ipcm n. 44 Magazine – March/April 2017 – English Version by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

ISSN 2280-6083

ipcm digital on

www.myipcm.com 2017

8th Year - Bimonthly N° 44 - MARCH/APRIL

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• Steel Bronze 2

A X A LTA C O AT I N G S Y S T E M S

Architectural Pow[d]er Coatings on Stock e!

dat Save the

on! o s g in m o c ICONICA is ctural powder coatings.

archite ighlight in itta. The new h Palazzo L ilan at the M , e il b o el M l, Salone d 4. – 9. Apri

190

RAL colours in architectural polyester

semi-gloss

155

RAL colours in architectural polyester

Picture © svveter|Shutterstock

ﬁne textured

190

RAL colours in architectural polyester

matt

Axalta Coating Systems Italy S.r.l. Socio Unico · Via Roma, 80 20873 Cavenago Brianza (MB) Italia Tel: +39 0 29 59 19 61 powdercoatings.italia@axaltacs.com

190

RAL colours in architectural polyester

gloss

Your local contact can be found at: www.powder.axaltacs.com

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CONTENTS MARCH/APRIL 2017

Cleaning - An Essential Step in the Pretreatment Process

HIGHLIGHT OF THE MONTH

Axalta Discusses Trends and Future of Metallic Architecture

ANALYSIS

30 05 06

FOCUS ON TECHNOLOGY

Quality First. A New Horizontal Coating Plant for Aluminium Profiles: Feal’s Choice to Stay True to its Motto

EDITORIAL ANALYSIS Is Revamping the Solution to Be at the Forefront of Innovation?

12 22 26

BRAND-NEW BRAND-NEW ANALYSIS Technology Interchange: The Powder Coating Summit

42 46

SUCCESS STORIES

Axalta Coating Systems Protects Façade of Turkmenistan’s New Airport

BRAND-NEW

HIGHLIGHT OF THE MONTH

PURAL® ZEROZERO: A Second Generation ZLD Wastewater Treatment (With no Evaporator and Without the Formation of Liquid Sludge)

“Good Lack” – Industry Partner Since 1937

FOCUS ON TECHNOLOGY DFV: A Certified and Guaranteed Coating Process with the Application of the Industry 4.0 Innovations to Aluminium Finishing

INNOVATIONS: PRESENT&FUTURE

FOCUS ON TECHNOLOGY A Diamond Spray Paint Booth for the Selective Coating of Aluminium Profiles: Aluron’s Choice

CONTENTS MARCH/APRIL 2017

JÜRGEN EMPTMEYER: Custom Made Hanging and Masking Solutions for Industrial Coating

FOCUS ON TECHNOLOGY

Uteco Implements a New Coating Plant for the Treatment of Extra-large Complex Items

HIGHLIGHT OF THE MONTH

106 74 78

INNOVATIONS: PRESENT&FUTURE

Strategic Planning: Back to the Business Definition

BRAND-NEW

BRAND-NEW SUCCESS STORIES Ecopaint RoDip – Optimum Immersion Now Also for Vans

Continuous Pursuit of Quality in the Decoration of Door and Window Frames with Sublimation

FOCUS ON TECHNOLOGY Nanotechnology Conversion: High Corrosion Protection for the Aluminium and Iron of Road Signs in One Process

SUCCESS STORIES Paint Systems from R-M® Set the Right Tone for Design Concepts for Electric Vehicles

79 86

114

INNOVATIONS: PRESENT&FUTURE

110

120

Customer Satisfaction Analysis & Management – Part 1

124

FOCUS ON TECHNOLOGY Manual Pre-treatment and Powder Application Processes Combined with a Suitable Hanging System: a Contribution to Flexibility

BUSINESS TRAINING

STANDARD & LEGISLATION - UCIF Informs The Most Frequently Asked Questions About Industry 4.0

128 130

TRADE FAIRS & CONFERENCES ZOOM ON EVENTS

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r te wa te es as l lin e w Coi th m nd fro g a D in t CO oa e) rg nd , C ha l a ing sc , A iz Di , F od id O4 An qu Li e S in o ov ts er m en (Z re tm to ea LD r t rZ gy lo um fo no ini gy lo ch m Te Alu no ch of Te

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INNOVATIVE PRE-TREATMENT SOLUTIONS Pre-treatment is changing. You need solutions that meet the real demands of the industry: efficiency, savings, and most of all, safety. You need solutions that are reliable and adaptable to your operations – not someone else’s. That’s why you need Quaker Chemical. Our new heavy metal free solutions can be tailored to your particular requirements to ensure not only excellent corrosion protection but also reliable adhesion to subsequent paint coatings. Because at the heart of the metal surface treatment industry, you’ll find us.

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EDITORIAL

Alessia Venturi Editor-in-chief Direttore Responsabile

ince its founding, ipcm® has considered architects, designers and specifiers to be among its main target readers. First of all, like the automotive and fashion industries, architecture “produces” dreams and emotions. Secondly, it is a medium of cultural and historical memory: the daring buildings that are rising around us and the increasingly complex and high skyscrapers that now defy the laws of physics will be the legacy of our presence on Earth. Contemporary architecture is more and more frequently tied to aluminium, which is no longer the “material of the future” but a present choice thanks to its exceptional workability and to its lightness and strength characteristics that make it practically eternal. In the last few decades, aluminium has taken design and architecture to a higher level. Like every year, we dedicate our March issue precisely to the fields of aluminium and its finishing, offering an industrial and technological perspective that reveals what is hidden behind the buildings that surround us. These pages are very rich in content and inspiration not only for the experts, but also for all those who need to be constantly updated on the new technical and aesthetic possibilities offered by this material, such as designers and specifiers. We have gone through almost all Europe to collect a series of case studies about highly innovative companies that offer contracting aluminium extrusion, transformation or coating services and that during the last year have stood out for having introduced advanced technologies. They all have done so to improve their finishing processes, with the ultimate goal of meeting the ever more complex demands of the market effectively and efficiently. This trip has taught us that aluminium is gaining momentum also in very different industries from architecture and transportation, sectors requiring increasingly complex profiles and more and more resistant surface treatments. We have also found out that the subject of Industry 4.0 is emerging in the aluminium coating field, in which several Italian plant engineering companies stand out as great innovators and market leaders. Smart vision systems, sensors interfaced with each other, and machines that are interconnected and managed by central “brains” cease to be mere ideas on paper and enter the industrial test phase. Unfortunately, we have also learned that the replacement of chromating processes with eco-friendly chrome-free cycles has not been completed, yet. This issue will be published just before some important events for the aluminium and aluminium finishing industries to be held in the coming months. On the one hand, Aluminium Middle East will take place on May 15 to 17 in Dubai as a spinoff of Aluminium, the most important exhibition in the world for the aluminium industry held in Düsseldorf, for the Middle East markets. On the other hand, Aluminium Two Thousand will be held in Verona on June 20 to 24 within Metef; every two years, this international conference catalyses the world’s attention on the aluminium extrusion, manufacturing and finishing processes. Finally, let us not forget the Milan Design Week that begins on April 4, where aluminium will play a key role in the design and furniture worlds. Ipcm is the media partner of the first two events and will be present at all three of them with this issue full of innovative ideas.

international PAINT&COATING magazine - MARCH/APRIL 2017 - N. 44

ANALYSIS

Is Revamping the Solution to Be at the Forefront of Innovation? Giuseppe Manara info@antaresitaly.net

Antares Srl, San Martino Buon Albergo (VR), Italy

he owners of a coating plant often manage, after a few years of use, to become familiar with its productive mechanisms, getting to know its strengths, flaws and limitations, as well as its positive and negative properties. However, over the years, the production needs of the market or of the company itself may change for several reasons: consequently, the plant will need minor changes or additions to meet the new requirements.

1 Figure 1: The lubricator installed by Antares.

Those who have owned a coating system for many years know the importance of the care, maintenance and cleaning of its working environment, particularly near the machine, where the operators perform their duties. That is why, with the passage of time, their users achieve a particular affinity with these machines, to the point that they feel the need to maintain them up-to-date with new production and energy saving technologies, instead of replacing them. In fact, an old plant can still be at the forefront of innovation thanks to simple strategies, expedients or added components. Faced with all these needs arising during the life cycle of a coating system, often a company does not know who to trust and may try the “do-it-yourself” approach, or even rely on a partner that could only pretend to be an expert, ending up causing a lot of damage. With its engineers, Antares responds to all these issues with knowledge, expertise and field experience thanks to many years of activity in the sector.

Here below, you will find a few examples of technical interventions that Antares has performed.

Powder coating plant

It was a very outdated powder coating plant for contracting operations, with a Morris chain

conveyor system. The customer needed to solve a big quality problem on its painted parts, but also to improve the lubrication of the chain and of the conveyor bearings because they consumed a lot of oil. Following an inspection and a counselling session, Antares found that the defects detected by the customer on the painted parts were caused by the obsolete lubrication system originally fitted with the plant. Despite constant adjustments, this spray lubricator left traces and oil drops that irreparably damaged the surface of the end products. Antares installed a modern and effective lubricator (Fig. 1) adapting it to the Morristype monorail. Thanks to individually adjustable micro air pumps, it delivers on the chain only the strictly necessary oil for the lubrication of joints and bearings, thus avoiding soiling of the workpieces and wastage.

Coating system for aluminium proﬁles

2 Figure 2: The advantages of the “LYCAN” heat exchange system, manufactured by Antares.

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

A few years ago, the owner of one of the first coating plants for aluminium profiles, built in the ‘80s but still fully functional, productive and innovative, contacted Antares after hearing of a revolutionary system that the company had been offering for a short time and that would have enabled it to achieve energy savings in the drying and curing ovens. This system was becoming increasingly popular in Northern Europe, where energy savings and eco-friendliness are traditionally salient issues.

ANALYSIS

calls and e-mails to understand the problem and The customer informed Antares that it seek a solution, Antares decided to intervene wished to take action on these critical on site and solve the issue problems. The company by disassembling and answered explaining all the reassembling the filters economic and environmental (Fig. 3), also proving the advantages of this new heat technical preparation and exchange system called experience of its engineers. “LYCAN” (Fig. 2). Back then, Antares had not installed any Automatic unloading plant with this revolutionary of components from a burner, yet, but it managed to coating plant convince the client by proving The owner of a coating the validity of its solution with plant for aluminium profiles theoretical calculations and needed to produce batches examples of interventions of very short bars. It asked performed on other types of Antares to find a solution to systems. unload them automatically The installation, carried out from the system. After on one of the two ovens of analysing the problem the plant, was challenging. together with the customer, However, in 2016, five years 3 Antares installed an auxiliary after the implementation of unloading device that the first burner, the customer Figure 3: Air ﬁltration units. works in synchrony with contacted Antares to revamp the main one enabling to also the second oven with arrange horizontally even the the “LYCAN” heat exchange shortest bars (Fig. 4). system, which has proved an effective device to keep a Conclusion plant up-to-date. It is not always necessary to Suction and ﬁltration own the latest equipment units with a dust leak available on the market issue in order to be at the Antares’ engineers intervened forefront of innovation. to resolve a dust leak problem Thanks to companies and on the air suction and partners like Antares, one filtration units downstream can often find the right of the paint spray booths of solution while preserving a plant, which was due to a the already existing plants maintenance operation for and continuing to be the replacement of filters competitive. performed by a third party. The maintenance, care and 4 The customer contacted replacement of worn parts the company after buying keeps your system “young Figure 4: Solution for the automatic its filters but having relied and energetic”. unloading of short bars. on a neighbouring firm for Antares is the right partner their installation. It reported for you: it provides support, a continuous leak of dust from the exhaust components and services for all that concerns the of the suction units. After several phone components of finishing equipment.

ÂŠ Chemetall

Opening Picture: Visual defects or bad paint adhesion are often related to problems with the conversion coating. However, in the process, many defects can be traced back to the prior cleaning and rinsing stages.

ANALYSIS

Cleaning - An Essential Step in the Pretreatment Process Dr. Stefan Birkenheuer Chemetall GmbH, Frankfurt am Main, Germany

stefan.birkenheuer@chemetall.com

he quality of the cleaning process has a direct effect on the quality of the final product and the service life of the plant (Ref. Opening picture). Nevertheless, the cleaning process is often taken into account only insufficiently, which can lead to costly errors and quality problems. The global surface treatment specialist Chemetall, which is part of BASFâ&#x20AC;&#x2122;s Coatings division, supports its customers to balance cleaning efforts and quality requirement to achieve an optimized pretreatment process.

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

Bad paint adhesion, corrosion protection or visual defects are often related to problems with the conversion coating. However, many quality problems are caused during the cleaning and etching processes, and in the following rinse zone. Those stages are often not looked at, and as a result not taken into account sufficiently in optimizing the overall pretreatment process. As a leading global supplier of surface treatment technologies Chemetall is well aware of the

ANALYSIS

importance of each individual process steps, including the cleaning performance. With regard to cost-effectiveness and environmental reasons, the company supports its customers to balance cleaning efforts and quality requirement.

Alkaline, acidic and neutral cleaners meet different requirements In most applications, cleaning is the first essential process step before any further surface treatment. It removes both organic contaminants such as metalworking oils and lubricants, as well as inorganic contaminants such as salt residues or particles. At the same time, it prepares the surface for subsequent treatment and can also fulfill special requirements such as temporary corrosion protection. Cleaning should be cost-effective and easy to perform and manage. In most cases, companies use alkaline products which provide a very good cleaning performance due to the surfactants and the “builders” (inorganic salts) that they contain. There are also neutral cleaners available. These cleaners are based on amines, generally do not contain any builders and provide an inhibiting effect of their own. A third option is to use cleaners that contain acidic phosphates. These are suitable primarily for short pretreatment lines when there is no rinse bath required between cleaning and conversion steps. Chemetall offers a broad portfolio of Gardoclean® cleaning and Gardacid® etching technologies.

Cleaning enables homogeneous coating layers The purpose of a good cleaning is to increase the energy of the surface and thereby its water wettability; this will enable a homogeneous conversion coating and paint layer. However, there are many things that can go wrong during the process (Tab. 1). For example, organic residues must first be removed from the surface since its water wettability is very sensitive to oil residue. Poor de-greasing can lead to surface defects such as crater building after painting, to corrosion and to poor paint adhesion. Increasing the bath temperature or the cleaner concentration, enhancing the mechanics of the bath or extending the treatment time can solve the issue. Welding scales that are difficult to remove, such as traces of smoke, can be removed using neutral or acidic pickling methods; vitrified glass can only be removed using acidic pickling. Local corrosion can generate white spots that show up on the paint surface. This surface defect is often fixed by polishing the surface. This is an expensive manual process that could have already been prevented by using inhibitors or by increasing the pH-value in the cleaning bath. In acidic cleaners with a high iron content, a flash rust film can form which deposits on the substrate surface in the form of Fe(III) oxide. The Fe(III) oxide forms amorphous layers and contributes to poor paint adhesion.

Tab 1: Cleaning – Frequent problems. In the cleaning phase, a variety of defects can occur which can be fixed through simple means. Problem

Reason

Measures

Bad wettability / particle residues

• Insufficient degreasing (e.g. highmelting separating agents, tenacious metal-working fluids) • Inorganic particles not removed

• Raise temperature • Raise cleaner concentration • Raise convection/spraying pressure • Extend treatment time

White spots

Local corrosion

• Raise pH-value • Add inhibitor

Flash rust

Fe(III) oxide deposit on substrate

• Add conditioner and filter Fe(III)oxide • Heighten overflow

Tenacious welding scales

E.g. vitrified glass after welding

• Mechanical pretreatment (e.g. brushing, blasting, polishing) • Acidic etching (glazing) • Neutral etching (smoke residues)

Tab. 2: Etching – Frequent problems. Too strong or too weak etching can result in different defects. They can usually be fixed through simple means in the process bath, such as regulating the etching time or temperature. Problem

Reason

Measures

(Chemically) heterogeneous surface, pre-corrosion products not completely removed

Insufficient substrate quantity removed by etching (etching too weak)

• Extend etch time • Raise temperature • Use stronger etchant

Exposure of microstructure defects

Too much etching may expose e.g. cavities (etching too strong)

• Reduce etch time • Reduce temperature • Use weaker etchant • Add etch inhibitor

Finding the right balance between etching and cleaning In the etching zone, substrates are descaled, or difficult-to-remove adhering materials are cleaned off. There are strong mineral acids on the market to accomplish this, such as sulfuric acid, hydrochloric acid or phosphoric acid. The combination of cleaning and etching processes is important (Tab. 2). For example, results on aluminum substrates have shown uneven etch rates and poor adhesion after strongly alkaline cleaning and weak etching. On the other hand, mildly alkaline cleaning and strong etching achieve a higher and more even etch rate, thereby resulting in good adhesion. Over-etching, however, can expose cavities in cast parts caused by etchants that are too strong, etching time being too long or etching rate being too high. Problems such as paint defects

and local corrosion can arise. In the case of too weak or too strong etching, simple modifications of the process bath, such as regulating the etching time or temperature, can improve quality.

Avoiding runners and dry-on marks caused in rinsing zone Poor paint adhesion, and poor appearance, as well as lower corrosion protection, can also be caused in the rinsing zone (Tab. 3). If the pH-value is too low (≤ 8) or if the salt concentration is too low (conductivity ≤ 50 μS), a flash rust film can form or corrosion can occur in the rinse bath. Runners, as a result of heavily contaminated rinse baths, are also a problem. Often, these defects only show up in the form of a heterogeneous film after the conversion treatment or painting is done. More rinse water, or the installation of an overflow, can fix the problem. Dry-on marks behave the same way as runners. For

example, a dry-on mark of etching residue can leave behind residual salt on the surface, which can lead to adhesion problems and corrosion. In this case, reducing the cleaning temperature, and hence the evaporation rate, can minimize dry-on marks. Alternatively, the transfer times can be reduced.

Realizing an optimized pretreatment To enhance the quality of the pretreatment process, it is important to focus on each individual process stage. Often simple modifications in the cleaning zone can help to avoid paint adhesion or corrosion problems. With many years of expertise and a broad portfolio of cleaning and etching technologies, Chemetall is in the position to support its customers in finding the right balance between cleaning efforts and quality requirements and thus, enabling a stable and high-quality pretreatment process.

Tab. 3: Rinsing – Frequent problems. Poor paint adhesion and low corrosion protection can also be caused in the rinsing zone. Suitable measures prevent flash rust, runners and dry-on marks. Problem

Reason

Measures

Runners

Baths too heavily contaminated

• Use more rinsing water • Set up overflow

Dry-on marks

Rinsing baths too heavily contaminated / transfer times too long

• Reduce cleaning temperature • Increase speed

Flash rust/corrosion of rinsing bath

Local corrosion

• Raise pH-value • Add conditioner

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

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

QUALITÀ QUALITY

D U R ATA E D E S T E T I C A DURABILITY & AESTHETICS

AMBIENTE

Zaniolo CdA - 1.17

ENVIRONMENT

R I S P O S T E _ A O G N I R I C H I E S TA A N S W E R S _ TO EACH REQUEST

Europolveri, offre una diversificata varietà di Vernici in Polvere caratterizzate da elevato standard qualitativo, ottime performances ed un basso impatto ambientale. Un'ampia gamma di prodotti standard disponibili in più di 1800 toni cromatici ed una serie di 240 effetti speciali formulati per garantire un plus in termini di valore estetico e durabilità. Cinque linee di prodotti innovativi formulati ad hoc per rispondere ad esigenze ed applicazioni specifiche. Europolveri: Esperienza, Efficienza, Evoluzione. Europolveri offers a wide range of Powder Coatings characterized by high quality, great performances and an environmentally-friendly formula. A wide range of more than 1800 chromatic tones are available and a series of more than 240 “Special Effects” have been designed for increasing durability and enhancing surface appearance. Europolveri designed five innovative product lines for special needs and applications. Europolveri: Experience, Efficiency and Evolution. 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

BRAND-NEW

Valde Steel: The Corrosion Resistance Guarantee for Powder Coated Steel Surfaces

C © Inver

orrosion is a major challenge for the industrial paints and coating sector because it is directly responsible for the quality degradation of products over time. The coating product therefore must adapt to the complexity and variety of materials used in the industry and in particular assure protection of edges that tend to accumulate less coating compared to flat surfaces.

Corrosion categories C1 Very weak C2 Low C3 Medium C4 High C5-I (Industry) Very High

C5-M (Marine) Very High

Internal Heated buildings Clean atmosphere Unheated buildings with condensation High grade production rooms with humidity Chemical plants, swimming pools, shipyards Buildings or area with permanent condensation and high pollution Buildings or areas with permanent condensation and high pollution

Substrate Pre-treatment

Surface preparation

VALDE STEEL ST2

Steel

Mechanical

Sandblasting Sa 2.5 Ra 6.3 ou 12.6

VALDE STEEL ST2

Steel

Chemical

System Name

1 Figure 1: New powder coatings that are suitable for indoor and outdoor environments.

Atmospheres with low levels of pollution Urban and industrial atmospheres, moderate sulfur dioxide pollution Industrial and coastal areas with moderate salinity Industrial area with high humidity and aggressive atmospheres

Hot Dip Mechanical Galv. Steel

VALDE STEEL HD2

Hot Dip Chemical Galv. Steel

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

Figure 3: Recommended coating system.

Coastal and marine areas with high salinity

Primer TopCoat

Valde Steel VALDE STEEL HD2

Figure 2: Corrosion categories.

External

P-0554 P-0106 P-1097 P-0737 P-0554 P-0106 P-1097 P-0737 P-0554 P-0106 P-1097 P-0737 P-0554 P-0106 P-1097 P-0737

PE/P/Q PE/P/M PE/P/S PE/P/Q FTX PE/P/Q PE/P/M PE/P/S PE/P/Q FTX PE/P/Q PE/P/M PE/P/S PE/P/Q FTX PE/P/Q PE/P/M PE/P/S PE/P/Q FTX

Number of Organic Layers

Corrosivity Class

Approval Number

PE-0066

PE-0069

C5IH C5MH

PE-0070

C5IH C5MH

PE-0071

BRAND-NEW

In order to promote and ensure the quality of service, Valspar has developed new powder coatings, which are in accordance with the Qualisteelcoat specifications based on UNI EN ISO 12944-1 up to Category 5, the highest category of corrosion resistance. The paints of this category guarantee corrosion resistance in indoor environments, buildings and areas with permanent condensation and high pollution, but also in challenging outdoor environments (Fig. 1) such as coastal and marine zones with high salinity (Fig. 2). To obtain an anti-corrosion powder coating with Qualisteelcoat certified Valde Steel, a traditional process consisting of pretreatment, primer and topcoat is applied (Fig. 3). The pretreatment can be applied mechanically through sandblasting or chemically by phosphating in compliance with EN 13438 standards and subsequent passivation for both steel and galvanized steel. The Valde Prime base coat was developed to provide excellent edge coverage. Inverpul powder-based topcoat is a Qualicoat Class 1 certified polyesterhydroxyalkylamide, which can be glossy, satin, matt or textured. Qualisteelcoat is an organization committed to maintaining and promoting the quality of topcoat and steel surface coating (www.qualisteelcoat.net). For further information: www.inver.com, www.valspar.com

BRAND-NEW

Evonik Develops New PEEK Powders for Tribological Coatings

1 Figure 1: New VESTAKEEP® PEEK powders for tribological coatings.

reater efficiency thanks to lower friction: The innovative polyether ether ketone (PEEK) powders VESTAKEEP® developed by Evonik significantly reduce the wear and tear of components in demanding industrial applications (Fig. 1).

PEEK powders for demanding applications The PEEK powders of Evonik’s VESTAKEEP® brand are particularly suitable for applications that are subject to extreme mechanical, thermal and chemical requirements. The coating material is able to withstand permanent operating temperatures of up to 250°C and is characterized by its unique ability to resist abrasion and chemicals.

Thanks to the excellent tribological performance of coatings made from specially developed VESTAKEEP® powders , the friction between sliding surfaces is significantly reduced, which in turn increases efficiency and economy of operation – for example lower fuel consumption and lower CO2 emissions in combustion engines, extended service life of bearings, or higher turbine speeds. These special VESTAKEEP® coatings also allow for employing more costefficient substrate materials for components used in applications with sliding friction.

High performance in powder form The various VESTAKEEP® PEEK powders are comprised of particles with average particle sizes ranging from 5 to 110 μm. They can be

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

applied by flame and electrostatic spraying methods, or as aqueous dispersions. With electrostatic application, layer thicknesses can range from 20 and 300 μm; dispersions are suitable for thinner layers. Based on over forty years of experience, Evonik has been a leader in the development and production of high performance polymers. VESTAKEEP® PEEK powders are part of the hightemperature polymers product portfolio offered by the Resource Efficiency Segment. For further information: www.vestakeep.com, www.evonik.com

BRAND-NEW

Axalta Coating Systems Introduces Alesta Lync Dry-on-Dry System

xalta Coating Systems, a leading global supplier of liquid and powder coatings, introduces Alesta® Lync, an innovative Dry-onDry (DOD) powder coating application system. Alesta Lync is a cost-effective solution to the energy-consuming process of conventional two-layer systems that require two separate bake cycles. It is also engineered to provide a significant performance improvement compared to single layer systems. With its unique topcoat and primer combination, Alesta Lync is designed to provide two paint layers but requires only one cure cycle. As a result, Alesta Lync reduces process time, paint shop footprint and capital investment while increasing productivity. The process is energy-efficient and has excellent edge corrosion protection. By contrast, traditional direct to metal monolayer powder systems often fail to protect edges, as surface tension during the liquid state causes paint to pull away from sharp

edges. Conventional two-layer systems require an intermediate bake step between primer and topcoat. “Alesta Lync is the result of Axalta scientists around the world listening to the needs of our customers and then working closely with them to develop an innovative technology that is designed to improve their business,” said Michael Cash, Axalta Senior Vice President and President, Industrial Coatings. “I couldn’t be more excited about this new system, and I look forward to seeing the creative ways our customers will take advantage of its value.” Alesta Lync has been engineered initially for ACE segment coaters, but also is suitable for many other general industrial applications. Coaters using direct to metal systems today can get better edge coverage and corrosion resistance with Alesta Lync without having to add an additional oven to gel cure a primer. For more information: www.powder.axaltacs.com

REAP THE BENEFITS OF OUR EXPERTISE End-to-end surface-finishing solutions for your agricultural and construction equipment. Pretreatment, dryers, spray booths with overspray removal, conveyors, waste water treatment, and thermal oxidation with heat recovery.

www.eisenmann.com

BRAND-NEW

BYK-Gardner – Complete QC Solutions for Testing Paints and Coatings

Next generation of smart-chart software BYK-Gardner has launched the next generation of the smart-chart software, encompassing BYK-mac i, cloud-runner, wave-scan and now additionally the new micro-gloss. New features have been added: - Data Export to Excel using Pivot Function - allows fast customization of data to be exported to Excel - Data Analysis using multiple Databases - Manual Input of additional parameters and scales such as film thickness

- New color and appearance scales based on customer studies. A complete product range of spectrophotometers for solid colors and effect colors will be displayed: The spectro-guide family for solid color control and the BYK-mac i family (Fig. 1) for multi-angle color and effect measurement. All models are available with different aperture sizes and / or accessories to measure small parts as well as powdery or wet material.

Viscometers In the wide range of testing instruments of physical properties, BYK-Gardner is introducing a complete new line of byko-visc Rotational Viscometers. Viscosity is an important property for QC testing in a wide variety of industries. BYK-Gardner aims to make QC testing of viscosity simple and compatible worldwide. The new byko-visc line of rotational viscometers operate with high performance at competitive prices. This new line consists of Basic, Advanced and Premium series (Fig. 2), which enables you to purchase the functionality that you need. Additionally, each series is available in low viscosity, medium viscosity and high viscosity models. For unusual and more complicated applications, accessories are also available: Low Viscosity Adapter, Small Sample Adapter, ThermoChamber Accessory, and byko-visc Helio Stand. The byko-visc models have a user 2 calibration feature to allow for re-calibration of the viscometer. There is no need to return the viscometer to BYK-Gardner for calibration. Figure 2: Byko-visc Advanced.

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In the appearance product range, the new micro1 gloss Family with color display and the new smart Figure 1: BYK-mac i. communication with smartchart chart software allows fast data transfer, easy graphical and statistical data presentation and an instant QC report. The new family member, micro-gloss XS with its ultra-small port (2x4 mm) guarantees reliable gloss measurement of small parts. The new microgloss family offers the same high accuracy under even harshest circumstances (10°C – 40°C) as its predecessor – the unsurpassed industry standard. A range of accessories is also available to measure powder or wet draw-downs.

YK-Gardner offers complete QC and Process Control solutions for evaluating color, appearance and physical properties. It’s part of Altana and a direct subsidiary of BYK-Chemie, the leader for paint and plastic additives. At the ECS 2017 the following new products and highlights were presented.

BRAND-NEW

to be analyzed in more detail (e.g. cure chart graphs to determine the minimum temperature at shortest baking time) the answer is the temp-gard 8p or 16p with the full temp-chart data analysis software. QC testing tools to measure the performance of paints and coatings objectively (from the wet to dry stage, evaluating viscosity, degree-ofgrind, hardness, adhesion, flexibility, film thickness amongst others). These will be shown in practical use - including sample preparation methods to guarantee repeatable test conditions and measurement results. The line of byko-drive, automatic film applicator, was expanded by a new model to allow large draw-downs (approx. A3 size) and have programmable speed control from 5- 500 mm/sec in 1 mm/sec increments.

Figure 3: Byko-visc DS.

In addition to the “all-rounder” byko-visc, two “specialists” primarily designed for the paint and coating industries will be introduced: The NEW byko-visc DS (Fig. 3) is a stormer type viscometer that has direct digital readout in Krebs Units (KU), centipoise (cP), and grams (g). And the NEW Cone & Plate viscometer for high-shear viscosity applications using small sample volumes.

The temp-gard oven recorder family is expanded with new economical temp-gard models The small temperature data logger with large color display is placed in a heavy-duty thermal barrier to withstand highest temperature requirements of paints and coatings curing and at the same time guarantee excellent reliable measurement data. Up to 6 temperature probes can be connected. The temp-chart lite software saves the data in a measurement database and analyzes the temperature profiles efficiently with simple Pass/Fail analysis and Cure index. If more temperature probes need to be connected or the data needs

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Opening photo: Axalta’s powder coatings were chosen to coat the exterior façade as well as the interior walls of Brussels Environment.

HIGHLIGHT OF THE MONTH

Axalta Discusses Trends and Future of Metallic Architecture Alessia Venturi ipcm®

pcm® interviewed Franck Derouen, Global Segment Director – Architectural, Axalta Coating Systems, to discuss coatings in the architectural sector: The relationship between metallic architecture and powder coatings, the relevance of liquid paints for exteriors, colour trends for exterior architecture, Axalta’s offer for metal architecture and aluminium profiles and two major projects in which the company was involved.

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ipcm: “The relationship between metallic architecture and powder coatings is increasingly close, especially in Europe, or outside Europe where the suppliers are European. In which direction is Axalta’s research and development going regarding this relationship?” Derouen: “As Europe is a mature market, our R&D goals for powder are two-fold. First, to convert other technology, such as anodising, to powder. With our Anodic range, which replicates the look of anodizing,

HIGHLIGHT OF THE MONTH

specifiers can achieve the appearance of anodizing at a more competitive price and reap the technical benefits of a powder coating, including excellent colour consistency and environmental friendliness. Our second R&D goal for powder is to increase the worth of our products for our customers. We do this by offering higher durability, with Alesta SD for example, or increased colour choice of special finishes. Bonded metallic finishes, for example, provide architects and designers unique appearances while ensuring ease of application for the applicators”. ipcm: “How important are liquid paints for exterior architecture (e.g. differences between Europe, USA, Middle East etc)?” Derouen: “In Europe, liquid paint is generally not used because of environmental reasons. The North American market is currently converting from liquid to powder as well.

In Asia and in the Middle East, both more mature markets as far as exterior architectural coatings are concerned, powder is used very widely, with liquid only used for specific requirements traditionally not suitable for powder, such as PVDF. However, this too is changing, as powder is now developing to be used for this application. Our extremely durable Alesta UD range is a viable and successful alternative to PVDF liquid coatings in these regions because of the severe UV conditions. ipcm: “What is Axalta offering for metal architecture and aluminium profiles?” Derouen: “As a global leader, we offer three levels of performance for metal architectural components. First is Alesta AP, which is a range suitable for residential or small projects in normal climate conditions. Then we have Alesta

VERNICIATURA, SIGILLATURA, INCOLLAGGIO Pompe per qualsiasi tipo di applicazione – EcoPump

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SD, which is a range of super durable powders that provides better colour and gloss stability. And finally we have Alesta UD, a range of extremely durable powder coatings suitable for prestigious buildings or for regions with severe UV conditions such as the Middle East. All our Alesta AP and Alesta SD are approved by European standards including Qualicoat and GSB, and Alesta UD complies with AAMA2605, the American specification. And they can be backed by a Global Warranty when applied by Axalta Approved Applicators: up to 15 years for Alesta AP, 25 years for Alesta SD and 30 years for Alesta UD. We are constantly developing new colour collections to provide as much creative freedom to architects and designers as possible. Our Timeless Collection is a palette of bright metallic finishes in two levels of durability: Alesta AP and Alesta

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

ipcm: “What are the exterior architecture colour trends for the next few years?” Derouen: “We are seeing the increasing interaction between colour in architecture and the fashion and furniture industries. Other notable trends are significantly lower gloss levels for metallic finishes, in fact everything from slightly matt to completely super matt, and everything in between. For interior architecture, tactile effects are becoming more popular. Our Fine Textured and Soft Touch collections are excellent solutions to meet this trend”.

ipcm: “In what way is Axalta involved in the choice of finishing in a project? Through the architect, the customer or the manufacturer/painter?” Derouen: “It differs from project to project. If we are involved in a project at a specification stage, then we usually

SD. These products are processed using bonding technology to ensure stability during application. We’ve developed unique technologies to make our powder coatings “smarter”. Alesta Cool helps to reduce air conditioning costs. Alesta AG is a robust anti-graffiti powder coating, and Alesta Speed is formulated especially for aluminium coil coatings. We also consider service as an essential part of what we deliver to our customers. We have more than 1,500 powder products always in stock in our European warehouses that we aim to deliver to our customers within 24 hours. And to further underscore our focus on our customers, we have developed a smart, innovative webshop that we are testing in one or two markets and that we plan to rollout more widely soon”.

ipcm: “Can you describe a couple of projects where Axalta supplied its paint? Derouen: “Brussels Environment, the government authority for environment and energy (Brussels, Belgium) studies, monitors and manages air, water, soil, noise and biodiversity for the more than one million people living in its local region. It also delivers environmental permits, controls compliance, develops and supports educational projects and is active in the fields of environmental construction (Ref. opening photo). Architect Philippe Samyn & Partners and architectural firm Cepezed designed the structure. The brief for the building was that it needed to be a national and international example of environmental responsibility. It had to address environmental issues at every touch point. The central glass-domed atrium for example plays an important role in this, not least because the heat it captures is reused. With this ethos in mind, the environmentally-responsible powder coatings from Axalta were chosen to coat the exterior façade as well as the interior walls. Axalta worked with Kyotec Belgo Metal on the external façades, which were coated in Alesta AP quality Black RAL 9005 in matt and semi-gloss finishes. For the internal walls, which were coated in the same outdoor quality in White RAL 9003 in a matt finish, Axalta worked with Sapa Aluminium B.V. in Hoogezand, Belgium. 1 The second project was Zlota 44 (Fig. 1), a 52-storey residential Figure 1: Project Zl ota 44: Axalta AP powder coatings used in skyscraper in central Warsaw, Poland. this project were White RAL 9010, Silver RAL 9006, and two shades of greys RAL 7040 and RAL 7045. It was designed by Polish-American architect Daniel Libeskind and constructed by Kyotec - Belgometal. At a height of 192 meters, it is one of the tallest connect directly with the specifier. Once residential buildings in the European Union. It the architect has selected the appropriate comprises 287 apartments. Axalta AP powder product in terms of durability and colour, coatings used in this project were White RAL we follow the project downstream with the 9010, Silver RAL 9006, and two shades of greys fabricator and then subsequently with the RAL 7040 and RAL 7045. applicator”. ⁄

ipcm: “What is Axalta’s relationship with architectural companies?” Derouen: “We have very strong and long-lasting relationships with architects, construction companies and façade fabricators across Europe. These strong links allow us to identify new trends and spot clear customer demands, which in turn enable us to better serve the market and maintain our leadership position”.

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Courtesy of ECKART

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BRAND-NEW

H2O GmbH at Hannover Messe. Improve Coating Results Using Patented Technologies uality standards relating to surface technology processes are becoming increasingly demanding. The leaders in zero liquid discharge from H2O GmbH will attend the world’s biggest industrial trade fair Hannover Messe from 24–28 April 2017. They explain how users can improve the quality of their processes and save costs. The company will be on hand in the Welt der Oberfläche area (‘World of surfaces’) at booth B40 (19) in Hall 6 (Fig. 1). Here they will present patented technologies for efficient processing of industrial wastewater from surface technology processes. These technologies include, for example, the Clearcat technology. Experienced experts from H2O developed this technology at the application centre for zero liquid discharge production. The module is built into the VACUDEST system and processes used rinse water so well that it meets the strictest limits. No consumables or chemicals are needed, making this module particularly economical and easy to maintain. One of the benefits for the user is that the distillate is oil-free, crystal clear and cleaner than the distillate from conventional evaporator systems. This quality of the distillate makes it perfect for reuse in production processes.

This form of recycling allows you to save on disposal costs and improve the quality of the product. Eight out of ten customers working in the fields of painting pretreatment, part cleaning and electroplating already opt for the VACUDEST system with Clearcat. About H2O GmbH - The experts for zero liquid discharge from the H2O GmbH are worldwide technological leaders in the field of efficient and reliable vacuum distillation systems for the processing and recirculation of industrial wastewater. Thanks to a modular composed technology, each system is tailored individually according to the

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customer’s needs. 30 years of experience lead to exceptional products, which set technological standards. Since the spin-off of the Mannesmann Demag Group in 1999 the owner managed H2O could win a growing number of loyal customers who appreciate the scope of services of the H2O. The turnover increased since the foundation on an average of 15 percent up to 17,9 million Euro in the year 2015. The H2O employs today more than 100 colleagues worldwide, thereof 80 at the head office in Baden Steinen. For further info rmation: www.h2o-de.com

BRAND-NEW

NoxorSokem Group: OHSAS 18001 Compliance Certification

GS Group, a world leader in certification services, has certified the NoxorSokem Group according to the recognised OHSAS 18001 standard for the assessment and authentication of occupational health and safety management systems. The standard OHSAS 18001 has been designed to be compatible with ISO 9001 and ISO 14001 in order to facilitate the integration of management systems dealing with quality, environment, and health and safety at work. This organisation tool enables to systematically manage the safety of workers with no major changes in the corporate structure. It focusses on the following principles, among the others: - adoption of a policy for the management of safety; - hazard identification, risk assessment and risk control, in close connection with the legal requirements or other measures; - personnel education and training; - consultation, communication and participation procedures with employees and stakeholders; - implementation of the control procedures of activities related to identified significant risks, including processes such as design and maintenance; - definition of specific programs and objectives with the Plan – Do – Check – Act approach; - creation of measures to detect, prevent and control any accidents, near misses and emergencies; - monitoring and assessment of the performance of the health and safety system, also for maintaining regulatory compliance; - definition and implementation of controls on the adequacy of the management system; - identification and assessment of risks and dangers related to activities carried out by third parties at the organisation’s site. The new OHSAS 18001 certification, together with the already existing ISO 9001 and ISO 14001 standards, enables to maintain and improve a company’s quality standards, a feature that has distinguished NoxorSokem Group on the market for decades. For further information: www.noxor.it

BRAND-NEW

Chemetall Introduces Medium-Temperature Sealing Technology for Anodized Aluminium

hemetall, a leading global surface treatment supplier and a global business unit of BASF’s Coatings division, has launched a new generation of ecologically sound, medium-temperature sealing product for anodized aluminium surfaces. Gardo® Seal 1999 allows the process to run at lower temperatures and shorter treatment times without compromising the appearance and quality of the surface finish.

Signiﬁcant energy savings “Manufacturers can achieve substantial energy savings while realizing higher production rates,” says Martin Ings, Chemetall’s Global Segment Manager for Aluminium Finishing, and adds: “The Gardo® Seal 1999 process enables

customers to realize significant process cost savings.” Another benefit is the extended service time of the Gardo® Seal 1999 process baths, which significantly reduces the amount of water required for new bath make-ups.

REACH-compliant and Qualanod-approved Chemetall’s new sealing technology is a robust process with a broad processing window. Surfaces sealed with Gardo® Seal 1999 are free of sealing blooms and meet all relevant quality standards such as DIN EN ISO 3210. The process is REACH-compliant and approved by Qualanod, the quality label for Sulphuric Acid-Based Anodizing of Aluminium.

Aluminium substrates sealed with Gardo® Seal 1999 ensure lightfastness and corrosion resistance of anodized and colored surfaces and thus, preserve their high-quality appearance for many years. Besides the anodizing of aluminium for architectural applications, Gardo® Seal 1999 is also suitable for interior and exterior parts of vehicles, electric consumer goods such as mobile phones and tablets, lighting systems as well as machinery and construction equipment in the mechanical engineering industry. Gardo® Seal 1999 promotes greater efficiency and a cost reduction while meeting today’s targets for an ecologically sound sealing process. For more information: www.chemetall.com

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ANALYSIS

Technology Interchange: The Powder Coating Summit Kevin Biller

he 2016 PC Summit provided a cornucopia of advancements in powder coating technology (Fig. 1). Topics ranged from two-coat systems to smart in-line powder application to fluoropolymer chemistry. Allow me to give you a synopsis of some of the topics presented.

kevinbiller@yahoo.com

ÂŠ Powder Coating Research Group

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Optimal Process When Layering Powder Coatings Rodger Talbert, noted powder coating expert and Director of Business Development at Col-Met presented a tutorial on multi-layer powder coating technology. He explained how single coats of powder can meet 1 indoor specifications but typically have limited corrosion resistance. Figure 1: The 2016 Powder Coating Summit. Double coats with the same powder provide improved edge coverage and better corrosion resistance than a single coat (Table 1). Table 1 - Layering Powder Coatings: Salt Spray Resistance The combination of a primer plus a topcoat Process ASTM B-117 Salt Spray Hours (rating of 10) powder offers substantial corrosion protection. Primer options include standard epoxy, Iron Phosphate/One Coat 500 to 750 hours Mil-Spec (military specification) primer and Iron Phosphate/Primer + Topcoat 2,000 to 7,000 hours zinc rich epoxy. Zinc rich powder primers provide superior corrosion resistance over Zinc Phosphate/One Coat 1,000 to 1,200 hours blasted steel. Talbert cautioned that fully Zinc Phosphate/Primer + Topcoat 6,000 to 8,000 hours curing a primer followed by a topcoat could risk intercoat adhesion and recommended either Blast Only/One Coat 500 to 750 hours partially curing the primer prior to topcoat application or applying a dry-on-dry primer/ Blast Only/Primer +Topcoat 2,000 to 7,000 hours topcoat layered system. The latter could Courtesy Col-Met Engineered Finishing Solutions present application challenges.

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ANALYSIS

bad technologies, just bad applications”… of technologies.

Returning speaker, Marty Sawyer, presented an excellent treatise on the pros and cons Lab Demo – Twin Screw Extrusion Technology of various curing technologies for powder coatings. She began her presentation by Randy Kincer and Paul Young of Baker Perkins distinguishing between the various types of were first time laboratory demo contributors heat transfer, namely convection (movement of and regaled attendees with a video simulation a fluid – gas or liquid), conduction (direct contact) and radiation (electromagnetic waves). With infrared (radiation) heating absorption is key as black absorbs more than white and matte absorbs more than shiny. Convection can be either through gas combustion or electric resistance. Infrared on the other hand can be generated with gascatalytic or electric techniques. Sawyer didn’t promote a one-size-fits all approach to curing powder coatings. She 2 identified the advantages of ease of operation, flexibility and Figure 2: Catalytic infrared vs. convection test results. tradition of using convection, but also pointed out the slow of the inner workings of a twin screw extruder. cure, cost and environmental impact inherent The video depicted how the materials fed to this technique. Gas catalytic is low cost to into the extruder transition from a dry blend operate, uses a small footprint and is very of disparate components to a homogeneous environmentally sound. Drawbacks include mixture. Baker Perkins has perfected the high initial capital cost, unsuitability for a diversity of parts and the learning curve screw design of these complex machines to necessary to master operation. Electric Infrared maintain a consistent introduction of raw provides the fastest cure, highest gloss finish materials having differing particle size, shape, and is also environmentally friendly. On bulk density and specific gravity. The video the other hand, electric IR has the highest and accompanying commentary underscored operating cost, requires a learning curve the criticality of feed zone screw configuration, extrusion RPM and kneading zone design for and is the most unforgiving for diverse part optimal dispersion of pigments and distribution geometries (Fig. 2). Marty provided an excellent video depiction of resinous components. of surface temperature profiles of parts passing through a gas catalytic IR tunnel. This Smart In-Line Powder Application demonstrated the speed of heat-up and the Chris Merritt, General Manager for Gema USA, relatively good heat distribution on the coated updated the conference delegates on the part. The part required only 6:45 minutes gas advantages of improved design powder pump catalytic infrared compared to 30:00 minutes of technology. Gema’s patented technology gas convection to complete the powder coating utilizes a dual chamber powder pumping cure. Sawyer concluded with, “there are no system which is actuated by opening and

closing pinch valves (Fig. 3). This enables the powder to be transported in a much denser phase (powder to air ratio) which translates to more constant powder output, less wear and higher transfer efficiency. These attributes are beneficial to the powder applicator challenged with a variety of powder types including thin film products, bonded metallics and unbonded metallic/special effect powders. These systems dubbed SIT include internal performance monitoring and process feedback to ensure consistent atomization of the powder as it exits the gun. The reduced air velocity required with this design ensures lower overall maintenance costs as internal parts experience reduced wear. © Trimac Industries Inc.

Selecting the Right Oven – Convection or Infrared

Fluoropolymer and Superdurable Polyester Blends Shun Saitoh from AGC Chemicals, Japan spoke about his interesting findings with FEVE (fluoroethylene vinyl ether) based powder coatings. Coatings based on this copolymer technology offer the ultimate in UV durability, typically enduring 20 or more years in a South Florida environment without exhibiting significant chalking or coating degradation. Saitoh recommends introducing superdurable hydroxyl functional polyester resin to FEVE based formulas for improved economics while still exceeding all common architectural specifications. In addition he explained how this approach can be advantageous in metallic containing formulations as the polyester component stratifies below the fluoropolymer leaving the metallic portion intertwined between the FEVE and polyester. This phenomenon protects aluminum flake from the hydrolysis commonly seen with exposure to outdoor environments. Saitoh presented EDX (energy dispersive x-ray spectroscopy) cross sectional analysis to verify this stratification (Fig. 4). Not only does this formulation system exhibit exceptional UV durability but also

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3 Figure 3: Smart In-Line Technology: Easy replacement of the ﬁlter chamber and pinch valves.

excellent corrosion resistance as evidenced with AGC’s 4000 hrs. Salt Fog test results. A unique formulating approach for environmental dirt repellency was presented as well. Saitoh’s theory is predicated on lowering the Water Contact Angle (low surface energy) of the surface by the incorporation of 3% by weight of sodium dodecyl benzene sulfonate. This allows rain to rinse and effectively remove deposited dust and dirt particles. Performance was verified by vertically orienting coated test panels for one year in the industrial area of Chiba (east of Tokyo). Saitoh also offered formulation tips on achieving matte finishes with FEVE based powder coatings. The incorporation of 8% by weight of 4 micron particle size Tospearl (Momentive) produced a 60° gloss of 30 GU. Impact resistance, adhesion and UV durability were not compromised by this matting technique.

Surface Appearance Characterization Jeralyn Camp, End-User Manager from BYK-Gardner, formerly a coatings chemist, displayed her expertise in coating characterization with her discussion on Orange Peel and Distinctness of Image (DOI). She deftly dissected the aspects of surface appearance explaining how waviness and brilliance (DOI) influence one’s perception of appearance. Real world examples were presented of how observation distance impact human eye resolution of a surface. The measurement principle that BYK-Gardner has mastered involves analyzing the reflection of concentrated light beams at a number of incident angles then using mathematical filters to discern long, medium and short wavelength patterns. This technology utilizes a total of five wavelength ranges to define surface topography. Jeralyn concluded with an offer to assist the powder coating industry in further defining and assigning hard numbers to smoothness standards.

ANALYSIS

4 Figure 4: Cross-Section Analysis: Fluoropolymer-AluminumSuperdurable Polyester.

Conductive Primer for Non-Traditional Substrates Our efforts to inspire students to pursue careers in the powder coating industry was evident as PCI’s 2015 Scholarship awardee, Atman Fozdar of Eastern Michigan University delivered a talk on his work on the powder coating of non-traditional substrates. Fozdar, under the tutelage of Dr. Vijay Mannari, has been investigating techniques to make wood and plastic substrates conductive. By making these substrates conductive electrostatic deposition of powder can be accomplished. Fozdar identified 106 to 1012 ohms/sq. surface resistivity as a suitably conductive surface (static dissipative). The technique used to measure this is ASTM D257. Conductive liquid primers based on various acrylic based binders were prepared using varying concentrations of conductive agents. These primers were applied to MDF (medium density fiberboard), polycarbonate and glass then cured conventionally. UV curable powder was then applied to surfaces coated with these primers. The deposited powders were melted then cured with medium pressure UV lamps. Adhesion was tested per ASTM D4541. Primers containing Deuteron™ conductive agent were found to provide the best deposition and adhesion.

Conclusion All in all this was the best attended and supported PC Summit. In addition to the fine technical presentations, Bob Cregg of DSM Resins gave a sparkling keynote exploring “Powder Coatings – Ten Years from Now” and a group of industry experts conducted a lively and informative panel discussion exploring “Penetrating New Markets”. In addition we continued to support students expressing an interest in powder coating technology. PCI Scholarships were awarded to Youcheng Du and Diana Marcela Rodriguez, both students from Eastern Michigan University. And the Nordson Builds – PCI Scholarship was awarded to Jakob Waffen from Ohio University. We look forward to bringing more new technology to market in 2017.

www.defil.it

Opening photo: The Zagreb arena, designed by the architectural ﬁrm UPI-2M and built in 2008 by Aluferit d.o.o. with Feal’s Fassade 60 K system.

FOCUS ON TECHNOLOGY

Quality first. A new horizontal coating plant for aluminium profiles: Feal’s choice to stay true to its motto Alessia Venturi ipcm®

luminium is one of the most common building materials in the architectural, automotive and many other industries. The manufacturing of high engineering profiles of the utmost quality, suitable to meet the needs of such a wide variety of

sectors, involves complex production processes that require cutting-edge technologies. “Quality first” is the motto of Feal, the major extruder of aluminium profiles of the Balkan region. This high-tech company is

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constantly evolving because it is well aware of the changing nature of the demands and requirements of its target markets. Feal annually provides several major European brands with more than 45,000 tonnes of aluminium: its profiles and architectural

FOCUS ON TECHNOLOGY

construction fields (Fig. 3), FEAL d.o.o. has its headquarters and production plants in S˘iroki Brijeg, Bosnia and Herzegovina, and numerous branches in various European countries. It was established in 1976 as a state company owned by the Yugoslav government, but in 2000, with its factory semidestroyed by the Balkan war, it was bought by Jozo Bogdan, thus becoming an entirely private capital company. Currently, Feal has 560 employees, including 80 engineers specialising in various fields, and a long tradition in aluminium working. Jozo Bogdan’s vision was to create a highly efficient, high-profile factory, whose wealth could be of benefit to all its employees as well as its surrounding area. Declared “Entrepreneur of the year in the aluminium sector” in 2013 by the Chamber of Commerce and Industry of Berlin, Bogdan does not like to talk about himself. He prefers to speak of the results of his company, which continues to invest in the latest technologies to meet the European standards and quality certification requirements. Besides its plants in S˘iroki Brijeg, hosting three 14, 18 and 35 meganewton extrusion presses (Fig. 4) 2 as well as the machining, finishing and profile Figure 2: From left to right, Marko Novak, Ante Musa and Anela Dumanc˘ic´.

systems have been used for the construction of excellent buildings all over the world, turning the designers’ visions into reality (Ref. opening photo). True to its motto “Quality first”, Feal has recently invested in a major production expansion plan 1 that included the implementation of Figure 1: The new horizontal coating plant provided by Trasmetal. a fourth extrusion press and of a third horizontal powder coating plant, for which it True to its motto has relied on the technology of Trasmetal, an Italian company based in Milan (Fig. 1). “Quality first”, Feal has “The demand for large-sized profiles is recently invested in a major growing. At the same time, new industries production expansion are approaching the aluminium profile sector. plan that included the The requests are ever more complex, but implementation of a fourth they all have something in common: the extrusion press and of a search for flawless quality in terms of both third horizontal powder manufacturing and finishing. That is why we coating plant” are now equipped with extrusion presses up to 35 meganewtons and why we have made a major investment in a horizontal coating system with cuttingedge technical features. This ensures a very high productivity and, above all, precisely the finishing quality that distinguishes us,” Feal general manager Ante Musa says (Fig. 2).

Feal’s development parable A supplier aluminium profiles, parts and structures for the industrial and

international PAINT&COATING magazine - MARCH/APRIL 2017 - N. 44

3 Figure 3: The bus station of Osijek, Croatia, designed by the architects Predrag and Bruno Rechner and built in 2011 by IMAL Plast d.o.o. with the Fassade 60 K, 50 K E Thermo 50, Thermo 65 and Z40 systems.

assembly departments, Feal has a factory in nearby Mostar with a 25 meganewton extrusion press. The extrusion process starts with the primary aluminium selected based on the specifications of Feal or of its customers. The company has two main suppliers of this material: Aluminij Mostar, a neighbouring firm, and Dubal, in Dubai. After extrusion, the profiles, which can be up to 50 m long, are cooled with liquid nitrogen to improve their resistance. The extrusion tools have tight tolerances and they are continuously checked. All the logistics and heat treatment processes are fully automatic. The machining and cutting department is equipped with high speed CNC machining centres that are up to 30 metres long (Fig. 5). The profiles intended

Jozo Bogdan’s vision was to create a highly efficient, high-profile factory, whose wealth could be of benefit to all its employees as well as its surrounding area.” for train windows are treated with high precision benders and then welded. The finishing treatments are entrusted both to the anodic oxidation department, equipped with two of the most advanced anodising lines in Europe (Fig. 6), and to the paint shop, featuring three fully automatic horizontal plant for the electrostatic powder coating operations.

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There is also a sublimation line for the realistic decoration of profiles (Fig. 7). Quality control is the key to the international clients’ satisfaction: the chemical and physical properties of all Feal products are checked and certified by the firm’s own laboratories. This ensures that each profile is traceable. “Feal is an industrial group that works across Europe,” so Marko Novak, Feal’s marketing manager. “We offer forty-two architectural systems for the construction of façades, windows and doors. We also produce custom-made aluminium profiles for other engineering companies as well as profiles for the generic, automotive and railway industries. The latter, in particular, is a growing and very demanding sector.”

FOCUS ON TECHNOLOGY

The ﬁnishing process: excellent quality with the latest technologies “Feal possesses all the most important quality certifications for its target markets: Qualicoat Seaside and Qualanod for architecture, GSB, International Railway Industry Standard (IRIS) for the railway field, ISO 9001 and 14001, and so on,” Marko

Novak explains. “Our two anodising lines have a maximum capacity of 22,000 tonnes per year and treat profiles up to 7,100 mm in length. Our coating lines, with the addition

Feal possesses all the most important quality certifications for its target markets: Qualicoat Seaside, Qualanod, GSB, International Railway Industry Standard (IRIS) ISO 9001, and 14001.”

of the third one supplied by Trasmetal, have a capacity of 15,000 tonnes per year.” “We invested in this third painting line because we needed to expand our capacity © ipcm ®

“In the last four years, our company has grown exponentially. We went from a turnover of 70 million Euro in 2012 to 180 million Euro in 2016 Novak adds. “We produce 8,000 different profiles, from the 10 mm thick flat ones and 420 mm wide to the round ones with a 350 mm diameter. Our new office building was opened in 2012 and is a veritable showroom for our products, since it has been built using almost all our forty-two architectural systems (Fig. 8)”.

4 Figure 4: One of the three extrusion presses installed at the ˘ iroki Brijeg, Herzegovina. premises of Feal in S

Trasmetal Viale Monza 338 20128 Milano Italy +39 02 270941 info@trasmetal.net www.trasmetal.net

VERTICAL and HORIZONTAL Coating Lines for Aluminum Pro¿les.

Figure 5: The proﬁle cutting station.

Figure 6: One of the two anodic oxidation plants.

of the profiles. It is true, however, that the production process with a horizontal system is slightly less productive and more expensive than with a vertical plant, because it applies a greater amount of paint. According to our estimates, 6-7% more coating product per profile is used compared with a vertical system; the average amount of powder applied on a 6.5 m long profile is about 125 gr with a vertical

following the installation of the new press, which had greatly increased our coated profile production,” Ante Musa says. “We made a very quick agreement with Trasmetal because we had to install and start the line as soon as possible. It was a challenging project, since we wanted to achieve different goals: first of all quality, but also productivity. It was also a very stressful process, because there was little time to start the system. Trasmetal provided us with excellent service. Unlike our other two horizontal coating lines, which feature an immersion pre-treatment station separated from the painting one, we chose a system with an integrated spray pre-treatment tunnel. However, we selected another horizontal plant because we believe that the coating quality ensured by this technology is better than that offered by vertical systems.” “This plant brings two main advantages,” says Francesco Gioia, Trasmetal’s sales director. “The first one is the fact that the powder paint also falls on the profiles by gravity and not only due to an electrostatic effect, thus ensuring coverage of the whole surface and uniformity of the coating thickness. The second benefit is the possibility to also perform manual touchup operations to achieve perfect coverage or improve it in the most critical areas

7 Figure 7: Sublimated proﬁles.

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

We invested in this third painting line because we needed to expand our coated profile production.”

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

8 Figure 8: The new ofﬁce building is a veritable showroom for Feal’s products, since it has been built using almost all of the forty-two architectural systems manufactured by the company.

plant and about 135 gr with a horizontal one. With a horizontal system, the focus is on quality and not quantity: that is what Feal was looking for when it contacted Trasmetal.”

demineralised water,” says Anela Dumanc˘ic´, the chemical engineer in charge of the pre-treatment stage. “The process is the same for all three

The arrangement of the new horizontal coating line

In 2006, we replaced the chromating technology with a Qualicoat Seaside certified chrome-free cycle.”

“The pre-treatment process includes alkaline degreasing, two rinses with fresh water, acid degreasing, two further rinses with fresh water, one rinse with demineralised water, surface conversion with a chrome-free titanium-based product, and a final rinse with atomised

systems. In 2006, we replaced the chromating technology with a Qualicoat Seaside certified chrome-free cycle supplied by Alufinish. Since then, we

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

have never had any quality or corrosion problem; indeed, the pre-treatment results have remained constant. Actually, some of the technological features designed by Trasmetal for our pre-treatment tunnel have even improved the quality of the process by avoiding any dragging and tank contamination issue.” “In order to always perform an excellent pre-treatment process, we have equipped the tanks devoted to the active baths, i.e. alkaline degreasing, acid degreasing and conversion, with a double circuit,” Francesco Gioia from

FOCUS ON TECHNOLOGY

High coating efficiency with the OptiCenter

9 Figure 9: Before entering the tunnel, the load bar is tilted so as to move forward with its front part upwards and thus avoid any dragging or contamination among the different process stages, since the liquids are discharged towards the rear.

Trasmetal says. “When a tank is operating, the other one is idle or under preparation. In this way, when a bath is saturated, the operators can immediately swap the tank circuit without the need to stop production to prepare another bath and warm it. This expedient is very important for a factory working on three shifts, but it is definitely costly; however, Feal’s objective was not saving on the investment costs, but rather to achieve maximum quality and efficiency.”

OptiCenter OC02 - Simplified powder management - Closed loop powder circuit for a dustfree working environment - Constant powder transport using low-maintenance powder pumps - Optimized coating results - Constant mix of fresh and recovered powder - Automated cleaning process - High level of material utilization - Flexible equipment options 10 Figure 10: At the exit of the pre-treatment tunnel, the bar returns to its horizontal position to enter the drying oven.

Gema Europe Srl | Via Goldoni, 29 20090 Trezzano s/N | Italy T +39 02 48 400 486 F +39 02 48 400 874 www.gemapowdercoating.com

Particular attention has been paid to the pre-treatment tunnel, since the conveyor constantly moves back and forth to a certain extent, so as to provide a perfectly homogeneous surface treatment”

11 Figure 11: Each Magic Cylinder booth supplied by Gema is equipped with 16 Venturi technology guns.

“In order to facilitate the drainage of fluids from one tank to another, the load bars are tilted before entering the tunnel, so as to move forward with their front part upwards,” Gioia adds. “The excess liquid is therefore discharged in the tank that the load bar is leaving behind (Fig. 9). When exiting the tunnel, the bar returns to its horizontal position. This is crucial to the tunnel’s efficiency, because the dragging phenomenon is minimised, the contamination of the tanks is averted and the consumption of chemicals is limited to

the minimum necessary. Finally, the load bars also move back and forth inside the tunnel to achieve greater homogeneity of the pre-treatment results.” “The line has a cycle time of 210 seconds, corresponding to about 17 parts per hour. The different process stations are connected by chain conveyors. The fastmode transfer of the loading/unloading areas, the tunnel and the ovens takes place at 9 m/min, while near the powder application booths the pace is slow and constant (3 m/min). Particular attention has been paid to the pre-treatment tunnel, since the conveyor constantly moves back and forth to a certain extent, so as to provide a perfectly homogeneous surface treatment,” the coating line manager Miro Kolobaric´ states. “The pre-treatment tunnel is followed by the drying oven, with a capacity of 8 bars (Fig. 10). If it is full, a sensor stops the following load bar at the exit of the tunnel,” Kolobaric´ adds. “Each bar must

Figure 12: Each booth has an IR station for the powder pre-gelling.

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

CONVEY YOUR SUCCESS

FOCUS ON TECHNOLOGY

13 Figure 13: The plant is equipped with several storage buffers: the photo shows the 5-bar one placed before the pre-treatment tunnel.

remain in the oven for 25 minutes at 120°C. Then, it reaches our two Magic Cylinder spray paint booths supplied by Gema Europe, each featuring 16 Venturi technology guns (Fig. 11). We chose these booths because their rounded shape ensures reduced powder deposits and quick cleaning operations without even entering. The colour change operation takes about 10 minutes. The first booth only applies light shades and the second all other colours. During loading, the operator chooses the right booth for each load bar, thus grouping the batches by colour. After coating, each booth has an IR station for the powder pre-gelling, where the bar remains for 5 minutes before entering the polimerisation oven, which has a capacity of 13 load bars (Fig. 12).” “Thanks to the IR stations, we could work on both booths at the same time and have load bars with components of different colours enter the oven one after the other. However, in order to achieve the highest quality, we prefer to avoid this and rather group the batches by

colour,” Kolobaric´ says. “The bars stay in the polimerisation oven for 42 minutes 200-210°, and then stop in the overhead cooling buffer, which has a capacity of 25 bars. After one hour (one hour and a half for the largest profiles), an operator unloads them.” “The plant has 8 storage buffers,” says Gioia from Trasmetal. “One is in the loading area and has a capacity of 7-8 bars; a 5-bar buffer is in front of the pre-treatment tunnel; in front of the booths there are two dedicated buffers with different capacities, i.e. 8 and 14 bars; after each booth, there are two 6-bar buffers; a 7-8 bar buffer is located after the polimerisation oven for the first cooling stage; and, finally, there is a large overhead storage buffer with a capacity of 25 bars. The power&free heavy size conveyor has a maximum load of 400 kg per bar, compared with an average of 80-90 kg. The takt time of the line is 1 load bar every 3.5 minutes, i.e. 15 to 17 bars per hour; a complete cycle takes about 40 minutes (Fig. 13).”

INTERNAL HANDLING SYSTEM IMPIANTI MOVIMENTAZIONE INTERNA

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

14 Figure 14: The two tanks of the paint stripping system provided by Alit from San Bonifacio (Verona, Italy).

use Class 1 or 2 metallic and special effect powders; at the moment, we have not received any request for Class 3 coatings, yet,” Marko Novak states. “Powder coating accounts for about 70% of the required finishes, anodising for the remaining 30%. However, there is no definite trend: everything depends on the project and its specifications; sometimes, both methods are required within the same project. We can provide a very wide range of combinations of systems, colours and finishes.” “Our mission is to maintain a regional leadership position in the production of aluminium profiles for construction and to expand on the European market in high added value industrial segments,” Novak adds. “In order to do so, every day we follow the global trends in design, supplying aluminium to meet the present and future market needs while staying true to our motto: Quality first!”

Finally, Feal needed to paint-strip the material discarded after the coating stage. The company has proven to be at the forefront of innovation also for the recovery of defective profiles by installing the Fastrip system build by Alit Technologies, a firm based in San Bonifacio, Italy. “The plant is located before one of the two anodisation lines and it is composed of two tanks,” Lidija Djurasevic, customer service manager at Alit, says (Fig. 14). “The active bath works at 40° C with our alkaline product Metalstrip 1334 and the activator 1534. The product is able to paint-strip aluminium parts without any chemical attack. Depending on the thickness of the applied coating, the material must be immersed for more or less time. Afterwards, the workpieces have to be rinsed to remove any paint stripper residues. The second tank, therefore, is dedicated to the rinsing of the profiles, which are then dried with hot air. Finally, the parts can return to tunnel to be pretreated again before coating. “Feal uses this plant especially for the recovery of defective train windows. It is equipped with a filter press that constantly cleans the active bath, so as to ensure the correct removal of the paint stripped from the profiles and therefore lengthen the useful life of the product (Fig. 15).”

Paint stripping process

The company has proven to be at the forefront of innovation also for the recovery of defective profiles by installing the Fastrip system.”

Conclusions “Feal powder coats its products upon request. We have a few standard colours, but most of the times we paint based on our customers’ specifications. We mainly

15 Figure 15: Train windows before (left) and after (right) the paint stripping process.

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

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BRAND-NEW

Brand New Product Catalogue App: The Whole World of Viledon® Filtration – Always at Hand

The fastest connection to the world of ﬁltration: anytime, anywhere Users of the app can find valuable information, view and compare products or directly request a personal product selection - with the new Viledon® app (Fig. 1) from Freudenberg Filtration Technologies, all important information concerning air filtration is immediately available. “The Viledon® app complements our printed product catalogue and further increases the user-friendliness of our products and services for our customers and prospective customers”, explained Dr. Daniel Schmitt, Global Vice President Industrial Filtration at Freudenberg

ith a catalogue app that is unique in the industry, Freudenberg Filtration Technologies provides mobile access to its complete range of air filtration products and services. This will enable customers and potential customers to use a smartphone or tablet to instantly explore the company’s extensive product portfolio, in detail and at any time. Thanks to the clear structure, arranged according to application and product areas as well as a convenient search function, it is extremely easy to make a targeted product selection. Freudenberg Filtration Technologies is the first filtration specialist to present innovative product catalogue app including ISO 16890 filter classes.

1 Figure 1: With the Viledon® app, important expert knowledge and up-to-date product information covering all aspects of air ﬁltration from Freudenberg Filtration Technologies can be called up anytime, anywhere.

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

Filtration Technologies. “Whether in production areas or in the office, the app makes all relevant information available anywhere and anytime via a smartphone or tablet.” In common with the 148-page printed product catalogue 2017/2018, the Viledon® app presents the complete product portfolio of Freudenberg Filtration Technologies in a new, easily comprehensible form. For example, colorsubdivided tables facilitate an overview of the different test standards relevant to Viledon® products, including for the first time filter classes according to ISO 16890. A further highlight is the integrated request function for filters. Users can photograph filter products within the app and request them directly from the Viledon® service team with a single click. Printed product catalogue, website and app - with this information and service initiative, Freudenberg Filtration Technologies is once again setting standards in the 60th year of their filter business’ existence, underscoring its position as a technology and consulting leader for innovative filtration systems. The Viledon® app is available online at www.viledon-app.com for free download, right now. The Viledon® Product Catalogue 2017/2018 is also available as a PDF download at www.freudenberg-filter.com. Requests for printed copies should be sent to: viledon@freudenberg-filter.com. For further information: www.freudenberg-filter.com, www.viledon-app.com

BRAND-NEW

coReflect from Dürr is an innovative light tunnel for checking surface quality (Fig. 1). With an innovative light concept and a perfectly ergonomic environment design, it delivers precise and highly focused vision. This permits continuous detection of irregularities in paint with maximum accuracy. Before car bodies leave the paint shop and go into final assembly, the paint structure is checked for the smallest flaws like inclusions of dust or small hairs. The EcoReflect light tunnel provides the best visual and ergonomic conditions for this difficult quality inspection task.

A Focused and Accurate Detection of Flaws With EcoReflect: An Innovative Light Tunnel for Checking Painted Surface Quality fatigue symptoms for operators. With EcoReflect, appropriate prisms at the lamps ensure that as much light as possible is shone onto the car bodies, and that the operators are not subjected to glare. The radiation principle of asymmetric lighting helps here.

Dürr has also enhanced the luminaire concept with the use of LED modules. The result is both high contrasts in the reflected image and areas with homogeneous illumination. The LED 1 technology used requires just the half of the energy of conventional Figure 1: The innovative EcoReﬂect light tunnel offers the fluorescent tubes. EcoReflect is also best visual and ergonomic conditions for checking the more economical than standard LED quality of painted surfaces. Detecting deviations calls for a reflected designs because the arched shape image with high, but not too stimulating, of the light tunnel casts a particularly contrasts. With EcoReflect, the number of lines, with this system the operators do large amount of light onto the car body. contrast lines in the field of vision is also not have to keep looking up and down, EcoReflect can be constructed as an based on a suitable stimulus frequency. which is much more ergonomic and less individual station or as a line. The system can Since it generates vertical contrast lines, the physically strenuous. also be extended and customized in terms of operators can follow the progression of the Glare-free vision is another important light colors and materials for complex flaw car bodies when checking them. In contrast prerequisite for detecting surface types. to conventional systems with horizontal flaws and at the same time minimizing For further information: www.durr.com

SUCCESS STORIES

Axalta Coating Systems Protects Façade of Turkmenistan’s New Airport

Ashgabat International Airport (Figs. 1 and 2), one of Turkmenistan’s most prestigious infrastructure projects, required a façade coating that would be extremely resistant to weather degradation and that would provide lasting gloss and color retention. Willi Müsgen, Managing Director of KölnColor, the company in Cologne, Germany, who handled the coating of the airport’s

striking 32,000 m2 falcon-shaped façade, explains: “As the metal fabricator wanted RAL 9016 HFW Matt Traffic White for the huge shape, we chose Axalta’s Alesta SD Matt RAL 9016 knowing it would meet all the requirements. We work with Alesta SD powder coatings very frequently, so we know how the product behaves.” Köln-Color received sections of the façade between October 2015 and June 2016 from

xalta Coating Systems, a leading global supplier of liquid and powder coatings, has provided its Alesta® SD (Super Durable) line of super durable powder coatings for the façade of Central Asia’s largest airport, the new Ashgabat International Airport. Alesta SD has been specifically developed to provide better color and gloss stability, making it ideal for commercial building projects such as this, in addition to high-end residential projects.

1 Figure 1: Alesta® SD, line of super durable powder coatings, has been provided for the façade of the new Ashgabat International Airport.

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

SUCCESS STORIES

international façade specialist Christian Pohl GmbH, also based in Cologne, Germany. Once coated in Alesta SD, the panels made of 3mm aluminum were shipped to Ashgabat in sections for assembly. Olaf Duisberg, Architectural Powder Coatings Key Account Manager for Axalta in Germany, adds, “We are delighted to have worked with Christian Pohl and Köln-Color again to realize the architect’s vision for this stunning project. Our Alesta SD range is designed for buildings that are exposed to direct sunlight, as it is extremely weather resistant, so it was an ideal choice for the Ashgabat International Airport, helping to keep it looking good for years to come.” Thorsten Evenkamp, Vice President and Head of Sales of Christian Pohl GmbH, says, “This was a very important project for us. We had to make sure every aspect of the façade fabrication met the exacting standards and performed at the highest level. We’ve also worked closely with Axalta for a number of years, so we were pleased to know our work would be protected by, and made to look even better with, Alesta SD powder coating.” The international airport project, which is valued at an estimated US$2.3

2 Figure 2: The international airport project encompasses 30 buildings on a 350,000 m2 site.

billion, encompasses 30 buildings on a 350,000 m2 site just outside the capital, Ashgabat. It includes two passenger terminals, and will be able to serve more than 17 million passengers and handle more than 200,000 tonnes of cargo a year. The SD – standing for Super Durable - designation is one of three widelyused durability levels in the powder coatings industry. Alesta AP, which is

a range of architectural polyester powder coatings suitable for residential or smaller projects in normal climate conditions. Alesta SD powders provide better color and gloss stability, ideal for high-end residential and commercial buildings. And finally, Alesta UD are ultra durable powder coatings designed for prestigious buildings or for regions with high levels of UV radiation. For further information: www.powder.axaltacs.com

WHO CAN MEASURE SURFACE FREE ENERGY WITH ONLY ONE CLICK IN LESS THAN A SECOND? WE CAN. AT KRÜSS. Visit us at European Coatings Show in Nuremberg | April 4 to 6 | Hall 5, Stand 5-327 | www.kruss.de

Opening photo: Rembrandtin Lack GmbH Nfg. KG celebrates its 80th anniversary.

HIGHLIGHT OF THE MONTH

“Good Lack” – Industry Partner Since 1937 Cornelia Camondo Helios Group, Vienna, Austria

cornelia.camondo@helios-group.eu

he Rembrandtin Lack GmbH Nfg. KG (Ref. opening photo) is one of the leading coating producers of the European industry. The company has decades of experience particularly in the areas of heatresistant systems, protective coatings, zinc flake coatings, road marking materials, core plate varnishes, and railway coatings, and is the driving force behind many innovations in the industry. About 35 % of the staff work

in research and development and constantly develop new energy-efficient, environmentally friendly high-tech coatings. This very commitment is one of the many secrets to the success of the company. This year, Rembrandtin celebrates its 80th anniversary. For 80 years, the name Rembrandtin has been standing - almost as a matter of course – for top quality coatings and first-class services within the coatings industry. Above average

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

commitment, highest quality, innovative power, and team spirit are the major factors for today’s success of the company, which has been accompanied and shaped by Hubert Culik for 50 years. The visionary used his ambition not only to advance the success story of Rembrandtin but also to improve the image of the entire industry. Hubert Culik was Board Member of CEPE (the European Coatings Association) for 6

HIGHLIGHT OF THE MONTH

years, and today he is President of the Austrian Research Institute for Chemistry and Technology, Chairman of the Chemical Industry Association and CEO of the Helios Group. Rembrandtin is part of the Helios Group which ranks among the top ten companies of the European coatings industry and will soon belong to one of the largest coating companies worldwide. On 6 December last year, the share purchase agreement was signed with Kansai Paint Co. Ltd., the new strategic partner of the Helios Group. Helios will become the European center of Kansai Paint for R&D as well as innovations and company development. Rembrandtin will play an important role within this Group. During the last eight decades, Rembrandtin has developed into a specialist for

high-tech coatings in the most different industrial sectors meeting tomorrow’s requirements already today. The latest coatings technologies such as high solids, water-borne and UV-curing combined with nanotechnology are an integral part of this development. The use of nanoparticles enhances coating systems with additional functions such as barrier effect, high scratch resistance, insulating and deflecting functions as well as other special properties. The tailor-made and environmentally compatible industrial coating systems of the Austrian traditional company are applied worldwide and have a large number of international certifications. Rembrandtin Coatings has been focusing for decades on effective environment protection. The company is a pioneer within the chemical industry with regard

to environment protection documented by a number of awards. Continuous improvement processes, the optimization of internal environment protection as well as occupational and plant safety help increase this strength constantly. The integrated management system for quality, environment and safety is implemented actively by management and all employees. Rembrandtin Lack is audited and certified according to ISO 9001, ISO 14001, Responsible Care and EMAS. Dietmar Jost, Managing Director of Rembrandtin Lack GmbH Nfg. KG, is certain: “The combination of experience and the willingness to try out new things will lead to new development opportunities and international growth potentials for Rembrandtin also in the future.”

Coating and painting with efficiency and highest quality! The new manual airspray gun Topfinish GM 1010-G CAT-X guarantees excellent coating results due to outstanding ergonomics. It is convincing with: Optimum atomization quality Easy to use Individual adjustment of the spray jet width Wide selection of nozzles sizes and air caps

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N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

DFV: A certified and guaranteed coating process with the application of the Industry 4.0 innovations to aluminium finishing Alessia Venturi ipcm®

owner of DFV, decided to install it also FV is a major coater of extruded In the last two years, DFV has replaced all on the vertical systems of the other two and rolled aluminium for the spray paint booths of the vertical plants factories. architecture and an Italian leader in installed in its three facilities with last Well aware that nowadays diversification the field of powder-on-powder wood-effect generation “V”-shaped booths designed is the key to success, especially for a decoration (ref. opening photo). With its by SAT (Verona, Italy). Two patents cover contractor treating three plants in Surano workpieces with very (Lecce), Meolo (Venice) different shapes and Favara (Agrigento), even within the same this firm covers almost product category the entire national and working with territory thanks to increasingly small sophisticated logistics, production lots, highly computerised production DFV has chosen to start an advanced management and industrialisation plan cutting-edge coating whose requirements systems. can only be met This modern and with technologies technological approach to contracting coating 4.0, that is, with the enables DFV to interaction among 1 machines. In this maintain consistently framework, DFV is high quality and service Figure 1: From left to right: Alessia Venturi, Luciano De Francesco, Andrea Trevisan and Pino implementing the standards. This makes Coppola, production manager DFV. Smart Coat vision it a strategic partner for window manufacturers, system patented this system, one concerning its layout and by SAT, able to recognise a profile from distributors of aluminium profiles and the other related to the cyclone cleaning its section and automatically control all metal architecture designers. Being at the forefront of the coating sector since system, which reduces the powder process settings, thus ensuring a fully recovery time during the colour change repeatable finish. When fully fine-tuned, the late ‘90s, it could only be among the operations. Initially installed only at the the Smart Coat system will enable DFV to first companies in Italy to implement the principles of Industry 4.0 and the Agrigento plant, the new booth proved achieve a level of efficiency and production so efficient that the De Francesco family, optimisation rarely, if ever, achieved so far. technological innovations related to it. Opening picture: White wood effect on aluminium proﬁles.

international PAINT&COATING magazine - MARCH/APRIL 2017 - N. 44

DFV “This company was established in 1972 as a distributor of aluminium profiles. In 1997, however, it transitioned to coating. At the beginning, it only worked with wood-effect finishes, which had recently appeared on the market and had considerable appeal to consumers,” says Luciano De Francesco (Fig. 1). “The wood-effect aluminium windows have quickly become successful in Italy and particularly in the South, where the aluminium market has always served more the residential construction field than the commercial or public ones. In 2000, we opened our first plant coating with the whole RAL range in Surano. In 2004, we became part of the Trevisan/Cometal group and we annexed the Agrigento plant, which was in its starting phase. In 2009, we decided to buy back the shares sold to Trevisan/Cometal, thus returning 100% owners of the company, and to acquire TSM Italia, another coating firm of the group that had the plant in Meolo, in the province of Venice. Since then we operate in three factories from which we cover the entire national territory. The Agrigento plant serves the markets of Sicily and Sardinia, the Venice one Northern Italy up to Tuscany and Marche, and the Lecce one Southern Italy to Lazio.”

LONDON | UK

o t t a f n e B NEW FETTER LANE

DFV is the undisputed leader for what concerns the powder-on-powder technology, of which it owns nearly 90% of the Italian market shares.”

“The three plants are virtually clones of each other: despite the different areas of competence, they all have the same manufacturing organisation and the same finishing systems. The administrative management, the sales office and the R&D department are located only in Lecce,” De Francesco adds. “Our typical customers are distributors of window systems, retailers of aluminium profiles and to a lesser extent the door and window frame industry, especially from the shutter, mosquito net and awning fields. We provide our clients with a complete service that goes beyond the coating process, as storage at our warehouse, and order picking from their stock.”

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engineered by Focchi

» INGEGNERIA ITALIANA PER FACCIATE » VERNICI IN POLVERE AUSTRIACHE

The plant organisation: working like clockwork In the plant of Surano, there are two coating lines. The horizontal one (Fig. 2) treats sheets as well as small and very small extruded parts, while SAT’s high productivity vertical one finishes 90% of extruded workpieces, applying both RAL and metallic colours as well as the basecoats needed for the wood-effect coatings (Fig. 3). Such finishes remain DFV’s core business: the company holds a relevant share of the market of wood-effect coated profiles. In particular, it is the undisputed leader for what concerns the powder-on-powder technology, of which it owns nearly 90% of the Italian market shares.

FOCUS ON TECHNOLOGY

LONDON | UK

e n o d l l e W MOOR PLACE

2 Figure 2: The horizontal plant for aluminium sheets and proﬁles.

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» ITALIAN FACADE CONSTRUCTION » AUSTRIAN SURFACE SOLUTIONS

In order to handle such large volumes, DFV uses all the technologies available on the market. The Lecce factory is equipped as follows: three powder-on-powder profile coating systems (Fig. 4) from SAT’s EZY range, which includes horizontal and offline wood-effect coating plants with great flexibility; an EZY system for metal sheets; a sublimation plant; and an EFFECTA system, a project of SAT dating back to a few years ago, integrated in the vertical plant. It is used for the in-line powder-onpowder application of wood-effect coatings and it ensures high productivity and low costs, but also less flexibility and greater handling difficulties when treating profiles with very different shapes. The vertical coating plant (Fig. 5) was installed in 2005, but it has been retrofitted several times, the last of which for the addition of the new spray paint booths designed by SAT. “Some interventions have been carried out to prevent a loss in productivity when switching from RAL colours to the basecoats of wood-like effects,” Luciano De Francesco explains. “The conveyor has been changed many times: we have extended some segments inside the ovens and we have created a bypass storage buffer for the application of the basecoats that cure at a low temperature.”

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3 Figure 3: Several wood effects produced by DFV.

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applied with the silk-screen technique in the case of EZY systems and with a roller in the case of the EFFECTA machine – would remain on the surface, “unbound” from the basecoat and with an unrealistic aesthetic effect. Conversely, the basecoats for the sublimated wood-effect finishes are polymerised at a higher temperature than normal. We have added a second conveyor with an alternative route and a second oven in the middle of the line to avoid having to empty the curing oven and lower the temperature for every incoming wood-effect batch. The profiles treated with a basecoat follow the secondary circuit and remain in this second oven for about ten minutes, while the ones coated with RAL colours follow the main route. The production flow, regardless of the circuit followed by the profiles, is always based on the First In First Out (FIFO) approach.” © ipcm ®

The profiles treated with wood-effect finishes in the in-line EFFECTA system are sent to The problem was the first coating booth for the application of achieving a good the basecoat, then to the oven at 120°C for productivity level in terms the gelation stage, to another booth for the of RAL coatings but, at the application of a powder layer, and finally to a same time, optimising roller (Fig. 6) that applies the wood effect on the wood-effect profiles’ such layer. The cycle ends in the main curing production.” oven, which polymerises both layers. The profiles with a wood-effect finish obtained with the EZY machines follow the same route but, after exiting the low temperature oven for the gelation of basecoats, they reach the bypass storage buffer (Fig. 7). Here, they wait to be hung again in the same position selected at the time of loading. “The basecoats for the powder-on-powder woodeffect finishes are cured at 4 115-120°C, because, if they were completely polymerised, Figure 4: One of the EZY machines in use at Surano DFV plant. the subsequent powder layer –

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With the new booth out of 100 grams of sprayed paint, at least 50% is deposited on the profile.”

5 Figure 5: The loading station.

with a cleaning system positioned at their base (Fig. 10), so that all the powder that settles on the carpets is recovered and recirculated after passing through the cyclone. The Surano plant was the last company’s facility to implement it. © ipcm ®

“The problem here was achieving a good productivity level in terms of RAL coatings but, at the same time, optimising the woodeffect profiles’ production,” states Andrea Trevisan from SAT. “We have chosen a monorail conveyor with transferable hooks (Fig. 8) because the profiles that enter the oven for the gelation of basecoats can follow the circuit created to bypass the main oven (Fig. 9) and fill the gap on the chain in order to return to the main route for the unloading operations. In the past, DFV lost two hours of production for every switch from a RAL to a wood-effect coating, which required a transition from high to low temperature within the same oven. With the additional oven and the alternative route, they no longer have any production downtime.”

The new spray paint booths The vertical plant is equipped with two booths working alternately to minimise the time lost during the colour change operations. In August 2016, DFV replaced its old booths with SAT’s new self-cleaning, “V”-shaped ones. They feature opposing guns in groups of four and two carpet walls

6 Figure 6: The roller of the EFFECTA machine.

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“What is interesting is that, in the past, DFV had replaced only one of its booths, namely that of the Meolo plant, with our previous generation self-cleaning booth. After we launched on the market our “V”shaped booths with opposing guns, in 2013, the company has replaced all six of them within eighteen months,” Trevisan says. De Francesco explains: “SAT’s previous generation, “C”-shaped booths only ensured benefits in terms of cleaning time. The new generation, “V”-shaped ones, despite featuring the same concept of self-cleaning carpet walls, have greatly improved the application efficiency and quality level.” First of all, the guns divided into four opposing groups improve the efficiency of the first application process (Fig. 11). “Out of 100 grams of sprayed paint, at least 50% is deposited on the profile; with our old booths, only 30% was. This gun arrangement also ensures better surface coverage: it is possible to perfectly cover even the most difficult-to-reach areas while depositing a lower thickness on the parts in sight,” De Francesco says. “This has enabled us to perform quicker colour change operations, but also to increase the quality of our coated profiles and save about 20% of paint. The four groups of guns are started in sequence as the profile passes through the booth. This results in a great saving of paint, whereas in the past, when we used twenty guns simultaneously, we threw away some coating for about two minutes.” Secondly, a booth designed with a more acute angle requires less suction power. “We used to have 40-45 Kw suction fans, but now a power of 30-35 kW is sufficient. Moreover, the suction action is dynamic: it is activated only when the guns spray and

FOCUS ON TECHNOLOGY

operational safety, according to the stroke of because SAT has greatly the reciprocator,” Andrea unburdened the old Trevisan explains. “In this reciprocator by mounting way, we have reduced the the gun groups on three total intake, but suction is different reciprocators that more efficient and takes are very efficient linear place only where needed. tracks,” De Francesco The powder does not leak states. out of the booth and it is not taken away from the Maximum profile.” productivity The third and main The productivity of DFV’s advantage offered is vertical plant in Surano the new arrangement exceeds 20 tonnes per of the guns in opposing shift, about 40% of which groups of four, enabling 7 is made up by wood-effect the profiles to be profiles. The company simultaneously coated on Figure 7: The bypass storage buffer. performs a colour change both sides. “The powder operation every half cloud has a lower hour, with a total of speed compared 30-40 daily changes. with the booths The whole production with guns located in flow is computerised front of the profiles, with a MES1 system which incidentally to follow every no longer have to order step-by-step. rotate,” Trevisan However, with adds. “A lower speed such a variability of means that the the profiles to be electrostatic process painted, optimising has more time to production and work, so that the making it more powder penetrates efficient was a more effectively in challenge (Fig. 13). the profile cavities. “The operating The suction units principle of the placed at the vertices 8 9 vertical plant is of the triangle make almost a detail in the sure that the powder Figure 8: The transferable hooks system. Figure 9: The curing oven. global production cloud properly moves process, because towards the suction those 20 tonnes of coated aluminium per shift openings, encountering the transiting profiles (Fig. 12). In the older booths, the sprayed The four groups powder was sucked in the opposite direction 1 The phrase Manufacturing Execution System (MES) indicates a computerised system that has the main to the profile transit.” of guns are started in function to manage and control the production ﬂow of a factory. This includes the dispatch of orders, the All these factors have resulted in a 10% sequence as the profile progresses in terms of quantity and time, and the productivity increase, since DFV has raised passes through the booth. storage operations, but also a direct connection with the machinery to collect useful information for the integration the speed of its line from 1.5 to 1.64-1.7 m/ This results in a great of the different manufacturing aspects as well as the min. “Lastly, we have achieved greater saving of paint.” generation of data for the control of production. international PAINT&COATING magazine - MARCH/APRIL 2017 - N. 44

account for about 350 orders with an average of 120-130 kg of components in different shapes,” De Francesco states. “Moreover, since our reference market is residential architecture, we are required hundreds of different colours and several wood-effect finishes. We deliver 80% of orders within five working days. Considering that, in some areas, transport only takes two days, we deliver a batch in an average of three days. We offer about 150 colours with a five-day delivery, while for non-standard shades we require five further working days for the procurement of the coating. “This requires a highly advanced production © ipcm ®

11 Figure 11: Two of the four groups of spraying guns.

The future: SAT’s Smart Coat vision system

SAT’s smart vision system is self-learning: it can recognise the shape of each profile and match it with a coating program among those preset by the client in its database.”

scheduling system. Having several regular customers, we have managed to computerise all our processes. The orders are transmitted before aluminium reaches the plant, so that when the material arrives in the morning, it is immediately checked and already in the afternoon it is available for painting. However, no customer takes any commitment with us: they submit orders according to their requirements, regardless of colours or quantities. We do not know what we will have to paint until we receive the orders.”

12 Figure 12: The inside of the coating booth.

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Figure 10: The “V” shaped coating booth.

The new Smart Coat system patented by SAT, an innovation for the coating field in the direction of Industry 4.0, has been developed for coating contractors like DFV, which must handle a huge number of different profiles. “Our IT production system ensures that all orders are identified and located for maximum traceability. Once checked, the orders are sent to our automatic warehouse and used by a software application to compose the operators’ work program. Every batch hung onto the vertical system is assigned a tag that identifies it,” Luciano De Francesco explains. “During coating, the tag records the profile’s tracking information, that is, the working parameters and conditions (from the oven temperature and the curing time to the baths’ concentration), which at the moment are set manually. We create an “identity card” for each order that is also available for our customers to monitor the processing of their orders via internet. We are currently working to enable them to print a certificate of conformity attesting that their components have been produced in a given period of time of a certain day, with certain characteristics (metal

removed, chrome coating thickness, gloss value) and in compliance with the standards Qualicoat 1, 2 and/or Seaside.” “However, the choice of the coating program for each profile is still a manual process performed by operators. The same applies to the adjustment of the spray guns depending on the parts’ shape,” De Francesco says. “The fact that the new booth enables to adjust the guns in groups of four, rather than all at once, is a big advantage compared with the old one. On the other hand, the Smart Coat system that we are testing and gradually implementing will allow for an individual gun adjustment to the shape of the profile to be treated.” SAT’s smart vision system (Fig. 14) is selflearning: it can recognise the shape of each profile and match it with a coating program among those preset by the client in its database. “This implies the recognition of individual profiles and not just of orders,

FOCUS ON TECHNOLOGY

13 Figure 13: DFV work with a very high productivity: only few centimetres are left between two colours.

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the burner’s settings, the temperature of the oven to be changed according to the incoming aluminium mass, or the chain speed to be reduced to improve the aluminium attack in the alkaline bath required to comply with the Qualicoat Seaside standard (Fig. 15).”

Conclusions

In the last few years, DFV has heavily focussed on logistics 15 and customer service. Standardisation, Figure 15: The entry of the pre-treatment of quality, real time tunnel. parameter control, and the automatic setting of machines according to the sensors’ readings enable the company to offer a product with a high and constant quality standard (Fig. 16). “We have strived to perfectly organise both our physical flows and the information and logistic ones,” Luciano De Francesco says. “We should manage to operate paperless by the end of 2017, and our activity will be constantly monitored for constant quality and cost control, down to every order. We aim at enabling our customers to automatically download online a 10 year warranty certificate for the Qualicoat Class 1 products and a 15 year certificate for the Class 2 ones.” © ipcm ®

as happens now. The guns can be automatically adjusted to the coating program to be performed,” Trevisan states. “This will be a strategic innovation especially for aluminium coating contractors, for which it is normal to simultaneously have profiles with different shapes in the same booth. With this vision system, the assigned coating program will “follow” the profile in the booth even if it is 14 hung among different parts. This will result in Figure 14: The video camera of SAT’s Smart a more standardised Coat vision system. production.” “The ultimate goal of the Smart Coat system will be recognising a profile and having an algorithm instantly create the ideal program for that component and that kind of coating. The idea is to provide our booths with a vision system with this knowledge, namely a smart system that knows how to coat,” Trevisan adds. “We will get close to this objective by gaining experience and with the help of other companies that are already testing such interaction among machines. DFV is still in the setting and algorithm development phase. The profile recognition will then enable us to work on other parameters, such as the amount of chemical product to be dosed according 16 2 to the m of material Figure 16: The unloading station. loaded on the line,

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INNOVATIONS: PRESENT&FUTURE

PURAL® ZEROZERO: a second generation ZLD wastewater treatment (with no evaporator and without the formation of liquid sludge) Franco Falcone San Zenone al Lambro, Milano, Italia

franco.falcone@cieeng.com

IE Srl is a company specialising in the can be applied to both horizontal and design and installation of purification vertical aluminium coating systems. systems for the wastewater of However, the treatment is facilitated in pre-treatment, coating, anodic oxidation and aluminium finishing processes. This firm (Fig. 1) has been a pioneer in the Zero Liquid Discharge (ZLD) water treatment technology. The surface attack that occurs during a pre-treatment process for preparing aluminium to coating is relatively limited: about 1 or 2 gr/m2 of metal are removed, both with chrome-based and with more modern chrome-free systems. That is why the concentration of chemicals, salts, pollutants and metals in the rinsing water is relatively low. The ZLD technology 1 was initially developed for the purification of pre-treatment Figure 1: Franco Falcone, the founder of CIE Srl. water precisely because it is a less difficult process. The first system of this type was installed at the vertical ones because the dragging the All.co plant of Pisa (Italy) in 1992. Over of pre-treatment water from one process fifty plants have followed, up to the most phase to another is limited, compared with recent ones installed at the premises of horizontal lines. Metra in Brescia (Italy) and in Canada. CIE Srl The remarkable development of this is now a world leader in the zero discharge technology has been due to two main industry, with a percentage of installed factors: the increasingly frequent use of equipment that exceeds 80% of the total. chrome-free pre-treatment processes Most of these systems are to be found in and the transition from alkaline to acid Italy, Greece, North America and Middle East. chemicals to attack aluminium surfaces. The ZLD wastewater treatment technology These elements have enabled an easier

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

development of the ZLD technology, also making it relatively less expensive in terms of both plant cost and management expenses. The absence of chromium in the rinsing water makes it “lighter” and characterised by a lower concentration of salts, while the absence of soda in the baths, and therefore in the water to be treated, facilitates the chemical purification process. Incidentally, these two factors are of benefit not only to the ZLD technologies, but also to the conventional ones. In the water coming from acid-based pre-treatment processes, acids can be neutralised and metals abated, so that there are no more residues after treatment. In the water coming from alkaline-based pre-treatment operations, on the other hand, sodium has to be neutralised; however, it will always be present in small amounts in the treated water. ZLD systems are crucial in countries or at production sites with inadequate availability of water, where the discharge limits are particularly restrictive, and in all the cases in which a more eco-friendly treatment system is required.

INNOVATIONS: PRESENT&FUTURE

PURAL® ZEROZERO: the second generation of ZLD systems

liquid, but only solid sludge. It is worth mentioning that sulphates and fluorides are abated without the use of barium, known for some time but never used The great innovation that has emerged in the last due to its high two years is the new handling costs. PURAL® ZEROZERO The PURAL® system, created by the laboratory of ZEROZERO process is MST Chemical, a company of CIE Srl’s completely chemical. Its only group. Both firms physical aspect is invest substantial resources in the final filtration of water. The research and are elimination of equipped with the demineralisers latest tools: an 2 and evaporators atomic absorption makes the water spectrometer Figure 2: The ICP atomic absorption device for the analysis of treatment system (Fig. 2), a all metals and elements. significantly spectrophotometer more economical (Fig. 3), a liquid in terms of both purchase chromatography device, a and management costs. water treatment pilot plant, The PURAL® ZEROZERO It can be said that and so on. the cost of a PURAL® As is well known, the technology completely abates ZEROZERO plant is now currently used ZLD systems the sulphates and fluorides very close to that of a require a rinsing cycle with present in an acidic solution conventional system, ion exchange resins and the and therefore recycles with a maximum gap of final use of an evaporator, wastewater without any 20%. As a result, it is which inevitably produces demineraliser or evaporator easily predictable that in liquid sludge to be disposed and, without producing any the near future at least of, often at a high price. liquid sludge.” 80% of the new plants Combined with the fact that the plant’s installation costs will be second generation ZLD systems. about twice as much that of standard systems, this is certainly a disadvantage. The water obtained with PURAL® ZEROZERO is The PURAL® so pure that ZEROZERO their discharge technology (Fig. 4) into sewer completely abates (in full respect the sulphates of the most and fluorides stringent present in an limits) would acidic solution and be a real therefore recycles waste. This wastewater without technology any demineraliser is predicted 3 or evaporator and, to develop of course, without precisely in Figure 3: A spectrophotometer for the in-line analysis of water. producing any that direction.

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Application ﬁelds In addition to the coating and anodic oxidation of aluminium profiles, the PURAL® ZEROZERO technology is successfully applied to the treatment of water in sectors such as coil coating, sulphuric acid pickling, stainless steel pickling processes using sulphuric and hydrofluoric acids, galvanisation, radiators, alloy wheels, and so on.

Conclusions

Figure 4: A diagram of the PURAL® ZERO ZERO technology applied to Aluminium PAINT LINE.

The main problem posed by the development of this process was finding a system that could eliminate any sulphates from pretreatment water without the use of barium, which, as is well known, generates high costs as well as the formation of an amount of sludge that is three times higher than normal (Fig. 6). PURAL® ZEROZERO’s strength is the use of a proprietary, economical chemical specialty (Fig. 7). Its first application to an anodic oxidation

PURAL® ZEROZERO for the wastewater of anodic oxidation processes Anodic oxidation processes include stages with both acid and alkaline products. As already stated, the PURAL® ZEROZERO (Fig. 5) technology is effective in the treatment of acidic solutions. Also in this case, the purification is carried out without the aid of any evaporator or demineraliser. The acid component of water is treated with the PURAL® ZEROZERO system and the resulting liquid, with a conductivity of less than 400 μS and an amount of sulphates lower than 150 ppm, is recirculated in the alkaline process instead of fresh water. Then, after use, it is sent to the final neutraliser, which can also be an already existing standard purification plant. In anodic oxidation processes, on average, 50% of water is used with acidic solutions. This means that the use of the PURAL® ZEROZERO treatment ensures a saving of at least 50% on water consumption. This system can be also applied to any already existing wastewater treatment plant, even those not manufactured by CIE Srl.

5 Figure 5: A diagram of the PURAL® ZEROZERO technology applied to the ANODIC OXIDATION PROCESS.

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

6 Figure 6: A ﬁlter press to assess the quantity and quality of the sludge produced.

plant has been performed for Talex, a leader in the extrusion and coating of aluminium profiles in the United Arab Emirates based in Abu Dhabi. For obvious reasons, regulations in its area are focussed on saving water resources; they impose a limit of salinity in wastewater and require the use of the best technologies to reduce water consumption by at least 50%. The metal treatment industry accounts for 70% of the use of sulphates and their discharge in water. Just think of the thousands of companies in the mining sector discharging water containing sulphates in much higher concentrations than the allowed limits, but having special permissions because there is no alternative treatment technology. The PURAL® ZEROZERO process unquestionably represents a little big step forward for the safeguard of water resources and for a cleaner sea.

Figure 7: A small pilot plant.

Opening photo: Aluron manufactures aluminium systems for wood-aluminium, PVC-aluminium or aluminium-only used in modern building industry. The company’s ﬂagship product is its welded proﬁle obtained with a process that makes the seam between the various components virtually invisible after coating.

FOCUS ON TECHNOLOGY

A diamond spray paint booth for the selective coating of aluminium profiles: Aluron’s choice Alessia Venturi ipcm®

esigning indoor and outdoor environments with the use of aluminium systems is becoming increasingly easy and economical in architecture. Transparent façades open up unlimited possibilities, also enabling the harmonious integration

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

of buildings with their surroundings while still focussing on safety, functionality and aesthetics. Modern, minimalist but effective design, excellent energy efficiency, comfort, and greater exploitation of natural light are just some of the requirements of the increasingly demanding

customers, which the designers meet using new generation doors, windows and façades. Having a wide range of systems, colours and finishes to choose from allows them to create stunning combinations. That is why the manufacturers of aluminium systems for frames and façades do not only diversify their profiles’ shapes, but also their finishes.

Aluron: an impressive range of options for metal architecture

FOCUS ON TECHNOLOGY

1 Figure 1: Aluron’s plant in Zawiercie, Poland, near Katowice.

The aluminium systems produced by Aluron (Zawiercie, Poland - Fig. 1) have dominated the Polish metal architecture market and Transparent façades successfully penetrated many other European open up unlimited markets since 2002. The mission of this possibilities, also enabling company is providing innovative technologies the harmonious integration for windows, doors and façades. In the last of buildings with their few years, it has grown very rapidly also surroundings while still thanks to the diversification of its offer: focussing on safety, indeed, Aluron manufactures coated profiles functionality and aesthetics.” for wood-aluminium, PVC-aluminium or aluminium only systems and offers a contracting coating service. Customers, architects and joiners appreciate the variety of its profiles’ shapes, functions, materials and finishes. “In order to try to meet all our customers and designers’ needs, we have focussed on the development of some exclusive colour collections in collaboration with our suppliers of powder coatings,” Aluron’s Export Sales Director Adrian Musik says. “In addition to our RAL, Pearl Effect RAL and 2 NCS ranges, we now have four exclusive colour series (Fig. 2). Figure 2: The four Aluron Colour Collections.

Three of them include special effect powder finishes (metallic, textured, hammered, etc.), while the fourth one is made up by wood-like and bonze-like finishes that we obtain with the sublimation technique. The Aluron Colour Collections include a total of 120 shades that we offer in addition to the RAL and NCS ones.” That is an impressive range of options. “This explains our decision to invest in a new vertical coating plant for aluminium profiles,” says Cezary Dziecinniak, the Chief Investment Officer of Aluron (Fig. 3). “This system has been operational since the end of February and it will enable us to speed up our colour change operations, on average 30 to 40 per shift, thus increasing our productivity and reducing our time-to-market. Moreover, we will be able to acquire numerous customers working with different production batches and a wide range of colours. Finally, the new booth concept will greatly facilitate the coating of our profiles, which have to be painted on one side only because, in most cases, they are intended for use with wood or PVC.” For its new plant, Aluron has chosen the technology of Euroimpianti, a company based in Valeggio sul Mincio (Verona, Italy) and represented in Poland by Eco-Line from Krosno. This firm has supplied it with a vertical system for profiles that are up to 7 metres long (Fig. 4), whose most innovative aspect is the new, patented spray paint booth. Euroimpianti calls it “diamond booth” due to its symmetrical layout, which is very different from that of

international PAINT&COATING magazine - MARCH/APRIL 2017 - N. 44

construction, finishing and shipping of profiles. We receive 90% of our profiles from different Polish extruders, but we also have a few suppliers based in other parts of Europe. The main advantage for our customers is that we provide most of our systems as a finished product, that is, already welded or mechanically connected frames, equipped with all Advanced production accessories, and coated. technologies for Our clients, most of which the most atypical are joiners, only have to requests couple the aluminium part “Aluron was established as with their wooden or PVC a manufacturer of profiles elements.” for wooden windows and “Our strength are our 3 doors,” Cezary Dziecinniak welded profiles, whose states. “The second step was connections are practically Figure 3: From left to right, Cezary Dziecinniak, Aluron’s Chief Investment Ofﬁcer, the production of aluminium invisible after coating Iwona Laskowska from Eco-Line, and Adrian Musik, Aluron’s Export Sales Director. profiles for wood-aluminium (ref. opening photo),” systems, a sector in which Adrian Musik adds. “Our we are very successful both on the domestic Our strength are our production department is equipped with and the foreign markets. Then, we started automatic cutting machines, welding robots, welded profiles, whose manufacturing profiles for PVC- aluminium CNC machining centres, and punching and connections are practically windows, and finally we developed some bending machines: we are very focussed invisible after coating.” aluminium-only on the modern systems. We never market need for lost our focus on the atypical buildings door and window requiring advanced industry, but we production have expanded technologies.” our product range The new very quickly. We coating plant, now design and crucial to manufacture systems decrease the for indoors, outdoors company’s and curtain walls. time-to“Here, in the new market site of Zawiercie, Aluron started its we take care of new vertical coating the whole process, from the design line devoted to 4 profiles in late of systems and accessories to the February. Figure 4: A bird’s eye view of vertical coating plant designed by Euroimpianti. © ipcm ®

the conventional vertical ones. Indeed, its elements are totally symmetrical: the opposite and self-cleaning walls; a double suction unit arranged in a regular manner so as to create the ideal conditions for the application of powders on the profiles in the coating area; and a special pressurising system that avoids the emission of powders in the environment.

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

5 Figure 5: The loading of proﬁles with a length up to 7 metres.

The company already owned another vertical plant as well as a horizontal one, now used for the finishing of metal sheets and of all the products that cannot be treated in a vertical system. “We have installed this new plant mainly to increase our productivity in terms of coated parts,” Adrian Musik explains. “In fact, a rise in sales has prompted us to invest in this additional, modern coating system. Shortening our time-to-market was very important.” “Aluron is known for both the quality of its products and its on-time deliveries. Being able to ensure the same delivery times throughout the year, in both the high and the low season, is crucial to us,” Cezary Dziecinniak says. “This plant will enable us to do so. Our flagship, highest quality product, our welded aluminium frames with coating, has a 3-week delivery time; our individual profiles have a 7-day delivery time, which we are trying to lower to 5.” The line speed is 1.4 metres/minute. Its productivity is 630 profiles per hour, with an average of 30 to 40 colour change operations per

6 Figure 6: The pre-treatment tunnel is equipped with automatic controls of the process parameters and the product dosage.

Figure 7: The vertical spray paint booth patented by Euroimpianti.

After the loading station (Fig. 5) featuring a monorail conveyor, the profiles undergo a 7-stage

9 Figure 9: The booth has a particular diamondlike shape, with its guns divided into four opposing groups.

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pre-treatment. It is a mixed spray-cascade process performed in an energy-efficient tunnel with the chrome-free Oxsilan technology supplied by Chemetall (Fig. 6). The profiles’ surfaces are optimally prepared for the subsequent stations of the tunnel by the acid attack that takes place on aluminium both through contact obtained with the cascade system and in a mechanical way with the spray nozzles’ action. After the subsequent drying step, the workpieces enter the spray paint booth. The innovative aspect of the system lies precisely in these booths (Fig. 7), designed by Euroimpianti and equipped with Opticenter guns and an Opticenter powder feeding unit using the 10 Venturi technology (Fig. 8), provided by Figure 10: While spraying, each reciprocator Gema Europe. adapts its stroke to the length of the proﬁle. “These booths It is also possible to choose which side of the were developed proﬁle must be coated. © ipcm ®

The plant layout

Figure 8: Gema Europe’s Opticenter powder feeding unit, using the Venturi technology.

The particular “diamondlike” design and the presence of 4 reciprocators with 4 groups of guns each eliminates the need to rotate the profiles, since they move along the chain with all their faces exposed to the guns groups.”

shift. “Aluron is currently working on one shift because the new line has only been operational for three weeks and it is still being fine-tuned,” so Iwona Laskowska, Eco-Line’s Plant Sales Manager. “In the near future, thanks to its high availability, this system will enable them to acquire many customers with lots characterised by small sizes and different colours. Aluron is well known for the high quality of its service: it is Qualicoat Seaside certified and it is accustomed to meet the complex demands of the architecture market in a very short time. The line designed and built by Euroimpianti will enable Aluron to strengthen this corporate image.”

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Figure 11: The bars with optical sensors (left) placed before the entrance of the booth enable the reciprocators to change their stroke according to the length of the incoming proﬁle. Figure 12: The control panel of the booths and the guns.

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Cecilia Ghizzi Gola ghizzi-gola@emptmeyer.it Fon: +39 02 947 58 58 2

www.emptmeyer.it

by Euroimpianti two years ago,” Eco-Line’s Iwona Laskowska says. “The particular “diamond-like” design and the presence of 4 reciprocators with 4 groups of guns each (Fig. 9) eliminates the need to rotate the profiles, since they move along the chain with all their faces exposed to the guns groups. This results in the installation of a simpler conveyor and in the possibility to hang profiles with greater thicknesses. A second advantage is the possibility to choose the side of the profile to be coated (Fig. 10).” “Compared with the conventional “V” or “U”shaped booths, this one enables us to paint only the required side” Adrian Musik states. “The booths feature another technical characteristic resulting in significant savings,” Laskowska adds. “Contour-detection optical sensors are located at the entrance of the booths, at a distance of 250 mm from each

other (Fig. 11). The reciprocators adapt their movements, and therefore the spraying of the guns, to the profile length, so as to apply the coating only where it is needed.” The two booths work alternately. The cleaning operations are performed automatically with a conventional belt system (Fig. 12). “We are very satisfied with the solution provided to us and with the cooperation with Euroimpianti, who has given us and continues to give us full assistance through Eco-Line. Actually, we have known Eco-Line for over ten years, because it had provided us with some automatic guns for our old plant. If we have any problems, they support us in an excellent and fast way, and this is very important for us because we work with a just-in-time approach,” Cezary Dziecinniak states. “This new coating system could open up the possibility to offer a contracting coating service,” Adrian Musik says. “The new concept

FOCUS ON TECHNOLOGY

SURFACE TECHNOLOGY “MADE IN GERMANY”

of Euroimpianti’s spray paint booth has certainly capacity of 2,000 litres/hour and discharges the proven suitable to meet our specific needs in terms wastewater into sewer in full respect of the very of productivity and efficiency.” stringent limits imposed for metals, fluorides Aluron’s vertical plant has all the characteristics and sulphates (Fig. 14). With the installation needed to give a Qualicoat Seaside quality of a small evaporator, this stage can be easily level, e.g. automatic dosing of the pre-treatment turned into a zero-discharge process. chemical products; control of all operating Finally, aware of the importance of keeping parameters; a 10,000 litre demineralisation and the hanging hooks in perfect condition in order recycling station (Fig. 13) with a double line, to achieve maximum coating quality, Aluron which can work 24 hours a day; and a physicalhas decided to equip its plant with a paintchemical wastewater stripping Fastrip system, treatment plant. Both developed for lines the demineralisation with a maximum speed “Contour-detection optical station and the of 1.5 m/min (Fig. 15). wastewater treatment Designed and provided sensors are located at the system have been by Alit (San Bonifacio, entrance of the booths, at a supplied by Saita Verona, Italy), it consists distance of 250 mm from each (Padua, Italy), which of an ultrasound other. The reciprocators adapt has implemented its stripping tank installed their movements, and therefore exclusively owned immediately after the the spraying of the guns, to the Desulfate technology unloading station (Fig. profile length, so as to apply at Aluron’s premises. 16). It requires the use the coating only where it is The system has a of a paint remover called needed.”

13 Figure 13: The demineralisation station has a double circuit and can work non-stop 24 hours a day.

www.emptmeyer.it

Figure 15: Alit’s in-line paint-stripping system for hanging hooks.

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

Figure 16: Hooks in the paint-stripping bath, operating at 55°C.

Metalstrip 1460 Conclusions and an activator All Aluron’s systems called Metalstrip meet the increasingly Aktivator 1660. The stringent technical solution operates requirements of at a temperature public and residential of about 55°C and architecture. it is designed to The solutions offered quickly remove the by the company powder paint from undergo numerous the dirty frames and assessment hooks. Fastrip ISP processes according uses an ultrasound to the most recent technology with a regulations and to series of batteries the quality standards carefully placed in issued by national certain areas of the and international tank. In order to certification bodies 14 allow for a long life such as ITB, IFT of the solution, the Rosenheim, LTB, Figure 14: The physical-chemical wastewater treatment plant with Saita’s Desulfate process. paint-stripping bath Passiv Hause and, of is constantly filtered course, Qualicoat. with a suitable The company’s system also designed by Alit. Such market crosses the European borders and filtration systems are called Fastrip FP extends to Russia and the United States, The installation of and their size depends on the amount while the end products manufactured with of paint to be removed daily. They Aluron’s systems are sold worldwide. the new vertical coating enable to obtain the driest possible The installation of the new vertical coating plant, ensuring even sludge, so as to recover as much plant, ensuring even greater productivity, greater productivity, product as possible in the tank. They efficiency and quality, will certainly open up efficiency and quality, can also be integrated in conventional new market opportunities for this dynamic will open up new market immersion paint-stripping tanks. Polish company. opportunities.”

BRAND-NEW

Verinpaints by Verinlegno

Through Verinpaints, Verinlegno S.p.A. has opted to focus on the production of paints for metal, developing the know-how that has always been available within the company and updating the range, which includes rust prevention products, quickdry synthetic enamels, textured enamels, polyurethane enamels, epoxy, acrylic and synthetic oil products, mono- and bicomponent micaceous iron oxide products and chlorinated rubber products. Both for steel and galvanised sheet metal. The entire range is available in water-based and solvent versions, and is suitable for all types of application. Verinpaints (Fig. 1 and 2) bases its new range on research into the maximum results achievable from painting process, working in close contact with customers. A complete

ongoing training to constantly improve the skills of its employees. The brand aims to be seen as an interpreter of the future of industrial paints with a continually diminishing environmental impact. The national and international distribution network of Verinlegno is a vital means of support that allows Verinpaints to provide rapid, efficient customer care. The Italian network efficiency is guaranteed through warehouses located in 17 regions. In each area, Verinpaints can count upon a reference agent. Verinpaints is present on the European and international markets, exporting to 50 countries with a distribution network of the highest quality in terms of support and qualified advisors. For further information: www.verinpaints.it

knowledge of the entire production erinpaints powered by Verinlegno process of its business partners is the key offers high-quality, high-efficiency to providing paint products with the best industrial painting solutions. possible price/efficiency ratio. The brand’s production technology makes This is why Verinpaints is backed by it highly reliable, ensuring success for its partners as a result of the extraordinary synergy of Verinlegno Group experience. State-of-the-art laboratories (covering the areas of control for incoming raw materials, research and development, testing and application of finished products, colour mixing) guarantee product excellence and ongoing improvements. Painstaking compliance testing meet 1 the highest ISO standards. Research into sustainable Figure 1: Through Verinpaints, Verinlegno S.p.A. has opted to raw materials and low VOC focus on the production of paints for metal. emission processes are in the DNA of Verinpaints.

2 Figure 2: Verinpaints is present on the European and international markets, exporting to 50 countries.

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

BRAND-NEW

Helios Acrylic Resins for 2K PUR Coatings a perfect combination of drying speed and pot life

elios Resins was excited to meet their existing and potential partners at the leading coatings trade fair in Europe, European Coatings Show 2017 in April. Being a part of this fair since 2005, Helios Resins business unit of Helios Group invited to attend this yearâ&#x20AC;&#x2122;s in-depth product presentation on novel acrylic resins for 2K PUR coatings, which was given by an expert in the field, dr. Martin Ocepek, on April 5.

Acrylic resins are commonly representing the major ingredient of the polyol component in two-component polyurethane systems. Very often, formulators must find a compromise between drying speed and pot-life. However, this issue is solved by using Heliosâ&#x20AC;&#x2122;s state-of-the-art acrylic resins for Metal, Car refinish and Wood clear/top coats, which provide fast drying and long pot life. The presentation covered high/ medium solids solvent-borne and also some water-borne systems.

Helios Resins stands as a separate business unit of Helios Group, producing the highest quality of liquid resins for advanced coating and composite manufacturers globally. Experience in resins production in the Helios Group dates back to 1908. Domopol, Domacryl, Domalkyd and Domemul coating resins brands have achieved a strong market position and are trusted for their quality and reliable service. For further information: www.resinshelios.com

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BRAND-NEW

obot systems are becoming cheaper and therefore attractive to a growing number of industrial companies. As a result, WAGNER is now offering the new TOPFINISH RobotBell 1, a versatile, high-rotation atomiser for automated, robot-operated coating systems. From metal workpieces and plastics to wood: the new TOPFINISH RobotBell 1 (Figs. 1 and 2) from WAGNER can be 1 used for automated liquid coating in a range of industrial settings. The highFigure 1: The new TOPFINISH RobotBell 1 from WAGNER. rotation atomiser has been designed especially for use on a robot arm. “The TOPFINISH RobotBell 1 is an High-quality coating results all-round device for automated applications Thanks to its high-quality coating results, that are currently growing considerably the TOPFINISH RobotBell 1 is suitable in volume. Its versatility, long service life for numerous market segments. This is and robust characteristics make it the achieved partly through the different bell ideal coating tool for discerning industrial disc combinations. WAGNER offers bell clients. It therefore represents the perfect discs in various sizes (30, 50, 70 mm) complement to WAGNER’s existing product with varying serration (smooth, straightrange”, explains Peter Neu, Senior Product Manager at WAGNER Industrial Solutions.

Efﬁcient liquid coating by robots Thanks to its superb efficiency, the TOPFINISH RobotBell 1 is ideal for highly automated coating systems. Under the right conditions, it can achieve an application efficiency of over 90%. An additional flush valve ensures rapid flushing processes and short colour change times. This, together with the reduced compressed air consumption, robust construction and simple maintenance without any special tools, results in lower running costs.

High-rotation Atomiser for Robot Applications serrated, cross-serrated) and in various materials (Consistal, titanium). As a result, the ideal bell disc can be chosen according to the material to be applied and the workpiece itself. Added to this are adjustable shaping air streams that vary the diameter of the spray jet between 70 mm and 800 mm: depending on the demands of the workpiece geometry, both a wide, soft spray pattern and a small, harder spray jet can be produced. This means that workpieces of all shapes and sizes can be coated easily and with high-quality results. The backwardsdirected exhaust air ensures that the spray jet is not impaired. Thanks to its ultra-fine atomisation, the TOPFINISH RobotBell 1 ensures an optimum coating result.

Flexible production processes For discerning industrial customers, a coating system’s flexibility is a crucial advantage. Consequently, WAGNER has designed the atomiser system so that the bell head can be easily replaced with an Airspray gun adapter without having to change the existing hose installation or robot program. This means that the system can be switched very quickly between Airspray and bell applications. The TOPFINISH RobotBell 1 is available from WAGNER sales partners.

Figure 2: TOPFINISH RobotBell 1 is ideal for highly automated coating systems. Under the right conditions, it can achieve an application efﬁciency of over 90%.

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

For further information: www.wagner-group.com

SUCCESS STORIES

Paint systems from R-M® set the right tone for design concepts for electric vehicles

ovestro, the manufacturer of high-tech polymer materials for the automotive and other industries, has already presented an innovative concept for electric cars that incorporates the latest trends in external design at the K 2016 plastics trade fair. The concept car (Fig. 1) occupied pride of place at the Covestro stand at the European Coatings Show 2017 from April 4 to 6 in Nuremberg. An eye-catching presence was ensured by a specially developed paint formulation based on the color and design expertise of BASF’s Coatings division and its premium R-M brand. The formulation incorporates the ONYX HD waterborne paint from R-M.

rapidly hardens even at low temperatures, creates optimum paint adhesion and – thanks to the low viscosity – ensures excellent flow properties. The finished coating polishes up well and offers a high gloss. “It underlines the total effect of the concept car,” says Marc Schreiber, Marketing manager for refinish paints at Covestro.

The developments implemented in the design concept open up new approaches for the attractive design of comfortable, functional and energy-efficient cars. The focus is on lightweight designs using plastics. The use of these materials increases the range of electric cars and reduces the fuel consumption and CO2 emissions of gasolinepowered vehicles. However, The innovativeness and technical this places new demands on the refinement of this vehicle concept paintwork which the worldwide is underlined by the exclusive design team of BASF’s Coatings ‘Verbosian Orange’ color tone. division addressed in its annual “The effect of the color orange is Automotive Color Trends to draw the attention and create a publication. The collection sense of presence. At the same time, the color is warm and passionate, includes 65 new trend colors for the automotive industry and expressing the energy theme. To create a special optical effect, reflects both global and regional we have used a metallic luminous trends. Thus the multifaceted orange, which ideally harmonizes relationship between the virtual with the black and anthracite gray and real worlds plays a key accessories and really grabs the role in global trends right now 1 attention,” is how Mark Gutjahr, and is expressed in the varied head of Automotive Color Design color palettes for cars. Artificial Figure 1: The specially developed paint formulation is based on Europe at BASF, describes the effect metallic blue, silver and white the color and design expertise of BASF’s Coatings division and its of the basecoat. The paint system tones, for example, reflect the premium R-M brand. fulfills all requirements with respect trend to digitalization of the to sustainability, efficiency and performance and is comparable world of work. The next issue of Automotive Color Trends will be with modern polyurethane production line paints. The pigmented presented to car makers at exclusive color shows in summer 2017. waterborne coating is protected by a transparent clearcoat For further information: based on polyurethane precursor materials from Covestro. This www.covestro.com

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

BRAND-NEW

Chemetall Receives Highest Airbus Supplier Award for the Third Time chain and expanded our production capacity at the Langelsheim plant in Germany. We are delighted about this highest supplier award from Airbus because it acknowledges the continuous efforts of the Chemetall staff.” The aim of the SQIP program is to advance the major strategic Airbus suppliers towards the goal of industrial excellence with regard to product quality and delivery reliability. In view of increasing production rates, this goal is of particular importance. Every year, the performance of each participating supplier is reviewed and either confirmed or – in case of non-conformity with the requested quality standards – downgraded or even rejected. Over the past 25 years, Chemetall and Airbus have established a long-lasting and successful business relationship. From production sites in Langelsheim/Germany and Soissons/ 1 France, Chemetall supplies numerous European Airbus sites with aircraft Figure 1: Chemetall representatives (from left to right) Kirstin sealants, corrosion protection Uhl, Strategic Marketing Manager and Lean Six Sigma Master Black Belt, Hendrik Becker, Global Segment Manager Aerospace products, cleaners and pretreatment and Ronald Hendriks, Quality Manager and SQIP Coordinator, technologies. and as well as Ulrich Eberhardt (not in the picture), Head of For further information: the Aerospace production plant in Langelsheim, Germany, are delighted about the award. www.chemetall.com His colleague Ronald Hendriks, Quality Manager and SQIP Coordinator, adds: “Last year, our experts Kirstin Uhl and Ulrich Eberhardt conducted three Lean Six Sigma projects together with Airbus. These projects contributed significantly to our success: we strengthened and optimized our internal and external delivery performance along the value

THE ROTAMAT – THE IDEAL SOLUTION FOR COATING OF SMALL PARTS UÊanti-friction coating UÊcoating with bonding agent UÊdecorative coating of plastic, metal and wooden parts

www.walther-trowal.com | Tel. +49(0)2129-571-0

hemetall, since December 14th 2016 a global Business Unit of BASF Coatings, has been honored with the highest supplier award in the Airbus “Material & Parts SQIP” (Supply Chain & Quality Improvement Program). For the third year in a row, the leading global supplier of surface treatment technologies has achieved the “Accredited Supplier” status, which values Chemetall’s outstanding performance and continuous commitment to provide top quality products and excellent delivery reliability. Only four out of a total of 68 strategic key suppliers of Airbus have received this “Accredited Supplier” award in 2016. “We are very proud to having met the high Airbus SQIP requirements once again in 2016”, says Hendrik Becker, responsible for Chemetall’s Global Aerospace Segment and explains: “Our customer can rely on the ongoing commitment of the Chemetall team to maintain our excellent quality and performance standard and to accompany the Airbus growth strategy.”

BRAND-NEW

High-efficiency monocyclone saves energy and powder

any companies ask themselves how they can use less energy to reduce costs and protect the environment more. For powder coating, WAGNER has an excellent solution: the EEP series with its potential savings of up to 40%. One of the biggest global trends is energy-saving. This also affects powder coating systems. Here, energy is needed directly in the form of electrical power, for example to drive motors, and also indirectly in the form of compressed air. Even in the past, WAGNER has used energy-efficient components and energy-optimised processes in its powder coating systems. They have a function, for example, which switches off the lifting devices in gaps, or only activates guns if a workpiece actually travels in front of it. This function is known as gap and height control. These savings may appear small, however they add up to a significant sum at the end of the year.

Cutting energy costs for powder coating by up to 40% The biggest energy consumer in powder coating, however, remained the fan motor in the final filter, which still consumes up to 37 kW of power and more. Now, WAGNER has developed a comprehensive energy-saving concept for this fan motor and successfully implemented it in 2016 in the “EEP” monocyclone and final filter series. EEP stands for “Energy Efficiency Package”. In the EEP concept, two measures come together to reduce airflow resistance and therefore compressed air consumption: First is an optimised pipe conduit between the cabin and the cyclone, and second is a special air guide within the monocyclone. With this setup, a smaller motor is sufficient to generate the same volume of suction. In this way the EEP series is able to reduce energy costs by up to 40% overall.

These values can be achieved by combining a high-efficiency monocyclone with a corresponding conduit and matching filter to create the “Energy Efficiency Package” (EEP).

Powder savings by boosting cyclone efﬁciency In addition to energy savings, the flow-optimised construction of the cyclone also increases the cyclone efficiency by 1-2%. This is a positive side effect that should not be under-estimated. Depending on the system configuration, powder savings can be quite considerable. In example calculations (Table 2 and 3), cost savings of 20% can be achieved. “Energy and powder savings are important for many industrial clients and their significance is increasing. Partly, of course, due to lower costs – but also because more and more companies have set themselves the goal of reducing their energy consumption to protect the environment. With the EEP series, we are able to help our clients to achieve these goals”, explains Michael Topp, Global Product Manager at WAGNER. Table 2: example of powder savings Example calculation 1 Transfer efficiency on the workpiece Cyclone efficiency Powder output [g/min]/gun Number of guns Powder loss [%] Powder loss per work shift (7h) [kg] Powder loss per year (230 days / € 4/kg) [€] Cost saving

Starting position

Cyclone efficiency + 1 %

30%

95.0% 180 16 10.4% 42

96.0% 180 16 8.5% 34

€38,949

€31,159 20 %

Table 3: example of powder savings This is also illustrated by the example worked out in Table 1 Table 1: examples of savings achievable with a final filter from the EEP series Volume of Conventional Final filter Savings* in € Additional suction monocyclone from the and % per year savings solution EEP series 12,000 m³/h 30 kW 18.5 kW Euro 3,974 38.3% Lower 16,000 m³/h 37 kW 22 kW Euro 5,154 40.5% installation costs for 20,000 m³/h 45 kW 30 kW Euro 5,184 33.3% power 24,000 m³/h 45 kW 37 kW Euro 2,765 17.7% supply * Based on 240 days, 8 hours, 18 ct/kWh

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

Example calculation 2 Transfer efficiency on the workpiece Cyclone efficiency Powder output [g/min]/gun Number of guns Powder loss [%] Powder loss per work shift (7h) [kg] Powder loss per year (230 days / € 4/kg) [€] Cost saving

Starting position

Cyclone efficiency + 1 %

50% 95.0% 180 16 4.8% 30

50% 96.0% 180 16 3.8% 24

€27,821

€22,257 20 %

For further information: www.wagner-group.com

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Opening photo: EMPTMEYER workers on the factory building in Bad Essen, Lower Saxonia, Germany.

HIGHLIGHT OF THE MONTH

JÜRGEN EMPTMEYER: custom made hanging and masking solutions for industrial coating Alessia Venturi ipcm®

ince 1987, JÜRGEN EMPTMEYER GmbH (Ref. opening photo) is a leading company in hanging and masking solutions in the field of industrial surface technology. Its services include consulting, design and construction stages, up to the delivery of customized systems and after-sales services. The company can guarantee an easy order process as well as an on schedule delivery. ipcm® interviewed Katharina Emptmeyer (Fig. 1), Business Development, to offer an insight about the history of the company, their markets and innovative ideas. ipcm: “Can you please briefly outline the history of JÜRGEN EMPTMEYER company and its current structure?” Emptmeyer: “For more than a quarter of a century JÜRGEN EMPTMEYER has offered specialized knowledge on bending technology. Like many

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

other midsized German companies, our company history started from a cellar. My father´s first contact, Jürgen Emptmeyer (Fig. 2), with powder coating plants was as a 19 year old trainee whose boss in need of hooks challenged him to provide a mass production solution and that´s when a manual bending machine ended up being installed in the cellar of our family house. The powder coating technique at that time was still quite innovative but the volumes where very fast growing”. “In 2014, JÜRGEN EMPTMEYER opened the door for the next generation and so I started to promote our products to our customers in Switzerland. Today our main objective is to develop our business in the Eastern and Southern European markets. Since the beginning of 2017, Mr. Bernd Kulgemeyer (Fig. 3) is officially CEO of JÜRGEN EMPTMEYER in Germany and is ambitious in offering our clients a convenient hanging and masking

expertise. We really enjoy the co-working era with the new management: my father represents 1 the knowledge gained in 40 years in the industry; I will work hard on promoting our service internationally and Mr. Kulgemeyer, whose passion is very customer-oriented and will find new solutions in digitalization”. “Today, JÜRGEN EMPTMEYER has more than 70 employees and a European-wide infrastructure with branches in Belgium and Switzerland. Our company´s production facilities have grown strongly leading us to invest in automated equipment and machinery all made in Germany. Thanks to a great internal team of technical managers, around 50% of our sales is based on custom made solutions in hanging & masking. Our standard 2 products are available within 24h in Germany. With 1.100 pallets Figure 2: Jürgen Emptmeyer, owner. places we are already able to market a great range of hooks, racks, tapes and silicon masking and this will be further expanded with the opening in the summer of 2017 of our new warehouse boasting more than 2.500 pallets places” (Fig. 4 and 5). ipcm: “Which are your biggest markets?” Emptmeyer: “We are market leader in Germany. Since a personal customer support is important to us, we have a strong sales force here in Germany. We also see great potential in Italy, where well known plant engineering is taking place. Since the 70s, Italian surface industry developed its knowledge in coating profiles and vertical plants, an efficient innovation made in Italy. We provide our Italian costumers a local on-site maintenance with our Swiss office, only two hours from the Italian border”. ipcm: “What is the company’s development strategy on the market?” Emptmeyer: “We have an international team of costumer assistants

and we continuously hire. This is the perfect manpower to further develop our European neighbour countries, large potential markets we will look after directly, whereas we are definitely open to the opportunity of finding distribution partners in smaller 3 countries. Our approach is always local. We think local but Figure 3: Bernd Kulgemeyer, CEO of act global. In Switzerland, for JÜRGEN EMPTMEYER in Germany. example, the surface industry shows great pride in high quality and manual, handmade processes. Therefore, we develop a lot of custom made solutions not only in masking but also racks. Here, technical project management is essential. In Poland, on the other hand, we push our company image by promoting our standard bestseller portfolio where costumers can make a buying decision on their own. If you have a look at our new landing page, you will find your costumer assistant support in your language”.

Figure 1: Katharina Emptmeyer, JÜRGEN EMPTMEYER GmbH, on EMPTMEYER Rack.

HIGHLIGHT OF THE MONTH

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

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

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N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

of view?” gives you the ideal flexibility to hang profiles horizontal and slip into tight Emptmeyer: “When we come back to my example of the magnetic masking, we can profile openings. I am also a big fan absolutely speak of faster handling. This helps of magnetic masking. If you have a pipe, for example, and need to the worker being more time efficient and cover the inside and colour it only therefore more cost-efficient”. outside, using a sticker would take ipcm: “How much does it affect the final way too long. Also, hands suffer quality of the painting? with precise masking. Having a Emptmeyer: “We try to encourage our magnetic sticker is very efficient, 4 reusable and flexible. “Christmascustomers to go for an individual masking solution. If you have recurrent components, you tree-plugs” for protecting holes Figure 4: Small components efﬁciently hanging via should develop the ideal silicon masking shape. in a wide range of dimensions, crossbar system. Nowadays, we can offer the whole construction, easyFlex, the non-welded multiple project management and 10 prototypes for rack system - just plug together to just a few hundred euros. It is not expensive ipcm: “Which is your strongest technology and hang on. I could name some more but we will anymore to have a custom made masking what does differentiate JÜRGEN EMPTMEYER shortly present a new catalogue with all these from the competition?” solution. Costs for the final product vary with little helpers”. size, volume and quantity.” Emptmeyer: “First of all, we are a manufacturer. In most markets, our ipcm: “What do you think about Chinese competitors are simply dealers or retailers. competition in the field?” We have a direct approach and can therefore guarantee direct support, a Emptmeyer: “As competitors honestly, we haven’t really thought about them so broad product portfolio and reasonable far even though the whole EMPTMEYER pricing. A second reason to buy from us is our masking portfolio is produced in China. When we think of custom expertise on customer made solutions. made competence, we see the new We invest time to create a hanging or masking solution hand in hand with opportunities lying in 3D printing. This will 5 our costumer and, moreover, we try to for sure bring back production to Europe. Moreover, our asset is our maintenance in use standard components. This gives Figure 5: EMPTMEYER also offers masking solutions. Europe and we hope our customers value the costumer not only flexibility but good value for money when using, e.g., the face-to-face partnership. Working ipcm: “How important is the masking system in crossbars from mass production. Last but not with JÜRGEN EMPTMEYER is not working with a the current painting process? company: We work with people. least, we are a family business where quick Emptmeyer: “From 1 to 10, when 10 decisions can be made and we constantly invest is the highest, I would rate it with to improve our service. In 2017 we will build a huge new high bay warehouse and add new a 10. Lean production, Industry capabilities to our machinery. We are able to 4.0: These are only two keywords which show a strong development. bend wire up to 30 mm in house” (Fig. 6). Automated coating processes will ask for new and custom ipcm: “Can you please describe a couple of innovations that JÜRGEN EMPTMEYER made masking solutions. We are experimenting with 3D printing introduced on the market in recent years?” and are confident to work with this Emptmeyer: “My favorite product invented by technology intensively”. JÜRGEN EMPTMEYER is a profile rack system, originally designed for Schüco profile system, 6 ipcm: “Which kind of role does it who is a great partner of our company. It is a play from the cost-efficiency point Figure 6: Machinery park. really strong, easy and long lasting rack which

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SUCCESS STORIES

Ecopaint RoDip – Optimum immersion now also for vans

The individually programmable transport units enable optimized dip curves for the respective car body. The end result is better coating quality and increased energy efficiency. The rotational process means

Dip, flood, drain: Even very large car bodies, such as those of transporters and vans, can rotate around their own axis with a rotational movement of 360°. When planning the plant in North Charleston, Dürr conducted extensive tests in its technical center. This included testing ways of using the RoDip rotational dip process for painting larger car bodies than had ever been immersed before. The result? RoDip guarantees high-quality corrosion protection as a basis for further surface coating, even for large vehicles. The Ecopaint RoDip E version will be used in the Mercedes-Benz Vans paint shop in North Charleston, that is currently under construction. The system with electrical drive will transport the closed car bodies of the next generation of the Mercedes-Benz Sprinter through pretreatment (PT) and cathodic electro-coating (EC). Each of the freely programmable transport units has a separate drive for rotation in addition to the conveying drive (Fig. 1).

is suitable for all applications, from spraying insulating material to sealing seams. The EcoGun2 3D is much more streamlined and lightweight than its predecessor model, making it ideal for getting into even hard-to-access areas of the body shell. The fully automated interior and exterior painting steps are performed cost-effectively in their own zones in stop and go mode using a special atomizer of the type EcoBell3 HX designed for painting detailed and exterior surfaces. Interior painting in the cargo space is performed by nonrail-mounted swingarm robots. With their extended arms, they are specially designed for use in large cargo spaces. This is the first time they are being installed in this form in the USA. © Dürr

ar bodies up to eight meters long rotating through an immersion bath is something that has never happened before. The Ecopaint RoDip rotational dip process is now being used in practice for the first time for vehicles of this size. Dürr will be installing this technology in the new Mercedes-Benz Vans factory in North Charleston, USA. It will form part of a complete paint shop being built by Dürr on behalf of Mercedes Benz Vans.

Vans have a large number of different colors applied to them. In order to be able to apply this Figure 1: Body shells up to eight meters long will have their base coats applied using the Ecopaint RoDip variety with minimal paint loss rotational dip process for the ﬁrst time (principle during paint changes, the robots drawing). are connected to the EcoSupply P special paint supply system that smaller bath volumes are possible; with pigging technology (Fig. 2). The these need less chemicals and fresh water semi-automatic system EcoDry X for and at the same time reduce the energy dry separation of the overspray in consumption and volume of wastewater. the paint booths requires absolutely Following pretreatment, the seam sealing, no water or chemicals. This system, underbody protection, and rocker panel designed for simplicity and robustness, protection are applied within a single zone. works on the basis of cardboard filters. These combined tasks are performed The paint shop equipped entirely by by four rail-mounted EcoRS robots with Dürr also includes paint application the new generation of the EcoGun2 3D with primer and 2-wet process for applicator. This standardized applicator topcoat. 1

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

Mercedes-Benz Vans announced its plans to extend its existing assembly location for vans and build a new factory for the production of the Mercedes-Benz Sprinter in North Charleston in South Carolina (USA) back in 2015. Production is due to start before the end of the decade. Up to now, Sprinters for the USA will be manufactured in Germany. Due to high import duties, however, they will be partially disassembled in a complex process and reassembled in the plant in North Charleston.

SUCCESS STORIES

2 Figure 2: EcoSupply P special paint supply system ensures a wide range of paints and minimal losses.

We create chemistry that makes smooth surfaces love rough climates.

Modern paint systems provide Long-lasting protection for cars, buildings and wind turbines from corrosion, UV radiation and weathering impacts. In this way, they improve performance and longevity which in turn contributes to sustainability. When coatings provide protection and, at the same time, conserve resources and are easy on the environment, it’s because at BASF, we create chemistry. www.basf-coatings.com

According to Daimler this additional step puts MercedesBenz Vans at a clear competitive disadvantage on the US market. The new factory and vehicles “made in USA” will enable the division to service the growing demand from North American customers much more economically in the future, and significantly reduce the delivery times in the market. The division is therefore investing around USD 500 million in the construction of the factory. Mercedes-Benz Vans is the only manufacturer in the large transporter segment that is still manufacturing in Germany (Düsseldorf and Ludwigsfelde).

Opening photo: A ﬂexographic printing machine produced by Uteco.

FOCUS ON TECHNOLOGY

Uteco implements a new coating plant for the treatment of extra-large complex items Monica Fumagalli ipcm®

teco Converting Spa is a global leader in the design and manufacture of flexographic, rotogravure and high-tech machines with special configurations (laminating, roto-offset and digital machines, etc.), sometimes in co-partnership, while constantly focusing on research and innovation. The company’s headquarters are located in Colognola ai Colli (Verona, Italy) and they include three plants covering an area of over 65,000 m2. Since its establishment in 1985, Uteco’s core business has been the production of printing machines for flexible packaging (ref. opening photo).

N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

This industrial sector has evolved rapidly starting from the geared rotary machines popular on the market over thirty years ago, and the development of ever more efficient systems has become the mission of Uteco as well as the key to its global success. “The machines we produce are now 80% automated,” says Diego Taioli, Uteco’s Lean Project Team Leader and Assembly Manager (Fig. 1). “Our aim is supplying our customers with an easy to use and manage product in compliance with the objectives of Industry 4.0, whose principles are being gradually implemented in our plant. In turn, we

FOCUS ON TECHNOLOGY

product after only two hours. None of our of coils with the layers of paper or plastic, demand the same flexibility and ease of competitors can provide a machine with perfectly possible for this type of machine. management from the products and plants similar characteristics.” Our most recent projects have all been that we buy from our suppliers. This was Uteco is further expanding its range aimed at integrating the various stages of the case also with the design of our new the printing process in one solution, thus of systems aiming at speeding up paint shop. This project, started last year the printing process to obtain a more enabling our customers to obtain a finished and completed a few months ago, involved compact machine, with two firms located in the province integrated drying hoods of Verona like us: Euroimpianti and fast maintenance and (Valeggio sul Mincio), a coating task changes. “We have plant manufacturer, and Comaind designed a machine to Srl (San Giovanni Lupatoto), the meet the needs of those Italian distributor of the spraying who work in limited space. and paint dosing equipment In fact, our plants generally produced by the multinational require large space in terms company Graco.” of footprint, of number of In 2007 Uteco replaced the devices and accessories that solvent-based coatings with the must available on their side, water-based ones. Recently the such as inks and coils, and of company has decided to replace maintenance operations, such its coating plant and equipment 1 as the washing of trolleys.” with two goals: creating a even healthier working environment Figure 1: Diego Taioli, the Lean Project Team Leader and Assembly Extra-large printing for its employees, and improving Manager, shows a large-size machine manufactured by Uteco. machines its application performance by “The production cycle starts converting its pneumatic system with the design stage, when our technical into a more effective electrostatic one. staff meets to define the characteristics of Our aim is supplying The evolution of Uteco’s the machine that we want to offer to the our customers with an easy printing machines market. This is a very important phase, to use and manage product in “We produce printing machines that stamp because most of our systems have to be compliance with the objectives a repetitive subject in different formats on integrated into already existing plants of Industry 4.0, whose coils made in various type of material. Until and departments. If we cannot customise principles are being gradually 2003, our machines were operated with a product already in our catalogue, we implemented in our plant.” mechanical drive gears, now with design a new machine from direct drive motors. scratch. Afterwards, we activate “Our flagship product is a the supply chain that allows us flexographic machine able to print to buy the materials needed to with electron beam (EB) inks, a build our systems, especially technology presented by Uteco for iron and the raw materials used the first time in 2008. Its compact for the large structures that design and integrated HMI system are treated in our carpentry enable the operators to manage all workshop and machine tool the work areas without leaving their department.” control position, while ensuring Uteco has a highly automated quick maintenance operations and machining department equipped task changes. It also ensures the with 3+2-axis numerical control 2 absence of harmful emissions and machines for the milling-boring allows for an instant polymerisation operations and 4-axis turning Figure 2: The Silvi washing machine for the cleaning operations process; this facilitates the coupling centres featuring devices for and the application of protective oil.

international PAINT&COATING magazine - MARCH/APRIL 2017 - N. 44

Uteco – Industry 4.0 is realised*

The high automation printing presses manufactured by Uteco minimize the need of human intervention and guarantee an even higher accuracy and safety. The machines are also equipped with digital interfacing systems that allow a continuous dialogue between Uteco and the customer, offering support during job setting and remote service. The innovative UDAA systems (Uteco Data Acquisition Analisys) and Data Collection serve this purpose. The UDAA, in particular, is interconnected to the printing machine and has the ability to acquire, process and store all sensitive data for the analysis of energy and ink consumption, and of the machine efficiency (or of more machines at the same time), generating automatic reports, which are then made available to the customer through a web interface. Moreover, thanks to a profitable collaboration with Swansea University, Uteco has developed a study about RFID (Radio-Frequency IDentification) technology, that makes “smart” the objects on which they are installed. Finally, Uteco is committed in leading-edge studies concerning the digital printing introduced to their printing technologies, in order to reach hybrid solutions, starting with the automotive field. Digital technology will allow an increasing just in time flexible information integration with the promotional marketing of the final users and Food & Packaging main brands. *Source: Uteco Group

Uteco Group proves to keep up with the times, by investing and operating in the main fields of application that make the industry “4.0”. Uteco accomplishes this by giving new impetus to investments, with particular attention to those in research, development, knowledge and innovation. What is called the “Fourth Industrial Revolution”, which will lead to the connection of innovative technologies within the manufacturing industry (in general), is partly already implemented and partly in progress within the Verona-based company. All Uteco production machineries are equipped with calculation software O.E.E. (Overall Equipment Effectiveness), which supplies information on the press efficiency during production process. It also allows for the supervision of activity and inactivity times. Moreover, it controls functions and indicates possible alarms or functioning faults. This allows the system to operate efficiently by reducing non-production times. The Uteco machines are interconnected by means of a remote pc which receives and catalogues information, having also a dialog with the machine manufacturer. This simplifies the realtime communication and the continuous supervision process. Regarding the data management and data storage, Uteco is investing in a software system which will allow for the “cloud” data migration. Presently Uteco is using a

performing open-source backup software which can manage, verify and, if needed, recover data restoring critical lost or damaged files. In addition, Uteco works with a high performing CRM system which allows to reinforce, improve and establish a better exchange of information and greater interconnection between the customer and the company. The CRM software supplies technological solutions to automate the direct contact business process. It is designed for a smart dialogue with the user, sending alerts for any error or malfunction. The 3D mechanical design software allows to work in prototyping different and specific fields in order to get information as single pieces and features automatically generated lists, renderings, tables and the interference analysis. A software for structure calculation is implemented to forecast the real world product functionality. Other investments are planned as part of the product life cycle management (PLM), which will allow the creation of a coherent data structures by means of the systems consolidation as well as to design, build and provide for product collection. Moreover, it allows the company to take unified decisions (according to a cross-path logic which involves all business fields) in every stage of the product life cycle. Still in the “4.0 Industry” target, Uteco stands at the forefront in the manufacturing field, technologies and innovative solutions, always keeping an eye to the future.

Figure 3: The new cleaning and coating plant by Euroimpianti.

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Figure 4: Spear cleaning stage before coating.

FOCUS ON TECHNOLOGY

5 Figure 5: The touch screen control panel where the two functions (cleaning and coating) can be selected.

the monitoring of performance and the optimisation of working cycles. After the machining operations, the production cycle is diversified. Some components, such as pulleys, gears, brackets and pivots, require a high degree of protection against the wear to which they are subjected by their nature, but also against the difficult conditions of transport to overseas countries. These products are treated in a cleaning machine installed by Silvi (Lesmo, MB fig. 2), equipped with a pre-treatment system including phosphating and degreasing stages. Protective oil is then applied to avoid any additional surface treatment that could compromise the workpieces’ compliance with the strict parameters imposed. The parts are then directly transferred to the assembly stage. 70% of the machined components, however, are sent to the plant’s new paint shop, designed to meet the firm’s requirements in terms of both greater protection and better look of the workpieces. This is in line with the machine branding concept: Uteco’s brand is now recognised around the world also thanks to the visual linearity and beauty of its products.

70% of the machined components, however, are sent to the plant’s new paint shop, designed to meet the firm’s requirements in terms of both greater protection and better look of the workpieces. This is in line with the machine branding concept: Uteco’s brand is now recognised around the world also thanks to the visual linearity and beauty of its products.”

6 Figure 6: Inside one of the two spray paint booths.

Coating large-size parts: a plant engineering challenge

and coating stages in one compact system managed by a PLC that alternatively activates the two functions (Figs. 3, 4 and 5).” The coating plant includes a first booth, an oven and a second, larger booth that is 11 m long (Fig. 6). It is possible to coat and clean workpieces in both booths. The oven performs

“One of the biggest challenges we faced when choosing the characteristics of the new line,” Taioli adds, “stemmed from the large size of some of our components. The first selection concerned the type of coating system: we opted for a liquid coating line due to the greater ease of polymerisation of the film on metal components with a large mass to be heated. The extra-large size of our workpieces posed a challenge for the plant engineering company that we involved to design and implement the system. Thanks to its open-minded staff, Euroimpianti proved a partner that could provide us with a satisfactory solution. They offered us a flexible plant 7 born out of a new project, which integrates the cleaning Figure 7: Inside the oven.

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both the post-washing drying process and the polymerisation of the coating film (Fig. 7). “This ensures high flexibility because the material can access the coating system through both booths indistinctly. Moreover, when we need to paint large structures with a length up to 11.8 m and the second booth is occupied by the overhead crane for their transport and positioning, we can continue to use the other booth to treat other components (Figs. 8 and 9). As a result, we can now coat about 250 m2 of metal sheets per day. Thanks to the installation of the dual-purpose oven, also the manufacturing flow management has improved: currently, our coating operations take place both in the morning and in the afternoon, with a takt time adapted to our needs. In the evening, the painted workpieces are brought to the assembly

8 Figure 8: A large component waiting to be painted in the second spray paint booth.

Figure 9: Workpieces with different formats, all treated by Uteco.

department, so that the next morning the operators can start assembling the components without waiting for the arrival of the material.” The consolidated use of the water-based coatings has also facilitaded a major change in the paint application technology. The old pneumatic system has been replaced with an electrostatic one specifically designed according to the company’s requirements by Comaind, a distributor of Graco products.

and featuring a tank with a stirrer devoted to coatings and a hermetically sealed tank with a silicon salt filter devoted to catalysts, and a Merkur 30:1 cleaning pump for water (Fig. 10 and 11). The main characteristics of this dosing unit are its ease of maintenance and its higher yield: it features easy to maintain cartridge valves, full access to all components of the fluid, air filters mounted externally and the ability to schedule maintenance notifications. “In both booths, the Graco Gun Flush Boxes (Fig. 12) have been installed. They are interfaced with the electronic dosing systems for the automatic cleaning of the guns as well as with the Graco Pro XP WB airassisted guns, equipped with a high finishing nozzle from Graco’s AEF range. The gun’s small and light body is balanced so as to enable to spray with a constant flow rate 11 throughout the day. The integrated power supply Figure 11: A close-up of the tanks increases its efficiency containing the water-soluble by eliminating any heavy two-component paint.

Graco systems: application functionality and effectiveness “The coating plant designed for Uteco,” states Davide Galvani from Comaind, “is composed of two separate systems for the application of twocomponent paints with high pressure electrostatic manual guns. Each unit also includes a Graco 2KE 30:1 compact variableratio electronic dispenser, made in stainless steel

10 Figure 10: A detail of Graco’s compact dosing unit.

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In both booths, the Graco Gun Flush Boxes have been installed. They are interfaced with the electronic dosing systems for the automatic cleaning of the guns as well as with the Graco Pro XP WB air-assisted guns, equipped with a high finishing nozzle from Graco’s AEF range.”

FOCUS ON TECHNOLOGY

The results are excellent not only in terms of aesthetics, but also of cleanliness and overall efficiency. The Gun Flush Box has an articulated arm ensuring a convenient equipment handling and has no ground cables that could be a hindrance inside the booth”

power cable that could slow the work down. “The application of water-soluble twocomponent paints takes place at a pressure of 80 bar with a reduced atomisation air flow. In this way, we have decreased overspray and obtained a 40% paint saving.”

“Thanks to the system installed by Comaind,” Taioli adds, “we have significantly reduced the paint and water waste coming from the cleaning phase. Moreover, the booths’ filters are cleaner than before. The results are excellent not only in terms of aesthetics, but also of cleanliness and overall efficiency. The Gun Flush Box has an articulated arm ensuring a convenient equipment handling and has no ground cables that could be a hindrance inside the booth. Ground insulation also creates a high amount of induced electrostatic energy, which improves the application effectiveness. We had already used some Graco devices in our old plant, such as the ProMix Easy mixer recently abandoned in favour of the electrostatic system; therefore, we knew this was a reliable supplier.”

The switch to the electrostatic technology with the waterbased coatings Uteco coats its parts with Inver-Valspar water-based two-component acrylic products, applied in one coat. “The company’s environmental policy has counted a lot in the choice of the coating system: we have opted for a big investment not only to improve the quality of our products, but also to renew our plant. In the past, the coating station was conceived as an area of the mechanical workshop, now it has become a separate department. The previous system was made up of an automatic spray cleaning and a drying unit, with an overhead conveyor and a semi-automatic handling system. In our new plant, we have eliminated the semiautomatic system and opted for manual

Conclusions

12 Figure 12: The Graco Gun Flush Box.

the filtration system with which both booths are equipped for the recovery of wastewater. It features cardboard and paint stop filters and pumps with a 3.5 m immersion reservoir. The filtered water, coming from the cleaning operations, is sent to a silo and disposed of by an authorised firm (Fig. 13 and 14), in full compliance with the regulations.

“Accustomed to meet the demands of our customers for higher performance, multifunctional and compact printing machines, we have embraced these values and turned them into requests for our suppliers,” says Taioli. “The design of our new paint shop was complex, and it was difficult for us to find a supplier. In the end, we chose Euroimpianti, one of the few companies that had accepted the challenge. Together with it, Comaind has managed to adapt Graco’s devices to this project, modifying them according to our specific production needs. They have both been impeccable and highly skilled partners. “Our coating plant project is not finished, yet: some aspects can be improved or implemented. However, most of the work is done. Now, our operators work in a healthy, easy to manage and maintain department. The first goal of Uteco has therefore been achieved. Obviously we face further challenges and we will always be vigilant and innovative in according with the principle of the “constant and daily improvement”, that has to distinguish us. The future will see the integration of the various production systems and the different departments so that our company will become a true manufacturing model of industry 4.0.”

preparation and cleaning operations: we now remove the machining residues from the workpieces with a practical and handy cleaning spear. “One of the aspects of the project which is yet to be implemented concerns the handling operations, which we would like to improve. The new coating line allows us to enter the larger items from the top with the crane and reach the two pre-treatment and coating booths, but we are currently exploring further ground conveyor solutions. “Finally, we have improved the conditions of our working environment thanks to

The company’s environmental policy has counted a lot in the choice of the coating system: we have opted for a big investment not only to improve the quality of our products, but also to renew our plant. In the past, the coating station was conceived as an area of the mechanical workshop, now it has become a separate department.”

Figure 13: A detail of the ﬁlters installed in the spray paint booths.

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Figure 14: The booth ﬂoor with grilles for water ﬁltration.

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

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Â© Vis Mobility

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FOCUS ON TECHNOLOGY

Nanotechnology conversion: high corrosion protection for the aluminium and iron of road signs in one process Luca Antolini ipcm®

he corrosion of metal items causes Vis Mobility and offices in its Santa Sofia headquarters significant costs to repair or replace Vis Mobility is an Italian leader in the (near Forlì, Italy), with three production damaged structures every year. production and installation of vertical, units covering a total of about 12 thousand If the structures are installed in outdoor horizontal and bright signs, as well as in the square metres. Vis Mobility is a one stop environments, the critical issues associated handling, transportation and installation of shop that can meet multiple needs: design with aging, corrosion, weathering and pollution metal structures in the road, railway, airport, of structures and signs, graphic design, increase exponentially. In the field of development of signalling plans, road signs, therefore, these problems digital and screen printing, pose particular concerns about the construction of light and heavy corrosion that can affect the signs framework structures for static themselves. and variable message signs, In order to maintain these products’ installation, and maintenance. integrity, their manufacturers must “Our company is well known and perform finishing processes able to give respected especially in the public them excellent anti-corrosion properties, sector, where our major customers, also in compliance with the strict such as Autostrade per l’Italia, specifications of bodies like Autostrade Ferrovie dello Stato and ANAS, per l’Italia Spa. Adequate pre-treatment, operate,” says Francesco Lotti therefore, plays a vital role, even more (Fig. 1), the production manager so than coating. In the framework of of Vis Mobility. “Established as continuous improvement, Vis Mobility, A.C.I.S. in 1968, the company 1 an Italian company specialising in the has grown through acquisitions design and production of road, railway and major contracts, such as Figure 1: Francesco Lotti, the production manager of Vis and information signs (Ref. opening the securing operations of Mobility. photo), has recently revolutionised the Mont Blanc tunnel in 1999 its pre-treatment process. In fact, it for which we produced and Adequate pre-treatment plays a has greatly improved the corrosion installed all the safety signs. We resistance of its products with the have also manufactured signs vital role to give excellent anti-corrosion advanced solutions supplied by with photoluminescent films, properties to components” Dollmar S.p.a., especially a flexible innovative for their time, for the nanotechnology conversion process that high-speed train gallery in the can effectively treat both iron and aluminium Apennines. Among our current projects, civil and industrial construction, and building without the need to change the concentration we are working on the complete renewal sectors. Born from well-known companies that levels, the pH values or the plant arrangement, have operated in the Italian road sign field for of the signage of all the provinces of Emilia while ensuring perfect adhesion of the paint. Romagna.” the last fifty years, it hosts its productive plants © ipcm ®

Opening photo: Vis Mobility is an Italian company specialising in the design and manufacture of road, railway and information signs.

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Having to treat and paint two different materials such as iron and aluminium, it was critical that the new pretreatment process was highly flexible, able to avoid any dragging of contaminants from the first stages to the nanotechnology conversion one, and effective in terms of corrosion protection.”

2 Figure 2: The production of road signs starts with the cutting to size of coils.

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All the vertical road signs produced by Vis Mobility are coated in-house, whether they be in iron or aluminium; the only exception are the support structures and joints, which are subjected to a hot-dip galvanising process by a contractor. “Our carpentry department receives the sheet metal and aluminium coils and cuts them depending on the sign or billboard to be produced,” (Fig. 2) Lotti explains. “In order to have the required wind resistance properties, the signs must be subsequently subjected to bending by means of presses, benders or, for higher volumes, bending robots. Their corners are rounded with forming machines for security reasons. The stiffening bars are fixed on their backs by electric welding or riveting to make the signs sturdier and also to help fastening them on their structures.” Having to treat and paint two different materials such as iron (mainly used for the temporary signs of construction sites) and aluminium, which are loaded sequentially on the bars of a monorail conveyor, it was critical that the new pre-treatment process

was highly flexible, able to avoid any dragging of contaminants from the first stages to the nanotechnology conversion one, and, of course, effective in terms of corrosion

3 Figure 3: The pre-treatment tunnel.

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protection. “The first phase of the pretreatment process that we have implemented at the premises of Vis Mobility on an already existing coating plant is an alkaline degreasing process. It is extremely effective in degreasing both iron and aluminium,” says sales director André Bernasconi from Dollmar S.p.A., the company based in Caleppio di Settala (Milan, Italy) that was chosen by Vis to improve its pre-treatment process (Fig. 3). “This step is followed by two rinses with fresh water, a rinse with demineralised water and a surface conversion process with Dollcoat® SA 117.

FOCUS ON TECHNOLOGY

Superior Technology – Signiﬁcant Savings

4 Figure 4: Screen printing is applied to a reﬂective ﬁlm.

This particularly innovative nanotechnology product features oligomers that are relatively resistant to contaminants that may be dragged from one stage to another and, as with all products of this kind, they can cause serious problems of rapid decay of quality. In this case, moreover, we also had to seek a solution to simultaneously pre-treat both ferrous and aluminium alloys. This is not an easy-to-solve problem, considering that also good corrosion resistance was required – especially with aluminium, which is affected by the presence of iron in the solution. The products’ formulation, the adopted parameters and the careful management of the process have offered an operational solution enabling to meet the customers’ requests with the already available plant.”

Bring more colour to your product

Reduce downtime and save powder with Spectrum HD® Powder Feed Centre With over 800 global installations, Nordson dense-phase technology has proven it’s multiple beneﬁts in the most challenging applications. Nordson customers are achieving competitive advantages by using Spectrum HD Powder Feed Centre:

Clean operating environment and automated colour change

Signiﬁcant powder savings with high level of process control

High ﬁnish quality with integrated ultrasonic sieve for fresh and recovered powders

Unmatched powder application efﬁciency delivered by Encore® HD spray systems

For a new fast colour change system or easy integration with your existing cyclone booth, get in contact with Nordson for more information. 5 Figure 5: Sign supports to be painted.

ics.eu@nordson.com www.nordson.com/powder

Figure 6: Only the backs of aluminium signs are coated.

Figure 7: After coating, the signs are transferred to the unloading area.

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FOCUS ON TECHNOLOGY

8 Figure 8: Highway signs.

“Our old system performing fluorozirconate treatments was less flexible and more sensitive to contaminants. We had to constantly adjust the concentration and the pH of the product and ask for technical assistance from its supplier. This inefficiency problem, which could compromise the quality of our final results, has now been solved,” Lotti states. “Thanks to its resistance to contaminants, Dollcoat® SA 117 can also be used on conventional plants with spraying nozzles, as is the case for Vis Mobility, without the need to install any atomising system,” Bernasconi says. The nanotechnology conversion stage is followed by a final rinse with demineralised water. The flexibility of this solution does not affect its effectiveness in any way. “We have been using it for two years now and, compared with the previous system, we have more than doubled the salt spray resistance of our products, achieving a result of 700 hours,” Lotti says. Depending on the specifications of the customer, in fact, a highway sign may have to ensure a rated life of 7 to 10 years.

9 Figure 9: A road sign made by Vis Mobility.

good cost savings and The pre-treatment is a lower replenishment followed by a drying stage frequency rate. Dollmar’s and a one-coat electrostatic assistance during and powder coating operation. after the installation “The paint applied on of the line was perfect road signs must perform and prompt: thanks to two functions: protect the constant monitoring, we object from corrosion and have found no particular enable perfect adhesion problem in these two of the reflective film which years. In collaboration will be applied later,” (Fig. with them, we have also 4) Lotti states. “The front developed a software part of aluminium signs, application to carry out where the film is to be concentration and acidity applied, is not painted, readings in the alkaline but the iron items must be 10 and conversion baths. fully coated for corrosion This ensures quick checks protection: our new preFigure 10: The coating system of the Elan Signage plant in Doha, Qatar. and, therefore, consistent treatment process ensures quality.” perfect adhesion of the In the future of Vis paint. We use industrial Mobility there is also a prestigious Thanks to its resistance polyester-based coatings supplied by collaboration with the ELAN Group, the major Inver-Valspar, which are semi-matte and to contaminants, Dollcoat® advertising space dealer of Qatar. “A few silicone-free not to compromise the film SA 117 can also be used on years ago, we won a contract to manufacture adhesion. For the EC approval, the films conventional plants with a thousand luminous signs and over two must pass a 2000 hours accelerated spraying nozzles. We have hundred road checkpoints for Q-Media, aging test. The colours we use the most more than doubled the salt the company now renamed ELAN Group. are RAL 7016 anthracite grey, required spray resistance of our Satisfied with our work, they have asked us by law, and RAL 5002 blue for the signs products, achieving a result of to work jointly for the creation of a “copy” of of railway stations (Fig. 5 to 9).” 700 hours.” our production plant Conclusions in their country. Product durability and Therefore, we have operational flexibility: bought and installed these were the our own machinery goals of Vis Mobility and processes, for the renewal of transporting them its pre-treatment to Qatar (Fig. 10 process. According to and 11); we will also Lotti, they have been directly manage the completely achieved: firm Elan Signage for “In addition to the the manufacturing remarkable increase and marketing of in the corrosion products together resistance of our with our Qatari products, thanks partners: a perfect 11 to the new preexample of the treatment process we successful export of Figure 11: The Doha plant has been installed by Vis Mobility following the collaboration have also achieved “Made in Italy” .” agreement with the ELAN Group.

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Pulverit S.p.A. Italia

Pulverit Polska Sp. zo.o.

Via Carlo Reale, 15/4 20157 Milano - Italy Tel +39 02 376751 Fax +39 02 37675400 email: pulverit@pulverit.it www.pulverit.it

ul. Strefowa 16 43100 Tychy - Polska Tel. +48 32 329 14 11 Fax: +48 32 329 14 12 email: biuro@pulverit.pl

Pulverit Deutschland GmbH Pulverit Iberia s.l.u. Lager & Vertrieb Am Barnberg 2 73560 Böbingen - Rems Tel.: +49/7173/9146055 Fax: +49/7173/9146045 email: info@pulverit.de

c/ Caravis, 28, 1º 3ª 50197 Zaragoza España 2¿FLQD GH YHQWDV Tel. +34 607163259

Opening Picture: The ColorMax3 powder coating booth installed at Aluron.

INNOVATIONS: PRESENT&FUTURE

What is Dense-Phase Technology? Corinna Hellwig Nordson Deutschland GmbH, Erkrath, Germany

ics.eu@nordson.com

esides its brand new vertical powder coating plant, the Polish company Aluron - featured in the case study at pages 64-72 of the present issue - has a horizontal powder coating line for the finishing of aluminium sheets and for small batches of aluminium profiles. This line was already equipped with Nordson’s ColorMax3 Powder Booth (Ref. opening photo), Spectrum HD powder feed center (Fig. 1), iControl, HDLV® transfer and gun

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pumps, and Afterfilter. For using the dense-phase technology in its complete performance (better process control and finish quality), Aluron changed the old SureCoat Venturi guns to the Encore HD guns recently. With more than 10 years of field-proven experience, Nordson remains at the cutting edge of dense phase pump technology in the powder coating industry.

INNOVATIONS: PRESENT&FUTURE

Nordson’s patented HDLV pumps use dense-phase technology with high-density powder, low-velocity air to pump more powder to the spray gun with a minimum of air, and maximum process control.”

Nordson’s patented HDLV pumps - or “High Density Low Velocity” - use dense-phase technology with high-density powder, low-velocity air to pump more powder to the spray gun with a minimum of air, and maximum process control. This results in superior efficiency, unmatched coverage, and reliable self-clean colour change, boosting productivity and reducing operating costs. An integrated coating solution, the system includes the Encore HD gun, the Nordson HDLV pump and iControl® integrated control system to achieve the ultimate in process control.

The HDLV pump Central to the system operation is the HDLV dense phase gun pump, which operates much differently than a traditional Venturi pump. Venturi pumps use high velocity air, which – when coupled with abrasive powders and/or high powder output rates – causes them to wear over time. They also wear at different rates, requiring frequent adjustments to the gun settings to achieve consistent output. The Nordson HDLV gun pump does not use a Venturi throat, which means it does not wear out. As a result, powder output stays consistent over time. Additionally, the pump meters powder to the gun using less air to propel it – in fact, it is four times slower. This provides better charging as the aerodynamic forces are secondary to the electrostatic forces, producing a “softer” and more thoroughly charged powder cloud. This also minimizes the possibility of over-pressurization and impact fusion as with a conventional Venturi-style transfer pump.

Nordson dense-phase technology removes the guesswork and variables in repeatability and uniformity, replacing it with simple, linear output control. This simplifies equipment set-up and adjustments and leads to a more accurate distribution of film thickness.”

®Nordson

Encore® HD Automatic Powder Coating Guns The Encore HD Automatic Powder Spray Guns incorporate a proprietary, integral HDLV module for the most versatile and efficient performance available today (Fig. 2). Designed specifically to work with Nordson HDLV pump technology, the unique and innovative design of this gun allows easy adjustment of the powder concentration and spray velocity to achieve optimum coating coverage and cured finish quality for every conceivable part type. From a highly dense phase spray to a more diluted (powder and air) mixture, and everywhere in between. The pump and gun also provide exceptionally fast, contamination-free color change.

The optimized electrostatic time provides better coverage into Faraday cage areas and improves overall transfer efficiency. In addition, in a traditional Venturi powder pump, the atomizing air and the flow rate air interact, producing non-linear output. This is difficult to control and can lead to inconsistent results. Nordson dense-phase technology removes the guesswork and variables in repeatability and uniformity, replacing it with simple, linear output control. This simplifies equipment set-up and adjustments and leads to a more accurate distribution of film thickness.

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®Nordson

Figure 1: The Specturm HD powder feed center.

2 Figure 2: The Encore HD spray guns.

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INNOVATIONS: PRESENT&FUTURE

Stable air input to the pump ensures consistent, repeatable powder output. This translates to faster coating speed, unsurpassed film thickness control, excellent finish appearance, and maximum material utilization efficiency.” iControl® Integrated Control System The iControl Integrated Control System provides advanced controls for the complete powder coating process. Utilizing digital, closed-loop air pressure control technology, the production-proven pump controls continuously compensate for variations in plant air supply pressure. Stable air input to the pump ensures consistent, repeatable powder output. Combined with the exceptionally efficient Encore HD spray gun, this translates to faster coating speed, unsurpassed film thickness control, excellent finish appearance, and maximum material utilization efficiency. With the ability to control 32 guns in one console, the iControl system also offers significant space saving benefits. Unlike Venturi systems, which can manage only 16 guns, the iControl system provides twice the capacity in the same amount of valuable manufacturing floor space. The iControl system can accept input from part identification sensors for gun triggering and in/out positioning, and can accommodate up to 255 presets. These presets can be tailored to each color and each part for substantial powder material savings and consistent, repeatable film build. The presets allow operators to adjust various gun control parameters such as flow rate, atomizing, kV and current for various part styles. Included are five advanced coating modes – Standard, Recoat, Deep Recess, Special for dry blend metallic and mica based powders, and a User-Programmable mode that can be customized for specific part configurations or application parameters. The system also features a “Percent Adjust” function for global adjustment to preset airflow settings to compensate for changes in the coating environment. A built-in dual flash card unit provides operating system and program storage.

Opening photo: A workpiece coated by Remaver.

FOCUS ON TECHNOLOGY

Manual pre-treatment and powder application processes combined with a suitable hanging system: a contribution to flexibility Monica Fumagalli ipcm®

ne of the tools that enable small and medium-sized companies serving local markets to counter the competition from large companies – which are more and more frequently equipping themselves with plants and devices in line with the Industry 4.0 principles, in order to be competitive – is flexibility seen as a guarantee of quality. In the contracting coating field, small firms must be able to apply

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suitable coatings on any type of workpiece, from large steel structures to small metal components. On the one hand, automation contributes to higher productivity but, on the other hand, the use of devices for manual processes can be a significant help, especially in the case of frequent alternation of production batches featuring workpieces with different formats and sizes.

1 Figure 1: The sandblasting chamber with a large-sized structure.

Remaver, a powder coating contractor based in Lugo (Ravenna, Italy), is a good example of such small businesses. It was established in November 2010 and it has significantly grown over the years. It currently has a staff of 15 young professionals, with an average age of about 30 years. One of the two founders, Alessandro Rensi, currently manages the company along with Cristina Coralli. “The primary activity of the company,” Rensi says, “is the powder coating of parts from the most varied sectors, such as agriculture, carpentry, building and plant engineering (Ref. opening photo). In order to fully meet the needs of our customers, however, 3% of our workflow is devoted to liquid and thermoplastic coating. Remaver mainly serves its local market, with Emilia Romagna accounting for 85% of orders due to the presence of numerous multinational companies that export their products around the world.” Remaver has turned to another Emilian company, Tecno Supply – the division of Ibix Srl dedicated to the industrial coating and corrosion protection fields – for the supply of a sandblasting plant, a hanging system, and a few masking and thermoplastic application devices needed to ensure high flexibility and greater coating quality. © ipcm ®

FOCUS ON TECHNOLOGY

2 Figure 2: Manual application of powder coatings.

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Attention to “quality” is one of the most important factors behind the application cycles performed by Remaver, as is evident in the firm’s attention to detail. In order to achieve this goal in its production flow, the company has decided to rely on Tecno Supply’s hanging technology. “The protection of threads and other components is one of the most common requests from our customers. In order to meet The pre-treatment process: them, we use high temperature resistant caps, sandblasting plugs and tapes.” The sandblasting plant is used for the The loading and unloading of materials is one preparation to coating of large-sized parts, of the most critical stages in any coating plant. mainly heavy carpentry structures (Fig. 1). That is why Remaver has cooperated with “They needed a manual sandblasting system Tecno Supply to build a system with pushing able to treat any type of carbon steel part,” tracks for the transfer of workpieces, rather states Adriano Antonelli, Ibix’ sales manager. than implementing handling trolleys. “The two “The Ibix 40 portable sandblaster is the tracks can carry parts up to 30 tonnes,” Rensi 3 ideal solution for companies like this, which says. “We have preferred a system in which the require to adapt the treatment to the different workpieces are suspended above the ground Figure 3: A frame with small metal formats of their components. The pressure to avoid any contact that could damage the components. can be adjusted in a range between 0,5 and coating applied during transfer from the booth Adequate hanging optimises the 7 bar and the tank has a capacity of 40 litres, to the polymerisation oven as well as at the production ﬂow so as to avoid any constant refilling operation exit of the oven, contrary to what might happen “We perform electrostatic powder application that could be detrimental to the production with trolleys (Fig. 3). processes in one or two coats depending on takt time. This system uses Garnet abrasive, For the hanging system devoted to the smallest our customers’ needs (Fig. 2),” Alessandro composed of silicon-free quarry sand with a components, we have asked Tecno Supply a Rensi explains. “We use mainly polyesters and hardness value of 8 on the Mohs scale. The solution that was flexible and could be adapted epoxy-polyester powders; the latter are mainly surfaces treated by Remaver achieve a value to workpieces of different sizes: they have employed if an orange skin texture is required of SA 2.5. The machine is very versatile and offered us their frames with the HSQ quick on components intended for industrial environmentally friendly; it is also suitable for hanging system to maximise space and enable plants. Both types of powder are suitable for working in outdoor environments, for instance to use as many of them as possible. This also products intended for both indoor and outdoor in the construction industry, and it enables reduces the time needed for the polymerisation environments.” to recirculate the material: in this case, that stage, which is the most complex one. occurs through a manual collection With Hang On’s universal frames, operation with the use of screens.” distributed by Ibix, we only need “We carry out salt spray tests about 3 or to change the hanging accessories 4 times a year to assess the resistance according to the products to be treated.” of our coating systems,” Rensi says. “The hanging and masking phases “We have noted that, compared with are extremely important for us,” optimal phosphating results equal to Rensi adds. “These are fundamental approximately 280-300 hours, Ibix’ processes to optimise production. sandblaster ensures a much higher Thanks to the technologies developed resistance (500-600 hours) with by Hang On and Tecno Supply, we polyester applied in one coat without are able to fully meet the high quality any basecoat. Incidentally, we had needs (Fig. 4) of our customers as 4 opted for this technology also because well as our requirements in terms of Garnet abrasive slows down the flexibility and adaptability to the parts Figure 4: Coating thickness measurement with Automation oxidation process on surfaces.” to be coated.” Dr: Nix thickness gauge, distributed in Italy by Tecno Supply. © ipcm ®

Remaver is now equipped with a 10 m long, 5 m wide and 4 m high manual sandblasting plant; this is separated from its coating line, which is made up by a booth and a static oven with a capacity of 10.5 x 4 x 4 m. It also has a small pressurised booth for liquid coating operations, in case a mixed system is required.

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ÂŠ Decoral System Srl

Opening photo: The false ceiling of the Dubai Metro, lined with wood-effect aluminium panels.

INNOVATIONS: PRESENT&FUTURE

Continuous pursuit of quality in the decoration of door and window frames with sublimation Ivana Giacomello and Andrea Piva Decoral System Srl, Arcole (Verona) - Italy

andrea.piva@decoral-system.com

he idea of designing a truly innovative product in the sector of aluminium door and window frames was born in 1993 following a decline in production due to the industrial crisis of that period. VIV - Verniciatura Industriale Veneta, a company established in 1974 to perform aluminium coating processes, sought a solution that could differ its production from that of its competitors.

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Giancarlo Fenzi, one of the founders of VIV, thus began designing a few new finishes for their clients; the first woodeffect aluminium profile was conceived two years later. The idea seemed interesting from the start because, in the Italian residential building market, aluminium frames were no match for wooden windows and shutters. VIVâ&#x20AC;&#x2122;s contracting coating activity,

INNOVATIONS: PRESENT&FUTURE

still in its experimental stage, enabled the firm to offer these new finishes to a small circle of friends and relatives: their shutters, doors, windows and other metal structures were coated with a finish that made their surfaces aesthetically identical to solid wood (Fig. 1). These first trials also enabled the company to assess the durability of its new finishes. Once sure that its wood

sublimation process was performed by VIV - Verniciatura Industriale Veneta. Then, VIV Decoral® was established: the acronym VIV was synonymous with the expertise and reliability gained by the company over the years, while the phrase Decor-al (DECORazione ALluminio, i.e. ALuminium DECORation) highlighted the innovation brought by the new finishes intended for aluminium doors, gates and windows.

These first trials also enabled the company to assess the durability of its new finishes. Once sure that its wood effect coatings could be launched on the market, VIV began to participate in the most important trade fairs of the sector and to be met with great interest from their visitors. The first patents of the “metal sublimation” process were registered, then followed by many others.”

The increasingly pressing and numerous requests from all over Italy, but especially from abroad, were such that one coating firm could not meet them all. At that point, VIV decided to “sell” its own process: Decoral System® was established in 1995 as a company in charge of selling the patented Decoral® sublimation system all over the world. Nowadays, Decoral System® is the point of reference for this aluminium decoration process, providing highly technological plants and their related raw materials (powders and films) as well as contracting coating and decoration services.

Srl

effect coatings could be launched on the market, VIV began to participate in the most important trade fairs of the sector and to be met with great interest from their visitors. The first patents of the “metal sublimation” process were registered, then followed by many others.

Nowadays, Decoral System® is the point of reference for this aluminium decoration process, providing highly technological plants and their related raw materials (powders and films) as well as contracting coating and decoration services.”

VIV Decoral, the world leader in the metal sublimation sector In the first phase of development of this new product, the wood-effect

The sublimation technology in the Decoral® process Figure 1: Wood-effect aluminium furniture.

VIV Decoral® is now present in Italy with four factories: the original plant in Arcole (Verona) and three facilities in Volpiano (Turin), Udine and Anagni (Frosinone).

The sublimation technology can be applied on surfaces of any material able to withstand temperatures of 200°C as well as to be coated, i.e. almost all types of metals but also ceramics, glass and many more. A special powder coating layer is applied; then, special inks are transferred on it by

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2 Figure 2: Another structure installed by VIV Decoral® at the Robinsons Mall in Singapore.

sublimation, through a combination of heat and pressure. When this wood-effect sublimation process for aluminum profiles was developed, VIV relied on a few suppliers of powders and films. However, its constant pursuit of quality and the need to provide its customers with guarantees of product durability have led Decoral System® to decide to produce in-house all the components necessary to the process: thermosetting powders intended for sublimation, films, inks and even sublimation plants, in order to ensure better repeatability and quality.

The Qualicoat certiﬁcation All Decoral® systems are Qualicoat and Qualicoat Class 2 certified. Powder coatings are designed to protect components in order to ensure their functionality and corrosion resistance and give them an aesthetically pleasing look. The sublimation technology, however, requires the use of a coating able to

The sublimation technology, however, requires the use of a coating able to protect also the “drawing” created by the inks that are applied and incorporated in the powder film. This has generated several problems in the formulation of painting products. That is why VIV decided to gear up and produce coatings exclusively designed for this technology.”

INNOVATIONS: PRESENT&FUTURE

protect also the “drawing” created by the inks that are applied and incorporated in the powder film. This has generated several problems in the formulation of painting products. That is why VIV decided to gear up and produce coatings exclusively designed for this technology. The powders are of polyurethane nature to enable the transfer of the drawing and the subsequent film polymerisation that homogenises and protects the surface. There are two types of Decoral System® inks: durable, for films intended for the decoration of Qualicoat level products, and hyper-durable, for Qualicoat Class 2 finishes. Both have called for a thorough research phase to identify the best inks able to sublimate simultaneously at a temperature between 190 and 196°C.

The pursuit of quality The factors that have led Decoral System® to become a global leader in the field of sublimation for the decoration of aluminium can be attributed to the great advantage offered by the presence of VIV Decoral®, capable of manufacturing decorated profiles and sheets for 24 hours a day. VIV Decoral® is also a sort of pilot plant where the new ideas of the Decoral System® laboratories are immediately tested.

VIV Decoral® is also a sort of pilot plant where the new ideas of the Decoral System® laboratories are immediately tested.”

When something new is added to the sublimation concept, an updated system is installed at VIV’s premises to test the new solution in an environment characterised by high production volumes. Only afterwards does the company apply these innovations to the new plants to be sold, certain that they will meet its customers’ demands. The new film designs and the improvements in the chemical properties of powders are tested in the firm’s daily production, too. These trials are important also because the vast experience of VIV Decoral®’s operators and their first impressions and advice help the company’s designers to fine-tune all products at best. The key to Decoral’s success is precisely its daily use of its own products, a habit that is almost impossible to find in other equipment, film or powder coating manufacturers. Decoral System® produces all the elements needed for the process, but there is more: the result is used for the production cycles performed by all its factories. The quality of

INTERNATIONAL PATENT

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

NITROTHERM The performance is reff ered to fl uid enriched in nitrogen with concentration of 93% ± 1%, at environment temperature of 20 °C and atmospheric pressure of 1013 mbar. Inlet compressed air must be free from impurities (water, oil, solid particles). We advise to use filter elements supplied by Eurosider. All the data and images are merely approximate and can be changed; the performance vary in accordance with environment and working process pressure and temperature. Eurosider reserves a right to make modifications, even without advanced notice.

EUROSIDER Piazzale Thailandia 6 | 58100 GROSSETO | ITALY ph. +39 0564 425117 | fax +39 0564 418833 www.eurosider.com | info@eurosider.com

3 Figure 3: The west façade of the Les Docks complex in Marseille, made of metal.

the thousands of sublimated profiles daily leaving VIV Decoral®’s plants all over Italy is a guarantee of the soundness of Decoral System®’s process. They are not the result of some lab tests, but of actual manufacturing processes that are tested in terms of both production and product duration. VIV Decoral®’s products have all Qualicoat, Qualideco and many other certifications. The most recently acquired one is QUALITYDECORAL® GOLD, with 15 years of warranty. The certified finishes are created with super-durable coatings and hyperdurable sublimation films; they are

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Quality assurance

By producing films and powders in-house, Decoral System® can make sure of the quality of its whole process.”

suitable for use in outdoor environments under extremely severe climatic conditions. The approval process requires passing particularly rigid tests: - accelerated aging (2500 hours); - Florida exposure (3 years). These tests are in line with the Qualicoat and Qualideco specifications for Class 2 products.

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By producing films and powders in-house, Decoral System® can make sure of the quality of its whole process. In order to obtain the Qualideco Class 2 special approval, the use of Class 2 certified coatings and films is not enough, because they may be incompatible and thus not suitable for the intended use of a workpiece: the combination of powders and films must be tested in order to ensure proper durability. VIV’s new target markets are architecture – with important structures such as the Dubai Metro (Ref. opening photo), the CityLife building of Milan, and the Düsseldorf and Mumbai airports – store furnishing, shipbuilding, lighting, and outdoor and interior design (Figs. 2 and 3).

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

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

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

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

BUSINESS TRAINING

Customer Satisfaction Analysis & Management – Part 1 Felice Ambrosino consultant

simeida@tin.it

Preliminary remarks In our last article (Strategic planning: Back to the business definition, ipcm®_International Paint&Coating Magazine no. 43, Vol. VIII, 2017, pages 84-86), we mentioned two methods that companies can use if they wish to make a quantum leap and start focussing

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on Customers rather than on Products. In this article, we will describe the first one, called Customer Satisfaction Analysis & Management. This enables to numerically assess the satisfaction degree of clients, namely to measure their feeling that their expectations on a given characteristic of the

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purchased product/service have been met or exceeded. This method is the core of a more general management philosophy called Customer Intelligence, which suggests to concentrate all the company’s activities on its customers (i.e. their needs, aspirations and behaviours) in order to create value for them

BUSINESS TRAINING

and increase their loyalty. Indeed, the clients’ fidelity should be considered a primary resource.

Primary resources Generally, nowadays, companies are able to control and numerically assess many of their activities and resources. The value of their properties, plants and equipment is controlled through a careful accounting activity and precisely defined in their financial statements, together with that of their inventories and receivables. Their income statements, on the other hand, faithfully include the value of their sales (revenues), costs and expenses. However, there are also corporate activities and resources of primary, if not vital importance that are not as well controlled or controllable and that have never been assessed or indexed in any way. Incidentally, such resources are not only of primary interest, but also increasingly scarce, sometimes rare: customers, for example.

Better a loyal customer today than a new customer tomorrow.”

Of course, the sales of a company or, even better, its market shares correspond in some way to the volume of its clientele. However, these parameters do not take any account of the customers’ quality, significance, strategic importance, and value for the business. It may happen that, despite having the same market share, two companies run totally different businesses, one working with solid, competitive and loyal customers and the other with clients in difficulty and in search of alternatives. Therefore, it is worthwhile examining these aspects and understanding what determines the quality of a customer, how it can be expressed and, above all, how it can be measured.

The value of ﬁdelity In many global or even local markets, two dominant characteristics have emerged with which competitors must be faced: oversupply, resulting in fierce competition, and customers’ expertise, thanks to which they can compare the offers of different suppliers with great ease. These factors are making it difficult for a company to grow, at least by subtracting market shares to competitors. Indeed, companies fight tooth and nail for their shares; it is also hard to define a differentiation strategy that goes beyond prices, with customers who “know it all”. Consequently, the cost of

The value of loyal customers depends on the duration of their relationship with the company and on the frequency and size of their purchases.”

gaining a new client is very high and the return of this investment, if any, is not a short-term ROI. Furthermore, even if the company decides to take this risk, it has to spend further resources to deal with the counter-offensive of its competitors, meant most of the time to “even the score”. In the end, after several (Pyrrhic) victories and (painful) defeats, the market shares remain essentially the same; however, resources decline, even those to be allocated to the maintenance of the essential quality, service and image levels. In this framework, economists and scholars have searched for alternatives for the development of a business and came to the conclusion that the best opportunities lie in the loyalty of existing customers. We could state that intensively tending one’s own garden is much more profitable than intruding the others’ ones. “Better a loyal customer today than a new customer tomorrow” (Bridelli e Berni, L’impresa, 1991, no. 4) is the new creed of marketing experts. Besides the conventional methods and the ever-needed analyses, research activities, decisions, segmentations, etc., pursuing the Zero Defection or Total Retention approach is very important. This means that maintaining and retaining one’s own valuable customers by ensuring their loyalty is now crucial. The quality of customers and their strategic value identifies with their fidelity. Loyal customers are more valuable beyond their annual purchases: their value depends on the duration of their relationship with the company and on the frequency and size

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of their purchases, perhaps repeated all their life.

Happy client, loyal client One might ask, on what does the loyalty of customers depend? What motivates buyers to become faithful customers and keep buying from the same supplier? The answer is easy: their satisfaction. If buyers are globally satisfied with their purchase, they will repeat it at the first opportunity. If this time they feel that they got what they expected, or even more, they will come back. And so on, as long as they are satisfied. However, if it is true that satisfied customers are loyal customers, the reverse is not always true: clients, in fact, may also be loyal because they are forced to. This applies to purchases made under monopoly regimes (e.g. many public services), with high barriers to change (e.g. banks and insurance companies, whose terms and conditions deter the clients from breaking the contracts) or in markets with high

The loyalty of customers can be obtained with two types of strategies: aiming for their satisfaction (Customer Satisfaction Management) or raising barriers.”

switching costs (e.g. for a complete stock renewal, for a significant change in procedures, for issues related to the distribution network, and so on). It follows that the loyalty of customers can be obtained with two types of strategies: aiming for their satisfaction (Customer Satisfaction Management) or raising barriers. However, we believe that this second strategy (or, better, tactic) does not lead to real success and

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has no real strategic content, as well as being pursuable only in particular cases. Therefore, we prefer to take care of the customers’ satisfaction, the true pillar of a company’s position and a truly primary resource, without which it no longer makes sense to speak of a Company. We will now deal with its definition, its benefits and its assessment.

Satisfaction is a state of mind What is meant by customer satisfaction? When can a customer be called happy? Satisfaction is a subjective feeling, a personal way of conceiving things, interacting with one’s own environment

There is no objective method, mathematical calculation system or common sense system to reveal if clients are happy with our offer or not.”

and experiencing one’s own condition. Therefore, how can one be sure that a customer is satisfied? Let us state this clearly: there is no objective method, mathematical calculation system or common sense system to reveal if clients are happy with our offer or not. There is only one thing to do: asking them. Interview and ask them: “What do you think of this aspect of our performance? Are you satisfied? A lot or a little? What should we improve?” and so on. Once the answers to these and other questions (as we will see later) have been obtained, one can begin to process them. In this way, this “state of mind” called satisfaction can be rationalised by defining its main components and laying the foundations for an in-depth analysis. (to be continued on the next issue of ipcm®)

STANDARD & LEGISLATION - UCIF Informs

The most frequently asked questions about Industry 4.0 Marcello Zinno UCIF-Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

CIF, in close collaboration with the ANIMA Federation, is investigating with great interest the Industry 4.0 concept, born as a result of the latest technological developments and formalised within the Italian Budget Law by the will of the Renzi Cabinet. A national plan for the provision of subsidies (first and foremost, a 250% hyperamortisation plan) has been created in order to facilitate industrial investments in the “factory of the future”, that is, to encourage the interconnection of a plant’s various production departments and systems.

First of all, the list of goods subject to the hyper-amortisation plan is not enough: the fact that the good being purchased is mentioned in the Attachment A, for example, is a necessary but not sufficient condition to get the benefits provided by the law. In fact, the new machine must have five characteristics: 1. Computer Numerical Control (CNC) and/ or a Programmable Logic Controller (PLC); 2. interconnection to the factory’s IT systems with remote instruction and/or part program loading; 3. automated integration with the logistics of the factory or with the supply network and/or with other machines in the production cycle; 4. simple and user-friendly humanmachine interface; 5. compliance with the latest standards in terms of safety, health and hygiene.

The current Budget Law includes a list of material (Attachment A) and non-material (Attachment B) goods that are the subject of these subsidies but that must meet certain conditions and technological requirements to ensure the “4.0 nature” of the investment. However, their applicability has raised a number of questions and doubts related to different interpretations of the law. This has led the Ministry of Economic Development to issue some guidelines drafted together with the main players of the industrial world, including the ANIMA Federation. Over the past few months, the ANIMA Federation and UCIF have supported several companies by helping them understand the law’s criteria, thus facing some very interesting cases. Here below, we will describe a few examples in order to help any company facing a similar situation.

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info@ucif.net

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Moreover, all machines must be equipped with at least two of the following characteristics in order to be considered equivalent to or integrated with cyber-physical systems: a) remote maintenance and/or remote diagnosis and/or remote control systems; b) continuous monitoring of working conditions and process parameters with suitable sets of sensors, and adaptivity to process drifts; c) integration between the machine and/or plant and the modelling and/or simulation of their behaviour during the process (cyber-physical system). Also as regards intangibles, there is an additional condition besides the inclusion of the purchased good within the Attachment B: The connection of the investment with a material good. Even if it is in the list, therefore, a non-material good cannot be hyperamortised if it is not a part of an investment referring to an interconnected material good. In any case, if an investment is not related to an interconnected good, it can still meet the requirements of the 140% super-amortisation plan. On the other hand, for purchased goods that are interconnected only at a later time, the progressive interconnection rule applies: as long as the machine is running but not interconnected, the company will benefit from the super-amortisation plan, whereas it will be able to benefit from the hyper-amortisation one from the effective date of interconnection.

WASHING

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Passion is our engine. For over 60 years, we have come a long way. Our mission has always been reaching new horizons in industrial washing, coating and impregnation. It was a call of innovation that has led us to an outstanding achievement: to become the appreciated partner of the most important companies in the automotive market. For us, it is the recognition of our ability to offer solutions and to respond in the shortest time to constantly accelerating customersâ&#x20AC;&#x2122;demands. For our clients, making choice of our plants has guaranteed reaching their best performance over all type of surfaces, for all their products. All around the world.

TECNOFIRMA S.p.A. - Viale Elvezia, 35 - 20900 Monza (MB) Italy - Phone +39 039 236 01 - Fax +39 039 324 283 - www.tecnofirma.com - tecnofirma@tecnofirma.com - Company Certified ISO 9001 since 1992

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Milan, Italy May 17-19, 2017 www.madeinsteel.it/en/

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Turin, Italy May 03-05, 2017 www.afﬁdabilita.eu/aet/default.aspx?site=ENG

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FOR SURFACE

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CONTROL

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Stuttgart, Germany May 09-12, 2017 www.control-messe.de/en/control/

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MACH-TECH

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Budapest, Hungary May 09-12, 2017 iparnapjai.hu/en

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MACH-TOOLS AFRICA

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Nasrec, South Africa May 09-12, 2017 www.machinetoolsafrica.co.za

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AUSTECH

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Melbourne, Australia May 09-12, 2017 www.amtil.com.au/Austech

Nuremberg, Germany May 30-31, 2017 www.automotive-engineering-expo.com

EUROFINISH

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Nuremberg, Germany May 30 - June 01, 2017 www.sensor-test.de

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CHEMSPEC EUROPE

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Munich, Germany May 31 - June 01, 2017 www.chemspeceurope.com

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METEF 2017: An Increasingly Richer and Qualified Exhibition METEF proposes the sector’s international public a very specific offer, based on four topics: production chain, custom solutions, automotive and networking. A coherent and integrated path encompassing foundry, transformation processes and the relating machining, products and solutions as well as raw materials and recycling. A virtual visit to the show platform will tell you that the hall

The area dedicated to foundries will play a role of undisputed importance for the large number of visitors received during the last editions of the show and for the large presence of exhibitors this year. The industrial automation sector is also gaining importance since it’s being affected by a streamlining and rationalization process of the aluminium processing production flows. Many global leaders in this sector – which is the real keystone of the manufacturing development within the Industry 4.0 strategy – will take part at Metef. © METEF Srl

rom June 21st through 24th Verona will be the gathering place of the global leaders in the aluminium and innovative metals industry for a business matching that will involve over 400 exhibitors, one third coming from abroad (Fig. 1). Some of the most important halls – such as diecasting, foundry and industrial automation – are already sold out and will offer the chance to test live the sector’s most advanced technologies.

The eleventh METEF, to be held at VeronaFiere METEF will be from 21st to the ideal place to th 24 June 2017, open and carry is the world’s out a debate on reference event all these topics at for the aluminium, an international innovative level, benefiting metals, foundry from the ongoing equipment collaboration and solutions with many foreign sector, and the organizations automotive and and associations transport division – such as Nadca, is the driver for Foundry Planet, all the industrial Fundigex, STOP 1 induced activities. (Polish Foundry The countdown Association) etc. – Figure 1: METEF will take place from from 21st to 24th June 2017 at VeronaFiere (Verona, Italy). of the show and the confirmed already marks presence of several out the data that official delegations validates METEF as a must-go event dedicated to the diecasting sector is from the most advanced western countries for international operators: over 400 already sold out: all the manufacturers of such as the United States and Germany exhibitors (30% from abroad) and a very machines and plants will be there and the as well as from emerging markets such as large number of professional visitors visitors will have a first hand experience Poland, Czech Republic, Slovak Republic, the (over 10,000 in 2014, 35% from foreign of the different technologies displayed Balkan Countries, Spain, Iran, etc. countries). for the first time during this show. For further information: www.metef.com

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HANNOVER MESSE 2017: Adding value with Industry 4.0

and collaborative robots (cobots), companies ANNOVER MESSE 2017 opens in systems will incorporate machine-learning of all sizes today have a multitude of highabout four weeks’ time. The show, technologies that analyze this data centrally tech solutions to choose from. But often they which runs from 24 to 28 April, will and feed the results back to the production find it difficult to predict what value these machines in question, thereby enabling sport a rich array of highlights, including a sorts of solutions might add. Which is where record 500-plus Industry 4.0 applications, them to learn and self-optimize. As such, HANNOVER MESSE 2017 comes in. Köckler: machine learning is fundamental to predictive self-learning robots with near-human touch “The world’s leading trade fair for industrial maintenance – a highly promising aspect of sensitivity, and advanced technology solutions technology will present solutions for all parts Industry 4.0 that will feature prominently at the for a more sustainable energy future (Fig. 1). of the industrial landscape. It’s a landscape upcoming HANNOVER MESSE. “The technologies needed for the successful in which mechanical engineering and IT digitalization of industrial production are fully developed and ready Digitalization as a driver of to go,” commented new business Deutsche Messe models Managing Board member Jochen Integrated Industry will reach far beyond Köckler.” “The task the walls of smart now is to ensure that decision makers factories. The goods produced by smart from industry and factories will stay the energy sector connected with understand the direct, their manufacturers long-term benefits throughout their that digitalization service lives, can offer them and supplying a constant their organizations, business models stream of valuable 1 and employees,” he data. This data added. “Challenging will enable the Figure 1: HANNOVER MESSE will take place from 24 to 28 April 2017 in Hanover, Germany. people to ‘think manufacturers to outside the box,’ develop additional are converging. This is digitalization, and highlighting all the various ways in which web-based services and to pursue new HANNOVER MESSE will show visitors how to digitalization can add value, and opening business opportunities outside the confines recognize its benefits and make them their up new markets – that’s what this year’s of their traditional industries. At the upcoming own.” HANNOVER MESSE is all about, with its lead HANNOVER MESSE, industrial subcontractors theme of Integrated Industry – Creating Value.” will demonstrate how digitalization helps them The show will have around 6,500 exhibitors Predictive maintenance through to offer innovative and highly customized machine learning and feature Poland as its official Partner solutions more quickly than ever before. “The Country. Digitalized production processes generate vast biggest value-adding potential of digitalization With Industry 4.0, integrated energy, quantities of data which are then analyzed by lies in the development of completely new digital twins, machine learning, predictive various upstream and downstream systems. business models and in the markets these maintenance, smart materials, and networked In the not-too-distant future, manufacturing business models tap into,” explained

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ZOOM ON EVENTS

Köckler. “HANNOVER MESSE is increasingly turning into a platform for previously unheard-of partnerships. For instance, partnerships between IT companies and engineering firms, or between startups and major corporations. From radical, highly disruptive new business ideas to proven 4.0 business models – it will all be there this April.”

Technologies for the energy transition Digitalization is also transforming the energy industry. Without digitalization, it will not be possible to make the switch from today’s outmoded centralized power plants to modern, highly efficient energy systems that are based on renewables and distributed generation structures. Under the “Integrated Energy” banner at the upcoming HANNOVER MESSE, the world’s leading providers will highlight the changes the energy industry will undergo as well as the individual technologies that will play a critical role in this transformation. “HANNOVER MESSE will showcase integrated solutions all along the energy value chain – from generation, transmission, distribution and storage, right through to alternative mobility solutions,” explained Köckler.

New “Plasma and Laser Surface Technology” pavilion HANNOVER MESSE will feature also a brand-new showcase: the Plasma and Laser Surface Technology Pavilion. The group exhibit aims to raise awareness of the applications and innovative potential of the latest plasma and laser systems. It will be located in the SurfaceTechnology Area which has been moved to the Industrial Supply show (Hall 6) and covers the full spectrum of surface finishing solutions. Among much else, visitors to the pavilion will find expert advice and plenty of contacts who can assist with just about any issue related to the plasma or laser treatment, modification and coating of surfaces. Whether the subject is pre-treatment, research and development, potential applications or plant and equipment, the pavilion has all the answers.

New Venue Expanded Exhibit Space Sponsorship Opportunities Visit With Suppliers To The Coatings Industry On Our Trade Show Floor For Registration, Hotel and Program/ Show Information Go To Our Website:

www.easterncoatingsshow.com For Speciﬁc Questions Please Contact Us: Email: info@easterncoatingsshow.com Hosted By: Eastern Coatings Federation, Inc.

HANNOVER MESSE – Get new technology ﬁrst! The world’s leading trade fair for industrial technology will next be staged from 24 to 28 April 2017 in Hannover, Germany. With its core focus on “Integrated Industry – Creating Value,” HANNOVER MESSE is the world’s leading showcase for the digitalization of production (Industry 4.0) and energy systems (Integrated Energy). The upcoming HANNOVER MESSE will feature seven parallel shows: Industrial Automation, MDA – Motion, Drive & Automation, Digital Factory, Energy, ComVac, Industrial Supply and Research & Technology. Poland will star as the Partner Country of HANNOVER MESSE 2017. For further information: www.hannovermesse.de

MAY 15 TO MAY 17, 2017 HARRAH’S RESORT ATLANTIC CITY, NEW JERSEY

ZOOM ON EVENTS

TST 2017: What will be the future of surface science?

he conference organised by POLIEFUN on research in the field of surface treatments and coatings will be held on May 18th, 2017 at the Politecnico di Milano.

TST’17 – Trends in Surface Technology Now entering its fourth edition, the conference aims at analysing the international scenario and the state of the art of scientific research in the surface treatment industry, with an interesting programme and the prestigious contributions of prominent personalities of the academic and industrial research worlds. This free event also aims at putting university and research in contact with the industry. The companies themselves will be called to active participation and to a stimulating (a hopefully lively) debate in which they will be able to participate in a direct, effective and constructive way. Several exhibition spaces are available for those companies that would like to be present at the event as sponsors. The stands will be located alongside the hall, in the “networking” area of the event, also dedicated to the registration process,

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N. 44 - MARCH/APRIL 2017 - international PAINT&COATING magazine

the breaks and the Conference Secretariat. They will be pre-fitted stands, identical for all exhibitors, equipped with a desk with the company logo, a totem customisable on three sides, and two stools. On the website www.poliefun.org you will find the specifications of the three types of outfitting offered and the services included in each one of them. In the “networking” area, posters will also be displayed with the logos all of the participating companies, printed on special panels. The symposium will also include the Award Ceremony for the “Prize in Memory of Anna Da Forno” for the Best Graduation Thesis in the field of surface treatments and coatings. The assessment of the theses and the choice of the two winners will be entrusted to a special board composed of at least three experts, appointed by the Board of Directors of Poliefun. In order to participate in the conference or to book an exhibition space, simply fill out the online form on Poliefun’s website (“TST’17”, “Participating”) and send it to segreteria@poliefun.org, or contact the Conference Secretariat: Smooth – Pina Licata – phone: +39 02 89054867, email: pina@smoothadv.com For further information: www.poliefun.org

smoothadv.com

www.poliefun.org

SIMPOSIO GRATUITO TRENDS IN SURFACE TECHNOLOGY ADVANCED SURFACES: CHARACTERIZATION & PERFOMANCES

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SUPPORTATO DA:

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SEDE: ﬁeramilano Rho, ingresso dalle porte Est, Ovest TIM e Sud TIM PERIODO DI SVOLGIMENTO: da mercoledì 17 a sabato 20 maggio 2017 ORARIO: dalle 9.30 alle 18.00 INGRESSO: biglietto giornaliero 12,00 â; gratuito con preregistrazione da mercoledì 1 marzo 2017

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32nd International Exhibition for Fine and Speciality Chemicals

Known for its focused profile Chemspec Europe is the place to be for international experts of the fine and speciality chemicals industry. Purchasers and agents looking for highly specialised products and bespoke solutions will find leading companies from all over the world presenting a maximum range of fine and speciality chemicals. Benefit from excellent networking opportunities and be inspired by the latest results in research and development at top-class conferences.

Top-class conferences

Agrochemical Outlook Conference Chemspec Careers Clinic Pharmaceutical Update Conference Pharma Outsourcing Best Practices Panel REACHReady Regulatory Services Conference RSC Symposium

Chemspec Europe 2017 – The driving force for tomorrow’s business! Exhibition Conference Networking

31 May – 1 June 2017 Munich Trade Fair Centre, Germany

www.chemspeceurope.com

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8th Year - Bimonthly N° 44 - MARCH/APRIL

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New Interpon D2525 Collection Anodic III features 12 exclusive trendy colors including 6 new products:

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