ipcm® n. 66 - November/December 2020 by ipcm® International Paint&Coating Magazine

The smart journal for surface treatments

ipcm digital on In this issue: SPECIAL ON ACE & OFF ROAD VEHICLES & INDUSTRIAL CLEANING TECHNOLOGIES

INTERNATIONAL PAINT&COATING MAGAZINE

ISSN 2280-6083

www.myipcm.com

2020

11th Year - Bimonthly N° 66 - NOVEMBER/DECEMBER

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

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

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

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CONTENTS NOVEMBER/DECEMBER 2020 © AdobeStock

HIGHLIGHT OF THE MONTH

INNOVATIONS: PRESENT&FUTURE

Adapta HCR, Invisible Protection: The Best Anti-Graffiti Powder Coating Available on the Market

New Graco Finishing Equipment and Accessories

FOCUS ON TECHNOLOGY

66 07 08 10 24 26

Creativity at the Service of Technology to Design a Highly Versatile, Compact System for the PVD Coating of Fashion Accessories

EDITOR’S LETTER

BRAND-NEW

BRAND-NEW MARKET CLOSE UP Positive Post-Pandemic and Post-Brexit Perspectives of the British Coatings Sector

FOCUS ON TECHNOLOGY

INNOVATIONS: PRESENT&FUTURE

FOCUS ON TECHNOLOGY

BRAND-NEW HIGHLIGHT OF THE MONTH

Budchem: The Completely Automated Coating of Plastic Car Components through an Articulated Robot Opens the Future to New Finishing Projects

IPCM IN REVIEW

BASF Releases CODE-X, its 2020-2021 Automotive ColorTrends Collection

28 30

FOCUS ON TECHNOLOGY

Advancements in Near Neutral pH Descaling

Zanardo Spa: The Best of Process, Product, and Digital Technologies for a New Cataphoresis and Powder Finishing Line Devoted to Electrical Cabinets

60 62 76

INNOVATIONS: PRESENT&FUTURE Guardian AM: Stardust’s Answer to The Current Need to Guarantee Surfaces that Are Also Protected Against Microbial Agents

HIGHLIGHT OF THE MONTH Simple as a Powder Application!

Infrared RHT Gas Burners for the Complete Curing of Coatings: A Unique Application in Europe

INNOVATIONS: PRESENT&FUTURE

Pulvercoat®: The Key to Switching from Liquid to Powder Coatings for Finishing Pre-Assembled, Heat-Sensitive Workpieces

BRAND-NEW

HIGHLIGHT OF THE MONTH For.Tec., the Sustainable Pyrolysis Specialist

INNOVATIONS: PRESENT&FUTURE Line-Met: The New, Revolutionary Concept of Metallising Plants Created by Arzuffi Srl

L’unica vernice in polvere rapida a bassa temperatura

The unique fast and low bake powder coating

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

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

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

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

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

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

www.pulverit.com

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

CONTENTS NOVEMBER/DECEMBER 2020

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

FOCUS ON TECHNOLOGY

112

FOCUS ON TECHNOLOGY

Athena’s New Waste Water Treatment Plant Cancels the Anthropic Impact of the Chemical Nickel Plating of Engine Cylinders

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

140

From Metalwork to R&D for the Construction of Coating Plants: The Successful Path of Montagna Srl

104 105 106

122

INNOVATIONS: PRESENT&FUTURE

174

Oltrogge: A Partner for Heavy-Duty Challenges

HIGHLIGHT OF THE MONTH

BUSINESS CARDS

126

Resilient Contracting: VP Verniciatura Continues to Invest and Relies on Pre-Treatment Nanotechnology to Obtain International Quality Certifications

HIGHLIGHT OF THE MONTH KUBE: The Digitalisation of Coating Processes Becomes Reality

Coating Process Digitalization Thanks to a New SprayVision Technology

FOCUS ON TECHNOLOGY Italian Technology for the Semi-Automatic Powder Coating Installation with a High Throughput installed at Zürn Harvesting

132

138 148

156 158

SUCCESS STORIES

BRAND-NEW FOCUS ON TECHNOLOGY Formas Descanso: Automatic Powder Coating of Healthcare Beds to Improve Competitiveness and Profitability

FOCUS ON TECHNOLOGY The Importance of Shot Blasting in the Treatment of Machinery Components Subjected to High Stress: The Choice of Carantini

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

FOCUS ON TECHNOLOGY

Streparava: Sustainability and Application Ecotechnology for the Low-Environmental Impact Coating of 4x4 Axles

SUCCESS STORIES

152

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

PRESENT FUTURE 164 INNOVATIONS: Walther Trowal Develops &

AM Post Process Machines

GEINSA Supplies Cochet with a Surface Treatment Line for Powder Coating

HIGHLIGHT OF THE MONTH 168 Whatever it Takes!

SUCCESS STORIES

178

Top Quality Pretreatment for Trailer Chassis

FOCUS ON TECHNOLOGY Into the Future with Zero Emissions

Master RemoverÂŽ 7000 A superior approach to paint removal

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Features and benefits â&#x20AC;˘ b]_Ń´Â&#x2039; ;==;1|bÂ&#x2C6;; r-bm| u;loÂ&#x2C6;-Ń´ ruo1;vv =ou - Â&#x2C6;-ub;|Â&#x2039; o= roÂ&#x2030;7;u r-bm|v â&#x20AC;˘ omĹ&#x160;-tÂ&#x2020;;oÂ&#x2020;v vbm]Ń´; r_-v; ruo1;vv

Master RemoverÂŽ 7000 was developed with the highest level of versatility in mind. Capable of operation in spray or immersion as well as off-line or in-line applications, Master RemoverÂŽ 7000 is a robust and rapid paint removal process for hooks, racks and fixtures. It is compatible with ferrous and light metals (aluminum, zinc, magnesium) and can be used in conjunction with proprietary filtration to extend solution life, offering a sustainable and flexible paint removal process.

Atotech Group +49 30 349850 info@atotech.com Global head office

atotech.com

CONTENTS NOVEMBER/DECEMBER 2020

SPECIALIZED TRAINING

INNOVATIONS: PRESENT&FUTURE

184

Excellent Corrosion Protection and High-Performing Paint Adhesion

ICT - INDUSTRIAL CLEANING TECHNOLOGIES

198

The Future of Vocational Training for Coating Operators

TECHNOLOGY OVERVIEW

220

SAT Presents its Vertical Lab

188

CASE STUDY

Rotary Solutions for Castings and Stampings Save Time, Space and Costs

182 HIGHLIGHT OF THE MONTH FOCUS ON TECHNOLOGY From Office Furniture to School Desk Components, the Growth of Etra Through Management 4.0

194 ART WITHIN SURFACES Unique Raku Ceramics Through Non-Repeatable Colour Effects

202 STANDARD&LEGISLATION Brexit: Threat or Opportunity?

ICT - INDUSTRIAL CLEANING TECHNOLOGIES

206 211 212 214

224

ZOOM ON EVENTS

An Effective Water and Detergent-Based Cleaning Cycle for Hydraulic Blocks with Blind Holes and Grooves

230

TECHNOLOGY OVERVIEW Innovation in CO2 snow-jet cleaning: faster, more effective, and more efficient thanks to pulsating jet

ICT - INDUSTRIAL CLEANING TECHNOLOGIES

234 INDUSTRY NEWS CASE STUDY When Cleaning Becomes Crucial in the Production of Components Intended for Highly Sophisticated Measuring and Control Instruments

ZOOM ON EVENTS

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

Alessia Venturi Editor-in-chief Direttore Responsabile

ovember 2020. I am writing the editorial for the last issue of ipcm® to be distributed in 2020, a year that will be remembered for the pandemic still underway. A year that, after only two months from its inception, catapulted us into a reality of uncertainty and fear. A year that has brought out the best, but also the worst traits of human beings. In eleven years of ipcm® magazines, I do not think we have ever produced a greater number of articles about tangible, revolutionary innovations ready to be industrialised in the coating sector than that included in this issue. An issue dealing with people, success and resilience stories, completely new technologies, and developments of what we have known so far. An issue created halfway between the “old way”, that of on-site visits and personal meetings, and the “new way”, through video calls and remote interviews. An issue to be proud of. By scrolling through its pages, you will have the perception of a dynamic industry, which has not surrendered to production stoppages nor to operational and travel difficulties. An industry that has focussed on “doing” rather than “fearing”. An industry that has invented new ways to keep doing something old: producing, selling, and innovating. It is as if the world of industry and research had turned against the turmoil, uncertainty, and disorientation brought about by this new virus in order to reconfirm the humankind’s ability to resist and be reborn by innovating. Whereas some of these innovations are still driven by the current situation – in the next pages, you will find a press release about the first positive tests on a powder coating with virucidal effects – most of them offer solutions to critical issues related to production, sustainability, and products’ service life. These include ultra high-performance anti-graffiti paints with unmatched protection results and a revolutionary in-line sputtering metallising concept, which makes this technology more accessible to users in various sectors. There are also a low-temperature cross-linking powder with a chemical formulation never used before, which opens new horizons to powder coatings in the markets of metalwork and heat-sensitive products, and new ranges of liquid and powder application equipment. Finally, there are innovations involving the digitalisation of coating systems: a software package with a library of over 600 finishing systems that helps users choose the most appropriate solution, a vision device digitalising the application process to control its quality, and the most complete 4.0 platform for coating plants available on the Italian market. Even the success stories in this issue, including those of the industrial cleaning sector presented in the supplement, belong to the most diverse fields: from electrical cabinets to fashion accessories, from transmissions for commercial vehicles and plastic car components to refrigerated counters for supermarkets and delicatessens, and from components for vacuum pumps and hydraulic blocks to school desks. All their protagonists have invested in the latest innovations and technologies, trusting in the relaunch of production activities. We therefore look forward to the new year with confidence. During the on-site visits of the last two months, we have breathed optimism and industriousness. Despite some predictable losses, our sector has held up and some markets, such as architecture and metal furniture, are even growing thanks to contingent needs. If it is true, as we hope, that a vaccine will be already available at the beginning of the new year, I believe we will see the beginning of a market euphoria phase to which companies will have to be able to respond – we have already seen the first signs of this with the trend of international stock exchanges following Pfizer’s announcement. Ipcm®’s wish for 2021 is for you to treasure this year’s experiences, in order to be responsive to the changes that await us.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

IN REVIEW

September and October in review Barbara Pennati ipcm

It’s time for human transformation.

eptember has always been a month

LinkedIn company page reached over 3000

But perhaps, today more than ever, it is

of new beginnings.

followers, a milestone that makes us proud

reductive to talk about digital transformation.

And indeed, in September the training

and testifies to the growth of the MyIpcm

What we are witnessing is actually a human

course by ipcm® Academy started. At the

community and its continuous support for

transformation: we are evolving, we are

end of it, the students will have been trained

our work.

changing to expand our capabilities and

as Technician of industrial surface finishing

An important recognition also came from

adapt to new situations by exploiting

processes, the new professional figure

overseas: during episode 12 of Ask Joe

technologies. The historical period we are

created by ipcm Academy in collaboration

Powder Powdcast, a US podcast that

experiencing testifies to all this.

with ASP Mazzini recognized at national and

provides interesting insights into the

Here at ipcm® we have long started this

European level.

powder coating industry, our magazine was

process of digitalization, of human and

In September we also published the ipcm

called a ‘monumental publication’. Again,

technological transformation with some new

special issue on architecture and design, one

we can only be honoured and grateful

formats with high digital content that we will

of the most important issues of the year,

for this recognition, further proof that we

make available to our customers. The next

which also features an important novelty:

managed to achieve the goal we set for

step in this sense will take us along a path

the presence, among the pages of the

ourselves 11 years ago: to become the first

of renewal and total redesign of the ipcm®

magazine, of QR codes and links that expand

truly international magazine on surface

website. The goal? Respond in the best way

the reading experience, enriching it with

treatments.

possible to the new needs of divulgation and

multimedia content showcasing applications,

In this period, we often hear about digital

above all of digital promotion.

video interviews, product demos and more

transformation, that is the use of new

published online.

digital technologies to modify or create new

Speaking of digital communication ipcm

business processes, cultures, experiences.

Scan to know more

This past October was a bittersweet month: if, on the one hand, we were able to travel abroad and participate in trade fairs once again, on the other, the second wave of the pandemic and the consequent stricter regulations have once again caused a postponement of normality. We are among those who are aware of the criticality of the health situation but also of the value of their work and who will therefore continue to carry it out by using technologies and new formats, by adapting

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

IN REVIEW

and counting on the collaboration of a team

components. It also aims at debunking the

with the same mindset, which is rowing in

idea that new materials are deceptive. The

the same direction.

conference program and the modalities of

So, during October as well, two magazines

participation will soon be available.

have been published: the supplement ICT

Last but not least, while this year’s students

Industrial Cleaning Technologies and the

are preparing to conclude their training

issue of Protective Coatings dedicated to

course with the final exam, at the end of

corrosion protection technologies in the

which they will receive the certification valid

wind energy sector.

at Italian and European level as Technician

As anticipated, this month we were able to

of Industrial Surface Finishing Processes, the

meet the sector in person once again at the

division of ipcm® Academy is working on the

BIMU trade fair, held in Milan from 14 to 17

2021 professional training program, which

October. An edition that, despite taking place

includes two training sessions in order to

in a health emergency situation, was able

offer companies and workers the utmost

to guarantee the safety of all exhibitors and

flexibility.

9000 visitors. For our part, we have found a

We are also working to launch a new website

sector that, like us, still has a lot to say and

dedicated to the world of ipcm® Academy.

a great desire to keep doing business, as

A world with which, from today on, you can

testified in the pages of our magazines.

stay in touch also through the LinkedIn and

Speaking of events, we are working to

Facebook pages, which will soon be updated

organize our first digital conference entitled

with all the novelties awaiting us in 2021.

P25 system

fewer components to handle tested and always clean joint

fewer parts to be stripped robust and easy to position

‘Architecture and Design of the future: natural materials vs engineered materials’. It aims to explore the potential of new materials in the field of architecture and design for energy-efficient, sustainable, low-weight, anti-seismic buildings, and for hygienic and smart furnishings, devices and

Scan to know more

HANGING SYSTEMS

COMPLETE SOLUTIONS FOR HANGING AND MASKING

www.rostirolla.it

BRAND-NEW

Fastrip T5: The Versatile and Sturdy Paint Stripping System by ALIT Technologies Fastrip T5 is the range of paint stripping tanks with a capacity of 800 litres, which combines sturdiness, flexibility and process efficiency for an optimal stripping result.

LIT Technologies, specialist in the

lifting and moving it safely and in any place

developed a two-phase chemical process for

chemical paint stripping of metals,

with a forklift. All this, combined with process

all types of metals. The Metalstrip Up&Down

presents Fastrip T5, its range of paint

versatility, which ensures the optimal paint

stripping range allows for improved

stripping tanks, which allows to efficiently

stripping of different types of metal parts,

management of paint residues, making their

remove paint from hooks, frames or pieces

makes Fastrip T5 the ideal solution for a safe,

separation more effective and extending bath

to be recovered, whether they are of ferrous

effective and quick paint stripping.

life. The formulation of these paint strippers

metals or light alloys, without compromising

ALIT Technologies offers extra options such

is free of halogenated hydrocarbons,

their surfaces.

as customizable workpiece holders for an

phenols, chromates, ammonia, amines,

• The Fastrip T5 system is available in three

easy and effective hanging process, and a

organic or inorganic acids.

versions:

fume extraction system.

• T5-US with ultrasound technology;

For further information:

• T5-MT with a series of tanks in parallel with

Chemical product and sludge management

gantry-type handling.

To optimise the use of this system, ALIT has

• T5-MIX with a mechanical mixer;

www.alit-tech.com

Sturdiness and ease of use Fastrip T5 systems are built in AISI 304 steel to ensure sturdiness, and are based on the concept of “tank within a tank”, with the external hermetic tank acting as a safety basin for liquids. In addition, the system is perfectly insulated on all sides, features an interlocked cover and is set up for fume extraction. The machines are equipped with a separate, plug and play electrical panel with a touchscreen that allows to programme easily. Moreover, they are equipped with a heating system and a thermoregulator that enables to adjust and reach temperatures up to 80°C. A version that allows to reach temperatures of 150°C is available for all models.

Safety, eﬃciency and time-saving The design, 100% Made in Italy, entails a new discharging method and the possibility of

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

the process parameters independently and

BRAND-NEW

AkzoNobel To Build a State-of-the-art, Fully Automated Powder Coatings Plant in Taiwan AkzoNobel announced that work is underway to build a state-of-the-art and sustainable powder coatings plant in Chungli, Taiwan.

kzoNobel invested €20 million to build a new, fully automated

in the local paints and coatings industry.”

and sustainable powder coatings plant in Taiwan in order

AkzoNobel’s Chungli site, in which the new powder coating plant

to meet the growing demand in the architecture, auto

will be added, the company already manufactures powder coatings,

accessories, telecommunications, electronic components, furniture,

decorative paints, packaging coatings and specialty coatings.

domestic appliances, sports equipment and machine tools markets.

“AkzoNobel has been in the Taiwan market for more than 40 years

Once operational, the new plant will bring the company closer to its

and is a known leader of its paints and coatings industry,” said Karen

overall energy and water sustainability ambitions, as it’s expected to

Yin, Director of Commercial Powder Coatings at AkzoNobel. “The new

reduce energy consumption by 30%, increase the water reuse rate

plant is driven by growing customer demand for tailored solutions

to 60% and achieve zero VOC emissions. All this will also contribute

and will consolidate our leading position.”

to creating a safer and healthier working environment.

The powder coatings plant in Chungli is expected to start operating

“The COVID-19 pandemic has brought a lot of uncertainties to global

in the third quarter of 2021.

markets,” said Fred Moreux, Director of Manufacturing for Asia at AkzoNobel. “Investing in a new plant in Taiwan at this critical time will help us streamline our supply chain while setting a new benchmark

For further information: www.akzonobel.com

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

BRAND-NEW

Stardust Powder Coatings Develops First Antiviral Powder Coating Against Human Coronavirus Stardust Powder Coatings, a manufacturer of powder coatings based in L’Aquila (Italy), has tested for the first time and with positive results an antiviral coating that can inhibit the human Coronavirus NL63

n March, Stardust Powder Coatings has started the development

amount of infectious virus in each suspension was quantified using

and testing of coatings with antiviral properties.

a TCID50 assay. For the assay to be valid, the material tested must

Powder coatings with antiviral properties are special virucidal

have no cytotoxic activity on the cells used to quantify the virus, nor

coatings that can inhibit the viruses present on the metal surfaces

interfere with cell sensitivity to infection.

they are applied on. These coatings find wide application wherever it

In the material treated with Stardust antiviral coating, virucidal activity

is necessary to reduce the risk of the active virus coming into contact

against human Coronavirus NL63 was observed with R value (antiviral

with humans due to a contaminated surface.

activity) 1.34 at a contact time of 2 hours, and with R value 1.10 at

While tests on other grades of powder coatings manufactured by

a contact time of 24 hours. An R value greater than 1 is considered

Stardust Powder Coatings are currently underway, the company

virucidal. Furthermore, no cytotoxic activity was detected against the

announced the first positive outcome for the Metalgrey 1050k

cells used to quantify the virus.

product, a metallic epoxy powder coating that is widely used in the

“Surface hygiene is one of the fundamental factors to reduce the

architecture and design sector.

risk of cross-contamination – an extremely current need, especially in crowded places such as public buildings, schools, hospitals,

The testing process

transportation, gyms, restaurants or coffee shops”, explains Guido

The tests, conducted by the Virology Research Services laboratory

Pozzoli, CEO of Stardust Powder Coatings. “To meet the growing

in London, were

demand for coatings

performed against the

that can ensure greater

human Coronavirus NL63

surface hygiene, we

according to the standard

immediately set to work

protocol ISO21702, which

to bring the protective

quantifies the antiviral

effectiveness of our

properties of surfaces.

coatings to the next level

The protocol entails the

in order to provide an

dispensation of a pre-

antiviral property as well”,

determined concentration

continues Pozzoli. “The

of virus on a surface treated

future goal of Stardust

with the antiviral coating

is in fact to expand the

and on an untreated

range of antiviral coatings

control surface. Both

to include any colour and

were incubated at room

finish, and any field of

temperature for 24 hours in

application”.

a humidified chamber. Next, the samples were recovered by washing with media (neutraliser), and the

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

For further information: © Louis Reed

www.stardust72.com

BRAND-NEW

CEPE Appoints New Chairman and Welcomes New Board Members The European Council of the Paint, Printing Ink, and Artist’s Colours Industry (CEPE) appointed André Vieira de Castro as new Chairman of the CEPE Board and welcomes new Board members.

ndré Vieira de Castro, CEO of Argacol -

an SME representative to lead CEPE and believe

Tintas e Vernizes, S.A., a Portuguese SME

that André Vieira de Castro is the right person to

active in the Decorative and Industrial

take our sector forward. I wish him good fortune in

segment, has been appointed Chairman of the

the times ahead.”

Board of CEPE.

The General Assembly has also appointed Klaus-

Vieira de Castro joined the Board in 2015 and

Georg Gast, Axalta Coatings, to become the new

served as Treasurer since 2018. He replaces

Treasurer. Martin Beck (BASF Coatings), Toon

Harald Borgholte, Vice-President of BASF Coatings,

Bossuyt (BOSS paints), Peter William Lockley (INX

and longstanding Board member since 2014, who

Europe), and Jan Piet Van Kesteren (AkzoNobel) will

successfully served as CEPE Chairman since 2017.

also join the Board. In addition, Roald Johannssen,

“It is an honour for me to take on this role. As

Vice-President of PPG Industries, will be the new

Chairman, firstly, I will ensure the best possible

Vice-Chairman.

representation of our whole industry. At the same time, the contribution of smaller companies to the

For further information: www.cepe.org

EU economy is substantial and I will put forward the important role of SMEs in the paints, printing

inks and artists’ colours industry,” commented André Vieira de Castro. With regards to the European political agenda, André Vieira de Castro explained: “I support the climate ambition of the EU Green Deal to become carbon neutral by 2050. Our products are part of the solution for a Circular Economy and contribute to sustainability. At the same time, we need politics with a sense of proportion, and this is what I hope for the chemical strategy for sustainability. We already have the strictest chemical policy worldwide. We need to carefully, not fundamentally, make adaptations to remain competitive and achieve a sustainable recovery.” Former Chairman, Harald Borgholte remarked: “It has been my pleasure to act as spokesperson and serve this very dynamic coatings sector. I welcome

André Vieira de Castro, the new Chairman of the CEPE Board.

segr@italgard.it - www.italgard.it

BRAND-NEW

Peerless’ Tests Against NL63 Human Coronavirus Show Positive Results Peerless Plastics and Coatings, a manufacturer of hard coatings for plastics based in Thetford (UK), has tested its MicroGuard™ Anti-Fog coating range against NL63 Human Coronavirus, proving 99% effective.

eerless provides a range of protective coatings for application

needed to put in place longer-lasting solutions or products which

on to different types of plastic.

met users’ demands”, explains Peter LlewellynStamp. “Two examples

Among the range of products manufactured by the

would be Anti-Fog on the inside of medical visors so that they don’t

company there is MicroGuard™, an anti-bacterial coating for

mist up during the course of the day and sneeze screens which have

plastic launched in 2015, available also with an Anti-Fog option,

been installed into retailers, supermarkets and restaurants, which

which has already been used and tested within industries such

would benefit greatly from scratch and chemical resistance to meet

as Healthcare, Veterinary, Dentistry, Food Processing and Aerospace.

the day-to-day wear and tear”.

Following the heightened demand for coatings with special

“We have grown our team from 35 to over 40 people and will need to

antimicrobial and antiviral properties, Peerless MicroGuard™ Anti-Fog

take on more people in the coming months as we expand operating

coating range – which can be used on a number of items including

hours to meet demand,” adds LlewellynStamp. “The MicroGuard™

visors and screens – has now been tested against NL63 Human

coating range can add value to many applications and will enable

Coronavirus and proven 99% effective.

us to now offer coatings to companies across Europe and beyond, looking for long term anti-microbial or anti-viral protection on face

The testing process

coverings and surfaces such as desks, doors, screens, handles, car

After the coronavirus outbreak, Peerless immediately had

interiors and any other area where there is a high traffic of people.”

MicroGuard™ tested against FCoV (Feline Coronavirus) as the nearest test available at that time.

For further information: www.peerless-coatings.co.uk

After initial tests showed it reduced FCoV, the company carried out more work to improve its effectiveness, with the aim of offering antifog coatings for items such as visors and goggles. The MicroGuard™ Anti-Fog and the MicroGuard™ Clear Hard coatings were submitted for testing against the NL63 (Human Coronavirus) using the ISO21702:2019 test method. “Results on the MicroGuard™ Clear Hard Coating are still awaited but MicroGuard™ Anti-Fog results are in and the coating has proved to be 99% effective against NL63 (Human Coronavirus) meaning that it offers anti-viral performance”, explains Peerless. “We are very encouraged by these test results and will continue to develop new hard coating solutions to meet on-going demands,” adds Peerless Managing Director, Peter LlewellynStamp.

The growing demand for improved performance Interest in Anti-Fog coatings has risen as manufacturers of personal protective equipment (PPE) seek to improve the performance of their products and offer wearers of essential face coverings – such as NHS and other key workers – better gear. “There was a growing interest in the products as people realized they

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

BRAND-NEW

Axalta Presents Alesta AP QualiSteel for the Coating of Galvanized Steel To meet the demands for durability, appearance and sustainability in protecting galvanized steel, Axalta has developed Alesta® AP QualiSteel powder coating.

hen it comes to protecting galvanized steel

Alesta® AP QualiSteel has hazardous label free

structures and products, the demands for

formulations and, compared to a traditional two-

durability, appearance and sustainability

step process application, it enables an increase in

have increased significantly. In response to this trend,

productivity without affecting the appearance of the

Axalta offers Alesta® AP QualiSteel powder coatings in

coated surface.

architectural quality.

The powder coatings, which are part of the

This coating – which is typically used for coating

international QUALISTEELCOAT quality label,

steel structures, machine components, garden

also offer very good UV stability and mechanical

and outdoor furniture, fencing, railing, playground

resistance, leading to a longer life cycle of the

equipment, urban and outdoor lighting and many

components. Alesta® AP QualiSteel is available in

more – can be applied without a pre degassing step

popular RAL based colours from stock.

and, depending on the substrate to be coated, it can be cured at as low as 160°C. This enables material

For further information:

and energy savings.

www.axalta.com/qualisteel

BRAND-NEW

AkzoNobel To Acquire Industrias Titan’s Decorative Paints Business AkzoNobel announced the acquisition of the decorative paints business of Spanish paint and coatings manufacturer Industrias Titan S.A.U..

kzoNobel will acquire Titan’s decorative paints business.

exciting possibilities for combining our technologies and expertise,

Completion of the acquisition is subject to regulatory

which will result in us developing better and more sustainable

approvals and expected before the end of Q1, 2021.

products.”

Industrias Titan S.A.U is a paint and coating manufacturer based in

“We’re delighted to hand over Titan’s decorative paints business to a

Barcelona, Spain, which also has a relevant presence in Portugal. The

global leader like AkzoNobel. We’re confident they will care for Titan’s

business shares AkzoNobel’s commitment to sustainable product

legacy in the same way the family has done for over 100 years”,

innovation, with much of its portfolio having received recognition for

added Alberto and Joaquin Folch-Rusiñol, Industrias Titan S.A.U

environmental performance.

administrators, commenting on the deal.

“The Spanish market has strong growth potential and this is an

“Titan has a proud heritage and a long track record of innovation

excellent opportunity for us to reinforce our position in the region,”

and continuous improvement – qualities that we strongly relate to.

said AkzoNobel CEO, Thierry Vanlancker. “The acquisition will enable

It’s therefore a perfect fit for us and will provide a solid platform to

us to better serve our customers and provides added momentum,

further grow our position throughout the region”, added Vanlancker.

while also offering further proof of us being the reference in paints and coatings in Europe. The fact that a significant part of Titan’s portfolio has been awarded the European Ecological label also offers

For further information: www.akzonobel.com

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

BRAND-NEW

b+m Acquires Service of the Eisenmann Business Division “Application Technology” b+m surface systems GmbH has acquired the customer service and spare parts business for the “Application Technology” division of the insolvent system manufacturer Eisenmann. This includes the hardware and software of the application technology from material supply to the atomizer.

he transfer comprises the patents and industrial property rights

“With b+m, we have found a strong and competent buyer from

for the production and supply of original Eisenmann spare parts

the industry. Additionally, we successfully have preserved more

at a consistently high level of quality. Notably, the competent

jobs through the acquisition,” comments Eisenmann insolvency

experts from product development, sales, and commissioning could

administrator Joachim Exner on the sale.

be recruited to strengthen the b+m team.

b+m surface systems GmbH is a technologically leading manufacturer

“Comprehensive customer service is important, and also the long-

of fully integrated paint lines. Around 450 employees ensure smooth

term assurance of a fast and smooth spare parts supply,” emphasizes

project implementation and competent service. Important key

Sebastian Merz, CEO of b+m surface systems.

components, including the two in-house robot series T1 X5 and T2 X5,

The independent business division will retain its headquarters in

are manufactured by the Eiterfeld company itself.

Baden-Württemberg, but at the same time will have access to all the functions and resources of the global b+m network.

For further information: www.bm-systems.com/en

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INNOVATIONS: PRESENT&FUTURE

Adapta HCR, Invisible Protection: The Best Anti-Graffiti Powder Coating Available on the Market Alessia Venturi ipcm

ÂŽ

Nowadays, the boundary between street art and vandalism is still very blurred. There are few tools to impede graffiti on public goods, but the coating sector offers a chance to prevent them through anti-graffiti paints. ADAPTA has entered the landscape of anti-graffiti coatings with a new high-performance powder product for the protection of the metal surfaces of public goods, such as street furniture, train and subway wagons, buses, faĂ§ades, door and window frames, and the cladding of public and private buildings. Based on the test carried out by various independent laboratories in Europe, the new ADAPTA Anti-Graffiti HCR has proved to be the best anti-graffiti powder coating currently on the market.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

exponents of street art and of the current

street furniture, train and subway wagons,

phenomenon of “guerrilla art”, which

buses, façades, door and window frames,

finds expression in the street and public

and the cladding of public buildings.

dimension of urban spaces by creating

Based on the test carried out by various

pieces that document the poverty of the

independent laboratories in Europe, the new

human condition.

ADAPTA Anti-Graffiti HCR has proved to be

However, there is a very blurred distinction

the best anti-graffiti powder coating currently

between what is art and what has the

on the market.

presumption of being art to the detriment

of the community. The graffiti phenomenon

Technical features

is transformed from art into vandalism,

ADAPTA’s new specialty, Anti-Graffiti HCR

when it concerns public transport, street

(High Chemical Resistance), was developed

furniture, public utility infrastructure, but

to protect structures of public utility from

also public and private buildings of historical

disfiguring vandalism, such as graffiti made

interest. The whole world has been a

with spray paints or markers. This new

victim of vandalism for years, especially in

powder paint enables surfaces to be cleaned

metropolises, where the problem affects

with commonly used solvents, without

urban decorum and the protection of public

degrading the coating itself.

assets and of the artistic and architectural

It can be produced in any colour and finish,

masterpieces that are these cities’ pride.

including clear and metallic ones. It has good

Few “social” weapons can be deployed

outdoor resistance and excellent chemical

against vandalism. On the other hand,

resistance to conventional solvents such

technology, especially in the coating sector,

as xylene, acetone, white spirit, and methyl

offers some tools if not to counter, at least to

ethyl ketone (MEK). The resistance degree

prevent the damage of vandalism.

of the latest version of ADAPTA’s Anti-Graffiti

Anti-graffiti paints are colourless, liquid

HCR powder coating to the latter solvent, in

or powder coatings designed to protect

particular, is more than 24 hours: this is the

raffiti was born in the late 1960s

structures of public utility and the first 2-3

biggest difference between the new ADAPTA

in New York. Its origins are tied to

meters of buildings from street level against

specialty and other similar products on the

the concept of metropolis and the

graffiti. How? By facilitating the cleaning of

market in terms of performance.

discomfort that large cities instil. Indeed,

their surfaces.

ADAPTA Anti-Graffiti HCR’s quality has been

many anonymous artists chose large spaces

Soiling with paints and/or markers

approved with extraordinary results through

left empty by urban decay or abandoned

constitutes serious damage for both metal

tests carried out by various international

structures to express their idea of plasticity

and wall surfaces, because any removal

laboratories and in relation to different

and decoration. Over time, this phenomenon

system, be it mechanical or chemical,

standards. The results are shown here

has transformed into a real form of artistic

involves an alteration of their physical

below, in chronological order with respect to

expression, even crossing cultural and

characteristics.

the tests performed.

geographical boundaries1.

Therefore, more and more clients and

Many names of well-known artists are

owners of public assets are requesting

Results of the resistance tests

included in the ranks of graffiti writers, from

anti-graffiti protective coatings to protect

1- MIBK/MEK resistance test

Keith Haring and Jean-Michel Basquiat,

surfaces against graffiti, which could deface

Resistance to methyl isobutyl ketone (MIBK),

who managed to bring this movement

them already a few days after inauguration.

a ketone widely used as a solvent, was

from metropolitan streets to art galleries,

ADAPTA has entered the landscape of anti-

measured for 72 hours in compliance with

to Banksy. This anonymous English writer

graffiti coatings with a new high-performance

the standard ASTM D5402, with positive

and artist is considered one of the greatest

powder product for the protection of the

results in relation to wet rubbing (Table 1

metal surfaces of public goods, such as

and Fig. 1).

www.associazionean graﬃ .it

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

2 - Tests carried out by the materials laboratory of the French Railway Test Agency of the SNCF (Société Nationale des Chemins de Fer) and of the RATP (Régie Autonome des Transports Parisiens) according to method B of the French standard NF F 31-112. • Aggressiveness tests: the cleaning product is placed in contact with the coated surface, which is examined on two occasions: immediately after cleaning and drying and after 24 hours of storage. No surface degradation was observed. © Adapta Color, SL.

Figure 1: Comparison of MEK resistance test results between a standard anti-graﬃti paint and ADAPTA’s HCR anti-graﬃti paint. After the exposure to the solvent no coating’s alteration is observed.

Table 1: MIBK resistance test results after 72 hours of exposure and wet rubbing.

Gloss at 20° Initial condition Measures

Average

57.7-57.857.5-56.9-57.3

57.4

After the exposure S

Measures

Average

0.4

57.6-57.4-57.757.3-57.9

57.6

Diﬀerence (%) S

After the exposure

24-hour exposure to the agent. • Efficacy tests: complete elimination of colours after 3 cycles of graffiti application and subsequent cleaning (Table 2). 3 - Tests carried out by the laboratory of the German association for the quality Gütegemeinschaft Anti-Graffiti e. V. according to the set of rules for the evaluation of

Colour Initial condition

cleaning products, with positive results for 1 and

of long-lasting anti-graffiti systems

-0.35

0.2

The coating, therefore, shows good resistance to

procedures, technologies, and materials for

Diﬀerences

the removal and prevention of graffiti (ReGG).

∆L*

∆a*

∆b*

∆E*

• Basic test: functional assessment of the sample

96.20

0.63

-0.97

96.60

0.63

-0.87

-0.40

0.00

-0.10

0.41

after the application and chemical removal of ten predefined dyes. In all cases, total removal of graffiti took place (Figs. 2a and 2b).

Table 2: Results of the tests carried out by the materials laboratory of the French Railway Test Agency of the SNCF and of the RATP according to method B of the French standard NF F 31-112.

Marker

Red colour SNCF/RATP Blue colour SNCF/RATP Black colour SNCF/RATP

∆E* (CIE1976; D65; 10°; SCI)

Cycle value

0.68

0.60

0.39

0.74

0.46

0.76

0.61

0.58

Markers value

Maximum value

for 15 cycles. The maximum value of 100 (i.e. complete colour removal) has always been reached (Table 3).

Results Performances

application of 10 dyes and their subsequent cleaning operations with a chemical product

Number of eliminations with the cleaning product

Cycle

• Stress test: durability assessment after the

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

• Functional test after the application of inks for 60

markers. Functional assessment after application and subsequent removal of 60 predefined marker inks. Out of the 60 colours, in no case

were there any shades of tint left after cleaning. This corresponds to a success rate of 100% (Figs. 3a and 3b).

180

180 100%

4 - Tests carried out according to the set of rules of the London Underground Standard S2180 T3.5.2. • Eight graffiti signs (including leather dyes, which

INNOVATIONS: PRESENT&FUTURE

Figures 2a and 2b: The same test sheet painted with ADAPTA Anti-Graffiti HCR before and after the removal test with 10 different dyes. Table 3: Summary table of the results of the stress test carried out by German association Gütegemeinschaft Anti-Graffiti e. V.

Initial condition

Measurement 2 hours after the first cleaning

Measurement 2 hours after the 15th cleaning

Colour L*

89.35 (0.33)

90.14 (0.55)

90.48 (0.45)

0.25 (0.04)

-0.02 (0.13)

-0.01 (0.10)

3.39 (0.29)

2.96 (0.33)

2.87 (0.31)

Gloss Reflectometer value

144 (5)

Contact angle θ

100 (2.1)

143 (5)

144 (5)

Contact angle 96.9 (3.9)

82.7 (3.9)

are much more difficult to remove than inks

performance score of 14.0 “Very good” and 16.00

and spray paints) are applied and left in contact

“Excellent”, excluding leather dyes. The powder

with the surface for a period of 72 hours. After

paint causes the application of markers and

elimination, graffiti removal effectiveness and

leather dyes to create a stagnation of the ink/dye

surface damage are assessed. The application

due to surface tension. It should be noted that

and removal cycle is repeated for 14 times. The

this effect also represents a deterrent for vandals.

acceptability criterion is that the overall graffiti

Moreover, since there is no penetration inside

removal score is greater than 13.0, with excellent

the surface, the graffiti is easier to remove. The

(16.0) or very good (13.0 - 15.9) results.

liquid graffiti removal agent also stagnated on the

• ADAPTA Anti-Graffiti HCR achieved an overall

surface. This resulted in the ink / dye’s reduced

tendency to re-deposit in the coating and further mark the surface (Tables 4, 5 and 6).

Conclusions In conclusion, the new powder coating ADAPTA AntiGraffiti HCR has shown excellent performance in terms of graffiti removal effectiveness and absence of surface damage after elimination. Above all, it has proven to be a valuable deterrent to vandalism itself, since the surface tension created on the coated structures makes writing with markers or painting with aerosols particularly difficult. Thanks to ADAPTA’s Anti-Graffiti HCR, society now has a highly effective, low environmental impact graffiti prevention tool (powder coatings do not generate any VOC emissions), which can also give © Adapta Color, SL.

Figures 3a and 3b: Panels for the functionality test with inks for markers performed by Gütegemeinschaft Anti-Graﬃti e. V.

thanks to the numerous combinations of colours, effects, textures, and opacity degrees.

Table 5: The performance level of the ADAPTA Anti-Graﬃti HCR powder paint has reached values between 14.00 and 16.00, with results from “Very Good” to “Excellent”.

Table 4: Evaluation table of the test performed according to the rules valid for the London Underground Standard S2180 T3.5.2.

EFFECTIVENESS EVALUATION

the treated structures an excellent aesthetic value

SURFACE DAMAGE EVALUATION

OVERALL GRAFFITI REMOVAL SCORE

CLASSIFICATION

Extent of Removal

Score

Extent of Damage

Score

16.0

Excellent

Completely removed

Undamaged or no visible surface damage

15.9 - 13.0

Very Good

Eﬀectively removed, a faint shadow visible

Minor irreversible softening

12.9 - 11.0

Good

Mostly removed, a definite shadow visible

Significant softening

10.9 - 7.0

Fair

Partially removed, a coloured outline visible

Significant softening, discoloration or surface trauma

6.9 - 4.0

Poor

No removal or clearly visible, although lighter in intensity

Surface destroyed or rendered visually unacceptable

Under 4.0

Very Poor

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

Table 6: Breakdown of graﬃti resistance testing results.

Buntlack Black Spray Paint

Buntlack Silver Spray Paint

Edding Black Marker Paint

Edding Red Marker Pen

Edding Green Marker Pen

Edding Blue Marker Pen

Fiebing Brown Dye

Fiebing Purple Dye

Average Removal Score

3.75

3.625

3.5

Average Removal Score (excluding dyes)

4.00

Average Overall Score

4.00

3.75

3.63

3.50

Average Overall Score (excluding dyes)

4.00

Surface Damage Score

4.00

Overall Performance Score

16.00

15.00

14.50

14.00

Overall Performance Score (excluding dyes)

16.00

Cycle Graﬃti mark

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

BRAND-NEW

Novel Silver Metallics for Autonomous Driving ECKART is the first effect pigment manufacturer to launch pigments for silver metallic color shades on the global OEM paint market, which were developed specifically for use in the field of autonomous driving.

ntil now, the concept of autonomous driving has presented

Technically, the encapsulated pigments are convincing thanks to

the industry with a challenge: Vehicles must be able to reliably

their uncomplicated processing in all common aqueous, solvent- and

perceive their surroundings via sensors that are usually

UV-based systems, their ideal intercoat adhesion and their extremely

hidden from view. This makes it necessary to make the paintwork

long durability.

as transparent as possible for the frequently used radar beams. Conventional silver-metallic paints dampen the radar waves more than is permitted and thus lead to faulty sensor detection. The innovative combination of selected ECKART metallic pigments with SYMIC OEM Opaque Silver offers paint manufacturers the opportunity to develop attractive silver color shades for vehicles - while at the same time ensuring the greatest possible radar transparency. Due to their synthetic mica base, the pigments in the SYMIC OEM Opaque Silver portfolio are ideal for both colored metallic effect paints and brilliant silver shades.

ÂŠ ECKART GmbH

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

For further information: www.eckart.net

New 2020 2018

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HIGHLIGHT OF THE MONTH

BASF Releases CODE-X, its 2020-2021 Automotive Color Trends Collection Edited by the BASF’s Coatings Division Münster (Germany)

joerg.zumkley@basf.com

The 2020-2021 Automotive Color Trends collection by BASF aims at representing the blend of the physical and digital worlds in a constantly changing environment, playing with concepts that intertwine surface, texture and colour.

ASF has released its 2020-2021 Automotive Color Trends collection with a variety of shades and effects. The collection, called CODE-X, is the result of the

collaboration between designers of BASF’s Coatings division around the globe. Every year, these designers study future trends which they use as foundation for the development of surface, texture and colour positions. They draw inspiration from industry, fashion, consumer products, and nature, share their research with the automotive designers and help develop the colours of the future. The colours, which features new, reimagined whites, dark jet blacks, and a variety of vibrant colours, serve as inspiration to automotive designers for vehicles that will be on the road in three to five years. Many have effects or textures, contributing to create a tactile and visual experience. The global key colours vary from a greyish green, to a warm beige, to a coarse grey. “As new thinking drives big transitions in the values around society, identity and progress, this collection represents the blend of the physical and digital worlds to stay hopeful and positive while coping with change”, declared BASF. From top to bottom: Pundits Solution designed in EMEA, Social Camouflage designed in Asia Pacific, Dark Seltzer designed in North America.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

The key colours of EMEA The key colours of EMEA are soothing, calming colours with bold, new, distinct positions, which feature a variety of effects. “We are in a time when nothing is the same. We may reference the old colours, but add something new, something different,” said Mark Gutjahr, head of Automotive Color Design, EMEA.

The key colours of Asia Pacific

Efﬁcient and reliable solutions for surface coating since 1988.

Asia Pacific’s key colours are warm and aim at reflecting a positive, flexible attitude for change, action and the future. They are not black or white, but more blurred and floating. “Individuality is the trend in play here. We live for today and want to make the future better,” said Chiharu Matsuhara, head of design, Asia Pacific. “We try to enjoy life and be positive as much as possible, and change what we did in the past.”

The key colours of North America North America’s colour designs convey grace and simplicity, and look to build off advancing colorant technologies that exhibit a greater sensitivity to the environment. “It’s not unusual to presuppose technological stewardship

electrostatic systems for liquid painting

dominates research, but it’s refreshing to see just how much the consumer is willing to forego traditional norms of beauty in order to satisfy the hunger for smart and responsible colour designs,” said Paul Czornij, head of design, the Americas.

Why is it called CODE-X? The word “codex” originally described manuscript books from past centuries. Now it describes the format of nearly every printed book, which stacks pages, then secures them with a bookbinding method. “X” has been separated with a hyphen, as X is a variable. This collection goes deeply into the way we live – the codes of interaction – and adds the variable X to create and encourage change.

electrostatic systems and spraying booths for powder coating

pneumatic systems for high-, medium-, and low-pressure painting

IR and UV drying systems

robot and reciprocators

CM SPRAY s.r.l. eosmarketing.it

www.cmspray.it

BRAND-NEW

WAGNER Launches its own Service App WAGNER Group announced the launch of the WAGNER Service App, developed to provide on demand fast and reliable support to its customers.

AGNER has developed and launched its own Service App, an application available for iOS and Android that aims at providing a reliable and fast support

to industrial users of equipment and systems of the WAGNER Group. WAGNER’s customers will be supported directly by a qualified service employee of WAGNER Industrial Solutions, who will be able to communicate via live audio and video. This will ensure shorter response times, without the need to be directly on site. Through the app, it will be also possible to translate text and voice messages into different languages to ensure smooth communication with the service employee regardless of the country in which the user is located. The WAGNER Service App also features a documentation function, which ensure the traceability of the service provided and thus enables a continuous improvement process.

For further information: shorturl.at/befrD

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

ITALY

BRAZIL

SPAIN

GERMANY

USA

MARKET CLOSE UP

Positive Post-Pandemic and Post-Brexit Perspectives of the British Coatings Sector Tom Bowtell, CEO BCF - British Coatings Federation

The United Kingdom is one of the Countries to which international political and economic attention is being directed the most. Not only because one of the Countries most affected by the pandemic, but also because it is about to face one of the most significant historical steps: its exit from the European Union. Tom Bowtell, CEO of BCF-British Coatings Federation, talks about it with a broad overview and in-depth analysis of the situation.

o say 2020 has been a challenging time for the UK coatings sector

large drop in demand as, for instance, the auto and aero sectors halted

would be an understatement of significant proportion. And yet,

production, retail paint manufacturers and printing ink companies saw

as we draw to the end of the year, it is worth reflecting how well

output increase as the money from cancelled holidays was ploughed

the industry has done weathering the storms and responding to the

into DIY and money that would have been spent on restaurants was

unprecedented demands thrown at it, as well as looking further ahead

used to buy more packaged food to be cooked at home (graph 1).

at how the coatings sector will look to adapt, improve and grow in future.

BCF worked hard to ensure that the UK government provided proper support to business over this period. We switched meetings and

Impact of the coronavirus pandemic

training events to online webinars, held weekly board meetings to

Like other businesses, the impact of the coronavirus pandemic came

stay on top of members’ needs and provided practical support and

as a real shock. The full lockdown implemented in the UK from March

materials to help companies navigate the smorgasbord of new – and

saw demand for products significantly altered, although members were

sometimes contradictory - legislation used to underpin the lockdown.

affected in different ways. Whilst industrial coatings members saw a

We also launched our #essentialcoatings and #essentialinks campaigns

Graph 1: Sales volume by major BCF sector.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

MARKET CLOSE UP

to showcase just how much our members were contributing to the

the UK will implement its own, independent chemical regulations

Covid19 response, for instance by supplying key coatings and inks

from 1st January, setting up duplicate UK REACH, CLP, BPR and PIC

used in products and components for items such as ventilators,

regimes. Whilst not a day one issue we have serious concerns about

hospital beds and trollies, sneeze guards for checkout counters, oxygen

the estimated costs of the duplicate REACH system, estimated at over

cylinders, hospital isolation units, and also in meeting the increased

£1 billion to industry across Europe as data will have to be acquired and

demand for food and pharmaceutical packaging. It was a proud

registered in the new UK REACH database. The UK Government has

reminder of just how important our sector is to the UK economy and

admitted that these changes are going to hit SMEs harder than larger

society.

companies and given our membership of 250 is around 70% SME, that is of major concern. We have been lobbying for changes to the UK

The future of the coating sector outside the EU

REACH system and, while the UK Government has made some small

In addition to responding to the COVID pandemic the other big

concessions so far around the length of time suppliers have to register

challenge for our sector over the past year has been preparing to

some substances, we need to see more done to mitigate the extra

deal with life outside the EU. The UK coatings sector is a net exporter

costs and administrative burden this new regulatory regime will place

and the bulk of its trade is with Europe. Changes to customs and

on the UK coatings industry and its supply chain.

border controls will have a big financial and administrative impact and

Again, the BCF has been working hard to help members prepare for

members have had to get their heads around how these will work.

the end of the Brexit transition period. And, as noted above, we have

And, as I write, there is still no outcome on Free Trade Agreement

been lobbying the UK Government hard on key issues: from the need

negotiations. Should a deal not be agreed we will see tariffs imposed

to agree an FTA at all to prevent tariffs being imposed; to supporting

on goods and raw materials moving between the EU and UK which we

a Chemicals annexe as part of that FTA; and in urging changes to the

have estimated will cost the sector some €75 million in finished goods

structure of UK REACH. We have built a Brexit ‘hub’ on our website, put

alone: there will be additional tens of millions of Euros spent in added

on training webinars for members, provided weekly e-bulletins flagging

raw material costs, which will likely impact UK members harder than

up key new guidance and information, hosted fortnightly ‘surgeries’ or

their EU counterparts.

‘clinics’ where members can ask questions and share best practice, as

New chemical regulations post-Brexit are of particular concern. As

well as handling hundreds of questions through our helpdesk.

the EU will treat the UK as a third country from 1st January 2021, UK businesses are now having to comply with EU REACH in a different way,

The EU’s influence

including setting up legal entities or registering addresses in the EU to

Of course, even though the UK will not be a member of the EU from

comply with REACH and CLP regulations. On this side of the Channel,

next year, and regardless of whether we get an FTA between the UK

UK paint trade between 2014 and 2019.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

es as a % of all volume sold.

Table 1: UK Coatings Industry manufacturing environmental performance, 1996 – 2018.

MARKET CLOSE UP

and EU or not, the reality is we will continue to be affected by EU rules

across the country. The use of digital technology will continue to be

and regulations. As a net exporter many, if not most of our members

taken up and new machinery and processes introduced.

will still need to be manufacturing to EU standards. Decisions the EU

We know that the UK Government has set out plans to significantly

makes on restrictions on substances will still therefore impact on us, as

improve the Environment and legislation such as the Environment Bill

will broader policy decisions like the Green Deal. Actions initiated in the

currently making its way through Parliament will have an impact on

EU are also likely to drive decisions on the same subjects in the UK. Our

our sector. We will of course need to look to ensure business is not

sector will need to continue to work closely with our counterparts in the

unduly – or indeed unfairly – impacted by this legislation. However, the

EU and I am pleased to say that BCF will remain a member of CEPE, the

truth is we are keen to be proactive and do much more in terms of

European Coatings Association, which made the decision to extend its

improving sustainability and the circular economy on a voluntary basis.

territorial area to include the UK from next year. It’s also important we

We have already taken great strides forwards: since 1996 our Coatings

maintain our active participation in the World Coatings Council, as the

Care programme has been tracking the environmental performance of

UK looks to have more global influence in the future.

our members manufacturing output and the table 1 shows how much progress has already been made. From a consumption perspective,

Looking Across the Ocean

coatings products accounted for 0.1% of the UK’s carbon footprint in

At the same time, the UK is looking to negotiate new trade deals around

2016 and the carbon level in 2016 was 21% of that of 1990 – a near

the world, including with the US. How that might affect the direction of

five-fold reduction. We have also been working hard to lower VOCs

travel vis-à-vis the UK’s new independent chemical regulatory regime

and the industry has moved away from higher VOC decorative solvent-

remains to be seen. Additional trade deals could open new doors and

based paints to water-based paints.

provide opportunities for members although we know that proximity

Moving forward we are looking to increase paint recycling and

matters, especially in our sector, and at this present time it is difficult

remanufacturing through an enhanced Paintcare scheme. However,

to see many potential gains to offset the losses we currently anticipate

there is more for us to do and we will be working closely with the

leaving the EU will bring.

Department of the Environment in the UK to make these schemes and initiatives as successful as possible. So we still have work to do to assist

Sustainability and circular economy post-Brexit

our members to navigate their way through the challenges faced over

But enough of that – what else will the future bring? Well, we want to

the final months of 2020 but we are looking forward to next year and

continue to drive our sector forward. When Brexit is finally clarified, we

beyond at ways we can support the coatings sector in achieving greater

hope that certainty will help unlock fresh investment in the industry

things in the future.

1996

2018

Energy use per tonne of production (kWh)

640

205

Total waste per tonne of production (kg)

Percentage of waste to landfill (%)

Percentage of waste recycled (%)

Total solvents purchased per tonne of production (litres)

285

115

ENVIRONMENTAL IMPROVEMENT?

Table 1: UK Coatings Industry manufacturing environmental performance, 1996 – 2018.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

ENVIRONMENTAL PERFORMANCE INDICATOR

Tom Bowtell, CEO of BCF - British Coatings Federation.

HIGHLIGHT OF THE MONTH

New Graco Finishing Equipment and Accessories Philippe Godbil Graco Distribution BV, Maasmechelen - Belgium

philippe.godbil@graco.com

An overview of the key benefits of some of Graco’s latest innovative products from their finishing lines. Configuring spray guns by application

for high solid and abrasive coatings, materials applied at very high

Graco’s range of air spray and air assisted electrostatic spray guns for

paint flow rates, and durable, longer lasting componentry.

industrial applications has been extended with new models. These

New HVLP gun models come standard with an HVLP air cap. They are

models have been added to meet customers’ specific application

mainly used where environmental standards and HVLP labelling are

needs, for example new round spray and soft spray models.

required. They can be used with electrostatics off if needed and still

New aerospace gun models are equipped with an aerospace air cap, a

meet HVLP requirements.

high wear electrode and a precision high wear nozzle to help achieve

New fixed fluid flow gun models come with an electrostatic on/off

a finer, even spray with same-sized particles. These models are ideal

switch and a fixed fluid valve that extends electrode and nozzle life.

The new Pro Xp spray gun group by Graco. © Graco

HIGHLIGHT OF THE MONTH

Scheme of the Graco’s new radial piston agitator installation.

A Pro Xp gun installed on a robot during spraying phase.

This gun model is made to last when applying extremely abrasive

which makes it ideal for highly abrasive materials. A new and improved

materials and has more durable electrodes and nozzles that extend

round spray nozzle has an optimized soft spray (bell-like) pattern. High

applicator life.

wear electrodes have also been added for high abrasive fluids.

In addition, there is a new Pro Xp WBx External Charge Waterborne

Other new accessories have been added to improve flexibility for

Gun for reducing material and environmental costs without the

customer’s changing needs. An air assist fluid filter with finer mesh

expense and limitations of an electrostatic isolation system. The

sizes (150 and 200) to keep the smallest contaminants from a finished

waterborne material stays grounded in the gun and is charged at the

product. Quick fan adjustment allows the operator to adjust the fan

tip of the spray gun with the assistance of a probe. Benefits include

pattern quickly. A new moulded composite gasket ensures longer life

reduced equipment costs, improved transfer efficiency, and more

and better shape retention.

complete coverage with less overspray.

More durable components of Pro Xp spray gun range

Increasing savings by decreasing air consumption Energy costs – particularly compressed air – continue to be a hot topic.

Many of the existing components of the Pro Xp range have now

Rotary vane air motors driving agitators in many paint kitchens typically

even greater durability. A more durable fluid tube improves longevity

have high air consumption rates, as well as high noise levels. They

when spraying low resistivity materials. It’s ideal for abrasives and

often require air line lubrication and maintenance to function properly.

metallic coatings. Multiple kits are also now available for 40 kV, 60 kV

More and more end users are looking for solutions to monitor and

and 85 kV high conductivity spray guns. The kits are available with a

control agitator speed to achieve optimal agitation results.

removable black fluid tube cover that allows the operator to view fluid

Graco’s new radial piston agitator addresses these challenges head-

movement (or with only a see-through protective cover).

on. The main feature of a radial piston is that it can rotate at a very low

A new high wear nozzle made from acetal incorporates a metal tip,

speed, so it needs less air than any rotary vane piston.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

Thanks to the active compensation, Graco’s surge suppressor eliminates the need for periodic air pressure checks.

The new Graco sealed 4-ball+ lower pump.

This leads immediately to reduced air and energy costs – and also

on resources.

reduces paint shear. Slower rotation cuts noise levels, improves

Graco’s active surge suppressor is mounted in-line to keep the

reliability and reduces maintenance costs. Air line lubrication is no

pressure stable. It works with regular shop air, eliminating the need

longer required.

and extra cost for high-pressure charge air. Thanks to the active

The agitator is compatible with Graco’s Intelligent Paint Kitchen (IPK)

air pressure compensation it eliminates the need for periodic air

pneumatic solution for speed monitoring and control. This relatively

pressure checks. The automatic adjustment feature eliminates the

light weight solution is compact for easy installation and handling. A

need for manual adjustment of air pressure if target fluid pressure

simple drop-in replacement for any current rotary vane air motor can

changes. Finally, the backup seal helps prevent paint from leaking out

be performed in minutes. It has been tested at Graco’s lab for up to

in case of diaphragm rupture.

one billion revolutions (and still counting); 14 units have been field tested for up to one year.

Increasing equipment lifetime The new Graco sealed 4-ball+ lower pump provides long life and

Automatic control of pulsations in the line

maintenance-free operation while delivering the industry’s highest

Traditional surge suppressors require separate mounting, high

fluid delivery at the lowest cycle rates. This leads to benefits such as

pressure charge air that may not be available for initial set up, a

leak-free long life and easy service, while the new XL motor eliminates

regular check on pressure, and re-charge to maintain a desirable

icing induced stalling.

pressure level in air chamber of the surge suppressor. Moreover, some require manual adjustment of pressure in the air chamber

Increasing consistency between operators

when the target fluid pressure changes. In case of diaphragm

Graco’s existing ProControl 1KE Plus is an electronic flow control

rupture, paint can leak out. All these challenges add to cost and draw

device that ensures consistent fluid flow to a manual or automatic

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

gun and monitors material usage. The system can be equipped with closed loop fluid control to fully control the flow rate. It is designed to always have a consistent output to the gun. The ProControl 1KE Plus is thus a cost-effective solution to maintain and improve spray quality and consistency, even when material viscosity or pressure changes. It combines fluid control and fan or atomizing air control on 1 single unit. It tracks and reports material usage by part, operator and time, improving operator efficiency and overall quality. It “locks” job parameters to optimal target or range, and avoids unauthorized adjustment, ensuring spray quality and consistency.

www.cmautomazione.it

hi-tech

HIGHLIGHT OF THE MONTH

conveyors

Graco’s electronic flow control device, ProControl 1KE Plus.

Graco’s ProControl system layout.

CM AUTOMAZIONE srl - FA Ganci

Ufﬁci e produzione: Via Monte Bianco 20 - 20833 Giussano (MB) - IT p. +39.0362.314075 - f. +39.0362.861222 - info@cmautomazione.it

Budchem is specialised in the painting of large quantities of small and very small plastic pieces for the automotive industry

FOCUS ON TECHNOLOGY

Budchem: The Completely Automated Coating of Plastic Car Components through an Articulated Robot Opens the Future to New Finishing Projects Alessia Venturi ipcm

If the implementation of a robot allows doubling productivity without doubling the coating booths, then we can speak of a successful application. This is what happened to Budchem (Mysłowice, Poland) thanks to the installation of a 7-axis Lesta MV robot.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

hen a company wants to

the good results obtained, we retained

increase its productivity,

the customer, which entrusted us with

standardise its quality level,

many other orders. One of these had

and make production results repeatable,

a particularly strategic importance: it

automation is the only way to go. In the

involved applying a complete three-layer

coating sector, the term automation

system on 2,000 small plastic components

has more than one meaning: in order to

per day, intended to be mounted on the

automate a painting line, an automatic

front grille of the Fiat Panda. These were

part handling system (conveyor or bridge

the first external car parts we treated.

crane) can be added, reciprocators can

Later, for the same customer, we also

be used in the spray booth, or, as often

took care of the painting of the spoilers of

happens, robots can be entrusted with

all Panda 4x4 cars sold in the world, using

the work of line operators.

15 different colours matching with the

Budchem is a Polish company with over

bodies.

twenty years of experience in coating

“Fiat was our first customer and it is

plastic components for the automotive

currently the largest,” states Szlachcic.

sector. The installation of a robot,

“Over the years, we have also worked for

combined with the general revamping

Hyundai, in particular for the interiors of

of its coating plant, has enabled it to

the ix35, the largest SUV of this brand.

double production capacity by being

We have come to apply a complete

able to apply a complete three-layer

coating system on 4 components for the

system on two batches simultaneously.

interiors of 800 cars per day. In 2012, we

Budchem has succeeded in this project

also managed to move to our current

with the collaboration of Lesta (Dairago,

location in Mysłowice, near Krakow.

Varese, Italy), specialising in the design,

Finally, we received a huge order from

construction, and software integration of

Fiat, this time for commercial vehicles: the

articulated robots specifically conceived

coating of the four air vents on Ducato vans’ dashboards. Fiat thus became our

for coating. © ipcm

Budchem: geared to the automotive coating sector

Adam Szlachcic, founder of Budchem.

Like many successful businesses, including

exclusive customer, because our manual coating plant had hit full capacity. Now, thanks to the machine’s revamping and the complete automation achieved with

global companies such as Apple e Microsoft, in 1998 Budchem was

the system developed by Lesta, we are in a position to return to work

created in a garage, where Adam Szlachcic had started a small body

with other customers and engage in new, ambitious projects, such as

shop. Back then, the industrial development of Poland was still in

the coating of the bumper mouldings of Fiat Abarth cars.”

its beginning phase and there were not many industrial coating

“Budchem has always specialised in the painting of large quantities of

companies, and even less specialised in the treatment of plastics

small and very small workpieces. Now, thanks to this investment, we

for the automotive sector. This was the reason why Budchem

can expand to treat even larger parts, such as spoilers or mouldings,

encountered its first industrial customer, which asked it to paint a

and to serve new sectors, such as the household appliance one,” says

small plastic part for the Fiat 600’s cockpit.

Budchem quality manager Iwona Drewicz-Markowska. “The positive

“It was a small flat cover with a square shape, which had to be

side of the pandemic is that the resulting slowdown in production

painted with a special antistatic primer in just one colour,” recalls

freed up some time and resources for the development of this project,

owner Adam Szlachcic. “The job was very profitable and it enabled

the installation of the robot, and the total revamping of our coating

us to grow in terms of technical knowledge and, above all, move to

line. We now have a more modern, efficient system with a far greater

a larger location with industrial characteristics. Moreover, thanks to

production capacity, which will enable us to face yet another challenge:

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

the finishing of the aluminium engine cover of the Fiat 500 Abarth.”

A four-phase revamping project: conveyor, booth, robot, and oven The revamping of Budchem’s coating plant consisted of four phases. The first one was the replacement of the overhead, semi-automatic conveyor with a floor-mounted, power&free one-rail conveyor. This improved the factory’s logistics, thanks to the creation of buffers in front of the coating booth and inside and after the drying oven. In the second phase, the old booth with a floor overspray recovery system, in which the workpieces were loaded manually and the operator moved around to cover all surfaces, was replaced with an enclosed, pressurised booth equipped with a waterveil, double-side spraying system and with

Plastic components for the automotive industry painted by Budchem.

a 7-axis articulated robot located in the middle. The third phase, the most important one for the purposes of automating and increasing production capacity, saw the implementation of a Lesta MV robot. Thanks to its ability to rotate and slide guaranteed by the seventh axis of movement, it coats the parts by 360° while alternating left and right side. The most innovative aspect of this application is that 3 pneumatic spray guns are mounted on the robot’s wrist: these can apply three different wet-on-wet coating products, i.e. primer, coloured base coat, and clear coat, which only undergo one final curing phase. Furthermore, a fourth gun can automatically replace the third one to spray a wild-card product. In the fourth and final revamping phase, carried out by Astherm (Zalesie Górne, Poland), the drying system was lengthened © ipcm

Plastic pieces right after completing the painting process.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

and divided into two segments devoted to flash-off and conventional hot air drying.

FOCUS ON TECHNOLOGY

Curing ovens

Powder painting booths

Liquid painting booths Washing tunnels

Shotblasting booths

Innovative solutions

Soluzioni Innovative

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

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

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

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

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

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

The Robot LeBot MV supplied by Lesta in Dairago.

A description of the painting process For many components, Budchem also takes care of the injection moulding process. The workpieces are then prepared for coating by masking and cleaning with a rag and alcohol or a manual flaming operation for polypropylene parts. Budchem is working mainly with paints used in automotive industry, that are acrylic paints, metallic and non-metallic paints as

Headquarter: based in Turin (IT)

Number of employees: 65

Plants realized in 2019: 180

well as clear coats (with matte and glossy finish). The Lesta robot is equipped with 3 guns that are mounted on its wrist. These guns are responsible for applying the following materials:

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

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

• 2k primer • metallic 1k base coat

Eurotherm S.p.A. T +39 011 98 23 500 | M info@eurotherm.eu Eurotherm Lackieranlagen GmbH T +49 711 400 545 13 | M contact@eurotherm.eu

www.eurotherm.eu

• 1k solid paint or clear coat. The guns are connected to the paint management unit located in a separate room where they integrate with pumps. Each gun has its own pump and paint circuit in order to make a quick colour change. Multiple guns and separate painting circuits allow a quick painting process, which is completed in one cycle. When parts enter the spraying booth, they stop in front of the robot in the painting area. The robot’s controller switches to one painting circuit that is 2k primer and the robot applies this material to parts that are hanging from the frame that has just arrived. There are two conveyor rails inside the booth and these are parallel to each other. After the primer is sprayed on parts on the right side, the robot turns 180° to the left ready to spray the parts on the other side. When the cycle

is completed, the robot turns 180° again The new floor conveyor.

and the robot’s controller switches to the second painting circuit that may be 1k metallic base coat. The robot applies the metallic paint onto parts on the right side and then again turns around 180° and applies the same paint or a different paint on parts placed on the left side. After this, the robot can apply either a non-metallic paint or a clear coat. These operations are possible due to the robot being fitted with axis 2 360°. In addition, Lesta integrated its robot with the double conveyor rails, the entrance/ exit doors of the booth as well as with the paint management unit. The robot’s controller receives logistical signals from other devices to control on and off operations.

Advantages of Lesta’s automation system at Budchem The new plant and the Lesta robot have © ipcm

completely changed the finishing process The painting booth with the double-side painting wall with the robot in the middle.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

and improved its speed and quality. With the old manual booth, painters were working much slower due to its one-rail overhead conveyor and manual operation. As they were painting one set of parts, they had to wait a few minutes to be able to apply another paint. In the new booth, the robot works with two conveyor rails and there is no waiting time for another set of parts to be painted. Two sets of parts arrive inside the booth at the same time and the robot begins to paint immediately, changing its position from side to side, backwards, and forwards. The painting operation is fully completed after the first entry inside the booth. All painted parts are cured in a drying tunnel, which completes the finishing process. “One of the reasons that prompted us to choose Lesta’s robot is its excellent ease © ipcm

The paint kitchen.

of programming,” says Adam Szlachcic. “Programming can be performed by the painters themselves and it takes exactly the same time as the actual coating cycle.” “Creating an off-line coating program characteristic for industrial robots means investing a lot of time and highly skilled labour force such as programmers. On the other hand, the use of our robots does not require any advanced programming skills. It is sufficient for a painter to initiate the painting sequence while the robot motors are deactivated, thus starting it in the free-floating learning mode. At that point, the software generates the robotic code of gun movement and then memorizes it in the flashcard of PC. In few minutes program is done, saved and ready for using in automatic mode”, explains Lesta representative Igor Kania.

The Lesta robot is equipped with 3 guns that are mounted on its wrist.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

About Lesta’s MV robot with a floor slider

EBOT MV robots are Lesta’s newest systems. This 6-axis articulated robot is equipped with the new LeCRob Electric Control system and the latest version of the LeCRob Robot Manager control software, which can work in self-

learning mode, point 2 point, 3D offline and/or CADLight and EasyPanel for automated painting. The LeCRob electrical panel can control up to 12 axes and comes with a touchscreen LCD monitor. Its aluminium arms, available in different lengths, are built to cover any working areas. The robots are Atex certified according to (reference to specifications according to which conformity is declared): EN 60079-0: 2006, EN 60079-15: 2005, EN 61241-0: 2006, EN 61241-1: 2004. Category: Ex Group II - Category 3 G D- Zone 2/22. The Robot Paint Software manager called LeCRob Robot Manager, developed by Lesta Srl, meets all requirements of modern painting robots. The robot supplied to Budchem is fitted with it. The LeCRob Robot Manager software package’s key features are: • Self-learning programming • Point to point programming • Sub-program easy manager, equipped with data sheet and images • Rotation management unit • Additional axis management (carousel or transfer unit) • Motor/encoder programming • Interfacing with paint control unit • Multiple languages • Alarm management and log event • Multilevel user access • Online remote support • Interfacing with external DB for the production control • Smartphone connection • EasyPanel and CADLight integration A slider mounted on the floor increases the working area of the robot to 3000 mm so that it may work along 3000 mm of conveyor rails. The movement of the slider in the Y axis is performed by using an option called FOLLOW ME. With this function, when the operator teaches the robot a new program, the Y unit automatically follows the position of the robot to assist in the operation and keeps the robot arms in a better position. This robot follows the operator in a range of 3000 mm along the conveyor and the 360° rotation of two axes makes it flexible and effective.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

Your Aluminium Powder

Coating Partner sataluminium.com · gemapowdercoating.com

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

INNOVATIONS: PRESENT&FUTURE

Advancements in Near Neutral pH Descaling Brandon Lloyd Atotech Deutschland GmbH – Berlin, Germany

brandon.lloyd@atotech.com

In order to enhance paint performance in welding and laser cutting operations and to overcome the deficiencies of conventional descaling methods, Atotech introduced UniPrep® AC near neutral descalers.

n recent years, consumer’s aesthetic preferences have pushed

and economical method of oxide scale removal is achieved through

manufacturers to transition from traditional plating to more painted

integration of innovative chemistries into the pre-treatment system.

surfaces while the demand for longer lasting products has increased.

Atotech, a global leader in surface finishing innovations, has introduced

For welded and laser cut components, the necessity for improved paint

the UniPrep® AC line of near neutral pH scale removers within the past

coverage and corrosion resistance has likewise increased. The removal of

5 years to overcome the inefficiencies of conventional methods while

oxide scale prior to painting or evaluation in corrosion testing for welds

offering a safer and more sustainable solution for manufacturers.

and laser cuts is often ignored by manufacturers, considered too costly

The importance of oxide scale removal from welds and laser cut areas

or incapable of operating safely. These scales prevent proper adhesion

stems from manufacturer’s desire to improve the overall performance

of paint to the metal surface, resulting in premature failure. Conventional

of a painted part. Oxide scale inhibits paint from adhering properly to a

methods can be effective for scale removal but are unsustainable and

metal surface, and when corrosion or delamination of the paint occurs

have many associated disadvantages. However, the most effective

on welds or laser cuts it reduces the lifetime of the component. For © Atotech

Complete removal of oxide scale with UniPrep® AC, preparing the surface for subsequent paint application.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

UniPrep® AC successfully removes weld and laser scale from metal substrates, creating a clean surface for application of e-coat/KTL, wet paint and powder paint.

certain industries like automotive, motorcycle,

UniPrep® AC processes do not have any risk of

construction and agricultural equipment, it is

hydrogen embrittlement and offer a lower etch

a risk that manufacturers cannot afford, nor

rate compared to strong acids, allowing for a longer

consumers compromise on. Conventional scale

solution life. By extending the life of the descaling

removal applications such as grinding, media

chemistry, it also places less burden on wastewater

blasting or strong acids are most frequently used

treatment operations. UniPrep® AC products also

in manufacturing to address scale removal but

support the removal of organic contaminants on

have several drawbacks. First and foremost, both

metal substrates, making it possible to degrease

mechanical and conventional chemical descaling

and descale in the same process step. Removal

processes pose a severe HES risk. Specific to

of inorganic and organic contaminants supports

mechanical descaling, it can be very labour intensive

improved paint performance and corrosion

in manual application, generate dust and debris

resistance, especially in e-coat/KTL applications;

in the manufacturing area that creates a potential

without properly removing these contaminants the

contamination source for the paint applications and

paint will not adhere to the metal surface, leading

may have line-of-sight issues for recessed areas or

to paint loss and corrosion. Heat affected or burn

complex part geometries. Considering strong acid

areas, which are created near or on the reverse side

pickles, they often have a very high etch rate on

of a weld during the welding process, often have

ferrous substrates, which results in rapid increase

poor paint adhesion as well. Much like the scale on

in iron build-up and a short solution life, which

welds and laser cuts, UniPrep® AC offers enhanced

ultimately leads to a greater burden on wastewater

paint qualities for these areas, especially when

treatment operations. The outcome of these

comparing to mechanical methods that may have

conventional descaling methods is a process that is

line-of-sight concerns. UniPrep® AC was developed

not cost effective for applicators.

with sustainability at the forefront, formulated

Atotech introduced UniPrep® AC near neutral

without strong acids, alkylphenol ethoxylates (APE)

descalers to overcome the deficiencies of

and hard chelating agents, further reducing the

conventional descaling methods and create a

burden for wastewater treatment operations and

more sustainable process for manufacturers.

creating a safer work environment for manufacturing

Primarily operating at a mild, near neutral pH,

employees.

FOCUS ON TECHNOLOGY

Infrared RHT Gas Burners for the Complete Curing of Coatings: A Unique Application in Europe Alessia Venturi ipcm

IGLOO Sp. z.o.o. was the first company in Europe to implement a curing oven that uses exclusively Infragas Srl’s infrared RHT burners for gelling and curing the powder coatings it applies on both flat and three-dimensional workpieces in different lengths. Thanks to the combination of three companies’ know-how, IGLOO has managed to obtain a high finishing quality level, 15% energy savings, and a low environmental impact process.

he infrared technology offers numerous advantages to the heat

edge application was Infragas Srl (Mappano, Turin, Italy), which has

treatment sector, which includes processes such as drying and

produced both catalytic and micro-flame, pre-mixed gas IR radiant

curing within finishing operations. The use of gas IR radiant

burners since 1971, thus covering the entire IR technology spectrum. In

panels guarantees energy savings, environmental sustainability, smaller-

particular, in 2016, Infragas launched its RHT radiant panels, powerful

sized ovens, and, last but not least, excellent finishing quality. However,

high-temperature infrared burners with a micro-flame on their

IR panel manufacturers do not usually recommend their exclusive

surfaces that makes them particularly suitable for the heat treatment

use for the complete curing of powder coatings on complex parts

of materials requiring high process speeds, such as powder curing.

with undercuts. In fact, they are generally used in combination with

These characteristics have made the Radiant High Temperature

conventional hot-air ovens to increase process speed by accelerating

(RHT) burners the ideal solution to meet the needs of IGLOO, since it

the powder gelling phase. This was not the choice of IGLOO Sp. z.o.o.,

was already using an IR technology that, however, was not providing

a Polish manufacturer of refrigerated counters for supermarkets,

satisfactory results due to the rapid, progressive decrease in the overall

bakeries, and delicatessens, which opted for the installation of two

performance of emitters.

ovens, one for drying after chemical pre-treatment and one for powder

“Our collaboration with Infragas was divided into two phases,”

curing, equipped with IR panels alone. This has resulted into one of the

explains Jacek Podsiadlo, IGLOO’s technical director and coating plant

most innovative and unique applications of infrared RHT burners in the

technology manager. “We initially installed RHT emitters in our drying

European coating sector.

oven; then, once we assessed their effectiveness, we decided to extend

The partner chosen by IGLOO for the development of this cutting-

their use to the complete curing of our applied powder coatings.”

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Top left: IGLOO specialises in the production of refrigerated counters for supermarkets, bakeries, and delicatessens. Top right: The IR drying oven after the pre-treatment tunnel.

From left to right, IGLOO marketing manager Marcin Wojtkiewicz, Mariusz Biel from MD Coat, IGLOO technical director Jacek Podsiadlo, Francesca Marabotti from Infragas Srl and Alessia Venturi from ipcm®.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

“RHT burners were the ideal choice for IGLOO as they are pre-mixed systems: the IR radiation, in this case a shortwave one, is emitted through the use of gas pre-mixed with air. The combination of shortwave-infrared radiation and air guarantees excellent performance on both exposed surfaces and the hidden areas of geometrically complex parts,” says Mariusz Biel from MD Coat, the company that applies the Infragas technology in Poland and that developed the system supplied to IGLOO. “The success of this application also depended on the great work made to improve the recirculation of hot air inside the oven, thanks to IGLOO’s extensive experience in the field of IR application. All these elements, together with the know-how of the three companies involved, IGLOO, Infragas, and MD Coat, have enabled us to create a unique system at the European level, which uses exclusively infrared RHT burners for gelling and curing the powder coatings applied on both flat and three-dimensional workpieces in different lengths.”

IGLOO: more than cooling “IGLOO is a Polish manufacturer of commercial refrigeration equipment for the retail food store, confectionery-bakery, and gastronomy industries based in Nowy Wiśnicz, near Krakow. We have been present on the market for thirty-five years now, always investing in the latest technologies and in human capital. We know how important customer satisfaction is for a company: therefore, our mission is to help our customers thrive by successfully using our equipment. Our current development strategy foresees the further strengthening of our leadership position in the refrigeration sector through the expansion of our distribution channels in Europe and other continents,” explains IGLOO marketing manager Marcin Wojtkiewicz. IGLOO was established in 1986. From the start, it has focussed on creating innovative systems with unique aesthetics and excellent performance. The 1990s saw the dynamic growth of IGLOO. The modernisation, expansion, and fine-tuning of production plants, together with the expansion of its infrastructure, enabled it to increase its productivity very quickly and consolidate its position within the refrigeration sector. In 2000, the company undertook further modernisation and development in terms of both IT and advanced machinery, including machining centres, semi-automatic assembly lines, fifth-generation lasers, bending machines, coating systems, and wood, aluminium, and glass processing stations. The 21st century has brought new opportunities and new challenges for IGLOO. Its upgrading projects have enabled it to significantly increase its sales in the countries of Central and Western Europe and North America. Now, after thirty-five years in business, IGLOO’s equipment is sold in over sixty countries around the world, with an export share of 55% and counting. It produces over 2,000 systems per month, with 400 basic models including supermarket, deli, and bakery types, and boasts

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FOCUS ON TECHNOLOGY

brands such as Metro, Tesco, Carrefour, and Eurocash among its © ipcm

customers. It has over 350 employees across five manufacturing sites and it is currently building a new factory that will also house a new powder coating line. “We will certainly implement Infragas’ IR technology on the new plant, too,” states Jacek Podsiadlo, “given the excellent finishing results we are obtaining with the ones currently in use.”

The production process IGLOO manufactures environmentally friendly systems with modern design and extensive functionality. This makes them complex machines that integrate a myriad of different devices. Moreover, the company has recently differentiated its production by expanding its range to include air conditioners and, in 2020, an innovative air steriliser. This is called Sterylis and it uses three technologies – mechanical particle filtration, exposure of air to UV-C rays to destroy the DNA of pathogens, and air treatment with ozone in the absence of people – to continuously purify indoor air. IGLOO and the other companies of the Group have a fully integrated production process that starts with raw materials and ends with finished products, thanks to their vast experience in sheet metal machining, processing, and even coating. Most components of the refrigerators produced by IGLOO are made of stainless steel, especially those intended for contact with food: this amounts to about 12,000 workpieces per day in this material alone. All the other components, including the refrigerated counters’ bodies, are powder coated and their finish is of great importance for both aesthetic and protective purposes. © ipcm

“We have developed our production methods so that they do not have any negative impact on the environment. We also make sure that our business partners have an appropriate environmental policy. Finally, when we build our equipment, we pay special attention on energy efficiency and the use of environmentally friendly refrigerants. The choice of exclusively using IR radiation for drying our parts and curing our coatings is in line with this. Although aware that it was a complex, unique technical choice, we stubbornly continued on this path until implementing our current system: this has enabled us to lower the environmental impact of the coating phase, which is highly energyintensive,” says Marcin Wojtkiewicz.

Top left: IR ovens with Infragas Srl’s RHT burners can also treat complex-shaped parts. Bottom: The inside of the curing oven. Top right: The powder application booth.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

MILAN, IT

ALLIANZ TOWER

The RHT burners’ control modules outside the curing oven.

PERFECT SINERGY » ITALIAN FACADE CONSTRUCTION » AUSTRIAN SURFACE SOLUTIONS » ANODIZED EFFECT POWDER COATINGS

The powder coating process All the IGLOO’s parts requiring coating are treated in one automatic plant. “We installed our first coating system over twenty years ago, which featured an air oven with a conventional burner. In 2010, we installed our first IR unit gas radiators with an electric heating system, which initially gave good curing results with an efficient use of energy. The plant was equipped with the remote

temperature control of different horizontal levels, which is very important to ensure treatment uniformity. However, already after two years, we found a net decrease in the efficiency of the electrical IR panels. We decided to replace them through a huge new investment but, after another two years, the units started to lose efficiency again. Therefore, we chose to turn to another partner and we contacted MD Coat and Infragas,” says Jacek Podsiadlo. “We realised that the problem was the contamination of catalytic panels with the powders suspended in the air circulating inside the oven. That is why we changed our emitters’ internal areas

www.tiger-coatings.com

FOCUS ON TECHNOLOGY

WHEN IT HAS TO BE © ipcm

A feeding module.

PERFECT

by opting for Infragas’ RHT gas burners and we improved air recirculation inside the curing oven. The drying and curing stages are now more economical: energy costs were reduced by 15%, our emitters have a much longer service life, and the panels are no longer contaminated with paint. Our next step will be to implement the remote control of IR panels.” “The curing oven used by IGLOO is 11 metres long and it only takes 10 minutes for the complete treatment of parts, with a maximum line speed of 1.2 metres/minute,” indicates Mariusz Biel from MD Coat. “In the first segment, the radiant panels are closer together to guarantee greater energy density, because they are used for quicker powder gelling. In the curing area, on the other hand, the panels are more spaced apart. An identical bank of RHT

HIGH

PERFORMANCE POWDER COATINGS

panels was also installed in the drying oven after pre-treatment.” “Compared with a hot-air oven, the components come out hotter, since the infrared radiation remains on the surface. Cooling, however, is faster and therefore the parts can be handled immediately on the line,” adds Francesca Marabotti, the Marketing

www.tiger-coatings.com

Manager of Infragas Srl. “The thickness of the workpiece to be cured

A one-of-a-kind plant in Europe

is decisive: the higher its thickness and mass, the greater the time

IGLOO owns the first system to use infrared RHT burners for the

and curing temperature.

complete curing of powder coatings in Europe. “There were many

Furthermore, each Infragas radiant panel is equipped with a control

doubts around the success of this application, since generally

unit that can adjust the power by reducing it up to 50% depending on

Infragas does not suggest curing complex-shaped parts featuring

the treatment program, the component’s mass, the type of material,

hidden surfaces with the IR technology alone. In IGLOO’s case, the

and the conveyor’s speed.”

curing system’s design, combined with numerous tests and a lot of

“The service life of panels is another very important factor, because

determination on both sides, allowed finding the right solution,” says

the excess powder coating present in the air that circulates inside

Francesca Marabotti. “Currently, the system works for 16 hours a

the oven is burned by the radiant panels themselves, which are built

day without ever stopping and without any drops in temperature or

with a special metal fibre,” says Francesca Marabotti. “Compared with

efficiency.”

catalytic panels, which feature a flameless high technology but which

“We found two excellent partners in Infragas and MD Coat, with which

is less powerful and more delicate, RHT burners are very sturdy.

we have established a fruitful collaboration based on technological

With a metaphor, we can say that RHT panels are the Hard Rock of

exchange. We are very pleased with their customer service and quick

infrared technology.”

availability of spare parts,” notes Jacek Podsiadlo. “Now that we have

“Our next goal is to automate our coating plant. We want the system

optimised this application, we have great hopes for the future. Soon,

to know independently what material is proceeding to what stage of

we will implement the temperature remote control of all the three

treatment, so that the curing parameters are automatically adjusted

horizontal levels – low, middle, and high – since we currently observe

without any manual intervention and the parts are fully traceable,”

a temperature difference ranging between 15 and 25 °C. Although

states Jacek Podsiadlo. “The new plant will probably be based on the

it is already acceptable in terms of quality, we want to minimise it to

same concept.”

further improve our system’s performance.”

A touch screen allows adjusting various parameters for each bank of panels.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

Your fast efficiency. 5/5

We care. Surface cleaners

dn-chemicals.com

INNOVATIONS: PRESENT&FUTURE

Pulvercoat®: The Key to Switching from Liquid to Powder Coatings for Finishing Pre-Assembled, Heat-Sensitive Workpieces Francesco Bellucco Pulverit Spa, Italy

f.bellucco@pulverit.it

n the 2000s, the coating sector has made one of the most

very fast, low-temperature curing (3 minutes at 120 °C for embossed

important and “longest” technological leaps in its history: the

finishes) with excellent chemical resistance, UV resistance, surface

gradual abandonment of solvent-based liquid paints in favour of

hardness, and scratch resistance performance.

water-based products in many strategic industrial sectors, including furniture, components for agricultural and construction machinery

Technological preconditions

and heavy vehicles, metalwork, and electric engines. Now, those same

Pulverit started developing this product based on a will to overcome

sectors are offered the opportunity to make a further technological

the limits of powder coatings, including high curing temperature

leap: the adoption of powder coatings to replace liquid ones thanks

(typically 150 to 180 °C) and long curing times (15 to 20 minutes).

to Pulvercoat , recently developed in the Pulverit laboratories and

The idea was to attack the market shares of liquid paints, or, in other

patented at the European level. This newly developed powder is a

words, of all applications for which a cross-linking temperature of

kind of product not yet existing on the market to date. It combines

180 °C is an issue. These include pre-assembled products with

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INNOVATIONS: PRESENT&FUTURE

A panel after a 700-hour neutral salt spray test on sandblasted steel.

Adhesion.

Buchholz hardness higher than 140.

heat-sensitive components or materials, e.g. aluminium sheet +

UV resistance and of gloss and colour retention.

polyurethane foam, products containing printed circuits, hydraulic

However, Pulvercoat® was not conceived for architectural or purely

cylinders with fluids inside them, whose seals’ tightness might be

aesthetic applications: it gives the surfaces a functional finish, with

jeopardised by high temperatures, and steel components with a

two types of textures depending on the type of cross-linking process:

significant mass, e.g. heavy metal structures, agricultural machinery

• Embossed: 3 minutes at 120 °C

frames, or high thickness panels, which would require very long

• Smooth: 8 minutes at 140 °C or 14 minutes at 130 °C or 20 minutes

curing times if coated with traditional powders. Pulvercoat® also

at 120 °C.

brings benefits in terms of sustainability of the coating operations: it

In particular, textured finishes made with Pulvercoat® are

zeroes emissions, water consumption, and waste because, similarly

aesthetically pleasant and uniform, since the product does not build

to traditional powder coatings, it is largely recoverable during

up on edges, it does not create any “cloud effect” on large surfaces,

application, according to the “use what you buy” approach.

and it is much less subjected to the polishing phenomenon due to friction with other surfaces, thanks to its high hardness value.

Pulvercoat®’s technical features Pulvercoat® has a completely different chemical nature than any

Pulvercoat® can be applied as a regular powder. However, two

other existing coating, because it is based on a resin never used

of its downsides are its lower Tg and cross-linking trigger values

before in the powder industry, adapted by the Pulverit lab with the

than conventional powders, which require working at an ambient

help of its resin supplier. It shows very high cross-linking density,

temperature not exceeding 25-28 °C. This results in the need to

which guarantees much higher chemical and mechanical resistance

air-condition the application booth, the power feeding circuit, and

properties of the coating film than conventional powders. With a salt

the fluidised bed to prevent the product from sintering in the pipes.

spray resistance value of 700 hours on sandblasted steel, Pulvercoat®

This powder has a shelf life of 6 months and it must be stored at

can be compared to anti-graffiti polyurethane in terms of surface

controlled humidity and temperature (less than 20 °C). It can be

hardness and to Qualicoat class 2 polyester in terms of outdoor and

formulated in all colours, including non-bonded metallic versions,

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

although pure white hues are more complex to obtain.

The advantages and disadvantages of Pulvercoat® This product combines quick and lowtemperature curing properties (up to 3 minutes at 120 °C) with unrivalled chemical, UV, and scratch resistance. Due to its high surface hardness, on the other hand, it has poor crease resistance. The use of Pulvercoat® guarantees a dramatic reduction in the energy required during

Standard curing cycle.

the coating process. If switching from liquid paint application to powder coating with Pulvercoat®, the ROI is very high. In terms © Pulverit

of production, its greatest advantage is the ability to shorten cycle times and therefore increase process speed: Pulvercoat® can in fact triple the productivity of a line. However, this requires the part hanging and preparation operations to be speeded up, too, in order to take full advantage of such benefits. Moreover, this product is suitable for application through systems with perfectly controlled coating parameters, especially for the curing oven, as it has a very narrow curing window: compared with a

Low bake curing cycle.

conventional polyester powder coating cycle with a duration of 1 hour and 40 minutes, Pulvercoat® allows lowering the cycle time © Pulverit

to 40 minutes. On the other hand, quality tests carried out with cycles of 36, 40, and 44 minutes have shown that the product could be under-cross-linked, correctly cross-linked, or over-cross-linked. In order to make the most of Pulvercoat®, therefore, application operations should be controlled and repetitive and the curing oven should feature homogeneous heat dispersion and uniform, constantly controlled temperatures.

Pulvercoat® curing cycle: a clearly shorter time is needed to heat and cool the part, which dramatically reduces the total time required by the production cycle.

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INNOVATIONS: PRESENT&FUTURE

MEK resistance test (double rubs).

Application fields Pulvercoat® is particularly suitable for application on steel doors, workpieces for the ACE sector, and already-assembled parts

The ultimate coating solution for large parts MagicCompact® EquiFlow® XXL

with liquids or heat-sensitive components. It is ideal for coating large series of similar items, but it is not recommended for small batches of highly variable components. It is therefore a product mainly intended for OEMs, rather than coating contractors. In general, it is a step forward compared with UV powders, because it cross-links in conventional hot air ovens while guaranteeing the same productive advantages of UV powders, but without causing any cross-linking issues on components with complex threedimensional shapes and undercuts.

Conclusions As proof of the quality, originality, and uniqueness of Pulvercoat®, the European Community has awarded Pulverit a significant non-

- Color change friendly solution for the coating of big parts - Superior EquiFlow technology - Perfect coating conditions inside the booth - Flexible design concept for any customized solution - Perfect integration with 3D Dynamic Contour Detections

repayable loan as a part of the Horizon 2020 projects, in order to continue developing this new technology.

Industry 4.0 Ready Gema Europe Srl | Via Goldoni, 29 20090 Trezzano s/N | Italy T +39 02 48 400 486 F +39 02 48 400 874

gemapowdercoating.com

BRAND-NEW

The Next Generation in Orange Peel Measurement The appearance of paint and plastic surfaces is affected by structures, often referred to as orange peel. In the production of cars and similar multi-component goods many materials are used under various manufacturing processes. The goal - and challenge - is to create a harmonious overall impression of all parts. Especially the paint application process is influenced by many parameters, being paint viscosity, substrate roughness or film thickness, to name just a few examples. Objective measurement data are required for quality communication and to guarantee process stability.

isual perception of orange peel

saving. “Organizers” let you guide through a

essential appearance parameters with Pass/

depends on the size and distinctness

customized sampling procedure to measure

Fail tolerances. Its “Organizer” set-up enables

of wavy structures. The wave-scan

a car body. In the “Measure” menu, use own

clear sample identification and a menu guided

analyses waviness intensity with 5 wavelength

standards with scales and statistics defined

operation on the instrument. From single test

ranges (0.1 mm - 30 mm) and evaluates the

in the instrument or in smart-chart including

series to trend reports over time or special

brilliance of the surface. The results form a

the limits for Pass/Fail. The big display offers

charts for trouble shooting, smart-chart is the

“structure spectrum” and help to analyse and

enough space for all statistical data and - for

global tool for process stability. The software

optimize the surface quality based on material

the first time, the data can now be displayed

includes many NEW functions like e.g. “Drill-

and process parameters.

even with Pass/Fail indication in colour.

in” on any data point will show the history of the last 20 readings. Dynamic print layout

A new, additional approach is developed using Fast Fourier Transformation (FFT), to

Measure orange peel on high and semi-gloss surfaces

determine dominant waviness sizes and their

Substrate quality can telegraph through the

intensity. In visual studies it became obvious

coating and cause a “fuzzy” appearance. The

For further information:

that observers can distinguish samples based

substrate can be steel, e-coat or primer which

www.byk-instruments.com

on the dominant wavelengths. This data

are often low gloss finishes. The wave-scan 3

can be used to improve e.g. fibre-reinforced

dual uses additional sensorics for semi-gloss

composites.

surfaces. Thus, the surface quality after each

to filter the optical profile of the surface

let you create own reports for professional documentation.

process step can be specified and objectively evaluated. From substrate to top coat, from

The new wave-scan 3 family comes with a

film thickness to levelling - wave-scan is the

fresh design to accommodate an extra-large

diagnostic and QC tool at the same time to

colour touch display. Operation and feel is as

keep the process under control.

intuitive as you are used to with your smarta state-of-the-art haptic touch. The fastest chip

Standardized process monitoring with smart-chart

ever calculates complex waviness scales in no

Transfer your measuring data via docking

time at all and lets you do more in the same

station or directly connect with USB-cable.

time.

Optionally, wireless data transfer with Wi-Fi

The new touch display enables an easy,

function can be activated on request.

intuitive menu navigation with new functions

The software smart-chart includes powerful

like e.g. “Quick Check” for measuring without

standard management for defining all

phone. Capacitive display technology provides

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

wave-scan 3 - The next generation

INNOVATIONS: PRESENT&FUTURE

Guardian AM: Stardust’s Answer to The Current Need to Guarantee Surfaces that Are Also Protected Against Microbial Agents edited by Stardust Powder Coatings L’Aquila, Italy

info@stardust72.com

Stardust Powder Coatings, a company based in L’Aquila (Italy) specialized in the production of powder coatings, has recently developed and launched the Guardian AM range of antimicrobial coatings, with integrated BioCote® silver ion technology. © Stardust Powder Coatings

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

The eﬀectiveness of BioCote® additives integrated in Guardian AM coatings against Escherichia Coli and Staphylococcus Aureus bacteria.

he current situation has resulted in a hyper-awareness of the

This is why one of the most effective hygiene measures to protect

importance of strong hygiene measures in key environments.

surfaces from the risk of cross contamination is using antimicrobial

This is to reduce as much as possible the risk of microbial

coatings capable of reducing the presence of microbes such as

cross contamination. The first approach should always be thorough

bacteria and mould.

disinfection, especially of high touch surfaces, such as handles, doors,

Stardust Powder Coatings, a company based in L’Aquila (Italy)

windows and tables.

specializing in the production of powder coatings, has recently

However, when it comes to surfaces, sometimes cleaning regimes may

developed Guardian AM, a range of antimicrobial coatings with

not be enough, especially in particularly critical environments such

integrated BioCote® technology.

as hospitals, transportation, public buildings and all those high-traffic

Together with BioCote®, a leading supplier of antimicrobial additives,

venues.

the company has embarked on a development process to create a

One of the most effective strategies to ensure superior surface

range of coatings capable of reducing bacterial growth while ensuring

protection to complement existing cleaning regimes, thus improving

high aesthetic quality and long-term durability. From this process – for

the permanent hygiene of surfaces and adding a second layer

which the Stardust R&D team and BioCote® technicians collaborated

of defence, consists in the application of antimicrobial coatings,

closely – the Guardian AM antimicrobial coating range was developed.

that is, special coatings capable of inhibiting the proliferation of microorganisms.

The antimicrobial power of silver ions

In fact, in nature there are several types of microorganisms, very small

The Guardian AM powder coatings, formulated with BioCote® additives,

living beings (less than 0.1 mm), visible only

release silver ions in a controlled manner through an ion exchange

under a microscope, which include bacteria, fungi and moulds.

mechanism contained within the coating, ensuring a long-lasting and

Some play an important role in nature and can have beneficial

effective protection against all common bacteria, fungi and moulds.

effects, so much so that they are actually used by humans in various

It has been demonstrated that BioCote® active substances contained

industries, such as the food and beverage industry. Others can cause

in Stardust Guardian AM coatings can reduce up to 86% of the

unpleasant smells, food waste and a reduction in some products’ shelf

bacterial load on a product protected with the coating in 15 minutes,

life.

and up to 99.5% in just 2 hours.

These microbes can be transferred by way of food, animals and in

In addition, the protection provided by BioCote® additives to the

the environment, or spread through contact between humans or with

coating they are integrated into is permanent and guarantees

contaminated surfaces, on which they can survive for several months.

continuous action against microbial colonisation.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

Tailor-made antimicrobial protection

features such as resistance to scratching, light, penetration by cold

BioCote® technology can be integrated into all product families

liquids (cleaning/disinfection products), wet heat and dry heat.

offered by Stardust, such as epoxies, epoxy-polyesters, available in all finishes – from super matte to

The importance of ensuring the permanent antimicrobial protection of surfaces

gloss – and colours, including metallic ones.

In a delicate period as the one we are experiencing, we have all

In addition, to provide to its customers a truly tailor-made service,

become more sensitive about the importance of ensuring more

the Guardian AM coating range by Stardust can be chosen by sample

hygienic environments. When it comes to it, antimicrobial coatings

or by the major international colorimetric systems, such as RAL, NCS

are one of the most effective and long-lasting solutions. In fact, by

and PANTONE®.

applying an antimicrobial coating to high touch surfaces such as

To meet the specific needs of two particularly demanding sectors,

radiator covers, handles, window frames, tables and chairs, those

such as the architecture and hospital ones, Stardust has also

surfaces will be more hygienic because they contain a technology

developed two dedicated versions of Guardian AM: Guardian AM

that has been deliberately included to actively reduce the number

Architectural and Guardian AM Medical.

of microbes on the protected surface. This will reduce the potential

Guardian AM Architectural coatings have returned positive test

for cross-contamination from surfaces – surfaces that will also be

results when integrated with Qualicoat-approved polyester coatings,

kept clean more easily and are less likely to become stained from

making them a functional solution to coat aluminium profiles,

microbial growth, like mould. In addition to being compatible with

curtain walls and metal architecture in general, ensuring a winning

existing cleaning and sanitizing products, Guardian AM is classified

combination of antimicrobial effectiveness, outdoor durability and

as non-toxic to humans by the relevant authorities. This means that

attractive finishes.

these coatings offer a second layer of hygienic defence to existing

polyesters and polyurethanes. The Guardian AM coatings are also

For the hospital sector, Stardust has developed Guardian AM Medical

cleaning regimes, thus becoming part of the ultimate hygiene

which, in addition to integrating BioCote technology, has specific

solution, alongside cleaning and hand hygiene.

Bacteria Guardian AM coatings by Stardust have been tested against: © Stardust Powder Coatings

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

The new electrostatic powder range Inocoat

LDWI OR

Inogun R Robotic powder coating gun

Inogun A

Inogun M

Automatic powder coating gun

Manual powder coating gun

INOCOAT, A WIND OF NOVELTY IN POWDER SOLUTIONS High productivity Unique application performance Remarkable sustainability www.sames-kremlin.com *: except wearable parts

Easy to integrate and use Efficient powder transfer thanks to the TEC-5 technology

Some of the special eﬀects that Made Black obtains on buttons with the PVD sputtering coating technology.

FOCUS ON TECHNOLOGY

Creativity at the Service of Technology to Design a Highly Versatile, Compact System for the PVD Coating of Fashion Accessories Monica Fumagalli ipcm

By definition, creativity does not belong to technical designers and manufacturers of equipment and systems. Yet, in trying to grasp the most diverse customer needs and solve any production issues, they also end up resorting to original ideas and technical measures that later often turn into innovations. This article deals with the requirements of a coating contractor in the fashion industry, which met its customers’ varied needs by designing a compact, highly versatile coating line together with its equipment supplier, DBM Tecnologie.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Made Black’s new headquarters in Chiuduno (Bergamo, Italy).

ne of the most famous statements attributed to designer Coco

expression. This is also the core of the job of those who convert ideas

Chanel emphasises that “fashion is not something that exists

and concepts into clothes and accessories able to meet the most varied

in dresses only. Fashion is in the sky, in the street, fashion has

requests of creative talents. One of them is Made Black (Chiuduno,

to do with ideas, the way we live, what is happening.” This sentence

Bergamo, Italy). Specialising in the contracting coating of accessories

perfectly summarises the creativity that has always characterised the

for clothing, leather goods, and footwear, this company has turned its

fashion industry and the meaning of its limitless inventive process –

flexibility and ability to meet even impossible requests into a winning

fashion, like art, architecture, and design, has endless possibilities of

weapon, while always maintaining a high quality level thanks to the PVD

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

technology with magnetron sputtering and thermal evaporation methods. “Not a week goes by when our staff is not asked to develop new colours, new effects, and new finishes,” states Made Black Operation Manager Eros Mancabelli. “This is the ‘price to pay’, but also the most stimulating aspect of serving an eclectic industry that constantly strives to amaze its audience with surprising effects and that, in order to do so, needs to delve into the infinite facets of colours and hues.” With an extremely high production capacity, Made Black employs different coating technologies tailored to each process batch. “We treat about 600 million workpieces a year: these are mostly buttons of any type and material, including Zamak, brass, plastic, rubber, and natural materials such as wood, but also studs, eyelets, shoe heels, buckles, and carabiners. Versatility has characterised our business since 1995, its foundation year,

and has enabled it to grow rapidly. Nowadays,

The pre-coating cleaning system installed by DBM Tecnologie in Made Black’s new factory.

we can apply one, two, and three-coat systems of any nature, including epoxy, acrylic, polyurethane, and hybrid, in order to obtain

the most diverse effects, such as pastel, metal, mica, pearlescent, sheer, and tactile.” Another key to Made Black’s success is the choice of partners that support it in the development of cutting-edge processes and technologies in line with the creativity of its customers. “In January, we moved to a new factory, in which we have combined maximum energy efficiency and eco-sustainability. In order to double our production capacity, we have also installed a new pre-coating cleaning line and two new automatic coating systems at these new premises. We chose to rely on DBM Tecnologie Srl (Casale sul Sile, Treviso, Italy), which specialises in the design and installation of cleaning machines and frame coating systems for small parts.”

Made Black’s varied production Fashion accessories are treated with three different technologies: bulk barrel coating, which is a niche surface treatment service, flat

The handling system moving the frames through the various cleaning stations.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

PROTECTING YOUR CUSTOMERâ&#x20AC;&#x2122;S CONFIDENCE The ideal antimicrobial solution for aluminium profiles, curtain walls and metal architecture.

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ANTIMICROBIAL EFFECTIVENESS, OUTDOOR DURABILITY AND ATTRACTIVE FINISHES Protect yourself and others by improving the permanent hygiene of surfaces with Guardian AM, the antimicrobial coating with integrated BioCote ® technology. Stardust has developed a new generation of antimicrobial coatings, which offer long-lasting protection without compromising on appearance, and ensure antimicrobial on the parts of buildings with which we constantly come into contact, such as windows, doors and all related ﬁxtures. A new upgrade of the Stardust antimicrobial coatings is the Guardian AM Architectural, which has also returned positive test results when integrated with Qualicoat-approved polyester coatings.

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FOCUS ON TECHNOLOGY

coating, and frame coating. “We particularly believe in the latter,” states Mancabelli. “The investment made for the purchase of the new cleaning line and of the two automatic systems, which were added to the two already present, was motivated by our will to make our coating line even more efficient. It is currently constituted by a manual loading area, a pre-coating cleaning system, four coating machines from DBM’s DAV1 series, eight flash-off stations, curing ovens, and two PVD coating plants supplied by Kolzer (Cologno Monzese, Milan, Italy).” The critical issues encountered by Made Black in treating the surfaces of very different products and materials are well known to all coating contractors; this company, however, found an innovative solution to them. “We had a plant in mind that was able to autonomously ‘decide’ the process stages to be performed based on the parts’ material and shape,” explains Mancabelli. “We wanted to get as close as possible to the concept of the fully automatic lines

The immersion phase of small workpieces in the cleaning tanks.

used in large factories for eyewear production, but of course with a machine that was proportional to our needs. We thus designed a system that was as compact as possible, with a reduced number of stations for manual unloading, and able to reproduce the structure of galvanising plants in terms of technology. Thanks to the collaboration of DBM, which we already knew because it had supplied us with the two coating machines already present in our department, we managed to create a non-standard line that gives us the flexibility we need and the reliability of an efficient system.”

Scan this code to view the cleaning process or click here h ps://youtu.be/QygF3Y_M6Yo

Static water recovery after each cleaning phase.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

The parts are arranged in two ways: flat (plateau) or hanging on frames.

Technical characteristics of the new pre-coating cleaning line “We have designed a 3-stage cleaning line,” indicates Alessandro Mattiuzzo from the Technical Sales Department of DBM Tecnologie Srl. “The process starts with a degreasing step using an alkaline detergent to remove any release agents, oils, and greases and eliminate any risk of contamination due to the manipulation of parts by the operators. A second degreasing stage neutralises the alkaline element and activates the surfaces to achieve correct wettability and get the workpieces ready for paint application. Two rinses follow, the last of which uses demineralised water. Blow-off and drying phases end the process. The system can manage up to 25 different cleaning programs. Today about 10 programs are used.” Drying was one of the main problems to be solved in the design of the most suitable cleaning line. “We performed several tests to find a system that allowed perfectly drying products with complex geometries. The plant is also ready for the future implementation of an acid

pickling phase on the metal components that require this The coating machine from DBM Tecnologie’s DAV1 series.

particular surface protection operation.” “This will enhance our metal PVD coating capacity,

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

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The two tilted guns move horizontally for uniform application.

together with the installation of two new devoted systems at the end of this year,” says Mancabelli, “aimed at increasing the quality of our coatings particularly on titanium, steel, and hard metals. Another innovative feature of the line are the trolleys used for handling the frames. I define them as ‘sentient’ because they are able to identify the type of process to which each particular workpiece must be subjected, based on pre-set parameters. The plant has the task of optimising the production flow and the operator that of setting the process sequences correctly.”

The automation of DAV1 machines Upon leaving the cleaning plant, the frames are unloaded, placed on trolleys, and collected in a buffer from which they are picked up according to their subsequent destination: the primer application machine or directly the PVD coating system. The flat coating system consists of five © ipcm

automatic booths equipped with robots and

One of the machines of the flat coating line.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Kolzer’s PVD coating plant.

five manual booths. The frame coating operations are performed in DBM Tecnologie’s DAV1 systems. “Compared with the plants already used by Made Black,” notes Mattiuzzo, “these two new ones were modified by updating the control PLC and adding a user-friendly panel. We chose to automate some adjustment operations that were previously manual, such as cycle setting through pre-set programs to minimise the risk of errors. Moreover, the two systems are equipped with encoders enabling to know when a frame is not completely full and thus avoid spraying on empty spots with the start and stop technology. They each feature two tilted guns that move horizontally for complete and uniform application on both the internal and external surfaces of parts. Finally, they can integrate with the most diverse paint feeding technologies, from half-kilo colour pots to traditional coating management units. We also developed a customised paint container for Made Black, namely a small, pressurised cup positioned above the gun. This is just one of the several tailored solutions we have made available to this customer.”

Environmental management of the coating process Regarding the company’s environmental policy, Mancabelli says that “Made Black strives to protect people’s health and the environment

by committing to perform adequate waste management operations and

implementation of a fully automatic cycle with no frame unloading step

periodic assessments of its atmospheric, sound, and water emissions.

during the process: the frames will be loaded at the beginning of the line

It has significantly reduced the environmental impact of its emissions

and unloaded at the end. The current plant structure has already resulted

into the atmosphere with the installation of a modern post-combustion

into fewer surface defects due to excessive part handling: this further

system. The pre-coating cleaning plant installed was also designed with

evolution would eliminate them completely. It would also be preliminary

this in mind, with the inclusion of a static water recovery stage after each

to the already-planned integration of two new plants for the PVD coating

cleaning step to reduce water consumption. It is a zero liquid discharge

of metal accessories, aimed at complementing the treatments we already

system, with the exception of eluates and waste liquids generated by the

perform on plastic. One of the next investments will also concern a new

baths at the end of their service life.

batch cleaning plant. This will eliminate the manual operation now carried

“The system also exploits the electricity made available by the photovoltaic

out on small parts washed in bulk in a dedicated line and will enable us

system, which, at full load, produces a third of the electricity required by

to apply the same versatile cycle we use with the new frame coating line,

the factory, and the hot air generated by the afterburner, which enables

as it can be employed for different materials. Since the DBM system has

the recovery of 250 thermal kW to be used for production through an air-

been installed only recently, we are still collecting useful data relating to

water heat exchanger. The cleaning plant’s baths and the ovens all benefit

the advantages it has brought; we are also still testing the depletion point

from this.”

of the degreasing product, in order to prevent any progressive loss of cleaning quality.

The evolution of the line concept

“The growth of Made Black also happens through the innovative ideas and

“The development of Made Black’s coating lines will not stop there,”

solutions that our staff has been and is able to find in collaboration with

reveals Mancabelli. “The next step already agreed with DBM will be the

our most qualified suppliers.”

The PVD sputtering metallisation department.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

Zaniolo CdA-2.20

QUAL TY Europolveri offers a wide range of powder coatings that are available in several different

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advanced

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R&D laboratory steadily works in the development of new products and performance improvement in order to enable the company to be an innovation leader and to give solutions to the many technical requests coming from the market. Products development, their industrialization and their use are always directed to obtain the best results and the highest respect for the environment.

EUROPOLVERI S.p.A. - Sandrigo (VI) Italy - Ph. +39.0444.750643 - Fax +39.0444.750653 FILIALI/Branch Office: Cernusco sul Naviglio (MI) Ph.+39.(0)2.92148001 - Erbusco (BS) Ph.+39.(0)30.7704158 DEPOSITO/Depot: Iori Colori, Reggio Emilia Ph.+39.(0)522.327248

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P O W D E R C O AT I N G S I N C E 1 9 8 2

HIGHLIGHT OF THE MONTH

Simple as a Powder Application! Marie-Anne Guilldou SAMES KREMLIN – Pioltello (Milan), Italy marie-anne.guilldou@sames-kremlin.com

High utilisation rate, low environmental impact, quality of finish, cost reduction... Powder coating would be an ideal solution if its application was not hampered by a multitude of practical details. SAMES KREMLIN is doing something about this with Inocoat, a new automatic and manual range that plays the simplicity card.

owder coating is on the upswing: market studies promise an annual growth of 6.3% per year by 2025, compared to 5.4% for all paints. Its growth is driven by several sectors: household

appliances, car parts, shipbuilding, oil and gas industry, and so on.

Powder, so eﬃcient but so complex to apply There are several reasons for this craze. Firstly, paint that has not set

on the part to be treated does not dry; it can be recovered and used. Secondly, the powder is safe: no volatile organic compounds, no risk of storage, and reduced exposure for the operator. It is also known for its finish quality, its resistance to flaking, scratching and discolouration, and for the properties it can give to surfaces: anti-graffiti, antimicrobial, anti-corrosion, resistance to abrasion, heat, etc. Finally, powder is 10 to 30% cheaper than liquid paint depending on the parts and quantities. However, the application of powder paint is not simple. Adjusting the projection parameters is delicate, the distance between the part and the gun is accurate to the nearest millimetre, the paint jet is not always stable, some part geometries require pre-touches or retouches.

Compatible with all fieldbuses “Inocoat was designed to overcome these obstacles” explains Laurent Magnier, range manager at SAMES KREMLIN. “We innovate in terms of productivity, application quality, ease of integration and use. 17 beta tests conducted in Europe and Latin America validated this choice”. This range is very complete. In the automatic version, it includes a cabin, self-positioners and reciprocators, an electrostatic bell, a powder unit that can be replaced by a simple tank, a control module and, of course, spray guns.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

Inocoat is also compatible with all major fieldbus standards: Profibus, Profinet, CC-Link, Ethernet IP and Ethercat. Again, the principle of simplicity: integration into the existing industrial environment must be easy. Line programming is disarmingly easy. Just four parameters to be set: voltage and current of the spray guns, injection air and dilution air for the powder flow. In just a few minutes, the operator has his installation in hand. And he no longer has to worry about gun-to-part distances. When the gun enters the booth, two 3D laser sensors record its dimensions and position the guns to the nearest millimetre. This is why the Inocoat range does not have any kinetic programming.

Fewer or even no pre-touches or retouches at all For the application, the user has the choice between an electrostatic bell - a rarity on the powder lines on the market - and spray guns. The first is a reference in terms of productivity and thickness control: plus or minus 5 microns for an average layer of 50 microns on a flat part. The latter benefit from a patented control technology, TEC-5. “It enables more voltage and current to be applied at the same distance from the part than the competition” continues Laurent Magnier. “The powder is propelled with greater force and better charged, resulting in a better transfer rate”. The difference is evident on cylindrical parts, which the powder bypasses before being deposited in an even layer; and at the smallest angles (15 degrees and less), where it penetrates without difficulty. Even on simple workpieces, the application quality rises by several notches. “The pre-touch-up and post-touch-up operations that hamper the productivity of the powder are lightened. In one of our beta tests, they were eliminated for 80% of the products”.

A manual trolley popular with job coaters SAMES KREMLIN has also paid particular attention to the colour changes, which are inevitably frequent: 5 minutes for the automatic line - an absolute record - 30 seconds for the manual trolley. The latter stood out in the beta tests for its design, lightness, manoeuvrability, ergonomics of the gun and, of course, the quality of application. 14 French and British job coaters used it. 11 said they were ready to buy it right away. Simple as a powder application.

Top: Manual powder coatings application with the Inogun M spray gun.

Bottom: Automatic application with Inogun A spray guns. This system benefits from a patented control technology, TEC-5.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

HIGHLIGHT OF THE MONTH

For.Tec., the Sustainable Pyrolysis Specialist Edoardo Belgrano For.Tec. Srl – Francolise (Caserta), Italy

info@fortec-inceneritori.it

For.Tec., a company that has been specialising in the thermal decomposition of organic compounds for over forty years, has established itself internationally thanks to a wise quality management and environmental protection policy. It now presents to the industrial paint stripping sector the pyrolytic ovens of its new TR line, designed to remove paint from hooks and racks, recover poorly coated components, and regenerate electric motors.

yrolytic processes are used on a large scale in the industry. Specialising in this particular thermal decomposition method means developing and offering technologies capable of meeting the needs

of the most diverse sectors, such as oil & gas, general industry, healthcare, household waste, and paint stripping of coating plant accessories or workpieces to be recovered. Flexibility and the ability to adapt to the specific needs of each customer are among the characteristics that distinguish the production of For.Tec. - Forniture Tecnologiche (Francolise, Caserta, Italy), with an experience

The assembly of a For.Tec. pyrolytic system.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

For.Tec. CEO Edoardo Belgrano.

HIGHLIGHT OF THE MONTH

of over forty years in the design,

such as local public institutions and

construction, sale, and installation of

private companies, and that is based

eco-friendly waste incineration plants

on the integration of the principles of

and industrial pyrolytic ovens.

pollution prevention, environmental

Developed based on the

protection, and continuous

know-how of Cesare Belgrano,

improvement of performance and

a company operating since the

energy efficiency.

1970s, and currently managed by Edoardo Belgrano, For.Tec.

The TR pyrolytic ovens

is now a benchmark supplier in

For.Tec.’s TR pyrolytic ovens are

its sector, especially thanks to

among the most significant plants

its efforts in terms of constant

developed based on such a quality and

research, continuous technological

environmental management system,

improvement, and insourcing. It has

which has helped the firm to establish

more than thirty distributors in as

itself on the national and international

many countries around the world and

markets. They can be used for the

it installs its plants all over the globe

paint stripping of hooks and racks, the

in compliance with the environmental

recovery of poorly coated components,

regulations issued by each nation.

or the regeneration of electric motors.

Its main target markets are the

These new generation ovens are ideal

European one for pyrolytic ovens and

to:

the American one for incineration plants.

• paint strip rejected parts due to

The company currently produces

non-optimal coating through a heat A small-sized TR oven.

a range of over 70 systems,

treatment; • regenerate metal components to be

including incinerators capable of treating almost all types of waste,

subjected to further coating;

sophisticated cremation furnaces, and new generation industrial

• paint strip coating booth accessories such as hooks, racks, rods,

ovens. Its team, made up of engineers, architects, and mechanical

and grids;

designers, is characterised by the ability to customise every product

• regenerate electric motors by heat-removing insulating resins and

based on the different needs of each customer.

then performing a curing stage, which is done by selecting another program from the specially-adjusted microprocessor control system.

The development of eco-sustainable products

The ovens are designed by using last generation thermo-fluid

One of the primary goals of For.Tec. is to offer complete, highly

dynamics simulation software, able to guarantee uniform heat

technological products that can serve as a starting point for

distribution within the treatment chamber and minimise fuel waste.

innovative development and growth projects. This is why its

The insulators used guarantee the reduction of any heat loss towards

management has always emphasised the importance of adequate

the outside and a long service life. The energy recovery systems

quality management and environmental protection policies. The

contribute substantially to process cost savings. The TR ovens can

adoption of an environmental management system in compliance

be equipped with customised automatic loading/unloading systems

with the standard ISO 14001 and the consequent commitment

and managed remotely via a PLC with constantly updated software,

to continuously improve one’s own environmental and energy

enabling to enjoy the benefits guaranteed by the Industry 4.0.

performance – particularly in terms of reduction of greenhouse gas emissions, reduction of consumption, and energy recovery – are in

The pyrolytic cycle developed by For.Tec.

line with the goal of sustainable development, linked to social and

This Italian company has developed a multi-stage treatment system

economic evolutions and to the reproduction and enhancement of

to make the process as less invasive as possible and help protect

environmental resources. With this in mind, For.Tec. has developed

the materials to be treated. At first, the controlled-atmosphere oven

a detailed environmental program that guarantees a high, well-

maintains its heating temperature for a pre-set period. In the second

informed level of participation for both employees and third parties,

phase, the oven temperature gradually increases until the workpieces

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

are heated at about 430 °C (depending on the materials treated) and

materials, with different design and sizes depending on customer

the coating is completely decomposed. The third phase, finally, sees

needs.

the gradual, controlled cooling of the material in order to avoid any

Upon request, the TR ovens can be equipped with as follows:

thermal shock. A system of probes located in strategic places allows

• a remote control system for supervision and management via GSM

constant control of the process and continuous adjustment of the

or a dedicated web server;

operating parameters.

• an automated weighing and program setting system based on the

The effluent gases generated in the pyrolysis chamber are conveyed

quantities of material detected, which automatically checks the weight

to a post-combustion chamber. Here, at a temperature above

of the material loaded inside the oven and selects the right cycle.

900 °C, the gases from the primary chamber are oxidised to eliminate

• customisable automatic systems for the loading, unloading, cooling,

any unpleasant fumes and odours and comply with the limits imposed

and cleaning of parts.

by both national and European anti-pollution regulations. Thanks to a system for recovering energy from effluent gases, through a heat

Conclusions

exchanger it is possible to recover heat, which otherwise would be

Its reliability, high system efficiency and safety, high material quality,

dispersed into the atmosphere, and recirculate it in the combustion

great attention to detail, full compliance with delivery times, and, last

process. This guarantees considerable economic savings in terms of

but not least, the attention it pays to the environmental impact of

operating costs.

its manufacturing processes and the plants it builds make For.Tec. a

In order to avoid direct contact of fire with the materials to be treated,

benchmark supplier in its sector. This company’s belief that the arrival

the pyrolysis chamber is equipped with a firebox made of refractory

point of a research work is the starting point for the development of

material, inside which the flame of the primary burner moves. The

new technologies has enabled it to achieve significant goals and still

oven also features a practical metal trolley facilitating the loading of

continues to spur it towards new goals and product innovations.

The production department.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

A 32 m3-TR oven.

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FOCUS ON TECHNOLOGY

Zanardo Spa: The Best of Process, Product, and Digital Technologies for a New Cataphoresis and Powder Finishing Line Devoted to Electrical Cabinets Alessia Venturi ipcm

In 2019 company Zanardo S.p.A in collaboration with Imel (Codroipo, Udine, Italy), started to develop a new, and advanced coating line able to guarantee a productivity level adequate to its growing needs. This resulted into a plant that integrates all the latest cataphoresis and powder coating technologies as well as Imel’s 4.0 platform i4paintshop, which has in fact tripled the productivity of the previous powder finishing systems used by the company. It is also the first line in Europe to use Elecron LB 280, an epoxy cataphoresis coating produced by Kansai Paints.

The components of Zanardo S.p.A.’s electrical cabinets are subjected to cataphoresis in the plant designed by Imel. The picture shows the two elevators of the Futura conveyor, which handle four racks at a time in the two treatment tanks.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

ÂŠ ipcm

A birdâ&#x20AC;&#x2122;s eye view of the three-station loading area. In this photo, it is possible to see the variety of sizes and shapes of the components treated by this company.

f all the finishing technologies, cataphoresis is always

the European leaders in the production of cabinets, protective

associated with the idea of increasing the functional

enclosures, and components for electrical panels. In 2019, in

quality of a coating, as happens when it is used as the first

collaboration with Imel (Codroipo, Udine, Italy), a plant engineering

layer in car painting. Perfect surface coverage, greater corrosion

company specialising in the design of large automatic and

resistance, absence of aesthetic defects, and colour consistency:

digitalised high-productivity coating systems, it started to develop

these are the main qualities of cataphoresis. Although difficult to

a new, advanced coating line able to guarantee a productivity level

control, it is a completely automatic operation that ideally, once

adequate to its growing needs. One of its main requirements was

the process and control parameters have been optimally adjusted,

the integration of a cataphoresis process before the traditional

leaves no room for surprises. Moreover, when combined with

powder coating operation to which Zanardo had been subjecting

cataphoresis, both powder and liquid coatings are elevated to

its products for over forty years.

the premium finish grade. All of this makes it the Best Available

This resulted into a plant that integrates all the latest cataphoresis

Technology among all primer application ones. That is also why the

and powder coating technologies as well as the 4.0 platform

growth of cataphoresis within the industrial coating segment was

i4paintshop developed by Imel, which has in fact tripled the

7.5% in the 2015-2020 period, compared with the 6.5% increase of

productivity of the previous powder finishing systems used by the

other paints .

company. It is also ambitious in terms of cataphoresis product

It is therefore clear why any firm intending to compete in its target

employed: this is the first line in Europe to use Elecron LB 280, an

market on equal terms as regards finishing quality will consider

epoxy cataphoresis coating with a low cross-linking temperature,

using cataphoresis as the basis of its coating system. This was

very little yellowing after curing, and a solvent content in the tank of

also the choice of Zanardo S.p.A. (Susegana, Treviso, Italy), among

less than 1.5%, produced by Japanese firm Kansai Paints.

Source: Kansai Paints.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

The human-machine interface of the Visual Management system at one of the plant’s loading station.

Panels leaving the pre-treatment tunnel before entering the drying station.

Zanardo, forty-seven years of success

finding new technologies, and investing in new infrastructure, new

Zanardo S.p.A. is a leading manufacturer of metalwork fabrications

machinery, and staff training have led us to compete with the major

for electrical panels, junction boxes, and industrial automation.

companies on the international market, especially the German

Dino Zanardo founded it in Susegana (Treviso, Italy) in 1973.

ones.

Over time, it has expanded up to including a sales department,

“The idea of equipping Zanardo with a plant combining cataphoresis

a technical department, an additional production area equipped

and powder coating – a process that we had already known and

with laser and punching systems, a factory in Rovigo (Italy), an

applied for forty years – was born from this approach. We wanted

associated office in the Netherlands, and distributors in various

our enclosures and electrical cabinets’ finishing quality to be equal

foreign countries. “Electrical systems, control machines, PCs, and

to that of our international competitors, also following an increase

industrial automation units all need a sturdy case to house their

in the durability requirements of our products, often placed in

delicate mechanisms,” states company owner Guerrino Zanardo.

environments with a C3 or C4 corrosion class. Moreover, coating

“We are a market leading firm with a highly professional team,

had become a bottleneck, because the systems we were using

able to meet the most varied requirements and paying extreme

could not keep up with the pace of the latest generation machine

attention to details: our customers must receive properly-built,

tools that we had installed in our production department: our panel

simply perfect products. This continuous effort towards improving,

bender, for example, produces a panel every 20 seconds.”

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

This ambitious idea of installing a cutting-edge system soon

compliance with the parts’ treatment times with the company’s

developed into the project of a future-ready machine integrating

required takt-time. “The system allows performing three different

the latest process and product technologies, such as Imel’s 4.0

finishing cycles. In fact, Zanardo produces electrical panels in

platform i4paintshop and the new epoxy cataphoresis product

various shapes and sizes, from small units to polished or pickled

of Kansai Paints. The goal to triple this company’s productivity

sheet metal structures that are over 2 m high. Furthermore,

in terms of coating and cope with the expected increase in

since Zanardo’s production also includes oversized workpieces,

production for the next ten-fifteen years was the leitmotiv of this

up to 6 m in length, the path of the two-rail conveyor includes

whole endeavour.

a bypass section that skips the cataphoresis station and takes these parts directly to the two powder coating booths, after

The plant project’s evolution

adequate post-chemical treatment drying. Finally, on the other

“For Zanardo S.p.A., we developed an electrical panel coating line

hand, a part of the production only undergoes the cataphoresis

that automatic handles parts by means of a two-rail conveyor

treatment and it is then sent directly to the unloading station.”

designed and supplied by Futura Convogliatori Aerei,” says Lucio

Built by Imel in the course of a project that lasted about 12

Grillo from Imel, while walking us along this new, imposing plant.

months, this plant replaced two of the three powder coating

“It has a very high productivity, and a short takt-time which

systems used by Zanardo until 2019, i.e. the two plants installed

prompted us to find some technical solutions such as doubling

in the Susegana factory. Therefore, there was also the need not

some plant stations. For instance, the cataphoresis area was

to stop production while assembling the new line, located in a

equipped with two tanks, who work simultaneously to reconcile

separate building.

A bird’s eye view of the power&free two-rail conveyor designed by Futura Convogliatori Aerei (Robecco Pavese, Pavia).

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

Racks entering the cataphoresis area. The tanks have been installed at the same level as the other machines that make up the line and motion sensors ensure operational safety.

General description of the system

automatic tracking supplied by the control software interfaced

The cataphoresis + powder coating line is completely automatic

with the i4paintshop platform, and archived by the system at the

and digitalised. It interfaces with the company’s SAP management

end of the cycle, thus ensuring constant monitoring and complete

system and it provides the operators with process instructions,

traceability of all racks. The smart monitors, which constitute the

displayed on the smart monitors installed at the loading and

Visual Management HMI interface, show their position at any time.”

unloading stations. “The loading area includes two stations for

The six-stage pre-treatment process (degreasing, two rinses with

standard workpieces, with a three-rack storage buffer each, and

mains water, one rinse with demineralised water, nanotechnology

one station for oversized parts. Each workstation is equipped with

passivation, and a final rinse with demineralised water) uses Henkel

a Visual Management HMI operator panel: the line operator sees

chemicals and it is equipped with an automatic product dosing

the incoming order selected from the general production plan

system. “After pre-treatment, the parts reach a buffer in front of

and thus identifies the product to be loaded on the rack. When

the cataphoresis tanks, where the conveyor splits in two parts,

this is ready to enter the line, it is baptised with a number and

while a bypass section enables the racks with workpieces longer

matched with a product code. This information determines its

than 4 metres to skip cataphoresis and be diverted directly to the

path,” explains Grillo. “Treatment programs, operating parameters,

drying station. 95% of the production, however, proceeds towards

and consumption data for chemicals, powder paints, electricity,

the cataphoresis treatment, carried out in two tanks with a capacity

and gas are collected by the rack during the process thanks to

of 90 m3 each. At this point, the conveyor branch entering this area

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

The cataphoresis area is equipped with two 90 m3-tanks in order to achieve the productivity required by Zanardo in compliance with the parts’ treatment times.

further divides into two parallel branches, each equipped with an

and a traditional Venturi feeding unit. One booth only applies one

elevator, for the simultaneous immersion of 4 racks,” says Grillo.

colour, the one most used for Zanardo’s production, while the

“We chose to keep the cataphoresis tanks at the same level as the

other can be used for the most varied tints. The powders applied

other machines that make up the coating line, placing all ancillary

are industrial hybrid and polyester products manufactured by

systems underneath them.”

the Ecopolifix brand, which belongs to the Kansai Group. The

After immersion, the parts undergo a double cleaning step

booths communicate their powder consumption (per rack or per

with ultrafiltrated water. Then, they reach a buffer in front of

hour) in real time. The smart racks incoming from the drying oven

the cataphoresis drying oven, a heat retention system with a

automatically proceed towards the buffer of the first or second

conventional burner. Two buffers follow for cooling and stripping;

booth, while these prepare for the application process. The cycle

the latter is used at the end of the shift to empty the system

ends with oven curing and unloading as described above.

and safeguard quality. At that point, the parts that only require

“One of the strengths of this versatile, flexible, and completely

cataphoresis proceed to the unloading area, where the Visual

digitalised coating line is its operational safety degree, as for

Management system displays information about the incoming rack

all systems designed by Imel,” states Grillo. “We spend a lot of

in order for the operator to prepare the correct container, scan the

energy and resources to ensure maximum operator safety. For

associated product code, and reset the system.

example, we compartmentalise our cataphoresis areas with coated

On the other hand, if the rack carries products that need to be

panels, which also contribute to making the plants’ aesthetics

powder coated, it reaches the application area, equipped with two

homogeneous and pleasant to the eye. On the other hand, what

last generation Gema booths with a quick colour change system

makes Zanardo’s coating line unique is its automation degree:

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

this is the largest plant equipped with complete management

maintenance calendar that is adapted to the customer’s equipment

software created exclusively by Imel, including conveyor and line

and habits. The Smart Doc module creates a unique QR code for

management systems and our 4.0 platform. If we consider that

each strategic component, be it a valve, a pressure switch, or a

the installation and start-up phases were completed during the

pump: if scanned, this provides any kind of information about that

lockdown in March, also thanks to the excellent collaboration of

part through the Imel app. This includes technical attachments,

Zanardo, it is easy to understand why we consider this line one of

assembly and maintenance instructions, spare part lists, the

our flagships.”

availability of a spare part in stock (if connected with the customer’s automated warehouse), and even its price”.

i4paintshop: an Industry 4.0-oriented platform

“Finally, a very important part of the i4painthsop platform is the

“The plant is integrated with Imel’s complete 4.0 platform: it

Production module, which keeps track of the production flow,

includes almost all the operating and service modules included

including loaded batches, the number and type of parts they

in the i4paintshop concept,” indicates Luca Maddalena from

contain, treatment times, and process data for each rack. In the

the Industry 4.0 Sales Department of Imel. “In particular, the

case of Zanardo, the Production module was integrated with the

Environment module monitors consumption for every functional

company’s SAP logistics system. In a nutshell, SAP generates the

area. The Smart Maintenance package monitors the usage

production plans and sends them directly to the plant’s PLC; this, in

times of the various system components to create a customised

turn, sends all the process data collected on each production batch

All the ancillary systems connected to the cataphoresis system were placed under the tank, which is at floor level.

The powder application area with two Gema booths and two storage buﬀers.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

back to SAP, immediately after unloading from the coating line.” “In addition to this little apparent IT infrastructure, which operates in the background, the i4paintshop platform also integrates the already mentioned Visual Management system, including three HMI smart monitors at the loading area and three at the unloading area, which display the information sent by the control PLC about the production plan. In the loading area, in particular, the system displays the batches that should be loaded to follow the production plan issued by SAP, as well as the plant status, any alarms, and other basic information for running the system. In the unloading area, on the other hand, the system displays the incoming racks so that operators already know how to organise the packaging operations.” “Indeed, the i4paintshop platform is modular, with some basic packages to which other packages or accessory features can be attached,” says Grillo. Powder application with Gema guns fed with Venturi injectors. Each booth has a manual post-retouching platform.

“Zanardo, for example, did not implement the Overall Equipment Efficiency (OEE) module, simply because it carries out quality control actions with other systems. © ipcm

Every company, therefore, can adjust its Industry 4.0-related investment according to its specific needs, also considering that i4painthsop can even be implemented on already existing plants. Actually, Imel is the only Italian plant engineering company and one of just four firms in Europe to own a 4.0 platform with such a level of complexity and quality, the result of three years of study and investment.”

Innovation in cataphoresis: Elecron LB 280 Zanardo’s investment brought significant innovation also in terms of cataphoresis product. Indeed, the company did not choose a conventional acrylic coating, Example of process data visualized on the Visual Management HMI.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

but rather an innovative water-based

FOCUS ON TECHNOLOGY

epoxy product developed by Kansai Paints especially for the automotive, ACE, and transport sectors. Elecron LB 280 is innovative for the following reasons: • It shows very little yellowing even after the annealing of the powder finished surfaces: the ΔE measured after annealing is less than 1, with a thickness between 17 and 25 μm; • The amount of solvent in the tank is less than 1.5%, which makes it one of the most environmentally friendly products currently on the market; • Its cross-linking temperature is 165 °C, another sustainability-oriented feature that reduces the energy required for curing the cataphoresis layer; • It has high penetration and edge coverage properties, a wide process window, and excellent bath stability. “Kansai’s Elecron LB 280 has already been approved by car manufacturers

The Smart Doc module of Imel’s i4paintshop platform allows accessing information on the system’s strategic components via a QR Code.

such as Toyota, Nissan, Subaru, and Renault, but it is particularly suitable for all companies wanting to achieve a premium finishing quality degree also in combination with powder or liquid top coats. It main advantage, in fact, lies in its colour stability despite its epoxy nature, as it shows a yellowing behaviour very similar to that of acrylic cataphoresis products,” states Massimo Bazzucco, the Metal Coatings Sales Manager of Kansai Paints in Italy. “Other benefits of Elecron LB 280 compared with the acrylic technology are its greater corrosion resistance performance and the reduction of the coating costs per square metre. Of course, being an epoxy product, it does not withstand direct sunlight: this is why it is ideally applied together with a liquid or powder top coat. Its colour stability, finally, makes it an excellent choice for all those © ipcm

cases in which a part of a component must be treated with cataphoresis alone and,

Zanardo produces electrical panels in various shapes and sizes, from small units to polished or pickled sheet metal structures that are over 2 m high.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

From left to right, Lucio Grillo from Imel, Guerrino Zanardo, and Alessia Venturi.

therefore, any unpleasant tint differences with the parts covered

considerable investment we made in this Imel cataphoresis line

with a top coat must be avoided.”

was aimed at achieving this sustainability goal and maintaining it for the next fifteen-twenty years. Our choice fell immediately

A future-proof investment

on Imel: we did not made any tender. We had no personal

“For Zanardo, sustainability is synonymous with love for the

acquaintance with it, but we knew it as a highly qualified company

environment, which we want to safeguard through recycling,

in the sector of large-sized coating plants. One year after the

smart waste disposal, investment in solar panels as a form

beginning of the project and after a few months of operation, also

of green energy, and, above all, the development of eco-

considering the difficulties caused by this historical period, I can

friendly technologies with a lower environmental impact and

say I am very pleased with the increase in productivity we expect in

reduced resource consumption,” states Guerrino Zanardo. “The

the years to come.”

Scan the code to view the process or click here www.youtube.com/watch?v=AGzPxA3C1lg

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

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The Line-Met V1 system with its user interface.

INNOVATIONS: PRESENT&FUTURE

Line-Met: The New, Revolutionary Concept of Metallising Plants Created by Arzuffi Srl Danilo Arzuﬀi, CEO Arzuﬀi Srl – Bernareggio (Monza e Brianza), Italy

info@arzuﬀisrl.it

Active in the high vacuum coating sector for over thirty years, Arzuffi Srl has launched its new metallising plant range called Line-Met. Thanks to complete automation, in-line integration, and digital technology, this breaks with the past and lays the foundations for a revolution in the concept of these machines, made accessible to all users and easy to integrate into traditional production flows.

urface metallising, particularly on three-dimensional

Arzuffi’s vision has always been preempting customer needs by

components, is a complex process that has undergone

developing solutions that are at least five years ahead of market

considerable development in terms of performance, equipment,

trends. With its Line-Met range, it has solved some of the typical issues

and technologies over the last few years. The Line-Met range of

of sputter coating plants through complete automation. Indeed, the

metallising plants developed by Arzuffi Srl, a company operating

Line-Met machines are the first in-line, modular, compact metallising

in the high vacuum coating field especially for the automotive and

systems to be available on the market with affordable costs and to

cosmetic packaging sectors, can be considered the culmination of this

guarantee such an operational flexibility as to be suitable for any

technology.

application on plastic and metal.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

The future in automation

simultaneously with the others: this guarantees high performance

So far, the market has been offering off-line batch plants, which require

while avoiding any surface contamination during the transition

a considerable expenditure in terms of time, costs, and labour, and fully

between different process stages. The Line-Met plants integrate

automatic machines characterised, however, by prohibitive costs and

perfectly with pre-existing forming or coating lines without requiring

low productivity. By making automation and flexibility its mission, Arzuffi

any modification and their loading and unloading phases can also be

has managed to change the rules of the game: with Line-Met, costs

separated with the installation of two handling robots.

become accessible to all users, from coating contractors to the biggest players in the automotive and cosmetic industries, and productivity

The new systems’ advantages

becomes very high, up to 14 m per minute. Moreover, thanks to

The main advantages of these systems are as follows:

compact and modular design, these machines can be integrated

• possibility to use the same workpiece-holder already used in the

and adapted to the most diverse production areas and their robotic

production department;

loading/unloading stations can receive any workpiece-holding container

• fully automated machine, which does not require the presence of any

(trays, grids, or bars) from any previous processing department.

operators; • high coating quality thanks to limited part manipulation, process

Line-Met: tailor-made plants

repeatability, and low number of scrap parts, and ability to even reach

These systems consist of a different number of chambers depending

the undercuts of complex-shaped parts while maintaining them in a

on the type of part to be treated and of treatment needed: plasma

fixed position;

etching, sputtering, reactive sputtering, multilayer, and plasma

• 85% surface reflectivity, even with three-dimensional parts;

polymerisation are the most frequently required processes. They

possibility to mask the components;

can also perform hydrophobic and hydrophilic treatments and green

• simple and ergonomic maintenance with easy target change;

chrome processes (as an alternative to electroplating).

compact layout;

The takt time of a standard cycle is less than 40 seconds, but this

• maximum flexibility and adaptability to different customer needs;

can vary based on the type, size, and material of the parts to be

reduced energy consumption thanks to the installation of turbo-

treated. Unlike the two external emptying chambers, where vacuum

molecular pumps in place of conventional diffusion pumps (the

and atmospheric pressure alternate, the central chambers always

average consumption of a standard machine is 51 kW/h, compared

operate under vacuum. Each chamber works independently, but

with the 35 kW/h consumption of Line-Met);

The Line-Met V2 metallising plant.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

1950

2010 © Arzuﬃ

1920

2019

2000

The evolutionary chronology of Arzuﬃ Srl’s metallising machines.

• user-friendly interface;

V1 was the first plant of the range, the pioneer of a revolution in the

• a dedicated web platform, where customers can consult the

field. It immediately evolved into the V3 type, which can metallise twice

exploded views of their plants and directly manage the requests for

the surface in the same time (less than 40 seconds). The V2 type is a

any spare parts.

special system: it features an additional chamber devoted to the reactive sputtering process in order to achieve a high degree of reflectivity, up

Coatings: endless application possibilities

to 95%. Finally, Line-Met V4 was conceived for car radome systems and

It is possible to apply coatings through both conventional sputtering

two-dimensional parts.

deposition and reactive sputtering operations. Reactive sputtering is a coating process whereby gases or a mixture of them react with metal,

Conclusions

thus creating coatings with particular chromatic or functional effects.

The launch of Line-Met at the end of 2019 has changed not only

The Line-Met range guarantees maximum flexibility also in terms of

the market’s approach to this kind of plants, but also its production

application. It is even possible to sputter different metals in the same

mentality. Arzuffi’s philosophy has always been based on the

chamber thanks to a workpiece-holding tray or trolley recognition

customisation of its systems also in terms of technological development.

system on board the machine and to the possibility to automatically

Thanks to the possibility of meeting the demand for metallising

switch from one cycle to another.

plants that treat components in any shape, size, and material, Arzuffi’ revolution did not only have consequences on the factories’ production

The Line-Met range

flows, but it has also made this process accessible even to customers

The Line-Met range currently consists of four plant types. Line-Met

with no technical skills in the field of surface treatments.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

Â®

HIGHLIGHT OF THE MONTH

From Metalwork to R&D for the Construction of Coating Plants: The Successful Path of Montagna Srl Alessia Venturi ipcm

Some key partners to the success of the most important international projects remain hidden behind the scenes of the coating equipment industry. These companies are able to build individual system components while, at the same time, offering design support, research and development, and purchasing management services. One of them, Montagna Srl, is celebrating 50 years of activity, during which it has collaborated with all major European plant engineering firms in the car and industrial coating sectors.

n our pages, we are used to presenting success stories about

perhaps unknown to most, but which is behind the most important

large coating plants characterised by amazing grandeur,

paintshops built all over Europe (and beyond), some of which have

build quality, and operational efficiency. On the other hand,

been featured in ipcm® articles.

only seldom do we venture behind the scenes, in the design and

Walter Montagna established Montagna Srl as a craft metalwork

construction work required by these industrial machines, whose

business in 1970, in the Camonica Valley (Italy), a place where

technology is a flagship of the whole European mechanical industry.

craftsmanship is a value as well as a cultural element to cultivate over

2020 marked the 50th anniversary of a company whose name is

time: now that firm operates in the construction of several carbon

©Montagna

The Montagna’s headquarters in Rogno (Bergamo, Italy).

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

©Montagna

An assembly department.

©Montagna

The technical department.

and stainless steel electro-welded components for industrial plants.

for conveyors and robotic automation.

Its consolidated collaboration with plant engineering companies

In short, this firm is a strategic partner for all the main suppliers of

from both the car and industrial coating sectors (e.g. household

coating plants and lines in Europe. “In 2020, we have reached an

appliances, radiators, aluminium profiles, refrigeration compressors,

important milestone: we have been working in the coating plant field

alloy wheels, bumpers, and much more) has led it to be a recognised

for 50 years without ever becoming the competitors of our customers,”

specialist in the construction of booths, ovens, air heating units, heat

smiles Domenico Ducoli, the Technical and Commercial Director as

exchangers, pre-treatment tunnels, immersion tanks, piping, equipped

well as one of the three operating partners of Montagna Srl together

skids, doors and frames in aluminium, steel, and stainless steel, and

with Administrative Manager Elisabetta Magri and Production Manager

other components and accessories related to coating systems except

Diego Bianchetti. “At the same time, we have created a specialisation

©Montagna

Domenico Ducoli.

©Montagna

The fibre laser cutting machine with a cutting surface of 2.5 by 9 metres.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

for ourselves that has been enabling us to collaborate with our customers from the design phases, taking care of the 3D modelling of the requested workpieces starting from simple technical diagrams. We have simply outgrown the mere ‘metalwork’ field.”

About Montagna Montagna is a typical company that has been able to transform itself from a simple labour lender to a strategic partner offering services such as design, material purchase, component production, and even research and development. Its design department can process the customers’ layouts and project sections to analyse and define the required structural, mechanical, and composition elements. With 2D and 3D CAD and specific software for sheet metal processing, but ©Montagna

above all thanks to the professionalism and experience of its technicians, Montagna

The modular wall made up of glass and aluminium profiles specifically developed for manufacturing coating booths.

supports coating plant engineering companies along the path that begins with the idea and ends with the production of the best possible system. “One of our strengths is our design expertise, which enables us to shorten the construction times of a machine because we can anticipate the order of materials based on the 3D modelling of components, without waiting for the end of the design phase. Other strengths include operational comprehensiveness, that is, the ability to provide everything is needed to build a plant, and execution speed, because we have 35 specialised operators and a network of contractors helping us cope with any production peaks,” explains Ducoli. “This has enabled us to move away from the business model of selling workpieces by weight and to approach an integrated production strategy enabling us to also handle purchases, logistics, scheduling, and the coordination of all design and construction phases on behalf ©Montagna

The automatic welding bench.

100

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

of our customers.” Sheet metal processing and assembly take

made

in Ita ly

HIGHLIGHT OF THE MONTH

place within the 6,500 m2-wide production area of Montagna in Rogno (Bergamo, Italy). Certified, specialist operators, with the

FOR. . TEC SRL

help of comprehensive, highly advanced plant equipment, work here by applying methods designed with the aim of ensuring maximum reliability and the ability to adapt to any request. In order to offer a complete, reliable service, Montagna has also developed collaborations with trusted craftsman firms and suppliers for processes such as water jet cutting, special surface treatments including hot and cold galvanising and powder coating, machining, and plastic treatment. “Our production department’s flagship is certainly our fibre laser cutting machine with a cutting surface of 2.5 by 9 metres, one of the few in Italy. This allows steering our component design activity according to the amounts we are able to produce,” says Ducoli. “By exploiting such a potential already in the design phase, we are able upgrade in terms of construction even components that have produced in the same way for years.”

Research and development: making Montagna a strategic partner Its extreme specialisation in the coating plant field also enables Montagna to devote resources to the R&D of innovative construction solutions. “An example of this is the modular wall made up of glass and aluminium profiles that we have developed for coating booths intended particularly, but not only for the automotive industry,” explains Ducoli. “It is composed of 7 different profiles with flush glued glass without gaskets, which is very useful to simplify booth cleaning operations. Over the years, therefore, we have also become a research and development firm that designs innovative solutions to help plant engineering companies to improve their systems in terms of construction. This role of ours, on the other hand, never generates any conflicts at the operational level, because our professionalism, discretion, and safe data handling are widely recognised.”

Current and future development trends of coating plants Where is the coating industry going? This is a question that Montagna gets asked a lot, since it participates in the

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construction of the most important coating plants in the world. “Many companies are focussing on innovation, especially those operating in the car coating field. The major developments have occurred in terms of environmental savings and equipment compactness, as systems have an increasingly small footprint,” answers Domenico Ducoli. “The general industry field, on the other hand, is more static: paint and chemical product manufacturers drive innovation. Both the car and general

Sverniciatura bilancelle

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Rigenerazione motori elettrici

Pulizia estrusori

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Hooks paint stripping

Gas tanks paint stripping

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Extruders cleaning

Body work restoration

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mail: info@fortec-inceneritori.it web: www.fortec-inceneritori.it

industry sectors are now also focussing on the use of overspray dry removal systems. This is why they are exploring the application possibilities of both underbooth and vertical cardboard filters to replace conventional water-veil abatement units. “Moreover, the importance of sustainability and the circularity of raw materials has grown, including nontangible ones such as air: the systems equipped with recirculation units have changed a lot in terms of construction, also thanks to the development of robotic automation and the decrease in the operators’ number. Finally, as regards materials, we are witnessing an increasing use of stainless steels and aluminium, which is lighter and recyclable and always guarantees high minimum quality standards. “I often say that, if you know how to make a panel well, which is the basic building block of our product, the whole system will turn out well. It is about metabolising the love for a simple object into something big and complex.” ©Montagna

Manual pulsed arc welding.

overing a 10,000 m2-wide area, 6,500 of which are covered, Montagna is equipped with numerous machines and equipment for processing and assembling sheet metal, including the following ones:

• 1 250 t-hydraulic press brake (L = 7 m) • 1 160 t-hydraulic press brake (L = 4 m) • 1 80 t-hydraulic press brake (L = 2.5 m) • 1 hydraulic shear (L = 4 m) • 1 fibre laser cutting machine (work surface = 2.5 x 9 m) • 1 4.6 x 12 m automatic welding bench equipped with a MIG cold welding machine • 1 tube bending machine • 1 calender (L = 2.5 m) • 20 electric pulsed arc welders (TIG, MIG, MAG) • 1 liquid coating booth • 1 pickling booth for stainless steel.

Scan the code or click the link www.youtube.com/watch?v=fgKRR_QRyAA to see Montagna’s fiber laser cu ng machine

The flagship of Montagna’s production department is a W-Fiber laser system supplied by Warcom, a manufacturer of excellence in the laser cutting machinery sector. It enables the company to guarantee high quality standards, a wide range of processed materials (including highly reflective ones), thicknesses from 0,5 to 20 mm, short processing times, savings on ancillary processes (thanks to machining tolerances within a tenth of a millimetre), increased cutting quality (smooth cutting edges and greater cut perpendicularity), and the possibility of creating elaborate cutting profiles. Montagna’s welders are ISO 9606-1:2013 and ISO 14732:2013 certified. The company manages quality in compliance with the standard ISO 9001:2008, according to which it has been certified since 1998.

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N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

booths

ovens

cataphoresis

tunnels

complete plants

eosmarketing.it

conveyors

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ON THE ROAD TO ipcm

104

Â®

n. 66

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SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

106 112 122 126 132

FOCUS ON TECHNOLOGY Resilient Contracting: VP Verniciatura Continues to Invest and Relies on Pre-Treatment Nanotechnology to Obtain International Quality Certifications

FOCUS ON TECHNOLOGY Athena’s New Waste Water Treatment Plant Cancels the Anthropic Impact of the Chemical Nickel Plating of Engine Cylinders

HIGHLIGHT OF THE MONTH KUBE: The Digitalisation of Coating Processes Becomes Reality

FOCUS ON TECHNOLOGY Italian Technology for the Semi-Automatic Powder Coating Installation with a High Throughput installed at Zürn Harvesting

FOCUS ON TECHNOLOGY The Importance of Shot Blasting in the Treatment of Machinery Components Subjected to High Stress: The Choice of Carantini

138 SUCCESS STORIES

GEINSA Supplies Cochet with a Surface Treatment Line for Powder Coating

140 148 152

FOCUS ON TECHNOLOGY Streparava: Sustainability and Application Ecotechnology for the Low-Environmental Impact Coating of 4x4 Axles

SUCCESS STORIES Top Quality Pretreatment for Trailer Chassis

SUCCESS STORIES Oltrogge: A Partner for Heavy-Duty Challenges

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

105

FOCUS ON TECHNOLOGY

Resilient Contracting: VP Verniciatura Continues to Invest and Relies on Pre-Treatment Nanotechnology to Obtain International Quality Certifications Monica Fumagalli ipcm

VP Verniciatura is a coating contractor that has always been able to be one step ahead of the ever-changing market trends and that has managed to overcome the current difficult situation with some significant investments. Its resilience is reflected in the approach of DN Chemicals, a company specialising in the supply of pre-treatment chemicals that can compete with the large multinationals in the sector thanks to its expertise and eco-sustainable innovations.

“R

esilience”, the ability of any material to absorb shocks without breaking, is a term that has long since entered the everyday language to indicate someone’s ability to face and overcome

traumatic events – and now more than ever has it spread throughout the Internet, newspapers, and television. Nowadays, for a medium or small business, being resilient does not only mean overcoming the difficulties related to daily work, customer relationship, and product quality, but also being as versatile as possible to quickly respond to changing market demands. This has precisely been the winning strategy of VP Verniciatura (Ponzano Veneto, Treviso, Italy), a coating contractor specialising in the treatment of large-sized parts, in order to achieve significant results. “My father, Daniele Bellotto, founded our company in 1997,” says Andrea,

VP Verniciatura (Ponzano Veneto, Treviso) specialises in the surface treatment of large-sized products.

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N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

the current CEO of the firm. “At that time, we had an area of 1,500 m2, one

FOCUS ON TECHNOLOGY

The VP Verniciatura’s factory.

coating plant, and eight employees. Our factory now covers an area

to the construction and agricultural sector. We are able to meet

of 30,000 m , of which 15,000 are covered, it is equipped with five

the requests of our customers thanks to five large-sized systems.

plants of a considerable size, and it has fifty-eight employees.” The

The liquid coating plant has a footprint of 9 x 3.3 x 2.4 m, the three

pride of having reached such an important milestone emerges in

powder coating machines of 10.8 x 3.3 x 2.4 m, and the current

Bellotto’s words while describing the last few years: “Our main goal

sandblasting system of 15 x 2 x 1 m. However, a new, larger plant

has always been to spread the culture of quality painting, as well

is going into operation in May 2021; it will be installed in a building

as offering resistant, durable coated products. Our perseverance

devoted exclusively to this process.”

has been rewarded: we are the second Italian company to have

VP Verniciatura has chosen to equip itself with the most advanced

obtained the QualiSteelCoat certification, the international quality

coating systems, able to guarantee uniform application and adequate

mark for coated steel. We have achieved this objective thanks to

penetration even in the corners and profiles of the most complex-

the implementation of the pre-treatment nanotechnology provided

shaped components. “We have always paid great attention to the

by Kemmex, recently merged into the DN Chemicals Group, which

phases that precede and follow the treatment: we always store the

specialises in the supply of solutions for all surface pre-treatment,

products in covered areas in order to protect them from any external

nanotechnology, water treatment, and paint stripping processes.”

aggression and we label them to ensure total traceability. Another

factor that guarantees the quality level for which we are well known

Five treatment lines for diﬀerent types of materials and products

at the regional and national level are our last-generation curing

“We perform coating and finishing treatments on different types of

thicknesses and materials and adjusting the cycle time accordingly.

materials,” says Bellotto, “such as steel, aluminium, galvanised iron,

In this way, we give greater resistance and colour quality to the

black iron, and COR-TEN steel. We treat a wide range of parts, such

products we deliver to our customers.”

ovens: these ensure uniform treatment by automatically identifying

as components for ACE ladder machinery, large outdoor structures, This means that we coat products finding application in several

Nanotechnology pre-treatment: a strategic factor for quality certifications

different sectors and contexts: from design and architecture to

VP Verniciatura performs both a mechanical and chemical pre-

metalwork and door frames, from the agri-food and naval industry

treatment process. The first one takes place by shot peening with

railings, perforated sheets, gates, and architectural structures.

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The inside of the pre-treatment tunnel.

The inside of the automatic coating booth supplied by Gema Europe.

Manual touch-up of coated workpieces.

metal grit and silica sand. The second one is carried out in two

since we started using DN Chemicals’ pre-treatment products, we

different plants depending the material to be treated. “We integrated

found a decisive qualitative improvement, which has enabled us to

nanotechnology into our workflow about three years ago,” explains

increase our treatment’s salt spray resistance guarantee from 250

Bellotto, “when we contacted DN Chemicals to solve a problem

to about 500 hours. This was a key step to obtain the QualiSteelCoat

related to the pre-treatment of galvanised sheet. They suggested

international quality certification for coated steel. Currently, VP

replacing the phosphodegreasing process, which was not providing

Verniciatura is the only Italian company to hold this certification for

our required quality results, with phospho-pickling. The solution

four corrosion categories on three different substrates.”

proved excellent and we have since chosen DN Chemicals as our

“Our nanotechnology products,” states Gianni Zilli, area manager at

sole supplier of pre-treatment products. We collaborate closely with

DN Chemicals, “are used in two plants with different characteristics.

their technical staff, always available to offer professional on-site

The one-chamber system performs continuous rinsing and a final

assistance, and with their laboratory, where we carry out our salt

nebulisation phase with a solution constituted by zirconium salts,

spray resistance tests.

surfactants, and correctors. The tunnel plant with a two-rail conveyor,

“I can say that this is the technology that best reflects our way of

on the other hand, can carry out two different initial phases

understanding work. The use of nanotechnology prior to coating

depending on the material type. Iron and pickled sheet metal, from

guarantees perfect cleaning of surfaces, thus protecting them

which it is easier to remove impurities, undergo a phosphodegreasing

from oxidation and increasing paint adhesion. This slows down the

treatment; galvanised sheet, especially if passivated with trivalent

corrosion process of metals, improves film penetration, and gives

chromium, and steel with residues of processing and storage oils are

unparalleled strength and elasticity to coatings, thus significantly

subjected to acid phospho-pickling. Both treatments are followed by

increasing the weathering resistance of our treated parts. Ever

two rinses, one with mains water and the other with demineralised

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FOCUS ON TECHNOLOGY

water with a conductivity of less than 30 μS, in order to completely

and, in general, the collaboration of DN Chemicals is evident in his

remove non-anchored treatment salts without leaving any saline

words: “When there is a combination of forces aimed at achieving a

deposits on surfaces. A chromium-free, no-rinse, fluorescent zirconia-

common goal, excellent results can be obtained. Our achievements

based nanotechnology passivation phase follows to deposit a thin

were guaranteed by both parties’ ability to quickly adapt to market

layer of zirconium fluoride with a thickness of 0.5-0.6 μm and with

needs. On the one hand, DN Chemicals has found the right solution

excellent chemical anchoring properties, necessary to improve

for our processes; on the other hand, our team has been able to

corrosion resistance and paint adhesion.”

manage the resulting production flow at best by adapting from time to time to current trends, with professionalism and passion. This has

Characteristics of the coating systems

resulted not just in the improvement of our process quality level, but

As for powder application, the Venetian company uses one-coat,

also in the reduction of our environmental impact and, in general,

two-coat, and cataphoresis + powder coating systems. “Before the

in excellent collaboration, as their support team is very helpful and

products enter our coating plants, we seal and mask the parts to be

their lab is always looking for innovative solutions that can facilitate

protected,” notes Bellotto. “In some cases, we just electrostatically

their customers’ work in terms of both process management and

apply thermosetting powder enamel with a brilliance of 20 to 90

consumption.”

gloss. For our two-coat cycles, we apply a zinc primer followed by a gelling stage in a forced-air oven for 15 minutes at 180 °C, the

The reduction of process temperatures

application of a thermosetting polyester powder, and a curing step

“One of our next steps,” indicates DN Chemicals sales director André

in the oven. Finally, our customers can opt to replace the primer

Bernasconi, “is going to be the implementation of pre-treatment

application with a cataphoresis process. With the two latter systems,

processes at a lower temperature than conventional cycles, as is

we are able to achieve salt spray corrosion resistance values of no

already happening in VP Verniciatura’s factory, until reaching room

less than 970 hours.”

temperature (about 20 °C). These latter treatments are already used

Bellotto’s satisfaction with the nanotechnology pre-treatment

by some companies and they have aroused the interest of many

Parts in the drying oven.

Products in diﬀerent colours and sizes treated by VP Verniciatura.

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others. The potential of this innovation is significant especially for some pre-treatment processes carried out on materials that are not heavily contaminated by oils, calamine, and other difficult-to-remove pollutants. The technologies required are already available and used in an increasing number of plants. However, it should be emphasised that low-temperature processes are not always usable and that, in any case, a careful preliminary assessment is needed. On the other hand, all the conversion nanotechnology cycles of the DOLLCOAT SA series have always been utilised at room temperature and they do not produce any type of process sludge.” “This is exactly what I mean when I talk about resilience,” states Bellotto. “It is not only about overcoming a difficult situation, but also about the ability to quickly adapt to new market needs by focussing on innovation and investing in the future. This is why VP Verniciatura, which never stopped even during the national lockdown period, © ipcm

VP Verniciatura’s passion for colour can be seen even in the smallest details.

keeps on investing in human resources, systems, and technologies to continue its growth path.”

Components ready for shipment.

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The Bellotto family at the helm of VP Verniciatura. From left to right: Edoardo, Daniele, and Andrea.

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FOCUS ON TECHNOLOGY

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Athena’s New Waste Water Treatment Plant Cancels the Anthropic Impact of the Chemical Nickel Plating of Engine Cylinders Monica Fumagalli ipcm

Galvanic processes are very delicate treatments in terms of both operation and possible environmental impact. Athena, a well-established company specialising in engine components, has developed a unique nickel plating treatment without losing sight of the importance of limiting the anthropogenic impact normally entailed by this kind of operations. This is why it turned to Water Energy, an industrial water treatment specialist, to find the most sustainable and innovative solution for the purification of its nickel plating process’ liquids.

s is well known, the bodies responsible for the formulation

was born at the beginning of the nineteenth century, but it has

of environmental regulations pay much attention to the

been constantly upgraded up to being used on various substrates

management of galvanic treatments. Considered one of the

to give them particular surface characteristics. Many experts have

processes with the greatest environmental impact, this technology

The cylinders manufactured by Athena Spa. © ipcm

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emphasised the benefits that the use of this particular treatment can

FOCUS ON TECHNOLOGY

An area of the machining department.

bring to products. For example, the website of Ecometal, a non-profit

a benchmark business for other firms partnering with it or belonging

consortium promoted by Assogalvanica1, states that “modern galvanic

to its supply chain through a wise environmental policy. This was

processes contribute to saving resources and reducing greenhouse

the case of Athena, a company established in the production of

gases and they are perfectly in line with the philosophy of sustainable

components for internal combustion engines. With a corporate

development.

profile and history studded with product innovations and sustainable

“Electrodeposition is now able to produce very thin linings of valuable

initiatives, it has recently upgraded its headquarters in Alonte

metals such as zinc, nickel, chromium, etc. with a thickness of a few

(Vicenza, Italy) with an innovative continuous flow treatment system

micrometres on base materials that would otherwise deteriorate

for the waste water generated by its galvanic processes, which

very quickly. This allows, for example, protecting a tonne of steel

has improved its water quality degree up to class A. The project

screws against corrosion with just 1 kg of zinc. With the newest

was developed by the team of Water Energy (San Pietro in Casale,

treatments, electrodeposition can enable to double the life of a car,

Bologna, Italy), a firm operating in the industrial water treatment

also improving its efficiency in terms of fuel consumption and halving

sector since 2006 and specialising in the development of tools and

greenhouse gas emissions. Moreover, without thick hard chrome,

technologies to optimise and reduce industrial consumption of water

modern airplanes could not fly and land (flap and landing gear

resources and thus improve its environmental impact.

movements).”2 This is certainly not the right place to open a debate on how polluting

One company, three souls

(or not) the galvanic technology can be. Here, we would just like to

“Athena,” explains the company’s communication manager, Matteo

underline the importance that a company can assume by turning into

Schenato, “is a world leader in the fields of motorcycle and car spare parts and technical products for the industry. In Italy, it is also a

1 2

The Italian Associa on of Galvanic Industries. h p://www.ecometal.org/art-32/storia_della_galvanica_moderna (04/11/2020)

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The cleaning phases before and after the galvanic process are essential for the final quality of components.

distributor of some major brands of the sports sector. Established

and agricultural machinery, and professional appliance sectors. The

by current president Gianni L. Mancassola in Bagnolo di Lonigo (Italy)

Athena Parts division is an international benchmark provider for

in 1973, its original core business was the production of gaskets, but

the fields of motorcycles, cars, and engines in general. It designs

it was subsequently expanded to include the variety of components

and produces spare parts for motorbikes, scooters, maxi-scooters,

that we are now able to manufacture. At the end of the 1980s, with

and off-road and automotive vehicles of any brand and type. The

the aim of becoming an innovative and advanced manufacturing

Athena Sportech division, finally, deals with the distribution in Italy of

centre of spare parts for motorcycles, we also started an aftermarket

brands with high innovation content and appeal to meet the needs

division. This launched the first components to carry our own brand,

of passionate consumers in the fields of sport, technology, and the

which now account for about 70% of our production.”

outdoors.”

With a turnover of 129 million Euros in 2019, the Athena Group now has 10 factories located in Italy and around the world (Spain,

The design and production phase of thermal units

the United States, China, India, and Brazil) and approximately 750

“One of our Athena Parts division’s core products,” says motorsport-

employees. “The Athena Industries division is among the world

technical product manager Luigi Vangelista, “are thermal units,

leaders in the production of components for industrial applications

consisting of an aluminium cylinder, a head, a piston, and a series

and supplies for OEMs. It mainly designs and manufactures

of gaskets: the core of a two-wheeler’s engine. The design and

applications and supplies for the automotive, heating, earthmoving

development phase can start within our R&D office following the

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FOCUS ON TECHNOLOGY

request of an OEM sending us a workpiece’s technical drawing or due to our own need to develop an original spare part or fine-tune a component. “We only outsource the production of cylinder moulds and the casting of raw cylinders: for the rest, our entire production cycle takes place within our factory. This includes machining, our galvanic process (performed through the deposit of Nikasil, an alloy of nickel and silicon used to coat cylinder liners and give them greater resistance to friction), grinding, and the assembly of the accessories that make up thermal kits. Between one phase and another, we perform numerous cleaning operations, crucial for the preparation of surfaces before the galvanic treatment and the subsequent grinding of cylinder liners. Quality controls also follow the various

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Athena’s warehouse, managed with the Kanban method.

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phases. The production flow ends in our R&D Test Room, on one of our 6 acceleration or inertial test benches: in addition to conventional tests, Athena subjects its products to the Finite Element Method (FEM) test, which enables to carry out a comprehensive series of performance simulations to assess factors such as stiffness, strength, and the distribution and displacement of stress points.” Finished parts are then stored in the warehouse and managed with the Kanban method. “Closely linked our production planning activities, this system enables us to reduce stocks, avoid the overabundance of material, reduce waste, and prevent our components from deteriorating or getting damaged due to a long storage period.” © ipcm

The waste water treatment plant designed and installed by Water Energy.

Nikasil: Athena’s flagship galvanic plating process Over the years, the Athena Parts division has specialised in the production of engine cylinders

made with exclusive special treatments. “10% of our cylinders are made of aluminium with a co-cast steel liner,” says Vangelista. “Their treatment starts with the delivery of the steel semi-finished parts to a foundry that inserts them into the moulds and performs the casting in the G AI Si 9 or 12 alloy. The blanks are then processed with a CNC machine and, after the galvanic treatment has been performed on the cylinder liners, they are completed through the last cycle phases. We are one of the few companies to have developed a process that enables aluminium cylinders with steel liners to be treated as if they were simple aluminium parts. We are also the only ones to have applied a galvanic treatment to steel parts (excluding endothermic cylinders).” On the other hand, 90% of Athena cylinders are made entirely of aluminium, with a galvanic plating process called Nikasil. “Athena is one of the world’s top three suppliers of engine cylinders obtained with the Nikasil plating technique. After casting, the cylinder in G AI Si 9 or 12 aluminium alloy is subjected to the galvanic treatment. A layer of nickel and silicon carbide is deposited on the inside of the liner with a thickness of 4 tenths of The recirculation pump contributes to maintaining water homogeneity.

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millimetre. This is then ground with a diamond tool to obtain perfect surface roughness and shape.

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An overview of the waste water treatment plant with the storage tank.

Thanks to this technology, we ensure our pistons to have adequate

plant structure no longer able to support our production. When we

wear resistance.”

decided to replace it, we turned to several suppliers, but our choice

The development of this system, representing the know-how of

fell on Water Energy because it offered a different solution than a

Athena, started about four years ago to find a solution to increase its

conventional batch system, which stops after each treatment cycle.

engines’ displacement without compromising their operation. “We

We liked the idea of a continuous flow plant, able to eliminate the risk

work with near-limit thicknesses,” says Vangelista. “The thickness of

of any loss of water quality and to cope with our target productivity.

the liner cannot be less than 3 mm. This is why we started searching

Another key factor in the selection phase was the supply service of

for a process enabling to treat steel as if it were aluminium and the

the chemicals to be used for water treatment: besides designing and

result has rewarded us.”

installing systems, Water Energy also provides chemical specialties, which it formulates in-house.”

Waste water treatment, a fundamental operation in a galvanic process

Preparing the cylinders’ surfaces for the galvanic treatment is

“The frequency of our galvanic treatments has increased to keep

materials featuring difficult-to-match mechanical properties, the

pace with the ever-growing production of cylinders,” states Francesco

parts must undergo a preparation phase with mordanting and

Fazio, the company’s time and methods manager. “The chemical-

pickling operations in order to optimise the adhesion of the Nikasil

physical water treatment plant we had been using for a long time had

plating layer on aluminium. The chemical-physical plant is essential

become a bottleneck. It was outdated and it had a technology and

to manage the water coming from the various cleaning stages

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a very delicate phase. “Dealing with two completely different

FOCUS ON TECHNOLOGY

undergone by the cylinders during such preparation phase.”

An Industry 4.0-oriented chemical-physical plant “The system we have installed at Athena’s factory is linked to the two rinsing tanks of this pre-treatment system,” indicates Water Energy owner Tommaso Ponara. “The storage tank supplied has been chosen based on its ability to guarantee consistent water quality in the preparation phase. The tank’s recirculation pump allows mixing the water continuously and thus making it as homogeneous as possible for subsequent treatment. “The plant consists of two tanks. At the entrance to the first one, acid coagulant is added to make any necessary corrections of the pH value, in order to both promote © ipcm

the formation and precipitation of flakes and comply with the legal parameters for

The storage tank.

the discharge of waste water. In addition to the acid coagulant, an adsorbent material is added through a hopper that contributes

to the formation of flakes. When the fluid reaches the second tank, flocculant is added.” “The plant ends with a sedimentation tank,” explains Ponara. “Sludge has a greater density than water and therefore it tends to precipitate to the bottom of the container. A few blades clean the walls of the sedimentation tank by conveying the removed sludge to its bottom. Purified from chlorides and heavy metals, water precipitates and it is collected in a storage tank. During the clean water precipitation phase, we check the compliance of its pH value with legal requirements and the absence of any residues of suspended material through a turbidimeter.” The continuous control of parameters and the technical measures implemented to ensure constant water quality ensure class A water is produced: in conditions of hydrogeological balance, this process’

Remote control of the system parameters.

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One of the main advantages of this Water Energy system is its ease of management.

anthropic impact is null or negligible, in addition to meeting all the

old system required continuous operator interventions, whereas this

parameters for the discharge of surface water. “These controls on

one operates independently. Thanks to its Industry 4.0 readiness, we

both the pH value and water turbidity are carried out continuously,”

can even work remotely from home. This has greatly facilitated the

says Fazio. “If the latter is not optimal, the system sends the liquid

management of the process and enabled the department manager

back to the beginning through a solenoid valve in order repeat the

to spend more time checking the characteristics of the galvanic baths,

waste water treatment cycle, while reporting the issue to the plant

which represent Athena’s know-how and, as such, must be managed

manager. We can perform these checks thanks to the connection of

accurately. Finally, the previous plant was not equipped with a filter

the Water Energy system with our company network, which allows its

press and sludge had to be stored and disposed of with high disposal

remote management. In case of problems, we can interface promptly

costs, due to the volume of water contained. The addition of a filter

with Water Energy’s staff, who modifies the parameters so that the

press has guaranteed considerable economic savings: we have

system is always able to meet the chemical-physical needs of our

calculated that the ROI will be achieved very quickly.”

processes. This is a truly 4.0-oriented solution.”

“Our new Water Energy plant will become the green core of the factory,” says Schenato. “We are assessing the idea to create a vertical garden

Athena’s green philosophy

and sorround it with plants that we can water with the liquid treated by

“The plant has been in operation since June,” states Vangelista.

the system itself – an original idea to reconcile innovation, technology,

“Besides the obvious environmental benefits, the quality of our waste

and sustainability, on which Athena has insisted with all its partners ever

water treatment phase has significantly improved. Moreover, our

since its establishment.”

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HIGHLIGHT OF THE MONTH

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KUBE: The Digitalisation of Coating Processes Becomes Reality Interview with Davide Terzoli Export Sales Director of Franchi&Kim’s Industrial Coatings division

s it possible to digitalise coating processes? The answer to this

and retail stores that market industrial tinting systems. In the pre-

question is KUBE, the new software package developed by the experts

COVID period, we also witnessed a significant increase in terms of

of Franchi&Kim, which enables users to search for the best coating

turnover and production of painting products and colouring pastes

system for their needs within a digital library of over 600 entries. Although

intended for some related sectors, such as aerosol coating, colour

it is going to be officially launched over the next year, Davide Terzoli,

palettes, and fibre cement sheets. With the acquisition of Damiani

the Export Sales Director of Franchi&Kim’s Industrial Coatings division,

Industrial Paints, our ownership wanted to further strengthen our

presents it to us in this exclusive interview for ipcm .

offer without however overlapping the two brands, due to both

geographical reasons and motives relating to their market positioning Can you outline the history of Franchi&Kim, especially following

and product range. The establishment of a new company that did not

the recent creation of a new Group?

break with our past was a natural consequence. The aim was creating

In the last few years, Franchi&Kim has increasingly consolidated

a solid, totally Italian Group that is always ready to seize the new

its position in the industrial sector, with both corporate customers

opportunities that may arise in the local and foreign markets.

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HIGHLIGHT OF THE MONTH

In which markets is Franchi&Kim the most

Tell us about the KUBE coating software

active, in terms of both geographical areas

package, which will be presented next

and industrial sectors?

year.

In terms of geography, Franchi&Kim is

KUBE is the result of a long period of joint

present throughout Italy thanks also and

studies between our IT & ERP department,

above all to the countless resellers located all

Marketing department, and R&D laboratory.

over the country. We are also permanently

This software package allows searching for

active in many European countries, including

the most appropriate product within a digital

for example France, Spain, Poland, Romania,

library of over 600 painting and coating

Portugal, Great Britain, and Russia, as well as

systems. It is a know-how portfolio at the

non-European areas such as North Africa, the

service of our customers.

Arab Emirates, and some areas of Asia.

The search is structured on several levels,

Our brand is clearly known for the reliability

from the sector up to the individual

and quality of its tinting systems for the

components of the products to be treated.

industry and industrial bodywork sectors

There are also numerous tools and additional

and for any other field related to colours.

functions available, but we would prefer

In terms of end users, we serve all sectors of the generic and manufacturing industry, especially ACE (Agriculture, Construction and

Davide Terzoli, the Export Sales Director of Franchi&Kim’s Industrial Coatings division.

not to reveal anything else. We recommend scanning the QR Code in this article in order to view further details and book a free demo. KUBE will be presented in the first part of

Earthmoving machinery and equipment), machine tools, robotics and industrial

increasingly often sold and used. Their

2021. The period has not been defined yet, of

automation, handling and lifting machinery,

performance levels have nothing to envy to

course, for the reasons we all know.

and light and heavy metalwork fabrication.

their solvent-based counterparts and they guarantee the exceptional advantage of

What needs does this software meet and

On the pages of ipcm®, we have presented

significantly reducing the pollutants released

how do you think it will be received by the

numerous articles about your monolayer

into the atmosphere and in the workplace.

market?

DTM systems. What are the coating

That is why this transition is happening also

KUBE enables users to identify the right

products you have developed that are

thanks to greater regulatory and ethical

coating system for their needs by searching

enjoying the most success?

awareness on the subject by governments and

based on customised parameters. Systems

With time, we have decided to give increasing

companies.

can be selected according to the plant, substrate, surface, workpiece type, metal

visibility to this type of products, which are becoming more and more popular in

What does it mean to “digitalise coating”

thickness, preparation operation, corrosion

the industrial sector. They enable users to

from the point of view of a paint

category and durability according to ISO

save time in the application phase without

manufacturer? Do you also have ambitious

12944, maintenance and repainting process

sacrificing essential factors such as corrosion

projects in this field?

type, expected performance, and other

resistance, thanks to the presence of special

In order to answer this question, we should

parameters. All of this cannot but ensure that

passivating inhibitors in the formulation,

take into consideration both our traditional

an ad hoc, tailor-made solution is found.

applicability on different substrates, excellent

and standard ranges. Currently, through

We believe that KUBE will be received by the

spreading rate, verticality, and high colour

our numerous tinting and management

market in a very positive way. It meets the

retention, just to name a few. Among other

software programs, we can guarantee the

needs of all target users and it can help all

reasons, that is why they are enjoying great

automation of the formulation and colouring

of them to speed up their coating selection

success without overlapping with high-

phases. A piece of the puzzle was missing: the

process, from retailers, including their whole

performance two-component cycles.

automated identification of the most suitable

internal and external sales networks, to

Moreover, thanks to over twenty years of

coating cycle for each customer need. And this

final users, including all positions (coating

proven technology, one and two-component

is precisely what we will offer to the market

managers, quality managers, purchasing

water-based industrial coatings are now

with KUBE, in the coming months.

managers, etc.). It also preempts the selection

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of systems and the technical advice services that our company

including ours. A slight decline was easily predictable. After the first

provides. Therefore, our workflow in partnership with our customers

lockdown, the spring and summer months had made it possible to

does not change: it is just quicker and sees all players speaking the

regain many percentage points and align with past figures, albeit

same language, so that any customisation need can be immediately

with some predictable downturns. The months of November and

grasped.

December, on the other hand, do not seem to confirm this trend. It is all pretty unpredictable. Claiming the opposite would simply be

What market situation do you expect to find when this health

unrealistic.

emergency and its related production discontinuities end? There are no doubts that the pandemic has more or less decisively

What are the development projects of the Franchi&Kim and

plagued any sector, including ours and those of our customers.

Damiani brands?

However, I am quite optimistic: the Italian industrial sector has been

Now that both brands are clearly positioned, all that remains is to

able to face and overcome the difficult moments of the last decades

proceed on the path of digitalising our offer. As KUBE demonstrates,

in an excellent way, including the financial crisis of 2008.

we want to provide our customers with digital tools that are

We do not have a crystal ball to know for how long the emergency will

increasingly aimed at meeting their needs quickly, easily, and in an

continue or what will be left afterwards, but I reiterate my confidence

accessible way. Without falling into self-referentiality, we would like to

and positivity. Usually, the best energies are gathered after crises, and

align our “audience” with the digital initiatives that have already been

our company can certainly exploit its unique characteristics in terms

present in the company for years, with the objective not so much to

of technical and quality services to stand out. Italians have many flaws,

convert but to make our technical material usable and educational.

but they are rather resilient in times of difficulty.

As regards our products, moreover, we are preparing many novelties for the coming year. We will target new market niches and further

What are the real conditions of the market, at the moment?

improve some of our high performance (class C5) products that are

As was inevitable, the current situation has slowed down all markets,

already giving us great satisfaction.

Scan the code or visit http://lp.kube-software.it/ to discover KUBE

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Zürn Harvesting manufactures headers for harvesters of all brands.

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Italian Technology for the Semi-Automatic Powder Coating Installation with a High Throughput installed at Zürn Harvesting Alessia Venturi ipcm

Zürn Harvesting, a German manufacturer in the field of agricultural machinery, decided to internalize the coating of its production to get full control over the coating quality, to reduce logistics costs and the environmental impact of its activity and to increase the throughput of its production process. Today, thanks to the installation in 2019 of a semi-automatic powder coating line designed and manufactured by Eurotherm, an Italian company, Zürn has reduced the lead time of the coating phase from 15 to only 2 days.

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The overhead conveyor system.

anufacturers in the field of agricultural machinery and

and for a good surface preparation to ensure optimal adhesion and

attachments have two options for the finishing of their

durability of the coating), including top performance coating products

products: one is wet painting, which today is always more

could fail.

often a direct-to-metal mono-layer paint; the other is powder coating,

The choice of Zürn Harvesting, a German manufacturer in the field

which can be a single coat or include a cataphoresis primer. Both

of agricultural machinery with 135 years of activity behind, has been

options are valid, what is going either to enhance or to impel the

to internalize the coating of its production to get full control over the

final quality of the finish is the system used to apply this finish. With

coating quality, to reduce logistics costs and the environmental impact

the lack of a good coating installation, especially designed for the

of its activity, and last but not least to increase the throughput of its

requirements of this field (i.e. pieces with a high mass and large

production process. Actually, Zürn used to have different job coaters,

dimensions that ask for a precise regulation of the coating parameters

some of them located more than a hundred of km away from its

Buﬀer with semi-finished products.

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The blasting chamber.

premises: this meant a processing time of its products up to 15 days.

Johann Zürn started the production of farm trailers, harrows and

Today, thanks to the installation in 2019 of a semi-automatic powder

other agricultural equipment. After starting the dealership of

coating line designed and manufactured by Eurotherm in Turin, Italy,

agricultural machinery produced by the German manufacturer

Zürn has reduced the lead time of the coating phase to two days.

Eicher, first, and John Deere-Lanz after, in 1965 Zürn moved to the current headquarter in Westernhausen. It was during the Eighties

135 years of passion for agricultural machinery

that Zürn started the production of agricultural machines with its

In 1885, Johann Zürn founded the Zürn company as a blacksmith shop

own brand, in particular of rapeseed harvesting equipment. Zürn

in Westernhausen, Germany. At the beginning of the last century,

developed soon into a harvesting specialist and made combines even

The filtration skid.

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The cleaning booth.

more efficient. For over 30 years, Zürn has been developing and producing attachments for combine and forage harvesters for all manufacturers. Its wide portfolio of products ranges from header attachments for rape and sunflower harvesting to the direct cutting ProfiCut header - a universal header for the harvesting of whole crops with powerful forage harvesters – and the high-performance PremiumFlow belt header for combines. Header transporters complete Zürn’s portfolio. “At present Zürn Harvesting GmbH sells its machinery worldwide with a special focus on Europe and North America” Florian Löckle, marketing and product manager at Zürn says. “We supply all the major brands in the agricultural sector, like Claas, CNH, John Deere, and especially with the latter we are working very close”. Today, Zürn runs two factories, the manufactory in Hohebuch, specialised in the production of plot combines for field research, and a production plant in Merchingen, where last year Zürn Harvesting created a new surface treatment centre with a modern powder-coating facility supplied by Eurotherm. Zürn’s is now one of the largest powder coating installation in the region. “Our components can be up to 14 metres long, so it was difficult to find somebody who could paint them. In addition, we had many logistics problems,” Florian Löckle explains. “These problems got bigger as we extended our portfolio in the last years, so we decided

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Cleaning booth and curing oven.

The manual powder application.

that it was time to install our own powder coating system. Today I can

The powder coating system comprises:

assert that we are very satisfied of the investment because Eurotherm

• Overhead conveyor with a trolley and a lifting station for loading and

coating system ensures the best possible finishing quality of our

unloading the parts coming from the welding shop;

machinery. In addition, as the system has a bigger coating capacity

• Central buffer for the sorting of incoming and outgoing components,

than our requirements we can offer the coating service to third parties.

which can house up to 20 racks. The large storage areas offer enough

Besides achieving our goals in terms of quality and savings, with this

space for loading and unloading trucks directly in the paintshop;

investment we were able to open a new business for Zürn”.

• Blasting chamber with automatic filtration and complete recovery of the blasting media for parts up to 10 tons;

A production with a complete vertical integration

• One-chamber cleaning tunnel with a suspended, automatic rollover

Thanks to its many years of production and service experience, Zürn

washing system equipped with waste water recovery, osmosis and

can supply its customers with high-performing, reliable machines and

filtration skids;

attachments, which are designed for use in all conditions.

• Powder coating booth with two manual application stations and

At its production site in Merchingen, about 85 employees are

latest generation Wagner equipment;

currently working for the engineering, finishing, assembly, logistics,

• Wet painting booth used as a back-up;

administration, marketing and sale of its high value-added agricultural

• Drying/curing oven between the cleaning and coating booth. Curing

machinery.

time and temperatures can be adapted to the single component’s

Zürn’s production process is vertically integrated and goes from steel

requirements.

construction with automated welding in all common procedures (MAG/

• Air handling unit for air compensation inside the paintshop.

WIG) to powder coating on the semi-automatic line recently installed

Washing chamber, oven and painting booths has the following internal

by Eurotherm, to assembly and logistics.

dimensions: 15 length x 5 width x 4 m height. “We wanted a machine that could wash automatically our large pieces and Eurotherm was

Surface Centre in Merchingen: Zürn coats your parts

the only engineering company in Europe to be able to supply such

Zürn powder coating plant pre-treats, dries, powder coats, and cures

a large installation,” Martin Filz, director of Zürn surface centre says.

metal parts in steel with a length up to 14 metres and weighing up to

“Eurotherm fully met our requirements and we worked really well

4 tons.

together”.

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The pieces leaving curing oven.

Improved corrosion resistance with an optimized pre-treatment cycle

Conclusions

One of the coating stages that Zürn mostly focused on was the pre-

technology they have for the pre-treatment stage of such large pieces”

treatment.

Martin Filz ends. “In addition, the system is very accessible and easy

“Together with our supplier Haug Chemie and Eurotherm we studied

to maintain than other systems we saw before closing the deal with

a pre-treatment cycle able to improve the corrosion resistance of

Eurotherm. The main thing is that we really worked well together, they

our products,” Martin Filz explains. “The system performs a first

have an excellent customer service and, most of all, we have saved

iron-phosphating and degreasing, then two rinses with tap water,

time, costs, and improved our quality.”

“One the key strength of Eurotherm’s coating system is the very good

one rinse with deionized water and a final no-rinse passivation. The combination of iron phosphating and passivation ensures both optimal adhesion and improved corrosion resistance of the powder coating film. In addition, we can perform two-coat systems, if a higher

corrosion resistance is required. We can offer a powder primer + topcoat in any RAL colours as well as different gloss levels (matt, silky, silk glossy, glossy), special effects and textures”. “As for the powders, we apply polyesters with a 70 microns thickness. The film as high UV-, impact and scratch resistance,” Florian Löckle, marketing and product manager at Zürn, explains. “We have many different suppliers of powder coatings but as we also offer the coating service to third parties, we are often asked to use powder coatings certified by the end customer. The number of colours is increasing together with the number of parts we coat: at present we have 40 different colours on stock, while the standard colours of our production are only three.”

Martin Filz, director of Zürn surface centre.

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The Importance of Shot Blasting in the Treatment of Machinery Components Subjected to High Stress: The Choice of Carantini Marta Fumagalli ipcm

Carantini Sabbiature e Verniciature is focussing on the immediate future. It has invested in a last generation shot blasting machine to cope with the growing request for finishing large-sized products intended, also for the separate urban waste collection sector.

n Italy, the waste collection sector has experienced significant

included in the eighth edition of the Green Book 2020, the report on the

growth following the legislative decree issued by Minister Ronchi in

national municipal waste sector issued by the Utilitatis Foundation and

1998, which gave rise to a series of rules that regulated the waste

presented in Rome in October, “the production of urban and related

management and transportation operations and defined guidelines for

waste in Italy amounts to about 30 million tonnes per year, whereas

the separate collection of municipal solid waste. According to the data

special waste amounts to 130 million tonnes.

One of the dump bodies shot blasted and coated by Carantini Srl. © ipcm

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Italy has an urban waste recycling rate between 45.2% and 50.8%, in any case above the European average, equal to 47%. Landfilling accounts for 22%. The sector has a total turnover of over 10 billion Euros, largely derived from waste fees, and over 95,000 employees. Despite the critical issues arisen during the lockdown period, the waste management service continued to contribute to urban cleanliness and public health. Together with other essential services of high economic importance, this can be one of the sectors capable of positively impacting the relaunch of the national economy.”1 “In the last five years, the demand for the coating of dump bodies and frames for waste collection vehicles has grown exponentially,” states Pierpaolo Piccinini, Administrative Manager of Carantini S.r.l. Sabbiature e Verniciature

The Tunnelblast 2530/16 tunnel shot blasting plant installed by OMSG.

(Valdaro, Mantua, Italy), a company that has been operating in the surface treatment field for over thirty years. Its contracting coating service is specialised in medium and heavy-weight metal structures: it sandblasts and coats aerial platforms, crane arms, concrete mixing systems, frames, heads, and trailers for agricultural machinery and it finishes trash compactors. “This sector has a huge potential,” explains Riccardo Carantini, the company’s owner with his father.. “The number of separate collection lorries travelling on our roads is growing exponentially and their producers’ requests are becoming increasingly stringent in terms both of coating quality, as the finishes must withstand the harsh conditions to which these vehicles are subjected, and of quantity of products to be treated. Currently, the ‘ecological’ vehicle sector accounts an increasingly large slice of our turnover. In fact, for © OMSG

years we have consolidated a close Some complex-shaped parts shot blasted by Carantini. 1

h ps://www.confservizi.emr.it/2020/10/settore-rifiu -in-italia-fa urato-da-10-miliardi-e-oltre-95-mila-occupa / (10/11/2020)

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The new cluster shot blasting machine type Capri 20/35 H22.

A component entering the new shot blasting system.

professional relationship with the Novarini S.r.l. company located in

high surface roughness, thus promoting paint adhesion.

Vigasio (Verona), a manufacturer of this type of equipment, which is

“We are currently equipped with two shot blasters supplied by

proving to be impressive and profitable for both companies”.

OMSG-Officine Meccaniche San Giorgio (Villa Cortese, Milan, Italy), a firm specialising in the design, construction, and installation of shot

The importance of the pre-treatment process

blasting, sandblasting and shot peening systems,” indicates Riccardo

These structures are subjected to high chemical and mechanical

Carantini. “We installed a tunnel shot blasting machine in 2003 and a

stresses and, therefore, their pre-treatment process is essential to

double hoist one more recently, in order to meet the new needs of

guarantee an excellent aesthetic quality and mechanical resistance

the market. This latter system replaced another OMSG shot blasting

degree. Having to guarantee high quality and performance standards,

plant that, although fully functional, was undersized compared with

the company carries out a pre-treatment operation on all workpieces

the growing number of small and medium-sized parts we were asked

by shot blasting and subsequent cleaning. These eliminate any

to treat.”

calamine and impurities and make sure that the substrates reach a

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A detail of the sandblasting chamber.

Technical characteristics of the shot blasting machines

“Indeed,” adds Riccardo Carantini, “the

The Tunnelblast 2530/16 tunnel shot blasting

heavy metal parts. Following the increase in

system has a chamber section of 2500 mm in

more and more diversified requests from the

width and 3000 mm in height and it is equipped

market, we converted it in such a way that it

with 16 single disc, direct drive 7.5 kW-turbines.

could treat any type of part. However, as it

“Since Carantini also treats heavy, large-sized

requires a high amount of power, it was not

components, together with their staff we

convenient to employ it for smaller workpieces.

developed a handling system that exploits the

Hence the need to install a new shot blasting

department’s overhead crane. It was a challenge

machine.”

because, back then, this was not common

“The new cluster shot blasting machine,”

practice,” states OMSG CEO Enzo Dell’Orto.

says Dell’Orto, “is a type Capri 20/35 H22. Its

Ɣ Conveyors Ɣ Conveyor chains Ɣ Special components Ɣ Automations

Tunnelblast system was initially used to process

Se.Po.

di Pozzi Sergio

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

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sandblasting chamber has a diameter of 2000 mm and a height of 3500 mm and it features two hoists lifting up to 2000 kg each. The components to be treated are hung on a frame that automatically enters the shot blasting machine; at the same time, the operator can unload the already sandblasted workpieces and prepare the new ones to be introduced into the machine, thus reducing downtime. This system is equipped with 5 single disc, direct drive 7.5 kW-turbines type SG350 patented by OMSG. It is also Industry 4.0-ready.”

The coating process After shot blasting, it is necessary to clean the components from the impurities deposited on them in the manual sandblasting booths. This is crucial to prepare them for the subsequent coating phase. “In 90% of our coating treatments, we use thermosetting

powders and we adopt a mixed system following sandblasting: this includes an epoxy

Powder finishing medium-sized parts.

primer application stage and a finishing one by powder coating,” explains Riccardo Carantini. The company has 3 powder application booths, 2 manual booths devoted exclusively to liquid coating, and 2 static ovens. For the application of powders, it uses Gema manual units in both their conventional and dense phase versions. “As the workpieces we treat do not have standard sizes, a manual operation helps us make sure we cover their entire surfaces.”

Conclusions “Once again, an OMSG machine proved to be a winning choice. This long-standing collaboration enables us offer an excellent shot blasting service in line with the highest quality and market standards,” states Riccardo Carantini. “Carantini’s plant equipment is now ready to cope with any future increase in requests from our main customers, operating also in the fast © Novarini

developing sectors of ecology and urban waste collection.”

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Novarini S.r.l., a company specializing in ecological vehicles, is among the consolidated customers of Carantini.

eosmarketing.it

SUCCESS STORIES

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GEINSA Supplies Cochet with a Surface Treatment Line for Powder Coating GEINSA, a Spanish company that designs and builds industrial surface treatment plants, has provided Cochet, a manufacturer of agricultural equipment and greenery maintenance products, with one of its systems.

ochet, a manufacturer of agricultural equipment and

station, a system for the production of osmosis and demineralised

greenery maintenance products, has decided to rely on

water, a drying oven to eliminate any moisture residue, and a curing

GEINSA for the installation of a surface treatment line. The

oven. It is completed by an independently programmable electrical panel

new plant consists of a four-stage treatment tunnel, a nebulisation

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and a touch screen.

SUCCESS STORIES

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The parts are moved through a Power&Free conveyor, which takes them into the treatment tunnel. This is equipped with a droplet separator featuring an automatic cleaning unit and a 99% efficiency degree. At the exit of the tunnel, a station for the nebulisation of recirculated osmosis water further improves the cleaning process. The last nozzle bar is fed with pure osmosis water to guarantee the highest finishing quality. The dosing system is automatic, thanks to its PLC-controlled dosing pumps. After treatment, the workpieces enter the drying oven and they are finally ready for the subsequent application of a powder coating. Motorised doors have been installed at the entrance and exit of the ovens to prevent any heat loss. For the same reason, active hoods were installed for air suction during the automatic opening of the doors, which is controlled by the PLC. Finally, the plant includes a remote assistance system for reliable communications in real time. For further information: www.geinsa.com

Top left - The curing oven and the loading and unloading areas. Bottom left - The tunnel (left) and a workpiece entering the drying oven. Right - The inside of the treatment tunnel.

ÂŠ GEINSA

ÂŠ ipcm

The 4x4 front suspension intended for vehicles for military and civil use, made by Streparava.

FOCUS ON TECHNOLOGY

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Streparava: Sustainability and Application Ecotechnology for the Low-Environmental Impact Coating of 4x4 Axles Monica Fumagalli ipcm

ÂŽ

The role of Tier 1 suppliers is becoming increasingly strategic. It is no longer sufficient for them to supply components with high performance levels and in compliance with all the requirements, but it is necessary to establish a relationship of mutual trust with OEMs based on shared values. Streparava Spa, specialising in the construction of high-precision powertrains and chassis, chooses technologies and coating products with a low environmental impact in order to confirm its position as an international supplier for light and heavy-duty vehicle manufacturers.

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he producers of components for light and heavy-duty vehicles

ethical and environmental code of conduct. We have adopted this

belong to a segment of the manufacturing industry that is

approach even when it came to choosing the right partners for a new

assuming an increasingly decisive role in the relationships with

coating system intended for a niche product of ours. Two companies

OEMs. “In the last few years, we have been witnessing the growing

emerged from this selection process: Verind, belonging to the Dürr

importance of Tier 1 suppliers’ role in the definition and development

Group, which developed and installed the paint feeding and dosing

of increasingly broad, complex, and multidisciplinary vehicle systems,”

system by implementing a low-environmental impact application

says Stefano Signorelli, the Process Engineer of Streparava Spa. This

ecotechnology, and LEM Impianti (Carate Brianza, Italy), specialising in

Italian giant has manufactured high-precision powertrain and chassis

the design and construction of coating systems for over twenty years.

components for the main motorcycle, car, bus, and commercial and the same level as OEMs, in order to be able to manage the complexity

Streparava: complex components from design to packaging

and variability of this ever-changing world, with solutions in line with

Streparava Spa is a Group of six companies located all over the world:

the main technological trends and, more generally, with the new eco-

besides the headquarters in Adro (Brescia, Italy), it also includes

sustainable business models of mobility services.”

companies Borroni Powertrain Srl (Saronno, Varese, Italy) and

Tier 1 suppliers must thus be able to adapt not only the components

SPT Srl (Valsamoggia, Bologna, Italy) and three international plants in

they produce, but also their entire production flows to the requests

Valladolid (Spain), Bommasandra (Bangalore, India), and Sete Lagoas

of increasingly demanding customers. Any economics essay will

(Minas Gerais, Brazil). “Differentiation,” says Signorelli, “has always

emphasise that the supply chain, understood as the set of individuals,

been the leitmotiv of our corporate strategy since our foundation in

organisations, resources, and activities that contribute to the creation

1951 by a group of partners including Angelo Luigi Streparava, who

of a product, is essential to guarantee good results and customer

soon became the company’s sole owner. He had the foresight to

satisfaction. The technologies used, although often less considered,

propose his services in different sectors, from machining to machine

are equally important for this purpose. They are one of the key

tool manufacturing, up to steel press forging, in order to meet the

elements of a distribution chain and, if perfectly integrated with a

most diverse requests in the hectic years of post-war reconstruction.”

production cycle, they can be strategic in contributing to the creation

Nowadays, the Brescia-based company focusses on two main sectors:

of value for an entire production chain.

powertrain components, such as rocker arms for heavy vehicles,

“Our management carefully chooses the providers of our plants and

crankshafts, camshafts, connecting rods, engine brake systems,

equipment,” states Signorelli, “with a focus on whether they share our

and transmission components, and suspension systems for cars,

industrial vehicle makers since 1951. “That is why we must operate at

The coating plant installed in 2018.

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commercial vehicles, buses, off-road vehicles and trucks. “Thanks to the experience and competence acquired in the technologies applied to all the materials used in our sector, such as stamped plates, aluminium and steel forgings and aluminium and cast iron castings, we are able to supply both individual components and complex assembled units by acting as a system supplier, while always guaranteeing the control of any critical characteristics and even offering the chance to carry out functional tests. We design, develop, test, and produce independent front suspension for light commercial vehicles with a just-in-sequence approach. We also carry out the final assembly of complete suspensions on dedicated lines, with automatic checks and the recording of all safety-related data. To date, we have delivered over 3,000,000 workpieces, while also managing complex part lists, sometimes with over 200 components, and dozens of suppliers located all © ipcm

over the world. Such significant figures confirm our recognised experience in the field.”

The one-rail Stop&Go conveyor takes the components into the single cleaning chamber.

Ad hoc coating of 4x4 suspensions Signorelli explains: “Three years ago, one of our well-established customers modified its 4x4 front suspensions intended for military vehicles. It then decided to extend their application to civilian vehicles, which are now the main target market of this complex component. The plant where we coated the previous suspensions was obsolete: the product modification implemented by our customer, therefore, resulted in the updating of our assembly and coating lines devoted to this specific product. Back then, we had already been converting our coating lines to water-based product for some time. That is why our choice fell on a water-based, two-component polyurethane product distributed by Inver, a brand of The SherwinWilliams Company, which we already knew and which was also approved by the customer because it meets its standard anti-corrosion specifications, namely a salt spray resistance value of 200 hours and humidostatic chamber tests results of 120 hours.” The coating plant thus installed in 2018 was © ipcm

The tanks of the pre-treatment plant, with minimised dimensions.

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the result of a partnership between three wellestablished companies in the field: LEM Impianti, Verind, and Inver.

FOCUS ON TECHNOLOGY

A system made to measure for coaters

installed, and by the presence of different

of adequate masking and proper surface

materials. These include rubber, untreated

preparation with water-based products is

The line was designed to handle already-

cast iron for brake discs, which must not

essential to obtain optimal coating results.”

assembled large workpieces up to 500 kg in

undergo any superficial alteration, forged

“A particular measure requested by Streparava

weight. “When outlining this project,” explains

steel, and plastic. We solved the first critical

with a view to energy saving,” indicates Sala,

LEM Impianti owner Luigi Sala, “we strived

issue by adopting a blow-off system aimed at

“was the feeding of the line through a gas

for a functional layout, due to the limited

the most critical areas, where water stagnates;

boiler, rather than a conventional burner. The

space available, which, at the same time,

as for the second problem, we chose a non-

boiler heats water, which heat exchangers

met all the technical specifications. The plant

aggressive cleaning solution. The combination

then convert into hot air for the blow-off,

consists of a 3-stage automatic pre-treatment tunnel (degreasing and two rinses) and a single cleaning chamber equipped with tilting channels for emptying the tanks. This allowed installing motors with lower power and tanks with reduced dimensions, ideal for such a small space. The pre-treatment cycle, lasting 7 minutes, includes a final nanotechnology nebulisation phase; after each cleaning phase, the parts are subjected to a blowoff phase through hot air cones located at the height of the most critical areas of the suspensions.” “The surface treatment of such an alreadyassembled product,” notes Signorelli, “is complicated by its particular structure, on which the differential unit and several sensors (masked before cleaning) are already

The inside of the cleaning chamber and its rinsing nozzles.

The blow-oﬀ cones deliver hot air fed by the central boiler.

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The inside of the coating booth.

post-cleaning drying, and post-coating drying

Two drying stages at room temperature

yet widespread in the automotive market,

phases.”

and a final drying one in the oven at 75 °C

the system is currently oversized: for this

After cleaning and its related drying step,

conclude the coating cycle. After cooling, the

reason, we intend to soon integrate a second

a one-rail step-by-step conveyor supplied

workpieces are unloaded through a lowerator

colour in addition to the grey tint approved

by Se.Po. (Olginate, Lecco, Italy) takes the

and they are ready to be packaged and sent

by our customer, in order to be able to also

workpieces to the pressurised dry coating

to the customers. “The capacity of the plant,”

coat other products. The flexibility of our line

booth. “The booth,” says Sala, “was tailored

states Signorelli, “is 20 axles per day in one

enables us to do so.”

the needs of the operator assigned to manual

shift. As this is a niche product that is not

coating. We designed the whole line on one level because Streparava’s management preferred to avoid the masonry work necessary for lowering the cleaning tanks. One of the difficulties encountered by the coater was related to the application of paint on the upper side of the workpieces with the electrostatic system. Given the weight of the components, it would have been difficult to build a lowerator. Therefore, we suggested moving the operator, instead of the parts: the booth was thus equipped with a movable platform controlled directly by the employee, with a maximum lifting height of 50 cm. The booth floor features a system with cloth filters for the initial filtration stage, Andreae filters for the next one, and fibreglass boxes for the final one, positioned on a frame that follows © ipcm

the movement of the platform.” Zone of the insulated paint box, made of dielectric material supplied by Verind.

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The fibre optic gear flow metres allow controlling process parameters such as flow rate, consumption, and catalysis ratio, as well as alerts.

The new ecotechnology of the coating management unit

technologies of the automotive industry,”

an automatic grounding device;

explains Verind Industry Sales Manager

• EcoDose 2K dosing system with fibre optic

Verind, one of Streparava’s well-established

Alessandro Soba, “and implement it into

gear flow metres that allow controlling process

suppliers, developed the new application

Streparava’s system. The plant is composed as

parameters such as flow rate, consumption,

system by meeting its requests in terms of

follows:

and catalysis ratio, as well as alerts;

low environmental impact. “Verind, a company

• pumping units with a paint recirculation

• volume control for the cleaning and colour

of the international Dürr Group, chose to

system;

change cycles and product recovery in a

borrow one of the most innovative application

• insulation system with safety interlocks and

specific tank, which avoids booth pollution; • high-transfer efficiency electrostatic technology for the reduction of overspray and VOC emissions. “The main features of the system are flexibility, but also reliability in the one-coat application of the two-component coating. These guarantee high stability and finishing quality because, thanks to the electrostatic system, application takes place uniformly and on all surface areas, even the non-exposed ones. Moreover, the operator can intervene in complete safety and at any time for colour change and cleaning operations.” “The EcoDose 2K device offers the same level of reliability,” notes Marco Assorgia, Industry Area Manager at Verind. “It guarantees high dosing and mixing precision, thus

ensuring a considerable saving in terms of consumed coating product. In other words,

EcoDose2k: the PLC control panel for managing the complete dosing process.

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this flexible and modular system combines a manual

characterised by great professionalism and flexibility, which enabled them to

application operation through an electrostatic system with

adapt their system to our needs. Inver staff, in the person of Gianmaria Guidi, has

an automatic dosing and mixing device for 2K paints. The

actively participated to define the painting process parameters from the very early

coating management unit is equipped with stainless steel

project phases, confirming his professionalism and the profound know-how that

tanks for the storage of paint products, Dürr pumps, and

has characterised INVER Spa part of the Sherwin-Williams Company for years in

a recirculation system. The EcoDose 2K machine is an

the development of coatings products with optimal performance. This is exactly

advanced electronic system for the stoichiometric dosage

what we mean by value chain.”

and mixing of 2K water-based paint products (see the Box).”

Conclusions “We opted for a coating solution that reflected two elements at the heart of our company policy: an ergonomic and safe working environment for our operators and the selection of machines minimising the environmental impact of our processes. Most of the OEMs we work with share our ethical approach; in turn, we require our suppliers of raw materials, products, and plants to do the same. In addition to these fundamental characteristics, Verind’s technical staff has provided us with help and assistance from the early design stages, as their innovative 2K paint dosing technology was completely new to us. Their collaboration with our coating department enabled our © ipcm

engineers to understand its functioning and the plant’s start-up phase to run smoothly. LEM Impianti’s team is

From left to right: Francesco Stucchi from ipcm®, Alessandro Soba from Verind, Stefano Signorelli from Streparava and Marco Assorgia from Verind.

Main technical characteristics of the EcoDose 2K dosing system: • function control through an industrial PLC and an operator panel with colour graphics;

consumption, and total consumption values;

• catalysis ratio from 1:1 to 30:1;

• alarm page with extensive diagnostics and VOC display;

• possibility of storing over 1024 programs;

• data transmission to the supervision system for the

• dosage tolerance less than 1%; • Direct Injection Technology (DIT) with two channels (A and B); • independent cleaning circuits for component A and component B;

analysis and printing of real-time and previous data; • advanced management of the pot life and pot time parameters; • closed-loop flow control; • local and remote function control;

• consumption measurement of coating and cleaning products;

• predictive maintenance on all application components;

• modular and expandable automatic colour change

• interface for remote assistance.

system for paints and catalysts;

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• graphics pages displaying data on real flow, program

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INDUSTRIAL COATINGS FOR AGRICULTURE AND CONSTRUCTION EQUIPMENT The color of your equipment is as important to your brand as your logo. When your customers have bought your products for generations, the color and ﬁnish need to last. That’s why SherwinWilliams designs coatings that protect the color and ﬁnish of your brand. Your customers and your equipment work hard, our coatings do too.

Vectrogard and powder polyester For small and complex components

Vectrogard, Duraspar or Valde ECP Multiple solutions for difﬁcult-to-coat cabs Duraspar 430 or Powder High Heat For temperature sensitive components

Polane® or Polane Inverflex Inverﬂex or For non-metallic substrates such as plastic

Inverpur, Duraspar or Acrilinver DTM For ground-engaging parts

Duraspar For engines with complex geometry and rapid handling

Idroxinver and Inverpur For surfaces with extreme durability requirements

Valde ECP,or Powder polyester extra Valde ECP OneCure R-Cure 100 and 800 High Solid For wheel rims

Idroxinver Polane® D250, and Inverpur KemNiso For chassis components

For sheet metal components

or Inverpur

For chassis components

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Top Quality Pretreatment for Trailer Chassis With an innovative pretreatment system from Chemetall, the Krone Commercial Vehicle Group is setting new standards in corrosion protection and value retention.

erlte, a tranquil town in the Emsland region in Lower Saxony,

risk of corrosion. To ensure these conditions do not harm the trailer

Germany, is well known in the transportation sector: Here

chassis even after years of use, precision in manufacturing and high-

the headquarters of Fahrzeugwerk Bernard Krone GmbH &

quality corrosion protection play an important role. Forwarders and

Co. KG are located. Being the largest factory of the Krone Commercial

haulage firms benefit in the long term, as Krone trailers retain their

Vehicle Group the Fahrzeugwerk produces complete trailers or

value thanks to their market-leading durability.

trailer chassis for curtainsider and closed box semitrailers, container

To protect the investment of haulage firms, Krone and Chemetall

chassis, carrier systems, trailers and bodies. This makes Werlte one

have joined forces to develop a pretreatment process that optimally

of Europe’s largest production sites in the trailer industry. And one of

meets the tough quality requirements. The results of this co-operation

the most advanced as well, to ensure customers have the stability and

are substrates with long-lasting protection against corrosion which

robustness in their trailers Krone is known for.

have an extremely robust surface quality that is perfectly suited for

To meet the challenges of today’s transportation and roll out durable,

all subsequent coating applications. With Chemetall, Krone placed its

robust chassis on the road, Krone incorporates pretreatment

trust in a strong partner for the customized surface pretreatment of

technologies from the global Surface Treatment business unit of

trailer chassis: Working as a team the two companies developed a

BASF’s Coatings division, which operates under the Chemetall brand.

tailor-made and highly innovative process.

High requirements, ideal protection

Tailor-made process for Krone

Trailer chassis must be tough, as they have to withstand a great deal:

“We aim for continuously optimized processes in order to provide

constant loading and unloading, heavy loads, long distances in all kinds

our customers with cutting-edge solutions and sustainable quality for

of wind and weather conditions, damage from stone chippings and the

trailer chassis that retain their value,” commented Volker Perk, Head © Krone

The headquarters of Fahrzeugwerk Bernard Krone GmbH & Co. KG in Werlte (Germany).

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The pretratment process of Krone trailer chassis.

of Industrial Engineering at Krone and responsible for implementing

technology for the solution composition: “It all starts with the analysis

the Chemetall pretreatment process. “Our goal is to offer chassis

of the substrate to be treated and the conditions in the plant and

in a quality that is recognized as a benchmark to the industry. Like

covers all the other treatment steps.”

coatings that provide anti-corrosive protection to withstand a 3,000 hours salt spray test.”

Preparation in the research center

To achieve this, Krone and Chemetall have changed the original

The preparation work for the changeover of the pretreatment process

pretreatment process: Switching from iron phosphating to zinc

was managed by Chemetall’s research center in Frankfurt am Main

phosphating with additional passivation should not only prove to

and tested on 300 panels. The entire pretreatment process was

be functionally and economically sound but would also be suitable

simulated in the research center and the coating tested to ensure

for integration into the new Krone Coating Centre in Werlte. This

it passed the 3,000-hour salt spray test. Regular inspections of the

facility with state-of-the-art trailer chassis production technology and

treated metal using the scanning electron microscope at the analysis

a sophisticated level of automation, represents the single largest

laboratories in Frankfurt confirmed the effectiveness of the treatment

investment in the history of Krone.

process and the resulting corrosion protection.

Pretreatment experts from Chemetall supported the changeover of

The flexibility to adjust the pretreatment process to the individual

the pretreatment process on site and made sure the OEM quality

procedures, plant layouts and subsequent painting operations such

Krone desired was achieved.

wet and powder coatings are core competencies of Chemetall. “We

Henrik Fliedner, who heads the general industry sales group for

think of ways to enhance the pretreatment process and can prepare

Germany, Austria and Switzerland, and Frank Enneking, who works in

e-coating together with the supplier in accordance with their wishes,”

sales for general industry, cooperated closely with Krone. “To find the

comments Henrik Fliedner.

right process, we put every pretreatment step under the microscope,” comments Henrik Fliedner. “An analysis of the plant system and the

The pretreatment procedure

constructive collaboration made it possible to design the processes

The pretreatment process that Chemetall has developed for Krone

in line with the company’s objectives.” To this end, all parameters

begins with the removal of abrasive material from the trailer chassis

that are important for achieving the ideal pretreatment process

– using a Gardoclean® cleaner specially adapted to the substrate

were taken into consideration. Frank Enneking determined the ideal

and by high-pressure spray degreasing. During this step, a new and

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innovative surfactant is used that generates little foam even at a high

want to accomplish with Chemetall as our partner,” emphasizes

spraying pressure. During this procedure, the traversing motion of the

Volker Perk.

plant spray head ensures that the substrate is treated thoroughly. This

The welded and pretreated chassis can then be wet- and powder-

effort pays off at a later stage, as it provides the ideal preparation for

coated as a complete unit in all colors. This meets the customers’

the subsequent steps.

desire for more color variants.

There follow two immersion degreasing stages for removing greases and oils from all surfaces of the trailer chassis, including voids. “This

Results

is important in order to prevent minute defects on the substrate and

Volker Perk is happy with the achieved result: “With this level

to optimally prepare the surface for the subsequent treatment steps,”

of corrosion protection, we match the highest standards of the

explains Frank Enneking. Every single process step plays an important

automotive industry. Krone thus stands for highest quality.”

role for the quality and thereby also for retaining the functionality

With the new pretreatment process, Krone is investing in innovative

of the trailer chassis in the long term. After cleaning, the substrate

procedures: By transferring the process to the new Coating Centre

passes through two rinsing stages which remove residues from the

in Werlte, where the trailer chassis are pretreated and coated, the

previous cleaning step. Activation with Gardolene® now takes place:

company has created one of Europe’s most cutting-edge production

This technology prepares the phosphating structure and ensures that

systems. Additionally, it also contributes to environmental protection

the crystals in the subsequent zinc phosphating step have a fine and

thanks to its greatly reduced emissions and resource consumption.

homogeneous structure. During the Gardobond® zinc phosphating

Accordingly, Krone is continuing down its path of sustainable and

step that follows, the actual crystalline layer is created that is important

extremely durable surface pretreatment. “With Chemetall as a partner,

for the later coating steps.

we are fulfilling our value proposition and passing this advantage on

After two more rinsing stages, this extremely small, crystalline

to our customers,” concludes Volker Perk. That is Emsland quality for

phosphate coating is sealed through passivation. This results in an

the roads of our world.

increase in quality of the coating of between 10 to 15% compared to pure zinc phosphating and also enhances the surface evenness. “This

For further information:

increase in quality is at the heart of the Krone brand strategy, which we

www.krone-trailer.com and www.chemetall.com

Fahrzeugwerk Bernard Krone GmbH & Co. KG produces complete trailers or trailer chassis for curtainsider and closed box semitrailers, container chassis, carrier systems, trailers and bodies.

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Oltrogge: A Partner for Heavy-Duty Challenges Oltrogge, coating specialist from Bielefeld in Germany supported Jungheinrich AG & Co. KG, a company specialising in all areas of intralogistics throughout the process of designing, installing, programming and maintaining the new coating system for counterbalanced forklifts.

“E

fficient processes are decisive for corporate success.” Jungheinrich AG & Co. KG adopted this credo for all its products. For more than

In order to take the production area to a new level of automation, Jungheinrich relies on a state-of-the-art plant with a heavy-duty skid conveyor system.

65 years, the Hamburg-based company has been one of the leading suppliers in all areas of intralogistics. It offers a broad portfolio of solutions ranging from conventional forklift trucks to fully automated logistics systems. In view of making its production of counterbalanced forklifts at the main plant in Moosburg even more efficient, its longstanding service partner Oltrogge supplied a state-of-theart, fully automatic painting system and optimized the painting process for faster production and lower material consumption.

From manual work to full automation At its main plant in Moosburg, Germany, Jungheinrich AG & Co. KG, which employs some 18,000 people in 40 Countries, manufactures counterbalanced forklift trucks. The trucks, which can be used universally in warehouses for stacking and retrieving goods, or for loading and unloading trucks, are a real challenge in production: the special “counterweight” component, made of solid cast iron, weighs between 500 and 3,500 kg depending on the type of truck. Until now, painstaking manual work was necessary at Jungheinrich to be able to properly paint © Oltrogge / Christian Willner

Detail of one of the sanding and painting robots.

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this angled element in production. Moreover, manual sanding and painting with low pressure was not only

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laborious but also involved a huge accumulation of dirt, high material

supplies the painting robot with hardener and paint in a manner that

consumption and long drying phases.

is material-saving and safe. The use of high pressure in the painting

In order to raise this area of production to a new level of automation,

process also ensures a higher degree of application efficiency.

Jungheinrich now relies on a state-of-the-art plant with a heavy-

Jungheinrich can therefore save an entire painting and drying process

duty skid conveyor system, as well as sanding and painting robots.

and significantly reduce production time and money.

Oltrogge, coating specialist from Bielefeld in Germany and a longstanding partner, supported the company throughout the process

Comprehensive support

of designing, installing, programming and maintaining the coating

Oltrogge not only supported Jungheinrich in the installation

components.

and commissioning of the painting robot, but also took care of programming its complex movement patterns by means of a teach-in

An eﬃcient, easy solution for heavy equipment

procedure – a real challenge according to Oltrogge service technician

Thanks to the new, cutting-edge coating line that Oltrogge designed

Stefan Plobner: “Although the skid conveyor technology allows the

together with Jungheinrich and other partners, each counterweight is

components to be rotated through 360°, the angled components

now transported by a skid conveyor system to various stations where

need to be positioned so that the robot reaches all corners and

it is fully automatically sanded by robot and then painted. A 6-axis

surfaces quickly and efficiently. The motion sequences of the conveyor

type EPX 2800 painting robot from Motoman Yaskawa ensures ideal

system and the robot therefore had to be perfectly coordinated.” All

results. The Regular 30, a 2-component mixing and dosing system

programming work for new motion sequences is carried out on the

PC and is not transferred to the robot until the changeover to a new

the painting system. It does not require an additional hardener valve,

component has taken place. This prevents production breaks and

pressure regulator or a pre-mixing chamber, and therefore quickly

increases efficiency. © Oltrogge / Christian Willner

The forklift counterweights are sanded fully automatically by robots and then painted. A 6-axis type EPX 2800 painting robot from Motoman Yaskawa ensures optimum results.

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Oltrogge also prepared the company for the long term: accompanying the commissioning, employees received extensive training so that they could carry out small repairs and maintenance work themselves, as well as motion programming of the painting robot for new components. Bernhard Petermaier, project manager at Jungheinrich AG & Co. KG, is enthusiastic about the comprehensive support provided by the company’s longstanding partner: “It’s great that Oltrogge not only offers quick, efficient service but also passes on knowledge and provides comprehensive training. This gives us a decisive edge over others and makes us independent in handling the daily challenges. Real added value.”

About Oltrogge GmbH & Co. KG Founded in 1866, Oltrogge GmbH & Co. KG today develops and implements efficiency-

The Regular 30, a 2-component dosing system designed by Oltrogge, was installed to ensure the eﬃcient supply of the painting plant.

increasing solutions for existing or new production methods in industry. The Bielefeldbased company, which is managed by Daniel Oltrogge and Marcus Scheiber, is dedicated to making production processes safe and reliable. As an engineering partner for technically demanding industrial solutions, Oltrogge provides comprehensive service for the optimization of existing plants and the conceptual design of new production methods. With four locations nationwide and expertise gained over 150 years in the fields of surface, compressed air and welding technology as well as machine tools, Oltrogge supports its partners directly on site and thereby promotes sustainable production success. With 150 employees, the mediumsized company generates an annual turnover of 30 million euros (2019) and advises some 15,000 industrial customers from various sectors worldwide. © Oltrogge / Christian Willner

For further information: www.oltrogge.de

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Oltrogge supported Jungheinrich with the installation and commissioning of the painting robot and also handled the programming of its complex movement patterns.

N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

BRAND-NEW

Reinhardt Developed a Multivariable Coating System Reinhardt has developed a multivariable coating system to improve the material flow with intelligent part guidance.

einhardt, a technology leader in dip-spin coating systems, has developed a multivariable coating system, which allows to run

simultaneously different batches and coating states in one system. Also, the system guarantees traceability. The consumption of the coating media is minimised thanks to the new air-conditioning system in the coating chamber, which guarantees an even more continuous colour quality. The re-dosing system has also been optimized. Since there is only one drum or basket in the medium at a time, considerably less space and material is required during the actual coating process compared to multi-drum systems. The intelligent control of the speed, direction of rotation and angle of inclination produces excellent results even with scooping parts. Evaporation, drying and cooling is carried out in the furnaces developed and produced by Reinhardt GmbH. The renowned manufacturer of industrial furnaces guarantees a perfect air flow with high temperature uniformity at all times. The patented and proven pallet transport system over several levels saves expensive space in the user’s hall, and thus cash money.

What are the advantages of this system? • Very good coating quality • Coating plant and furnace technology from one manufacturer • All assemblies from one source • Perfect coordination of the individual components • Reduced material and energy consumption • High flexibility

For further information: www.reinhardt.gmbh

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• Low space requirement.

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A sanitary bed type Geri Carro, produced by Formas Descanso.

FOCUS ON TECHNOLOGY

Formas Descanso: Automatic Powder Coating of Healthcare Beds to Improve Competitiveness and Profitability Alessia Venturi ipcm

In order to increase the productivity and coating quality level of its healthcare beds for geriatric and home use, Formas Descanso has chosen a Cabycal automatic powder coating system, which guarantees competitiveness, sustainability, and result repeatability.

ormas Descanso (Yecla, Murcia, Spain) is a family business

founded a company devoted to the production of smart, unique, and

specialising in the manufacture of electric articulated beds

personalised sleep equipment. Formas Descanso’s products belong to

for geriatric and domestic use, whose motto is “Quality can

the following three categories:

be felt”. It was based on this idea that, in 2003, Alejandro Guardiola

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• Mattresses and beds for home use;

FOCUS ON TECHNOLOGY

• Specific solutions for geriatric and orthopaedic care; • Innovative products for the hotel sector, under the name of Contract. “We are the Spanish market leaders. Since the beginning, we have always focussed on specialisation. That is why we hold a health license. In the last few years, on the other hand, our business strategy has been internationalising our business and offer,” states Alejandro Guardiola. “Currently, exports account for 10% of our turnover. The Covid-19 emergency has given a great boost to our production: we are working at full speed to meet the demand for healthcare beds for field hospitals and new intensive care units.” With a 7000 m2-wide area, 48 employees, and an ISO 9001 and 14001 certified production process, Formas Descanso is a young and dynamic firm. © Cabycal

“Our production flow is fully integrated,” explains Guardiola. “We buy the material in different pipe

A bird’s eye view of the automatic coating plant supplied by Cabycal.

factories and we perform all phases in-house, up to coating and assembly. Our products’ finishes are very important, due to both aesthetic reasons, as they are tied to our corporate image, and durability requirements, especially in terms of scratch and chemical resistance. Precisely because of the strategic importance of our surface finishes, we decided to invest in an automatic powder application system to give our products more uniform coatings. At the beginning, we relied on coating contractors. In 2010, however, we installed our first, secondhand painting line. Then, in August 2019, Cabycal supplied us with this automatic powder coating line, which was crucial to increase our productivity and finishing quality.”

Formas Descanso’s finishing process The new plant designed by Cabycal coats an average of 4000 beds per month. “This is a system designed for a very specific product and based on the quality requirements of the market in which Formas Descanso operates,” indicates Emilio © Cabycal

Ferrando, the general manager of Cabycal, a plant engineering company designing, producing, and

The loading and unloading area.

assembling coating systems in Valencia (Spain).

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“The pre-treatment of steel parts is a key stage for the final quality of these products. Therefore, we have designed a cycle using a cutting-edge nanotechnology and osmotic water in its last stage, as well as a reverse cascade process to maintain a high treatment quality degree. In other words, the last cleaning phase with osmotic water discharges its liquids in the first rinsing station, which uses industrial water. The low-temperature hot process utilises a very versatile, biodegradable nanotechnology chemical with state-of-the-art surfactants. This has given Formas Descanso excellent treatment results in relation to the needs of its target market, that is, indoor products coated with hybrid epoxy-polyester powders.” The powder application phase is performed in the Cabycal booth, with a quick colour change system. “This powder application plant features numerous characteristics that guarantee

unbeatable coating capacity and ease of use for

The pre-treatment tunnel.

an unprecedented level of performance,” adds Emilio Ferrando from Cabycal. “Its ergonomic design allows for easy internal and external cleaning to facilitate colour change operations. It supplies 100 kV for maximum transfer efficiency already in the first application stage, through one of the most powerful Venturi application systems in the industry. The Cabycal coating management unit is supplied with a 36 kg-tank and it is designed to mount up to 8 Venturi-type pumps on its lid.” “The booth has an On/Off workpiece identification system,” notes Ferrando. “Before entering the machine, each part is detected by the bars mounted vertically on each side of the component. These bars assess the height and shape of the workpieces entering the system and they send a signal to the robots, thus guaranteeing precise application through the guns, as well as application control in the absence of hanging parts.” The coating application area is complemented by a recovery cyclone with an integrated sieve and a powder filtration module. “We try to

make as few colour change-overs per day as possible, although our Cabycal booth has a total

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The Cabycal powder application booth, featuring Nordson guns.

FOCUS ON TECHNOLOGY

cleaning time of just 15 minutes,” says Alejandro Guardiola from Formas Descanso. “Our work philosophy is to organise production by series of tints, so that our average is 5-6 colour change operations per day.”

Industry 4.0 “The plant is managed by a touch screen panel that controls process parameters within an interval of 2 hours,” says Ferrando. “The parameters checked are water quality, temperatures, and coating application. Each painted part is traceable. The plant is also ready to be used with a remote connection via smartphone or tablet in future. This possibility would give to Formas Descanso the freedom to work and monitor the system from anywhere and at any time, as if the operators were in front of it. Together with the other innovative features of this plant, this would let the company make a further step towards a fully Industry 4.0-oriented

The coating management unit with a powder storage capacity of 69 kg.

workflow, as well as enabling it to manage everything with the same application.”

Technical and construction characteristics of the automatic coating system The plant has a one-rail Teleflex conveyor with a capacity of 50 kg/m, integrated with a Caterpillartype dragging unit for correct operation and constant speed. The line speed ranges from 0.70 to 1.50 m/min. The plant includes a stainless steel tunnel with a height of 3,400 mm, width of 1,800 mm, and length of 11,000 mm for the 2.5-stage pretreatment phase. The tunnel is equipped with an osmotic water production system with a capacity of 500 l/h. The different stages are separated from each other by areas where the parts are drained on titled trays, so that the solutions return to their original tank and the risk of contamination is minimised. The entry and exit areas have trays slanted towards the first and last station, respectively; the intermediate stations are designed to limit any © Cabycal

dragging caused by vapour or by the workpieces

The powder application is carried out by Nordson guns with a traditional Venturi system.

and to prevent them from self-drying; this

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affects rinsing quality and water

excessive movement. © Cabycal

consumption. Moreover, doors have

The plant is completed by a curing

been integrated to allow inspecting

oven where the workpieces remain

the interfaces between the tanks,

for 22 minutes. “The air used as

with the exception the entry and exit

the heating fluid is constantly

ones, which can be inspected from

recirculated between the heating

their own openings. Along its entire

source and an insulated circuit.

length, the tunnel is equipped with a

Air recirculation increases the

grille corridor that facilitates periodic

exchange surface between air

maintenance and the recovery of

and components,” explains Emilio

any workpieces that could come

Ferrando. “The system features an

off their hooks. The conveyor

air vein direct combustion system in

is protected through a closure

order to achieve maximum energy

preventing the escape of aggressive

savings.”

vapours from the top of the tunnel,

and rinsing areas; the spraying

Repeatability, quality, and performance: the results obtained by Formas Descanso

system is designed to guarantee

“We are very pleased with our new

total coverage of parts. In the

plant,” states Alejandro Guardiola.

degreasing phase, a hydrocarbon

“We have chosen Cabycal because it

separator removes emulsions,

had provided us with our first plant

oils, fats, and suspended solids

and, since then, we had decided to

generated in the machining phases.

loyalise this supplier as we consider

The tunnel exit features a highly

it highly reliable. With this new

efficient blow-off system with an

system, we have reduced coating

installed power of 11 kW, which

costs, improved finishing quality,

helps lower the drying temperature.

and achieved higher productivity.

The components remain in the

This has entailed a very big change,

running along its entire length. Spraying is performed by angularopening nozzles in the treatment

drying oven for 15 minutes at 100120 °C. Then, they reach a natural-

The inside of the curing oven, with an air vein direct combustion system.

convection cooling station. In this

because our previous plant included several manual phases, such as degreasing. Complete

way, once dried, the workpieces enter the coating booth with the ideal

process automation and part traceability have made Formas

temperature for powder application.

Descanso very competitive. The density of our line is homogeneous,

The coating process takes place automatically in the antistatic

performance has increased, and the repeatability of our results is

plastic booth equipped with a quick colour change system. The

very consistent: all of this guarantees a high product quality degree.”

floor cleaning device automatically sends the powder to the suction

“Alejandro Guardiola is a young business owner with a great

unit for recovery. The platforms for manual operations guarantee

entrepreneurial vision, who managed to create a thriving firm

easy access to products. 8 lights integrated in the booth’s roof offer

in a market with strong competition, mainly consisting of large

perfect lighting in both the manual and automatic coating areas. The

companies,” says Emilio Ferrando. “He has strived to carve out

control panel encloses all electrical and pneumatic controls in one

a place in the market and he has already overcome a few major

housing. Application equipment includes 4 Nordson automatic guns

challenges. Our coating plant has helped make his company

and a manual touch-up gun. The automatic guns are installed on two

competitive.”

vertical reciprocators with digital height and stroke speed control; they

“Our strengths are our specialisation degree and the excellent value

also feature a modular counterweight system to adjust capacity. The

for money of our products,” says Guardiola. “We have a very wide

acceleration and deceleration system ensures smooth and consistent

range and in particular, at the moment, Formas Descanso is one of

movements, whereas limit switch sensors prevent any accidental

the most strategic suppliers for field hospitals.”

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S Salcomix è il marchio di AkzoNobel per un sistema di prodotti vernicianti industriali dal design modulare, che può essere utilizzato per fornire vernici per una grande varietà di applicazioni per l‘industria leggera, in modo rapido e flessibile. Questo è possibile grazie a un sistema di miscelazione che offre una superiore precisione del colore con la massima varietà di prodotto. Salcomix is AkzoNobel's brand for a modularly designed industrial coatings system that can be used to provide paints for a variety of small-industry applications, quickly and flexibly. This is possible thanks to a mixing system that offers superior color accuracy with maximum product diversity.

www.akzonobel.com infosalcomix@akzonobel.com

0087–04019

www.salcomix.com

A 3D printed gimble frame before (left) and after the “trowalizing” process.

INNOVATIONS: PRESENT&FUTURE

Walther Trowal Develops AM Post Process Machines Maximilian Beien Walther Trowal GmbH & Co. KG – Haan, Germany

m.beien@walther-trowal.de

Walther Trowal designed the “AM post process machines” model range AM for refining the surface of components produced with additive manufacturing.

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INNOVATIONS: PRESENT&FUTURE

o remove the markings of removed support structures and sintered-on powder residue which can be found on 3D printed components after their surface has

been polished, Walther Trowal has developed the “AM post process machines” model range AM, which can create surface finishes in one single step. In fact, most 3D printed components are produced by placing material layers on top of each other, creating a “staircasing” effect on their surface with, generally, a very high initial surface roughness. For this reason, many of these components must undergo a surface smoothing or polishing operation before the components can be further processed or utilized. Mass finishing has proven to be the ideal surface finishing © Walther Trowal

method for 3D printed components: these are completely embedded in the moving grinding media so that the process is very gentle and produces homogeneous and repeatable surface finishes. Moreover, the media also reaches internal passages and undercuts in the components.

The AM post process Depending on the size of the processing bowl, up to 100 small work pieces or single components with a size of 900 x 500 mm can be treated in the model range AM of the new “multivib” vibrators. The work pieces are mounted on a carrier plate, which in turn is clamped to the bottom of the processing bowl by mechanical or electromagnetic

A 3D printed blisk segment before (left) and after the “trowalizing” process.

The “multivibrators” of the model range AM were specifically developed for finishing the surface of 3D printed components.

A 3D printed nozzle before (left), after surface grinding (centre) and after polishing.

A 3D printed clip before (left) and after the “trowalizing” process.

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A 3D printed ear piece (above) for a hearing aid before (left), surface smoothing (centre) and after polishing (right) and a 3D printed metal baﬄe before (left) and after the “trowalizing” process.

the processing bowl. During the process compound and water are

pieces from around Ra = 2 to 80 μm down to a value of 0.025 μm.

continuously added. Three vibratory motors induce an intensive

“Additive manufacturing and mass finishing are an ideal combination

vibration into the processing bowl. Since the vibratory movement

because most 3D printed components must have an excellent

generated by the motors is overlapping, the component surface

surface finish to fulfil their function. For example, turbine blades

becomes smoother, while the edges are left intact. After a pre-

require an airflow with minimal friction loss. Components with

determined cycle time the process is completed, and the finished

stringent specifications for hardness and strength benefit from

work pieces can be removed.

the homogeneous peening effect induced by mass finishing.

Several manufacturers of automotive, aircraft and medical

This finishing method is especially advantageous for 3D printed

components are already using the new AM “multivib” vibrators.

components with bionic shapes”, said Maximilian Beien, Sales

The work pieces are mounted onto a carrier plate, which in turn is electromagnetically clamped to the bottom of the processing bowl.

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wal © Walther Tro

These machines reduce the surface roughness of the raw work

wal © Walther Tro

means. Once the work pieces are in place, the media is filled into

Large work pieces are electromagnetically clamped to the bottom of the processing bowl without the need for a carrier plate.

INNOVATIONS: PRESENT&FUTURE

Manager at Walther Trowal. Mass finishing is suitable for a wide range of materials utilized in additive manufacturing, i.e. for high performance, difficultto-machine metals like titanium, nickel based or cobalt-chrome alloys, but also for non-ferrous metals or plastic. Walther Trowal grinding media and other consumables are already approved for many materials and safety-relevant components and processes. “Compared to electro-chemical finishing methods mass finishing achieves the desired surface smoothness and lustre in one

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single operation. Another advantage is that the mass finishing equipment is very compact with a small footprint. The result: An excellent surface finish, surprisingly short cycle times and an overall high cost-efficiency, not only with regard to the capital

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expenditures but also the operating costs”, adds Beien.

Three vibratory motors induce an overlapping vibratory movement into the processing bowl.

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HIGHLIGHT OF THE MONTH

Whatever it Takes! Adriano Antonelli IBIX Srl, Lugo (Ravenna) – Italy

adriano.antonelli@tecnosupply.com

Masking and hanging costs account for about 5% of the total investment related to a coating process. With appropriate strategies, however, spending for the entire cycle can be cut by 50%. Adriano Antonelli, the sales manager of Ibix, division of Tecno Supply, distributor of HangOn products, explains how.

“W

hatever it takes!” I would like to begin with this sentence,

economy. The risk of speculation was putting not only the Euro, but

which will surely remain in world economic history.

also the financial and economic markets at risk: in other words, a

It was 2012 and European Central Bank president

financial crisis was heavily affecting the real economy. We managed to

Mario Draghi assured that “the ECB is ready to do whatever it takes

overcome it by stabilising finance, which had been quite creative for

to preserve the Euro. And believe me, it will be enough.” This was a

some time, offering certainties on the sustainability of the European

real turning point in the Central Bank’s strategy and the Eurozone

government debts, and injecting liquidity into the market.

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We might wonder what has been done in recent years to avert a possible financial crisis triggered by the same creative behaviours. Nowadays, on the other hand, we are witnessing another crisis, this time a health one, which has quickly affected both the real and financial economy. In this case, there is a problem in terms of both demand and supply. We are expecting from political institutions a truly reassuring statement, from which we can start to implement all that is necessary for global recovery. Such a crisis can clearly arise again and we will have to be ready to face it, as the whole current production system has been questioned. In particular, the idea that it is possible to

One of the masking plugs made by HangOn.

receive any component from any part of the world in a short time has faltered. The risk of having to interrupt a production cycle due to the lack of a component or product available exclusively in a specific geographical area, however, is no longer acceptable. That is why a new productive structure is recommended to address both this issue and the drastic reduction of world GDP. On the other hand, it is difficult to predict how and what the market will require – but we can start making a few assumptions. The demand for higher quality at a reduced cost will surely be one of the focuses of new production cycles. Therefore, let us ask ourselves what can be done in our field, that of surface treatments. The two

Coating cost reduction diagram.

macro-categories of masking and hanging only account for 5% of the total costs of a coating process. With appropriate strategies, however, spending for the entire cycle can be cut by 50%. As this figure might puzzle some readers, let us analyse a few examples of smart solutions. We can start delving into this topic with pin masking. It is a simple operation, usually carried out with a silicone cap featuring a dome at the end; generally, these caps have particular measures based on the conversion of inches to millimetres. Their insertion and removal are not easy, however, because air is trapped inside the dome, thus

Masking time reduction diagram.

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Masking is a key element to save time and costs in coating.

An example of special masking system.

Some examples of material for making caps.

increasing friction during both operations; friction occurs along the

minimal and it is necessary to close a hole hermetically and guarantee

entire length of the pin, thus further increasing difficulty. Moreover,

the mask stays still even during the movement of the component.

the possibility of gluing the lower part of the cap to the metal part

In the case of large bushings with through holes, good results have

causes the risk of breaking the masking device.

been obtained with expanded silicone. SP expanded silicone tubes,

Some elements, however, can facilitate the insertion and removal of

which can be cut to size, expand into the hole, thus creating a mask

masks. These include GAQ caps, a series devised based on Europe’s

that prevents any shading and build up effects. Their maximum

metric system, ribs that anchor caps to pins in a stable way while

diameter is 60 mm.

guaranteeing that friction occurs especially in the final part of the pin

GBH caps mask holes up to 110 mm.

and only in some areas (i.e. not along its entire length), and flat heads

As regards pins, we offer a few out-of- standard caps, such as the GAP

that avoid air trapping. But how much time can one save? After several

ones, protecting pins up to 50 mm and with variable lengths. GAP

tests and statistical assessments, we can state that it is possible

caps feature a ventilation valve to insert and remove the mask without

to halve the time required by traditional operations. This results in

air resistance.

important economic savings, because it has a decisive impact on the

In general, HangOn can produce specially moulded products for any

total cost of the coating cycle. In addition, the entire range is coloured

out-of-standard request. By taking any issues, tolerances, friction

to uniquely identify the right caps to be used with different tints.

values, treatment processes, etc. into consideration, we can design

Many products from the HangOn range, distributed by Tecno Supply,

and manufacture products for every special need. If the quantities are

division of Ibix, have already ensured the achievement of several

too low to guarantee the sustainability of a fixed moulding cost, it is

companies’ production objectives in terms of masking times, methods,

possible to make assembled caps from sheet material. The resulting

and pre and post management. The silicone systems’ line belongs to

product can be even composed of several types of materials glued

this group of high-performance products. It is also coloured, and tint

together to ensure rigidity and flexibility wherever it is needed. The

consistency is guaranteed for each batch. For example, the M4 size is

materials available in our stock ready to be cut and assembled are

white in all its various configurations, so that operators can recognise

solid silicone, foam silicone, magnetic silicone, magnetic PVC, MDF,

and classify it easily and quickly. Colours can also be modified and

EPDM, adhesive silicone and EPDM, and cork.

customised in order to match each device with a specific tint. Here are

In the hanging field, HangOn also offers economic solutions made

a few examples of products included.

entirely with automated and numerically controlled machines, aimed

GDM caps allow hermetically sealing through holes. The cylinder

at reducing operating times. These flexible solutions reduce the

terminal part enables to tighten the nut flare.

number of frames required and they are functional because they also

The GDM H series includes caps up to 83 mm in size. These caps are

guarantee grounding.

hollow for easier insertion.

HQC hanging levels are particularly innovative. These ready-made bars

QB caps are screw caps for blind holes, i.e. parts where depth is

are an evolution of HQL bars: their harmonic steel hooks are already

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HIGHLIGHT OF THE MONTH

TRADITIONAL HANGING STANDARD HOOK

SMART HANGING HQL

16%

-51% 25%

18%

44%

0.4% 2%

PARAMETERS STANDARD HOOK

PARAMETERS HQL LEVEL

Type of hanging Line (monorail) Line speed m/min (actual) Size painted plate (W x H) mm Products per conveyor meter Batch Coating capacity qty / h Batch process time (h) -TLADQ©NE©RGHȳR Productivity Available line hours / year -TLADQ©NE©AKTD©BNKK@Q©ODQ©RGHȳ

Type of hanging Frame + HQL Line (monorail) 1 Line speed m/min (actual) 2 Size painted plate (W x H) mm 25 x 80 370 Products per conveyor meter Y /QDG@MFHMF©NȮ KHMD Batch 88 000 35 000 Coating capacity qty / h Batch process time (h) incl. prehang (h) 12 -TLADQ©NE©RGHȳR 3 Productivity 80% Available line hours / year 5250 -TLADQ©NE©AKTD©BNKK@Q©ODQ©RGHȳ 5

COSTING COMPONENTS

Hook 1 2,2 25 x 80 28 88 000 3000 29 3 80% 5250 5

COSTING COMPONENTS

BATCH COST (€)

Fixed line cost

36 €/h

1 056

16%

Fixed line cost

36 €/h

443

Energy

56 kWh

1 643

25%

Energy

56 kWh

141

Variable line cost

10 €/h

293

Variable line cost

10 €/h

0,4%

Blue collar

97 €/h

2 845

44%

Blue collar

97 €/h

1 192

18%

Powder

0,002 €/pcs

200

Powder

0,004 €/pcs

352

Cost hanging point

0,005 €/pcs

440

Cost hanging point

0,012 €/pcs

1 030

16%

TOTAL COATING COST (0,074 €/pcs)

6 477 100%

51%

SAVINGS TOTAL COATING COST (0,036 €/pcs)

3 182 100%

Data comparison between standard hanging with single hook and HQL system on frame.

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Cross frame with hook diameter 1,5 mm on bar, ready to be used.

The final quality control phase.

inserted and ready for use. Each level is housed in a BH R58 bar

mm in length, while the slats are 1.0 mm thick and 18 mm high. It is

holder, welded on a 10 mm hook. The silicone protection ensures free

possible to create different configurations, e.g. slats on one side only

conductivity. These bars have been designed to be produced entirely

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

automatically and they can be used for a wide variety of parts, thus

HQL bars, finally, have been in our catalogue for some years now.

proving extremely economic. Moreover, it is possible to insert a series

They can be integrated on our universal frames. The 1 mm hook

of hooks in the bar holder to hang medium-sized workpieces, since

leaves only a slight mark on the coated part. For this bar range, we

the central hook has a diameter of 10 mm. The BH R58 central hook

have also launched a triple V-shaped bar preventing the workpieces

can also house H11B bars thanks to an adapter, where it is possible

from unhooking during pre-cleaning. This year, moreover, the HQL

to place hooks with a maximum diameter of 4 mm. In this case, a

series has been integrated with bars featuring double 1.5 mm hooks,

cross frame is obtained, housing bars with already-inserted 1,5 mm

which enable to hang particularly heavy parts with an opposed

hooks and bars that can accommodate hooks up to 4 mm for heavier

hanging system.

components.

Another important type of products that are complementary to

The HQS type it another tree frame, produced automatically and,

frames are trolleys for both off-line pre-hanging and tool storage

therefore, costing less than 2 Euros. It features metal slats to allow

operations. In particular, HangOn has conceived a modular trolley that

hanging different batches, from single parts up to several aluminium

allows modifying and adding optional elements based on the type of

profiles. The central 4 or 5 mm hook guarantees an overall resistance

frame to be used.

of the frame up to 100 kg. HQS frames have been recently revamped

Finally, a fundamental production phase is product control, a crucial

with various types of hooks, thanks to which each customer can find

activity in a company’s quality system, in the framework of a market

the best configuration for its specific use. The tree can be up to 2,400

that is increasingly demanding.

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ÂŠ Spra yVision

The SprayVision technology can provide information about paint thickness distribution in just a couple of minutes after spraying. It allows to analyse the whole surface and verify trajectories overlapping.

INNOVATIONS: PRESENT&FUTURE

Coating Process Digitalization Thanks to a New SprayVision Technology Petr Jahn SprayVision s.r.o. â&#x20AC;&#x201C; Ostrava, Czech Republic

petr.jahn@sprayvision.com

SprayVision developed a new technology for coating digitalization, analysis, evaluation, process control and surface thickness measurement.

prayVision is a technology for coating process digitalization

easily implemented in any sort of robotic painting system.

which is composed by the combination of hardware and

Furthermore, it allows to get digital results of real coating process. Such

software. It was developed based on a need from the coating

process, in fact, can be controlled, optimized and very flexibly adjusted.

industry to better understand the output of coating equipment and

SprayVision can also be used with wet paint. The implementation of

evaluate its results based on data which lead to the usage of more

such technology leads to material savings, quality improvement, scrap

optimal parameters.

parts reduction and most of all, it provides an immediate feedback

This technology can be used with any kind of paint and can be very

about results directly on painted parts.

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INNOVATIONS: PRESENT&FUTURE

Example of a SprayVision analysis of the paint distribution on a car bonnet.

Serial production under control

Optimization of coating parameters

Before starting a production batch, with SprayVision it is possible to

It is very difficult to understand what the ideal set-up of coating process

check if the results at the end of the production line will be aligned

is, but with proper data this is much easier. SprayVision gives you a

to your quality standards. The process control feature compares

clear view of applied volumes, paint distribution and thicknesses profile

the captured spray patterns with the standard production one and

so that you can objectively decide what combination of pressure, paint

should there be any deviation in size, shape or applied volume

flow and robot velocity use. All such measuring can be done during

of paint, it warns about it and suggests to check specific part of

wet stage without waiting for the paint to dry out. As a result, transfer

application technology.

efficiency can be increased by more than 10%.

on isi yV ra Sp

Device for capturing coating results: captured data are then evaluated by software.

The measuring can be done during wet stage, in such a way that transfer eﬃciency can be increased by more than 10%.

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Analysis of the whole surface and evaluation of trajectories overlapping can be made even on very complex parts as bumpers.

Surface thickness measurement When implementing new projects, but also during standard production, paint thickness on products is one of the most important aspects directly linked to quality. SprayVision can provide information about paint thickness distribution in just a couple of minutes after spraying. This allows to analyse the whole surface and verify trajectories overlapping even on very complex parts as bumpers.

Ideal pitch distance for trajectories After identifying the optimal spraying set up with The software provides ideal pitch distance for trajectories (SB 50) as output of dynamic coating and allows to create an initial robot program sketch quickly and easily.

the higher transfer efficiency and a good paint distribution it is possible to also obtain the ideal pitch distance for trajectories (SB 50) from the dynamic pattern. The software provides this result as output of dynamic coating and allows

to create an initial robot program sketch quickly and easily.

Droplets, an important part of coating process Coating equipment manufacturers, paint producers, but also industrial coaters use SprayVision to analyse coating to the droplets’ level. The technology provides information about count, size, and volume of each droplet in a selected area (up to 10cm x 10cm). The SprayVision technology provides information about count, size, and volume of each droplet in a selected area (up to 10cm x 10cm).

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www.infragas.com

INFRARED RADIANT GAS SYSTEMS FOR THERMAL TREATMENTS

FOCUS ON TECHNOLOGY

Into the Future with Zero Emissions Oliver Zanner Emil Frei GmbH & Co. KG, Döggingen – Germany

o.zanner@freilacke.de

The Christmann + Pfeifer (C+P) company specialising in steel furniture relies on new VOC-free anodic EC solution from FreiLacke.

he Hessian manufacturer Christmann + Pfeifer (C+P)

Breidenbach (Hesse), Gotha (Thuringia) and Legnica (Poland).

specialises in the production of high-quality steel furniture for

Sustainability is a key issue for the company, which has been

versatile areas, such as workplaces, archives or workshops.

in business for 95 years. “Steel can be melted down repeatedly

The company processes 1,500 tonnes of steel each month and

without a loss of quality”, explains Jens Pott, production manager

turns them into individual pieces of furniture or complete furniture

for surfaces at C+P. In Germany, nearly half of all steel is made

ranges for large facilities. They are manufactured in three plants in

using this secondary raw material. That lowers the energy required

FOCUS ON TECHNOLOGY

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

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FOCUS ON TECHNOLOGY

for production and therefore also CO2 emissions. To ensure the

recalls that the company approached FreiLacke, voiced its wishes and

durability of its steel furniture, corrosion protection is a major issue

then worked together on how to make them happen. The coating

for C+P. That is less of an issue for the furnishing solutions for office

specialist from the Black Forest accepted the job, got to work and

spaces but much more so for swimming pool lockers, furniture

was able to produce initial results after a few short months: it came

transported abroad by sea or furniture used outdoors in desert

up with a VOC-free product called FREIOTHERM-ATL-EcoOne – a

states like Dubai.

2C system without solvents or neutralising agents that need to be labelled. “That is the advantage of a family business: it offers real

Accepting the job

services that cannot be found elsewhere”, the production manager

The steel components are pre-treated with an iron phosphate

says.

coating. An anodic EC dispersion coating follows at the facilities in Thuringia and Hesse. While this is usually a primer, at C+P it is a finish

Field test reveals need for cooling

coating. The standard colour shade is RAL 7035, i.e. light grey; all

FreiLacke has been developing and using innovative

other colours can be applied using powder coatings.

electrodeposition coating systems since the 1960s. The latest

C+P has been relying on a solvent-based anodic EC system from

addition to the EC family is the new anodic two-component system

FreiLacke for many years. But the decision-makers also wanted

without VOC-relevant solvents and neutralising agents in the paste

to reduce emissions as much as possible and, as a result, meet

mixture, a product that is unique on the global market. “What is

regulatory standards throughout the foreseeable future. Jens Pott

available to the user here is a system that possesses all the qualities

Unloading area in the Christmann + Pfeifer (C+P) factory. FreiLacke has developed a VOC-free anodic EC product called FREIOTHERM-ATL-EcoOne.

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179

The EC anodising operation of steel furniture and, below, finished steel furniture.

of an anodic single-coat system, e.g. layer thicknesses of up to 40 μm, no yellowing and excellent wrap-around properties”, says Andreas Segin, who works on the development of electrodeposition coatings at FreiLacke. After the development of ‘EcoOne’ had been largely concluded, the manufacturer conducted various tests in a lab for a year to thoroughly examine the system. The next step was to test the recipe, which had been developed in a lab, in the field. A four cubic metre basin was filled with EcoOne at FreiLacke’s EC technical centre and then tested. “This demonstrated some of the practical challenges: for example, the new system was more sensitive to deposition as well as to heat input from pumps than solvent-based systems. That means it was absolutely necessary to sufficiently cool the material in the basin. That was an important finding because this effect did not occur in the tests in our lab”, recalls Segin.

The basin of the technical centre goes on the road In April 2019, the basin of the technical centre, as well as the basin contents, made a trip to North Hesse and to the C+P plant in Breidenbach. In light of its size, that posed a true challenge, © C+P Möbelsysteme GmbH & Co. KG

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according to Segin. At first, only individual sample parts were coated

FOCUS ON TECHNOLOGY

in Breidenbach. They were run through the iron phosphating of the

“When the series production with ‘EcoOne’ began, we were pleasantly

existing plant, dipped into the tank of the technical centre using a

surprised by the result”, says Pott. “We actually anticipated that

forklift and then, after the direct current had been applied, brought

there would at least be some minor problems, but the failure rate

back to the surface, rinsed with ultrafiltration and deionised water

was insignificantly low, and the wrap-around and the layer thickness

and then baked in the plant’s furnace. “Everything was a success”,

structure were better than expected!”. In the first few weeks, the tank

says Jens Pott in summarising the results from salt spray tests and

was further “tried out” and the anodic EC paste was refined further.

recoating to abrasion resistance and bending tests. Due to the

“The tank was much bigger than the test tank, which also permitted

very good results, the head of production met with the company

different voltages, and the shapes of the components also differ”,

management and they jointly decided to switch to the new system.

says Segin in explaining the process. “If you are looking for custom solutions, then FreiLacke is the place

Insignificantly low failure rates

to go to”, explains Jens Pott. The manufacturer from the Black Forest

And that’s how the big transition began in Breidenbach at the start of

likes to try different things, keeps developing, is an innovator and

October 2019. The old tank, which holds 69,000 litres, was drained

is always well positioned. “It’s not an accident that we have been

(and the contents properly disposed of) and then cleaned. After

working together for decades”, Pott says.

some minor repairs, it was finally refilled. As a result of the large

Due to the very good results from Breidenbach, the tank at the Gotha

volume, this took 12 hours. Prior to commissioning, the temperature

location, which holds approx. 74,000 litres, was also switched to

of the bath had to be increased to 25°C.

‘EcoOne’ in November 2019.

HIGHLIGHT OF THE MONTH

SAT Presents its Vertical Lab Interview with SAT Srl CEO Andrea Trevisan

n this interview with ipcm®, Andrea

What are the characteristics of this

application booth that is currently being

Trevisan presents the evolution of the

laboratory and what functions does it

completed, a Gema new generation coating

plant testing laboratory created at the

perform?

management unit with dense phase pumps,

SAT headquarters in Verona (Italy), which has

In our Verona headquarters, we decided to

and an automatic vertical warehouse for

proved to be an important tool for showing,

create a laboratory, which we called “Vertical

powders that interfaces with the coating

virtually or in person, the process technologies

Lab”, to gather the latest technologies

plant to feed it with the right product

offered by SAT to the world of aluminium

developed by SAT in the field of aluminium

according to the production plan.

treatments.

treatment. These include a new generation

Our firm has always strived to constantly

curing oven, an automatic vertical brushing

update its technologies: this calls for a space

machine for aluminium profiles with a

where we can develop and experiment

dust extraction system, a latest generation

with new projects. First of all, the main

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HIGHLIGHT OF THE MONTH

function of our laboratory is to create the

to the Vertical Lab. Finally, the laboratory

create the Vertical Lab to make all our latest

prototypes of the systems requested by

enables us to show all the potential of

technologies available to customers.

our customers and test them before their

powder coating to the new customers that

eyes, either in person or remotely. Such

are used to applying liquid paints, thus

In your opinion, what is the market

virtual access to our Vertical Lab has been

helping us to further increase our powders’

situation during the current pandemic?

the key to concluding many negotiations

market share.

The industrial sector in which we operate is very solid and, up to now, it has not been

and orders even during the lockdown period and despite the current restrictions

Why did you choose to offer this service?

particularly affected by this crisis. Actually,

on international travel. Our customers can

What market need have you met?

quite the opposite is true: at this time, the

attend the efficiency tests performed on the

It all started in 2013, when we realised that

aluminium market, especially for architecture,

system we have created for them.

our first Cube system’s compact dimensions

is sparkling and dynamic, both thanks to the

Another function of the Vertical Lab is to

enabled it to be installed inside our factory

renovation incentives offered and due to a

host the webinars we organise. During the

and used as a demonstration plant. The

change in buying behaviours. People are more

last one, for example, we explained how our

experience was extremely positive because

prone to investing the money saved due to

profile recognition system works, showing it

our customers had the opportunity to

the lockdown in durable goods, such as the

to an audience of players of the aluminium

see first-hand the technology they were

renovation of their houses; because of the

sector who connected from seven different

about to buy, which is an unbeatable

increased time spent at home, they are also

countries. It was a real success, all thanks

opportunity. Based on this, we decided to

focussing on making their outdoor spaces more enjoyable, for example with pergolas, awnings, folding windows, and winter gardens.

Aluminium is the material of choice for such structures and we are benefiting from this. This trend is also visible in markets such as the English one, which generally tends to be less interested in home renovations. How did SAT perform this year? It has not been easy for us in some ways, but we cannot complain. Without that threemonth production stoppage in spring, it would have been a great year. Fortunately, we were able to find creative but effective solutions to install a few plants overseas in March and April, by leveraging our on-site acquaintances and relying on local assembly teams. In Europe, in the last few weeks we have started up plants in Portugal, Poland, and Belgium. Let us see what 2021 has in store for us!

SAT Srl CEO Andrea Trevisan.

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INNOVATIONS: PRESENT&FUTURE

Excellent Corrosion Protection and High-Performing Paint Adhesion Sebastian Etschel, Peter Volk and Torsten Koerner SurTec International GmbH, Bensheim â&#x20AC;&#x201C; Germany

info@surtec.com

Following the intensive research to find an alternative method for passivation processes containing chromium(VI), SurTec has now succeeded in developing a chromium-free technology for aluminium elements in the architectural industry, able to guarantee improved paint adhesion and effective corrosion protection.

tructural elements made of aluminium play an important role in modern architecture, both outdoors and indoors. In the past, passivation processes containing chromium(VI) were generally

used to protect this material from environmental influences, but these are now classified as â&#x20AC;&#x2DC;substances subject to authorisationâ&#x20AC;&#x2122; under the REACH regulation. Since then, intensive research has been underway to find an alternative process that is both qualitatively equivalent to the processes previously used and harmless to the environment. SurTec, the specialist in surface technology, has now succeeded in developing a chromium-free passivation technology that convincingly

in order to meet the usual quality requirements in the technical

meets these requirements. Compared to other chromium-free

environment, further treatment of the aluminium surface is necessary.

processes, SurTec 643 offers improved paint adhesion and excellent

Probably the best protection against corrosion is provided by the

corrosion protection. In addition, the new process allows for a

anodising process. The micrometre-thick aluminium oxide layer,

simplified process control by means of make-up concentrate and

generated by this process has an excellent barrier effect due to its

replenishing additive. Thus, SurTec 643 enables aluminium coaters to

high capacitive resistance and thus effectively suppresses corrosion

reliably perform and control chromium-free processes.

processes at the cathodic reaction centres of the aluminium surface. Since the anodising process is neither always economical nor

Aluminium pre-treatment processes

necessarily easy to handle, conversion layers have become established

Due to its good alloyability and the resulting wide range of chemical,

for a wide range of applications. In general, a reaction solution in

physical and mechanical properties, aluminium has become the

contact with the aluminium surface produces a passivating layer

preferred material in a large number of industries. From the packaging

through precipitation of metal compounds [3]. This layer typically has

industry to the aerospace industry and the architectural sector,

a thickness in the range of 100 nanometres, protects the aluminium

aluminium and its alloys are indispensable [1, 2].

surface from corrosion and improves the adhesion of a subsequently

Since the natural corrosion protection of aluminium is not sufficient

applied organic coating [4].

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INNOVATIONS: PRESENT&FUTURE

Due to the high carcinogenic effect of Cr(VI) ions, however, intensive research is being conducted towards alternative methods. Trivalent chromium passivations have also demonstrated an excellent barrier effect in practice, but do not possess an inhibiting property like Cr(VI) coatings [3, 7]. In addition, some technical processes prefer chromiumfree processes, which has intensified the search for alternatives to chromium [8].

Transition metals Much attention was paid to transition metals such as cerium, molybdenum, vanadium and their compounds, as they can assume several stable oxidation states like chromium, with the expectation that this would create an inhibitor system with a similar performance like with Cr(III) / Cr(VI) [3, 6, 7]. The most successful systems that have made it into industrial practice since the 1980s and 1990s use titanium and zirconium compounds, whose oxides and hydroxides form stable, passivating films and are toxicologically harmless [7, 9]. In addition, the conversion layers of titanium and zirconium are said to have good adhesive properties for subsequent organic coatings [10], which could be further enhanced by the use of organic additives in addition to corrosion protection [3, 7, 11–15].

SurTec 643, the new chrome-free passivation technology In the following, the new chrome-free pre-treatment process from SurTec for the architectural industry is presented in detail. A fine tuning of the inorganic and organic components in the passivation process enables better adhesion of an organic coating compared to other corresponding technologies, while at the same time providing effective © SurTec

corrosion protection of the aluminium surface. SurTec 643 is a passivation technology, which is applied as standard after degreasing, pickling and desmutting on the aluminium workpiece

For a long time, phosphating was the most prominent process among

by immersion, spraying or surge process. For the preparation of the

the conversion treatments. However, due to environmental protection

bath the concentrate SurTec 643 MU is used and for the adjustment of

requirements on the one hand and their characteristic sludge formation

the bath during the running process the replenishing additive SurTec

during the running process on the other hand, they are getting

643 Repl. The process is generally applied at 0.5-2Vol%, 20-40°C and an

increasingly replaced by phosphate-free passivation processes [5].

exposure time of 30-90s. At the end of the passivation step, no rinsing is necessary, which makes SurTec 643 a “no-rinse” process.

Alternative methods to passivation with hexavalent chromium

The properties of SurTec 643

Passivations on the basis of hexavalent chromium compounds are still

Figure 1a shows schematically the coating structure of SurTec 643

frequently used as a reference system for high-performance corrosion

compared to a chromium-free benchmark process. The specific

protection. Not only do Cr(VI) compounds form stable, closed films

binding motif between the organic additives and the aluminium

consisting of Cr(III) hydroxides, which form an excellent barrier against

substrate provides a more uniform distribution of the inorganic

corrosive media. Remaining Cr(VI) oxoanions in the passivation layer

components of the conversion layer on the aluminium surface. This

also provide an often described self-healing mechanism by inhibiting

aspect is particularly important in “no-rinse” processes in vertical lines

cathodic corrosion processes through the reduction of Cr(VI) to Cr(III) [6].

where the aluminium profiles to be treated are fixed vertically. In the

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185

comparison process, this fixing leads to an accumulation of the conversion solution at the lower end of the profiles, which is difficult to control, with resulting higher layer weights at this point. With SurTec 643, this effect is significantly weakened by the effective binding of the organic additives on the substrate surface, which in turn control the distribution of the inorganic components of the conversion layer, as the X-ray fluorescence measurements (XRF) in Figure 1b show. The grey dotted line represents the XRF measurement of the chromium-free comparison process on AA 6060 profile sections (dark = lower profile edge, light = upper profile edge). Compared to the XRF measurement of SurTec 643 (blue line, dark = lower edge, light = upper edge), the chromium-free reference process shows clearly larger fluctuations during the running process. Figure 1: a) Schematic representation of the distribution of the conversion layer on vertically treated aluminium profiles of SurTec 643 (right) and a chromium-free comparison process (left); b) normalized layer thicknesses of SurTec 643 (blue, dark = lower profile edge, light = upper profile edge), applied against a chromium-free comparison process (grey, dark = lower profile edge, light = upper profile edge); values were measured by X-ray fluorescence (XRF) on AA 6060 profiles.

Figure 2a shows the ball impact on a grid cut (1mm scribe distance). The AA 5005 test panels were powder-coated (Interpon SGJ02G - polyester) after pre-treatment with the respective passivation solution, then cross-cut and subjected to the ball impact

test. Both SurTec 643 and the chromiumfree comparison system show a very good paint adhesion in comparison. Figure 2b shows the measurement of the Erichsen cupping test according to ISO 1520 at different film thicknesses. In contrast to the ball impact test, the Erichsen cupping test allows a more precise differentiation of the different systems, because a concrete numerical value is delivered. The blue measuring points belong to panels, which have been pre-treated with SurTec 643, the grey measuring points belong to a chromium-free comparison process. The AA 5005 test plates were prepared for the

Figure 2: a) Ball impact (60 cm drop height) on cross cut (1 mm scribe distance) for AA 5005 test panels, pre-treated with SurTec 643 and a chromium-free comparison process; b) Erichsen cupping according to ISO 1520 at diﬀerent paint film thicknesses for AA 5005 test panels, pre-treated with SurTec 643 (blue) and a chromium-free comparison process (grey).

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Erichsen cupping test the same way as for the ball impact test and then subjected to the cupping test. Both systems, SurTec

INNOVATIONS: PRESENT&FUTURE

643 and the comparison process, meet the requirements of Qualicoat and GSB, according to which at least 5 mm deepening has to be achieved. However, the direct comparison of both systems shows that SurTec 643 always delivers higher cupping values than the chromium-free comparison system. This finding can be attributed to the specially adjusted organic additive system, which provides a very good binding of a following organic coating besides the even distribution of the conversion layer. Figure 3 shows the result of the Filiform test according to ISO 4623-2 and Qualicoat. The test panels were taken from the process during increasing bath load (m2/3L), powder coated (Interpon SGJ02G - Polyester) and subjected to the Filiform test for 1000h (ISO 4623-2, Qualicoat). With 15-19 Filiform

Figure 3: Filiform corrosion test of panels, which were pre-treated with SurTec 643. The test panels were treated after diﬀerent process loads (m2/3L) and were subjected to the Filiform corrosion test according to ISO 4623-2 and Qualicoat for 1000h.

corrosion sites per 10cm scribe length and a length < 1mm, SurTec 643 shows an excellent corrosion protection. The corrosion inhibiting effect of different organic additives has been described in the literature many times and is again demonstrated here [3, 7, 11–15].

References:

Conclusions

[1] D. Ashkenazi, Technological Forecasting & Social Change, 2019 143, 101–113.

In summary, this article presents a new

[2] D. Rabinovich, Nature Chemistry, 2013, 5, 76.

passivation for aluminium in architectural

[3] R. L. Twite, G. P. Bierwagen, Progress in Organic Coatings, 1998, 33, 91–100.

applications, which stands out in comparison

[4] S. Olbrich, Journal für Oberflächentechnik, 2016, 6, 44–47.

to benchmark systems due to improved paint

[5] B. List, B. Lloyd, S. Taylor, Organic Finishing, 2012, 110, 12–16.

adhesion and effective corrosion protection.

[6] M. W. Kendig, R. G. Buchheit; Corrosion, 2003, 59, 379–400.

This is mainly due to the specially adapted

[7] M. Becker, Corros. Rev. 2019, 37, 321–342.

organic additives, which ensure an even

[8] R. G. Duarte, A. C. Bastos, A. S. Castela, M. G. S. Ferreira, Progress in Organic Coatings, 2005, 52, 320–327.

distribution of the conversion layer on the

[9] I. Milošev, G. S. Frankel, J. Electrochem. Soc. 2018, 165, 127–144.

aluminium surface and an effective cross-

[10] F. Andreatta, A. Turco, I. de Graeve, H. Terryn, J. H. W. de Wit, L. Fedrizzi, Surface & Coatings

linking with a subsequent organic coating. In

Technology, 2007, 201, 7668–7685.

addition, the additive system exhibits corrosion-

[11] X. Gao, W. Li, H. Ma, Surface & Coatings Technology, 2017, 329, 19–28.

inhibiting properties. SurTec 643 consists of a

[12] M. A. Amin, S. S. Abd El-Rehim, E. E. F. El-Sherbini, O. A. Hazzazi, M. N. Abbas, Corrosion Science, 2009,

make-up concentrate (SurTec 643 MU) and a

51, 658–667.

replenishing additive (SurTec 643 Repl), which

[13] F. Andreatta, L. Paussa, A. Lanzutti, N. C. Rosero Navarro, M. Aparicio, Y. Castro, A. Duran, D.

allows an easy process control and adjustment

Ondratschek, L. Fedrizzi, Progress in Organic Coatings, 2011, 72, 314.

by e.g. conductivity or titration. The process

[14] X. Guo, B. Hurley, F. Yang, R. Buchheit, Electrochimica Acta, 2017, 246, 197–207.

can be applied as immersion, spray or surge

[15] M. A. Smit, J. A. Hunter, J. D. B. Sharman, G. M. Scamans, J. M. Sykes, Corrosion Science, 2003, 45,

process.

1903–1920.

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FOCUS ON TECHNOLOGY

From Office Furniture to School Desk Components, the Growth of Etra Through Management 4.0 Francesco Stucchi ipcm

ÂŽ

Etra, a manufacturer of metal furniture components, opened to us the doors of its factory, organised entirely according to the criteria of Industry 4.0, and especially of its paintshop. Here, the implementation of a new WAGNER Powder Center EVO has sped up colour change-over times, thus increasing production, dramatically reducing powder disposal, and improving application quality.

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FOCUS ON TECHNOLOGY

he Industry 4.0 parameters are now widely applied within

Established in 2006, Etra initially served only one customer that

the manufacturing industry in general and the coating sector

accounted for its entire production, which was carried out in a small

in particular. Etra, a company specialising in the processing

laboratory with the help of three employees. Nowadays, the company

of metal components and based in Maron di Brugnera, in the

has 65 employees and a new headquarters on an area of 10,000 m2,

industrious Italian province of Pordenone, offers an excellent

of which 4,000 are devoted to metal machining and 6,000 to logistics

example of the benefits that the fourth industrial revolution has

and coating. Besides this special production of school desks, Etra is

brought and can bring within a production site. Indeed, this firm has

a well-established supplier of structures for desks, partitions, and

chosen to implement an innovative production management system

steel and aluminium components for prestigious brands in the office,

that fully complies with the criteria of Industry 4.0. This has proved

kitchen, living, and bathroom sectors.

to be particularly crucial in coping with the production of 50,000

Its exponential growth started in 2016, with the relocation in the

school desks, required as a part of the contract awarded by the

Brugnera plant. “Within our new headquarters,” explains owner

Italian Ministry of Education to reorganise classrooms throughout the

Andrea Zilli, “we decided to create a highly automated industrial

country so as to guarantee social distancing and counteracting the

environment, which could operate as a factory 4.0. Therefore,

spread of the COVID-19 virus within school facilities.

we insourced all our production operations by acquiring new

Metal structures for school desks, after machining and before coating.

Furniture components produced by Etra and marketed under its own brand.

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The powder coating booth with the Powder Center EVO.

metalworking machinery and a coating plant equipped with

view the batches being processed in chronological order, with all

WAGNER’s new Powder Center EVO; we also reorganised our

their related parameters, dimensions, and drawings. In the case of

processes through the use of a customised management system.

a last minute emergency, the new order appears at the beginning of

coordinated by a management engineer who controls our entire

the list.

production flow.”

The entire production flow is computerised, run from a ‘control room’

Now, all processes are carried out within this factory: aluminium and

where the management engineer sorts the various orders by giving

iron bars enter and components packaged in boxes with the end

them processing priorities. “In the near future,” adds Zilli, “customer

customers’ brands exit. Besides such semi-finished products for its

orders will be managed automatically: each customer’s file will be

customers, moreover, Etra owns its own brand of finished products,

added to the management system, which will identify the product

Progetra. This includes grommets for desks, table bases, kitchen wall

codes and develop the order. This will eliminate paper orders that

units, height-adjustable tables, electrified sockets, and much more.

require manual management, with a loss of time and the risk of errors.”

From raw to end products Tubes and raw sheets are processed with cutting, bending, and

The importance of coating

welding machines of the latest generation. The workpieces are then

“Almost all our products are intended for the furniture sector,

coated and, finally, assembled and packed. Each workstation is

where finishing is of primary importance, especially given that our

equipped with a video terminal, where the operator can constantly

customers belong to the high end of the market,” notes Zilli. “In the

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past, we used to outsource our coating operations. However, this

and colours required, we realised that its old powder application

entailed numerous problems, above all in terms of processing times,

system had several limitations: the time required for the colour

considering our customers’ increasingly pressing demand for just in

change operations was too long and a lot of non-recoverable powder

time supplies.”

was produced. After the first year, we had already disposed of a large amount of powders. Besides our inexperience, this was largely due to

The coating plant with the new powder management unit

the system being outdated.

“With the transfer to the new factory and the decision to insource

manufacturer of our booth. Its team suggested us installing the new

all production processes, we purchased a second-hand coating

Powder Center EVO, which is a highly Industry 4.0-oriented system

system in good condition,” states Andrea Zilli. “We started painting

thanks to its software package for powder consumption management

our parts immediately after an almost total revamping operation.

and industrial diagnostics. Without thinking twice, we decided to

However, after some time, with the growing number of customers

purchase this powder management unit and some new dispensing

“We therefore turned to WAGNER (Valmadrera, Lecco, Italy), the

The powder application booth.

The inside of WAGNER’s Powder Center EVO.

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The powder tank of the Powder Center.

The manual pre-retouching operation.

guns, which went into operation in January 2020. The results were

Conclusions

immediate: since the first month, we have noticed an 80% reduction

“We are absolutely pleased with our choice to rely on WAGNER. All

in waste powder. Our colour change times have been reduced

the objectives that we had set out with the purchase of the Powder

from 40 to just 8 minutes: in fact, the operator only has to clean the

Center EVO have been achieved: quicker colour change operations,

booth, whereas the powder centre cleans itself automatically.” At

increased plant productivity, dramatically reduced amounts of

the entrance to the booth, an optical reader manages the guns by

powders to be disposed of, with both economic and environmental

stopping the powder flow in the lower part of the racks, where there

benefits, and significantly improved finishing quality,” says Zilli.

are no items to be painted. “The whole coating phase is integrated

chronological order.

and connected to our management system, so that we have constant control of all technical parameters.”

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ART WITHIN SURFACES

Unique Raku Ceramics Through Non-Repeatable Colour Effects Colours with unique effects, harmony, synergy with materials, simplicity, and beauty. In one word: raku. In this interview, Enrico Sioli explains that this ancient technique is not a mere form of art, but an actual philosophy of life.

rancesco Enrico Sioli was born

What relationship exists between art and

These do not stem from the need to “show

on 3 May 1963 in Milan. Now

industry and how does it translate into

off”, but from a company’s will to visually

an entrepreneur, manager, and

your creations?

express its philosophy and its objectives and

representative of a leading international

Art and industry: that is a long story…

convey them to its customers, the market in

insurance and financial Group, he has always

Their relationship has its roots in the late

which it operates, its competitors, and society

had a passion for art and he has found in the

eighteenth century and the early nineteenth

at large. Fondazione Prada, Fondazione Zegna,

ancient technique of raku pottery the closest

century, when the latter tried to elevate itself

and Fondazione Trussardi are just some of the

form of expression to his artistic tendencies.

from mere technical processes through

examples of the way in which many fashion

The work “Sguardi oltre l’orizzonte”, which

‘decorative arts’, which could help make

brands invest in contemporary art through

Sioli donated for the charity auction

industrial products pleasing to the eye. In

their foundations: contemporary art becomes

organised by EOS Mktg&Communication on

that period, art began being associated with

an inspiration for the business language.

its tenth anniversary, aroused the curiosity of

industrial production and it intertwined with

most of the guests1.

craftsmanship: mass-produced items were

Your professional activity is very far from

The raku technique was developed in the

enriched with decorations, while artisans often

the artistic world. How do you manage to

sixteenth century based on the ancient

made use of mass-produced bases to be

reconcile these two aspects?

Japanese art of processing ceramics to

decorated.

It is exactly in this antithesis that my creativity

create clay cups for tea ceremonies. This

Nowadays, the art-industry relationship very

is manifested. I was looking for a way to

particular form of art, which involves a

often takes the form of corporate collections.

express the both positive and negative

complex material processing method, was modified by Western artists in the 1950s, by maintaining the general preparation process – clay is fired at a temperature of 750-950 °C and then rapidly cooled in the open air – but customising the shape of objects. The particular colour effects, which enhance the beauty of these simple and natural items in harmony with materials, are due to the reactions of dyes to the quantity of oxygen released during firing and to the cooling method used. A passionate advocate of this technique, Enrico Sioli has told us a lot about it in this interview.

“Sguardi oltre l’orizzonte”: Giving body and colour to dirt, in ipcm® Interna onal Paint&Coa ng Magazine no. 65 (September/October 2020), p. 134. © Francesco Enrico Sioli

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energies that my profession generated in

and space, which first intrigued me and

Although a skilled, expert ceramist can

me. In Japanese, ‘raku’ means ‘enjoyment,

then amazed me for the uniqueness of its

design a piece with certain characteristics

satisfaction, joy, liberation’. The artist feels

process. A true passion arose after this

and get very close to the initial idea, the

these emotions before, during, and after the

chance encounter, which I nurtured over

unpredictability of the raku technique

operation.

time by participating in further studies and

means that each object is different from any

The ability to transfer my energy to

experiments.

counterpart.

something extremely tangible such as soil

Raku is alchemy and magic. It is earth, fire,

and the possibility of modelling it by following

air, and water: this is the essence of raku

How does your creative process develop?

my instinct and imagination make this form

pottery. Parts glazed with metal oxides,

Each work is developed starting from a

of art an ideal world where beauty and

alkaline frits, and enamels form effects of

particular ‘moment’. Inspiration becomes a

uniqueness take a sophisticated, tangible

iridescence on the parts that are exposed

shape, a colour, and ultimately an object that

shape. It is perhaps such uniqueness, along

to fire and, more generally, create colour

may or may be not useful. This gives origin

with the continuous evolution and fulfilment I

shades and crackle glazes of great effect.

to a process that is ever evolving, as this art

achieve by creating, to constantly incite me. I

Together with the hand processing of clay,

constantly alternates active moments and

am a culturally curious person, and this exotic

this makes each creation visually unique:

pauses, during which thoughts can change,

art pushes me to dare and create alchemies

each object has its own history, it is non-

thus leaving the initial idea behind and

capable of surprising every time.

repeatable, and it acquires value and beauty

finding concreteness in the effect of time

for this very reason. In one word, it is unique.

that passes by.

The raku technique, which you use in your work, is an ancient Japanese art of ceramic processing. Could you briefly describe it? How did you come into contact with this particular artistic form? One day, through my job, I met a raku teacher. His stories revealed a great passion for this ancient art, so far from us in time

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BBROADCASTING ROADCASTING IINNOVATION. NNOVATION.

stay tuned...

SPECIALIZED TRAINING

The Future of Vocational Training for Coating Operators From an interview with ipcm® Academy director Paolo Rami

ontrary to what happens in fields such as the corrosion

experience in organising courses for coating operators, and the ASP

protection one, where there are historically recognised

Mazzini Institute (Cinisello Balsamo, Milan, Italy), the role of Industrial

professional roles and internationally known bodies responsible

Surface Finishing Process Technologist has been recognised at the

for their certification, in the industrial coating field there have never been

regional, national, and European levels. We talked about this with

any certified roles or technical training bodies able to certify them – until

Paolo Rami, the director of ipcm® Academy, who spoke about his point

a few months ago, that is. Now, thanks to the collaboration between

of view on the current situation and the future of vocational training,

ipcm® Academy, the training division of ipcm® with over ten years of

also in the light of this important institutional recognition.

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SPECIALIZED TRAINING

Your collaboration with ipcm®

This method has certainly a future in

Academy began in 2016. How has the

all dissemination activities, also thanks

vocational training sector evolved in

to the increasingly high-performance

this period?

technologies available, which allow

In many sectors, I see growing interest

reducing costs and being more flexible.

and awareness of the importance

The only exception are practical activities,

of training, although unfortunately

which will always have to be carried out

companies are being forced to deal

in person.

with an anomalous situation and many

Personally, however, I believe and hope

uncertainties due to the COVID-19

that remote training will never completely

pandemic. I am also finding that

replace face-to-face training. I think

the major industrial Groups relying

that human contact between teacher

on surface preparation and coating

and learner and physical and social

contractors require increasingly accurate

interaction among individuals and within

process management and coordination

the group are very important to increase

by skilled, qualified technicians.

motivation, involvement, and even positive competition among students.

The courses organised by ipcm

Academy have always been hybrid,

Your contribution was fundamental

with both theoretical and practical

in defining the specifications and

parts. In a complex sector such as

requirements of the new professional

industrial coating, what are the main

role of Industrial Surface Finishing

difficulties encountered by students?

Process Technologist, officially

As regards ipcm® Academy’s course

recognised by the Lombardy region and included in its Framework of

delivery methods, I believe that there are no insurmountable difficulties, since we

Professional Standards (QRSP). Based

are always ready to grasp and assess any

Paolo Rami.

issue found by participants. The students

on what needs did this project arise and what purposes does it have?

receive all the necessary teaching material, consisting of handouts,

The project stemmed from the need to train new professionals

that is, two volumes of over 500 pages, and the presentation slides

recognised at the national and European levels and able to organise

used in each lesson. The practical tests involve the use of tools

and manage an entire coating process to guarantee proper

and control documents and they are organised by teachers with

corrosion protection. These technicians should not only be capable

consolidated experience acquired over years of activity in major

of performing destructive and non-destructive tests, but also of

companies.

collaborating both with an R&D office to design coating-ready

Perhaps, the greatest difficulty faced by some students is leaving their

products and with a production engineering department to find

habits and replacing them with professional and objective methods.

the most suitable protection system to guarantee the durability of

However, this is also a part of the mission of ipcm® Academy:

components in their intended environment. Finally, they should be

teaching and stimulating change in the approach to problems in the

able to assess the adequacy of a company’s production processes,

management of all surface treatment processes.

understand a customer’s technical documents, prepare process management and control documentation from work cycles to

A further form of hybridisation of our courses is the fact that

manufacturing and control plans, and coordinate production

they are currently held both in presence and online. What are

activities based on the technical and human resources available.

the advantages and disadvantages of this organisation, made necessary due to the COVID-19 pandemic?

Why it is useful to enrol in the courses of ipcm® Academy?

At this particular time, the benefits are clear. We would not have

This course, in particular, is very comprehensive, as it deals with all

been able to train anyone if we had not resorted to online solutions.

the typical issues of a protection process: from corrosion, which is

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

199

the “enemy to fight”, to surface preparation, from coating application

What characteristics will post-COVID-19 training have? What are

to failure causes, from controls to plants and technical documentation.

the ipcm® Academy projects and your own forecasts for the next

The students can also try their hands at performing destructive

year?

and non-destructive tests and drafting management and control

The current situation is certainly not easy for anyone, but we must

documents.

have the courage to look ahead, especially at these difficult times. I am

In general, ipcm® Academy’s courses especially stand out for their

convinced that we will be able to relaunch our country’s economy and

theoretical-practical structure. Each topic treated is deepened

that we will be more so if we manage to team up.

through practical examples brought by expert teachers, so that the

We are focussing on the future and we aim at making our courses more

students can immediately apply the information received to their

and more competitive and tailored to the specific needs of the sector.

own production environment or use it as a reference point for any

Therefore, we will try to further involve our industry’s companies. The

situation.

resulting synergy will help our school train professionals whose role is ever closer to the real needs of the market and, therefore, who are ever more easily hired.

Students during a session of ipcm® Academy training courses.

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N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

DGYHUWLVLQǨ LV WKH UHDO HQǨLQH that drives the word of mouth.

for advertising, contact sales@ipcm.it

your unique partner for the development of your company

STANDARD & LEGISLATION - UCIF Informs

Brexit: Threat or Opportunity? Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

info@ucif.net

ne of the thorniest issues

it will be possible to use the tried and

currently under discussion to regulate the

regarding the exports of Italian

tested CE mark for another year (until 31

movement of goods and avoid such specific

companies to European countries

December 2021).

controls. For example, on 1 January 2022,

currently concerns the UK’s exit from the

As for customs procedures, rules have

the CE marking will cease to be recognised

European Union, also known as Brexit. In

been created that oblige companies that

in the United Kingdom but not in Northern

fact, as you may have got to read on the

intend to have commercial relations with

Ireland.

March-April 2020 ipcm® issue1, this will

the United Kingdom to have an Economic

Finally, for people travelling to the UK on

have an impact not only at the European

Operator Registration and Identification

business, it will not be mandatory to have

level, but also on international trade (in

(EORI) Number; otherwise, there is a risk

a visa if the trips are limited to a period of

that article, we specifically dealt with

that the goods will be blocked at customs

less than 6 months. In any case, a passport

Italy’s relations with the USA), as well on

or even seized. It will also be important

will be required to enter the United

politics (the fall of Prime Minister Theresa

to prepare a certificate of origin of goods,

Kingdom as of 1 October 2021.

May and the election of Boris Johnson

since goods entering the UK from a

The regulatory process is still evolving but,

were encouraged precisely to promote

European country will be considered on a

as always, getting to know it and staying

the country’s exit from the EU). The new

par with those of a non-European country,

updated allows avoiding any risks and

situation that will be created shortly (the

and check Incoterms.

continuing to export without any problems,

so-called “transition period” ends on 31

Ireland is an even more particular and

while enjoying a significant advantage over

December 2020) will be full of pitfalls,

delicate matter, because Northern Ireland

those who do not have all the necessary

which deserve to be analysed in order to

belongs to the United Kingdom, while

guarantees. ANIMA and UCIF can support

understand if any opportunities will arise

Ireland (Eire) will continue to be a part

every company in this.

for companies interfacing with foreign

of the EU. Politics tend to agree that the

partners.

creation of a physical border between the

First of all, the United Kingdom’s exit raises

two countries should be avoided, in order

a series of questions about the rules to be

not to undermine the peace process signed

applied on the English territory when the

in 1998. At the same time, there will be

European ones will be no longer valid. In

the need to prevent products destined

practice, in order to ensure commercial

for the UK from travelling through Ireland

continuity, EU rules will continue to

to circumvent the new

apply, but the new mark called UKCA

legislation. An Internal

(UK Conformity Assessed) is going to

Market Bill is

progressively replace the CE mark. This mark, however, will be valid only within the UK borders, as is not currently recognised in the EU. In order to avoid hindering the European trade, it has been decided that 1

M. Zinno, Brexit: what eﬀects will it have on our rela ons with the USA?, in ipcm® Interna onal Paint&Coa ng Magazine no. 62 (March/April 2020), p. 201.

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17|20 MARZO 2021 ямБeramilano

BIM & TECNOLOGIE

madeexpo.it

COSTRUZIONI & MATERIALI

PORTE, FINESTRE & CHIUSURE

promossa da

INVOLUCRO & OUTDOOR

POWDER COATING WEEK 2021

owder Coating

Technical Conference

Custom Coater FORUM PRESENTED BY

POWDER COATING 101

Powder Coating Done Right: The Basics

NEW DATES! April 27 - 30, 2021 Renaissance Orlando at SeaWorld® | Orlando, FL USA

ZOOM ON EVENTS

New Date for European Coatings Show in Autumn 2021 The European Coatings Show (ECS), the leading trade fair of the international coatings industry, has been postponed. Instead of holding ECS 2021 in March next year as planned, Vincentz Network, the organizer of ECS, and NürnbergMesse have rescheduled it for 14-16 September 2021 because of the ongoing coronavirus pandemic and the associated travel restrictions.

ollowing close consultation with exhibitors and industry

ECS to the extent we would prefer in March.”

representatives, Vincentz Network and NürnbergMesse have

Amanda Beyer, Director Event Management Vincentz Network, shares

decided to postpone the European Coatings Show 2021 from

this assessment: “We did not take this decision lightly. Until recently,

spring until autumn. The leading exhibition of the global coatings

everything was pointing to the possibility of successfully holding

industry will be held in Nuremberg from 14 to 16 September 2021,

the European Coatings Show and the partly overlapping European

with the partly overlapping European Coatings Conference scheduled

Coatings Conference in March 2021. At the moment, however, the

for 13 and 14 September.

pandemic situation has worsened, and as the organizers we must be

“Even if the specially developed hygiene plan had allowed us to hold

true to our responsibilities and also listen to the mood of the paint

the ECS safely at the exhibition venue in spring, we need to look at

industry, which had strongly advocated a postponement.

every exhibition individually,” explains Alexander Mattausch, Director

The leading exhibition of the coatings industry, in particular, draws

Exhibitions, NürnbergMesse. “The ECS is a global industry gathering.

its vitality from meetings between people throughout the world.

For the previous show in 2019, exhibitors and trade visitors travelled

That’s why we are pleased to have found an ideal alternative for our

to Nuremberg from more than 120 countries to develop and expand

exhibitors and visitors so quickly with this autumn date, and we are

their international business relationships. These relationships are vital

looking forward to welcoming them to Nuremberg next September!”.

for the coatings sector, which is characterized by global supply chains and large, globally networked companies. Unfortunately, the ongoing coronavirus pandemic and the likelihood that the associated travel

For further information:

restrictions will continue mean we cannot meet this objective for the

www.european-coatings-show.com

ZOOM ON EVENTS

New Dates for the Powder Coating Week 2021 PCI announces new dates for the Powder Coating Week 2021: it will take place from 27 to 30 April 2021 in Orlando FL, USA. The program is complete and registration is open.

ith educational

your spirits with his impish

opportunities to meet

Irish humour and fascinating

the needs of every

program. He will provide

powder coater, the Powder

down to earth, memorable,

Coating Week 2021 program is

implementable ideas to ensure

complete and registration is open.

you, your family, and colleagues

Scheduled to take place April

keep on, keepin’ on.

27-30 at the Renaissance Orlando

Day two of the Technical

at SeaWorld in Orlando, Florida

Conference kicks off with

(USA), this comprehensive powder

Powder Coating Roundtables

coating event is comprised of

during breakfast. Some of the

best information exchange at

three separate programs that offer the perfect combination of

industry events occurs during

peer discussions, and these

keynote presentations, technical sessions, tabletop exhibits, roundtable discussions, expert panels, and

roundtables continue to be one of the greatest benefits of attending

networking. This four-day event is filled with all things powder coating.

the conference, providing a platform for attendees to share information

Don’t miss this opportunity to expand your knowledge and connect

on key topics in a casual setting. Following the general sessions each

with others in the industry at PCI’s Powder Coating Week 2021.

morning, attendees can choose from a wide range of concurrent

“We have developed a great line-up of new presentations for all

breakout sessions covering a myriad of powder coating-related topics.

experience levels, including some brand new areas of interest,”

The Tabletop Exhibition will be open during lunch on Thursday and

comments PCI Executive Director, Kevin Coursin. “It will be a great time

Friday and during a reception on Thursday afternoon. Then, to close out

to reconnect with the powder coating industry in person and talk to the

the Technical Conference, PCI will host “Troubleshooting Jeopardy,” an

experts to gain insight and additional knowledge or solve problems for

interactive and engaging session that covers a topic that affects coaters

your finishing operations.”

of every size and type of application.

Powder Coating Week 2021 begins with PCI’s popular Powder Coating

Attendees can register separately for each Powder Coating Week 2021

101 Workshop: Powder Coating Done Right - The Basics, which will

event or register for a combination of events. The Powder Coating 101

run concurrently with PCI’s Custom Coater Forum on April 27 & 28.

Workshop and Custom Coater Forum registration fees alone do not

PCI’s long-standing Powder Coating Technical Conference & Tabletop

include admission to the Technical Conference or Exhibition.

Exhibition will be held April 29 & 30. The tabletop exhibition held as a

PCI will follow all health and safety protocols determined by local and

part of the Powder Coating Technical Conference will include exhibits

state governments, as well as all safety guidelines provided by the

from powder coating manufacturers, powder coating application

Renaissance Orlando at SeaWorld® management.

equipment manufacturers, systems houses, chemical suppliers and various services that support the powder coating industry.

For further information:

On Thursday, April 29, the Technical Conference features a keynote

https://conference.powdercoating.org/ and

from Conor Cuneen, titled, “Keep On, Keepin’ On! Building Blocks to

www.powdercoating.org

Improved Teamwork, Collaboration and Productivity.” Cuneen will lift

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

207

ZOOM ON EVENTS

Over 9,000 Visits Registered for 32.BI-MU, One of the First Exhibitions Organised during the Health Emergency 32.BI-MU, the trade fair held at Fieramilano Rho from 14th to 17th October, was concluded. Over 9,000 visits were registered for the first exhibition dedicated to the machine tools sector organised during the health emergency.

aturday, 17th October was the last day of 32.BI-MU, the first

industry. About 50 events were held in the BI-MUpiù arena.

exhibition dedicated to the sector of machine tools, robot,

On the other hand, the BI-MUpiùAdditive area, organised by AITA-

automation, digital and additive manufacturing, and auxiliary

ITALIAN ASSOCIATION OF ADDITIVE TECHNOLOGIES, illustrated the

technologies, organised during the health emergency.

industrial applications of additive manufacturing, proposing some

Over 9,000 visits were registered over the four exhibition days. This is

components related to the mechanics, automotive, aerospace and

a satisfactory number, in line with the expectations for an event that

biomedical sectors, developed thanks to machinery that today can be

took place during the health emergency, but in full respect of all rules to

defined as “machine tools of the third kind”.

contain the spread of Covid-19.

A great novelty of BI-MU 2020 was BI-MUpiùDigital, a demonstration

Promoted by UCIMU-SISTEMI PER PRODURRE, the Italian machine

area set up in Hall 11 conceived to highlight the potential of a digital

tools, robots and automation systems manufacturers’ association, and

factory.

organised by EFIM-ENTE FIERE ITALIANE MACCHINE, before its start,

In addition, thanks to BI-MUonline, the event will continue after the

32.BI-MU obtained the Compliance Certification released by ICIM, with

end of the exhibition. As a virtual version of the real trade show, BI-

regard to the conformity with safety protocols to combat and contain

MUonline features the technological product offering on display, from

the spread of Covid-19.

the exhibitors’ real voice on the website bimu.it. Starting from the

Of the total visitors, 3.5% were foreign visitors representing 27

beginning of November and until the 2022 edition, the virtual exhibition

countries; Germany, Switzerland, France and Austria were the most

proposes videos, video clips and interviews directly collected at the

represented countries.

stands.

With over 350 exhibiting companies, 30% of which from abroad, two

The next edition of BI-MU will take place at fieramilano Rho from 12th to

exhibition halls and a large and varied technological product offering,

15th October 2022.

32.BI-MU also proposed a full programme of meetings focused on the main topical issues of interest for the operators of the manufacturing

For further information: www.bimu.it/en

AUTOMATIC SYSTEMS FOR GRINDING AND POLISHING Impianti automatici per smerigliatura e lucidatura DAN di DE ANTONI srl 25 03 0 Cocc a glio (BS) - Via G a zzolo 2/4 Tel. +39 030 77 21 850 - +39 030 77 22 477 s a l e s @ d e a n t o n i . i t - w w w. d e a n t o n i . i t

Supplemento a IPCM nÂ° 66 - Novembre/Dicembre 2020

ICT digital on www.myipcm.com

NEWS

ICT | INDUSTRY NEWS

Economical cleaning even at low throughputs The new cleaning unit S(uper)1 launched by PERO AG is designed for medium-sized production companies with low cleaning requirements. It has various interesting features including a powerful cleaning performance and a new operating concept.

ERO AG, the German company which has been developing and

assistance and with little eﬀort.

producing for more than 60 years innovative systems for the

Additionally, the user interface constantly displays the remaining

cleaning of workpieces made from metal, plastic, glass, ceramic

time left for the washing programs and automatic shifts. Filling levels,

and combined materials, launched S(uper)1, a cleaning unit that is

signal states and movements within the unit are also visualized.

particularly recommended for medium-sized production companies

The “Super1” cleaning unit features a short heating up period and the

with low cleaning requirements. It is suited for product carriers with

resulting quick operational readiness. It is able to perfectly degrease

the dimensions 530x320x200 or 530x365x250 mm.

parts which have large amounts of grease and oil adhering ad

The compact machine is designed as a standard machine with

reliably remove residual chips and foreign particles, also thanks to its

many serial components and consequently achieves a high level of

powerful ultrasonic unit.

operational reliability and excellent cost-eﬀectiveness. This represents

The fast filter drying, a manual charging unit for easy loading and

a major advantage in terms of both purchase price and operating

unloading of the washing baskets and the possible water ingress of

costs, because PERO S1 can be operated economically even at a low

up to 500 ml/hour are further positive features of the new PERO S1.

throughput of up to ten baskets loaded with parts per hour.

The new closing mechanism of the processing chamber guarantees

PERO also focused particular attention on a new operating

a high level of safety for the employees because it prevents any

concept with an easy-to-follow user interface and reduced input

possibility of intervention in the door travel path.

requirements. Thanks to numerous visualizations and several

At the PERO Competence Centre, it’s possible to experience the

automated maintenance functions, even employees without special

eﬃciency of the S1 cleaning unit, which is available for purchase or

training can operate and maintain the system easily and eﬃciently.

rent.

An eventual operating error is localized and clearly displayed by

the software enabling the operator to correct the error without

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For further information: www.pero.ag

ICT | CASE STUDY

FRANCESCO STUCCHI ipcm

When cleaning becomes crucial in the production of components intended for highly sophisticated measuring and control instruments Intermediate and ﬁnal cleaning phases play a strategic role in any production process, because only the total removal of contamination can guarantee that components are of quality, reliable, and perfectly functional over time. The industry of measuring and control instruments is among the sectors placing the highest cleanliness © Agilent

requirements on their products, together with the medical and dental ones. Agilent Technologies Italia (Leinì, Torino, Italy) also needed to reduce water consumption and completely automate a cycle where human error could not be a process variable. In March, it achieved all its goals thanks to the collaboration of MEG (San Martino di Lupari, Padua, Italy), a company specialising in the production of multi-tank water and detergentbased cleaning plants.

gilent Technologies is a global company, leader in life sciences, diagnostics and applied chemical markets, born back in 1999 as a spin-off of

Hewlett-Packard. Active in many sectors including pharmaceuticals, diagnostics, research, chemistry, and energy, it produces a wide range of analysis and research tools, such as devices for pharmaceutical companies and A turbo molecular pump produced by Agilent.

university research laboratories that analyse chemical elements or compounds. It has a Vacuum Products Division with a manufacturing plant in Leinì (Torino, Italy), where about 240 people work in production,

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ICT | CASE STUDY

R&D, quality, customer service, marketing, human resources, warehouse, and logistics departments. “This manufacturing site, established as the European branch of Varian Inc. in 1967, is now part of Agilent. It has always provided a wide range of solutions to create, measure, maintain, and control vacuum in different applications, including those required by the world’s largest particle physics laboratories. One application example is the Large Hadron Collider (LHC), the particle accelerator located at CERN in Geneva, where our ion pumps are installed to reach ultra-high vacuum,” explains quality operations manager Valentina Sacco. “We actively operate in the field of scientific research, laboratory analysis and nanotechnology. This is a niche market: there are very few companies in the world that make these products.”

The use of vacuum pumps in laboratory instruments

A ﬁnned part, a fundamental component of turbomolecular pumps.

“Different products must be used to reach the different vacuum ranges required by the sectors in which we operate. In a nutshell, a low vacuum level can be achieved with oil or dry primary pumps, high vacuum is reached with pumps like the turbomolecular ones, and finally, for very specific applications such as particle accelerators, ion pumps are used, which create ultra-high vacuum. For example, a target market where we operate and have a leading position both as Agilent and as vacuum division is the mass spectrometry, both as gas and liquid chromatography. In order to analyse a sample or to dissolve it, these instruments require operating chambers where there is no other element other than that of the sample itself, not even air. Such condition is obtained by creating a high level of vacuum inside the operating chamber with the use of

The new detergent cleaning system.

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ICT | CASE STUDY

the pumps produced in our factory,” says Diego Vai, one of Agilent’s Advanced Engineers. “We produce thousands of pumps a year in different sizes and types, from mechanical to ion and turbomolecular pumps.”

The production process “Most of our turbomolecular pumps’ components come from our supply chain, but we manufacture a few key parts in-house, such as rotors and the rotating part of electric motors. For instance, preassembly and EDM, milling, and grinding operations are carried out using our own precision machining department. Given the numerous operations performed and the use of coolants, it is easy to understand that the pre-assembly cleanliness level of these components is not adequate to the standards of the clean room where our pumps are © ipcm

Two Cartesian robots handle the baskets.

assembled and tested.” “Our collaboration with MEG for industrial cleaning operations began when we had not been acquired by Agilent yet,” states Valentina Sacco. “About ten years ago, we were already using a solvent cleaning system that had been supplied by MEG, which is still working today. Then, about five years ago, we started considering replacing our other cleaning machines, which were no longer functional, with a new system that brought together all the solutions we needed. The new cleaning plant, in operation since March, is dedicated to the components of our turbomolecular pumps. All their parts, except bearings, are treated in this new MEG system and then transferred directly to the clean room, where final assembly takes place.”

The importance of the cleaning phase “Cleaning quality is fundamental in the production cycle of a vacuum pump,” explains Diego Vai. “Only the perfect cleanliness of all pump components enables to reach the required vacuum degree. Besides performance, less-than-perfect cleanliness affects the service life of pumps. Bearings, for example, are very delicate components of vacuum © ipcm

The movable bulkhead through which the baskets with clean parts enter the clean room.

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pumps. Greased bearings, in particular, could

ICT | CASE STUDY

be polluted by the impurities present inside the vacuum chamber: as these components reach a rotation speed close to 80,000 RPM, any pollutant coming into contact with them could create vibrations and heat, thus compromising durability. Since we handle almost exclusively aluminium and steel components, the type of impurities that we need to completely remove are micro burrs, micro metal chips, sandblasting residues, processing oils, oxides, and so on.”

The cleaning plant: full automation A team composed of Agilent engineers together with MEG’s technicians developed the design of the new plant. Its main requirements were high cleaning quality, total process automation, flexible programming of complex programs, the ability to interface with our production systems (digital Kanban, manufacturing execution system, etc.), and the integration of filtration and recirculation

The empty baskets return to the loading area.

units to reduce water and detergent consumption. In addition, the plant had to be directly connected to the final assembly clean room, so that the workpieces could move from one environment to another without being contaminated. “This cleaning cycle with water and detergent was based on one of Agilent’s old manual cleaning processes,” indicates Diego Vai. “One of our previous systems was equipped with ultrasonic tanks for active baths, rinsing tanks, and a few drying stations. However, the baskets were manually transferred from one tank to another, whereas the manual drying phase, occurring through a blow-off operation in a simple resistance furnace, did not guarantee perfect part dehumidification. Moreover, most components underwent a spray cleaning treatment, with much lower quality standards than an immersion cleaning process.” “The new plant performs the following steps: precleaning with ultrasound, cleaning with ultrasound, first rinse in mains water, second and third rinse in demineralised water, and two drying stages. The process was completely automated and the drying phase was revolutionised with two air stations and

The loading area receives the empty baskets coming from the clean room.

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ICT | CASE STUDY

unit, in fact, we significantly improved our

a final vacuum chamber to eliminate any residual moisture,” says MEG sales manager

cleaning performance on these important

Giampaolo Rossi.

components: this was only possible thanks

The parts to be cleaned are placed on

to the collaboration between MEG’s technical

special holders, each designed by Agilent’s

department and us. Afterwards, we started a

engineers according to their different

more complete project for the development

characteristics and custom-produced with

of a totally new water and detergent cleaning

the additive manufacturing technology. Some

system, which led to the installation of this

components are arranged on static trays that

fully automated and very efficient tank line.”

are then inserted into baskets, others are mounted on geared fixtures that rotate inside

All goals achieved

the tanks. The baskets are then positioned

“The plant has been operational since

in the loading area, where a small buffer

March,” adds Diego Vai. “Its development,

enables the system to be loaded with multiple

design, production, and assembly took a

baskets. The first Cartesian robot of the

long time, but our initial needs were fully

cleaning line picks up one basket and takes

met. These included improving cleaning

it through the various stations, up to the last

quality, reducing the likelihood of human

rinsing one. Once the basket is immersed in

errors as much as possible, integrating all

the third rinse with demineralised water, it

the innovative devices developed over the

goes back to the loading area to pick up the

years such as filtration, automatic dosing,

following one.

water collection and discharge, and tank

Meanwhile, a second robot picks up the

water temperature and conductivity control

basket previously deposited by the first robot

systems, and integrating more efficient

in the demineralised water rinse tank and

drying systems that reduced the probability

takes it to the subsequent drying stations.

of oxidation of our workpieces. Finally, a very

After the last vacuum drying station, the same

important aspect was the management of

robot picks up the basket, now containing perfectly clean and dry workpieces, and

The pump rotors to be cleaned are mounted on special holding ﬁxtures that allow rotation.

places it on the belt conveyor. Through a

our consumption of demineralised water, which was definitely too high with the previous plant. Our factory is equipped with

movable bulkhead, this leads the basket

a centralised plant for the production of

inside the final assembly chamber. Finally, an

loading area, always with the two robots.”

demineralised water that also feeds other

operator places the empty basket on the belt

“MEG started working with our company

production lines, but our old cleaning system

conveyor, which passes through the bulkhead

about 15 years ago by providing us with

required an amount such as to put it under

again and leaves the basket where the robot

a solvent-based machine that is still fully

stress. This high consumption level forced

can pick it up and take it back to the loading

functional, dedicated to treating some

us to often regenerate the demineralisation

area, in order to be filled with other parts to

particular components,” says Valentina

units’ resins. At the same time, our

be cleaned.

Sacco. “Ten years ago, I met Giampaolo

consumption of mains water was also

“The system management software package,”

Rossi, to whom we presented the issues with

significant and this created high volumes

adds Rossi, “was designed by our technical

our manual detergent cleaning machine,

of waste water to be disposed of as special

department. It required a considerable effort

as the manufacturer was no longer able to

waste, with excessive disposal costs. Quality,

also in terms of the management of the two

provide us with assistance. Together, we

automation and digitalisation, reduction of

Cartesian robots. Indeed, I believe that one of

first developed a system that would improve

maintenance and environmental costs, and

the main innovations of this system is the fact

the cleanliness of the rotors we produce

process optimisation, therefore, were our

that the baskets, after being unloaded in the

in-house, which require special precautions.

objectives. I would say that we have reached

clean room, are automatically returned to the

By integrating the old plant with this new

all of them,” states Diego Vai.

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N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

Machines for precision cleaning with ultrasonics

Solvent cleaning: Cleaning, rinsing and drying in 10 minutes Use of last generation solvents: non-ďŹ&#x201A;ammable, non-ozone-depleting, low-boiling Strong reduction of energy consumption and environmental pollution Applications: mechanics and precision mechanics, electronics, medical and many more.

Aqueous cleaning: Maximum ďŹ&#x201A;exibility with different in-line positions as cleaning tanks, rinsing and hot air dryers Solutions for any cleaning need, even the most complicated Applications: mechanics, automotive, optical, jewellery, watchmaking and many more. Possibility of additional treatments as pickling and passivation

meg.it info@meg.it

ICT | TECHNOLOGY OVERVIEW

GEORG HARNAU Walther Trowal GmbH & Co. KG, Haan â&#x20AC;&#x201C; Germany g.harnau@walther-trowal.de

ÂŠ Walther Trowal

Rotary Solutions for castings and stampings save time, space and costs The new CB rotary finishing vibrators from Walther Trowal can be seamlessly integrated directly into the manufacturing flow.

hen it comes to surface finishing of die-castings and

deburring operation. For example, in case of die-castings containing

stampings, the optimized CB rotary vibrators from Walther

only small metal flashes or stampings demanding a slight edge

Trowal combine the technical features of linear continuous

deburring. Since they allow feeding the work pieces individually into

flow systems with the advantages of rotary vibrators. The CB machines

the machines in a continuous flow, the CB rotary vibrators can be very

are ideal for processing of work pieces, which merely require a light

easily integrated into interlinked manufacturing operations.

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N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

ICT | TECHNOLOGY OVERVIEW

The CB 5 rotary vibrator from Walther Trowal.

Die-castings embedded in the media mix.

Compared to just a few years ago the on-going technical

that allowed processing the work pieces in continuous flow mode

improvement of aluminium, zinc or magnesium die-casting

and, therefore, made it possible to integrate the rotary vibrators

production processes has resulted in significantly shorter cycle times

directly into the manufacturing flow.

for de-flashing and light deburring. Also, today many stampings have just minor burs. Likewise, the slight rounding of sharp edges

The advantages of the new rotary ﬁnishing vibrators

nowadays can be achieved in just a few minutes of ‘trowalizing’.

New is that the work pieces are no longer loaded into the work bowl

For example, based on improved production methods a renowned

in complete batches but are continuously fed into the rotary vibrator

die-casting company was able to reduce the cycle times for de-

in single piece flow at the actual production rate. For example, in die-

flashing and surface homogenization of the raw die-castings to

casting operations this allows linking the rotary vibrator directly to

merely five to six minutes. For this reason, in close cooperation with

the die-casting machine so that the raw die-castings can be finished

the customer, Walther Trowal implemented some technical changes

without the need for any additional material handling or intermediate

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

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ICT | TECHNOLOGY OVERVIEW

buﬀer systems. Contrary to the rectangular work bowl in linear continuous flow systems, rotary vibrators have a spiral processing channel with a steady incline towards the machine discharge section. This is equipped with a screen that permits the separation of the media from the finished work pieces. While the work pieces are discharged from the machine, the abrasive media is falling through the separation screen back into the processing bowl. Several customers have already made the switch from the much more intensive linear continuous flow AV systems to CB rotary vibrators. One user, who operates seven vibratory finishing systems from Walther Trowal, has confirmed that with a cycle time of five to six minutes all material flashes are consistently removed from his aluminium die-castings. The experience from actual customer installations has shown that with a CB 400 optimal finishing results can © Walther Trowal

be achieved with a cycle time of four minutes, whereas

A CB rotary vibrator equipped with a magnetic separator that removes ferromagnetic work pieces from the media mix and feeds them into a drier (visible on the right side of the photo).

The work pieces are transferred into the machine from the side with a conveyor belt.

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CZ the cycle time in the much bigger CB 800 amounts to seven to eight

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minutes. Christoph Cruse, sales director at Walther Trowal, identifies significant advantages for his customers: â&#x20AC;&#x153;Only four minutes for â&#x20AC;&#x2DC;trowalizingâ&#x20AC;&#x2122; of aluminium die-castings? Until recently this would have been considered as impossible. But our customers have refined their manufacturing methods to a point, where such short cycle times for de-flashing and light deburring are fully suďŹ&#x192;cient. Under such conditions our optimized CB rotary vibrators, seamlessly integrated into the overall manufacturing flow, are especially economical. And, compared to the technically more complex linear continuous flow AV systems, their price tag is considerably lower.â&#x20AC;? -NLM UJWKTWRFSHJ RTINKNJI FQHTMTQ HQJFSNSL RFHMNSJX

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require a minimum of space. Whenever a high processing intensity and/or a higher throughput is needed, the linear continuous flow AV machines are still the optimum solution. They allow practically any processing time that may be required for more diďŹ&#x192;cult applications.

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ICT | CASE STUDY

GIORGIA RICCHIUTI ipcm

An effective water and detergent-based cleaning cycle for hydraulic blocks with blind holes and grooves CPM Manifold, a manufacturer of high quality hydraulic blocks, has relied on the experience of STS, a company with speciﬁc expertise in solving cleaning and surface treatment problems, for the supply of a water and detergent cleaning machine using sodium bicarbonate. This guarantees the perfect cleanliness of hydraulic blocks with blind holes and complex shapes that need to be cleaned efficiently.

he phrase “oil hydraulics” refers to any system involved in the

growth of this sector worldwide, there is an increasing demand for

transmission of energy through pressurised fluids. A plant of this

ever-higher quality oil hydraulic components. Nicola Tofanelli is well

type is made up of several elements, such as a power source,

aware of this: he is the managing director of CPM Manifold (Paitone,

distribution components, connection components (rigid or flexible

Brescia, Italy), a company operating in the market of oil hydraulic

pipes), and actuators. Thanks to the continuous development and

blocks for over forty years.

ICT | CASE STUDY

Established in 1971, it initially performed machining processes on hydraulic press components. Twelve years later, it decided to specialise exclusively in the production of hydraulic blocks, thus becoming a leading company at the national and European level in the production and supply of these parts, intended for industrial systems related to machine tools, forming, and deformation, for power generation systems, and for machines used in the furniture, agricultural and earthmoving equipment, transport, and naval sectors. “We were one of the first firm in Italy to supply completely deburred, clean, and ready-to-assemble hydraulic blocks. Attention to cleanliness, in particular, has always been one of our strengths,” explains Nicola Tofanelli. CPM Manifold currently has about 70 operators working with highly automated machines. Always

A raw block positioned in one of the machining centres.

attentive to new technologies, its R&D department is now dealing with the enhancement of its workflow and the development of Industry 4.0-oriented software programs, which will soon result in the complete automation of its production processes. “We are one of the few companies that produce blocks in numerous materials according to our customers’ requests, from cast iron to stainless steel and aluminium, in order to serve as many sectors as possible,” says Nicola Tofanelli. “Each material requires its own automation technology and tools. Their management is complex, but it enables us to encompass numerus application fields. We have two diﬀerent product lines, which we call “single blocks” and “mass produced blocks”. Single blocks © ipcm

have significant dimensions, they weight from 100 kg upwards, and they are

Blocks awaiting cleaning.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

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ICT | CASE STUDY

produced in small series. Mass produced blocks can weigh from 1 kg up to a maximum of 100 kg and they are manufactured in large series. CPM Manifold is among the European leaders in the production of single blocks.” “Normally, we receive from our customers a technical drawing or a description of the required product functions, and we design and build our components based on these instructions. Some customers also demand specific surface treatments, such as phosphating, which we perform in-house, or other surface treatments, which we entrust to a contractor,” indicates Nicola Tofanelli. CPM Manifold’s main target markets are Europe and North America, where it exports more than 70% of its products, and China, with a small export quota.

The production of hydraulic blocks After receiving the base materials, the blocks are loaded onto a machining centre where mechanical processing operations are carried out. Subsequently, the workpieces undergo a first cleaning step to degrease and clean their surfaces. They are then subjected to mechanical or thermal deburring. For the latter process, the parts are placed in a chamber filled with a mixture of methane and oxygen, which generates an explosion that brings the internal temperature to a very high level, such as to cause the complete oxidation of the hydraulic The touch screen panel of the cleaning system.

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ICT | CASE STUDY

block. In this case, the components are subjected to an additional cleaning step, defined as “deoxidation” and performed in a one-chamber machine supplied by STS.

Technical characteristics of the cleaning machine The AQUAROLL EE40 plant consists of a cleaning module and two rinsing ones, which guarantee excellent cleaning quality thanks to the continuous rotation of the blocks under the combined action of high-volume, low-pressure jets and immersion cleaning. In a nutshell, it is a rotational hydrokinetic cleaning system performing both immersion and spray operations. Its cycle lasts about 15 minutes and it is composed of 6 stages: © ipcm

immersion cleaning, ultrasonic cleaning, immersion rinsing, ultrasound rinsing,

The cleaning chamber.

hot air blow-oﬀ drying, and vacuum drying. CPM Manifold’s hydraulic blocks require a double-rinse cleaning process because they need to be both degreased and passivated to prevent any subsequent surface oxidation. The products used are based on sodium bicarbonate, free from any aggressive surfactants and volatile compounds. They also have toxicity, flammability, and reactivity values of 0.0.0. and they present no handling risks. The cleaning solution’s service life is considerably extended thanks to the use of the oil separator, which reduces the amount of waste to be disposed of and any risk of chemical pollution in the work area. The plant was installed two years ago and it works on three shifts. “Before installing it, our parts’ cleaning process was completely manual,” says Nicola

Hydraulic block ready for the assembly of components.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

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ICT | CASE STUDY

The test laboratory.

Tofanelli. “With the implementation of the thermal deburring

must be perfectly clean and dry, in order to guarantee the correct

machine, the need arose to replace it with an automatic cleaning

operation of hydraulic circuits.”

operation able to deoxidise and perfectly passivate our parts. We turned to STS based on the high cleaning quality standards that it

Future projects

guarantees through the combination of its machines and products.

One of CPM Manifold’s goals for the immediate future is to also

One of the major advantages brought by its automatic cleaning

automate the cleaning of larger workpieces, which currently cannot

system is the fact that the workpieces are completely dry at the

be treated inside the STS system. More generally, thanks to the

end of the cycle and they do not require any processing by our

careful selection of materials and suppliers, it intends to guarantee

operators. Dryness is a fundamental aspect for the quality our end

an ever-higher quality of products, in order to be constantly at the

products, because hydraulic blocks feature several blind holes that

forefront of international markets.

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N. 66 - NOVEMBER/DECEMBER 2020 - international PAINT&COATING magazine

Impianti di lavaggio Washing machines

Novità aquasealer® Impianto di impregnazione Impregnation plant Soluzione in resina per le porosità Resin solution for porosity

aquaroll® EE40 con Rulliera Motorizzata per un’alta ed efﬁciente produttività for high and efﬁcient productivity

aquaroll® MR9 – Macchina Rotativa a 9 stadi per un’eccellente qualità di lavaggio nel rispetto delle speciﬁche piu restrittive for excellent washing quality in compliance with the most restrictive speciﬁcations

STS Srl - Sede legale e operativa: Via L. Galvani, 8 - 48123 Ravenna RA (Italia) Sede amministrativa e magazzino: Via G. Ferraris, 7 - 48123 Ravenna RA (Italia) Tel. +39 0544 456731 - Fax +39 0544 456733 - www.stsitaly.it - sts@stsitaly.it

DORIS SCHULZ

ICT | TECHNOLOGY OVERVIEW

SCHULZ. PRESSE. TEXT., Korntal, Germany ds@pressetextschulz.de

Innovation in CO2 snow-jet cleaning: faster, more effective, and more efficient thanks to pulsating jet

The quattroClean snow-jet technology has established itself as an economical and reliable process for the partial and full-surface cleaning of a wide range of parts. A newly developed two-component ring nozzle for a pulsating jet now enables further cost savings and technical advantages to be realized in CO2 cleaning operations.

n today’s quality-oriented production processes in all branches of industry, parts cleaning is an indispensable step. The cleanliness specifications to be fulfilled vary

according to the product, the manufacturing phase, and the next process in the production chain, such as coating, joining, assembly or packaging. Whatever the case, the trend is increasingly towards dry cleaning processes, such as acp systems AG’s quattroClean snow-jet technology. These ensure reliable cleaning results in line with requirements and are easy to integrate into production lines and connected manufacturing environments. The environmentally friendly alternative to wet chemical processes also offers advantages if only specific areas of a part require a defined level of particulate and/or filmic cleanliness, such as bonding, welding or sealing surfaces, or when it comes to cleaning readyassembled components. Furthermore, the technology can be used to clean and deburr hard and brittle plastics like PEEK and PPS simultaneously.

Four effects for consistently clean surfaces The cleaning medium used is liquid, non-corrosive carbon dioxide, which has an unlimited shelf life. A by-product of chemical manufacturing processes and biogas energy generation, this cleaning medium is environmentally neutral. The core of the cleaning system is a wear-free, two-component ring nozzle through which the non-flammable The new nozzle generates a pulsating jet with a frequency of 25 to 30 Hertz and a higher kinetic energy.

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ICT | TECHNOLOGY OVERVIEW

ÂŠ acp systems AG

The innovative pulsating nozzle improves cleaning efficiency and broadens the range of application of the quattroClean snow-jet cleaning system.

and non-toxic carbon dioxide is fed. On exiting the nozzle, the carbon

a pulsating jet with a frequency of 25 to 30 Hertz. The pulsating

dioxide expands to form fine CO2 snow, which is then bundled

jet of snow and compressed air has a higher kinetic energy than a

by a separate jacketed jet of compressed air and accelerated to

continuous jet, hence the optimized cleaning effect. For one, the

supersonic speed.

effect of the micro jets (mechanical method of action) is multiplied.

When the easily focused jet of snow and compressed air impacts

This is due to the impulse transmitted when the fine snow crystals

on the surface to be cleaned, a combination of thermal, mechanical,

impact at high speed on the surface to be cleaned or deburred.

sublimation and solvent effects occur. The interaction of these

Secondly, each time the pulsating jet strikes the material, an

four mechanisms of action reliably removes particulate and filmic

approximately 600-fold increase in volume takes place during the

contamination. The aerodynamic force of the compressed air carries

transition from the solid to the gaseous phase (sublimation effect).

away the detached contamination, which is then removed by an

This causes repeated micro-explosions that enable contaminants to

integrated extraction system. Since CO2 sublimates instantly under

be removed more effectively.

step and immediately ready for further processing or packaging.

Shorter processing times and lower costs

atmospheric pressure, the parts are dry at the end of the cleaning

Thanks to the increased effectiveness of the jet, in many applications

Higher cleaning efficiency thanks to new nozzle technology

the already short cleaning times can be reduced even further.

With the aim of increasing cleaning efficiency even more and

of deburring tasks, so that processing cycles can be shortened here

broadening the range of application, acp has further developed its

as well.

nozzle technology. The result is a nozzle technology that generates

This opens up new perspectives, especially if the quattroClean system

The enhanced impulse transmission also improves the efficiency

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

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ICT | TECHNOLOGY OVERVIEW

ÂŠ acp systems AG

The pulsating jet of snow and compressed air has a higher kinetic energy than a continuous jet, and hence an optimized cleaning effect.

is integrated into automated production steps with very short cycle

manufacturing environments. The scalable quattroClean process

times. Corresponding trials are carried out by the company in its own

can be adapted to different component geometries for partial or

technical center. The pulsating jet can also reduce the consumption

full-surface processing in an efficient and space-saving manner.

of carbon dioxide and compressed air, thus cutting cleaning costs

Through tests in the technical center, all process parameters such as

per part and contributing to higher economic efficiency. Furthermore,

the volume flows for compressed air and carbon dioxide, as well as

the snow-jet cleaning system with pulsating nozzle is both lightweight

the duration and area of application of the jet, are precisely tailored

and compact.

to the case in question, taking the properties of materials and the contamination to be removed into account. These parameters

Highly ďŹ&#x201A;exible systems tailored to requirements

can later be filed as part-specific cleaning programs in the system

The company develops customized system concepts based on

controls. Standardized interfaces allow easy integration into higher-

standard modules that are adapted to the respective cleaning and

level host computer systems for subsequent control. To ensure

cycle time requirements. The systems can be designed as stand-

full documentation and traceability, all process parameters are

alone solutions or can be integrated into automated or connected

automatically recorded and transferred to the host computer.

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H Y HIGALITteed QU aran

Immerse yourself in our solutions and take avantage of the cleaning power of water

H Y HIGALITteed QU aran

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Parts washers macro models

SIN 19 C E 67

machine versions available accessories inﬁnite combinations

12 107 220

Lavapezzi macro modelli versioni macchina accessori disponibili inﬁnite combinazioni

PA R T S WA S H E R S S I N C E 1 9 6 7

IMPIANTI DI LAVAGGIO DAL 1967

We have the experience, know-how and a wide range of machines to guarantee the best solutions for part washing.

Abbiamo l’esperienza, il know-how e una vasta gamma di macchine per garantire le migliori soluzioni per il lavaggio dei pezzi.

#sp ray # ultrasonic # hi d roci ne t i c # m a nu a l # com bi n a te d # tu n n el # f o r _ h ea v y _ p a r ts # f o r _ s ma l l _ p a r ts # r o bo t_ h an dled #In du s tr y_ 4 .0

www.teknox.net | www.youtube.com/user/teknoxitaly

www.gattomatto.biz

METAL CLEANING EVOLUTION

ICT | ZOOM ON EVENTS

Great Interest in the parts2clean Online Day More than 500 participants attended the parts2clean Online Day to learn about the latest developments in cleaning technology. The virtual format replaced the parts2clean expert forum, which was cancelled with the trade fair due to the corona pandemic. The plan worked. The audience experienced knowledgeable presentations. In between, exhibitors presented their products. And ideas were exchanged in the virtual foyer and at the Speakers Corner. he mood was still there on the first day of the fair: Although

Olaf Daebler, Global Director parts2clean at Deutsche Messe AG,

the parts2clean halls in Stuttgart had to remain empty this

also drew a positive conclusion: “Trade fairs will have to oﬀer hybrid

year, part of the community met virtually at the parts2clean

formats in the future. That is why I’m very pleased about this successful

Online Day. The fact that 530 interested parties had registered, and

start, and I’m also very pleased that we were able to be present with

more than 500 were present online, speaks to the great need for

parts2clean in October 2020 despite Corona.”

information and exchange. The proportion of international guests was

Fourteen speakers from the fields of science and industry passed

15 percent.

on their knowledge regarding cleaning processes, digitalization

“I had high expectations, but even these have been exceeded,”

and automation as well as analytics and technical cleanliness. The

summarized Frank-Holm Rögner, Cleaning Group Manager at the

average number of participants per lecture was just over 100, and

Fraunhofer Institute for Organic Electronics, Electron Beam and

20 presented their products between the two lecture blocks. There

Plasma Technology FEP and spokesperson for Fraunhofer Reinigung.

was also an opportunity for exchange among the participants: the

He and his team were responsible for technical management of the

Speakers Corner featured in-depth discussions and there was time for

parts2clean Online Day. “Seven hours online cannot replace three

networking in the foyer.

days of expert forums, but it was very good to see that such a format works,” said Rögner.

For further information: www.parts2clean.de/en

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ICT | ZOOM ON EVENTS

EMO MILANO 2021: meet “the magic world of metalworking” at Fieramilano Rho from 4 to 9 October 2021 It will be Milan to welcome the next edition of EMO, the world machine tool exhibition, alternately hosted in Italy and Germany and considered as the leading trade show for the operators of the world manufacturing industry.

romoted by CECIMO, the European Association of Machine Tool

professional updating and for observing the technological trends

Industries, EMO MILANO 2021 will take place at fieramilano Rho

characterising the production of the future.

from October 4th to 9th.

In this sense, EMO is an exhibition event capable, like no other, of

Undisputed leader in the scenario of the exhibitions regarding the

interpreting the industrial “spirit of the age” and, at the same time,

sector, EMO represents the articulated world of metalworking in the

of presenting the most futuristic technologies for the development

best way, combining vision and innovation, as proven by the data

and wellbeing of society, to such an extent that it can be considered

of the previous Italian edition (EMO MILANO 2015), hosting 1,600

the place that showcases “the magic world of metalworking” – as

exhibiting companies, on an exhibit area of 120,000 sq. m. and

highlighted in the slogan chosen for EMO MILANO 2021.

registering over 155,000 visits of operators coming from 120 countries.

The organisation of EMO MILANO 2021 is entrusted by CECIMO to

Metal forming and metal cutting machine tools, production systems,

the operational structures of UCIMU-SISTEMI PER PRODURRE, the

enabling technologies, solutions for interconnected and digital

Italian machine tools, robots and automation systems manufacturers’

factories and additive manufacturing will be among the products and

association. With more than ten years of experience derived from

solutions spotlighted at EMO MILANO 2021, which will transform

the organisation of the six previous editions of the world travelling

fieramilano Rho into the biggest digital factory ever set up within an

exhibition, (1979, 1987, 1995, 2003, 2009, 2015) and of BI-MU, the

exhibition fairground.

EMO staﬀ will be able to assist visitors, exhibitors, journalists and

After all, the halls of fieramilano Rho will present the best international

all the people who will take part in the event, proposing services,

products of the sector, which are more and more closely linked to the

initiatives and activities specially dedicated to them. Constantly

issue of interconnection, capable of enabling all those high added-

updated information and details regarding the exhibition are available

value functions that the manufacturing industry cannot longer do

on emo-milano.com. CECIMO has already conveyed the calendar of the

without. Therefore, once again, EMO MILANO 2021 will be a meeting

world travelling exhibitions that will be held after EMO MILANO 2021.

point for the most qualified operators of the industry, interested in

After the editions in Germany in 2023 and in 2025, EMO will take place

planning new investments in production technology.

again in Italy in 2027, thus confirming the established time period, in

The international origin of exhibitors is the hallmark of EMO MILANO,

which Milan and Hanover will alternate in the organisation of the world

(in 2015 foreign exhibitors were 68% of the total). This international

machine tool trade show.

presence will appeal to visitors from any part of the world, who have always considered EMO as an unmissable opportunity for technical-

For further information www.emo-milan.com

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2020 - N. 66

235

UNIONE COSTRUTTORI IMPIANTI DI FINITURA

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EDITORIAL BOARD Dr. Felice Ambrosino: Marketing

Prof. Massimiliano Bestetti:

Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Section of Applied Chemistry and Physics

Kevin Biller

The Powder Coating Research Group

Prof. Stefano Rossi:

Material Engineering and Industrial Technologies, University of Trento - Product Design

Dr. Franco Busato:

European environmental legislation and new technologies

Dr. Fulvio Zocco:

Environment and quality

Prof. Paolo Gronchi:

Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Chemical Engineering Section

EDITOR IN CHIEF / DIRETTORE RESPONSABILE

The smart journal for surface treatments

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ipcm digital on In this issue: SPECIAL ON ACE & OFF ROAD VEHICLES

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