vs. module testing”, it addressed possible factors influencing individual components in the module. The fastener manufacturer Revifa SpA reported on the approval process at the OEM, describing it as a “major challenge”. The conclusion to the trade programme on this day came in the form

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

of a paper by Dörken MKS on specification work in the USA. The second day of the event was initially focused on “screwed fasteners”. Following an introduction to this subject by Michael Stähler of Dörken MKS- Systeme GmbH&Co.KG, the participants received key background information on current amendments to screwed fastener standards. This was followed by the presentation of guest papers by REC Engineering GmbH, Schatz GmbH and TesT GmbH, who have established themselves in their field as manufacturers for screw test benches. The participants at the symposium praised the depth of information of the papers, with numerous practical benefits for everyday tasks, but also enjoyed the fact that the schedule allowed ample time for discussion and networking. Further information: www.doerken-mks.de

BRAND-NEW

Dörken MKS awarded prize for organisation

target group-oriented establishment and process organisation, which places the customer in focus at all times. From initial customer contact to the projectspecific development of solutions and on to production and continuous quality controlling, Dörken MKS offers comprehensive service and sectorspecific consulting in a one-stop format – both in Germany and internationally. In this respect the jury also had particular praise for the strategy of targeted growth at global as well as national level. “We are on the right track” At the award ceremony in Berlin on 12 October 2016 the Dörken MKS team (Fig. 1) with Marvin Urban (Business

Controller), Dennis Mulalic and Tobias Schmitz (both Global Sales Industry Sales Manager) were delighted with the distinction. Dennis Mulalic states: “We are very pleased to have convinced the jury of experts with our strategy of clear target groups and project orientation. This shows that we are on the right track.” The Deutscher Preis für Sales Performance was awarded for the first time in 2016 under the patronage of the Quadriga Hochschule and Vertriebsmanager magazine. Organised into various categories, it recognises outstanding achievement in the field of sales and sales management. Further information: www.sales-performance-preis.de

örken MKS has been awarded a prize by a jury of experts in Berlin for its exemplary market orientation and consistently customer-oriented organisation. After successfully making it to the final of the best companies, Dörken MKS fended off well-known firms in the category of “Organisation” to win over the jury of experts, which included experienced managers from ProSiebenSat.1, Samsung, Microsoft, adidas, Coca-Cola and Lufthansa. In the “Organisation” category of the Deutscher Preis für Sales Performance Dörken MKS was picked from a nominated list of six companies in the final round. Persuasive points were above all the new, more efficient and consistently

Figure 1: The Dörken MKS team with Marvin Urban (Business Controller), Dennis Mulalic and Tobias Schmitz (both Global Sales Industry Sales Manager).

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

2017

C O R S I D I FORMAZIONE

LA F OR MAZI ONE PER I TECNI CI DI VER NI CI ATU R A E I L CONTR OL L O QUALI TÀ NELLA GENER AL I NDU S T RY

L’informazione e l’aggiornamento per mantenere l’eccellenza

MILANO- Innovhub SSI - Divisione Oli e Grassi 1^ sessione _ 16-17-23-24 marzo 2017 / 13-14-21 aprile 2017 2^ sessione _ 12-16-19-20 ottobre 2017 / 9-10-17 novembre 2017

ROMA - Università degli Studi di Roma Tor Vergata sessione unica _ 11-12-25-26 maggio 2017 / 8-9 giugno 2017

PRESENTAZIONE La qualità finale di un rivestimento anticorrosivo e la sua “durabilità” sono strettamente correlabili alla corretta gestione del processo di protezione dalla corrosione. Le cause del degrado prematuro di un ciclo protettivo sono riconducibili a diverse problematiche quali per esempio materiali difettosi, Specifiche Tecniche non adeguate, processo non conforme e non adatto a garantire la “durabilità” attesa, utilizzo improprio del manufatto, e tutti i “protagonisti” che partecipano allo sviluppo e alla gestione del processo anticorrosivo oltre che all’utilizzo finale del manufatto, possono avere la responsabilità del suo precoce deterioramento: i progettisti, i produttori di cicli, gli applicatori, gli addetti ai controlli, i manutentori, gli utilizzatori. La “conoscenza” e un accurato controllo dell’intero processo protettivo possono evitare o limitare i danni derivanti dal degrado prematuro di un ciclo di verniciatura.

Docente: Paolo Rami, Maestro del Lavoro, esperto in progettazione e omologazione di processi anticorrosivi e di analisi sulle problematiche e difettologie specifiche dei processi di verniciatura

Collabora ai corsi di Milano: dr. Gianmaria Gasperini, responsabile del Laboratorio Pitture e Vernici di Innovhub SSI - Divisione Oli e Grassi

Questa serie di corsi modulari di formazione professionale - organizzati da ipcm_ academy – settore formazione della rivista ipcm® international paint&coating magazine – definisce le problematiche relative alla corrosione dei materiali metallici e approfondisce quindi le operazioni che si devono svolgere durante le fasi critiche del processo di verniciatura, partendo dal pretrattamento fino al controllo qualità. Obiettivo: informare, aggiornare e formare i tecnici del settore della verniciatura industriale sulle tematiche tecniche e sulle attività di maggior interesse per chi si occupa di impianti, vernici e verniciatura nella propria attività quotidiana. I corsi – modulari e contraddistinti da una parte teorica e una parte pratica – si rivolgono a operatori della verniciatura, responsabili di reparto, tecnici commerciali dei produttori di vernici, responsabili del controllo qualità. Il corso di Milano è ideato in partnership con Innovhub SSI e il suo Laboratorio Pitture e Vernici, struttura tra le più qualificate a livello europeo e specializzata nella caratterizzazione dei prodotti vernicianti e nella verifica della durabilità dei materiali. I diversi moduli compongono un percorso formativo in grado di affinare le competenze professionali dei partecipanti e fornire nozioni di base sulle tecniche, sui processi e sulle innovazioni in materia di sistemi applicativi, metodi e strumenti per il controllo qualità e sulle prestazioni dei rivestimenti elettroforetici. Come tratto distintivo, le lezioni, oltre alle spiegazioni tecniche approfondite, prevedono dimostrazioni e prove pratiche della fase di controllo qualità attraverso strumentazioni professionali e campioni, con l’interazione dei partecipanti.

MILANO

Innovhub SSI - Divisione Oli e Grassi Via Giuseppe Colombo 79 - Milano

MODULO 1A - CORROSIONE E ANTICORROSIONE Orario corsi 10>17 (1 ora di pausa)

1^ SESSIONE 16.03.2017 - 2^ SESSIONE 12.10.2017 i supporti metallici - la corrosione - corrosione e impatto economico - fenomeni e meccanismi HM GSVVSWMSRI GSVVSWMSRI EXQSWJIVMGE GSVVSWMSRI IPIXXVSPMXMGE GSVVSWMSRI TIV GSVVIRXM vaganti - altre tipologie di corrosione in presenza di umidità - corrosione dei metalli TMº GSQYRM TVSXI^MSRI HEPPE GSVVSWMSRI EXXMZE I TEWWMZE VMZIWXMQIRXM WYVJEGI XSPIVERX TVSKIXXE^MSRI HIM QERYJEXXM RSVQEXMZE HM VMJIVMQIRXS

MODULO 1B - IL PRETRATTAMENTO ALLA VERNICIATURA 1^ SESSIONE 17.03.2017 - 2^ SESSIONE 16.10.2017 M WYTTSVXM QIXEPPMGM GSRXVSPPM EQFMIRXEPM IH YQMHMX¡ VIPEXMZE MRXVSHY^MSRI EPPE TVITEVE^MSRI HIPPI WYTIVJMGM TYPM^ME TVIPMQMREVI XVEXXEQIRXM QIGGERMGM WEFFMEXYVE I XMTSPSKME HM graniglia - trattamenti chimici - anaforesi e cataforesi - controllo superficiale e impiantistico normativa di riferimento

MODULO 2A - APPLICAZIONE VERNICI IN POLVERE 1^ SESSIONE 23.03.2017 - 2^ SESSIONE 19.10.2017 introduzione - protezione dalla corrosione - come funziona un p.v. - prodotti vernicianti in polvere - vantaggi e svantaggi p.v. in polvere - campi di applicazione polveri termoplastiche - polveri termoindurenti - caratteristiche delle polveri e loro destinazione - controlli - sistemi di applicazione - cabine manuali ed automatiche forni - manutenzione

MODULO 2B - APPLICAZIONE VERNICI LIQUIDE 1^ SESSIONE 24.03.2017 - 2^ SESSIONE 20.10.2017 introduzione - protezione dalla corrosione - condizioni ambientali - come funziona un p.v. preparazione delle vernici - prodotti vernicianti liquidi - cicli di verniciatura - verniciatura dei supporti in composito - essiccazione/indurimento dei p.v. liquidi controlli - sistemi di applicazione - tecniche applicative - cabine manuali ed automatiche - forni - manutenzione

MODULO 3 base - TECNICHE DI CONTROLLO SUI PRODOTTI VERNICIANTI 1^ SESSIONE 13.04.2017 e 14.04.2017- 2^ SESSIONE 09.11.2017 e 10.11.2017 introduzione - normative e specifiche - specifiche e documentazione gestione processi controlli - controlli sui p.v. da parte del produttore - controlli del processo - omologazione difettologia p.v. liquidi - difettologia p.v. in polvere - strumenti d’ispezione - altre attività per il controllo del processo - identificazione e rintracciabilità - non conformità e azioni GSVVIXXMZI I TVIZIRXMZI GIRRM PYGI I GSPSVI ZMWMXE EM PEFSVEXSVM 773+

MODULO 3 avanzato - CONTROLLI AVANZATI DELLE SUPERFICI VERNICIATE 1^ SESSIONE 21.04.2017 - 2^ SESSIONE 17.11.2017 introduzione - buccia d’arancia e D.O.I. (principi funzionamento strumenti) - spettrofotometri multiangolo (principi funzionamento strumenti) - cloud/runner (misurazione delle macchie) Acet test - fallimento di p.v./ciclo anticorrosivo - difettologie comuni p.v. liquidi e cause HMJIXXSPSKMI GSQYRM T Z MR TSPZIVI I GEYWI IWIQTM GVMXIVM EGGIXXEFMPMX¡ TVSZI SQSPSKE^MSRI identificazione p.v. dopo reticolazione - schede controllo qualità - compilazione documenti di controllo

Università degli Studi di Roma Tor Vergata Via della Ricerca Scientifica 1 - Roma

ROMA

MODULO 1A - CORROSIONE E ANTICORROSIONE 11.05.2017 i supporti metallici - la corrosione - corrosione e impatto economico - fenomeni e meccanismi HM GSVVSWMSRI GSVVSWMSRI EXQSWJIVMGE GSVVSWMSRI IPIXXVSPMXMGE GSVVSWMSRI TIV GSVVIRXM vaganti - altre tipologie di corrosione in presenza di umidità - corrosione dei metalli TMº GSQYRM TVSXI^MSRI HEPPE GSVVSWMSRI EXXMZE I TEWWMZE VMZIWXMQIRXM WYVJEGI XSPIVERX TVSKIXXE^MSRI HIM QERYJEXXM RSVQEXMZE HM VMJIVMQIRXS

Orario corsi 10>17 (1 ora di pausa)

MODULO 1B - IL PRETRATTAMENTO ALLA VERNICIATURA 12.05.2017 M WYTTSVXM QIXEPPMGM GSRXVSPPM EQFMIRXEPM IH YQMHMX¡ VIPEXMZE MRXVSHY^MSRI EPPE TVITEVE^MSRI HIPPI WYTIVJMGM TYPM^ME TVIPMQMREVI XVEXXEQIRXM QIGGERMGM WEFFMEXYVE I XMTSPSKME HM graniglia - trattamenti chimici - anaforesi e cataforesi - controllo superficiale e impiantistico normativa di riferimento

MODULO 2A - APPLICAZIONE VERNICI IN POLVERE 25.05.2017 introduzione - protezione dalla corrosione - come funziona un p.v. - prodotti vernicianti in polvere - vantaggi e svantaggi p.v. in polvere - campi di applicazione TSPZIVM XIVQSTPEWXMGLI TSPZIVM XIVQSMRHYVIRXM GEVEXXIVMWXMGLI HIPPI TSPZIVM I PSVS destinazione - controlli - sistemi di applicazione - cabine manuali ed automatiche forni - manutenzione

MODULO 2B - APPLICAZIONE VERNICI LIQUIDE 26.05.2017 introduzione - protezione dalla corrosione - condizioni ambientali - come funziona un p.v. preparazione delle vernici - prodotti vernicianti liquidi - cicli di verniciatura verniciatura dei supporti in composito - essiccazione/indurimento dei p.v. liquidi controlli - sistemi di applicazione - tecniche applicative - cabine manuali ed automatiche - forni - manutenzione

MODULO 3 base - TECNICHE DI CONTROLLO SUI PRODOTTI VERNICIANTI 08.06.2017 MRXVSHY^MSRI RSVQEXMZI I WTIGMJMGLI WTIGMJMGLI I HSGYQIRXE^MSRI KIWXMSRI TVSGIWWM controlli - controlli sui p.v. da parte del produttore - controlli del processo - omologazione difettologia p.v. liquidi - difettologia p.v. in polvere - strumenti d’ispezione - altre attività per il controllo del processo - identificazione e rintracciabilità - non conformità e azioni correttive I TVIZIRXMZI GIRRM PYGI I GSPSVI ZMWMXE EM PEFSVEXSVM 773+

MODULO 3 avanzato - CONTROLLI AVANZATI DELLE SUPERFICI VERNICIATE 09.06.2017 introduzione - buccia d’arancia e D.O.I. (principi funzionamento strumenti) - spettrofotometri multiangolo (principi funzionamento strumenti) - cloud/runner (misurazione delle macchie) Acet test - fallimento di p.v./ciclo anticorrosivo - difettologie comuni p.v. liquidi e cause HMJIXXSPSKMI GSQYRM T Z MR TSPZIVI I GEYWI IWIQTM GVMXIVM EGGIXXEFMPMX¡ TVSZI SQSPSKE^MSRI identificazione p.v. dopo reticolazione - schede controllo qualità - compilazione documenti di controllo

TOR VERGATA

S E G R E T E R I A ORGANIZZATIVA EOS Mktg&Communication Srl Via Pietro Mascagni 8 20811 Cesano Maderno (MB) Tel. 0362 503215 - Fax 0362 1794768 e-mail: corsi@ipcm.it

eos eos

MKTG & COMMUNICATION MKTG & COMMUNICATION

TOR VERGATA

www.myipcm.it

CONFERENCES

ACE 2016: The technological evolution of coating plants and systems for agricultural, construction and earthmoving machinery

n December 14th 2016, ipcm organized overview of the state of the art and of the the technical conference “ACE 2016 – latest innovations as regards coating products The technological evolution of coating and plants. In this way, it gave the specialists plants and systems for the ACE industry” which of the agricultural, construction and took place at the CNR – Centro Nazionale earthmoving industry the tools to understand Ricerche (National Research Center) in Bologna, which innovation path is best for their Italy. companies in terms of feasibility, finances and The industry of agricultural, construction and performance. earthmoving (ACE) machinery is a very large The different reports will provide insights on sector that generates a significant demand for the concept of industry 4.0 applied to the coatings, posing very specific and stringent coating field and presented success stories requirements in terms of performance, corrosion protection and aesthetics. Actually, these machines call for finishes with an aesthetic quality comparable to that of the automotive industry, but with even higher mechanical resistance properties: in fact, the coatings applied must withstand extreme working conditions, able to trigger corrosion very easily. Furthermore, in terms of management of the coating systems, the ACE industry Figure 1: Overview of the audience at the conference. requires increasingly sophisticated and highly automated equipment, able to of companies from the ACE sector that have ensure energy efficiency, reduction of labor and process optimisation in order to boost profit adopted advanced coating systems over the past two years. margins. Finally, the plants must enable a company to The program of the conference was as follows: choose to replace the conventional solventbased systems with coatings characterised Technological trends in the coating industry for the ACE sector: the greatest challenges in by a lower environmental impact, such as the near future for paints - Massimo Trevisan, water-based and high solids paints, or with mixed systems that are perfectly adapted to the Komatsu Manufacturing Italy specific quality requirements. The ACE 2016 conference offered in-depth Pre-cataphoresis nanotechnology processes examination of these issues through a detailed - André Bernasconi, Dollmar

Coating plants: solutions for energy efficiency, reduction of manpower and maximum quality. Presentation of international cases of success - Alessandro Tramontin, Imel Benefits and developments of cataphoresis in the ACE Sector - Stefano Ballotta, Inver-Valspar Industrialisation of Direct to Metal paint cycles: the contribution to application technologies & engineering systems Alessandro Soba, Verind The trend towards the introduction of low VOC content paints: performance, appearance and application differences Marzio Marchesi, Arsonsisi Getting to the next level of ACE: new binders, adhesion promoters and grinding resins for low VOC coatings Heiko Alzer, Evonik Powder-on-powder systems to increase corrosion protection in the ACE sector Tullio Rossini, Akzo Nobel Coatings The concept of industry 4.0 applied to the coating field - UCIF Over 90 professional of the sector attended the conference in Bologna (Fig. 1): they could benefit both from the technical presentations and from the meeting area where they could interact directly with sponsor partners to create unique opportunity for business and information exchange.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2017 - N. 43

STANDARD & LEGISLATION - UCIF Informs

Italy’s 2017 budget law: hyper-amortisation plans have come to life Marcello Zinno UCIF-Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

used to give or change any surface characteristic of products and/or give any function to surfaces”). As regards these goods, however, the companies are not “simply” required to make expenditures in the form of investments and integration into their own production processes, but also to create an interconnection with other systems

e would like to talk again about Industry 4.0 and hyper-amortisation plans. In our last article, we have written that, in the new stability law issued by the Italian Government, the old “showers” of general subsidies have been replaced with aids aimed at economically supporting specific corporate investments. This is in line with the Industry 4.0 concept. The goal is to help modernise the Italian industrial fabric, but also give it a higher level of competitiveness than those of other countries and continents. Intensive work coordinated by the Ministry of Economic Development has been carried out to choose the target sectors of these subsidies and the categories of goods (including their related functions and enabling factors) that will be the subject of horizontal fiscal incentives. The ANIMA Federation collaborated in the proposal of the sectors that are most in need for such incentives, in order to move with the times and enjoy the benefits that the Industry 4.0 will bring. Among various tax policies for growth, the Attachment A of the stability law, called “Goods for the technological and/ or digital transformation of enterprises into Industry 4.0 companies”, includes a list of material goods that can be the subject of such incentives. There is also a clear reference to the surface treatment industry (“tools and systems

info@ucif.net

and/or devices in order to exploit the benefits in terms of modernisation ensured by the Industry 4.0 framework. The Attachment B of the law, on the other hand, refers to investments in intangible goods (software, systems and system integration, platforms and applications) and opens the way to a whole series of incentives for products that are not material goods but that can equally (if not more so) enhance the competitive value of a company, in the digital information era. Examples are referred to software, systems, platforms and applications for the design and

N. 43 - JANUARY/FEBRUARY 2017 - international PAINT&COATING magazine

re-design of the following: production systems able to take account of the material and information flows, virtual reality for the development of components and operations, artificial intelligence and machine learning systems, means of communication and data sharing (Industrial Internet of Things), industrial analytics for the treatment and processing of big data received from IoT sensors, and other advanced solutions. All these subsidies became a reality on January, 1st 2017, although the stability law was published on December, 21st in the Official Gazette. The presence of a hyper-amortisation tool, with an up to 250% amortisation rate of corporate investments, has been confirmed. Given the importance of this new tool, the Ministry of Economic Development plans to issue an explanatory guide for its application. The guide will provide companies, certification bodies and experts involved with the correct instructions for the application of the incentive. In order to speed up the process and write an effective and comprehensive guide, a working group has been created in which also the ANIMA Federation will be involved.

INTERALL IS PLEASED TO ANNOUNCE

THE MILLENNIUM EVENT THE ALUSPECIALIST’S MEETING

10TH ALUMINIUM WORLD CONGRESS 6TH INTERNATIONAL ICEB CONFERENCE

20 - 24 June 2017 PalaExpoCongress VeronaFiere y Verona - Italy

THREE EVENTS IN ONE: The Strength of Synergy and the Power of Innovation …CONFERENCE TOPICS… MARKETS & STRATEGIES, ALLOYS BILLETS & RELATED EQUIPMENT, ROLLING TECHNOLOGY, ARCHITECTURE & SPECIAL USES, TRANSPORT & AUTOMOTIVE INDUSTRY, ANODIZING, COATING, NANO TECHNOLOGY, AUTOMATION, MEASURING, TESTING & QUALITY TECHNIQUES, ADVANCED APPLICATIONS & RESEARCH, ENVIRONMENTAL PROTECTION & RECYCLING, CASTING & DIE CASTING, ICEB SESSION & EXTRUSION: PROCESS SUSTAINABILITY, PROCESS MANAGEMENT, PROCESS MONITORING, PLANT & PROCESS, PROCESS SIMULATION, PRODUCT QUALITY, ALLOYS, DIES, NEW PROCESSES

Along with Expo of customized technology for the aluminium & innovative metals industry

EVENT ORGANIZED BY: Interall Srl: Via Gino Marinuzzi- 38 - 41122 Modena - Italy - Tel. +39-059-282390 - Fax +39-059-280462 aluminium2000@interall.it - www.aluminium2000.com ICEB Organizing Committee at University of Bologna: www.ice-b.net

g ua

a lL

ia Àc f h O lis g En

21 / 24 GIUGNO 2017 VERONA

EXPO OF CUSTOMIZED TECHNOLOGY FOR THE ALUMINIUM, FOUNDRY CASTINGS & INNOVATIVE METALS INDUUSTRY

TRADE FAIRS & CONFERENCES

FEBRUARY 2017 PULVERSYMPOSIUM DRESDEN

ASTEC

Dresden, Germany February 02-03, 2017 pulversymposium-dresden.de/index.htm

Tokyo, Japan February 15-17, 2017 www.astecexpo.jp/en

FORNITORE OFFRESI Erba (Como), Italy February 02-04, 2017 www.fornitoreoffresi.com

ipcm

media partner

LIGHTWEIGHT VEHICLE MANUFACTURING SUMMIT

ipcm Detroit, USA media partner February 22-23, 2017 www.global-lightweight-vehicle-manufacturing.com

SURFACE DESIGN SHOW

SAMOTER

London, UK February 07-09, 2017 www.surfacedesignshow.com

Verona, Italy February 22-25, 2017 http://www.samoter.it/en

PACIFIC DESIGN & MANUFACTURING

MIDO

Anaheim - CA, USA February 07-09, 2017 pacdesignshow.designnews.com

Milan, Italy February 25-27, 2017 www.mido.com/en

BUDMA

SIMA

Poznan, Poland February 07-10, 2017 www.budma.pl/en/

Paris, France February 26 - March 02, 2017 en.simaonline.com

WIN EURASIA METALWORKING

INTERLAKOKRASKA

Istanbul, Turkey February 09-12, 2017 www.win-metalworking.com

Moscow, Russia February 28 - March 03, 2017 www.interlak-expo.ru/en/

AMBIENTE Frankfurt/Main, Germany February 10-14, 2017 ambiente.messefrankfurt.com

MARCH 2017

100

KYIVBUILD

TIMTOS

Kyiv, Ukraine March 01-03, 2017 www.kievbuild.com.ua

Taipei, Taiwan March 07-12, 2017 www.timtos.com.tw

ISRACHEM

MADE EXPO

Tel Aviv, Israel March 07-08, 2017 www.stier.co.il/ISRACHEM/index_en.asp

Milan, Italy March 08-11, 2017 www.madeexpo.it

INTEC

METAL & STEEL

Leipzig, Germany March 07-10, 2017 www.messe-intec.com

Cairo, Egypt March 09-11, 2017 www.metalsteelegy.com

MIDDLE EAST COATINGS SHOW

Leipzig, Germany March 07-10, 2017 www.subcontractingfair.com

Dubai, UAE March 13-15, 2017 www.coatings-group.com/show/mecs/dubai/

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ipcm

media partner

ipcm

media partner

ipcm

media partner

MARCH 2017 SFM SURFACE FINISHING MÉXICO

SURFACE WORLD

Querétaro, Mexico March 14-15, 2017 www.surfaceﬁnishingmexico.com

Birmingham, UK March 22-23, 2017 www.surfaceworldshow.com

ST. PETERSBURG TECHNICAL FAIR

MECSPE

St. Petersburg, Russia March 14-16, 2017 en.ptfair.ru

Parma, Italy March 23-25, 2017 www.mecspe.com

AUTOMATICON

POWDER COATING TECHNICAL CONFERENCE

Warsaw, Poland March 14-17, 2017 www.automaticon.pl/en/

SCANDINAVIAN COATING Copenaghen, Denmark March 15-16, 2017 www.scandinaviancoating.com

Indianapolis - IN, USA March 27-31, 2017 www.powdercoating.org

ipcm

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EXPO SURFACE ®

media partner

Kielce, Poland March 28-30, 2017 www.targikielce.pl/en

AGRITECHNICA ASIA

FASTENER FAIR STUTTGART

Bangkok, Thailand March 15-17, 2017 www.agritechnica-asia.com

Stuttgart, Germany March 28-30, 2017 www.fastenerfair.com/stuttgart/english/

WIN EURASIA AUTOMATION

COATING KOREA

Istanbul, Turkey March 16-19, 2017 www.win-automation.com

Incheon, Korea March 29-31, 2017 www.coatingkorea.com

SBIE SAUDI BUILDING&INTERIORS EXHIBITION

SURTECH KOREA

ipcm

media partner

Incheon, Korea March 29-31, 2017 www.surtechkorea.org

Jeddah, Saudi Arabia March 18-21, 2017 sbie-arabia.com

OMAN PLAST

SURFCOAT KOREA

Muscat, Sultanate of Oman March 21-23, 2017 silverstaroman.com/latest_events.html

Incheon, Korea March 29-31, 2017 www.setcor.org/conferences/SurfCoat-Korea-2017

APRIL 2017 EUROPEAN COATINGS SHOW Nuremberg, Germany April 04-06, 2017 www.european-coatings-show.com

SURCAR SHANGHAI

ipcm

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INDUSTRIE Lyon, France April 04-07, 2017 www.industrie-expo.com

Shanghai, China April 12-13, 2017 asia.surcar-community.com

ipcm

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HANNOVER MESSE

ipcm

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Hanover, Germany April 24-28, 2017 www.hannovermesse.de

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EXPO MECÂNICA Porto, Portugal April 07-09, 2017 www.expomecanica.pt/en/

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Conference “Building with steel: from production to architecture”

caff System Srl is a company based in Ostuni (Brindisi, Italy) specialising in the production of industrial shelving. It creates and strengthens synergies with architects and engineers interested in the use of steel for architectural projects in different sectors, from residential to commercial and industrial. This was also the target audience of the seminar “Building with steel: from production to architecture”, held on December 2nd, 2016 at the Auditorium of the former Santa Clara Convent in Brindisi after the success of the first edition of the event, held on February in Bari. This technical information meeting was organised by Scaff System in cooperation with the Order of Architects of Brindisi, the Bari Section of AIDIA and Edilportale, and it was sponsored by ADI. Essentially, it dealt with the use of steel and its possible applications, including the green building field. The subject was treated with a multidisciplinary approach, thanks to the several professionals and corporate representatives as the conference speakers. The aim was providing a picture as complete as possible of this material and its characteristics, which enable to create modular, earthquake-proof and light architectural solutions for faster and cheaper building operations.

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The greetings of the President of the Order of Architects of Brindisi, Maurizio Marinazzo, were followed by the following speeches: Scaff System’s CEO Licio Tamborrino, with a report on the “Steel industrialisation and technologies”; Angelo Maiolino, a freelancer talking about the constructive potential of steel; and Maria Cristina Angiuli and Aldo Greco, architects working for the architectural firm AG (Casamassima, Bari), analysing the development of steel architecture, from the design to the construction stages. The second part of the seminar saw the participation of the following speakers: Alessandro Largo, a material engineer from CETMA (Centre for the Design & Technology of Materials, Brindisi), dealing with “Ecoinnovative solutions for building infill walls on framed metal structures”; Leo Pedone from Pedone Working Srl, with a report titled “HI-LOW house: an envelope in hemp and high energy efficiency lime and a metal support structure”; and Francesco Monno from Axalta Coating Systems (Cavenago Brianza, MB), a major supplier of liquid and powder coatings worldwide, who examined the issue of “Metallic finishes: applications in the field of architecture and design.” For further information: www.scaffsystem.it and www.axaltacs.com

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haring, keeping up-to-date, and collaborating to build a shared future are the “ingredients” that have inspired the event – a technical meeting combined with a pleasant convivial moment – held on November, 15th to celebrate the 33 years of success and growth of the group at the regional, national and international levels (Fig. 1). The event was entitled “Innovation of the pre-treatment nanotechnology: inexpensive and technical advantages for users”. The main focus of this highly desired evening was the awareness that the best results in terms of customer assistance can be obtained only when both parts know every aspect of the creative, application and regulatory processes of each product. With this in mind, the Mr. Fulvio Truant ‘s speech with his technical examinations made the conference a lively moment of dialogue between qualified operators who discovered each interesting point offered during the evening.

A night event dedicated to the advantages of the pre-treatment nanotechnology

Figure 2: Danilo Callegari conquered the peak of the Manaslu Mount.

1 Figure 1: A moment of the evening.

There was also an exciting speech delivered by Danilo Callegari, the group’s testimonial. This extreme sport expert had recently returned from an amazing expedition in Nepal during which he had managed to conquer the summit of Mount Manaslu (8,163 metres high: the eighth highest mountain in the world, located in the Himalayan mountain range) by solo alpine climbing without the use of supplemental oxygen (Fig. 2). The words “challenge”, “commitment”, “sacrifice” and “success” have taken on a new meaning for his thrilled audience. At the end of the conference, the opportunity of celebrating the thirty-third anniversary of this Group came and finally, the pleasure of a dinner in the company of all participants (customers, experts and corporate staff) gave the opportunity to all guests to discuss, as well as enjoying the several happy moments that have characterised this very successful event. Similar events will be held again in the course of 2017 with the aim of providing the group’s clients with the chance to keep abreast of new technologies and their applications, but also to create partnerships with the other players of a market that is rapidly changing, but that is still tied to the sound values of mutual respect and esteem. For further information: www.noxor.it

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ALUMINIUM 2016: The lightweight route to success

1 Figure 1: A total of 992 exhibitors from 58 nations and 24,748 trade visitors attended ALUMINIUM trade fair in Düsseldorf (from 29th November to 1st December 2016).

arger, more international, more professionally accomplished: ALUMINIUM broke records again across disciplines. Six per cent more exhibitors, two percent more visitors and a 65 per cent increase in internationality make it abundantly clear that the potential of and outlook for lightweight solutions is still growing immensely. A total of 992 exhibitors from 58 nations and 24,748

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trade visitors came to the world’s largest industry trade fair in Düsseldorf (Fig. 1). “With that, ALUMINIUM is among a select group of industry shows that grow from event to event”, says Hans-Joachim Erbel, CEO Reed Exhibitions Deutschland, the organiser of ALUMINIUM. Since the debut event in 1997, the number of exhibiting companies has jumped nearly fivefold; the number of visitors quadrupled.

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Light but also hard, corrosion-resistant and easy to recycle. Those are the four properties that promise such a bright future for “white gold”. Whether it’s in the automotive industry, aeronautics or construction, “Mobility, lightweight construction and resource efficiency – global megatrends are the forces that drive expanding demand for aluminium”, says Christian Wellner, managing member of

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trade fair confirmed this point. More than 60 per cent of the over 500 responding companies expect demand to increase further; 27 per cent expect sales to remain flat; only 6 per cent fear a slightly weakening performance in the medium term. Many companies list high trade barriers and access to markets and raw materials as the biggest challenges. The globalisation of markets has reached the aluminium industry, bringing new structures and a global division of labour into the international value chain – a

development that was clearly reflected at ALUMINIUM. Two thirds of exhibitors – 649 altogether – travelled to ALUMINIUM in Düsseldorf from outside Germany. Germany (354) tops the list of 58 represented nations, followed by the second-strongest exhibitor nation Italy (116), China (90), Turkey (67) and Spain (29); the Netherlands and the UK tied for 6th (28 each). Strong contingents also hailed from the US (23) and Canada (22), which edged out France, Austria and Switzerland (all with 21 companies). “ALUMINIUM underscored its role as a global marketplace and recorded gains, especially from abroad”, said Olaf Freier, the event director of ALUMINIUM, at the end of the three-day event. The same is true for visitors, where ALUMINIUM achieved a top

Lightweight construction is a key technology of the future that’s making a critical contribution to the modernisation of industry”

Figure 2: An aluminium car body showed in the Automotive Area.

the executive committee of GDA, the German Confederation of the Aluminium Industry. “This demand occurs mostly in the transport sector, where demand for aluminium gone up by six per cent in 2016. Low-CO2 mobility is an important component of Europe’s strategy for a sustainable economy – and aluminium is part of the solution”, says Gerd Götz, the director general of the European industry association EA. “Lightweight construction is a key technology of the future that’s making a critical contribution to the modernisation of industry. Electro-mobility, for example, is inconceivable without lightweight engineering”, says Iris Gleicke, Parliamentary State Secretary at the German Federal Ministry for Economic Affairs and Energy. This boost in demand was noticeable at ALUMINIUM, impacting both the overall mood and the deal-making. A representative survey on the economy conducted for the

Figure 3 and 4: The “StickersProof ” and “Ethernal High Gloss Retention - multichrome effect”products by Adapta were chosen for the Building Innovations Area at the ALUMINIUM trade fair.

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10, Fig. 2) and “Building” (Hall 12) – enabled visitors to literally “grasp” the versatility of aluminium. In the Building Innovations Area, a company of the surface finishing field was present: Adapta Color S.L., a Spanish manufacturer of the powder coatings. Here Adapta showed its “StickersProof” and “Ethernal High Gloss Retention - multichrome effect” innovative products (Figs. 3 and 4). StickersProof powder coating enables the easy removal of a wide range of adhesives plastering streetlights, traffic lights, road signs and urban buildings in the cities. The product has been designed in super-durable quality (Adapta SDS) and its finish has a smooth texture or micro texture and can be manufactured in any colour. This product has also anti-graffiti ad anti-adherent features.

5 Figure 5: Euroimpianti’s booth.

internationality score of 54 per cent. At 20 per cent, the share of foreign visitors from overseas was remarkably high. “A benchmark for the worldwide relevance of ALUMINIUM”, says Olaf Freier. © ipcm ®

Special theme pavilions and areas

displays at their exhibition stands and at the theme pavilions, they had to do the same at two Innovation Areas returning to ALUMINIUM 2016. Two special areas - “Automotive” (Hall

As in the past, special theme pavilions have been set up in order to accomodate various focus topics, including the Competence Centre Surface Technology, the Foundry Pavilion, the Primary Pavilion, the Welding & Joining Pavilion, the Recycling Pavilion and the Magnesium Area. But exhibitors not only had to present new ideas and hands-on product

Adapta Eternal High Gloss is a special clear coat to be used like a shield in order to get the highest gloss retention after exterior exposure”

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6 Figure 6: Pulverit’s booth.

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Adapta Eternal High Gloss is a special clear coat to be used like a shield in order to get the highest gloss retention after exterior exposure. Eternal HG must be applied (preferred) on Adapta Vivendi SDS products (GSB Master, Qualicoat class 2) but can be applied (not suggested) on standard Vivendi products as

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The surface treatments industry was present at the fair with several companies who exhibited their most innovative products developed for a such delicate production phase as the aluminium surface coating process ”

9 Figure 9: ALUMINIUM sculptures on show. 8 Figure 8: Ipcm’s booth during the latest edition of the ALUMINIUM trade fair in Düsseldorf.

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The winners of the EUROPEAN ALUMINIUM AWARD 2016

From a 3D-printed motorcycle to a high-tech building facade designed by star architect Zaha Hadid: once again this year, the aluminium industry’s most creative and unusual new developments were honoured with the EUROPEAN ALUMINIUM AWARD. The award was presented on 29 November at ALUMINIUM 2016 (Fig. 14). Altogether, five innovations were recognised in four categories. The jury went on to present four additional coveted awards: the Special Prize, the Young Talents Award 2016, the Overall Jury Prize and the ALUMINIUM Lifetime Achievement Award. The last one on that list, the lifetime achievement award, was bestowed for the first time to honour AUDI AG for its outstanding achievements as a pioneer and innovation driver in the aluminium-automotive sector. The winner of the long-established Audience Award was once again determined by open voting in the “Design & Lifestyle” category. With 2,346 votes cast online, ViaLuce prevailed in the end.

10 Figure 10: Axalta Coating Systems’ booth.

well (GSB standard and Qualicoat class 1). The use of Adapta Rustproof primers could be needed in order to improve the corrosion protection properties on several substrates like aluminium, steel and galvanized steel. Eternal HG has been designed to exceed the international quality specifications like Qualicoat CLASS 3, GSB PREMIUM, AAMA 2605. Eternal HG is used on Architectural metal components and metal façades. The surface treatments industry was present at the fair with several companies who exhibited their most innovative products developed for a such delicate production phase as the aluminium surface coating process (Figs. 5, 6, 7, 8, 9, 10, 11, 12 and 13). Also ipcm® International Paint&Coating Magazine took part in this important event with its stand in the Hall 12.

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11 Figure 11: Eurosider’s booth.

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12 Figure 12: Adapta Color’s booth.

The winners “Architecture & Constructions” category: - BARCO ONE CAMPUS – Atrium Walls (AVC, Belgium) - Port House Antwerp (GrovenPlus, Belgium) “Automotive & Transportation” category: - REALCAR (Jaguar | Land Rover & NOVELIS, UK / Switzerland) “Design & Lifestyle” category: - ATTACH table system (Grumdesign & Lammhults, Denmark/ Sweden)

“Production Techniques, Tools & Machinery” category: - ALUMASTER High Speed Disc (August Rüggeberg, Germany) Special Prize: - Façade P+R Garage Trainstation Elst, NL (Van Campen Industries, Netherlands) Young Talents Award 2016: - Light Rider 3D-printed motorcycle (Niels Grafen TU München / Airbus APWorks, Germany)

Overall Jury Prize: - Solar Fingerplate (Philipp Griesacker / Austria Druckguss, Austria) ALUMINIUM Lifetime Achievement Award: - AUDI AG Public Prize: - ViaLuce (Project 21c / SAPA Extrusions Raeren, Belgium).

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About the EUROPEAN ALUMINIUM AWARD The EUROPEAN ALUMINIUM AWARD is an initiative by the Dutch Aluminium Centrum in cooperation with the industry association European Aluminium, the German Aluminium Association (GDA) and ALUMINIUM 2016. Altogether, 17 European aluminium associations support the competition. The trade magazines Aluminium International Today and Aluminium Kurier serve as media partners.

Figure 13: Sat’s booth.

The next ALUMINIUM, 12th World Trade Fair and Congress, will take place in Düsseldorf from 9 to 11 October 2018. For further information: www.aluminium-messe.de and www.aluminium-award.eu

14 Figure 14: The winners of the EUROPEAN ALUMINIUM AWARD 2016.

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Middle East’s multi-billion-dollar aluminium industry continues solid upward growth

The 2017 show will feature six international pavilions (Germany, Italy, luminium Middle East, the largest event of its kind in the region, India, China, North America and Egypt) and two new dedicated zones will once again showcase the Middle East’s growing industry (Occupational Safety and SMEs) meant to underscore how the Gulf at its 5th edition being held from 15-17 May 2017 at Dubai Cooperation Council will focus on other related sectors, in order to International Convention and Exhibition Centre (DICEC). The exhibition will diversify their economies to ease their dependence on energy revenues. feature more than 200 exhibitors from 30 countries, and is expected to Over 3,500 visitors are expected from over 70 countries at the 2017 attract over 3,500 industry professionals from over 90 countries (Fig. 1). edition, demonstrating the increased focus on global opportunities in this This year, the Middle East posted the second highest year-on-year sector. demand growth globally during the first quarter at +5.8% and the world As the Arab world’s largest Aluminium producer Dubai is the ideal now has its eyes set on witnessing how the GCC will continue to thrive platform for the global industry to converge, as the Emirate boasts an in a post-oil world, with aluminium as one of the major economy drivers. extensive industrial and manufacturing base, offering immense growth This regional growth is a major contributor to a growing global demand opportunity for global for aluminium which is industry players. estimated to reach 70 “The Gulf is one of the million metric tonnes per leading areas for the year by 2020. aluminum industry and “Bringing together key Aleastur is the major frontrunners of the supplier of AlTiB grain aluminium industry refiners in the region. from all over the world, Our presence at the the biennial Aluminium Aluminium Middle Middle East exhibition East Exhibition will is once again expected demonstrate Aleastur’s to become a gateway commitment to GCC for companies and customers and strengthen professionals to our growing position,” collaborate and tap Leopoldo Galan, COO into the region’s multi1 & CCO, Aleastur, an billion-dollar industry,” commented Daniyal exhibitor. Figure 1: The 5th edition of the Aluminium Middle East trade fair will take place from 15-17 “The UAE is focused on Qureshi, Group Exhibition May 2017 in Dubai. growing the aluminium Director of Reed industry, and for us this is Exhibitions Middle East, the perfect meeting place for both industry frontrunners and those who the official organisers of Aluminium Middle East. are only getting their foot in the door—to meet each other, learn the latest The event aims to highlight the Middle East’s future role as the world’s developments together, and hopefully, work together. Each year, we powerhouse in aluminium production. Together with suppliers of witness how these new alliances grow into strong business partnerships,” technologies and accessories for aluminium production, processing says Nehme Shehab, Show Manager of Aluminium Middle East. and refinement, there will also be facilitated discussions on uplifting the For further information: downstream sectors to support this phenomenal growth in upstream www.aluminium-middleeast.com industries.

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he Powder Coating Institute (PCI) will host its POWDER COATING 2017 Technical Conference from March 27-31, at the JW Marriott in downtown Indianapolis, Indiana. Long known as the event where the industry gathers to discuss all things powder coating, PCI is devoting an entire week to powder coating education, hands-on training, tabletop exhibits and networking with industry peers (Fig. 1).

The event begins with PCI’s popular Powder Coating 101: Basic Essentials Workshop, offered Monday and Tuesday, March 27 & 28. The workshop includes classroom instruction (Fig. 2) based on PCI’s Powder Coating: The Complete Finisher’s Handbook, an evening reception

where attendees can interact with workshop presenters & other attendees, and a trip to PPG Industries’ powder facility to experience hands-on demonstrations. The technical conference sessions take place on Wednesday and Thursday, March 29 & 30, with general sessions each morning, followed by more than 15 breakout sessions. There will be a tabletop exhibition featuring powder coating manufacturers, powder coating application equipment, system houses, chemical suppliers and the various services and suppliers that support the powder coating industry, along with hospitality salons sponsored by PCI members. This event offers the perfect balance of education and networking for all powder coating professionals.

PCI’s POWDER COATING 2017 Technical Conference Returns to Indianapolis

Figure 1: The Powder Coating Institute (PCI) will organize workshops and hands-on training during its POWDER COATING 2017 Technical Conference (March 27-31, 2017).

To round out the week of powder coating events, PCI will conduct its Custom Coater Forum on Thursday and Friday, March 30 & 31. The program is created based on the needs of our Custom Coater members. The forum allows for valuable interaction among custom coaters while they pick up plenty of great tips and information that can positively impact their business. For further information: www.powdercoating.org/ PowderCoating2017

2 Figure 2: A classroom instruction.

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7th International Exhibition for the Fastener and Fixing Industry

Visit the biggest international marketplace for the fastener and ﬁxing industry Industrial fasteners and ﬁxings

Fastener manufacturing technology

Construction ﬁxings

Storage, distribution, factory equipment

Assembly and installation systems

Information, communication and services

28 – 30 March 2017 | Messe Stuttgart, Germany www.fastenerfair.com/stuttgart

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New ways of Living Community-Driven Architecture

1 Figure 1: The GENNIUS A4AS modular structure allows to roof very large areas and offers signiﬁcant scope for customization.

he emergence of sharing approaches to life and lifestyles that embrace the principles of environmental, economic and social sustainability is gradually changing people’s habits and behaviours in a number of spheres, including consumption, work and the home. The values underpinning the Sharing Economy translate not just into leading-edge services but into new-concept spaces and

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buildings that offer shared living and coworking experiences. The MADE expo Outlook has been monitoring the latest lifestyles by listening to experts and undertaking global projects. All will be revealed at MADE expo, which runs at the Milan Fair in Rho between 8 and 11 March 2017, an event that offers an opportunity to meet, learn more and discuss a number of

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topics as it showcases the latest developments and innovations of international interest. Construction is undergoing major upheavals as it transitions from housing to new systems of co-housing in contemporary cities in Italy and, more generally, across Europe. This trend underwent a rapid acceleration in the mid-1990s, highlighting a cultural shift from a period of housebuilding that consumed large

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perforations were handled – something that meeting of the Korean Council for Presidents swathes of territory to one that is imbued is usually critical to the façade in terms of of Private Universities. The solution chosen with a new awareness of contemporary thermal bridge performance – was managed was to install 2 GENNIUS A4AS structures from living. In answer to this demand, private using the Trav Frame Hella system, which KE Protezioni Solari, a choice that combines individuals, builders and developers have makes it possible to simply integrate the style and quality given that the entire begun to invest in designing multifunction windows into the solar protection system, implementation would subsequently become complexes and refurbishing existing saving both time and costs (Fig. 2). permanent as a students’ sky lounge. One properties characterized by a blend of characteristic of Model A is its high degree of public and private space and a more Home automation, the sharing modularity, something that lends it to roofing streamlined management model that city, co-housing, eco-bonuses very large areas and offers significant scope for envisages flexible short-term rentals and and apartment buildings are all customization (Fig. 1). all-inclusive rates with utilities, training, centre stage at MADE expo Tomorrow’s apartment blocks will be closer to services and shared activities all part of the The Fair’s busy deal. programme MADE expo features the return showcases a of events that rich and varied have attracted overview of what thousands companies offer of industry in terms of shared professionals space innovation, to the Fair. One new products such event is and design. BuildSMART, Pilot ventures a platform of are being rolled conferences, out as a model meetings, nationwide: all of workshops, the stakeholders prototypes involved in the and interactive “home” world are laboratory helping to develop sessions that a virtuous and offers in-depth integrated system. investigations These new types of of technical, “hybrid” buildings 2 scientific and put community regulatory issues wellbeing and Figure 2: The Trav Frame Hella system simply integrates the windows into the solar protection system. spanning material needs at the heart and technological of the design solutions process, and are for designing, renewing and building the people who live there, less energy-hungry conceived for groups of socially-aware comfortable, secure and sustainable and have lower maintenance and management people who share common practices and buildings. One of the headline events costs. One example of this is the “Semonte” values. focuses on communities, user conduct residential project in Val Seriana. The job For example, the roofing on the top floor and consequently apartment buildings, focused on installations in particular, starting of the Soonchunhyang University building in a journey that takes in leading-edge with the photovoltaic system and heat pump was originally conceived as an add-on approaches, market players, protocols, and usage; a decision was taken not to install to provide an evocative and functional incentive schemes. a methane gas system. How the window covered space in the run-up to the annual

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P O W E R F U L

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V E R T I C A L

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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

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B R A Z I L

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solvent-based

water-based?

GEMINI SYSTEM A tinting system for all industrial coatings.

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Two identical sets of 24 solvent-based and water-based colourings, rheologically controlled, featuring the same resistance, colour index and shade. Speciﬁc formula for tinting systems. Totally compatible with all types of industrial coatings. A database of 2,500 ofﬁcial colours.

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

www.arsonsisi.com

100% made in Italy

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