ipcm® n. 65 - September/October 2020 by ipcm® International Paint&Coating Magazine

The smart journal for surface treatments

ISSN 2280-6083

ipcm digital on

www.myipcm.com

In this issue:

SPECIAL ARCHITECTURE & DESIGN

INTERNATIONAL PAINT&COATING MAGAZINE

2020

11th Year - Bimonthly

N° 65 - SEPTEMBER/OCTOBER

THE GLOBAL SOLUTION THAT GUARANTEES SUCCESS

THE MOST INNOVATIVE COMPACT ANODIZING LINE LOW SPACE NEED

SEE THE ARTICLE AT PAGE 50

FULL AUTOMATIC & EASY MAINTENANCE

MANPOWER OPTIMIZATION

PATENTED design

PATINACOLLECTION for architectural design EFFERVESCENT EARTH

La Patinoire - DUNKERQUE

PHOTOGRAPHY

ARCHITECTS - Agence Chabanne

@Guillaume GuÃ©rin

96 CHROMATIC EFFECTS TO MIMIC THE NATURAL OXIDATION OF METALS, INCLUDING WET EFFECTS

A NEW FOCUS ON INNOVATION www.adaptacolor.com

www.infragas.com

INFRARED RADIANT GAS SYSTEMS FOR THERMAL TREATMENTS

TIGER Drylac® Series 68 impresses with uncompromising quality focusing on aesthetics and long-term value retention. • • • •

Excellent gloss and color stability High chemical resistance Ecological and cost efficient one-coat system Approval in accordance with stringent quality standards such as GSB and/or QUALICOAT

Super Durable Powder Coatings

in stunning colors, effects and gloss levels. Scan me!

www.tiger-coatings.com | www.tiger.archi

CONTENTS SEPTEMBER/OCTOBER 2020 © Anton Paar GmbH

ANALYSIS

HIGHLIGHT OF THE MONTH

New Pioneering Technology to Objectively Evaluate Total Perception of Structured Surfaces

ow to Develop the Best Paints and H Coatings and Control Their Quality

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

FOCUS ON TECHNOLOGY

05 EDITOR’S LETTER 06 IPCM IN REVIEW 08 BRAND-NEW 14 BRAND-NEW 16 RAW MATERIALS

ovaresine Confirms its Corporate N Sustainability Strategy with a New Co-Incineration Plant

FOCUS ON TECHNOLOGY

Think Big: Powder Coating of Heavy Duty Parts

SUCCESS STORIES Effective Rust Protection From the Can for Triumph Spitfire Parts

32 42 45 46

BRAND-NEW SPECIAL ISSUE ON ARCHITECTURE & DESIGN

MARKET CLOSE-UP

The Aluminium Surface Treatments Industry Does Not Stop: The Positive approach to Current Market and the Circular Economy are the Key Items of its Future &

Anodikit® ZONE: The Most Innovative and Compact Plant Available for Anodising

Rose Gold and Black Chrome Finishes for the Bathroom Accessories of the Future: Now It Is Possible, Thanks to Italian startup Almain’s Sputtering Metallisation Process for Aluminium Profiles over 2 Metres

BRAND-NEW

50 INNOVATIONS: PRESENT FUTURE 52

FOCUS ON TECHNOLOGY

New Coating Plant to Custom Finish A OMSI Trasmissioni's Drive Units

SUCCESS STORIES

Remote Design of a New In-Line Paint Stripping System

INNOVATIONS: PRESENT&FUTURE

Aluminium Process Technologies of the Future

FOCUS ON TECHNOLOGY

The Profile Recognition System Helps New Zealand Company Altus Reaching New Quality Heights in the Powder Coating of Aluminium Profiles for Architecture

INNOVATIONS: PRESENT&FUTURE

78 82

New Elcosan® Moonlight Colours: Alsan Widens the Spectrum of Greys by Optical Interference

BRAND-NEW MARKET CLOSE-UP

Aluminium, The Metal of the Future: AITAL’s Point of View on This Ever-Developing Market

CONTENTS SEPTEMBER/OCTOBER 2020 © Stardust Powder Coatings

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

HIGHLIGHT OF THE MONTH

FOCUS ON TECHNOLOGY

102

Stardust Powder Coatings: Craftsmanship and Quality in Record Times for Batches Starting From 25 kg

Fisher & Paykel Chooses a Nanotechnology Pre-Treatment Process for the Production of ELBA-Branded Household Appliances

110 92

94 96

HIGHLIGHT OF THE MONTH

INNOVATIONS: PRESENT&FUTURE

Scientist at Fraunhofer Institute Develops Coating that Protects Steel from the Penetration of Hydrogent

122 ANALYSIS

Fondmetal Recovers 99% of Water with a New, Zero Liquid Discharge Water Treatment Plant

Cycle Times Halved in One of the Few Anti-Corrosion Powder Coating Lines of Northern Italy

A Low-Consumption Super Chain for the Green Conveyor of the Future

128 BRAND-NEW 132 RAW MATERIALS

144 ART WITHIN SURFACES

Promoting Flow and Levelling with Evonik Superwetters

“Sguardi Oltre l’Orizzonte”: Giving Body and Colour to Dirt

Efficient and Fully Automatic Finishing of Internal Passages

Artist Sacha Jafri is Attempting to Break a World Record Using AkzoNobel’s Dulux Products

146 STANDARD & LEGISLATION

134 ART WITHIN SURFACES

140 INNOVATIONS: PRESENT FUTURE

FOCUS ON TECHNOLOGY

The Perfect Combination of Art, Industry, and Technology: Creativity through a Coating Robot

“Fill the line”: A Modern Production Philosophy to Boost the Efficiency of Your Coating Line

126 INNOVATIONS: PRESENT FUTURE

BRAND-NEW

ART WITHIN SURFACES

136

Limitless Innovation Capacity: Tapematic’s In-Line Coating and Sputtering Systems Conquer the Cosmetic and Beverage Packaging Markets

116 FOCUS ON TECHNOLOGY

The Impact Assessment Study on the Revision of the Machinery Directive Has Been Published

148 TRADE FAIRS & CONFERENCES 150 ZOOM ON EVENTS

Celebrating performance, flexibility, service and thousands of colours and effects

RIPOL delivers top performing powder coatings that provide unmatched durability, ï¬&#x201A;exibility and colour retention while being environmentally conscious

international@ripol.com T: +39 02 97 48 411 www.ripol.com

ARCHITECTURE SUPERDURABLE ACE

ANTICORROSION DECORATIVE SPECIALTIES

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

or many of us, the return from the summer break coincides with the real start of the year. Forget about January 2: it is on September 1 that we reorganise production and work flows and we devise new projects based on the ideas that have blossomed just before the holidays and soaked in during the summer break, when we have given ourselves a chance to relax and be creative again. This September feels even more particular: we have left a few hard months, unexpected situations, and suffering behind us. However, we still do not know for sure what to expect from this new reality. With faith in the future, many of us have taken their courage in both hands and made bold decisions for their companies, without knowing exactly what will happen in the next few months. Ipcm® did the same, choosing to focus even more on the options offered by digital technologies and media hybridisation. We have gone beyond the simple digital distribution model, on our website and on our social channels. We have decided to further enrich our content offer. How? Starting from this issue, you will find a big novelty in some of our articles: the presence of QR Codes (on the paper magazine) or hyperlinks (on the digital version) that refer to information aimed at enriching your reading experience and expanding the articles’ content, such as, for example, videos showing an application in action, social media posts, in-depth video interviews, product demos, and much more. These are contents created by us or provided directly by the protagonists of our reports, who have figured out how to make the most of our magazine and its global visibility. What about the future? We intend do take advantage of augmented reality for an even more impactful communication, especially in anticipation of the resumption of events in 2021. As for the topics treated, our September issue is normally very rich, because it covers two of the busiest months of the year for trade fairs, October and November. Although all the fairs scheduled in 2020 for our sector and its related markets (automotive, furniture, and architecture, just to name a few) have been cancelled, this ipcm® issue does not fail to present the latest innovations made available as regards surface treatments, especially for the aluminium (for architecture and industry) and design sector. Inside its pages, you will find many technical articles on new systems, new products, and innovative start-ups ready to launch exclusive finishes that are unprecedented in the aluminium sector. We will also present the point of view of two aluminium associations, a European and an Italian one, on the post-pandemic market situation. This is the continuation of our series of meetings with the presidents of trade associations related to the surface treatment sector, conceived to provide you with a complete overview of what is happening in the world. There is also no shortage of success stories, even from overseas, many of which were completed during the lockdown period. This goes to show that nothing is impossible. Finally, although we usually do not like talking about our own successes, we would like to make an exception to celebrate the shout out received by ipcm from the United States: give it a listen! www.askjoepowder.com, the “powdcast” produced by The Powder Coating Research Group (Columbus, Ohio, USA), scan and listen to Episode #12.

Alessia Venturi Editor-in-chief Direttore Responsabile

Thank you, Joe Powder and thank you, Kevin Biller!

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

IN REVIEW

July and August in Review Barbara Pennati ipcm®

Refreshed by the lightness of summer holidays, we start again with more strength and new good ideas.

uly and August are the months par excellence for relaxing and recharging our batteries. Not only because, this year more than ever,

we deserve a break but also because rebooting the brain promotes positive thinking and the creation of good, new ideas. This is the spirit with which we published the summer issue of ipcm®, which offered several technological, process, management and product ideas that aim at stimulating new ideas and provide a positive framework, clearly showing the European industry’s industriousness and dynamism. Positivity is also the word that is accompanying the definition of the various projects set to take place during the latter part of the year and in 2021. We are aware that many projects have faded we had to review several plans ourselves - and that the news is often far from reassuring.

However, we firmly believe in the need to start anew. And starting anew does not mean waiting for an opportunity to materialize out of thin air but instead creating new ones, actively looking for them with a responsible and attentive attitude to the current situation but with a proactive approach, as well. So, although we still cannot go into the details of what’s in store, one thing remains certain: our commitment to keep providing the sector with new, cutting-edge platforms that can be exploited to communicate effectively with the industry. And speaking of technical knowledge, in July we

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

IN REVIEW

also held the webinar on cathodic protection and how to protect

guides for our magazines and web services, as well as for the

metal structures from corrosion. Presented by Marco Ormellese,

2021 trade fair and exhibitions calendar, a fundamental tool,

Full Professor in Materials Science and Technology at the

today more than ever, to learn about the industry appointments

Politecnico di Milano, this training session was widely appreciated

that await us next year and the new dates of postponed fairs.

and we are actively working to schedule new webinars, held as always by field experts, in order to give you the opportunity to deepen your knowledge on various topics related to surface treatments. Last but not least, we have published the second episode of Beyond The Pandemic, the ipcm® interview series which aims at offering an unfiltered point of view on how companies have

Scan to know more

dealt and are still dealing with the situation generated by the Coronavirus pandemic. In the second episode, we have recounted the point of view of an international company such as Sherwin-Williams, which provided very interesting and not-at-all predictable prompts.

Scan to know more

Upon our return to the editorial office, in August , we published the summer issues of ipcm® Ibérica and ipcm® LatinoAmérica, one of the richest editions of the year in terms of editorial content. The third episode of Beyond The Pandemic has also been online since the end of August: We got to chat with Andreas Orre of HangOn, a global company based in Sweden, a country that has adopted a very different strategy from most European nations. In these summer months we have also got to the heart of EOS’ business, which not only continues its informational work, sharing tips, latest news and trends from the world of marketing, communication and events, but has also undertaken collaborations with established companies as marketing agency and press office. The training courses of ipcm® Academy started on 16 September, which will issue the certification of Technician of Industrial Surface Finishing Processes, a title recognized at national and European level. Contact us at corsi@ipcm.it for further information. We have also begun to lay the foundations of the new media

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

BRAND-NEW

UC Berkeley Researchers Developed Coatings that Can Create False Infrared Images In a paper published in the journal Advanced Materials, two UC Berkeley researchers described how to imbed visual “decoys” into surfaces of objects in a way that can fool people into thinking they detect a specific image in the infrared that actually isn’t there. This kind of technology could prove useful for military and intelligence agencies to ensure national security.

nfrared light is invisible to the human eye, but can be detected by a

inherently self-adaptive to temporal fluctuation as well as spatial variation

range of devices, such as night-vision goggles and thermal-imaging

of the target temperature.

cameras. The coatings developed by Junqiao Wu, UC Berkeley

Additionally, by manipulating the configuration and composition of

professor of materials science and engineering, and post-doctoral

tungsten-doped vanadium dioxide on coatings applied to the PE tape,

researcher Kechao Tang can effectively tune target objects into emitting

researchers can create an infrared decoy.

the same infrared radiation as the surrounding environment, making

“How we grow the material changes the image people ultimately think

them invisible to infrared detection devices.

they see,” said Junqiao Wu.

Moreover, the coatings, which are made from delicately engineered thin films of tungsten-doped vanadium dioxide, can be manipulated in a way

The testing process

that a person trying to view the object with such a device would instead

In the paper, researchers described encoding the letters C-A-L onto

see a false image.

samples that they later placed on the surface of an object. The colour of

Tungsten-doped vanadium dioxide is a substance that at certain

the letters represents the temperature people see when viewing from an

temperatures can phase shift from an insulator, which suppresses electric

infrared camera. For example, the blue C shows it is at a constant 5°C,

conductivity, to a metal, which conducts electricity.

the lighter blue A at a constant 15°C, and the green L at a constant 25°C,

The insulator-metal phase transition can even out, allowing the substance

regardless of the actual temperature of the samples.

to emit a constant level of thermal radiation over wide range of

Even though the object’s actual temperature varies widely from 35-65

temperature variations (15-70 degrees Celsius). This state of equilibrium

degrees Celsius, a person who views the object through night-vision

prevents a camera from detecting the true infrared signals that an object

goggles will distinctly see a colder “CAL” that is independent of the actual

normally emits around room temperature.

temperature. © UC Berkeley

“We can both erase real information and create

How the coatings were developed

false information,” Wu said, “CAL stays cool when the

Berkeley researchers, backed by the National

environment is hot.”

Science Foundation and the Bakar Fellows

This kind of technology could prove useful for

Program, grew ultra-thin layers of vanadium

military and intelligence agencies, as they seek

dioxide (less than 100 nanometres thick) on

to thwart increasingly sophisticated surveillance

structures made from borosilicate glass and

technologies that pose a threat to national security.

sapphire. Using pulsed lasers, researchers doped

It might also incubate future encryption technology,

the films with different amounts of tungsten and

allowing information to be safely concealed from

then transferred the material onto a polyethylene

unauthorized access.

(PE) film tape. The researchers say this method provides better, more consistent camouflage because the

Coatings tune target objects into emitting the same infrared radiation as the surrounding environment.

product is mechanically flexible, power free and

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

For further information: www.engineering.berkeley.edu

BRAND-NEW

PhoenixTM Launched its New Website PhoenixTM has recently redesigned its website: It is already online with its new structure, new easier and clearer tools and 12 languages available.

hoenixTM, a German company specializing

in 12 languages, which can be selected via the

in ‘thru-process’ temperature measurement

menu bar, also contribute to this.

systems used to measure product and

In the newly designed login area, customers can

process temperatures through industrial heat

download the latest software versions at any

treatment processes, has recently redesigned its

time and are thus always up to date with the

website, by making it fresher and easier to use

latest technology in a simple and straightforward

thanks to a diverse and better structure.

manner. The redesigned library offers a download

With the redesign, PhoenixTM not only wanted to

area for brochures, technical reports and videos.

create a website clearer and more user-friendly,

It will be continuously being updated and offers

but above all focused on its products, particularly

not only information but also technical assistance

on new developments, such as the innovative

for frequently asked questions. In addition to a

optic system and the ATEX safety system. It was

content-related restructuring, attention was also

important that visitors would be guided quickly

paid to the current technical possibilities and the

and easily to their respective applications, but also

adaptation to all end devices.

that they could find all the necessary information

New website perfectly reflects the PhoenixTM’s

at a glance. Via the menu bar and the drop-down

mission: Innovation and customer satisfaction have

menus, this is easy: The individual application areas

been its goal for 10 years now.

and product groups are clearly displayed and offer comprehensive information. Thanks to the informative images and the clear structure, visitors

For further information:

can find their way around at any time. Translations

www.phoenixtm.com

ANALYSIS

New Pioneering Technology to Objectively Evaluate Total Perception of Structured Surfaces Christopher Groh, Jonas Harmeling and Gabriele Kigle-Böckler BYK-Gardner GmbH – Geretsried, Germany

gabi.kigleboeckler@altana.com

Our visual perception is influenced by colour, gloss and the surface structure. Our visual rating takes all three parameters into consideration and makes an overall judgement. Up to now, grain or surface structure could only be judged visually or with high sophisticated microscopes. This has changed with the new spectro2profiler, a pioneering technology combining colour, gloss, 2D reflectivity and 3D topography in a robust, portable tool with a short measuring time. Introduction - Colour analysis is not enough

structure or complex gloss behaviour of

Uniform appearance is a crucial quality

used to provide very detailed information of

criterion for many products. The choice of

the surface structure in the laboratory for

material and production process variations

research purposes, but not suitable for fast

influence the surface quality, for example

and easy analysis of production quality.

3D-surfaces. Therefore, 3D microscopes are

the cell size of powder coatings is highly conditions. Another example are injection

3D Topography analysis using photometric stereo technique

moulding applications where fluctuations

Photometric stereo is a technique for

in tool pressure and temperature will show

estimating surface normals in order to

up in gloss and contrast variations. With

calculate a 3D topography of that surface.

the change of just one material or process

The technique was originally introduced by

parameter, the visual perception of colour

Woodham in 19801. The surface normals

and appearance can be changed significantly.

are calculated by observing an object from

So far visual assessment was the only way to

different illumination directions. With each

deliver a complete judgement of a textured

direction, the object casts different shadows

dependent on paint film thickness and curing

surface including colour and gloss evaluation. The recent developments of colour and gloss meters significantly improved quality control, but do not include the effects of

Woodham, R.J. 1980. Photometric method for determining surface orientation from multiple images. Optical Engineerings 19, I, 139-144

Detail of Color Study, Squares with Concentric Circles by Vassily Kandinsky, 1913.

ANALYSIS

©BYK-Gardner

Figure 1: Image acquisition of different illuminations to calculate surface topography.

Figure 2: Height map of a powder coated surface measured with the spectro2profiler instrument. The unit P-µm is perceived height.

on the surface and a camera acquires images for each illumination

cells, marked as green lines in Figure 3.

(Fig. 1). Using shape from shading, the surface curvature is

Characteristic features of the surface can be calculated based on the

estimated, and the height map of the object can be calculated. The

watershed segmentation results to compare different structures or

result is a real 3D topography of the measured object surface (Fig. 2).

grains. Spatial length scales result from camera calibration and are traceable to SI-units. The calculated average cell size correlates to our

Watershed analysis to define structure cell sizes

visual impression of coarseness. The distribution of individual cell sizes

Topographies such as leather grains or coarse powder coated

is an indication for the uniformity of the surface structure. For example,

structures can be characterized by their structure cells. To divide

a natural leather structure varies in uniformity depending on the part

the topography into cells, the watershed algorithm is used, a

of the cow skin. A textured paint can form agglomerations during the

region-based segmentation approach. One can imagine that the

wet paint application, if the application parameters vary resulting in

algorithm gradually floods the valleys of the topography, building

an inhomogeneous appearance. The normalized cell size deviation

rivers until hill areas are surrounded2. These areas will be defined as

is calculated by dividing the cell size distribution with the mean cell size. It is an objective measure to compare the uniformity of different

Serge Beucher and Christian Lantuéj workshop on image processing, real-time edge and motion detection (1979). http://cmm.ensmp.fr/~beucher/publi/watershed.pdf 2

Figure 3: Raw data and segmented topography data of a leather grain on a plastic substrate.

structures independent of its absolute cell size.

©BYK-Gardner

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

Conventional measurement of reflectivity and gloss

a grey scaled reflectivity map in which every pixel represents a

Reflectivity and gloss are based on the interaction of light with the

reflectivity value allowing more detailed analysis of reflectivity

physical properties of the sample surface. The intensity is dependent

distributions of a surface.

on the material and the angle of illumination. The measurement reflected light from a black glass standard with a defined refractive

Combination of 3D topography data with 2D reflectivity data

index. Today’s measuring instruments are very precise and widely

In order to assess the overall appearance of an object, it is necessary

used in industry, but they hold some weak points in the measurement

to measure surface structure and reflectivity in parallel, as they are

of structured surfaces. Cast shadows and areas that are invisible

mutually interdependent, but are combined for an overall visual

to the measurement detector can falsify the measurement result.

assessment4. Because our eyes are only capable to acquire 2D

Moreover, the perception of gloss does not only depend on specular

information, the human visual system reconstructs 3D information

gloss but also on the observed contrast between specular highlights

of objects in our brain using shading and reflections5. That means,

and diffusely reflecting surface areas . A conventional gloss meter is

the perceived depth of a structure is dependent on the reflection

not capable to capture more complex reflective behaviour such as

behaviour on the hills and valleys. Since the spectro2profiler uses the

spatially distributed reflections e.g. high reflecting hills next to low

same camera and lens system for the acquisition of 3D topography

reflecting valleys which occur in leather-like structures.

and 2D reflectivity data, it is possible to combine the data of both

results of a conventional glossmeter are related to the amount of

measurement principles. Thus, the reflection of hills and valleys can

Spatially resolved 2D reflectivity measurement

be separated. The difference between reflection of hills and valleys,

The spectro2profiler offers a new camera-based technology to

describes the contrast and perceived depth of a structured surface.

capture the spatial distribution of reflectivity. An in-line illumination distortions so that the measurement is independent of orientation

A practical example as found in the automotive industry

(Fig. 4). The camera acquires 2D reflectivity images. Figure 5 shows

Many automotive interior components have a leather-like look and

3 Hunter, R. S. (1937). Methods of determining gloss. Journal of Research of the National Bureau of Standards, 18(1), 19–41.

4 Qi, L., Chantler, M. J., Siebert, J. P., & Dong, J. (2012). How mesoscale and microscale roughness affect perceived gloss. Edinburgh, Scotland: Lulu Press, Inc.

setup eliminates cast shadows, invisible areas and perspective

5 A. Nischwitz et al., Computergrafik und Bildverarbeitung, Vieweg+Teubner Verlag | Springer Fachmedien Wiesbaden GmbH 2011.

©BYK-Gardner

Figure 4: Setup of spatial resolved reflectivity measurement.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

©BYK-Gardner

Figure 5: Reflectivity map of a powder coated surface acquired with the spectro2profiler.

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ANALYSIS

©BYK-Gardner

Figure 6: Four dashboard slush skins of same material with different levels of contrast.

Figure 7: spectro2profiler from BYK-Gardner.

are manufactured by different suppliers with different processes and

Conclusion

made of various materials. The appearance of the products surface

spectro2profiler (Fig. 7) is a game changer and marks a turning point

is analysed in the different development phases, e.g. at the very

in the analysis of structured surfaces. The combination of colour, gloss,

beginning by the design department in the grain development to

3D topography and 2D reflectivity in one easy to use instrument is a

approve suppliers and at the very end by quality control in production.

milestone in the objective measurement control of textured surfaces.

Leather grain structures can appear different in contrast although

At this moment, the spectro2profiler incorporates three algorithms

colour and 60° gloss are the same (Fig. 6).

for surface structure analysis - leather-like structures, coarse paint

This can be caused due to different reflectivity levels of the surface

textures and fine paint or plastic textures. Due to its excellent

on hills and valleys. Up till now this had to be evaluated visually which

technical performance in regards to repeatability and inter-instrument

is subjective and non-repeatable. The results (Table 1) show how the

agreement, digital standards can be used as a reference, allowing a

reflectivity contrast Rc distinguished the samples despite having the

flawless communication within a global supply chain.

same colour and 60° Gloss. Moreover, the results of the reflectivity

From now on, our visual perception of colour, gloss and structure

for hills and valleys provide details about what causes the different

can be evaluated in a holistic and objective approach, colour and

reflectivity contrasts.

appearance harmony when combining different components can be

The new measurement parameter reflectivity contrast is an ideal

optimized and all this is possible in the laboratory as well as on the

measure for production QC of injection or slush moulded parts.

production line with the portable spectro2profiler.

Table 1: Reflectivity and gloss results of four leather grains of same grain type.

Checkzone

SAMPLE 1

SAMPLE 2

SAMPLE 3

SAMPLE 4

Mean Reflectivity R (a.u.)

162

156

155

Reflectivity Hills Rh (a.u.)

209

188

195

190

Reflectivity Valleys Rv (a.u.)

115

122

115

117

Reflectivity Contrast Rc

0.29

0.21

0.26

0.24

Gloss 60° (GU)

1.3

1.2

1.3

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

BRAND-NEW

FreiLacke Inaugurates New Administration Building After one year of construction, FreiLacke is moving into its new administration building, which features state-of-the-art workspaces for up to 70 employees.

he rapid growth of FreiLacke has prompted the company to invest

The new sustainable features of the workspace

in infrastructure and buildings.

Resource preservation, accessibility, sustainability and ergonomics

Following the grand opening of the expansion of the powder

became pillars of the project. For example, the toilets are flushed using

coating production (including a logistics centre) in September of 2019,

rainwater collected on the roof, while the building is heated using a

the new administration building has now also officially opened its doors.

low-temperature system and the exterior facade as well as the

The newly renovated building, which now covers an area of 1,407 m ,

basement walls received extensive insulation.

features an added floor and 70 state-of-the-art workplaces for the

Thanks to the renovation, the existing building achieved the KfW

different commercial departments.

energy-efficient house standard of 70 and the new building achieved

“The commercial departments grew along with the entire company and

a standard of 50.

some of them were approaching their limits. That is why the expansion of

As for the workspace, the building now features open group

the administration building was deemed to be an investment priority and

workstations, conference rooms on all floors, glazed single and double

implemented quickly and successfully”, said Rainer Frei.

occupancy offices, communication hubs as well as central, encased

“Together with the architects and design planners we engaged in an

printer stations.

intensive planning process that also involved the departments for the

The latest sound protection and lighting concepts were implemented

requirement analysis. Ultimately, the project was implemented very

and state-of-the-art office furniture, such as height-adjustable desks,

quickly and on schedule thanks to the collegial and professional teamwork

was installed to allow employees to work ergonomically.

everybody demonstrated”, added project manager Sandra Gehringer. The plans for the modernisation of the adjacent original building have already been drafted and will be implemented in due time.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

For further information: www.freilacke.com

Â®

RAW MATERIALS

Novaresine Confirms its Corporate Sustainability Strategy with a New Co-Incineration Plant Interview with Bruno Franceschini, Novaresine Srl CEO Colà di Lazise, Verona – Italy

Novaresine, a company producing synthetic resins for paints mainly intended for the coil, packaging, and wood sectors, has confirmed its green commitment with the installation of a co-incinerator for the abatement of polluting emissions. This is in line with its corporate policy, based on a combination of innovation and sustainability and on an optimistic approach to future.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

RAW MATERIALS

n increasing number of companies in the chemical sector are adhering to national and international programs for reducing

emissions and the resulting risks to health and environment, as well as committing to a circular economy approach through their business plans. An example of this trend is the project involving a plant for the co-incineration of reaction products and exhausted solvents implemented by Novaresine (Colà di Lazise, Verona, Italy), an internationally renowned manufacturer of synthetic resins for painting products mainly intended for the coil, packaging, and wood sectors. After a meeting held in January 20191, ipcm® returned

to talk with CEO Bruno Franceschini, in order to discuss the reason behind this investment, the project’s development, and its integration within the corporate sustainability strategy that has been guiding the company’s choices for some time now. During our previous meeting, you mentioned that you were planning to implement this new co-incinerator. What were the reasons behind it? The plan for the construction of this plant started in 2017, with the aim of solving the disposal issues related to the waste water generated by the chemical processes that take place in our reactors, which contain 15% of solvent substances. The specialised Italian company that we entrusted with this operation was no longer able to cope with the higher and higher amount of substances to be disposed of, due to an increase in our productivity. Therefore, we turned to a French company based in Marseille. 150 tanker trucks at a time had to travel six times the kilometres they used to, with an increase in carbon dioxide emissions, in the risk of spreading dangerous substances on our roads and, last but not least, in our logistics and © Novaresine

transport costs.

"Novaresine: the sustainable approach of a chemical company open to everyone", in ipcm® International Paint&Coating Magazine no. 55 (January/February 2019), pp. 58-64. 1

A detail of the incineration plant.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

How does the co-incinerator work? The new plant covers an area of 45 m2 and it was designed to eliminate the waste water created by our chemical processes for resin production. It uses a thermal combustion process, recovering 95% of solvents to become fuel for the operation of the system itself: it was designed to be able to self-regenerate, fully in line with the circular economy approach. The co-incinerator collects waste water from all our reactors: its size was therefore chosen based on the amount of by-products created in our factory, exclusively for internal disposal purposes. This is one of the reasons why we are sure that our plant does not cause any damage to the environment. The solvents we use for our reaction processes do not contain chlorides of any kind nor their derivatives and, therefore, they do not release dioxins or other toxic products into the atmosphere, but only water vapour with a percentage of pollutants close to zero.

The new reactor.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

RAW MATERIALS

Why did you find it difficult to get public opinion to accept your project and how did you manage to convince your opponents? Unfortunately, when hearing about an “incinerator”, one immediately envisages black fumes coming out of a chimney. Moreover, the area where the Novaresine factory is located saw a chemical plant burn

Get more from water

down in the early 1990s. I am not saying that such distrust was justified but, as the CEO of a company that embraces green economy and strives to constantly develop innovative, eco-sustainable products, I understand the concerns of the neighbouring villages’ people, also considering that 80% of our employees reside in the same areas. However, the whole Novaresine team has always had full confidence in the eco friendliness of this plant, and this has been our strength. We found a meeting point with the municipal bodies, which had launched a study to detect any elements against our project’s

Turn key solutions for industrial wastewater treatment Design and manufacturing of plants and chemicals for industrial wastewater treatment Chemical-physical plants

feasibility, by telling them that, if their resulting data had been different from ours, we would have immediately stopped production

Sludge treatment and compactor systems

and borne their analyses’ costs. We also agreed on the installation

Ion exchange demineralization systems and reverse osmosis systems

of air pollution receptors in a few critical areas, to be used before

Oil separators

and after the commissioning of our co-incineration system in order

Filtering systems

to check compliance with emission limits and detect any changes in

Batch type systems

parameters over time. It took us three years to design the plant and

Flotation units Chemicals and spare parts for water treatment Technical service, support and maintenance of wastewater treatment plants

The waste water collection tank.

info@waterenergy.it

www.waterenergy.it

complete the authorisation procedure, but

Novaresine’s products have now reached

everything went well and the start-up phase

Southeast Asia and South America. We intend

of plant with the instruments’ calibration was

to expand the distribution of our resins,

started on 9 March this year.

while continuing to pursue our vocation as an eco-sustainable company. We will further

Bruno Franceschini, Novaresine CEO and the Novaresine headquarters in Colà di Lazise (Verona), with the new logo, redesigned after the first ten years of activity.

Is the system currently running at full

focus on water-based resins, which in the last

capacity?

three years have come to account for 18% of

After a testing phase complicated by the

our production. Moreover, we are assessing

pandemic lockdown, the co-incinerator was

some new technologies for the development

definitively restarted on September. Everyone

of products from renewable sources and

can view its operation’s data, in the reports

recycled materials2: our customers are

we publish monthly on our website. Local

currently testing the bio resins created by our

authorities and ARPAV (the Veneto Region’s

laboratory.

Agency for Environmental Prevention and

“Finally, before the global health crisis, we were

Protection, Ed.) can monitor these data in

planning to build a new factory to support

real time by accessing them with a password,

our current productivity and develop new

just like Novaresine’s technicians do. We

manufacturing technologies. This project has

made this choice to further guarantee full

not been shelved, but only slowed down by

transparency. In line with this, we will organise

the pandemic. Our goal is to break with the

an Open Day in spring 2021 to show how the

past and build the image of an advanced

co-incineration plant works to all interested

company, where innovation, efficiency, and

parties. This is a way to confirm our bond and

sustainability go hand in hand.

attention to our area. From local to global: what are your projects for the near future? After establishing themselves in Europe,

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

2 C. Cattel e M. Sitta, Natures: fully biobased polyesters for coil coating applications, in ipcm® International Paint&Coating Magazine no. 62 (March/April 2020), pp. 14-16.

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

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

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Measuring instruments from Anton Paar.

HIGHLIGHT OF THE MONTH

How to Develop the Best Paints and Coatings and Control Their Quality Timothy Aschl, Olivia Kettner, Bernhard Scheicher and Martin Thomas Anton Paar GmbH – Graz, Austria

info.de@anton-paar.com

Considerable demands are placed on paints and coatings simply by all the different applications and situations they are used for. The high degree of complexity is also a result of the many different materials that are processed – an enormous variety of powders/particulates and liquids. It is necessary to precisely understand the materials to be able to develop new formulations, but also during production to guarantee a consistently high quality.

o cover and understand the whole life

and coatings exist in both states and have

processing is needed to guarantee the reliable

cycle of paints and coatings means

therefore completely different requirements

and homogeneous quality of the final products

to be able to measure and analyse

as they are also applied and used completely

(the paints and coatings). No matter whether

the right properties at any step – from the

differently. The measuring instruments from

in development or production, there are many

incoming raw materials, across all intermediary

Anton Paar make it possible to get to grips with

factors and parameters that influence the

steps like mixing, to the final and finished

this complexity by measuring the properties

manufacturing and application process which

product. But the life cycle doesn’t stop with

needed to ensure high quality products.

can be addressed:

the finished paint or coating – transportation,

Important sample properties regarding the

• Viscosity: measurement of the viscosity

long-term storage and the applicability are

life cycle of the paint or coating are shown in

of paints and coatings ensures consistency

central points, as well as durability and

Figure 1. The development of new products

of incoming raw materials and provides

scratch resistance of the applied materials.

necessitates understanding and predicting

information on processability and pumpability.

Another dimension of complexity comes

the behaviour during the manufacturing as

• Rheology: determination of viscoelastic

from the state the materials are in – liquid

well as the application process. Similarly, in

properties in order to follow changes in paints

or dry. Raw materials as well as final paints

quality control a consistent production and

and coatings to understand their deformation,

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

Figure 1: Life cycle of paints and coatings.

To characterize painted and coated products Anton Paar offers scratch testers, indentation testers, and Calotest instruments. For further information visit: www.anton-paar.com

flow behaviour, and structure.

formulations.

understand shear-rate-dependent behaviour,

• Zeta potential and particle size: to analyse

• True density: evaluating the skeletal density of

viscosity curves can be recorded (Fig. 2). With

the formulation stability and agglomeration

coating powder ingredients for the calculation

rotational tests it is also possible to measure

behaviour of dispersed particles using dynamic

of theoretical powder coating density.

short-term sedimentation stability, or to

and electrophoretic light scattering (DLS and ELS).

• Tapped density: to reveal the powder volume

retrieve the yield/flow point which describes

• Particle size by means of laser diffraction: for

filling and packing characteristics important for

the force needed to start the movement in

quality control and analysis of liquid samples

hopper use.

a pipe, through a pump, or from a nozzle. The rotational 3 interval thixotropy (3iTT) test

and dry powders. behaviour to recreate the complete real-life

Ensuring batch quality with viscosity measurements

processes – from fluidized powder systems to

Viscometers like the ViscoQC 100 and

consolidated powders.

ViscoQC 300 are commonly used for quality

• Surface area: determination of surface area

control of paints and coatings. They can be

Deep viscoelastic insights with rheology

by gas adsorption to determine how much

used for quick single-point tests, but also

Rheometers, such as Anton Paar’s MCR 92

dispersant is required in paint, coating, and ink

more intricate measurements are possible. To

or MCR 302, have the capability of oscillatory

determines the application behaviour of the paint like sagging and levelling.

• Powder rheology: characterization of powder

Figure 2: Viscosity of paint (23 °C) analysed at different speeds using a ViscoQC 300.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

Figure 3: Amplitude sweeps performed on two dispersions (A and B). Dispersion B does not have a flow point and will remain liquid and structurally instable.

Figure 4: Particle size distribution of a powder coating.

fine fraction during manufacturing and the

described above. These oscillatory tests

Evaluating zeta potential and particle size with ELS and DLS

enable deeper structural and behavioural

The Anton Paar Litesizer series is based on

software and robust design these instruments

analysis. Amplitude sweeps (Fig. 3) and

light scattering techniques to determine

are the ideal tool for quality control.

frequency sweeps can be run to retrieve

particle size down to the nanometre range,

information about the deformation and

transmittance, refractive index, and zeta

the time-dependent behaviour of samples.

potential in dispersions. Particle size directly

Sedimentation stability is analysed by

relates to properties such as appearance and

Complete powder behaviour characterization with powder rheology

oscillating at very low frequencies to simulate

uniformity of the coating layer. Measuring

Powder rheology helps to understand the

long duration and at higher frequencies for

the zeta potential is important to analyse

behaviour of powders. It can be used as a

short time durations. The oscillatory 3iTT

formulation stability and to avoid aggregation

quick quality control tool but also for in-depth

measurement yields information about the

of dispersed particles. Measurements are

powder analysis. Two different cells (powder

application behaviour similar to the rotational

possible up to a concentration of 70 % mass

shear and powder flow cell) make it possible

test (sagging and levelling). Additionally, in

per volume, avoiding time-consuming sample

to analyse powders in any state they are in

oscillation more can be learned about the

dilution and preparation.

during the process - from compacted and

tests in addition to the rotational tests

paints and coatings, such as information on

powder coating process. With its easy-to-use

consolidated to fully fluidized. In this manner all steps of the process can be simulated:

the cross-over (solidification) when at rest. The

Determining particle size for easy quality control

modularity of the devices makes it possible

The particle size analyzer PSA uses laser

hopper discharge and the fluidized bed

to measure under precisely controlled

diffraction to analyse the particle size and

reactor, pneumatic transport, and spraying

temperatures to learn about the samples’

particle size distribution of both liquid and dry

through a nozzle (Fig. 5). With the modular

drying and curing behaviour. The modular

dispersions. In addition to particle size (Fig. 4),

setup of the rheometers the powder shear

accessories can be swapped easily to perform

it is possible to perform a pressure series to

cell can be combined with an oven to control

powder rheology, tribology, and more.

evaluate the effect of pressure on a powder’s

temperature and even humidity.

the liquid-like behaviour during application or

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

starting from mixing to storage, including

HIGHLIGHT OF THE MONTH

Figure 5: Shear rate behaviour of a powder bed as a function of its fluidization state.

Figure 6: Change in tapped powder bed volume for two coating powders with different coarse-to-fine particle ratios.

Analysis of surface area, skeletal density, and tapped density

manufacturing process, as well as the quality

powder characteristics regarding filling and

of the final paint, coating, or ink. In liquids

packing, especially when using a hopper.

The surface area of pigments and extenders

(suspensions/dispersions) it is essential to

Anton Paar’s comprehensive portfolio of

is determined by instruments such as the

measure viscosity or viscoelastic properties

measurement instruments is ideal for

autosorb iQ or the NOVAtouch using krypton

such as the yield point, the sedimentation

quality control in manufacturing and for

and nitrogen absorption, respectively. This

behaviour, or what happens during the drying

the development of new formulations. The

is done in order to calculate how much

or curing process. Particle size and particle

portfolio further comprises instruments to

dispersant or stabilizer is required in

size distribution are crucial parameters for

analyse the applied paints and coatings: for

formulations. Measuring true and skeletal

quality control and can even be complimented

example, in terms of coating thickness, scratch

density of pigments and paint films with the

by zeta potential measurements. In dry or

resistance, hardness, and wear resistance.

newly developed Ultrapyc yields information

particulate powder systems the particle size

All instruments have features which make it

important for resin-to-pigment ratio. To

is also a central factor for quality control of

easy to measure challenging samples of any

obtain the powder volume filling and packing

incoming materials and during manufacturing.

type and determine sample behaviour under

characteristics, automatic tapped density tests

Powder rheology helps to characterize

different environmental conditions. Many of

with the Autotap (Fig. 6) can be carried out on

powder behaviour during the entire process

the instruments have modular accessories

single components or blends.

– from the incoming raw materials and

which even have automatic tool recognition

during manufacturing, but also during the

and configuration to ensure easy handling and

Bottom line: Master all challenges with high-quality instruments from one provider that complement each other

application, which often involves fluidized

to minimize errors. In addition, Anton Paar is

systems and compaction processes as in a

ready to support you with a global application

hopper. Surface area provides information

and service network, broad application

on how much dispersant is needed in the

knowledge, and local support in the regional

formulations and skeletal density can be used

technical centres.

A wide range of different properties

to calculate powder coating and non-volatile

influence the material behaviour during the

film density. Measuring tapped density yields

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

FOCUS ON TECHNOLOGY

Think Big: Powder Coating of Heavy Duty Parts Edited by Nordson Deutschland GmbH Erkrath, Germany

ics.eu@nordson.com

Giga Coating GmbH was founded to protect trailer and semi-trailer chassis with a length of up to almost 16 meters from corrosion. The largely automated, high-performance powder coating system is also available to external customers with large components as a job coater.

ruck semitrailers and trailers travel around the world and are subject to many years of hard use. Maximum corrosion protection plays a central role in the long service life of

these vehicles. System Trailers, a company based in Germany, relies with great success on the innovative combination of cathodic dip painting and powder coating. To this end, the medium-sized company has founded its own coating company Giga Coating GmbH and has built a state-of-the-art plant for surface finishing in two construction phases.

The challenge: external job coating as the eye of a needle Maximum corrosion protection plays an important role in the durability of trailers and semi-trailers. To be able to produce them economically despite high automotive requirements, System Trailers relies on a high degree of automation and optimized manufacturing processes. After powder coating by a job coater had become a challenge in production, managing director Ralf Saatkamp resolved by ÂŠ Nordson

In the powder coating booths, a total of 22 Encore HD automatic powder guns efficiently ensures highly uniform powder application.

founding Giga Coating GmbH in autumn 2015 as an in-house coating company for large-format components in automotive quality. An approximately 8,600 sqm hall was built on the company

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

premises, in which very large and

additionally equipped with the highly

very heavy workpieces are made

efficient Dynamic Contouring System for

corrosion-resistant by means of cathodic

complex product geometries.

dip painting KTL and powder coating.

Thanks to their compact design, the

Right from the start, the capacities were

booths are engineered for fast colour

designed to also process external orders.

change processes to minimize lengthy production interruptions with multiple

The solution: cathodic dip-paint coating and dense-phase technology highly automated

colour changes (usually batch size 1) per

Researching for a suitable partner for their

system. The entire system is operated via

new powder coating system, managing

the icon-based touchscreen interface of

shift. The Nordson Spectrum® HD powder feed center provides a complete powder management within the powder coating

director Ralf Saatkamp got in contact with Nordson - and with its dense-phase technology. The soft powder cloud of Nordson’s dense-phase technology with the Encore® HD spray system and the

Product geometries are scanned with the highest level of accuracy, quickly processed by the PowderPilot HD system controller and sent to the DCM.

the PowderPilot™ HD control system. The operator can call up the status information of all modules at any time and - for example in case of a colour change - be shown step by step where his attention is

patented HDLV (High Density Low Velocity) pumps ensures full coverage

needed. Thomas Maubach, coating operator at Giga Coating, says: “With

in corners, recesses, and delivers powder to the spray system with a

the excellent coating result, the simple operation and the fast and very

minimum of air offering the independent control of the powder and air

easy colour change, it is a pleasure for me to go to work every day”.

volumes.

In each booth, 22 Encore® HD automatic powder guns efficiently ensure

Further advantages of the technology are maximum process control, a

uniform powder application with maximum process control over a long

very high degree of automation and repeatability of the coating quality

period of time.

at the highest level. “This gave us the secure feeling of having found the

Two Encore HD manual guns are also available for coating very special

right partner in Nordson, so that Nordson was awarded the contract,”

shapes. The manual coating stations are equipped with lifting platforms

says Mr. Saatkamp.

for better access up to 2.7 meter high components. The first booth

Since the new plant was established in 2018, a sophisticated conveyor

without Dynamic Contouring naturally requires a little more post coating

system has been handling the workpieces, which can be up to almost 16

than the latest booth with the Dynamic Contouring system.

meters long and weigh up to 9 tons, through the 11-stage pre-treatment

The second ColorMaxE booth, equipped with the innovative DCM

process of blasting, degreasing, zinc phosphating and cathodic dip

(Dynamic Contouring Mover) system, provides even more precise control

painting before they arrive at one of the two ColorMaxE powder

of the powder guns - without any programming. Scanners in the booth’s

coating booths, (“E” = Engineered) built to customer specifications. The

entry area detect the geometry of the incoming part. They transmit the

installation of the second powder coating system followed in 2020,

data via PowderPilot HD to the DCM system to bring the powder guns to

INNOVATIVE FINISHING TECHNOLOGY FOR SOPHISTICATED SURFACES

Venjakob Maschinenbau – more than 50 years of innovation in surface technology made in Germany Surface pretreatment | Coating | Drying technology | Automation | Exhaust air cleaning www.venjakob.de www.venjakob.com anzeige_IPCM_9_2020_214x62.indd 1

31.07.20 09:55

The Nordson Dynamic Contouring Mover (DCM) System combined with the soft spray increases the automatic coverage of complex forms and achieves the highest process control in powder coating applications.

the optimum distance from the workpiece. The result is an even more

yet. The DIN EN ISO 11997-1 standard specifies only 1,000 hours”.

consistent coating of the complex geometries, even lower powder

The construction of the powder coating system worked well right from

consumption, less post coating and higher productivity. The system thus

the start - even though Giga Coating certainly had to put in a great

operates up to 95% automatically. The system control is also integrated

deal of effort to get a complete production line up and running in a

into the in-house ERP system “Giga-IT”.

short time. “In the first week after the installation of the line, we already produced 20 chassis with the desired coating thicknesses between 80

The customer benefit: Coating heavy-duty parts economically in automotive quality

and 120 µm - practically on the side while the line was being adjusted”,

After Giga Coating commissioned the first of the two powder coating

have the capacity for around 50 trailers per day”.

booths in 2018 and the second in spring 2020, Managing Director

In the environment of a “batch size 1 production” with maximum powder

Ingo Wildermann draws a thoroughly positive conclusion. “The

recovery, this is only possible if the frequent colour changes, including

decision to bring the coating into our own hall and automate it as

careful cleaning, can be accomplished within minutes.

much as possible has massively increased our production. And further

The trouble-free operation of the plant encouraged Giga Coating to start

optimizations are being carried out daily. The required powder quantity

contract coating for external customers after only one year. These are

per rack is stored in our Giga Coating ERP system and is analyzed daily.

mainly customers who, like Giga Coating, are looking for fast throughput

Mr. Wildermann is also completely convinced of the coating quality. “We

times with very high quality and who, with their large-format,

work according to the strict specifications of the automotive industry and

corrosion-prone components, contribute to good utilization of the

even exceed them. A salt spray test, which we carried out here on our

annual capacity of around 1.5 million sqm of coating in three-shift

own initiative, we stopped after 3,000 hours because nothing corroded

operation.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

Mr. Wildermann remembers the successful start-up phase. “We now

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SUCCESS STORIES

Effective Rust Protection From the Can for Triumph Spitfire Parts Classic cars are enjoying ever-greater popularity - and not just with dyed-in-the wool enthusiasts. Recent years have seen a boom in the number of classic cars on the roads of Germany. Regular care and maintenance are key to preserving the value and function of the historical treasures. This is also confirmed by Peter Messing. For the extensive repair work to his 1974 Triumph Spitfire the classic car fan turns to an innovative rust protection system – a room temperature curing zinc flake coating from the spray can, which recently became available for industrial applications. Regular maintenance work on the classic vehicle

in his day job he is responsible for zinc flake surfaces at Aalberts Surface

The Triumph Spitfire from the Californian city of San Francisco is a real find

Treatment, a service provider active in the field worldwide – occasionally

and the pride and joy of Peter Messing. Even after 45 years the bodywork

carries out repairs, taking the car apart and putting it back together

is still free of rust, whilst the interior of the sports car is in top condition.

again himself. Recent investments included new axle components, a

To maintain the vehicle in a drivable condition the technology specialist -

new transmission and a differential.

For the repair and overhaul of the 1974 Triumph Spitfire numerous parts were coated with the room temperature-curing zinc flake system from Dörken, which was recently made available for industrial applications.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

Peter Messing is Global Key Account Manager and responsible for zinc flake surfaces at the globally-active contract coater Aalberts Surface Treatment - and a passionate classic car enthusiast.

SUCCESS STORIES

The manifold, transmission, clutch housing, axle parts and brake drums were first pre-treated and then sprayed with DELTA-PROTEKT® REPAIR zinc flake spray.

Room temperature curing zinc flake system from the spray can

Peter Messing: “The steel tube manifold was not

Now more extensive maintenance and

on the welding seams. So I welded it, degreased

conversion work was required, including on the

and ground it before also coating it with the

drive shaft and bearings. Peter Messing was

zinc flake spray. Now the transmission, clutch

looking for suitable surface protection. “I thought

housing, bolts, flywheel, screws and other parts

about using the original black paint or something

are resplendent with a new shine.”

really in bad condition, but it had a few cracks

that would offer long-term protection against corrosion and also look good. As I’m familiar

Successful practical test

with Dörken zinc flake from professional use, I

After Peter Messing had put everything back

decided to use the new zinc flake coating from

together again, it was time for the practical test

the spray can – DELTA-PROTEKT® REPAIR - for the

– he drove the Triumph over 2500 km and was

new components. The advantage compared to

impressed: “I thought that the coating would peel

standard zinc flake systems is ease of use thanks

or burn off. I spent a long time looking at surface

to the curing of DELTA-PROTEKT REPAIR at room

protection and knew that the critical temperature

temperature. Standard zinc flake systems need

for zinc lies at 350-500°C. However, the coating

to be annealed at high temperatures.”

is still fully intact and is scratch-resistant and

optically almost unchanged after being subjected

Numerous components removed, cleaned, treated and given a new coating

to the heat.” His verdict: “I’m very satisfied. When

Each individual part was firstly cleaned down to

corrosion protection with zinc flake. Powder

the bare substrate, degreased and then sprayed

coating or KTL may look good, but is nowhere

with the zinc flake base coat. A number of

near as long lasting.”

COMPLETE SOLUTIONS for

HANGING and

MASKING

it comes to optimal surface protection for the components you cannot beat active cathodic

components subsequently received an additional aluminium spray coating - for enhanced robustness and a shiny appearance.

For further information:

Fixing the manifold proved to be a real challenge.

www.doerkencoatings.de

www.rostirolla.it

BRAND-NEW

AkzoNobel’s Salcomix PaintFinder Cloud Expands with Two New Colour Collections AkzoNobel has made two new colour collections available in its Salcomix PaintFinder cloud.

he Salcomix PaintFinder cloud was

launched by AkzoNobel last year to provide remote access to over 600,000 colour

formulations. This is a new service developed by the company using the latest technologies, in order to offer its customers the widest possible range of colours from which to choose the formulation that best suits their needs. Today, the 27 product lines already available at the time of the market launch of this new advanced tool have expanded the formulation offer by incorporating 2 new colour collections: • Sikkens 5051 Color Concept: the 2077 colours of the Sikkens Decorative swatch book are now available in various product formulations. With the relative fandecks, the customer will have the possibility to view a wide range of matte colours and will be able to activate the Sikkens 5051 colour collection in the Connecting Color app for smartphones using the pocket colourimeter Color Finder, the colour matching system launched by AkzoNobel at the same time as PaintFinder. • Sikkens Color Map: the 3867 pastel colours of this historic colour collection in gradation of shades used for the Sikkens car refinish range are available in different series of Salcomix products. The 2 new collections are available within the Standard Collections. Visit www.paintfindercloud.com/search or scan the QR code:

For further information: www.salcomix.com

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

BRAND-NEW

LUTRO b+m Service GmbH is LUTRO’s New Customer Service Following the insolvency of LUTRO Luft- und Trockentechnik GmbH in April, the company has restructured its customer service, partnering with b+m surface systems GmbH.

UTRO paint systems has restructured its customer service with b+m surface systems, a leading

technical manufacturer of fully automatic painting systems headquartered in Eiterfeld in eastern Hesse, as a partner.

After the insolvency of LUTRO Luft- und Trockentechnik GmbH in April, the service team was transferred to b+m surface systems GmbH, thus giving rise to LUTRO b+m Service GmbH. b+m surface systems GmbH employs about 450 people worldwide, and develops and manufactures key components such as painting robots, application technology, and automation itself. The service team both in the office and in the field, as well as the on-site service technicians, will continue to be available as a competent partner for LUTRO painting systems in the future. This means that service support, spare parts supply, as well as all technical aspects will be maintained for the customers. For further information: www.bm-systems.com

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The reliable service team both in the office and in the field, as well as the on-site service technicians, will continue to be available as a competent partner for LUTRO painting systems in the future.

FOCUS ON TECHNOLOGY

A New Coating Plant to Custom Finish OMSI Trasmissioni’s Drive Units Monica Fumagalli ipcm®

The new coating plant installed at the Italian headquarters of OMSI Trasmissioni Spa, an international Group producing power transmission systems, has increased the company’s production capacity and the customisation level of its mechanical drive components intended for the agricultural, industrial, and railway sectors.

ccording to the report of the Italian Association of Gears and

(25% of the entire production).

Transmission Elements Manufacturers (Assiot), this industrial

Such a substantial volume of business experienced a setback during the

segment in Italy “is among the top four worldwide in terms of

lockdown imposed by the pandemic, as it has happened for the entire

size and the second one in terms of technology (behind Germany), with

manufacturing industry. These days, however, it is starting to see the first

niches of absolute excellence”1. The association’s estimates indicate

signs of recovery. “Despite the lockdown, we have managed to complete

that the Italian power transmission sector is composed of about 300

our company improvement and revamping project according to the

industrial-size companies, to which we must add numerous artisanal

Industry 4.0 dictates which included the construction of a new factory

firms, accounting for 1.6 billion Euros in the country’s trade balance

for our coating, assembly, shipping, and warehouse departments,” states Renato Soncina, the CEO of OMSI Trasmissioni SpA.

https://www.assiot.it/it/#1474876268166-19eee455-3733 (07/09/2020)

One of the drive units manufactured by OMSI.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY An axle produced and coated by the Brescia-based company.

company, established more than sixty years

The company has specialised precisely

ago – from the mechanical force,

in the engineering and production

which goes through power

agricultural, industrial, and railway

transmissions manufactured,

vehicles since 1959. “This is proof

to the power of ideas, starting

of power transmission systems for

that anything is possible, with

from those of founder Giovanni Soncina, who turned 100 in

the management determination,

September and celebrated in the company

teamwork, and the involvement of

he created and watched growing. “It might be hard to

trusted partners, such as the ones we selected for the design and installation of

believe,” says Renato Soncina, “but my father celebrated his 100th

our new paintshop.”

birthday while still working on several projects related to our new

The partners Soncina refers to are as follows: Silvi Srl for the design

assembly lines. He designed the first transmission systems and power

and installation of the coating system, Futura Convogliatori Aerei for

take-offs that have enabled OMSI to establish itself on the market and

the heavy-duty conveyor, CMA Robotics for the supply of two coating

become known throughout the world: we now have plants in France, the

robots for the automated booths, and Anest Iwata for the paint spraying

United States and China, in addition to the first production site of Roè

system. “The factory and the coating line,” says Soncina, “were built in

Volciano (Brescia, Italy) and that of Bologna (Italy).”

record time: the plant has been operational since December 2019 and

Throughout its history, besides intermediate and engine power

it is still under continuous implementation with the addition of coating

take-offs, the company has gradually started manufacturing complete

programs for our various products.”

transmission systems for rail, road, and off-road applications, such as axles, reducers, couplers for pumps, and hydrostatic transmission

OMSI Trasmissioni: over sixty years of experience in the development and design of drive systems

units, produced together with another company of the Group, Cobra

‘Power’ is the element that has always characterised the history of this

OMSI has been able to apply its skills, thus gaining a unique

(Bologna). “These are heterogeneous fields,” explains Soncina, “in which

A detail of the new coating line with its pre-treatment oven and painting booths.

The overhead two-rail conveyor.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

A detail of the conveyor, with a maximum capacity of 2500 kg per load bar.

know-how in terms of knowledge depth and customisation capacity. “Our company’s flagship projects include the development of intermediate and engine power take-offs specifically aimed at providing high performance without the need for a second endothermic engine: they can be used when the vehicle is both stationary and in motion and they allow drawing all available power (up to 600 kW). Therefore, they are ideal to be applying on vehicles, like as cesspool purging and channel washing, hazardous waste transport, dry material and industrial dust suction, and fire prevention vehicles, concrete pumps, concrete mixers, street washers, and other special truck applications. Furthermore, we design and build mechanical-hydrostatic drive units able to switch from mechanical to hydrostatic mode through a dedicated

The inside of the pre-treatment tunnel.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

hydraulic circuit. Designed for controlled forward speeds, these drive systems are

FOCUS ON TECHNOLOGY

MOULDED PRODUCTS SILICONE and EPDM made TAPES in PET, Vinyl, PI, Creped Paper, Aluminium ... HOOKS for painting and weld STEEL and IRON made DIE-CUTS Standard and Bespoke on tape with liner The outside of the pre-treatment tunnel.

equipped with an additional output of engine power take-off that eliminates the need for an auxiliary engine. Possible applications include sweeper trucks, road cleaning vehicles, airport machines, fire-fighting vehicles, snow blowers,

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and cranes. â&#x20AC;&#x153;Since the 1980s, we have also been producing steering and rigid driving axles and complete gearboxes and transmission systems for agricultural, earthmoving, construction, mining, and heavy transport vehicles, all with several customisation options. Then, we manufacture a wide range of railway transmission systems in compliance with international regulations. Our wide range of products intended for railway maintenance vehicles includes hydrostatic, electrical, and mechanical traction systems and complete wheelsets with a capacity of 30 to 300 kN per axis or per bogies. We develop also road-rail axles to allow the regular use of wheeled vehicles both on tracks and roads.â&#x20AC;?

Quality controls on OMSI Trasmissioni products Since 1993, OMSI boasts a quality monitoring system able to cover all business processes, from raw material acquisition to product testing. Its internal metallographic laboratory is an essential resource for quickly carrying out chemical analysis

FINISHING GROUP srl v.le A.DeGasperi, 31 - 20045 Lainate - Milano tel. +39 02 9678 0055 - fax +39 02 9678 2993 i n f o @ e u r o m a s k - s h o p . c o m

www.euromask-shop.com

and checks on the strict mechanical requirements imposed by the most rigorous quality standards. “We have reached a high quality level in terms of materials, mechanical characteristics and assembly,” indicates Soncina, “but we found the need to improve our surface treatment process of finished product. The products we manufacture are functional components of machines: besides guaranteeing excellent wear and corrosion resistance properties, we also wanted to achieve good aesthetic results, in order to offer further added value in terms of product customisation. This is why we allocated so many resources to the construction of a new coating plant.”

The characteristics of the new plant The new coating line was designed based on the size and weight of the workpieces to be treated. “Very high capacity was required, as this company’s products can reach 2 tonnes,” says Silvi Srl owner Daniele Fumagalli. “Since we had to comply with the latest European directives on suspended loads, we offered to install an overhead two-rail conveyor supplied by Futura. The resulting system has a maximum capacity of about 2500 kg per load bar. The expected takt time is 13.5 minutes, with about 4.4 bars processed per hour. The plant, with a total footprint of 54 x 26 m, is composed of a 6-stage pre-treatment section and 3 coating booths, of which 2 are automatic

One of the two GR 650 ST robots supplied by CMA Robotics.

The application control unit with a CMA panel and an Anest Iwata management unit.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

The dry filtration system with Edrizzi® floor devices.

FOCUS ON TECHNOLOGY

systems equipped with CMA Robotics’ GR 650 ST

coating robots and 1 is a manual plant used for touch-up operations or to treat non-standard parts.” “We paint already assembled products,” notes Soncina, “inside of which there are seals that cannot withstand high temperatures. Therefore, we chose to use liquid water-based paints for both the primer and the top coat layers.” The coating cycle includes the following phases: • loading of the workpieces on the overhead two-rail, boxed conveyor through an elevator • spray pre-treatment in the 6-stage tunnel (including a final stage applying Chemetall Oxsilan® nanotechnology products) + final blow-off • oven drying at a maximum temperature of 80 °C manual blow-off and masking at room temperature automatic liquid coating through the robot and electrostatic equipment of the pressurised booth

The coating management unit.

no. 1 • water-based primer application

• oven flash-off at 20÷30 °C • primer pre-baking in the oven at 40÷50 °C • cooling to room temperature in the ambient air • automatic liquid coating through the robot and electrostatic equipment of the pressurised booth no. 2 • water-based top coat application • top coat pre-baking in the oven at 20÷30 °C • top coat baking in the oven at 70÷80 °C • cooling to room temperature in a dedicated tunnel unloading of the parts through the elevator. Fumagalli says: “We offered to OMSI a coating plant concept that met their requirements at best. In particular, they asked for a multi-metal pre-treatment process for both iron/cast iron and aluminium components, in order to remove any grease and oil deposits remaining after mechanical operations and to protect surfaces against under-corrosion resulting from any mechanical damage to the paint layers, thanks to the deposition of phosphates on every surface. Their second main requirement was related to the application system: thanks to Anest Iwata’s pumps, OMSI can now handle up to 12 colours, a number that can be further raised in future.” Finished axles ready for shipment.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

The technology 4.0 of the new line

automatically managing the regeneration of resins. Eco-friendliness was

“Generally speaking,” states Soncina, “the implementation of Industry

another aspect on which we particularly focussed while working with

4.0 principles did not entail a revolution in our company, but a simple

Silvi, in order to design a coating plant that would reduce emissions to

evolution of the production processes we had already in place: in

a minimum. Sustainability is one of the issues we care about the most,

our factory, every plant has been interconnected with our computer

so much so that we have created a division for the development of new

system for several years now. As regards the coating process, on the

projects and products exploiting clean energy sources.”

other hand, this new line certainly broke with the past. Its management system, which monitors the machinery status and tracks the processed components based on part codes, and its robots’ self-learning ability

Conclusions

(Tables 1 and 2) have brought about a significant leap in quality for us.”

“Our sector will once again be the protagonist of the global market,”

“Finally,” notes Soncina, “we confirmed our environmental vocation by

states Renato Soncina as a conclusion. “For instance, due to the serious

choosing water-borne coatings and a few special devices. For instance,

setback of air transport, our division producing drive units for trucks

our dry filtration system features Edrizzi® floor units, which guarantee

with aircraft antifreeze spraying devices and for snow blowers is still

considerable energy savings and increase our coating quality level by

completely inactive. But I am convinced that the manufacturing industry

preventing any accumulation of paint inside the booth. Other examples

will recover. In order to do so, it needs ongoing innovation: with this

are the water purification system of the pre-treatment tunnel, which

in mind, our new coating plant, that is already active, will support our

uses an automatic oil separator, and the demineralisation plant,

improvement and growing.”

Table 1: Technical features of CMA Robotics’ GR 650 ST robots.

ROBOT AXES

AUXILIARY AXES

PAYLOAD

5 Kg

MOTORS

AC Brushless

AXES’ POSITION

Table 2: Robots’ control panel.

PANEL PROTECTION DEGREE

IP 54

CONTROL PANEL SIZE

70 x 60 x h 120 cm

SQUARE WEIGHT

Approx. 160 kg

Absolute encoders

OPERATING TEMPERATURE

+ 0 °C / + 40 °C

ROBOT WEIGHT

450 kg

INSTALLED POWER

6 kW

REPEAT ACCURACY

1 mm

MAXIMUM SPEED OF AXES NO. 1 2 3

120°/s

CONNECTION CABLES

5 m (standard) or different upon request

MAXIMUM SPEED OF AXES NO. 4 5 6

360°/s

Industrial PC

PROGRAM SPEED CHANGES

From 1 to 200%

DATA AND PROCESS MANAGEMENT COMPUTER

MOVEMENT TYPES

Joint - Cartesian - Tool

OPERATING SYSTEM

WINDOWS 7

ROBOT PROTECTION DEGREE

IP 65

USER PROGRAMS MEMORY

OPERATING TEMPERATURE

+ 0 °C / + 40 °C

1GB CompactFlash (about 400 hours of programs)

MAXIMUM HUMIDITY

75% without condensation

SOFTWARE LANGUAGE

Italian

ROBOT COLOUR

RAL 6018

TEACH PENDANT

Mobile Panel + Joystick

AIR SUPPLY PRESSURE

7 bar – 20 litres/minute

DIGITAL INPUTS - OUTPUTS

ARM BALANCING

Pneumatic

36 inputs + 36 outputs (optional 24 + 24)

PROGRAMMING

Self-learning and PTP Joystick + teach pendant

POWER SUPPLY

380V AC 50-60 Hz

ATEX EXECUTION

Ex-p (optional)

COMMUNICATION

RS-232 – ETHERNET (optional PROFIBUS)

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

www.novaresine.com

BRAND-NEW

Digitalization: Dürr is a Pioneering Partner for the Industrial Cloud of Volkswagen and Amazon Web Services With its IIoT software applications, the Dürr Group is one of the pioneering partners for the new Industrial Cloud of Volkswagen and Amazon Web Services (AWS). The mechanical and plant engineering firm will initially provide two smart applications from its DXQ software range on the OEM’s open industry platform. Going forward, Volkswagen’s worldwide factories and other partner companies will be able to optimize their manufacturing processes and productivity by accessing applications in the Industrial Cloud, just like they would in an app store. Dürr can use the feedback from the automotive factories to develop its applications further.

n an initial step, Volkswagen and AWS have opened the Industrial

the painting robots and relates these results to the painting results.

Cloud to eleven partner companies. Dürr contributes a

Another Dürr software application in the Industrial Cloud enables

DXQ application, among others, to increase overall equipment

productivity enhancements in final assembly. The DXQ Filling Services

effectiveness (OEE). This software is deployed in the quality management

application analyzes the system status of filling stations, in which

of paint shops and uses artificial intelligence (AI) to identify error patterns.

cars can be supplied with fluids such as brake fluid, air-conditioning

To this end, algorithms compare process and order data from different

refrigerant or gear oil. This enables the filling process to be optimized.

sources. The DXQ application also performs an AI-based status analysis of

Dr. Jochen Weyrauch, CEO of Dürr Systems AG, says: “The integration of

The DXQ application also performs an AI-based status analysis of the painting robots and relates these results to the painting results.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

BRAND-NEW

part-ner software in the Industrial Cloud creates a win-win situation. Volkswagen can offer its factories a fast-growing range of diverse software applications. For us, the integration is valuable because it helps us gain new insights into production. This enables us to design our applications in an even more customer-oriented way and better establish them in the market.” In addition, Dürr is supporting Volkswagen, for example, in digitalizing the new paint shop in the Chinese plant in Anting. This is where DXQ applications for the optimization of processes, production quality, energy consumption and plant maintenance are used. The collaboration with Volkswagen in Anting is Dürr’s largest digitalization project to date. For further information: www.durr.com

The DXQ Filling Services application analyzes the system status of filling stations in which cars can be supplied with fluids.

● ● ● ●

Conveyors Conveyor chains Special components Automations

Se.Po. di Pozzi Sergio

Dürr combines its expertise in IT and mechanical engineering in a digital factory.

Via Concordia 43 23854 Olginate (LC) T.+39 0341605056 info@sepoitalia.it www.sepoitalia.it

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Ta ke a l o o k a t o u r t e ch n o l o g i e s i n a c t i o n !

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

MARKET CLOSE-UP The Aluminium Surface Treatments Industry Does Not Stop: The Positive approach to Current Market and the Circular Economy are the Key Items of its Future

50 INNOVATIONS: PRESENT&FUTURE

Anodikit® ZONE: The Most Innovative and Compact Plant Available for Anodising

SUCCESS STORIES

Remote Design of a New In-Line Paint Stripping System

INNOVATIONS: PRESENT&FUTURE

Aluminium Process Technologies of the Future

58 FOCUS ON TECHNOLOGY

66 FOCUS ON TECHNOLOGY

The Profile Recognition System Helps New Zealand Company Altus Reaching New Quality Heights in the Powder Coating of Aluminium Profiles for Architecture

INNOVATIONS: PRESENT&FUTURE

78 82

New Elcosan® Moonlight Colours: Alsan Widens the Spectrum of Greys by Optical Interference

BRAND NEW MARKET CLOSE-UP

Aluminium, The Metal of the Future: AITAL’s Point of View on This Ever-Developing Market

HIGHLIGHT OF THE MONTH 88 Stardust Powder Coatings: Craftsmanship and

Quality in Record Times for Batches Starting From 25 kg

INNOVATIONS: PRESENT&FUTURE

Scientist at Fraunhofer Institute Develops Coating that Protects Steel from the Penetration of Hydrogen

94 BRAND NEW 96 FOCUS ON TECHNOLOGY

Fondmetal Recovers 99% of Water with a New, Zero Liquid Discharge Water Treatment Plant

102 FOCUS ON TECHNOLOGY

Fisher & Paykel Chooses a Nanotechnology Pre-Treatment Process for the Production of ELBA-Branded Household Appliances

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

MARKET CLOSE UP

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

The Aluminium Surface Treatments Industry Does Not Stop: The Positive approach to Current Market and the Circular Economy are the Key Items of its Future Interview with José Almeida, President of ESTAL - European Association for Surface Treatment on Aluminium

n recent years, the demand for aluminium is constantly growing:

During the pandemic period, total aluminium business was less affected

thanks to its characteristics of versatility and lightness, this particular

compared to the other sectors such as automotive, tourism. However,

material has managed to conquer previously unattainable sectors,

the pandemic period brought considerable changes in the demand for

such as the automotive industry. The COVID-19 pandemic has

aluminium/aluminium surface treatments in most of the countries in the

only slowed its development, and that, consequently, of its surface

world. I will try to give you a picture of the European aluminium industry

treatments, without being able to stop it: our interview with José

with the actual situation from some of our members. In Portugal, the

Almeida, President of ESTAL, offers an overview of this optimistic

construction sector is one of the few that is still with significant growth,

approach to future developments of the market, which aluminium faces

whereas in Turkey, most of the surface treated aluminium goods are

as one of the leading elements of the circular economy.

consumed in the country for the architectural area and the construction sector was severely affected by the pandemic situation. Total exports

The European aluminium industry and, consequently, the

from Turkey decreased about 10% while total imports fell by around

sector addressed to its surface treatments, always shows great

5% for the aluminium sector. However, for Turkish surface treatment

ferment. Could you give us an overview of its pre- and post-

business, more decrease is expected.

pandemic situation?

In Belgium, many companies in the building industry immediately closed

In the past couple of years, most European countries recorded

their shops during the lockdown, others tried to continue but once the

a substantial growth in aluminium demand (and consequently,

suppliers from abroad could not deliver anymore, they also had to close

in aluminium surface treatment demand) in all sectors, namely

down. Three weeks after lockdown, things seemed to start up again and

construction, industrial, automotive markets for example.

the industry tried to make up for lost time/business. For Austrian companies, the situation seems to be stable but on a lower basis, with a loss of approx. 10% in 2020.

The industrial sector suffered considerably during the confinement

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

MARKET CLOSE UP

period, but it is recovering slowly, the demand for aluminium/ aluminium treatments being at this moment, basically the same as last year. The automotive sector is suffering considerably in these pandemic times, thus aluminium demand (and consequently, aluminium surface treatment demand) is in a historical low. We believe that the post-pandemic (if a vaccine is massively distributed in the near future) will be of great growth in the aluminium surface treatment. Currently interesting developments for the surface treatments sector concern the antimicrobial protection of aluminium surfaces. What are the most important projects? Many companies are searching different additional functions for their surface treatments, other than the simple colouring. Some companies propose enforced scratch resistance or bring anti-graffiti as well as antimicrobial properties. Although we know that various antimicrobial protection powder coatings are at this moment in our market, the demand for such kind of products is, for now, residual and insignificant in most countries. Most of these developments are also more expensive or more difficult in application. Therefore, the impact of changes in the market are there but come slowly. On the other hand, the anodized aluminium surface is already an antimicrobial surface. Depending on the evolution of the science on COVID-19, namely of its transmission rate by contact with surfaces, the state of the art at this moment is that this transmission isnâ&#x20AC;&#x2122;t very significant, so we believe that this antimicrobial surface protection will not transform itself into a trend, remaining simply as aÂ niche market product. What are the sectorâ&#x20AC;&#x2122;s current priorities, in general and from a legislative point of view, in particular? Generally speaking, in most countries, today's current priority is to survive the COVID-19-crisis. Currently most of the companies are concentrating on cost reductions, recovery of debts, maintaining human resources and sustaining the company. In the majority of the European countries/EU members, from the legislative point of view, one of the biggest issues for the aluminium surface treatment is the forthcoming revision of the BREF STM (Reference Document on Best Available Techniques for the Surface Treatment of Metals and Plastics), document, first edited in 2006. The future of the surface treatment business will be strongly conditioned by this new document, so ESTAL is following with great attention all this process. Another issue at the legislative level that we follow intensively is the

MARKET CLOSE UP

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

REACH (Registration, Evaluation, Authorisation

important in the EU, aluminium usage and business

and Restriction of Chemicals) legislation that

will increase gradually due to its unique properties

addresses the production and use of chemical

and highly recycling capability. Consequently, we also

substances, and their potential impacts on both

believe that circular economy will go from being a

human health and the environment. REACH

trend, to a standard policy in all industry, namely in

has great impact directly at an industrial level,

aluminium/aluminium surface treatment industry.

due to the fact that any substance included in

We have great interest in the surface treatment of

the List of substances included in Annex XIV of

secondary (recycled) aluminium alloys, with growing

REACH (“Authorisation List”) has its use banned

demand on a daily basis, and this is why, at ESTAL,

(or strongly conditioned) in all of Europe. For

we have initiated a working group in order to

example, the inclusion in this list in September

promote a systematic study of this issue. This work

2017 of Hexavalent Chromium (CR 6+) - the

is strongly supported by various members of ESTAL

substance that had been mostly used for the

and of European Aluminium.

pre-treatment processes for coating treatments in Europe for decades until the 90’s - has

For example, we believe that the aluminium window José Almeida, President of ESTAL.

to window recycling will be a fact in the next years.

forced a profound change to other alternative

This need will be created by consumer demand and

authorized products both in the pre-treatment

it will be inevitable.

and coating industry in Europe. Finally, the rising of recycled aluminium may increase the difficulty

Today it’s difficult to make a forecast of the economic situation

in the following production chain and may bring new challenges to

over the next year. From the point of view of your Association,

the aluminium surface treatment industry, for instance problems

could you give us some indications of future developments both

encountered with the corrosion resistance of powder coatings or bad

in your geographic area and in all the world?

surface structures in anodising.

Various European countries (Belgium, Austria, for instance) expect to see a temporary drop in activity in the first quarter of next year. Other

One of the most important themes concerns the circular

countries, like Portugal, are very optimistic and believe that the

economy applied to the aluminium sector. What future do you

post-pandemic aluminium/aluminium surface treatment market with

foresee for this particular approach?

be of great growth both in Portugal and in Europe. This growth may

As President of ESTAL and president of the Portuguese association APAL,

start slowly, but the growth trend from the last decade will continue,

I believe that the circular economy policy is the future, and one of the

and we believe that our business will thrive in the next years. The future

aluminium sectors greatest assets when compared with other materials

for aluminium and consequently for surface treatment of aluminium is

and industries. As the sustainability and green economy are getting more

certainly bright.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

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INNOVATIONS: PRESENT&FUTURE

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Anodikit® ZONE: The Most Innovative and Compact Plant Available for Anodising Elia Schaer Alsan, Álvarez Schaer S.L.U. – Paterna (Valencia) – Spain

alsan@alsan.es

Alsan has developed Anodikit® ZONE, a new compact, automated system that can carry out the anodising process in accordance with the Qualanod specifications.

hroughout the history of aluminium, several obstacles have

Pre-treatment of aluminium profiles before the anodising process

prevented sector players from entering the world of anodising.

This first automatic, multi-process spray tank houses all the aluminium

The high investment required, the need for large spaces

pre-treatment stages required before the formation of the anodic layer,

to install a system, and the obligation to hire different qualified

such as degreasing, neutralisation, etc. Each of the different chemical

employees able to follow the regulations in force are just a few of the

products is pumped, followed by its related rinse, without changing the

factors that have limited the development of one of the safest and

frame that carries the profiles. The dynamic system handling the parts

highest quality processes available to protect aluminium. Alsan’s new

guarantees treatment homogeneity on all their surfaces through the

plant, called ZONE, solves all these issues. It is a compact, automatic

precise control of process and emptying times.

anodising line, only requiring an area of 250 m2 for installation and little investment, which allows carrying out this process safely and in

Anodising stage

compliance with all Qualanod quality requirements. The full process

This station includes a standard immersion tank, a rectifier, refrigeration

is carried out in just three tanks with the following functions:

equipment with a closed-loop cold water circulation system, a bath

A bird’s eye view of the plant.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

recirculation unit, electrical contacts, aluminium cathodes, mechanical agitation systems, etc.. Sealing stage This occurs in a second automatic, multi-process spray tank. As in the first tank, pneumatic pumps and valves supply the various chemicals and their rinsing liquids. Chemical products specifically developed for this application guarantee the perfect sealing of the anodic layer. Line automation is managed through the AluZone special software package, which automatically and constantly collects data related to more than 200 parameters, while sending the necessary instructions

Curing ovens

Powder painting booths

to each process tank and checking temperature, conductivity, water supply, agitation system, and other essential monitoring parameters. In addition to the traditional anodising process, it is also possible to add an aluminium colouring phase. Finally, it is worth emphasising that this plant has actually two functions, as it can adapt its own process in order to carry out an anodic pre-treatment stage before aluminium coating. A patented plant in full operation in the city of Valencia (Spain). Washing tunnels

The multi-process tank of the pre-treatment stage.

Liquid painting booths

Shotblasting booths

Innovative solutions

Soluzioni Innovative

Eurotherm solves every problem concerning painting processes, creating complete lines for the entire process.

Eurotherm risolve ogni problema riguardante i processi di verniciatura, realizzando linee complete per l’intera lavorazione.

Our structure is organized and flexible and able to satisfy the most demanding requests.

La nostra struttura è organizzata e flessibile ed in grado di soddisfare le richieste più esigenti.

Customers who turn to Eurotherm are customers who, despite knowing the “painting process”, want to improve production by adopting highly customized technical solutions.

I clienti che si rivolgono a Eurotherm sono clienti che, pur conoscendo il “processo di verniciatura”, vogliono migliorare la produzione adottando soluzioni tecniche altamente personalizzate.

Headquarter: based in Turin (IT)

Number of employees: 65

Plants realized in 2019: 180

Other locations: Stuttgart (DE), Toulouse (FR), Verona (IT)

EU1: 3.500 m² of offices, carpentry and painting departments EU2: 5.300 m² for sheet metal department, assembly, storage and shipment

Eurotherm S.p.A. T +39 011 98 23 500 | M info@eurotherm.eu

Top view of the complete process.

Eurotherm Lackieranlagen GmbH T +49 711 400 545 13 | M contact@eurotherm.eu

eurotherm.eu

SUCCESS STORIES

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Remote Design of a New In-Line Paint Stripping System The lockdown due to the pandemic did not stop Alit Technologies’ team. Specialising in the design and installation of systems and products for the chemical stripping of metals, this company managed to complete the project for an in-line paint stripping machine, commissioned by a customer from Eastern Europe, despite the international travel restrictions.

lit Technologies (San Bonifacio, Verona, Italy) is an

generation machinery and technologies, whose development is the

internationally established manufacturer of products and

result of our research work combined with the valuable collaboration

systems for the chemical paint stripping of metal surfaces.

of our industrial partners. Its aim is to remove paint from hooks, frames, and metal products in different sizes (even aluminium

chemistry that can contribute to the reuse of metal products and the

profiles up to 7 meters) quickly, efficiently, and economically. The

reduction of waste,” explains CEO Loris Rossi. “We develop products

Fastrip ISP system, for example, is a unique in-line chemical paint

and systems inspired by this mission: Metalstrip, in particular, is our

stripping plant, guaranteeing the perfect removal of paint from

line of innovative, high performance, and low environmental impact

hooks.”

chemical products. Fastrip, on the other hand, is our range of new

During the health emergency of the first months of this year, an

“Alit Technologies believes in the use of efficient and low-impact

The paint stripping plant, belonging to the Fastrip ISP series. The ultrasound devices are integrated into the walls of the tank.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

SUCCESS STORIES

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

important Eastern European company contacted Alit Technologies for the design and installation of a system for the in-line paint stripping of hooks, to be integrated into a vertical coating line with a capacity of 2.2 m/min. “Although we received this request during the most critical period of the pandemic, that is, when national and international travel was completely forbidden,” says Rossi, “with the collaboration of the entire technical team of Alit Technologies, working through remote connection, we were able to provide the customer with the optimal solution. Finally, in September, we supplied them with a tank type 1600, among the largest in terms of size of the ISP range.”

Characteristics of the in-line paint stripping system The system supplied consists of a horizontal tank from the 1600 series, made entirely of AISI 304 stainless steel with dimensions of 8400 x 700 mm. The conveyor runs above the tank for the in-line handling of coating hooks and frames. These are immersed and let move inside the paint stripping bath for a variable time of

The filter press for sludge decantation.

about 3 minutes. While still hanging onto the chain, the hooks come out of the chemical bath without any paint © Alit Technologies

residue and they can be immediately reused for a new coating cycle. “This plant, designed remotely by our staff, has a few particularly innovative features,” notes Rossi, “that is, the ultrasound devices that we managed to integrate directly on the tank walls and the filter press with a vibratory hopper. This feeds the decanter for the use of a new flocculate called AlitFlock 4840, developed by us to make the stripping sludge mass much drier.” Finally, in order to optimise the operation of the paint stripping system and achieve the results requested by the customer, Alit Technologies formulated and developed some special products that are free from NMP (N-Methyl-2-pyrrolidone), which have already successfully passed the necessary laboratory tests. For further information: www.alit-tech.com Alit Technologies specialises in the formulation of chemical products for metal stripping.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

INNOVATIONS: PRESENT&FUTURE

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Aluminium Process Technologies of the Future Oliver Katschmareck Chemetall GmbH - Frankfurt am Main, Germany

oliver.katschmareck@basf.com

Change of parameters with new ways for anodising aluminium using Gardobond® additives.

erfect adhesion and long-term corrosion protection are typical

are maintained even after many years of use. Due to its excellent

requirements for surface finishing for aluminium. Due to its

properties, beyond the Architectural and Construction Industry,

combination of advantageous properties of density, high

aluminium is also used in a wide range of sectors from the Packaging,

strength, great formability, easy machinability, corrosion resistance

Aerospace to the Automotive industry including the new E-Mobility.

to name a few – aluminium has become one of the most widely used

The properties of the material can be specifically optimized by

metals worldwide for many industries.

refining the surface and coatings with specifically designed products

For example, aluminium alloys used in the architecture industry show

and processes for surface finishing and anodising which even

- after a suitable surface finishing - good weathering behaviour even

enhance these great advantages. To expand the portfolio and to

in a maritime climate, so that the mechanical properties and stability

realize new approaches, the Surface Treatment global business unit

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

of BASF’s Coatings division, operating under the Chemetall brand, provides technologies to optimize surface finishing processes with a complete portfolio for all types of aluminium finishing applications including conversion coating and anodising. Chemetall continues to develop innovations to achieve processes which are high-performing, safe and environmentally sound.

Sustainability and process cost eﬃciency Sustainability and process cost efficiency are the motivation for the product design at Chemetall – and not contradict each other. The anodising process is a good example of how this can be achieved. Due to its manifold possibilities for an attractive colouring and a high-performance corrosion protection for aluminium surfaces, anodisation is far more than simply a way of

Some examples of Chemetall´s current portfolio

GLOBAL SOLUTIONS FOR WATER TREATMENT with a complete service that includes system design manufacturing installation technical support chemicals

for Aluminium surface finishing, meeting all requirements under Qualicoat, Qualanod, GSB and AAMA specifications: • Gardoclean® – boron-free and phosphate-free cleaner series. • Gardacid® P – various acid etches for pretreatment free of HF or P- with special additives to avoid damages of the installation, by reducing sludge formation and resulting incrustations, leading to lower maintenance cost and extended plant lifetime. • Gardobond® X Cr free series and Oxsilan® Thin film technologies for the conversion stage, free from Nitrogen, Qualicoat and GSB approved. • Gardo® Seal 1999 – Qualanod approved additive for the sealing of anodized surfaces which enables reduced temperature and processing time.

SPRAY BOOTHS WATER SLUDGE REMOVAL RESIN DEMINERALIZATION SYSTEMS REMEDIATION OF CONTAMINATED SITES BIOLOGICAL SYSTEMS BATCH TREATMENTS PHYSICAL-CHEMICAL SYSTEMS ADSORPTION FILTRATION REVERSE OSMOSIS MEMBRANE SYSTEMS EVAPORATORS BIOGAS BIOMASS SYSTEMS OIL SEPARATORS DESANDERS DESALINATION SYSTEMS PYROCHAR OTHER SYSTEMS CHEMICALS

• Gardobond® Additive H 7526 –for usage in the anodising process, enables shorter process time, quality improvement, extended bath lifetime, energy savings and productivity increasement.

Via E. Torricelli, 79 - Z.I. Fossatone 40059 MEDICINA (BO) Tel +39 051 856263 info@hydroitalia.com www.hydroitalia.com

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

improving the appearance of the material.

simultaneously improving the material properties allowing to increase

“To improve the process, Chemetall has developed innovative

current density without risk of burnings.

technologies for its Gardobond® additives. These can be combined in the anodising tank” says Jorge Trolho, Global Segment Manager

Close cooperation with customers for tailored processes

Aluminium Finishing at Chemetall.

In a close cooperation and joint evaluation of the individual stages

“When added to the anodising bath, the new, highly efficient

in each of the customer's process steps, Chemetall can identify

additives produce a very homogeneous surface finish by reduction

opportunities not only to reduce total process costs, but also to

of the re-dissolving rate during the anodising process and reduce

increase productivity.

the sensitivity of the anodising process at higher content of dissolved

As dedicated and focused supplier of specifically formulated and

aluminium and the high temperatures used,” concludes Oliver

customized technologies and processes for all anodising and

Katschmareck, Global Product Manager Anodising and Conversion

pre-treatment applications to its customers, Chemetall ensures

Coating at Chemetall. The Gardobond additives contribute to

that their processes become even more efficient and the resulting

perfect quality coatings even with high aluminium concentration in

aluminium surfaces will combine aesthetics and brightness in form

the bath (a maximum of 30 g/l), a higher temperature (a maximum

and function.

of 30°C) and a lower concentration of sulphuric acid. The use of the

“The competence and dedication of our teams in Chemetall, driven

appropriate additive can save up to 40% in energy consumption”.

by our agile approach, our local presence and the focus on providing

Additionally, these advanced anodising processes lead to a shorter

sustainable solutions, will make the difference, allowing our customer

anodising process time and thus to more efficiency and productivity,

to achieve their growth and quality targets”, says Jorge Trolho.

with tailormade additives, which can be added to the sulphuric acid

The Gardobond® additives developed by Chemetall contribute to perfect quality coatings even with high aluminium concentration in the bath, a higher temperature and a lower concentration of sulphuric acid.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

SPECIALISTS IN PLASMA PVD COATINGS

ENJOY PVD TECHNOLOGY

Kolzer machines guarantee versatility in Metallization and PVD Sputtering treatments as well as repeatability in production. Kolzer systems perform well in all conditions, with all materials and for processing on each substrate. PVD is totally eco-friendly process with low environmental impact.

www.kolzer.com

Interior of the treatment chamber for PVD sputtering deposition.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The colour of bathroom fittings and accessories is also a driver of choice for shower enclosures. These are still made of glass and aluminium profiles mainly finished with a glossy silver tint, which, however, prevents sophisticated bathrooms to feature fully colour-matching furnishing elements. After two years of research, innovative startup Almain has developed a sputtering metallisation process patented with Kolzer machines for aluminium profiles with a pre-structured surface by anodic oxidation, presented in advance exclusively on ipcm®.

athrooms: in a few years, they have gone from being utility

to gunmetal black, and the market share of the glossy silver ones

rooms for hygiene practices only to becoming the “wellness

is gradually decreasing. In order to obtain such finishes, the tap

areas” of our homes, thus turning into elegant, comfortable

and fitting sector is making a technological leap by switching from

rooms combining functionality and practicality with aesthetics.

electroplating to PVD – a technology with a lower environmental

They are now rooms to live in, which must be in line with the other

impact, as it does not create any polluting emissions and waste water,

elements and the mood of a house and to which attention is

and with very high surface resistance characteristics. In short, PVD

increasingly paid in terms of furniture and décor.

offers a much wider and more sustainable range of surfaces and

In a bathroom, numerous product categories and different materials

colours.

coexist in a few square metres. Taps and fittings, in particular, have

The colour of taps and fittings is therefore an important driver of

undergone the most profound transformation, not only in terms

choice. This is also true for shower enclosures, still made of glass

of forms, now more essential and modern, but also of finishes.

and aluminium profiles mainly finished with a bright silver tint,

Designers are more and more often indulging in creating new finishes

which, however, prevents sophisticated bathrooms to feature fully

and colours in the ranges of satin gold, rose gold, and brass up

colour-matching furnishing elements. On the other hand, there is –

Tanks for aluminium profiles anodisation.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Aluminum profiles leaving the PVD sputtering metallization machine and, below, detail of the frame for hanging the pieces. © ipcm

or it would be more correct to say that there was – a technological

surface by anodic oxidation. This patented process can give to

problem in applying the innovative finishes of taps and fittings also on

profiles not only finishes in unique and never-before-seen colours,

shower profiles: the electroplating and PVD processes cannot be used

but also exceptional characteristics of resistance to chemical agents,

on parts that are longer than 2 metres. It is only possible to colour

temperature, and scratches, as well as water repellency.

these profiles without coating them, with the proven anodic oxidation

These are all essential features, for the bathroom furniture of the

technique. This offers a very high surface resistance but, due to

future.

intrinsic process limits, it cannot guarantee the complete repeatability of the most daring finishes, such as rose gold for example.

The startup’s creation

Technological innovation, which has always been supported by

“We live in an extraordinary era, in which the driving force behind the

ipcm®, has arisen in this framework from the collaboration among

design efforts of firms and companies is often the desire to overcome

three Italian companies, each with a long history of success in its

limits. Modernity is reflected in technological research and in the

own field. Sital (San Mauro Torinese, Turin) has been specialising

innovative use of materials with a flexible approach, thus opening up

for forty years in aluminium oxidation processes for furniture, cars,

to an infinite number of application options,” states Stefano Vismara

aeronautics, architecture, and much more. Vismaravetro (Giussano,

from Vismaravetro, offering highly customisable solutions for home

Monza e Brianza) is an Italian leader in the integrated production of

and hotel bathrooms. “Our company was established as an industrial

tempered glass shower enclosures, of which Sital is a supplier. Kolzer

business in 1947, although its history started back in 1907, when

(Cologno Monzese, Milan) has been designing and manufacturing PVD

Giuseppe Vismara began to work as a sales representative of glass,

metallisation and sputtering machines since 1952.

crystal, and mirrors in Mariano Comense. In the 1970s, his firm moved

An innovative startup called Almain was created from the synergy

from being a glass factory to a manufacturer of high-end shower

of these three excellence firms and their respective market needs:

enclosures, which are still its flagship product.

now, after two years of research work, it has developed a sputtering

“The treatment of the aluminium profiles that make up the supporting

metallisation process for aluminium profiles with a pre-structured

structure of a shower enclosure has increasingly become the element

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The PVD sputtering machine by Kolzer.

guaranteeing the quality and appeal of this product. Increasingly shiny

“Research and innovation are so deeply rooted in our vision that we

and glossy profiles featuring high water resistance properties and

immediately took the opportunity to create an innovative startup

ever-more daring, alternative finishes enable us to stand out from

and start this project for the implementation of a profile sputtering

low-end product manufacturers. Sital has been our partner for profile

metallisation process. This has a high market potential not only in

anodisation treatments for several years now. With their forty years

the design sector but also in the automotive one, in which water

of experience in the aluminium surface treatment field, it was natural

repellency and resistance to high temperatures (up to 200 °C) are

for us to start an innovative research project with them aimed at

increasingly common requirements for the external mouldings of

obtaining profile finishes matching with the new ones applied on steel

vehicles.”

and brass taps and fittings.”

As the technical partner for such an ambitious project, they chose

“Sital specialises in the aesthetic finishing treatment of aluminium

Kolzer, a company constantly looking for new applications of the

through mechanical surface preparation and anodic oxidation

sputtering metallisation process on new materials, such as fabric,

processes. For forty years, our vision has been to obtain the highest

leather – products made for Gucci and Dior are renowned – and

quality with the lowest possible environmental impact,” states Antonio

wood, not to mention several applications in the healthcare1 and

Mangano, the CEO of Sital, flanked by his two young sons. “We have

automotive sector: recently a Kolzer sputtering cycle has passed the

a highly specialised plant, designed and built to achieve the highest

homologation for car interior and exterior.

quality level while maintaining high production volumes. We can treat

Kolzer, on the other hand, had long been looking for an industrial

workpieces with dimensions up to 1.25 metres in height, 0.80 metres

partner to develop a large sputtering machine. In fact, with a system

in width, and 4.00 metres in length. Thanks to continuous research,

length of 2,500 mm and a chamber length of 2,200 mm, the PVD

carried out by our internal laboratory, Sital can guarantee a pH 13.5

sputtering machine installed by Almain is the largest on the market

resistance degree, which enables it to offer a unique treatment

today.

throughout Italy, with the competitive advantage of also providing advice on raw materials and on the mechanical processes prior to chemical finishing.

AnƟbacterial and anƟviral surface with Kolzer’s machines for the deposiƟon of copper nanoparƟcles, ipcm®_InternaƟonal Paint&CoaƟng Magazine, Vol. XI, no. 64, July-August 2020, p. 34

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Almain: the new way of treating surfaces

deposition occurs though a cold process, without consuming water,

Almain’s main objective is to industrialise the sputtering process on

without producing emissions, waste, or by-products to be disposed of,

aluminium profiles intended for the furniture and other sectors, such

and above all without using hexavalent chromium.”

as the automotive one, where there is a need for exclusive finishes

The process developed by Almain consists of a PVD sputtering

and very high surface resistance properties. “We have focussed on

deposition stage followed by the application of a nanotechnology clear

sputtering because it is a very environmentally friendly technology,

coat. “In the treatment chamber, a molecular migration occurs from

with a development and consolidation time horizon of twenty or

one metal to another,” explains Kolzer Director Antonio D’Esposito.

thirty years and with the capability to replace electroplating, a mature

“Once vacuum is created inside the machine, the sputtering process

technology with many process and environmental limitations,” says

prompts the migration of metal particles from the matrix (target)

Stefano Vismara. “We currently match the colour of our shower

to the product to be coated. The metal target is bombarded with a

enclosures with other metal bathroom accessories by using traditional

special gas and the metal particles are dispersed, thus depositing on

technologies. However, these methods do not guarantee any process

the workpieces. By varying the process parameters, the target metal,

repeatability, they achieve poor results in mechanical and physical

and the gas used, different colours and surface characteristics can be

resistance tests, and they have a high environmental impact. Almain’s

obtained. The machine is also very innovative in terms of construction.

research work has been aimed at obtaining these new finishes

We have equipped it with digital, dry rotary backing pumps, an

required by the market with a “green” technology that enables

innovative choice for vacuum processes, as well as with four high

to achieve colour consistency and higher performance with zero

vacuum diffusion pumps, thus making it an oversized plant in order to

environmental impact. This is made possible by the fact that metal

speed up production.”

The PVD sputtering system is characterized by its compact footprint and its sustainable treatment process.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

“Sputtering deposition guarantees excellent profile quality, exclusive colours, longer service life, lower production costs, and good productivity levels,” says Antonio Mangano from Sital. “Indeed, this machine allows coating up to 100 profiles/hour, also thanks to Sital’s ability to create workpiece-holding fixtures that enable to make the most of the system’s capacity and that can also be used for the previous anodic oxidation stage, thus eliminating the need for unloading and re-loading operations. The metallisation process is fully integrated and no component manipulation happens between the two plants.” “A second, particularly important innovative aspect is the fact that the PVD sputtering process does not require the application of a primer after anodic oxidation or of a protective top coat at the end,” notes Mangano. “The latter has been replaced by a transparent polymeric layer, deposited directly in the sputtering plant through an established and patented process by Kolzer.”

Aluminum profiles addressed to the bathroom furniture sector.

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Characteristics of the coating

coated products — so popular until the Nineties — has almost

The coating obtained with this finishing process has several interesting

disappeared, leaving space for new colours and finishes of every

technical characteristics for many industrial sectors, including

kind. With Almain’s process, we will be able to provide our products

furniture, fashion, design, medical, lighting, cars and motorcycles,

with aesthetic and performance characteristics that other traditional

and aeronautics, just to name a few. It is a flexible coating with

treatments cannot achieve. And we will do it in a sustainable and

excellent adhesion properties, which is chemically inert, non-stick,

economical way, thanks to its greater efficiency.”

anti-limescale, anti-scratch, and anti-wear. Moreover, it guarantees corrosion protection, water repellency, a barrier effect against gases, and resistance to impacts, humidity, and thermal shocks.

From the left: Dario Mangano, Gianluca Mangano, Alessandro Mangano, Antonio Mangano, Stefano Vismara, Elia Vismara.

In terms of aesthetics, Almain’s process ensures uniform multi-layer deposition with adjustable thicknesses (from semi-transparent to fully opaque), using a wide variety of colours and both glossy and matte finishes. “We are also testing a deposition process with custom metal alloys, in order to obtain personalised effects, as well as with metals such as niobium, which favour interesting technical changes to achieve even higher performance characteristics,” explains Antonio Mangano.

The green revolution: sustainability and cost reduction “In the medium-high end bathroom furniture sector, glossy polished finishes still hold absolute majority of the market,” indicates Stefano Vismara from Vismaravetro. “The second colour is oxidised or coated black and satin finishes follow. Among the goods in high-range white © ipcm

Some components treated by Sital.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

L’unica vernice in polvere rapida a bassa temperatura

The unique fast and low bake powder coating

Condizioni di cottura Curing Condition: Raggrinzato/ Fine textured: 3 min. @ 120°C Liscio / Smooth: 8 min. @ 140°C 14 min. @ 130°C 20 min. @ 120°C Caratteristiche tecniche Resistenza UV: 2000 ore Resistenza chimica: paragonabile a un poliuretano 5HVLVWHQ]D DO JUDႈR H GXUH]]D VXSHU¿FLDOL non paragonabili a polveri attuali Nebbia salina: 700 ore (su ferro sabbiato)

Technical Features UV resistance: 2000 hours Chemical resistance: comparable with polyurethane Scratch resistance and hardness: not comparable with existing systems Salt spray chamber: 700 hours on sandblasted panel

The Pulvercoat project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 825511

Pulverit S.p.A. Italia Via Carlo Reale, 15/4 20157 Milano-Italy Tel +39 02 376751 ĞŵĂŝů͗ ĐŽŶƚĂƫΛƉƵůǀĞƌŝƚ͘ŝƚ

Pulverit Polska Sp. z o.o. ul. Strefowa 16 43100 Tychy-Polska Tel. +48 32 329 14 11 ĞŵĂŝů͗ ďŝƵƌŽΛƉƵůǀĞƌŝƚ͘Ɖů

Pulverit Deutschland GmbH Im Wert 3 73563 Mögglingen- Deutschland telef.: +49 7174 7193000 ĞŵĂŝů͗ ŝŶĨŽΛƉƵůǀĞƌŝƚ͘ĚĞ

www.pulverit.com

Pulverit Iberia s.l.u. c/ Caravis, 28, 1º 3ª 50197 Zaragoza Tel. +34 607163259 ŵĂŝů͗ ŝďĞƌŝĂΛƉƵůǀĞƌŝƚ͘ŝƚ

Clo C oseosese e up of the SAT VISI-1 -1 pro -1 ofi fille recogn ogn nit it on ssys iti sy y ttem te em m. © SAT

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

The Profile Recognition System Helps New Zealand Company Altus Reaching New Quality Heights in the Powder Coating of Aluminium Profiles for Architecture Alessia Venturi ipcm®

Due to the small market size in New Zealand and customers requirements for large colour range and profile lengths optimized for efficient window and door fabrication, powder coating operations face a complex process with multiple colours and profile lengths. Altus NZ Ltd solved this problem by installing a SAT Cube vertical line equipped with two application booths and the state-of-the-art VISI-1 profile recognition system.

ew Zealand, like its “neighbour” Australia, represents a very

& doors companies work by “house-lot”, a very small order that

particular market. The construction business is relentless

needs to be processed quickly and with very high flexibility. That is

and the windows/doors industry refers mainly to residential

why several companies are deciding to install an in-house coating

projects, which means very small projects with final customers

facility to be able to process whatever order in a very short time.

choosing from a wide variety of solutions and colours. Most windows

They have a warehouse with raw material, and when they have the

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

order, they pick the material and coat it on demand.

for its own window systems, as well as for specific

Most of these companies relied on external job

industrial customer requirements.

coaters or on an in-house horizontal line, but

“We are a new organisation with a rich history

eventually chose to install or replace the horizontal

of providing market leading innovations and

line with a vertical coating line.

business systems for the construction and

This is what Altus NZ Ltd in Auckland did, relying

industrial sectors. Altus stands for height and

on SAT expertise in the vertical installations for

depth. We believe that by aiming high and digging

the powder coating of aluminium profiles. At the

deep for our customers, we can reach the very

beginning of 2020, SAT concluded the start-up of

pinnacle of our industry,” Mark Kennedy, National

the vertical powder coating plant with a twin booths

Operations Manager at Altus NZ Ltd says.

system for the finishing of aluminium-extruded profiles. It represents the second installation in

Mark Kennedy, National Operations Manager at Altus NZ.

New Zealand after the Cube vertical powder coating compact line built in 2016.

“We are experts in creating aluminium solutions for our customers. We work across a wide range of sectors, from marine, transport,

windows and doors, to mechanical engineering and agricultural industries, both in New Zealand and around the world. We provide

Altus NZ: the union of two great companies

quality aluminium products in accordance with stringent national

The word “Altus” means “High”. This is the word a leading

and international specifications. Our services include custom

manufacturer of award-winning window systems and industrial

extrusions and profile shapes; sheet, plate and coil products, design

aluminium in New Zealand has chosen to name the new company

and manufacture, finishing options in a wide range of colours, both

formed through the union of two great companies: Fletcher

anodising and powder coating. We also have service centres across

Aluminium and NALCO.

the country that provide off the shelf extrusion profiles, including:

Based in Auckland, Altus extrudes and finishes aluminium profiles

box sections, angles, and sheet, plate and coil products”.

The powder coating team of Altus NZ in front of the Cube installation supplied by SAT.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

The new vertical powder coating line: Altus’ requirements

change via a 2 booth system, an expected

the line features two “V” shaped powder

step change improvement in powder coat

coating booths with high transfer efficiency

At Altus, powder coated profiles have

surface finish quality, and an increase in

and 2 vertical self-cleaning walls rotating and

historically been produced on five

powder efficiency.

cleaning in continuous.

horizontal lines across three plants. With

In addition, due to the geographical

The booths are equipped with two Gema

the recent installation of the SAT Cube line

location of New Zealand, the time and cost

automatic powder application systems, each

in 2019, Altus will see the consolidation of

involved in bringing specialist technicians

one consisting of a GEMA Powder Centre,

powder coating operations onto a single

to New Zealand can be prohibitive, so it

model OptiCenter OC03, equipped with

site. Due to the small market size in New

was essential that Altus could install a line

18 GEMA automatic guns, model OptiGun

Zealand and customers requirements

that, following installation and training, they

GA03-P, with angled heads 60° and 18 GEMA

for large colour range and profile lengths

could run confidently with minimal on-site

dense phase pumps AP01.

optimized for efficient window and door

support.

SAT designed CUBE to be an intelligent system with the addition of modern

fabrication, powder coating operations face

technological components that streamline

The key requirements of the line for Altus

The scope of supply: highly eﬃcient line with state-of-the art technology

was to achieve the required capacity

Altus specified a 2-booth line to enable

requirements of the coating industry. Since

through 1.5m/min line speed, fast colour

effective management of the large number

then, CUBE has continued to evolve with

of colour changes required to meet market

updated process control and supervision

demands.

software to provide advanced automation

SAT supplied its Cube compact vertical line.

capabilities. Altus in particular, has

With small space required, low operating

implemented the Smart Coat vision system,

costs and a competitive price, Cube soon

which is able to recognise a profile from its

became a game changer in the aluminium

section and automatically control all process

powder coating market since its launch in

settings, thus ensuring a fully repeatable

2013. With a conveyor speed of 1.5 m/min,

finish. The Smart Coat system will enable

a complex process with multiple colours and profile lengths.

the aluminium finishing process in order to achieve the increasing repeatability

One of the new “V” shaped booths supplied to Altus.

The unloading station with the in-line paint stripping system for hooks.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Altus to achieve a level of efficiency and production optimisation rarely, if

ÂŠ Altus NZ

ever, achieved so far. SAT line, which also includes in-line chemical jig cleaning, was installed in a purpose built building at the Altus Hamilton site in New Zealand. The installation was supervised by SAT engineers with local installation labour for mechanical and electrical trades. The installation was completed to a high standard, on time and on budget, and commissioning was completed just prior to COVID-19 lockdown. Following the end of the COVID-19 lockdown, commissioning progressed well and the line is currently in full production on a single 8 hours shift per day, with plans to add a second shift later in the year.

SAT VISI-1 Vision System: how does it work? As it often happens, the idea of developing the Vision System technology follows a market demand. The need expressed by many players in the sector was to standardize the methods of painting in order to obtain products with a repeatable quality. Likewise, the need to scrupulously control production and the variability of geometries to be processed required equally meticulous planning and business organization. The vision system acts as a man-machine interconnection tool, so as

SAT technicians and Altus operators during the start-up of the line in January 2020.

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Detail of the cameras used by SAT VISI-1 profile recognition system.

to anticipate and categorize the data necessary for the production

Goals achieved successfully

process. It is a device that allows to detect the profiles hung on the

“Early indications show that the line will meet all of the expectations.

painting line through an images identification process.

Finish quality from the line has been excellent with a reduction in

Geometry and length of the extrusions are consequently used to

customer complaints, and powder efficiency has also improved.

associate pre-defined parameters for painting or other phases of the

However, further optimization is needed to meet our targets in

production process.

this area, although we fully expect to achieve them. The profile

A camera system snaps some photos of the profile loaded in the

recognition system has worked effectively, and is used to ensure the

line. Then an algorithm finds the most similar model contained in

most effective powder application settings. Key to the success so

the library, and associates it to the correct coating recipe required.

far has also been our partnerships with our powder and chemical

When the profile arrives in the booth, the guns are turned on and off

suppliers who has also bought significant experience to the table to

automatically with the right configuration.

ensure a successful start-up”, Mark Kennedy states. “Altus chose the

The most relevant advantages referred to the Visi-1 are the following:

SAT line based on its technical specifications, but more importantly

• Easy scheduling of the painting process;

on the recommendations from visiting a number of similar lines in

• Control and identification of the extrusions hanged on the conveyor

Australasia. This has proved to be a good decision, and overall Altus

(recognition);

is very pleased with the outcomes so far. We invested significantly

• Repeatability of process parameters through automatic or manual

in our people to ensure we had a well trained and experienced

assignment;

team, able to maximize the technical support provided by SAT, and

• Automatic adjustment of the reciprocator stroke, powder output

this has proved to be a good investment as our teams have quickly

and line speed (simplicity);

learnt the necessary skills to run the line effectively”.

• Data collection and production statistics for the single profile (traceability).

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

Bui u ldi diing g LOT T A9A1- Paris in 20 2017 17 7 ano no n odiz ized ed by Lac co oviiana ian ana na - Porrtug tugal (Elcos ossan n® Ra R inb bow ow Technolog ogy y in grey rey y an a odi d zing). di g)) g).

INNOVATIONS: PRESENT&FUTURE

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

New Elcosan® Moonlight Colours: Alsan Widens the Spectrum of Greys by Optical Interference Pilar Fagoaga Alsan, Álvarez Schaer S.L.U. – Paterna (Valencia) – Spain

alsan@alsan.es

Alsan, the Spanish company specializing in chemical products for surface treatments, launched Elcosan® Moonlight, a new technology developed to obtain new optical interference colourations, which allow to find a zone of stability and reproducibility within the range of grey colours.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

lsan began in 1981 with the introduction of Elcosan®

addition, it should not be forgotten that the grey colour represents in

DC / AC technology in a Valencian company, performing

Spain already approximately 8% of the colours that are applied in the

electro-colouring in bronze. In 1985 it moved forward with

powder coating of aluminium profiles.

the implementation of stainless steel colours under the application

Until now, Alsan standard titanium grey corresponded to an L *

of this same technique, but it was not until 1997 when it introduced

coordinate, which according to each anodizing plant could vary

Elcosan® Rainbow technology in Spain.

between lightness values of 35-42 pts, considered as dark grey.

Alsan has more than two decades of experience in optical

Façade architects and designers request more neutral and natural

interference colouring technology and that it is widely used around

tones, aspects as natural as stone, and the possibility to play with a

the world by many of its clients.

spectrum of colours in a range of lighter greys.

Applied research was necessary to, over time, improve the processes,

With its R&D department focused on this new challenge, Alsan has

the facilities and adapt the software of Alsan's colouring equipment, to

gotten down to work and have carried out various studies aimed to

achieve the best control of the electrical parameters and thus be able

developing new electrolytes and new ways of electrically modifying

to optimize the uniformity of production of colours by interference.

pore deformation systems to, with the wide possibilities provided

Currently, Alsan can be satisfied that many companies, using Elcosan

by its Elcosan® PCB equipment, to obtain new optical interference

PCB equipment and Elcosan Rainbow technology, are achieving

colourations, which allow to find a zone of stability and reproducibility

considerable attainments with colouring and have been able to gain

within the range of grey colours.

access to the award of large and emblematic works, with appreciable colours that to date Alsan offered with its technology.

New Elcosan® Moonlight interference colouring technology

But fashions change, and avant-garde architects have made the

Alsan is already very familiar with optical interference technology,

colour grey fashionable, and are currently requesting to have a

a technology that, as above mentioned, it has worked thoroughly

greater range of shades of grey in anodized aluminium finishes. In

at R&D department for many years. This advantage, from its

success in the colours sapphire blue, titanium grey and olive-green,

Figure 1: Colouration processes with Elcosan® DC/AC and with Elcosan® Rainbow.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Figure 2: Variations in distance between the Al base metal and the height of the metal salt deposit in the pore.

in-depth knowledge, has given it the

opportunity to find new loopholes in the way of applying current and to test with different combinations of pore deformation electrolytes and deposition of different metal salts, until the company reaches its goal. As usual for its technology of colouring by optical interference, Alsan has a series of tanks within the anodizing line, and unlike a standard colouring, it needs to have two more tanks: the first where it carries out the preparation of the pores of the anodic layer, Figure 3: Light beam’s diﬀusion and reflection with Elcosan® Moonlight.

and the second for the deposition of metallic salts. In this way it’s possible to select the type of electrolyte and the most suitable temperature to carry out the final colouring

that we want to obtain (Fig. 1). The Alsan Elcosan® Moonlight technology, which gives rise to a wide gamut of new shades in the grey range, has the following characteristics: • It achieves a complete spectrum of grey colours obtained by interference, by rigorously controlling the pore opening conditions and the distance between the Al base metal and the height of the metal salt deposit in the pore, which allows to move in a wide palette of greys, by modifying the effects of the optical interference phenomenon (Fig. 2). Figure 4: Pore opening graph.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

The variations in distance between the two

surfaces: the upper limit of the deposit of metal salts and the metal / oxide interface, are what make the different shades obtained in the final colouring, which takes place due to the effect of optical interference, caused when a beam of white light X falls on surface A (metal height), being partially absorbed or refracted (Z-ray). This refracted ray reaches the metal / oxide interface (surface B) where it is reflected again (ray Z) and is refracted through the surface A (ray Z’, Fig. 3). These two components from the diffusion and reflection of the same light ray between 2 very close surfaces (of the order nm) are potentially suitable for giving rise to interference phenomena if the distances between both surfaces A and B are adequate. The result is the appearance of colours that are controlled by the two reflective surfaces. • With the potential of the software from our Elcosan® PCB unit, it’s possible to control the deformation speed of the pores of the anodic layer, and modify it according to need, as well as achieve a rigorous control of the amount of salts deposited according to the different types of wave that these teams allow to apply, even look for small deviations towards more or less pure shades of grey, or with light touches of blue, which make the greys more attractive decoratively (Fig. 4). • It’s possible to obtain a wide gamut of grey colour intensities, only varying the working conditions. It allows to control from light grey tones of high luminosity with L * about 80 pts, going through different intensities of luminosity, 70, 60, 55, 50 to the classic greys of L * 35 to 40 (Fig. 5). • Likewise, we can work these tones “to taste” being able to establish the most appropriate working conditions to control the colour with a light brushstroke of b * (-) coordinate of blue, which makes the greys more decorative, and visually closer to the look of stainless steel. • Alsan team works under a new technique, incorporated into the classic Elcosan® Rainbow technology, where the range of grey tones has a wide stability in the metal deposition time and in turn gives us a greater margin of reproducibility between loads and profile models. • They especially want to highlight the good penetration obtained with this electrolyte and colouring technology, which at the same time presents a high performance in the assembly of loads. • Low consumption of metallic salts, characteristic of colourations due to optical interference where the amount of metal deposited is less than that of standard Inox DC / AC colours. Same as in all interference colouration processes, we want to

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remember the following basic principles to carry out this type of colouring:

Performance by design international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Figure 5: Wide gamut of grey colour intensities with Elcosan® Moonlight.

• A perfect current flow without voltage drop is needed, since at times

We cannot end the presentation of Elcosan® Moonlight without offering

the operation is performed at very low voltages and high precision.

the guarantees that must be met by any of the new technologies

• A perfect temperature control +/- 0.1ºC in the interference electrolytes

designed to perform a decorative finish on anodized aluminium intended

and +/- 0.2ºC in the anodizing bath (with Alsan temperature control

for buildings, under the requirements set by Qualanod. The entire range

equipment this precision can be trouble-free obtained).

of Elcosan® Moonlight grey anodizing colouration has satisfactorily passed

• For the previous process of pore deformation and the grey

the light resistance test, according to ISO 2135:2017-10, the results

colouration of a load, a total time between 6 to 10 minutes per load

achieved being those presented in the Table 1.

should be forecast. • Colour programming must be based on a specific surface (outer

We begin a new decade with a new technology: Elcosan® Moonlight, a

development) with a margin of +/- 5%.

wide spectrum of anodized grey at your fingertips.

Table 1: Results of the light resistance test, according to ISO 2135:2017-10.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

booths

ovens

cataphoresis

tunnels

complete plants

eosmarketing.it

conveyors

IDEAS NEED TALENT C.M.V. srl - Via dellâ&#x20AC;&#x2122;industria, 2 - 61036 Tavernelle di Colli al Metauro, PU - Italy - T +39 0721 892274 - info.cmv@cmvimpianti.it - www.cmvimpianti.it

BRAND-NEW

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Adapta Presents the ETERNAL Collection Adapta has launched its new ETERNAL Collection within the VIVENDI UDS range for architectural planning and design.

TERNAL, the new colour collection launched by

Adapta, is part of the VIVENDI® UDS (Ultra Durable

System) range for architectural planning and

design. The colours of the collection boast a two-coat system which provides excellent durability. Also, the application of a second layer of transparent Eternal clear coat provides an excellent chemical resistance.

Furthermore, all the colours have been developed with Adapta Bonding System® Technology, which provides and guarantees a homogeneous visual effect. Colour and gloss resist to light in compliance with international quality specifications such as Qualicoat Class 3, GSB Premium and AAMA 2605-17 (Table 1). In fact, after 3.000 hours Suntest and 2.000 hours QUV the gloss retention is among 50%-90% depending on the colour. The collection bears an environmental product declaration (EPD) and has been certified pursuant to standard ISO 16000-9:2006, having been awarded CHEMICAL TEST

RESULTS

MURIATIC ACID resistance

No blistering, no visual change

MORTAR resistance

PASS, no loss of adhesion, no visual change AAMA 2605-17 - 8.7.2

NITRIC ACID resistance

PASS

DETERGENT resistance

PASS, no loss of adhesion, no visual change AAMA 2605-17 - 8.7.4

of finishes provided by the collection.

WINDOW CLEANER

PASS, no loss of adhesion, no visual change AAMA 2605-17 - 8.7.5

The interaction between the absorption and reflection of

HUMIDITY

4000 hours PASS

AAMA 2605-17 - 8.8.1

the light produces fascinating effects, perceptible even

CYCLIC Corrosion Testing

2000 hours PASS

AAMA 2605-17 - 8.8.2

KESTERNICH SO2

30 cycles PASS no blistering

ISO 3231

WEATHERING TEST

RESULTS

FLORIDA COLOUR retention

PASS 10 years < 5 units ΔE

AAMA 2605-17 - 8.9.1.2

FLORIDA CHALK resistance

PASS 10 years

AAMA 2605-17 - 8.9.1.3

Also, the collection’s colour spectrum can be extended

FLORIDA GLOSS retention

PASS 10 years > 50%

AAMA 2605-17 - 8.9.1.4

combining the colours with a transparent matt or gloss

EROSION resistance

PASS 10 years

AAMA 2605-17 - 8.9.1.5

Eternal clear coat.

SUNTEST

PASS 3000 hours > 50% gloss retention

ISO 16474-2

QUV 313B

PASS 2000 hours > 50% gloss retention

ISO 16474-3

an A+ rating for extremely low emissions in indoor AAMA 2605-17 - 8.7.1

AAMA 2605-17 - 8.7.3

environments. The interference colours, capable of varying their chromaticity in accordance with the direction of the light and the viewing angle, stand out among the wide range

in poor light and intensified on spherical and curved-contour objects. Moreover, the continuous changes in the colour of the coating transfer the sensation of movement to the shapes, overcoming the intrinsic

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

immobility of the architectural elements, in a random intermix of a variety of colours, effects and shades.

For further information: www.adaptacolor.com

BRAND-NEW

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Scientists at TU Dresden Develop Self-Cleaning Aluminium Surface Scientists at TU Dresden and the Fraunhofer IWS have developed a periodic surface structure, which is water and ice repellent and also removes dirt particles.

fter years of developing functionalised

The method was developed in close

surfaces with laser-based manufacturing

collaboration with the Fraunhofer IWS. Together

processes, with a special focus on

with the Dresden Institute the professorship

aluminium, a team of scientist at TU Dresden,

for laser-based methods of a large area surface

in collaboration with the Fraunhofer IWS, have

structuring at the TU Dresden operates the

structured an aluminium plate with a laser

“CAMP – Center for Advanced Micro Photonics”.

process in such a way that water droplets no

The scientific evidence of the self-cleaning effect

longer adhere and dirt particles can be removed

has been published in the journal “Applied

from the surface without chemical cleaning

Surface Science”.

agents or additional effort. The newly developed periodic surface structure

For further information:

with direct laser interference patterning (DLIP)

https://rb.gy/wweb8n

removes dirt particles exclusively by rolling drops and is also water and ice repellent. “Aluminium is used in many branches of industry – whether in the automotive sector, aircraft construction or the food industry. The use of

aggressive cleaning chemicals is particularly critical in the latter, as we naturally do not want to associate these with our food,” says Stephan Milles, PhD student at TU Dresden. The Dresden scientists took a close look at the function of self-cleaning laser-structured aluminium. A special camera was used to analyse the self-cleaning effect of the aluminium surfaces and filmed the process at 12,500 frames per second. Thomas Kuntze, scientist in the Microtechnology Technology Field at the Fraunhofer IWS, explains: “This way we can see perfectly how the water drop can remove the dirt from the aluminium surface. This method is also suitable for understanding other processes, such as laser cutting and welding or additive manufacturing”.

Water drops do not adhere to the self-cleaning aluminium surface. The latter has been functionalized by a team of “CAMP” scientists using direct laser interference patterning (DLIP).

BRAND-NEW

Sherwin-Williams Opens a New Online Technical Support Service After the smart working experience during the months of lockdown caused by COVID-19, Sherwin-Williams decides to continue on the path of digital solutions.

hese months of lockdown caused

launched in the EMEAI region.

and Sherwin-Williams' goal is to keep it

by the COVID-19 pandemic have

Through a simple form, on the web-page,

operational and richer in content in the years

changed our working habits, limiting

you can request one of qualified technicians

to come, to give painters, quality control

travel and direct contacts with colleagues,

to be contacted regarding any need relating

managers, purchasing managers, plant or

customers and suppliers.

to paint products: recurring paint problems,

project managers a way to stay informed on

Sherwin-Williams has never stopped its

support for a change in paint technology,

the technological aspects of coatings, in a fast,

activities, adopting where possible smart

advice on choosing a new paint system,

practical and cost-free way.

working solutions and online meetings.

training on specific topics, advice on

These solutions have proven to be very

application processes or indeed any other

efficient and productive and for this reason

coatings topic.

the online Digital Technical Support Service

This service is already in operation with

For further information:

has now been expanded and formally

excellent results welcomed by customers

http://virtualsupport.sherwin.eu

ÂŠ Sherwin-Williams

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

MARKET CLOSE UP

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Aluminium, The Metal of the Future: AITAL’s Point of View on This Ever-Developing Market Interview with Giampaolo Barbarossa, General Secretary of AITAL – Italian Association for Aluminium Surface Treatments

e have asked a few questions to

reduced, divided between castings (34%),

AITAL General Secretary Giampaolo

extrusions (19%), sheets (15%) and all the

Barbarossa, in order to understand

remaining segments.

the trends in the aluminium surface treatment

In the first five months of the current year, in

sector in this particular economic situation,

the sectors of extrusions and sheets, which

characterised by a constantly evolving market.

are the types of semi-finished products that

Interesting ideas have emerged that confirm

almost always require surface finishes, the

the strategic role of the industry of aluminium

COVID-19 emergency led to sharp reductions

and its finishes for both the Italian and

starting from March (included), as also shown

international markets.

by the data of German aluminium association GDA. The restart of aluminium production,

In Europe, the aluminium industry and,

and therefore of its related finishing activities,

as a consequence, its related surface

resulted in a recovery in terms of volumes,

treatment sector, have always been very

with the exception of the automotive sector,

dynamic. Can you give us an overview of the pre and post-pandemic situation? When the Italian authorities started to talk

Giampaolo Barbarossa, General Secretary of AITAL.

about a possible lockdown, our association

which still seems to be reflecting on the future of cars and on the strategies available to possibly switch from heat engines to electric ones. Only in the next autumn will

cooperated with CENTROAL (the Italian

it be possible to understand whether this

Association for the Aluminium Industry) to help the companies in the

growth trend will continue or the recent increase was mainly linked to

sector to keep operating, while observing safety rules. Unfortunately,

previous orders.

we did not achieve this result, because the economic activities related to aluminium metallurgy and metal surface treatments were

The surface treatment sector is currently seeing interesting

not included in the final version of the Prime Ministerial Decree,

developments related to the antimicrobial protection of

which only enabled the suppliers of essential services to continue

aluminium surfaces. What are the most important projects

operating, upon notice to the prefecture.

underway?

As is well known, the market of aluminium surface finishes is directly

A distinction must be made between antimicrobial characteristics

linked to the industries that use them. In particular, coating accounts

and surface properties affecting the persistence of viruses. In the

for almost all finishes chosen in the construction sector, whereas for

case of the former, there are already established processes and

all other intended uses anodic oxidation accounts for slightly more

products capable of reducing, in shorter or longer times, the quantity

than coating does. In 2019, the year before COVID-19, aluminium

of bacteria that are present on certain surfaces for any reason. As

consumption in Italy had dropped by 2.2% compared to 2018,

concerns the latter, several studies have been conducted in the

settling at just over 2,000,000 tonnes. Consequently, the turnover of

past to assess the persistence of Coronaviruses on metal surfaces,

the entire sector, including the surface finishing field, had also been

including aluminium. A major study conducted in the United States

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

MARKET CLOSE UP

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

in 2000 found that the Coronavirus does not survive on aluminium

A variety of widely available products have proved effective in

surfaces after 2 to 8 hours from contact with its surface . These

cleaning and disinfecting surfaces, including aluminium ones, from

results were confirmed by trials conducted on a larger scale in the

the Coronavirus, such as soap and water, disinfectant wipes, and

early months of 2020. A comparison of these figures with those

chemical spray solutions. The EPA agency has a list of disinfectants

related to other materials shows the very high intrinsic efficacy of

approved for their effectiveness in destroying the Coronavirus.

aluminium in terms of minimum persistence time of Coronaviruses

Of course, it is recommended to carry out preliminary cleaning/

on its surfaces.

disinfection tests in small areas, in order to check that this operation

In any case, the COVID-19 transmission potential assessed by these

does not change the aesthetic and functional characteristics of the

studies, that is, the risk of infection through contact with everyday

surfaces to be treated.

objects, including aluminium objects, has been rated low to very low. In fact, the chance of infection transmission from a person to an

What are the current priorities of the sector in general and, in

object and then to another person is rather remote. Several specific

particular, in terms of regulations?

events should occur at the same time, such as a sneeze or cough of

Based on all the above-mentioned elements, the finishing sector

an infected individual resulting in the deposition of viral material on a

does not seem to be particularly affected by the ongoing health

specific surface, which is then rubbed by the hand of another person,

emergency. In fact, I believe that there may be excellent job

who touches their mucous membranes in their mouth, nose, or eyes

opportunities for companies that are already owners of processes

with the same hand shortly after. According to numerous research

and/or products capable of effectively fighting any type of virus or

laboratories, including FDA in the United States and the German

bacterium on surfaces. I refer in particular to fields already regulated

Federal Institute for Risk Assessment, no transmission through this

in terms of materials, surfaces, and sanitation products, such as, for

potential route has been confirmed so far.

example, the hospital, pharmaceutical, and food sectors.

hƩps://www.journaloĬospitalinfecƟon.com/arƟcle/S0195-6701(00)90795-3/pdf (21(09/2020)

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

MARKET CLOSE UP

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

What is the position of your association with respect to the current market? Our association has always been a strong supporter of quality products and a representative of companies that are fully compliant with the mandatory legislation on environmental, safety, and hygiene at work, as well as respectful of their employment contracts. We are devoted to innovation in a broad sense and we are lucky to be able to rely on Qualital (the Institute for the Industrial Certification of Aluminium and other Materials) in terms of support of professionals with great technical and scientific experience and of a state-of-the-art test laboratory (Qualital Servizi) for the characterisation of raw and finished aluminium. In line with our vocation, at the Qualital Servizi lab we have conducted tests on the formation of a surface layer on aluminium containing silver ions, capable of providing the substrate with antimicrobial characteristics. This is not an actual anodising process, but the deposition of a very thin layer with a barrier effect, obtainable in a very short time. This antimicrobial feature could be of interest for several sectors producing semifinished parts intended for the most varied industries: hospital, pharmaceutical, and food, but also door and window frames, furniture, and so on. This is why we are assessing the possibility to seek some partners among the producers of aluminium materials and components to carry out an industrialisation project. More recently, driven by the new interest sparked by the COVID-19 pandemic in different aluminium applications in the hospital, pharmaceutical, and food sectors, we have involved several AITAL members specialising in aluminium anodic oxidation in some new projects. At a special video conference that we held on July 9th, we invited aluminium expert Lorenzetti, with a vast know-how on the corrosion phenomena affecting this metal, its surface treatments, and its bio-reactivity characteristics. During her speech, Lorenzetti presented an accurate overview on the current knowledge and the processes and products already used to make aluminium surface bacteria-free (which does not mean virus-free!), starting from an old Japanese patent on the formation of hard oxide layers containing silver ions. Among the participants, there was also the representative of an AITAL member with experience in a particular anodic oxidation process that has reportedly proved effective in terms of antimicrobial characteristics. Based on the tests carried ÂŠ Adobe Stock

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

MARKET CLOSE UP

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

out by this company and on the observations of other members of

other hand, the recycling of aluminium guarantees a saving of about

the working group created to confirm their results, we will consider

95% of the energy needed to produce it starting from the mineral.

the need and/or usefulness of drawing up a guideline on these processes, on the assessment of their effectiveness over time, on the

At the moment, it is difficult to predict next year’s economic

use of treated products, and on the cleaning operations required in

trend. However, what future developments does your

order not to compromise the oxide layer’s aesthetics, quality level,

association expect, both in Italy and globally?

and, of course, antimicrobial efficacy.

Our association, as well as all other associations operating in the aluminium industry, has always been committed to defending and

The application of circular economy principles to the

promoting this metal and its characteristics: ductility, lightness, high

aluminium sector is a recurring topic. What future do you see

electrical and thermal conductivity, malleability, and recyclability.

for this particular approach?

The main strength of our organisation is our ability to understand,

It offers a further added value to this metal, as it is in line with its

defend, and promote every surface finishing process able to give

peculiar and universally recognised characteristics that make it

high functional and aesthetic characteristics to metals. Together with

optimal for a wide variety of applications. Aluminium is certainly a

other national and foreign associations, we look to the future with

“circular” material par excellence because it is infinitely recyclable, after

confidence, because we believe that aluminium has become and will

re-melting and transformation into new semi-finished products and/

remain irreplaceable in a variety of fields of use and that, in fact, it will

or products. It is worth emphasising that recycled aluminium is no

be increasingly employed for ever-new intended uses.

different from that obtained from the original mineral (bauxite) and

In addition to the leading position it has held in the construction

its fundamental characteristics always remain unchanged; on the

sector for several decades, I see strong growth in the use of

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MARKET CLOSE UP

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

aluminium in fields where lightness will become a must-have

these cases, the use of aluminium to replace traditional materials can

characteristic. It will certainly gain even more market shares wherever

lighten the vehicle by almost 1,500 kilos, thus reducing consumption

it replaces steel, simply because aluminium will allow reducing

and their dangerousness in the event of accidents. Other sectors

weights by over 40% while maintaining the same mechanical

in which aluminium and its alloys will be ever more present are

performance levels. This property will lead to an increase in its

shipbuilding and aeronautics.

consumption particularly in the transport sector.

Aluminium is also of particular importance in the packaging

Since the early decades of the 1900s, when the first aluminium

sector, especially for foods, and it will be even more so in the near

aircraft fuselage was produced, the use of this metal has significantly

future, especially in the face of the health emergency we are going

expanded with beneficial effects also on energy saving and safety.

through. For food and beverage packaging, aluminium is the only

Aluminium alloys improve aerodynamics and impact absorption

metal capable of being transformed into thin sheet, while maintaining

capacity. All of this translates into a significant reduction in energy

good ductility and ensuring total opacity to ultraviolet rays, which

consumption. According to well-established estimates, thanks to

cause rapid deterioration of food. It is totally airtight and, coupled with

its extreme lightness and strength, aluminium makes it possible to

other materials, it is ideal for vacuum packaging; it is impermeable to

create lighter cars with reduced consumption: every 100 kg of weight

fluids, gases, dust, and – speak of the devil – bacteria. Finally, going

reduction compared with steel, cast iron, and copper, it allows saving

back to the issue of circular economy, the spread of fully recyclable

1,500 litres of fuel over the service life of a car. Even more important

cans contributes, and will increasingly do so, to the reduction of the

results can be obtained by using aluminium for lorries and trailers: in

pollution of our beloved, but so far a little mistreated, planet.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

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Stardust Powder Coatings specialises in the production of powder coatings with a high level of customisation.

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Stardust Powder Coatings: Craftsmanship and Quality in Record Times for Batches Starting From 25 kg From an interview with Guido Pozzoli, Stardust Powder Coatings CEO

stablished in 2007, Stardust Powder Coatings boasts such in-

approach entailing the creation of a non-repetitive production flow and

depth entrepreneurial experience, know-how, and expertise that,

high customer participation in the definition of coating products. In

within a few years, it has managed to become an internationally

fact, its corporate growth has not prevented it from retaining its added

renowned company, with a production site in Italy, a plant in Russia,

values as an independent, family-owned company: direct relationship

and a highly specialised research laboratory. In order to stand out

with customers, maximum flexibility, decision making speed, and ability

in a competitive market such as that of powder coatings, Stardust

to develop customised solutions.

has focused on the production of small batches made-to-order â&#x20AC;&#x201C; an

Stardust started its own powder coatings production business in 2007,

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

entering a mature and growing market. “Back

design and service.”

then, the sector was dominated by multinational

“Stardust decided to specialise in the made-

companies capable of producing enormous

to-order approach,” says Pozzoli, “so as to

quantities of paints according to the principle of

manage short lead times and small batches

‘economy of scale’, with increasingly competitive

upon request, regardless of their colours and

prices for ever greater quantities. Production

finishes. Our choice turned out to be correct:

was mainly managed according to the made-to-

the financial crisis of 2009 irreversibly changed

stock approach, which involved the employment

the way of ‘doing business’, thus forcing

of financial fixed assets to store end products

companies to manage their financial resources

that were expected to be sold in the short

more carefully and, therefore, to reduce their

term,” states company director Guido Pozzoli.

inventories. Currently, Stardust produces

“This management system forced firms to

powder coatings in line with aesthetic standards

grow continuously, by investing in increasingly

such as NCS (of which it is an official partner),

powerful and productive plants or by acquiring

PANTONE, and RAL DESIGN, as well as sample

smaller companies to increase market

colours, always based on the specific needs of

shares and reduce unit production costs. In

the user’s application systems and products to

order to enter such a competitive market,

be painted.”

we strategically chose to aim at creating a

“Stardust’ pillars are, in order of importance,

different business model, able to meet the most

safety, quality, and quantity,” states Pozzoli.

particular requests in terms of both product

“First of all, we care about the ‘safety’ of our

segr@italgard.it - www.italgard.it

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

employees, because I think that 70% of a company’s

solutions. “The situation of the last few months

success is linked to its staff: over time, Stardust

has prompted me to work on this project to enrich

has built an efficient team of well-trained, willing,

Stardust’s offer,” explains Pozzoli. “First of all, we

and dynamic people. The second pillar is ‘quality’,

became partners of BioCote®, with which we have

which is even more important than ‘quantity’: if a

developed and tested an even higher performance

product does not pass all our checks, it is rejected,

product in terms of functionality, colour, finish,

at the cost of not delivering or slowing down the

and chemical nature. The products of this type

plant. Year after year, we are introducing more and

currently on the market are generally used in the

more sophisticated control procedures, in order to

medical-hospital field and they are mainly available

guarantee an ever higher quality standard.”

in very few light shades, in epoxy or epoxy-polyester versions: Stardust, on the other hand, has created

The company’s evolution: new headquarters and production process automation “Among other goals, we plan to move to a new

an antimicrobial powder capable of meeting any request for colour, gloss level, and chemical nature.

Formulating such an antimicrobial coating was Guido Pozzoli, CEO of Stardust.

location by the end of 2020, while remaining in the

complicated, since many variables can affect the result. We have carried out dozens of tests with a very

industrial district of Bazzano (L’Aquila, Italy). We aim at increasing

accurate methodology, in order to guarantee the same antimicrobial

our production capacity while providing the same service level

properties to the entire Stardust range. We have even expanded

in terms of delivery speed, even if production were to double or

our tests’ scope to include a broad spectrum of bacteria, fungi, and

triple,” notes Pozzoli. “A new challenge will be to focus as much

moulds. Also becoming a BioCote® certified partner was not easy,

as possible on the automation of processes. We are completely

because this global leader in the field of antimicrobial additives

renovating our entire production flow, by implementing increasingly

imposes very strict standards. However, being their partner is now

sophisticated software and digitised controls. Service quality, that is,

definitely an added value for Stardust.”

delivery speed and the ability to produce even minimum quantities

Stardust’s Guardian AM powder coating range, which helps reduce

of sample colours, is and will remain Stardust’s pride: our customer

microbial proliferation on metal surfaces by increasing their

orientation is crucial and it will never change, even if orders increase.

permanent hygiene degree, will be available in two versions. The

However, at this time Stardust wants to make a leap in quality both

Guardian AM Architectural one will be intended for the aluminium

nationally and internationally. Now that the company is solid and

and design sector and aimed at combining antimicrobial efficacy,

customers are loyal, we are finally ready to promote ourselves at the

outdoor durability, and aesthetics. The Guardian AM Medical version

international level, investing more resources in marketing despite

will be intended for hospitals, as it combines antimicrobial properties

the uncertain economic situation due to the pandemic.”

with scratch, light, cold liquid penetration, and humid and dry heat resistance characteristics. The whole Guardian AM range it will be

New projects: antimicrobial powders will drive many innovations

available on the market from next October and it will be the subject of an extensive advertising and social campaign.

“Stardust is not just synonymous with customised colours. We have a laboratory devoted to the development of ever-new tints,

Flexible growth

especially within the NCS standard, which is increasingly widespread

“Stardust’s main goal is ‘flexible business growth’, understood as the

in the architecture, design, and nautical sectors. On the other hand,

ability to increase production and turnover without decreasing our

however, we have always been very attentive to the issue of product

capacity to manufacture small batches in record time, which is the

certifications,” says Guido Pozzoli. “This is why we have a very

cornerstone of our success,” states Pozzoli. “Our investment in the

advanced research, development, and quality control laboratory,

new headquarters in L’Aquila, the acquisition of new technologies

which has several innovations in the pipeline for the next two years.”

for our production department and laboratory, and the choice

The first of these innovations is a range of new generation powder

to hire new staff, together with our investment in marketing,

coatings with antimicrobial characteristics, developed by Stardust

communication, and advertising, will enable us to continue to grow

to meet to the increased need for surface cleaning and hygiene

constantly and organically, in line with the last few years’ trend.”

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

New 2020 2018

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INNOVATIONS: PRESENT&FUTURE

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Scientist at Fraunhofer Institute Develops Coating that Protects Steel from the Penetration of Hydrogen Katharina Hien Fraunhofer Institute for Mechanics of Materials IWM - Freiburg, Germany

katharina.hien@iwm.fraunhofer.de

Lukas Gröner of the Fraunhofer IWM, MikroTribologie Centrum μTC, has developed a coating that effectively protects steel from the penetration of hydrogen. The barrier effect of this so-called MAX-phase layer is 3500 times greater than that of untreated steel.

egeneratively produced hydrogen is an

steel components that virtually prevent

The development process

environmentally friendly energy carrier,

the penetration of atomic hydrogen, and

In a vacuum chamber, Gröner first deposited

which can be used as fuel in cars or to

succeeded in producing thin MAX-phase

very precisely alternating layers of aluminium

generate electricity and heat in fuel cells. It can

coatings2 that protect steel very well against

nitride, an aluminium-nitrogen compound,

also be mixed with natural gas and used in

corrosion and hydrogen embrittlement.

and titanium on a steel surface using physical

gas-fired power plants to generate energy.

“MAX-phases have amazing properties

vapor deposition (PVD).

However, atomic hydrogen often induces

because they combine characteristics of both

This sandwich structure, which is only about

brittle behaviour in metals at high

ceramics and metals”, explains Gröner.

three micrometres thick, was then heated to

temperatures, which can lead to component

In fact, MAX-phases, like ceramics, are

form a very thin MAX-phase layer of titanium, aluminium and nitrogen (Ti2AlN).

failure.

insensitive to attack by oxygen and very

To provide a solution to this issue, in his

heat-resistant, but unlike pure ceramics, they

doctoral thesis physicist Lukas Gröner

are not brittle, so they do not break. Moreover,

deposition of titanium and aluminium nitride

developed and tested special coatings for

they are electrically conductive like metals.

in such a way that parallel Ti2AlN platelets

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

REM image of the fracture edge of a Ti2AlN coating with platelet-like shaped grains.

The challenge for Gröner was to control the

REM images of a Ti-AlN multilayer stack of the surface (a) and the fracture edge (b), as well as the surface (c) and fracture edge (d) of a resulting MAX-phase Ti2AlN layer.

INNOVATIONS: PRESENT&FUTURE

were formed during subsequent heating.

The results are impressive: steels with

same time can dissipate the electric current

“The platelets are close-packed like bricks in

a MAX-phase layer that were not heated

that is generated inside the fuel cell”, says

a wall”, is how Lukas Gröner described the

withheld hydrogen 50 times better

Gröner.

success in overcoming the challenge.

(PRF 50) than untreated steels. But the results

The results of Lukas Gröner’s work have been

In his doctoral thesis, Lukas Gröner also

were particularly impressive for the coated

recently published in the journal ‘Materials’3.

investigated how the MAX-phase coating

steels that had been heated and formed an

behaves when it is intensively heated, as

α-Al2O3 layer. These blocked the hydrogen

degrees and left it in the furnace for up to

New testing underway

1000 hours. This created a thin layer of a

In collaboration with cooperation partners

1 Lukas Gröner, Untersuchungen zur Synthese und Mikrostruktur von Ti2AlN-Dünnschichten sowie deren Schutzwirkung auf ferriƟsche Stähle, Fraunhofer IWM Forschungsberichte, Band 24, Fraunhofer Verlag, Freiburg, 2020, ISBN 978-3-8396- 1619-2. The doctoral thesis is available at the following link: hƩp://publica.fraunhofer.de/dokumente/N-593436.html

special aluminium oxide on the top side of

such as the Forschungszentrum Jülich, Gröner

the coating – α -Al2O3, which considerably

is currently testing how well the MAX-phase

increases the barrier effect of the protective

layers work when applied, for example on

layer against hydrogen.

high-temperature fuel cells (SOFC) that

To test how well the MAX-phase layer prevents

operate at temperatures of approximately

hydrogen from penetrating the metal,

600 degrees Celsius.

Lukas Gröner first developed a new test rig

“The MAX-phase coatings are ideal for these

for thin metal sheets. In this test he compared

types of applications because they protect

uncoated steels with MAX-phase coated steels.

the metallic components from heat and at the

it would happen with future gas turbines

from entering the metal roughly 3500 times

or fuel cells. To simulate normal operating

better than with the untreated steel.

conditions, he heated the material to 700

MAX phases (Mn + 1AXn, where M is an early transiƟon metal, A is a group A element, X is carbon or nitrogen and n = 1–3) are layered ternary carbides and nitrides exhibiƟng combinaƟon of properƟes of metallic and ceramic materials, Ed. 3 Gröner, L.; Mengis, L.; Galetz, M.; Kirste, L.; Daum, P.; Wirth, M.; Meyer, F.; Fromm, A.; Blug, B.; Burmeister, F. InvesƟgaƟons of the Deuterium Permeability of As- Deposited and Oxidized Ti2AlN CoaƟngs. Materials 2020, 13, 2085, hƩps://www.mdpi.com/19961944/13/9/2085

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BRAND-NEW

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Architectural Flex, the New Solution for Coil Coating by Europolveri Europolveri launched Series 2 Architectural Flex, a new powder coatings series for coil coating and Phase Change Materials.

he coil coating process, introduced in

(hazardous substances like TGIC and heavy

Architectural Flex that incorporates the range

the 50s’ for coating automatically steel

metals) while preserving the technical

of products suitable for coil coating and PCM

strips, drastically changed the way of

characteristics requested by approval and

(Phase Change Material) sheet plates.

thinking and designing architectural products.

regulatory body such as ECCA (European Coil

The above-mentioned products are highly

Today, thanks to its competitiveness, it is

Coating Association), Qualicoat, GSB, AAMA

customized since they need to meet the

estimated that approximately 80% of the flat

• Single coat application with 60-80 micron of

characteristics of each single installation, as

surfaces such as roofs, façades, countertops,

powder

they differ for one customer to another. For

sound absorbing panels, domestic appliances,

• Higher corrosion resistance compared to

this reason, Europolveri technicians and R&D

etc. are produced from pre-painted coils.

post-painted products

department develop products side by side

In the 80’s coil coating of aluminium strips with

• Improved thickness and shade stability for

with every customer to answer to their specific

powder coatings became an important reality

the production of large architectural projects

needs such as application speed, technology

in the architectural business even though it

(>500 m )

and crosslinking requests.

was not possible to technically achieve the

• Total recyclability of the finished product as

Coil coating with powder coatings still

application speed of 110-130 m/min typically

second-choice aluminium.

represents a market niche in relation to the

reached with liquid solvent-based coatings.

Founded in 1982 and leader in powder

whole coil coating sector; nevertheless, it is a

Among the several advantages linked to the

coatings production, Europolveri is well

still growing technology thanks to easiness of

use of this new technique, the most important

introduced in the architectural market since

colour change and to the wide availability of

is its “process sustainability” that gave a boost

it was homologated by Qualicoat in 1998. In

colours and finishing.

to the development of this technology.

addition, it is capable of providing all wood

Europolveri offers solid and reliable

Modern application plants that use powder

effects technologies such as “Sublimation”

partnership to face the new challenges of a

coatings allow:

and “Powder-on-Powder” (Qualideco PS-011

more demanding market regarding quality and

• Closed-loop processes (defined as zero-

approval).

speed of service.

discharge) that do not release pollutants

Regarding the specific coil coating application

• The use of coating free VOC-free (Volatile

technology, Europolveri created a brand-new

For further information:

Organic Compounds) and SVHC-free

series of products under the name Series 2

www.europolveri.it

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Fondmetal Recovers 99% of Water with a New, Zero Liquid Discharge Water Treatment Plant Monica Fumagalli ipcm®

A rare example of effective environmental policy in the alloy wheel manufacturing sector: Fondmetal is beginning to reap the rewards of its investment in a new, zero liquid discharge water treatment installed a year ago by Verind, a company of the Dürr Group. Some figures: 99% of recovered water, 91% less liquid concentrates to be disposed of, and sludge reduced by 77%.

“W

ater is an exhaustible resource.” With this statement, Fondmetal paintshop manager Marco Mora explains the reasons behind

the investment in a new waste water treatment plant made by his company, based in Palosco, Bergamo, Italy and specialising in the production of aluminium alloy wheels, already the subject of an article published in the pages of this magazine in 20161. “As a company that has always been attentive to its environment impact, the water footprint of our

Alloy wheels entering the pre-treatment tunnel.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

L. Antolini, “Fondmetal: a wide range of colours for top range light alloy wheels”, in ipcm® InternaƟonal Paint&CoaƟng Magazine no. 38 (March/April 2016), pp. 72-80. 1

FOCUS ON TECHNOLOGY

production was a topic on which our management had been reflecting for some time. The chemical-physical treatment plant that had been connected to our two coating lines since 1987 featured technologies that were outdated and undersized compared with our growing production needs. When we decided to replace it, we had two choices: sticking with the conventional chemicalphysical treatment process, obviously updated with the latest technical innovations, or opting for the best technology currently on the market, that is, a new concept, zero liquid discharge (ZLD) water treatment system. “In the end, we chose the latter solution. After consulting several companies, we turned

to Verind, a company of the Dürr Group

The outside of the pre-treatment tunnel.

specialising in the development of equipment and eco-technologies for coating processes, and already our partner lines of our factory. Verind’s project convinced us because it perfectly

The green revolution of a high-production capacity company

fit with the corporate sustainability policy that Fondmetal has been

Fondmetal currently has 137 employees and it produces 1 million

pursuing for some time now, but also because the system offered

wheels per year, mainly intended for OEM and aftermarket customers.

was highly efficient, the company’s team was really professional,

Its paintshop’s capacity is about 3 millions of wheels per year, as it

and they took into consideration our return on investment after five

also works on contracting orders. “Our production system,” indicates

years, an element that other suppliers had underestimated.”

Mora, “has not changed since our previous meeting: after metal melting

for the design and installation of the two liquid and powder coating

The double stage of reverse osmosis.

Water collection tanks.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

and treatment, the wheels are formed

contingent difficulties. When we decide

on robotic stations with gravity and low

that it is worth investing in a project, we

pressure systems, and then subjected

do not stop at the first obstacle, but we

to mechanical processing. The coating

carry it out. Especially when it comes to

operation is fully automated and performed

decisions concerning work environment

in two closed, filtered, and pressurised

safety, sustainability, and efficiency, we

lines with a floor conveyor. Each of them

cannot afford to “freeze” our production

can treat 200 wheels (up to 18 inches in

system in the condition that seems more

diameter) per hour, on 3 work shifts for 5

comfortable and easier to maintain in

days a week.

terms of investment. We approached our

“Confirming our environmental vocation,

ZLD water treatment plant project with the

one of our priorities is the plan to

same philosophy.”

implement a more eco-sustainable coating In 2001, we were among the first to replace

The closed-loop water treatment plant

solvent-based base coats with water-based

The system, intended for the purification

ones, but clear coats are more challenging.

and recovery of pre-treatment water, was

This is why we have not found a water-

custom designed by Verind’s technical

soluble solution yet that guarantees the

team based on Fondmetal’s needs. “The

film resistance values we achieve with

pre-treatment plant,” says Stefania Paloschi,

conventional paints.”

Sales Manager Environmental Technology

Such a “green revolution” should

expert at Verind, “includes three active

be encouraged, in this particular

stages and it is composed as follows:

manufacturing sector. “We strive to make

alkaline degreasing, two rinses with mains

courageous choices and go beyond

water, acid deoxidation, two cascade rinses

system including 100% water-based paints.

Above: The pre-osmosis water tank. Top left: The chemical-physical batch in which the electrolyte is dosed for sludge formation. Top right: The flushing tank.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

with demineralised water, passivation with chromium-free fluo-zirconia, final rinse with demineralised water, and drying. The concentrated water, both acidic and alkaline, and the diluted one resulting from this process are conveyed into two collection tanks. Here, they are taken in different percentages and sent to the treatment system. “The water recovery plant performs a first chemical-physical treatment phase, in which the acidification, neutralisation, and flocculation processes take place in order to precipitate most metals, especially aluminium. Within a chemical-physical batch, a polyelectrolyte is dosed for the formation of sludge flakes, which settle on the bottom during decanting. Once all the sludge has settled and all the water has

cleared up, a pump is activated to bring the

2040 pcs / h

The demineralisation plant.

9600 pcs / h

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

sludge mass to the thickener; the clarified water is filtered through two filters, one with sand and one with coal, for further clarification, and it is then stored in a tank of about 2 m3. “When the tank reaches a pre-set level, two osmosis stations are activated: the water in the tank consists partly of permeated liquid and partly of a residue concentrate; the latter increases in the course of the process: it is then sent to a second storage tank to feed the second osmosis unit. The resulting concentrate reaches a third tank, which, once the pre-set level of concentrate is reached, activates the evaporator. Here, water is heated to a temperature of 30-40 °C, evaporates, and condensates while cooling: the precipitated condensation is clean water, which is stored in the tank that feeds the rinsing stages

The filter press for water purification.

performed after degreasing, previously carried out with mains water. The system was completed with the installation of the demineralisation system to feed the demineralised water rinses.”

The new plant: facts and figures “We recover 99% of process water with this ZLD system,” states Mora. “The remaining 1% is the evaporator concentrate, which is regularly discharged into another tank and disposed of by a specialised company. In addition to saving significant amounts of water, this has also a higher quality level. We used to have a conductivity value equal to about 700 microsiemens, compared with the current 300.” “The system was installed a year ago,” says Paloschi, “and it is the most advanced result achieved with the environmental technology developed by Verind. Fondmetal’s choice was courageous also because it was a process completely unknown to them. Over time, they have learnt to manage and even optimise it:

The evaporator.

100

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

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FOCUS ON TECHNOLOGY

actually, we can say that they have now

reached full optimisation. “In terms of substances to be disposed of, they have reduced the quantity of liquid concentrates by 91% and that of solid sludge by 77%. The next value to be assessed will be relating to the chemicals used: for their water treatment plant, they use aluminium polychloride as a coagulant for polluting liquids, caustic soda to neutralise and precipitate most metals, and, if necessary, hydrochloric acid. Other than polychloride, no new chemicals have been introduced, because they already used these substances for the regeneration of demineralised water resins. Indeed, they have eliminated two: sulphuric acid and lime.”

Conclusions “The new plant has not only brought objective economic advantages,” states Mora. “It has also relieved us of the

A finished alloy wheel ready for shipment.

significant environmental responsibilities deriving from our previous system, which, despite never giving rise to problems, was subjected to frequent checks by

authorities. Our environmental choices have also rewarded us in terms of management. Not many companies in our sector make radical choices like ours: apart from the elimination of chromium that car manufacturers have requested from their entire production chain, there are no regulations requiring similar ecofriendly operations. Sustainability therefore remains an individual responsibility of each firm. However, everyone should be involved instead, because the energy resources of our planet are not inexhaustible. Water, which is a primary resource, should be preserved and rationed as much as possible not only in our everyday lives, but also within our production plants.”

From left to right: Alessia Venturi from ipcm®, Marco Mora and Alessandra Rumi from Fondmetal, Daniele Foﬀano and Stefania Paloschi from Verind.

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Kitchen modules in various colours.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Fisher & Paykel Chooses a Nanotechnology Pre-Treatment Process for the Production of ELBA-Branded Household Appliances Marta Fumagalli ipcm®

In collaboration with DN Chemicals, Fisher & Paykel has developed a nanotechnology pre-treatment cycle that evens out its raw materials’ quality level in order to obtain end products with an excellent aesthetic and functional degree, as required by the extremely competitive market of household cooking appliances.

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FOCUS ON TECHNOLOGY

Preliminary remarks

steel and zinc-plated sheets for our

In the extremely competitive market of

products’ aesthetic details to be

household cooking appliances, where

coated, such as our oven front frames.

the demand for quality and production

However, we sometimes encounter

flexibility is increasingly greater, service

degassing and pitting problems on our

is a decisive factor in distinguishing from

coatings, due to the low quality of raw

competitors. This philosophy has led the

material. We have no control over this

ELBA commercial brand, owned by New

factor, because our plant’s workload

Zealand multinational company Fisher

is prone to sudden changes and it is

& Paykel, to constantly grow and spread

not always possible to find materials

in over 70 countries in the world. ELBA

that are standardised or directly

appliances are inspired by passion and

come from steel mills. And the lack of

simplicity: they are completely made in

consistency in raw material can cause

Italy, from design to the production of

various issues,” states Stefano Ceccon,

individual components, which is carried

the operation manager of Fisher &

out in different plants throughout Italy.

Paykel Appliances Italy. “In order to

This guarantees superior product quality

cope with such fluctuations in material

and unique, elegant design, combining

quality, we use a pre-treatment cycle

creativity and craftsmanship to create

with a nanotechnology passivation

captivating but also practical products.

stage developed by DN Chemicals

Offering excellent aesthetics and

(Caleppio di Settala, Milan, Italy), which

meeting commercial requests while

specialises in the production and

maintaining the highest quality level

distribution of chemical products for

is not always easy: “We mainly use

surface treatments. The combined

An enamel application booth. © ipcm

The enamelling plant.

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Enamelled parts.

use of the chemicals they provide us with has proved to be crucial to improve and standardise our raw material, thus enabling us to achieve excellent aesthetics and repeatable results.”

ELBA: superior quality Elio Baggio established ELBA in Marostica (Italy) in 1950. Since then, this brand has always advocated Italian-made quality. Year after year, Elio Baggio has managed to grasp the requests and tastes of families, surrounding himself with partners who shared his values and were able to implement all his projects. Attention to detail, passion for technology, and talent led the company to become a fundamental part of the post-war “Italian economic miracle”. In 1960, it moved to Bassano del Grappa © ipcm

The pre-treatment tunnel.

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(Vicenza), in a larger production facility where it remained until 1987, when the De’

FOCUS ON TECHNOLOGY

The new curing oven installed by Euroimpianti.

Longhi Group acquired it and transferred it to Borso del Grappa, where it is still located. Following this acquisition, ELBA began to focus on cooking and heating appliances, thus gradually moving away from its previous core business of wood stoves and gas and kerosene stoves. In 2006, it was acquired by the Fisher & Paykel Group, which further focussed on the design, production, and marketing of cooking products for domestic use, such as builtin hobs and ovens and freestanding cookers. All products are powered by electricity, gas, or a combination of both; about three years ago, the company also began developing induction and steam cooking appliances. In 2013, the New Zealand Group was bought by Haier, a Chinese multinational company that is number one in the world for the production of consumer electronics and household appliances. Many elements contribute to the success of Fisher & Paykel Italy and of the ELBA brand: expertise, professionalism, designorientation, and the continuous pursuit of excellence. All these values can be summed up in one word: talent. The ability to translate customer wishes into attractive, simple, and functional appliances have also enabled the ELBA brand to cross the borders of Italy and conquer the Middle East, Africa, and the Far East. Nowadays, Fisher & Paykel Italy is one of the undisputed

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

leaders of the kitchen appliance market

and the ELBA brand continues to represent the company’s commitment to superior quality.

The importance of the pre-treatment cycle “The finishing process is a key step for a product of this kind, also because our target has changed in the last few years. We are focussing more and more on creating products of excellence for the mediumhigh segments of the market, although we maintain a share of medium-low range products with some long-standing brands,” explains Stefano Ceccon. “Our factory deals with numerous phases of our production flow, but our range is so wide that we necessarily have to entrust some processes The new Wagner powder application booth.

to third parties. Only enamelling and coating are carried out exclusively by us, in order to have greater control and flexibility and, therefore, guarantee maximum product quality.”

“We have a powder coating plant that has been recently modified with the installation of a new Euroimpianti curing oven and a latest generation spray booth, a Wagner SuperCenter type with an automatic colour change system. This has replaced the two booths we used previously and it has enabled us to significantly increase efficiency and reduce paint waste. We have organised our production in order to perform about three colour change operations per day, although we have a long-standing catalogue of a dozen tints to coat the aesthetic details of our appliances,” states Gianfranco Marin, the production manager of Fisher & Paykel. “Due to the aforementioned problem related to galvanised sheets’ inconsistent quality, we have also improved our pre-treatment process with the aim of increasing our coatings’ quality degree.” Wagner’s “Super Center” powder management unit,

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FOCUS ON TECHNOLOGY

“Fisher & Paykel’s plant was originally designed to perform a simple phosphating operation,” explains DN Chemicals area manager Gianni Zilli. “Over time, it has been converted to perform a pre-treatment cycle including two active stages and their related rinses. The first stage is a pre-degreasing process using a neutral surfactant. It is followed by a nanotechnology conversion phase based on zirconium salts, a rinse with mains water, a rinse with demineralised water, and a final rinse with directly-sprayed 20-microSiemens demineralised water. Although the cycle is pretty simple, it has increased the quality of our pre-treatment process and, therefore, of our coatings.” “Our quality control laboratory performs impact and adhesion tests and, above © ipcm

all, a hot water immersion test, which is fundamental for our products,”

The application of powder coatings.

“Visual” quality control.

indicates Gianfranco Marin. “After implementing DN Chemicals’ cycle, we have noticed an improvement in our

tests results, especially the cross-linking adhesion one. If our components’ zinc-plated sheets have not undergone any treatment prior to coating, with our pre-treatment process we are able to improve their substrates’ quality through the passivation phase based on zirconium salts. If they have been, for example, chromed, we have to calibrate the operation in a different way, but that does not pose any problem as this is a very flexible cycle.”

Future improvement projects: the implementation of Soft Rain equipment “After modifying the application and curing stations of our plant, we also intended to enhance our pre-treatment tunnel and drying oven to take a further Plates subjected to adhesion tests.

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

A part of the laboratories.

leap forward. However, after the lockdown due to the Covid-19

problems affecting the treatment’s effectiveness. Finally, Soft Rain

pandemic, we (luckily) had lots of orders to handle and we had to

guarantees nanotechnology product consumption optimisation,

pause the project, but we will try to carry it out as soon as possible,”

absence of waste water to be treated, and performance consistency,

says Stefano Ceccon.

as the workpieces are always hit by the same quantity of solution.

“In this revamping operation, in order to improve pre-treatment quality, it may be interesting to implement a nanotechnology

Conclusions

passivation process through the Soft Rain nebulisation technology,”

Very often, the great variability of the materials available on

states André Bernasconi, the sales manager of DN Chemicals.

the market causes problems for manufacturers, which must

“Soft Rain is a state-of-the-art

provide their customers with

nebulisation system inspired

consistently high quality. “Thanks

by the nanotechnology applied

to the help of DN Chemicals,

to the pre-treatment of metal

we have obtained an extremely

surfaces, which is able to

flexible nanotechnology

perfectly combine the principles

pre-treatment process that

of effectiveness, efficiency, and

allows meeting the high

sustainability. One of its main

quality standards imposed

advantages is the application of

by the market. However, we

a freshly-mixed nanotechnology

have further goals to achieve

solution that is never recycled

and several projects ready to

together with the pollutants

be developed,” says Stefano

carried over from the previous

Ceccon.

stages. This solves any dragging

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From left to right: Stefano Ceccon, the operation manager of Fisher & Paykel Appliances Italy, Gianni Zilli from DN Chemicals, Gianfranco Marin, the production manager of Fisher & Paykel, and Alessia Venturi from ipcm®.

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

Zaniolo CdA-2.20

SOLUT ONS advanced

Europolveri offers a wide range of powder coatings that are available in several

solutions for

different finishings and gloss level. A stock of approximately 1000 different colors is

always available and developed to assure the highest quality level as to satisfy the widest

metal surfaces treatment

needs of the market. R&D laboratory steadily works in the development of new products and performance improvement in order to enable the company to be an innovation leader and to give solutions to the many technical requests coming from the market. Products development, their industrialization and their use are always directed to obtain the best results and the highest respect for the environment.

EUROPOLVERI S.p.A. - Sandrigo (VI) Italy - Ph. +39.0444.750643 - Fax +39.0444.750653 FILIALI/Branch Office: Cernusco sul Naviglio (MI) Ph.+39.(0)2.92148001 - Erbusco (BS) Ph.+39.(0)30.7704158 DEPOSITO/Depot: Iori Colori, Reggio Emilia Ph.+39.(0)522.327248

info@europolveri.it - www.europolveri.it

P O W D E R C O AT I N G S I N C E 1 9 8 2

HIGHLIGHT OF THE MONTH

Limitless Innovation Capacity: Tapematicâ&#x20AC;&#x2122;s In-Line Coating and Sputtering Systems Conquer the Cosmetic and Beverage Packaging Market From an interview with Davide Perego, Tapematic Spa CEO Ornago (Monza e Brianza), Italy

We interviewed Davide Perego, the CEO of Tapematic Spa, a company specialising in the production of in-line sputtering and coating systems for the cosmetic and beverage sector. Starting from a very different production concept, it now offers a surface treatment process guaranteeing high production capacity, speed, finishing quality, and result repeatability.

hanges are scary. Lately, more than ever, we have experienced

changes in trends and demands, when one of its target market begins

first-hand what it means to face a radical break from our habits.

to recess, its entire corporate strategy must be reviewed. Only those

The same is true for the manufacturing industry. Although a

who manage to look beyond the contingent productive reality are able

company can be prepared for the rapid and increasingly fluctuating

HIGHLIGHT OF THE MONTH

????????? ??????? Autore Azienda, Indirizzo

110

mail

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

to stand out.

HIGHLIGHT OF THE MONTH

Tapematic Spa currently specialises in the design, construction, and

and 2.1 m in height and its weight of 4000 kg, this 3D sputtering coating

installation of in-line coating and sputtering systems for the cosmetic

system is a complete paintshop in miniature, as it is able to treat both

and beverage sectors. Established in 1975, throughout its history it

single parts and large batches. It can process up to 4 workpieces with a

has had the ability to renew itself several times by completely changing

maximum diameter of 56 mm and a height of 90 mm, or 8 workpieces

its production structure. “When you use efficient technologies,” states

with a maximum diameter of 28 mm and a height of 60 mm, thus

Tapematic Spa CEO Davide Perego, “changes are less scary.”

guaranteeing a productivity rate of 2000 or 4000 parts/hour. We have carefully designed our trays in order to make the most of the space

This Italian firm now employs forty-five people and it is divided into

available on the line. The workpiece holders consist of a steel sleeve

two businesses: Tapematic, which deals with the design, manufacture,

that remains the same for all configurations and an integrated fixture

and assembly of coating systems, and Discmatic, which produces

designed based on customer specifications.”

mechanical components for the Tapematic plants. The company is

The PST Line II series, on the other hand, is characterised by a larger

known worldwide thanks to its branches in Orlando (USA), Colchester

footprint (19 x 5 x 2.1 m) and a productivity rate that can reach 7800

(United Kingdom), and Hong Kong. Above all, it has never stopped

parts/hour. “This footprint,” explains Perego, “can treat up to 13

innovating: in fact, it files at least two patents a year.

components up to 102 mm in diameter and 130 mm in height. It is highly appreciated by companies that produce lipsticks, mascaras and

Eﬃcient technology making the diﬀerence

jar covers.”

“Our systems have obtained important awards in the medium-high range cosmetics market and in the beverage one,” says Perego.

The Tapematic systems’ coating and sputtering process

“Currently, our flagship coating plants are the types PST Line I and

All Tapematic’s lines include the following modules for surface

PST Line II, which use the same technology and differ only in the size of

metallisation:

the workpieces they can handle.”

• manual and/or automatic loading;

The PST Line I machines are the smallest ones of Tapematic’s whole

• cleaning and pre-treatment through goat bristle, active ionising bar,

range. “With its limited dimensions of 14.5 m in length, 3 m in width,

ostrich feather, and flame treatment devices;

The company headquarters in Ornago (Monza e Brianza),Italy.

Tapematic is a benchmark supplier of in-line sputtering coating systems for cosmetic products.

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111

A plant type PST Line II.

• primer application;

places them on another tray, at the entrance to the UV base coat

• UV base coat application;

application module. It then proceeds in the same way to lead the

• sputtering deposition;

workpiece holders into the pre-chamber (where the vacuum level is

• UV top coat application;

brought to the same value as the main chamber in 2 seconds) and

• manual or automatic unloading.

subsequently in the sputtering deposition and UV top coat application

The process always start with the manual loading of the workpieces on

stations.

trays and the pre-treatment phase with goat bristles or ostrich feathers

The two-station manipulator allows treating the components in 6

and a flame treatment operation. “Then, the actual finishing process

seconds, with a considerable advantage over traditional systems,

begins,” says Perego. “The two-station manipulator automatically loads

which require much longer times (a few minutes). “The operator can

two spindles at a time, locating them on a rotary table. Its clockwise or

set the desired parameters for each stage of the process, including

anticlockwise movement, depending on the set parameters, enables

for instance the rotation direction and speed value, which are an issue

the application of the primer. The manipulator picks up the parts and

on conventional lines due to the complex shapes of the products to

A detail of the top coat application phase.

Scan this code to view the process or click here: www.youtube.com/watch?v=UIGB8IrGoqY

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HIGHLIGHT OF THE MONTH

be treated, as these can compromise surface layer homogeneity and result repeatability.”

The history of Tapematic: from the record industry to the sputtering coating sector “In order to meet our customers’ need, we have never set limits to

Flexibility, speed, and sustainability: the Tapematic plants’ benefits

creativity. This has always characterised the history of our company,

“Our lines, which can be integrated into already existing production

which turned out to be strategic for our success on the market. He

flows, offer numerous advantages,” notes Perego. “These include, first

started operating in the record industry, offering an innovative system

of all, their configuration modules, which enable every customers to

for loading audio cassettes’ tapes, and then entered the audio-visual

select the layout structure that best suits its needs, their process speed

sector with VHS tapes. The transition to music in digital format with the

guaranteed by the complete automation of the lines, and the product

spread of compact discs, in the late 1980s, prompted a leap in quality

quality level they provide. The latter is guaranteed through one or more

for Tapematic. We were strategic providers of Philips: when the Dutch

cameras installed on the machine, in front of which the workpieces

giant understood the potential of this new product, it decided to help

can rotate 360°. Together with built-in ionisation and filtration, which

its suppliers develop a more efficient CD production process.

eliminates any possible contamination in the process area, this almost

“At the time, optical discs were manufactured with a batch production

reduces the rejection rate to zero. Moreover, paint consumption is

process starting with press moulding and high vacuum metallisation;

lower thanks to the ability to coat each part in just 0.15 seconds, thus

then the discs, were picked up from the bell and arranged on belts

reducing waste. Two further advantages are energy savings thanks

reaching a spinning coating station. With the help of Philips, we

to reduced consumption (30 kW of power) and the reduction of VOC

modified this process by introducing a sputtering coating system

emissions thanks to the innovative spraying system.”

equipped with a pre-chamber: in this station, the disc was brought

starting from the counter-current choices of my father, Luciano Perego,

Air Pollution Control Experts Dürr is a leading global supplier of environmental control technologies. Our air pollution abatement solutions reduce emissions and improve efficiency for a variety of industrial processes.

www.durr.com

A BT Coating II plant for the decoration of cosmetic, food, automotive, and pharmaceutical packages.

to the same vacuum level as the main chamber and then metallised

its creative mind, with his ability to see beyond the current needs of

with an aluminium target. The metal layer thus obtained had to be

customers and anticipate their requests. In the 1970s, he had the idea

protected from wear and scratches: that is why we began using

to launch a new system for reloading the tapes of already closed audio

UV coatings. Moreover, this new system developed by Tapematic

cassettes. It was him who understood that it was necessary to develop

was placed in line with moulding presses: therefore, it was no

an in-line coating system for compact discs to speed up production.

longer necessary to produce compact discs in batches. When the

And it was based on one of his projects that we offered to replace

CD market also declined due to the introduction of MP3s and the

offset printing with inkjet printing using UV inks, in order to decorate

ability to download music from the Internet, we decided to apply the

the polycarbonate plastic of CDs with writings and images. This

same production principle to the surface treatment of cosmetic and

technology, which guarantees maximum product customisation and is

beverage products.”

ideal for limited quantities, was then successfully used for printing on cosmetic, food, automotive, and pharmaceutical packages.

The decorations of future

“Currently, we are designing a new system that will revolutionise the

Its ability to reinvent itself, its creativity, and above all its use of efficient

field of digital decoration and that we will present on the market at the

technology have made Tapematic the successful company it is today.

end of the year. Yes, changes are scary. However, if we face them with

“Even if the firm is now managed by our family’s second generation,

the right amount of creativity and resourcefulness, positive results will

with my brother Mattia and me,” states Perego, “my father remains

come: the history of Tapematic is proof of this.”

Lipsticks are just some of the several cosmetic products coated with Tapematic’s systems.

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Master Remover® Sustainable paint removal technology

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Master Remover® processes provide a sustainable paint removal solution for paint applicators globally. It efficiently removes a wide variety of coatings from a various substrates and may be utilized off-line or in-line as well as by spray or immersion, offering superior process versatility. Master Remover® is the ideal in-house paint removal solution, supplying the performance, quality and safety demanded by automotive OEMs, Tier 1 suppliers, as well as e-coat/KTL and powder paint applicators. Atotech also offers technology to support sustainability with Master Remover® ESPRIT (Efficient, Sustainable Paint Removal Integrated Technology). It is a skid mounted plug and play system comprising all the features to ensure optimum performance at minimum operating cost. The system includes the process and rinse tanks, all accompanying equipment for agitation, heating, filtration and temperature control along with the electrical hoisting and rail system. Master Remover® ESPRIT is delivered ready to provide the best cleaning performance of the versatile Master Remover® 7000 and 2000S systems, to meet your highest quality standards.

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atotech.com

FOCUS ON TECHNOLOGY

Cycle Times Halved in One of the Few Anti-Corrosion Powder Coating Lines of Northern Italy Monica Fumagalli ipcmÂŽ

When a manufacturer of coating systems also works as a coating contractor, it can fully understand its usersâ&#x20AC;&#x2122; issues, thus being able to better solve them and take them into consideration in the design and construction of its own plants. This is how Eurotherm faced and solved the production problems of Colortec, its own contracting coating firm, currently specialising in anti-corrosion powder products.

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FOCUS ON TECHNOLOGY

n the surface treatment sector, it is rare to find a manufacturer

corporate structure,” explains Eurotherm CEO Paolo Ghiazza, “gives

of painting systems with a division devoted to contracting coating

us the ability to identify the production difficulties of any paintshop,

activities, as is the case with Eurotherm, a company that has

solve them, and then take them into account in the design and

specialised in the construction of complete industrial coating lines

construction of our systems.”

for over fifty years. In 2009, it acquired contracting business Colortec

Colortec’s first plant was implemented and improved with the

(Volpiano, Turin, Italy)1, thus transforming it into an international

technical measures described in an article published on the ipcm®

benchmark powder coater that treats not only its own plants’

issue of January 2018. The second plant owned by the company,

components, but also medium and large-sized parts for companies

however, had some critical problems in terms of cycle times and

from the most diverse sectors, including machine tools, furniture,

quality results. “When we decided to intervene to improve the

outdoor architecture, car wash systems, and elevators. “Such

operation of Colortec’ second line,” says Ghiazza, “together with our technical staff, we thought that this could be the right opportunity to

M. Fumagalli, “The key role of sheet metal preparaƟon in the manufacture of coaƟng systems and outdoor structures” in ipcm® InternaƟonal Paint&CoaƟng Magazine no. 49 (January/February 2018), pages 82-91.

diversify the two plants, thus exclusively devoting the second one to anti-corrosion treatments for galvanised sheets.”

Loading operation: the racks number has been increased from 33 to 39.

Loading area and pre-treatment plant.

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117

The coating line’s critical issues “Most of the workpieces treated by Colortec,” notes Ghiazza, “require

A solution integrating a new pre-treatment and coating cycle

a two-coat system, including a primer and a top coat. Therefore,

The revamping of the plant entailed the integration of an osmosis

after the initial surface cleaning and preparation phase, our cycle

system for the production of high quality water for rinsing, a no-rinse

continued with the primer application and the curing phase at

passivation tank in the pre-treatment line, a PVC sandwich booth for

140 °C. Afterwards, the two-rail conveyor’s bar returned to the

the base coat application, and an RHT gelling oven (at about 900 °C),

starting point and the parts were subjected to a second finishing

supplied by Infragas Srl (Turin, Italy) and located before the top coat

process, excluding the cleaning operation. Considering that the load

application booth. “In order to improve our pre-treatment process,

bar could support 33 racks and that a cycle lasted for 5 minutes, our

we followed the advice of Chemtec (Corbetta, Milan, Italy), a company

operators were only active for three hours out of six. This was an

specialising in the production of chemical products for industrial

issue not only in terms of production, but also of staff management.

surface treatments and already one of our trusted partners for

Moreover, the system has been designed to accommodate only one

solving the problems encountered with the first Colortec’s system,”

booth: therefore, it was difficult to improve also for space reasons.

says Ghiazza. “Thanks to the technical measures suggested by

Last but not least, its 3-stage pre-treatment cycle, which included

Chemtec, we achieved the good cleaning results we expected without

cleaning, phosphodegreasing, and rinsing, did not meet our paint

revolutionising the original configuration of the system. This can be a

adhesion requirements.”

Sandblasting plant with stainless steel grits.

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FOCUS ON TECHNOLOGY

Efﬁcient and reliable

considerable advantage for any contractor with little space available and facing cleaning problems similar to ours.” The critical issues related to process times were solved with the use of AkzoNobel’s dry-on-fused coating system, which allows applying the powder finishing layer on the still hot primed substrate, thus eliminating the intermediate cross-linking step.

solutions for surface coating since 1988.

The new coating process In addition to the line integrations described above, Colortec also installed an automatic belt sandblasting system provided by Cogeim, thus implementing a complete, traditional anti-corrosion coating cycle including as follows: • sandblasting with stainless steel grits • 5-stage pre-treatment: cleaning, phosphodegreasing, rinsing, osmotic rinsing, and no-rinse passivation + drying

electrostatic systems for liquid painting

electrostatic systems and spraying booths for powder coating

pneumatic systems for high-, medium-, and low-pressure painting

IR and UV drying systems

robot and reciprocators

CM SPRAY s.r.l. www.cmspray.it

eosmarketing.it

From right to left: Booth for application of primer, IR oven for gelation and application of top coat.

• application of the zinc-rich powder primer • gelation in the IR oven • application of the powder top coat.

The advantages of the new coating cycle “We can now perform a full cycle in just three hours, thus halving our process times and freeing up a work shift to coat other products,” indicates Ghiazza. “Such a system has considerable advantages also in terms of savings, because the coater has to bear only the costs of powders and of the gas used in the gelling oven. Finally, whereas the first Colortec plant can treat large parts (with a maximum dimension of 7.5 x 4 x 3 m) in small batches, this second, enhanced system will be devoted exclusively to the application of anti-corrosion powder coatings on medium-sized components (3 x 1.80 x 1 m) even in large batches. We have already increased the number of our racks, adding 6 to the existing ones. This gives us a significant competitive advantage in our area, as only a few coating contractors in Northern Italy offer anti-corrosion powder treatments.”

Conclusions Colortec’s objective is becoming a benchmark company in the anti-corrosion coating field, not only in Piedmont, but also in the neighbouring regions. “In Southern Italy, due to the harsher climatic conditions related to the proximity to the sea, most structures exposed outdoors are treated with anti-corrosion systems including several layers; our customers’ awareness in the North, on the other hand, is still limited. Recently, we have even had to refuse orders from public bodies requesting inadequate systems for structural elements such as road barriers. Colortec does not just want to fill a void in the anti-corrosion powder coating market, but also © Eurotherm

Application of the powder top coat.

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offer quality systems obtained with optimised processes: this is the winning formula for any coating contractor.”

ANALYSIS

“Fill the line”: A Modern Production Philosophy to Boost the Efficiency of Your Coating Line Edited by HangOn Hillerstorp - Sweden

"Be more efficient” is the mantra of our time in the industry. However, do you know what “Coating efficiently” really means? With “Fill the Line” HangOn has developed a denser hanging technique that can make a coating line more efficient and profitable with a potential 50% reduction of the total coating costs, according to the type of installation, and specific customer case.

“B

e more efficient” is the mantra of our time in the industry.

In an industrial complex, it means to minimise costs for the same

Efficiency is defined as the ratio between the result obtained

results or maximise results for the same costs. That is to say, a good

and the resources used to obtain that result. In the changed

use of time, energy, materials and labour in a way that does not waste

reality we are currently living in, it is important to send a message for

any.

efficiency to companies that are struggling with markets uncertainty.

On a coating line, hanging density is the first factor to make the coating

However, do you know what “Efficiency in production” really means?

process more efficient, more profitable, and less labour-intensive

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ANALYSIS

with an investment that is low compared to the savings that it allows. Being active on 40 different markets and with thousands of customer projects completed every year, HangOn knows that many coating lines are not profitably used. By improving hanging density, a company can achieve savings up to 50% of the total coating costs and increase its output 5 times. The concept of “filling the line” is a modern production philosophy related to lean manufacturing practices that should be the overall mind-set operating a coating line. Actually, fixed coating costs as investments for the installation and energy consumption are becoming every day more expensive: a good hanging density is a part of a strategy to increase the profitability of a coating line. With its smart hanging solutions, HangOn puts efficiency on the coating line. Creating smart and more efficient solutions for coating lines is our speciality. At HangOn know-how and industrial coating process experience run deep, which means that we quickly find the smartest solutions that give you the best result: a smart change today, for a stronger efficiency tomorrow.

Fill the line: how to? At HangOn to “fill the line” means to maximise the number of correctly coated products per hour. To implement this production philosophy, you first have to measure your process productivity (that is, the OEE – Overall Equipment Effectiveness) which, from a theoretical viewpoint, is a well-accepted measure.

Productivity losses can come in many different forms in a coating line and the first step is to understand what they are. This is not a widespread practice in the coating business yet but estimations can work to analyse where the potential for improvements is. OEE calculation answers two big questions: 1. Am I using the equipment in an effective way? 2. Where do I have to take action to improve equipment effectiveness? OEE is one indicator of the TPM (Total Productive Maintenance), a tool of the Lean Manufacturing philosophy. Within the TPM, a tool called the “Six Big Losses” can be of great help. A machine (or production line) does not produce values if one of the following losses occurs: • Breakdown • Changeover • Minor stops • Reduced speed • Scrap, rework, yield

• Start-up losses.

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The “Six Big Losses” can be grouped in three categories: Availability,

Hanging density: chain hanging vs HQC

Performance and Quality.

During two webinars hold on September 24 and October 1, HangOn will

Painting and coating companies seldom measure the OEE and lean

show its customers how to analyse and understand the efficiency in a

initiatives in this industry are rare and difficult. Nonetheless, after

coating line with lean tools as the OEE-measure and Six big losses. The

conducting an analysis of the six big losses in a coating line, it is

impact and importance of filling the line will be demonstrated through a

HangOn’s experience that often the speed factor stands for the biggest

practical case where a typical daisy chain hang situation with hooks will

potential for improvement by increasing hanging density.

be compared using a HQC - one of HangOns products in the quick series. In addition, HangOn technicians will give general tips about hanging

This is where the “fill the line” production philosophy is grounded.

solutions for typical coating situations.

HangOn has developed a calculation tool based on full coating line data

In displayed case using HQC – HangOn Quick Centre levels – saves 38%

where the effect of different productivity measures can be calculated.

of the total coating costs and coating 2.5 times faster compared to

By inputing 6 different parameters regarding the coating line and by

traditional daisy chain hanging, achieving a higher production efficiency.

analysing product assortment, the method calculates energy, labour,

The HQC is flexible (different hanging levels are available according to the

powder coatings and fixed line costs plus the cost per hanging point.

type of pieces to be hanged); it can be pre-hanged, thus saving coating

This allows the customer to develop an improved hanging strategy

line time and handling costs; it leaves minimal hanging marks on the

and calculate its saving effect. HangOn calculation method, though, is

coated parts and it allows for compact transport and storage of hangers.

so detailed and analyses so many different parameters that it can be

Based on the practical case HangOn will also show the great earnings

efficiently used to calculate the effect of other improvements of the

potential of using free capacity coming from filling the line.

installation, like adding more spray guns or introducing a powder with a higher quality.

Smart thinking is never stupid. HangOn focuses on small solutions that

At a later stage HangOn calculation model will come as an easy-to-use

make a big difference for your business. What you do with the resources

version for the public accessible on HangOn web page.

saved, well, that is up to you.

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eosmarketing.it

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INNOVATIONS: PRESENT&FUTURE

A Low-Consumption Super Chain for the Green Conveyor of the Future From an interview with Matteo Roda Orbita Srl, Cesana Brianza (Lecco) – Italy

info@orbita.it

As a specialised manufacturer of high-quality chains and bearings for conveyors, Orbita Srl has launched an advanced line of chains with special steel ball bearings that lower the coefficient of friction and a new type of chain that does not require re-lubrication. The combination of these two innovations allows creating a super chain with reduced energy consumption.

riction is one of the factors that most affects the transport

European leaders in the sector, has developed two innovative projects

efficiency of a conveyor. The variation of the chain’s friction

aimed at reducing the coefficient of friction of bearings and eliminating

coefficient as a function of its forward speed is one of the main

the need for chain re-lubrication.

causes of the problems encountered by users. Such friction coefficient

A young team has given new life to the company

common and most critical phenomena is the so-called “wobble”, that is,

Orbita is a family business, managed by brothers Massimo and

the irregular and jerky advancement of the chain. As a result, in order

Andrea Roda and by their sons, Matteo, sales manager who has

to maintain the efficiency of the system, the bearings integrated in the

already working in the company for several years, and Giacomo, who

chain must be continuously lubricated. Starting from this assumption,

thanks his linguistic mediator training has starting to manage relations

the technical team of Orbita, a company established in 1962 for the

with foreign customers. Matteo and Giacomo represent the third

production of chains for overhead conveyors and now one of the

generation working in the company.

variation, in turn, may result into several issues; one of the most

The super chain developed by Orbita.

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INNOVATIONS: PRESENT&FUTURE

Matteo Roda, “there has been a

Low maintenance: the new conveyor without re-lubrication

significant generational change within

The dripping of oil and grease on the

our production department. A few

components to be painted, caused by

long-standing employees holding key

the need for frequent chain lubrication

positions in our workshop have retired

operations, is a well-known problem

and a group of young people, with an

for coaters. “Two years ago, Orbita

average age of about 30, has replaced

conceived a system, currently still under

them. These employees, on the other

testing, which does not require any

hand, have been working with us for a

re-lubrication interventions. This has

long time and they are perfectly familiar

a double advantage: on the one hand,

with both our manufacturing processes

it avoids any contamination of the

and our products. Therefore, they have

workpieces hanging from the conveyor’s

managed to quickly establish an excellent

frames and, therefore, any need for

relationship not only with each other, but

reworking phases; on the other hand, it

also with suppliers and customers.” The

reduces the consumption of lubricating

two innovations that Orbita is currently

products such as oils and grease, thus

patenting and launching on the market

reducing the environmental impact of

were born precisely from the synergy of

these substances. In addition to greater

this new team.

conveyor efficiency, this also guarantees

“In the last three years,” acknowledges

greater production capacity, thanks to

The reduction of the friction coeﬃcient of bearings

Some Orbita’s team members.

the reduction of scrapped contaminated parts, and greater environmental sustainability.”

“We have implemented a new ball bearing machining method,” explains Roda, “which

Detail of the chain.

substrates. Thanks to this particular

Orbita’s super chain: faster, more productive, and more environmentally friendly

combination, our R&D centre has found

“Our next goal,” states Roda, “is to

the optimal solution to make the bearings

combine these two innovations into one

roll more smoothly, especially in the most

system, a “super chain” that represents

critical areas of the chain, such as curves,

an absolute novelty for our sector. With a

climbs, and descents. The chain’s traction

low coefficient of friction and without the

force is reduced because the conveyor

need to re-lubricate the chain, it is faster,

combines a mechanical and a surface treatment process on the special steels

encounters less resistance, thus becoming faster and therefore more productive

more productive, and more sustainable overall, thanks also to a reduction in

and, at the same time, using less energy

maintenance costs. One of our most

resources to operate. This is a crucial

important customers is currently

element, especially in the coating industry, which is one of the most

testing the chain developed by Orbita. At the moment, they are very

energy-intensive ones.” This innovative technology has been applied

pleased with it: despite the higher initial investment, as the chain

on the bearings that account for 80% of Orbita’s production, that is,

has some more complex and, therefore, more expensive technical

those with a diameter of 37, 40, and 45 mm. However, it can also be

characteristics, they are convinced they have made the right choice

used on components intended for smaller chains, such as those with a

and they fully trust our work.”

diameter of 28 mm. “We have already built a system conceived in this

We will not have to wait long for the conveyor of the future to

way, which is already in operation at one of our customers’ plant.”

become a reality.

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BRAND-NEW

New Intelligent App-Based Control System for Paint Facilities Ventherm A/S planned to launch a new App containing an intelligent and unique control system for the company’s paint facilities at PaintExpo in 2020. Now the App is complete and therefore it’s recommended to customers and partners around the world.

entherm A/S, a Danish company which over the years has

App contains brochures and other relevant information, it is available for

gained an international market-leading position in spray booths

iOS and Android and provided in 4 different languages including English

and other painting and surface treatment solutions, designed a

and German.

new intelligent App-based control system for paint facilities. The new

Rune Lund, Sales Manager and Co-Owner at Ventherm A/S, states:

App allows monitoring and operating the Ventherm’s paint facilities

“We are very happy and proud of this new product, and we hope our

directly on a smartphone. That applies for operators, management

customers will be happy about it as we receive very good feedback

and others interesting in following the daily operations, provided they

from the test-customers. The main target with our new App is to build

use version 2020 of Ventherm’s control system. The same functionality

a closer bond to users and make sure that daily operation of the paint

is also available on PC, which provides the added benefit of offering

facilities runs as smooth as possible. We are also sure our customers will

immediate and cheap online service and support for the customers

experience that service and predictive maintenance is provided before

regardless of geographical location.

any problems occur. Finally, we hope that they will have a different, more

The Ventherm App also contains a tool for dimensioning of paint

modern and positive user experience of their paint facility”.

facilities. This tool is very convenient for those who are most likely not aware about applicable standards for paint facilities. Furthermore, the

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For further information: www.ventherm.com

BRAND-NEW

EcoPaintJet: The New Painting Method by Dürr Available for All Industries Dürr has developed EcoPaintJet, a new technique that allows paint application over large areas or in simple patterns with high edge definition and no overspray. The technology is now available for the general industry in an easily integrated set.

o provide a solution that allows to paint diverse components with greater efficiency without waste, Dürr has developed EcoPaintJet, which allows the

application of paints over large areas or in simple patterns with high edge definition and without overspray. The new applicator, which has won this year’s innovation award “Deutscher Innovationspreis”, is part of the new overspray-free application set from Dürr. EcoPaintJet is already used in automotive series production and has made it possible to paint car roofs in contrasting colours with no masking. Now, it is also available for other industry sectors, such as woodworking, shipbuilding, electronics manufacturing, and many others.

More options for painting The EcoPaintJet applicator delivers precise coating with no overspray. This increases coating efficiency and offers companies more options when it comes to product design and the transportation of goods. Instead of adhesive film, decorative surfaces can be protected for transport through the targeted application of a spray film. This can be simply pulled off again at the destination. The technology also enables new options for the function and design of products. “The overspray-free application set enables application with high edge definition, fast color changes, and a custom surface design,” says Holger Beiersdorfer, Vice President Industrial Products at Dürr, in summarizing the benefits.

Overspray-free application The most important component in the overspray-free application set is the paint supply, combined with the cleaning and pre-painting process. The EcoPaintJet controls © Dürr Systems AG

The EcoPaintJet applicator increases painting eﬃciency and oﬀers companies more options when it comes to product design.

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this using three valves. The beating heart of the applicator

BRAND-NEW

itself is a nozzle plate that produces several dozen parallel paint jets depending on the design. These can be activated or deactivated at any given moment to start or interrupt the coating process. Unlike painting processes involving spray guns or high-speed rotary atomizers, this process does not require any atomizer air. The overspray that must be filtered from the booth air in a complex process when using conventional methods therefore does not occur. The width of the painting path can be adjusted by means of the applicator’s angle of application. The desired coating thickness is controlled via the applicator speed and solid content of the paint. The new Dürr technology makes painting faster, more cost-efficient, and more environmentally friendly in all industry sectors. “This makes our technology attractive even in scenarios where an automated painting method was not previously conceivable,” says Holger Beiersdorfer.The Austrian paint manufacturer Adler is promoting the new application technology together with Dürr, coming up with colourless and pigmented coating solutions that, in addition to the usual paint requirements, are precisely tailored to the special features of this technology. “For this visionary application technology, we developed innovative and environmentally friendly, water-based products that deliver maximum durability and at the same time visual individuality for more than just sheet material,” says Albert Rössler, CTO at Adler. For further information: www.durr.com

Precise painting paths enable surface painting and coating with high edge definition.

vertical&horizontal axis reciprocators | color centers dimensional detection systems | control panels | accessories

www.reind.it

i gent asi a libere c r e c one z per

RAW MATERIALS

Promoting Flow and Levelling with Evonik Superwetters Jos Van Oosterwijk Evonik Operations GmbH – Essen, Germany

jos.vanoosterwijk@evonik.com

Evonik designed a superwetters’ series in order to improve flow and levelling in both waterborne and solvent-borne coating systems, the DYNOL™ superwetting surfactants.

he superwetter portfolio from Evonik Operations GmbH has

improve the appearance of their vehicles to appeal to the

been on the market for several years and consists of the

ever-changing demands of their customers.

following products: DYNOL™ 604, DYNOL™ 607, DYNOL™ 360,

As illustrated in Figure 1, superwetters offer a combination of low

DYNOL™ 800, DYNOL™ 810, DYNOL™ 960, and DYNOL™ 980. The

dynamic surface tension (DST) and low equilibrium surface tension

latter two products are siloxane-containing, while the other products

(EST), hence providing an advantage over fluorosurfactants or

in the range are siloxane-free. DYNOL™ 360 offers the additional

traditional siloxane surfactants. This ability to lower both equilibrium

benefit of promoting coalescence in waterborne systems by lowering

and dynamic surface tension is what makes our superwetters

the MFFT (minimum film-forming temperature). Originally designed

suitable for improving flow and levelling.

to promote wetting on difficult-to-wet substrates (such as plastics

This article focuses on the performance of our superwetters and the

and contaminated metals), these products can be used to promote

effect they have, not only in the automotive coating layer in which

flow and levelling in both waterborne and solvent-borne coating

they are used, but also on consecutive coating layers.

systems. This is of particular interest for automotive coatings,

The combination of the ability to lower both EST and DST also helps to

because car manufacturers are constantly looking for ways to

prevent what is known as telegraphing (or ghosting), i.e. the visibility of

Figure 1: Positioning of Evonik superwetters.

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Figure 2: Eﬀect of (super)-wetters on LW and SW in a WB basecoat (values with a 2K PE clear coat).

RAW MATERIALS

wipe marks or sanding marks in the final layer of the coating system. Our superwetters also offer the possibility to meet the

SIMPLIFY COATING.

ever-increasing demands of OEM manufacturers to decrease the long- and short-wave (LW and SW, respectively) values of their coatings. DYNOL™ 960 and DYNOL™ 800 are especially effective in lowering both long-wave and short-wave values of the 2K PE clear coat applied on top of the waterborne base coat (Fig. 2). In this experiment, the thickness of the base coat is approx. 12 microns and the thickness of the clear coat is approx. 40 microns. Another important thing to note: It is possible to effectively lower the layer thickness of the clear coat while still obtaining very good flow and levelling results and high gloss values. The same effect is observed when adding the additives to the

Your information and management platform for simpliﬁed coating 4.0.

clear coat; by promoting wetting of the surface, flow and levelling is enhanced which enables the formulator to achieve excellent long- and short-wave values even at lower layer thicknesses. Figure 3 shows the results obtained with a 1K acrylic clear coat at a layer thickness of 35 microns. As shown, DYNOL™ 980 effectively improves flow and levelling of the clear coat.

Conclusion The use of superwetters is a very effective way to improve flow and levelling (even at lower layer thickness) in solvent-borne coatings. Superwetters can be added to either the base coat or the clear coat. In both cases, the formulator will see an improvement.

Figure 3: Eﬀect of wetting agents on LW and SW in a 1K acrylic clear coat.

wagner-group.com

ART WITHIN SURFACES

“Sguardi Oltre l’Orizzonte”: Giving Body and Colour to Dirt “Sguardi oltre l’orizzonte” is the work of art that Enrico Sioli donated for the auction held during the event ‘Art Within Surfaces’, organised by Eos Mktg&Communication on its 10th anniversary, last year. © ipcm

“T

he desire for freedom lives in each of us. It is like a bird that is always waiting to take flight. Sometimes, you are unable to feel its presence. Sometimes, it

is so cumbersome that you cannot help but feel its weight. Look, it is there, inside of you.” This is how Enrico Sioli, an entrepreneur, manager, and representative of a leading international insurance and financial Group, interprets his work of art titled “Sguardi oltre l’Orizzonte” (Gazes beyond the horizon). Sioli has always loved expressing himself through art, and in particular, for some years now, through the ancient technique of Raku pottery. “Sguardi oltre l’Orizzonte”, created in 2012, was presented at the exhibition “Terra del Corpo” on the Italian Memorial Day of the Exiles and Foibe. The sculpture consists of a bust with a bird in the centre (65 x 40 cm). It is made of clay with the hand-moulded plate technique, coloured with crystalline powder and oxides, and treated with the Raku baking technique. Raku is a baking technique of Japanese origin, conceived in harmony with the Zen philosophy and able to enhance the harmony of small things and the beauty of the forms’ simplicity and naturalness. The origin of Raku is tied to the tea ceremony: a ritual performed with humble objects, focussed on the cup the guests exchanged; its size was such that it could be contained in the palm of a hand. The core of Raku is the contact with the matter and the elements, Earth, Water, Air, and Fire – unique, one-in-a-million objects, as in nature. The use of this art entails a demanding choice: giving body © ipcm

and soul to an idea through soil. According to the Holy Scriptures, “man took shape from clay”. There is something mystical and at the same time earthly about handling soil: the sublimation of the idea and the materiality of the mixture, the realisation of a dream and the concreteness of

Enrico Sioli and its work of art “Sguardi oltre l’Orizzonte”, which he has showed during the event ‘Art Within Surfaces’.

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giving body and colour to dirt.

Your perfect cleanliness. 4/5

We care. Interoperational cleaners

dn-chemicals.com

ART WITHIN SURFACES

The Perfect Combination of Art, Industry, and Technology: Creativity through a Coating Robot Monica Fumagalli ipcm®

We interviewed Luca Maitan, the entrepreneur from the surface treatment sector who was able to see beyond the productive function of a coating robot and made it the protagonist of the creation of some works of art.

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ART WITHIN SURFACES

reating an artistic work with a coating robot: this is the

revolutionary idea of Luca Maitan, the General Manager of Varnish Tech Srl, with over thirty years of experience in the

surface treatment industry. Passionate about art, last year he founded Proximars together with designer Davide Vercelli in order to bridge the gap between technology, artificial intelligence, art, and the ways in which artists express their creativity. This start-up broke with the past by launching the first mass-produced works of art, created by a human artist and a robot, that is, a mechanical arm that “interprets” the creator’s perception. One of the first works made with this innovative method, “Caraibi” (Caribbean), was presented during the charity auction organised last year on the occasion of the tenth anniversary of EOS Mktg&Communication, the publisher of the ipcm® magazines. We described it more extensively in an article published on our March issue1. We interviewed Luca Maitan to analyse the reasons that led him to develop the innovative artistic vision behind Proximars and to understand what future he expects for this new form of artistic expression that he defines as “robot art”. Your works represent the ultimate combination of art, industry, and technology. How did you conceive the idea of a coating robot turned into an “artist”? The idea was born after visiting the Guggenheim in Bilbao: immersed in that world of visual perceptions, with an estranged mind, it came naturally to me to associate robotics with art. Can you describe the creation process of these works of art, from the design stage to the end product? How do you select the paints to be applied? I cannot describe the process in depth due to confidentiality restrictions. Basically, the artist’s creativity is translated into a material, mass reproduction process duplicating the work they have especially designed for Proximars. The paints, usually acrylic, are the same used by the actual artists in their work. We chose not to develop special products because we preferred to adapt our process to their habits. Finally, each piece is produced in a limited edition and, therefore, it comes with a certificate of authenticity bearing its author’s signature. Proximars also strives to promote and disseminate this new method for the creation of works of art. How has the public received it? It has received considerable interest, especially due to its product placement, halfway between a work of art and a design object, while

The robot at work for the creation of Andy_BOT, a project by tape artist No Curves.

Caraibi: Varnish Art Studio’s Work is a Fine Example of Robot Art, in ipcm® InternaƟonal Paint&CoaƟng Magazine no. 62 (March/April 2020), p. 73.

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remaining a niche item. We do not yet know if this will translate into purchases and, ultimately, lead to commercial success. How do Proximars’ collaborations with different artists arise? Collaborations start based on mutual knowledge or word of mouth; sometimes, we are contacted directly by an artist. We are currently working with NO CURVES, an internationally renowned tape artist, and we already have other agreements in place with other globally recognised artists. What does it mean for you to be a “visionary”? Seeing something before others, going beyond the horizon, transforming a vision into something tangible, and then sharing it. In September, the first Proximars collection will be

A detail of the spray nozzles for the application of acrylic colours.

made available for sale. What will be the channels through which we can buy the artworks? During the first phase of launching, the artworks © Proximars

will be available on our online shop website www.proximars.com. We are also evaluating the use of crowdfunding platforms, which are powerful accelerators, even if personally, although Proximars is a form of expression that is halfway between art and design, I don't think this instrument is the most suitable for such sector. In any case, precisely because of this innate cross-sectoral feature, we believe that Proximars can find its own place in more than one commercial channel, and therefore both online and in a physical store. It is also important to remember that our artworks, in addition to being beautiful and having an affordable price, are 'made in Italy', which is much appreciated internationally. Besides the launch of the first collection, what

Scan the QR code or click here: www.rb.gy/wdzzif

other projects Proximars has in store for the future? We have many projects in the pipeline, including new collections and collaborations with international artists that will complement the existing one. You can follow the website and the Facebook and Instagram profiles

A stage of the work creation process.

to stay up to date on all the news. This is just the beginning!

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INNOVATIONS: PRESENT&FUTURE

Efficient and Fully Automatic Finishing of Internal Passages Manuela Casali Rösler Italiana S.r.l., Concorezzo - Italy

©R ös ler

Ita lia na

m.casali@rosler.com

Additive Manufacturing allows the integration of precisely placed internal cooling channels into components. With the focus on automated post processing - removal of residual powder and surface smoothing of these channels the mechanical and chemical engineering departments of the Politecnico Milano (Italy) together with Rösler Italiana S.r.l. conducted a study with the surface treatment methods mass finishing, shot blasting and chemically supported mass finishing. The results clearly demonstrated that with all three methods a significant improvement of the overall surface quality could be achieved.

S.r .l.

ith Additive Manufacturing (AM) advanced component geometries can be produced that are not possible with conventional manufacturing technologies. Among

other things it allows the creation of highly complex components with integrated functional features such as precisely placed cooling channels. These unique AM characteristics are of great interest for tool and die making, hydraulic components and the aerospace industry. Especially for the tool and die making industry the integration of cooling channels offers significant technical advantages, because temperature fluctuations during the cool down phase increase the risk of work pieces getting warped. Moreover, with a cooling system following the contours of a component, overall cool down times can be decreased considerably. Finally, because work piece faults like warping and Prototype manufactured with AM.

heat checks can be prevented, a more effective cooling function for injection molded components results in a higher overall component quality.

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INNOVATIONS: PRESENT&FUTURE

The SLM 3D printing method is ideal for the manufacture of tooling components.

Selective Laser Melting – Perfect shape but high surface roughness

Since the internal surface areas of complex components with integrated

For the production of tooling components “Selective Laser Melting” (SLM)

innovative post processing methods are required.

is the primary manufacturing method. The creation of a component by

The choice of the most suitable surface finishing system is therefore

selective melting of the powder in defined layers by a laser beam results

critical for the service life of a component and the overall efficiency of a

cavities cannot be treated with conventional finishing technologies, new,

in an extremely dense work

system. One option for smoothing

piece. The downsides of this

the external and internal surface

manufacturing method are

areas of AM components is mass

that residual powder must

finishing. During the finishing

be removed from the cooling

process the work pieces are

channels and the high initial

immersed into a circular work

surface roughness of the

bowl filled with special processing

components with Ra values

media. In addition, dedicated

between 10 and 20 μm. A high

compounds are added during

surface roughness as well as

the process. The vibration of the

the powder deposits in the

work bowl causes the media and

channels negatively impact

work pieces to move around the

the functionality of the work

bowl in a spiral movement. The

pieces resulting in reduced

constant “rubbing” of the media against the work pieces produces

flow rates due to high friction, turbulences, pressure loss in the system and loose particles that can damage other equipment.

The trials were conducted with diﬀerent geometries containing inner passages with diameters of 3, 5, 7.5 and 10 mm.

a grinding/smoothing effect resulting in the desired surface quality.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

141

The surface of tooling components contains residual powder from the AM process and shows a high initial roughness.

Mass finishing allows the eﬃcient smoothing of internal channel surface areas

mass finishing. All three surface treatment systems produced surprisingly

To evaluate different treatment methods, among them mass finishing,

removed the roughness peaks and produced similar surface roughness

for smoothing of the external and internal surface areas of AM

profiles. However, the best results were achieved with chemically

components, the mechanical and chemical engineering departments of

supported mass finishing: the work pieces had the smoothest surface, as

the Politecnico Milano (Italy) together with Rösler Italiana S.r.l. conducted

shown in comparatively lower surface roughness readings, and displayed

a comprehensive study. This involved the treatment of parts with different

the typical chemically accelerated finish. With Ra values of

shapes and internal passages with different diameters (3, 5, 7.5 and

0.7 μm the chemically supported mass finishing method produced not

10 mm) with mass finishing, shot blasting and chemically supported

only the lowest surface roughness values, but it also required the shortest

similar results. Conventional mass finishing and shot blasting consistently

The treatment of parts with mass finishing, shot blasting and chemically supported mass finishing.

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INNOVATIONS: PRESENT&FUTURE

hi-tech

www.cmautomazione.it

conveyors

Final roughness values in the vertical and horizontal internal passages.

cycle time. The results also showed that the final

will not only allow the effective and targeted

roughness values were more or less identical in

treatment of internal passages in the future,

the vertical and horizontal internal passages.

but it will also be a fully automated system for

The study also proved that mass finishing can

consistent finishing of 3D printed components

create the required smoothing effect on the

without any manual work requirements. Of

internal surface channel areas without affecting

course, the loading and unloading of the work

the channel geometry. The treated surface areas

pieces can also be automated with a robot. The

were free of powder “splatters” and loose powder

precise dosing of grinding media and compound

remnants. All three treatment methods improved

with a special replenishment, respectively, dosing

the surface roughness readings on the internal

system and the equipment “Start” function can be

channel areas. However, as already pointed out,

also fully automated. Depending on the surface

chemically supported mass finishing produced the

finish requirements several grinding and polishing

best results in the shortest cycle time.

processes can be run in sequence. If required, a separate cleaning and drying stage can be added,

Fully automatic processing in one machine

of course, also fully automated. The same is true

The tests were conducted on a prototype of

to subsequent manufacturing stages. The system

a new concept machine from AM Solutions.

controls allow the storage and call-up of multiple,

The latter is a brand name of the Rösler group

work piece specific processing programs. The

that has specialized in the post processing of

process parameters for the various work pieces

3D printed components and offers a range of

can be selected by simply pushing a button or with

suitable equipment solutions. These include the

a work piece recognition system.

complete spectrum of post processing functions

To date internal work piece passages that are

like unpacking, removal of support structures,

difficult to reach could not be processed at all,

removal of residual powder, surface cleaning and

or only with a high degree of manual labor. The

smoothing, edge radiusing, high gloss polishing

automated post processing of AM components

and surface preparation for subsequent coating of

now allows doing this work within short cycle

AM components.

times at a fraction of the costs and, above all, with

The further development of the existing system

consistent, excellent finishing results.

for the work piece handling including the transfer

CM AUTOMAZIONE srl - FA Ganci

Via Monte Bianco 20 - 20833 Giussano (MB) - IT p. +39.0362.314075 - f. +39.0362.861222 info@cmautomazione.it

ART WITHIN SURFACES

Artist Sacha Jafri is Attempting to Break a World Record Using AkzoNobel’s Dulux Products Artist Sacha Jafri is attempting to create the largest painting ever created on canvas for its Humanity Inspired project and he is using AkzoNobel’s Dulux paints.

afri’s Humanity Inspired project, which aims to raise $30 million for

change through the hearts, minds and souls of the children of the

charitable causes within health and education, consist in creating

world – a springboard for a better future for all humanity. I aim to

a 160 meters long painting (larger than two soccer pitches laid

connect the world and re-connect humanity to ourselves, each other

end-to-end). For this project, the artist is using AkzoNobel’s Dulux

and ultimately the soul of the Earth. I’m delighted to have the support

products.

of Dulux and AkzoNobel in this record-breaking project, which has

He started his artwork, entitled The Journey of Humanity, when he

been called the largest artistic, social and philanthropic initiative in

was in lockdown for the COVID-19 outbreak, at Atlantis, the Palm

history”, added Sacha Jafri.

in Dubai, asking children around the world to send him drawings

Jafri’s project is being supported by Dubai Cares, UNICEF, UNESCO

themed around isolation and connection. These drawings, which Jafri

and the Global Gift Foundation Charity, and backed by the UAE

will paste into circular portals inside his painting, will act as windows

government.

intended to lead us to a better tomorrow, as seen through the eyes of

Once the work is completed, the canvas will be split into 60

our children.

individually framed, numbered, signed and catalogued artwork pieces

“We’ve always believed that paint has the power to transform

and sold via an online charity auction.

people’s lives and this is a fantastic way for us to support an amazing

Jafri – called “The Pioneer of Magical Realism” – is one of our most

initiative through our global ‘Let’s Colour’ program,” said Stephanie

celebrated living artists, whose work is owned by the likes of

Kraneveld, Global Marketing Communications Manager Paints. “The

Barack Obama, Bill Gates, George Clooney, Leonardo DiCaprio and

Humanity Inspired project aligns perfectly with our own commitment

Madonna.

to inspiring communities through colour and we’re delighted to have

The program AkzoNobel’s global “Let’s Colour” was launched in 2009.

an exclusive partnership with such a visionary and exciting artist.”

More than 2.000 projects have been completed to date, bringing

“My initiative, Humanity Inspired, aims to be a catalyst for true societal

positive benefits to well over 68 million people.

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N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

NOVITÀ

NEW NEUHEIT

TMCOAT

CATENE AD ALTE PRESTAZIONI

HIGH PERFORMANCE CHAINS | LEISTUNGSFÄHIGE KETTEN

con | with | mit TMCOAT

senza | without | ohne TMCOAT

Resistenza alla corrosione Corrosion protection | Korrosionsfestigkeit Durata alle alte temperature Life-time at high | Beständigkeit gegen temperatures | hohen Temperaturen Autolubrifcazione Self lubriﬁcation | Selbstschmierung Produttività Productivity | Produktivität

T.M.C. srl

Particolare are dei cuscinetti cuscinet et con TMCOAT O Detailil off b D bearing i with i h TMCOAT CO Ausschnitt der Lager mit TMCOAT

LESS

Aspetto dopo 200 ore in nebbia salina Surface after 200 hours of salt spray test Aussehen nach 200 Stunden in Salzsprühtest

STANDARD & LEGISLATION - UCIF Informs

The Impact Assessment Study on the Revision of the Machinery Directive Has Been Published Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

info@ucif.net

he European Commission has published

could generate an increased risk and create

decrease the number of non-compliant products

its Impact Assessment study on the

an uneven market, with some industry players

on the market; the adaptation and clarification

revision of Directive 2006/42/EC on

implementing stricter product requirements

of the list of low-voltage products excluded from

machinery. This was conducted to support the

than others. This section also explores problems

the directive’s scope; the improvement of the

impact assessment process of the possible

and risks related to networked machinery

definition of “partly completed machinery”; and

revision of the Machinery Directive. In other

and risks deriving from connectivity issues,

consent to the use of digital or partially digital

words, its scope was to assess the impacts of

collaborative robots, artificial intelligence and

formats for instructions, in order to reduce

the different policy options identified in view

machine learning, software and its related

environmental and printing costs.

of choosing the most cost-effective policy

updates, and cybersecurity. In particular, with

option that ensures a high level of health and

regard to the latter, a number of risks related to

Policy Option 3: Modifying Annex IV

safety. The study concludes that, overall, the

interconnected machinery are considered. The

One of the sub-options is the removal of the

Machinery Directive is fit for such purpose,

most often cited aspect to address cybersecurity

need for internal manufacturing checks on Annex

but implementing different revision options

are control systems. It also often noted that

IV products (self-declaration by the manufacturer

might potentially improve its effectiveness and

horizontal legislation on cybersecurity based on

when existing harmonised standards are fully

efficiency. Here below, we summarise the main

the New Legislative Framework (NLF) would be

complied with).

aspects analysed by the assessment and its

needed, as this issue goes beyond the machinery

findings.

sector’s boundaries. The Cybersecurity Act is also

Policy Option 4: Conversion of the directive

mentioned as a good starting point for further

into a regulation

Policy Option 1: Addressing new challenges

regulatory developments, in the event that these

Such conversion is widely recognised as

posed by technological developments by

legal requirements become mandatory.

beneficial, because it would reduce any delays in the national transposition processes and any

adapting the essential health and safety requirements (EHSR)

Policy Option 2: Addressing the problems

differences in interpretation among Member

Depending on the different aspects considered,

identified during the evaluation of the

States, thus lowering costs for the players placing

there are varying degrees of benefits possibly

Machinery Directive

machines on the market.

deriving from such adaptation. The study states

This section also analyses different aspects, such

that addressing the challenges of digitalisation

as the alignment of the directive to the New

The study is available on the European

through the self-regulation of market players

Legislative Framework, which is expected to

Commission’s website.

146

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

TRADE FAIRS & CONFERENCES INTERNATIONAL PAINT&COATING MAGAZINE

MEDIA PARTNERSHIP - ipcm® is present with own booth or press corner

SPECIALIZED EVENT FOR SURFACE TREATMENTS INDUSTRY

OCTOBER 2020 profintech

aluminium

izb

india chem

afribuild

chillventa

fakuma

euro lift north african coating congress vvs dagene

expo coating moscow

148

Brno, Czech Republic October 5-9, 2020

surface technologies September 13-17, 2021

Düsseldorf, Germany October 6-8, 2020

aluminium industry May 18-20, 2021

Wolfsburg, Germany October 6-8, 2020

October 5-7, 2021

March 17-19, 2021

www.afribuild.co.za

ONLINE!

Friedrichshafen, Germany October 13-17, 2020

heating, ventilation, air conditioning, refrigeration www.chillventa.de

plastics processing October 12-16, 2021

Kielce, Poland October 14-15, 2020

www.indiachem.in

building and construction

October 13-15, 2020

www.izb-online.com

chemicals and petrochemical industry

Johannesburg, South Africa

Nuremberg, Germany

www.aluminium-messe.com

automotive industry suppliers

Mumbai, India October 8-10, 2020

www.bvv.cz/en/profintech

www.fakuma-messe.de

elevators and escalators April 28-29, 2021

www.targikielce.pl/en

Casablanca, Morocco

coatings industry

October 14-15, 2020

www.coatings-group.com/nacc

Lillestrøm, Norway October 14-16, 2020

Moscow, Russia October 27-29, 2020

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

heating, ventilation, air conditioning, refrigeration www.vvsdagene.no

surface treatments www.expocoating-moscow.ru

TRADE FAIRS & CONFERENCES INTERNATIONAL PAINT&COATING MAGAZINE

contech vietnam

euroblech

orgatec

construction machinery, mining machines and construction vehicles

Hanoi, Vietnam October 27-30, 2020

Hanover, Germany October 27-30, 2020

http://contechvietnam.com/

ONLINE!

Köln, Germany

sheet metal working technologies www.euroblech.com

working environments

October 27-31, 2020

www.orgatec.com

NOVEMBER 2020 bauma conexpo india big 5 construct kenya indo aerospace

chemshow eurasia

composites europe

eurobuild expo

elmia subcontractor

formnext

New Delhi, India November 3-6, 2020

February 23-26, 2021

Nairobi, Kenya November 4-6, 2020

November 3-5, 2021

April 7-10, 2021

March 11-13, 2021

www.composites-europe.com

Kiev, Ukraine

building and construction

November 10-12, 2020

Frankfurt, Germany November 10-13, 2020

www.chemshoweurasia.com

composites technologies and application

November 10-12, 2020

Jönköping, Sweden

https://indoaerospace.com

fine and specialty chemicals

Stuttgart, Germany

November 10-13, 2020

www.thebig5constructkenya.com

aviation, aircraft and airport technology

Istanbul, Turkey November 5-7, 2020

www.bcindia.com building and construction

Jakarta, Indonesia November 4-7, 2020

construction machinery, mining machines and construction vehicles

www.tech-expo.com.ua/en/eseeng-2020.html

ONLINE!

industrial subcontracting www.elmia.se/en/subcontractor

additive manufacturing https://formnext.mesago.com

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

149

ZOOM ON EVENTS

METEF Reaches its Twelfth Edition and Opens the Registrations for March 2021 METEF, the exhibition specialized in aluminium and innovative metals technologies, will take place in Bologna (Italy) from 25th to 27th March 2021 along with MecSpe.

ew structure, new location and

METEF is more than ever before the ally

footprint green metal. For its continuous

new alliances: this is the METEF of

to create a network of companies in the

recyclability and environmental sustainability

the restart, of the ambition to face

production chains it represents and to ensure

– are going to open a new season. These are

new challenges and the awareness that

immediate and maximum visibility to the

some of the main themes of next

many things have changed. Veronafiere and

exhibitors who are invited to register as soon

METEF, ready to back the rebirth of the

Bolognafiere, two leading exhibition centres in

as possible but postpone the down payment

manufacturing industry according to new

Italy, have established a powerful 50-50 joint

to September as a contribution to attention

paradigms and with new enthusiasm, new

venture to enhance such strategic sectors

and sharing in this difficult moment.

targets and new strategies.

as aluminium and specialty metals as well as

One of the main issues of METEF 2021 will be

“METEF is ready to help in such a crucial

advanced manufacturing on the international

the Green Deal, the project promoted by the

moment for the Italian companies" – explains

market. It will be a rebirth that follows new

European Union to enhance the development

Mario Conserva, President of Metef." The

paths based on the added value of experience

of SME’s and to relaunch the industrial sector

industrial production chains that we’ve been

and foresight. METEF will be held in Bologna

in the Old Continent. Within this context

long representing have extraordinary technical

(Italy) on March 25 through 27 2021 along

aluminium plays a leading role as a champion

expertise and human resources therefore

with MecSpe, reference exhibition for the

of Circular Economy and Environmental

restart is at hand. The market choices will

manufacturing industry and for the smart

Sustainability as shown by the gradual yet

focus on local values and competence, and

factory.

revolutionary passage to this low carbon

the trump card will be the creation of a

network, a simple and already known solution yet not always adopted. The virtuous synergy of associations, companies and sector exhibitions is an opportunity but only when the industrial fabric is as rich, varied, lively and consolidated as ours. We have a higher gear, let’s engage it: we believe in year 2021 to make our manufacturing sector appreciated all over the world.” As always before METEF supports the firms and is ready to adopt no matter what communication tools to give visibility and generate opportunities for the rebirth of the manufacturing industry, especially on the international market, according to new paradigms and with new enthusiasm, new targets and new strategies.

For further information: www.metef.com

150

N. 65 - SEPTEMBER/OCTOBER 2020 - international PAINT&COATING magazine

ZOOM ON EVENTS

SFCHINA 2020 Will Be Either Online or Offline This Year The 33rd edition of SFCHINA exhibition will take place both online and offline at the China Import and Export Fair Complex (CIEFC) in Guangzhou, P.R. China on December 8-10, 2020.

he 33rd edition of SFCHINA exhibition will take place as scheduled in

and will stay online for 60 more days after the physical edition closes on

Hall 5.1, Area A of the China Import and Export Fair Complex (CIEFC)

December 10. Exhibitors and visitors can connect via our virtual platform

in Guangzhou, P.R. China on December 8-10, 2020.

anytime, anywhere, and for an extended period of time. Visitors can

Over 145 exhibitors from 12 countries/regions (as of September 14, 2020)

browse Exhibitors’ Pages, download product information, live chat, leave

have already confirmed their presence and will showcase their products

offline messages, participate in live streaming sessions and concurrent

and services in 3 exhibit zones, namely ‘Electroplating & Finishing

technical programmes, etc. In addition, a ‘Virtual Zone’ will be set up on

Technology’, ‘Environmental, Safety & Protection’ and ‘Coating Applications

the 2020 Guangzhou show floor, where onsite visitors can access and

& Coating Products’. With a history of more than 30 years, SFCHINA is

interact with virtual exhibitors instantaneously.

launching a NEW Virtual Edition in late November. For the first time ever, exhibitors and visitors can both enjoy a unique hybrid experience.

Concurrent technical programmes also going live SFCHINA continues to host technical programmes alongside the

Integrated online-oﬄine exhibition platform

exhibition, including a series of Technical Seminars presented by our

Some exhibitors and visitors, particularly from overseas, may be unable

exhibitors. Technical Seminars are also going live for the first time this

to travel to Guangzhou this year. However, now they can exhibit at or

year, where visitors who are unable to participate in person can join in

visit our brand new Virtual Edition as an alternative way to be present at

webinar format to interact and engage with speakers directly, and to

the annual industry gathering. The Virtual Edition consists of 2 parts: ‘GZ

collect relevant product information, latest technology trends and industry

Show’ section includes all exhibitors who are exhibiting in our Guangzhou

policies online.

Ground Show, whereas ‘Virtual Show’ includes those who are unable to exhibit in the Ground Show and choose to exhibit virtually this year.

For further information:

The Virtual Edition (www.sfchinavirtual.net) is going live in late November

www.sfchina.net and www.sfchinavirtual.net

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2020 - N. 65

151

UNIONE COSTRUTTORI IMPIANTI DI FINITURA

Eos Mktg&Communication srl www.eosmarketing.it - info@eosmarketing.it www.myipcm.com - info@ipcm.it Redazione - Sede Legale: Via Pietro Mascagni, 8 - 20811 - Cesano Maderno (MB) - Italy Tel. +39.0362.503215 - Fax. +39.0362.1794768

EDITORIAL BOARD Dr. Felice Ambrosino: Marketing

Prof. Massimiliano Bestetti:

Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Section of Applied Chemistry and Physics

Kevin Biller

The Powder Coating Research Group

Prof. Stefano Rossi:

Material Engineering and Industrial Technologies, University of Trento - Product Design

Dr. Franco Busato:

European environmental legislation and new technologies

Dr. Fulvio Zocco:

Environment and quality

Prof. Paolo Gronchi:

Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Chemical Engineering Section

EDITOR IN CHIEF / DIRETTORE RESPONSABILE

The smart journal for surface treatments

ALESSIA VENTURI

ISSN 2280-6083

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SPECIAL ARCHITECTURE & DESIGN

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INTERNATIONAL PAINT&COATING MAGAZINE

2020

11th Year - Bimonthly N° 65 - SEPTEMBER/OCTOBER

EDITORIAL DIRECTOR / DIRETTORE EDITORIALE

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