ipcm® n. 52 - July/August 2018 by ipcm® International Paint&Coating Magazine

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ISSN 2280-6083

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CONTENTS JULY/AUGUST 2018

SPE C IAL O N T RANSPO RTAT I ON

FOCUS ON TECHNOLOGY

Fainsa, Where Cutting-Edge Technology Meets Tradition: Double Production Speed and Higher Coating Quality for Public Transport Seats © Savim

Flawless Finishes for Alloy Wheels: The Secret Is in the Spray Gun

FOCUS ON TECHNOLOGY

S P E CI A L O N T R A N S P O R TAT I O N

SPE C IAL O N T RANSPO RTAT I ON

50 05 06

HIGHLIGHT OF THE MONTH

Future Mobility and Human Needs Inspire BASF’s 2018-19 Automotive Color Trends

EDITOR’S LETTER

INNOVATIONS: PRESENT&FUTURE

Alternative and Innovative Technologies Implemented in Coating Booths for Railway Vehicles

HIGHLIGHT OF THE MONTH Doing Paint Inspection Offshore? Your Current Certificate Is Not Enough

ANALYSIS A New Standard in Corrosion Prevention: How Self-Healing Coatings Enable Significant ROI to End-Users

S P E CI A L O N T R A N S P O R TAT I O N

BUSINESS CARDS

S P ECIAL O N T RANS PORTAT I ON

INNOVATIONS: PRESENT&FUTURE IDROLIN/K DTM: Easy To Use with Good Anti-Corrosion Performance

HIGHLIGHT OF THE MONTH The Synergy between Dollmar and Noxorsokem Group Creates a New Specialised, High Added Value Business

BRAND-NEW

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SUCCESS STORIES EcoInCure: Space-Saving Oven Technology for Electric Cars

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CONTENTS JULY/AUGUST 2018

INNOVATIONS: PRESENT&FUTURE

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DKC Group: Optimising the Pre-Treatment Process for Easier Plant Management and Constant Quality

FOCUS ON TECHNOLOGY

92 54 62

FOCUS ON TECHNOLOGY

BRAND-NEW SUCCESS STORIES The World’s Largest Preservation Line in the Ship Building Industry Goes to Finland

100

A Last-Generation Booth Can Make the Difference

INNOVATIONS: PRESENT&FUTURE Wet-on-wet Application in the Transport Sector. Technological Innovation, Automation, and Industry 4.0

HIGHLIGHT OF THE MONTH

Innovative Paint Stripping Solutions

INNOVATIONS: PRESENT&FUTURE The Evolution of Powder Spraying Systems: Digitalisation, Ergonomics, Connectivity

108 SUSTAINABILITY 110

STANDARD & LEGISLATION UCIF Informs The Importance of Design

98 BRAND-NEW 104 BRAND-NEW

112 113

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EDITOR’S LETTER

Sustainability and surfaces Richiedi la versione in italiano a info@ipcm.it

onventionally defined as a practice that «meets the needs of the present without compromisingbthe ability of future generations to meet their own needs», sustainability is an issue of great relevance and interest for everyone.

Understood as emission reduction, operational performance improvement with a view to energy saving, and functionality and service life enhancement, sustainability is currently an unbeatable USP (Unique Selling Proposition, that is, the sales argument of a product). There are many ways to be sustainable: the start of “green” projects, the search for natural alternatives to synthetic products, the implementation of operational and energy efficiencies, or the creation of projects for the community and about training, health, and safety. Sustainability practices are becoming a part of modern companies’ mission so much so that they are not just in an investment – they generate profits. The environmental profit value allows a company to assess the costs and benefits created for the environment with a monetary unit and, therefore, to make more sustainable operational decisions. In order to determine the real footprint of a productive activity, it is necessary to consider carbon emissions, the use of water resources and the rate of water pollution, air pollution, the amount of waste produced and their disposal operations, and even the amount of land occupied. These elements should be analysed for the entire value chain, from raw materials to retail stores. The surface treatment and coating industry, in particular, was one of the first to embrace this trend towards sustainability and it is now one of the most active sectors in terms of environmental, social, and economic projects. The coating industry can be sustainable for the end user: by making products more durable, paints increase their efficiency of use and reduce the disposal operations at the end of their service life. The supply of raw materials, energy, and water combined with production efficiency can have a significant impact on the environmental footprint of paint formulations. Improvements in the performance and functionality of coatings, in turn, can have a major impact on the sustainability of the whole life cycle of products. This issue of ipcm® inaugurates a new section on sustainability. Already widely discussed on our website www.myipcm.com and on our social channels (as I write this, the MyIpcm Coatings Community on LinkedIn has 9504 members),bthis topic will be dealt with in an even more organic and in-depth way on our publications. The brand new section will collect exclusive interviews, comparisons, projects, and activitiesbdevoted to environmental, social, and economic

Alessia Venturi Editor-in-chief Direttore Responsabile

sustainability. I will see you in September with an even richer content.

international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52

Â© Autonomic Materials

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

ANALYSIS

A New Standard in Corrosion Prevention: How Self-Healing Coatings Enable Significant ROI to End-Users Gordon Fischer, Magnus Andersson Autonomic Materials, Inc., Champaign, Illinois (USA)

grant@autonomicmaterials.com

orrosion is an immediate and pressing

even as they improve iteratively, have severe

Self-healing additives arrest the

problem for anyone who builds,

performance limitations. Even with improved

propagation of corrosion. AMI’s

maintains, and utilizes steel equipment

formulation techniques, more effective resins,

self-healing additive technology has

and structures.

etc., exposure of the substrate, after damage

demonstrated the ability to repair the

Asset owners make significant investments

to the coating has occurred, remains a major

coating and prevent delamination,

in preventing the occurrence and spread of

challenge. Once exposed, the substrate

thereby preserving the anti-corrosion

corrosion, as well as in repairing corrosion

succumbs to corrosion at the exposed site.

functionality of the coating. Moreover,

damage. According to data from NACE

The coating-substrate interface then degrades,

this technology is autonomic,

International, the estimated annual direct

leaving the coating unable to adequately

meaning it requires no mechanical

cost of corrosion in the U.S. is $276

or human intervention to

billion – approximately 3.1% of the

provide healing at the site

nation’s total GDPI. That figure is not an

of damage. Self-healing

outlier; similar costs apply globally. In China, it’s $310 billion USD, or 3.34% of GDP . In turn, preventing corrosion II

could result in global savings between 15-35% of the cost of damage, or anywhere between $375 billion and $875 billion. Corrosion, of course, results in structural degradation that can, if untreated, lead to complete failure. Worse, problems with corrosion can start almost immediately. The U.S. Army, for example, has used a conventional epoxy system on some

Corrosion is an immediate and pressing problem for anyone who builds, maintains, and utilizes steel equipment and structures. Asset owners make significant investments in preventing the occurrence and spread of corrosion, as well as in repairing corrosion damage. According to data from NACE International, the estimated annual direct cost of corrosion in the U.S. is $276 billion – approximately 3.1% of the nation’s total GDP. That figure is not an outlier; similar costs apply globally.”

additives for anti-corrosive coatings represent a qualitatively new technology that enables protective coatings to self-repair. When such coatings are damaged in service, the healing agent flows out of the coating into the site of damage, where it forms a protective layer, passivates the damaged area and delays or prevents further corrosion of the

of its seaborne vehicles – only to find

underlying metal substrate

that the epoxy system would begin to oxidize and corrode within 6 months at sea.

protect the substrate. Corrosion subsequently

(Fig. 1). Consequently, formulating

Then, problems can be widespread, as well: an

advances rapidly by compromising the

these microcapsules containing a

inspection of Canadian army vehicles found

coating’s adhesion to the substrate and causing

self-healing agent into paint greatly

that 25% of the fleet suffered from severe

delamination of surrounding coating and

extends the coating’s serviceable

corrosion .

exposing more substrate. In this way, corrosion

lifespan by minimizing repaints and

Unfortunately, existing protective coatings,

spreads faster and faster.

constant touch-ups.

III

Opening photo: AMI’s self-healing additive technology has demonstrated the ability to repair the coating and prevent delamination, thereby preserving the anti-corrosion functionality of the coating.

international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52

Exterior coatings with self-healing agents incorporated into the formulation can extend the lifespan of each individual coating, potentially significantly; and municipalities can reap significant cost savings as a result. To determine the lifetime cost of coatings for a municipal water tower meeting the characteristics described in Table 1, we

Figure 1: Microencapsulated delivery of liquid healing agents.

include all painting operations required to protect the structure for its complete Self-healing additives also reduce total cost

serious. Corrosion was blamed in the

service life. We assume a typical maintenance

of ownership. Performance improvements

collapse of a Kentucky water tower in

sequence that includes:

are an important consideration for any asset

2014, for example. “I think it was very

• The original coating;

owner. However, the total cost of ownership

fortunate this was not a more serious

• Spot touch-ups and repairs;

is just as important. Hence, any discussion

incident,” Andrew Melnykovych, a member

• Maintenance repaints (spot priming and a full

of an improved anticorrosion solution must

of the Kentucky Public Service Commission,

consider the cost impacts of the solution.

told a local news affiliate at the time. “It

This paper presents financial models for

reinforces the importance of maintaining

multiple scenarios demonstrating how AMI’s

infrastructure.”

overcoat); • Full repaint (total coating removal and replacement).

Table 1 - New water tower example.

self-healing additives are cost-beneficial. Specifically, AMI’s self-healing additives can

Indeed, even if most water towers escape

lower the cost of maintaining assets in both

such a fate, it’s only thanks to the continuous

moderate and extreme locations; from

effort and expense dedicated to maintaining

ubiquitous urban water towers to remote

and protecting these structures. Even mild

offshore oil rigs. In this case study, we will

corrosion at 10 mils per year will pierce

examine the economic benefit of using self-

¼-inch thick plate in 24 years, a fraction of

healing additives in both applications.1

the serviceable life of the structure – and

Asset Type

New Water Tower, Field Applied Paint

Standard Paint System

Three Exterior Coats of Standard Waterborne Acrylic Paint

Self-Healing (SH) Paint System

One Exterior Coat of SH Waterborne Acrylic Paint + Two Exterior Coats of Standard Waterborne Acrylic Paint

common urban pollutants, sun exposure,

Surface Preparation

SP-6 (Commercial Blast Cleaning)

Large urban water storage structures may

etc.

not face the extreme corrosive conditions

As a result, most water towers will require as

Square Footage

30,000

that can bedevil steel structures in more

many as half a dozen re-coatings during their

damaging environments, like those

lifespan, with each coating not only incurring

Service Life (Years)

encountered in marine settings, but the

direct added expense but also imposing

consequences of corrosion can be just as

service disruptions.

Service life and cost considerations for self-healing coatings in a moderate environment: municipal water towers

structural failure will occur long before total penetration. V Water towers are furthermore exposed to a series of environmental conditions that can contribute to corrosion: fluctuating temperatures, rainfall and relative humidity,

Water towers thus offer an excellent glimpse 1

The following calculations are based upon data from NACE International and utilize the same calculations NACE published in their Paper No. 7422, “Expected Service Life and Cost Considerations for Maintenance and New Construction Protective Coating Work.” That document details pricing information on paints and typical maintenance cycles and presents complete financial models for calculating lifetime costs of coating systems. This paper applies their model to coatings incorporating self-healing additives. An explanation of the specific factors incorporated into the cost and lifespan multipliers is outside the scope of this paper; we direct you to the NACE paper for more detail

into the impact of self-healing coatings on a steel structure; the nature and extent of

Environment

C3 (Medium – Urban and industrial atmospheres, moderate sulfur dioxide pollution; coastal areas with low salinity)

corrosion risks facing a water tower are very common. Modelling the impact of selfhealing coatings on this type of structure

Table 2 presents the total costs per square

thus helps to illustrate the impact on many

foot, including both materials and labour, of

kinds of structures.

each painting sequence.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

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Scenario

Table 2 - New water tower, exterior coating costs per square foot (Net Present Value) at 4% interest for 4 paint service life scenarios.

Paint Service Life

Original Painting

Touch-Up 1

Maintenance Repaint 1

Full Repaint 1

Touch Up 2

Maintenance Repaint 2

Full Repaint 2

TOTALS

Cost Savings

12 Years Standard

$13.41

Year 12 $ 4.80

Year 16 $ 8.00

Year 22 $ 14.60

Year 34 $ 3.90

Year 38 $ 6.50

Year 44 $ 11.80

$ 63.08

---

15 Years Self-Heal

Year 15 $ 5.00

Year 20 $ 8.40

Year 27 $ 15.10

Year 42 $ 3.90

Year 47 $ 6.40

$ 53.37

15.4%

19 Years Self-Heal

Year 19 $ 4.90

Year 25 $ 8.00

Year 34 $ 14.10

$ 41.52

34.2%

23 Years Self-Heal

Year 23 $ 4.60

Year 31 $ 7.50

Year 43 $ 13.00

$ 39.71

37.0%

$ 14.55

Net Present Value (NPV), in turn, works

For this scenario, we can reasonably estimate

into Net Present Value (NPV) costs.

backwards from NFV to tell us the present

the lifetime cost per square foot of a typical

Because of their long life, capital assets

worth, in today’s dollars invested at a current

three-coating system to be $63.08. This is the

require complex financial modelling to

interest rate of 4%, of the inflated cost of

baseline against which we will compare the cost

understand costs over their full lifespan.

future painting work. In other words, NPV

effectiveness of the self-healing agent.

Net Future Value (NFV – not represented

allows us to understand future costs in

in this table) incorporates inflation (here

today’s dollars and gives us an equal basis for

Self-Healing Paint Cost Savings Scenarios

assumed to be 3%) into the costs. In

comparing the costs of different scenarios.

The effectiveness of self-healing coatings

other words, NFV tells us how much the

Scenario #1 (the first row), based on a 12-year

depends on many factors, which makes it

touch up, maintenance repaint, and full

service life, is the control: this line assumes

difficult to pinpoint exactly how much the self-

repaint will cost in the (future) year in

three coats of waterborne acrylic, none of

healing technology will extend paint service life.

which it happens.

which contain self-healing agents. With an

Accelerated corrosion tests have shown that,

asset life of 50 years, this means two complete

depending on the paint system, service life can be

typical maintenance painting sequences

extended up to 9x. However, for our cost models,

(one initial painting, two touch ups, two

we kept estimates conservative, so our model

maintenance repaints, and two full repaints).

only examines examples that range from modest

Unfortunately, existing protective coatings, even as they improve iteratively, have severe performance limitations. Even with improved formulation techniques, more effective resins, etc., exposure of the substrate, after damage to the coating has occurred, remains a major challenge. Once exposed, the substrate succumbs to corrosion at the exposed site. The coatingsubstrate interface then degrades, leaving the coating unable to adequately protect the substrate.”

Note that all costs have been rendered

2 1

Figure 2: Adhesion test for self-healing additive vs. standard coating.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

ANALYSIS

Self-healing additives arrest the propagation of corrosion. AMI’s self-healing additive technology has demonstrated the ability to repair the coating and prevent delamination, thereby preserving the anticorrosion functionality of the coating. Moreover, this technology is autonomic, meaning it requires no mechanical or human intervention to provide healing at the site of damage. Selfhealing additives for anti-corrosive coatings represent a qualitatively new technology that enables protective coatings to self-repair.” life extension up to approximately double the standard service life, as shown in Table 2 (Scenarios #2-4). For example, in Scenario #2, we are extending paint service life by 3 years (from 12 years to 15). Although selfhealing paint is more expensive than the control (for the purposes of this exercise, we are assuming that the cost of the self-healing primer coat is double (2X) the cost of the standard primer coat), the extension in paint service life obviates the need for the second full repainting. As a result, the lifetime cost per square foot falls to $53.37, a cost savings of 15.4%. In Scenario #4, we are assuming paint service lifespan nearly doubles to 23 years. This means the initial coating lasts for almost half of the asset’s lifespan before even the first touch-up is required. As a result, the entire second maintenance painting sequence (second touch up, second maintenance repaint, second full repaint) is eliminated. Over the lifetime of the asset, the asset owner will pay a full 37.0% less. Table 3 shows an illustration of how this breaks down into total costs. Note, the Average Equivalent Annual Cost (AEAC) “converts the entire stream of present and future costs to a present worth (NPV) and then distributes that sum in equal annual amounts over the structure’s life,” as explained by NACE. In this case, total lifetime cost savings in these scenarios range from $678,209 for the most conservative estimate, up t to $1,631,5112. Table 3 Average Cost Equivalent Savings Annual Cost Per Year

Lifetime Cost Savings

12 Years (Standard Coatings)

$ 88,090

15 Years

$ 74,526

$ 13,564

$ 678,209

19 Years

$ 57,981

$ 30,110

$ 1,505,491

23 Years

$ 55,460

$ 32,630

$ 1,631,511

Paint Service Life

2 Again, for a more detailed explanation of the financial modeling behind these coating costs, please see NACE’s 2016 paper, “Expected Service Life and Cost Considerations for Maintenance and New Construction Protective Coating Work.”

Maintenance Costs Fall Under All Scenarios To reiterate, the

the damage is constantly rupturing new self-healing microcapsules; that’s why

effectiveness of self-healing

the slope of the blue line is

coatings depends on many

not as steep as the red line.

factors. The point of these

Service life and cost considerations for self-healing coatings in a harsh and highly damaging environment: oﬀshore oil platforms

scenarios is to demonstrate that costs fall significantly with virtually any amount of paint service life extension – even when the cost of the coating is itself higher than normal paint. In fact, testing reveals that all these scenarios are

The example of a municipal

conservative. Doubling

water tower helps us to

the paint service lifespan

see that self-healing agents

might seem excessively

can yield significant savings

hopeful at first glance,

over time, but admittedly,

but extensive testing has

municipal structures typically

found that self-healing

face only moderate corrosive

agents can triple or greater

distress. Our next example

the effective paint service

3 1

lifespan. For example, the following test found a life

Figure 3: Impact of environment on corrosion rates: more extreme environments necessitate nearly twice as many repaint cycles.

extension exceeding 300% (Fig. 2). However, to be capped our financial modelling at twice the normal lifespan

additives yield similar benefits in more extreme conditions. An offshore platform faces some of the most extreme corrosive

conservative, we

demonstrates that self-healing

conditions that can be found in any industry or

to keep our estimates

environment. In

conservative.

fact, with parts

There are two

of the platform

mechanisms at work.

either immersed

First, due to the initial

in seawater or

release of healing

constantly exposed

agents, the onset

to a splash zone

of adhesion loss

and salt air, the

around the damage

steel corrosion

is delayed, so the

can exceed 100

coating lasts longer

mils per year – ten

before any loss of

times the typical

adhesion (the flat

rate of corrosion

portion of the blue line). Then, once the coating starts losing adhesion, the rate of loss is slower because

4 1

Figure 4: Impact on service life of self-healing additives to coating system. Note: these tests are not indicative of guaranteed performance.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

for our water tower example above. In turn, those high corrosion rates translate into

ANALYSIS

frequent maintenance repaint cycles: the more extreme the environment, the shorter the service life, the costlier the asset (Fig. 3). Complicating this situation, the repaint cycle may not be implemented as rigorously as desired because of the difficulties of working in harsh environments – further adding cost and eroding serviceable lifespan. The logistical requirements of working in a space-constrained environment in a remote location can put pressure on workers to work fast and light. That, in turn, can result in workers taking unhelpful shortcuts. KTA University, which provides education and instruction around protective coatings, writes: “Too often, the level of diligence in performing the surface preparation of welded or hotwork areas and the reinstatement of the coating systems after the consolidation, is atrocious. It is not unusual to see evidence of epoxy coatings being poured out onto an uncleaned deck and spread out with a yard broom. The indelible proof, including the tread pattern from the worker’s boots, was still visible months or years later. Stories are in circulation of a hardhat being used as a bucket to carry paint that was then just poured onto weld joints on deck plates.” VI In other words, touch-ups, maintenance painting, and full repaints are not just a matter of slapping on another coat of paint but requires intense coordination and downtime on a structure that normally runs 24 hours a day. Fortunately, self-healing paint can remediate these logistical issues in addition to reducing costs. As with the municipal water tower, we have modelled the costs for a variety of scenarios. We include the same sequence of paint operations to protect the hypothetical structure (detailed in Table 4) for its complete service life. Table 5 presents the total costs per square foot, including both materials and labour, of each painting sequence. As before, the first row is the control: a standard coating system with a 12-year service life. Given the structure’s

The high cost of the coating system for offshore oil platforms is exactly what makes the self-healing coatings even more costefficient for this application. By eliminating one or more entire elements of the standard paint cycle, it reduces the total cost enormously. In fact, the self-healing coating achieves even greater savings, up to 53.9% in the scenario positing that the self-healing coating system offers a 23-year service life.”

ÂŠ Autonomic Materials

5 1

Figure 5: The cost of the coating itself is typically only a fraction of total painting costs.

Self-healing additives can create a win-win scenario for everyone, including paint formulators and manufacturers as well as end-users. Indeed, paint manufacturers have an opportunity to extend market share through a highly differentiated product with enormous potential value, while charging a premium to account for the reformulation expense and thus improving margins per gallon of paint. Still, even with the increased cost, self-healing paints still enable the end-user to save money over the full lifecycle of the product.â&#x20AC;?

years, even the standard system sees only one touch up, maintenance repaint, and full repaint. Those paint cycles are quite costly, given the difficulties

ÂŠ Autonomic Materials

relatively short serviceable lifespan of 25

described above. However, the high cost of the coating system for offshore oil platforms is exactly what makes the self-healing coatings even more cost-efficient for this application. By eliminating one or more entire elements of the standard paint cycle, it reduces the total cost enormously. In fact, the self-healing coating achieves even greater savings, up to 53.9% in the scenario positing that the self-healing coating system offers a 23-year service life. Table 6 shows a breakdown of how this breaks down into AEAC costs. Is it possible for self-healing agents to extend the lifespan of the coating system up to 23 years and thus save nearly $10 million over its life?

6 1

Figure 6: Self-healing coatings yield an increasing cost benefit the longer the extend service life.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

ANALYSIS

Any paint system for a big structure – regardless of composition, complexity, environment, or surface preparation – will see improved service life and cost effectiveness by incorporating self-healing agents. Further, the more it costs to maintain a structure and the more severe the environment it faces, the greater the proportional cost savings will be.”

We had an asset owner request testing to determine the answer to that very question. In Figure 4, we see the results of that testing. Their structure was deployed in a harsh environment, and with the customer’s current coating system, it consequently experienced a short paint service lifetime (the red line) of about 8-10 years. Their performance improvement target was for an increase in the service life to 10-12 years (the blue line), and as the NACE financial model demonstrates (Table 5), even such a modest increase would pay for itself very quickly. However, to determine the actual increase in paint service life and cost savings when using self-healing additives, we took this end-user’s system, added our self-healing capsules, and tested service life side-by-side over six months. Overall, testing indicates as much as 9x life extension with the autonomic self-healing coating (the green line), far exceeding the 23-year life extension included in our model. Table 4 - New off-shore oil platform example. Asset Type

Offshore Oil Platform Shipyard first paint, field applied thereafter

Standard Paint System

One coating each of: Organic Zinc / Epoxy / Polyurethane

Self-Healing (SH) Paint System

One coating of self-healing Organic Zinc, one coating of self-healing Epoxy, one coating of standard Polyurethane

Surface Prep

SP-11 (Power Tool Cleaning to Bare Metal) + Containment

Square Footage

100,000

Service Life (Years)

Environment

C5-M (Very high, marine – coastal and offshore areas with high salinity)

G RT

Scenario

Table 5 - Offshore oil platform, costs per square foot (Net Present Value) at 4% interest for 4 paint service life scenarios. Paint Original Service Life Painting

Touch-Up 1

Maintenance Repaint 1

Full Repaint 1

Touch Up 2

Maintenance Repaint 2

Full Repaint 2

TOTALS

Cost Savings

12 Years Standard

Year 12 $ 13.20

Year 16 $ 22.20

Year 22 $ 40.40

$ 112.65

---

15 Years Self-Heal

Year 15 $ 13.60

Year 20 $ 22.70

$ 75.76

32.7%

19 Years Self-Heal

Year 19 $ 13.10

Year 25 $ 21.70

$ 74.20

34.1%

23 Years Self-Heal

Year 23 $ 12.60

$ 51.95

53.9%

$36.96

$ 39.39

Table 6 - AEAC Costs and Savings of Self-Healing Paint. Paint Service Life

Average Equivalent Annual Cost

Cost Savings Per Year

Lifetime Cost Savings

12 Years (Standard Coatings) 15 Years 19 Years 23 Years

$721,083 $ 484,950 $ 474,997 $ 332,562

-$ 236,133 $ 246,086 $ 388,521

-$ 5,903,336 $ 6,152,150 $ 9,713,023

Even an Increased Cost Per Gallon Yields

coating. Coatings must be reformulated to adjust

Lifetime Cost Savings

for pigment volume concentration, pigment size

It should be reiterated that these models,

distribution, resin chemistry to achieve desired

which show greatly reduced volumes of

glass transition temperature (Tg), etc. As a result,

frequency and size scale of recoating is

coating, assume a price premium of double the

reformulation does add some up-front cost in

reduced;

cost of standard. Consequently, self-healing

addition to the cost of the healing agents, but

additives can create a win-win scenario for

this cost is minimal in the context of the ROI to

everyone, including paint formulators and

end-users and coating suppliers.

manufacturers as well as end-users. Indeed,

Even if the cost of the coating doubles, the

paint manufacturers have an opportunity

extension in serviceable lifespan more than

to extend market share through a highly

covers the increased price. Fundamentally, the

In short, any paint system for a big structure

differentiated product with enormous potential

self-healing additive effectively makes every

– regardless of composition, complexity,

value, while charging a premium to account for

gallon of paint less expensive.

environment, or surface preparation – will see

the reformulation expense and thus improving

It’s also worth noting that the cost of the coating

improved service life and cost effectiveness

margins per gallon of paint. Still, even with the

itself is typically only a fraction of the total costs

by incorporating self-healing agents. Further,

increased cost, self-healing paints still enable

associated with the total paint maintenance

the more it costs to maintain a structure and

the end-user to save money over the full

sequence – particularly for structures that

the more severe the environment it faces,

lifecycle of the product.

present logistical difficulties, like offshore oil

the greater the proportional cost savings will

platforms (Fig. 5).

be (Fig. 6). Ultimately, almost any scenario

The extended lifespan, however, continues to

will benefit from using a self-healing coating

pay dividends throughout the asset’s lifespan by:

system.

The cost savings speak for themselves Using calculations provided by NACE, we have shown that end-users can reasonably save hundreds of thousands or millions of dollars if they can extend the lifetime of the paint by even just a few years.

VOC emissions released; • Reducing material and labor costs as the

• Reducing business disruption and lost opportunity costs; and • Increasing overall asset lifetime because of longer lasting coatings.

• Preventing corrosion of the underlying substrate; • Maintaining adhesion to the substrate even after coating damage occurs; • Providing additional protection in areas of

Furthermore, those potentially massive savings

marginal coating application and difficult-to-

even incorporate an increase in the cost of the

inspect areas;

• Reducing environmental impact by lowering

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

References: I http://impact.nace.org/ II https://www.nature.com/articles/s41529-017-0005-2 III http://cradpdf.drdc-rddc.gc.ca/PDFS/unc53/p526285.pdf IV http://www.wlky.com/article/corrosion-blamed-in-water-towercollapse-last-year-1/3759831 V https://www.pnws-awwa.org/uploads/PDFs/.../Dist_FriAM_ RyderLarsen_Corrosion.pdf VI https://ktauniversity.com/maintenance-painting-practicespart-2/

BRAND-NEW

uropolveri recently introduced a new product line, 1R Arizona Series,

1R Arizona, the Latest Series Introduced By Europolveri as a further extension of its product

range. The Series is made of 44 products, all Ral references, with wrinkled finishing and different gloss level. 1R Arizona was developed with particular attention to customers that require not only an always higher level of quality, but also an adjustment to the market needs that put aesthetic of the finished goods first. All the colours available are part of the Pural Series 1R and are formulated in accordance to Qualicoat Class 1 requirements, therefore they grant a high level of protection and durability. From an aesthetic point of view, the wrinkled finishing allows to hide possible defects

2 1

Fig. 1 and 2: Due to its intrinsic characteristics and to its versatility, the products of 1R Arizona Series turn out to be ideal for the application in diﬀerent sectors such as architecture, furnishings, illumination, doors and gates.

of the substrate, but it also satisfies the need of an attractive look in line with the design requests. Due to its intrinsic characteristics and to its versatility, the products of 1R Arizona Series turn out to be ideal for the application in different sectors such as architecture, furnishings, illumination, doors and gates. All of these 44 products are available in stock with a minimum order of 25kg. They all add to the 207 new articles of the 5L4 Matt Series and to the other 750 products always available. Market requests are growing and so it is Europolveri willingness to meet them. For further information:

www.europolveri.it

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

BRAND-NEW

New End-Use Brochures of BYK-Gardner: QC Solutions for Coatings © BYK-Gardner

YK-Gardner, a global leader in the field of measuring color,

correlate to gloss, DOI and orange peel measurement?

appearance and physical

How can I control

properties announces

curing conditions in

new publications focusing

the baking process,

on QC solutions for

to assure optimum

specific end-use markets

mechanical and

like coatings, plastic and

decorative quality?

cosmetics.

Theory, customized

Coatings are fascinating.

to coating needs,

Not much thicker than a

is combined with

human hair, they combine

typical applications

a variety of functions.

including useful

Besides their protection

measurement

behavior and a perfect

techniques and best

finish, they are expected

practices. Typical

to retain their good look

measurement

and properties over a

needs with practical

long time. Consistent and

examples of the

uniform quality are of

various coating

particular importance when

applications from

parts are manufactured in

raw materials to

different production sites.

architectural and

The challenge is to find

decorative paints,

appropriate measurement

industrial and

procedures to guarantee

wood coatings are

defined quality over the

described in detail.

entire production chain.

At the end of the

BYK-Gardner’s new end-use

brochure, you will

brochure, “QC Solutions

find an overview of

for Coatings” (Fig. 1) covers

the BYK-Gardner

in an appealing way the various aspects of paint

solution for the Figure 1: The new end-use brochure “QC Solutions for Coatings” by BYK-Gardner.

testing, gives valuable

coatings industry. The QC Solutions

information and hints

metamerism? Color measurement of solid

for Coatings

for daily work in the lab or production

and metallic colors, flop index and sparkle

brochure is available in a variety of

site. The first section of the brochure

evaluation is explained in a compact

different languages.

describes the technical theory behind

and easy to understand way. How does

each method. How to define a “Honey

paint appear under different illumination

For further information:

Yellow” and what is the meaning of

angles or distances, and how does this

www.byk.com

international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52

BRAND-NEW

Collaboration Between KRÜSS and LINSEIS for High-Temperature Contact Angles

Concentration will be on the marketing

The system is also extremely flexible

specialists: KRÜSS GmbH,

of the Drop Shape Analyzer – DSA High

in the choice of ambient conditions.

global market leader in the

Temperature for analysis at up to 1550,

Measurements can be carried out

field of contact angle measurement,

1700 or 2000°C (Fig. 1).

in air (oxidizing atmosphere) or

and LINSEIS, as experts in thermal

The instrument, which is also capable

equally under inert gas, in reducing

analysis, have established a new

of measuring thermal expansion and

atmosphere or in vacuum.

cooperative venture. With immediate

deformation, provides everything

As a result of the collaboration,

effect, the two owner-managed family

needed for accurate wetting analysis

LINSEIS will benefit from KRÜSS’

companies will be following a common

at high temperatures with the help

expertise and market knowledge in

path in the field of high-temperature

of the contact angle. This includes

the field of wetting analysis, while

contact angle measurement.

precise and stable target temperatures,

KRÜSS will be able to call upon

High-temperature contact angle

the accurate control of temperature

LINSEIS’ expert knowledge in high-

measurements are of interest, for

ramps, the simple introduction of

temperature analysis and extend its

example, in energy recovery with

samples as well as contactless optical

market presence to new industrial and

mineral fuels, for investigating slag for

measurement with high-resolution CCD

research fields.

blast furnaces or in the production

camera and powerful image analysis

of robust enamel coatings. With such

software. Simultaneous measurements

For further information:

coatings in particular, synergies can

of the contact angle and thermal

www.kruss-scientific.com /

be utilized by combining the contact

expansion along with the melting

www.linseis.com

angle method and dilatometry.

deformation are particularly meaningful

Wetting between carrier material and

thanks to the continuous recording

coating is just as important for their

of the entire measurement in a video

stability as the thermal expansion of

image with documented temperature

the different phases.

characteristic.

ollaboration between two

Figure 1: KRÜSS Drop Shape Analyzer – DSA High Temperature powered by LINSEIS.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

teerayuttaeÂ©fotolia

CHEMICAL SOLUTIONS

Dollmar and Noxor become

DN CHEMICALS SPECIALTY CHEMICALS

PRE-TREATMENT AND SURFACE TREATMENTS

WASTE WATER TREATMENT

INTEROPERATIONAL PROTECTION

CHEMICALS FOR MRO

NANOTECHNOLOGIES

CHLORIDE-FREE PAINT STRIPPERS

DEGREASING AND CLEANING MEDIA

BRAND-NEW

Digital Color Card App: Effect Pigments Go Digital

at any time provides a new © Merck

erck, a leading science and technology company, presented a

service experience for everyone working with the company´s

new Digital Color Card application

effect pigments or seeking new

for smartphones and tablets. It

inspiration: “Coatings experts,

brings a realistic representation

designers or brand owners have

of the company´s portfolio of

now direct access to Merck´s

coating effect pigments to the

extensive palette of effect pigments

screen. The app is now available

and can explore their possibilities”,

both for iOS and Android devices.

underlines Felten.

The application is unique in the

The Digital Color Card is useful for

industry and gives a realistic idea

getting inspiration as well as for

how the effect pigments appear in

checking technical details. The app

motion under direct light: sensing

provides two ways to explore the

the movement of the device, the

portfolio: the inspirational view gives

app simulates the behaviour of a

a visual access to the wide range of

real panel being tilted.

colourful pigments. Another view

This enables to inspect a pigment from different angles. Alternatively,

provides more technical information

on each pigment. In depth details

it is possible to watch a video of the moving panel. “Digitalization plays a vital role in Merck´s constant development, and the Digital Color Card is one more step in that direction”, explains Friedhelm Felten, Head of the Surface Solutions Business at Merck. The app´s easy accessibility and availability

with all the technical data are Figure 1: The application Digital Color Card by Merck is unique in the industry and gives a realistic idea how the eﬀect pigments appear in motion under direct light: sensing the movement of the device, the app simulates the behaviour of a real panel being tilted.

PAINT SHOP 4.0 DIGITAL ∙ SMART ∙ EFFICIENT

www.eisenmann.com

available on fact sheets. This makes the app the digital supplement for Merck´s existing colour cards and a convenient resource both for designers and for more technically oriented users. For further information: www.merckgroup.com

HIGHLIGHT OF THE MONTH

Doing Paint Inspection Offshore? Your Current Certificate Is Not Enough Markéta Součková Paint-Inspector.Com s.r.o., Brno, Czech Republic

marketa.s@paint-inspector.com

Miguel Parra Corvera © Paint-Inspector.Com

s a paint inspector, you might be asked to go through different types of

training in order to oversee certain offshore projects. In order to work on an oil platform in the middle of

Even though the training is only three days, it takes a lot of courage and discipline to finish the course. The training includes physically difficult and potentially stressful elements. Before an acceptance

the sea, you will most likely have to

to the course, there is a need to

undergo the Basic Offshore Safety

provide a medical certificate.

Induction & Emergency Training

During these three days,

(BOSIET), including the Helicopter

participants learn theory as well as

Underwater Escape Training

go through a practical training.

(HUET) with Emergency Breathing

Safety induction, helicopter safety

System.

and escape, sea survival and first

Oil and gas companies worldwide

aid, and fire fighting and self-

require appropriate offshore

rescue are the topics to learn.

safety and emergency trainings

The first day is theoretical, the

from everybody who travels to

second day starts the real-life

their offshore assets such as oil

practice, which is most likely the

platforms (Fig. 1). Paint inspectors or those who already accepted the job must undergo these safety trainings as well.

hardest part of the entire training.

wanting to get a job at a platform

The demonstration of the rescue

Figure 1: Oil and gas companies worldwide require appropriate oﬀshore safety and emergency trainings from everybody who travels to their oﬀshore assets such as oil platforms.

boats and hands-on experience by visiting one of them is still not the worst part. The real challenge

The goal of these trainings is

starts in a swimming pool with

to teach attendees the generic

the helicopter underwater escape

hazards that can occur at the offshore oil and gas installations, potential risks associated with those hazards and how to eliminate or reduce them. Attendees also need to learn basic emergency response and skills from travelling to and from offshore installation by a helicopter and demonstrate (in a simulated environment) that they can use safety equipment during helicopter emergencies and follow procedures during a crash. This 3-day training might seem like an easy task to do before a fun ride in a helicopter, however, these impressions are deceptive.

training. Students have to actually escape

As a paint inspector, you might be asked to go through different types of training in order to oversee certain offshore projects. In order to work on an oil platform in the middle of the sea, you will most likely have to undergo the Basic Offshore Safety Induction & Emergency Training (BOSIET), including the Helicopter Underwater Escape Training (HUET) with Emergency Breathing System.”

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

the helicopter simulator. They need to unstrap themselves and leave the helicopter, however, they need to overcome few bumps on the road such as orientate themselves after the simulator twists or kicking out the window on their way to the surface. “Going underwater and going upside down is the weirdest feeling,” says Richard van der Wal, managing director at Paint-Inspector.Com (Fig. 2), “even though you know there is no danger at the moment you need to calm down and think straight.”

HIGHLIGHT OF THE MONTH

Paint-Inspector.Com is able to provide inspectors with BOSIET and HUET certificates anywhere around the world and is currently working for a leading Oil & Gas company, PetroGas, to support their maintenance program, and provide needed paint inspectors with BOSIET and HUET certificates. Third day continues with CPR training, working with fire extinguisher and how to behave in a room full of smoke. Going through additional training after getting your paint inspector certificates (FROSIO, NACE, Icorr etc.) might seem like an unnecessary work, but be sure that you will be glad to have this one! As a paint inspector, there is still a need to educate yourself and overcome some obstacles. Paint-Inspector.Com is able to provide inspectors with BOSIET and HUET certificates anywhere around the world and is currently working for a leading Oil & Gas company, PetroGas, to support their maintenance program, and provide paint inspectors with BOSIET and HUET

ÂŠ Paint-Inspector.Com

certificates.

2 1

Figure 2: Richard van der Wal, managing director at Paint-Inspector.Com during Helicopter Underwater Escape Training (HUET).

teerayuttae ÂŠ fotolia

Opening photo: Dollmar Spa (Caleppio di Settala, MI, Italy) and Noxorsokem Group Srl (Cusano di Zoppola, PN, Italy) combined their activities and skills into one company devoted to the development of products and services for the surface pre-treatment, paint stripping, and water treatment fields: DN Chemicals.

HIGHLIGHT OF THE MONTH

The Synergy between Dollmar and Noxorsokem Group Creates a New Specialised, High Added Value Business Barbara Pennati ipcmÂŽ

he industrial coating sector is

technological innovations. Changes and

Very often, collaboration between

undoubtedly a complex market,

transformations are therefore a constant

companies proved to be a winning choice

rich in nuances and still with

that any firm should take into account

to attain both individual and common

wide margins of growth. Like many other

to develop effective strategies for the

goals and give added value even to

industrial sectors, it is greatly affected by

achievement of its objectives.

products already known and established

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

for the surface pre-treatment, paint

The two divisions have therefore

two companies with over thirty years of

stripping, and water treatment fields (ref.

merged into a new company with its

history that decided to embark on a path

Opening photo).

own corporate identity. Fulvio Truant

of cooperation: Dollmar Spa (Caleppio

“The right synergies had been created

(Noxor) will be the technical manager,

di Settala, MI, Italy), established in 1947

in terms of both sales and R&D, so

André Bernasconi (Dollmar) the sales

and specialising in surface pre-treatment

we strengthened our collaboration

manager, and Gianluca Pinna (Noxor)

solutions, and Noxorsokem Group Srl

through the creation of one company,

the general manager (Fig. 2). “In

(Cusano di Zoppola, PN, Italy), established

DN Chemicals (Fig. 1), combining our

the first phase, the well-established

in 1983 and specialising in industrial

pre-treatment, paint stripping, and

brands Dollmar and Noxor will

chemicals for the waste water treatment

waste water treatment know-how under

still be present along with the new

and paint stripping processes.

one brand,” explains Noxor president

trademark. This will provide a sense

The two firms, which had long been

Gianluca Pinna. “The two companies had

of continuity between past, present,

collaborating in terms of sales and

already travelled a long way together and

and future while emphasising the

marketing, combined their activities and

this is a further step forward for us. It is

presence of a new, specialised

skills into one company devoted to the

a work in progress, officialised in March

structure,” says Dollmar CEO Andrea

development of products and services

2018.”

Zamberletti.

on the market. This was the objective of

Figure 1: The business unit in Pordenone.

international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52

2 1

Figure 2: From the left: Andrè Bernasconi and Gianluca Pinna, respectively sales manager and general manager of DN Chemicals.

A single identity for a variety of products and services

complete service. This is very important

development, and technical assistance

for us,” states Dollmar sales manager

synergies created.”

The new operational structure will

André Bernasconi. “We aim at developing

“With this operation, we especially aim at giving added value to all these

be devoted to the development of

elements,” says Zamberletti. “This

chemical specialties and it will be equipped with two R&D laboratories, but it will also be able to provide complete surface pre-treatment and paint stripping solutions. “By combining our experience in the field of pre-treatment and nanotechnology

The new operational structure will be devoted to the development of chemical specialties and it will be equipped with two R&D laboratories, but it will also be able to provide complete surface pretreatment and paint stripping solutions.”

is the most important factor of cohesion, because it enables us to specialise and clearly identify all our growth paths under one brand. We will therefore develop specific skills, but we will share them for a common goal of growth,

with Noxor’s expertise in flocculant products for the water treatment

complementary products to be offered

aiming for an increasingly cross-sectoral but

and paint stripping sectors, we will be

directly to our clients thanks to the

at the same time specialised service. We

able to provide our customers with a

wider sale network and the production,

used to do this as two separate companies,

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

whereas now it will be the objective of this new company devoted to all the corollary activities of coating processes.”

Towards new markets “In this first phase, we aim at consolidating our presence on our two firms’ long-standing target markets and at making our synergy

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more active and efficient,” explains Gianluca Pinna. “The interaction is constant, not only among professionals but also with clients, within a dynamic framework and with qualified personnel able to formulate and produce customised chemical specialties for any industrial process. Our peculiarities and expertise have proved to be perfectly

LeBot MV A5-A6: 5 and 6 axis articulated robot with self-learning, point to point and 3D offline programming, also available in chariot, carriage and carousel configuration with 3D Lesta shape acquisition system.

overlapping and they enable us to effectively manage all orders, regardless of their volume. We can thus meet the demands of all types of customers, fulfil the needs of various market fields, and offer a broader and more complete product range.” “Initially, we will consolidate our presence on the Italian market. Then, we will optimise the right strategies to promote our presence also on the foreign markets with which both companies already work through different distribution channels,” says Bernasconi. “In terms of industrial segments, we will focus on the fields of car components,

LeBot C5: 5 axis cartesian robot with 3D Lesta shape acquisition system. acqui ystem.

earth moving machinery, and contracting coating; subsequently, we will try to improve our presence in the sectors of coils, profiles, and aluminium wheels.”

An active collaboration for a future of growth “During the development phases that led to the establishment of this new business, we were very pleased with the fact that all the players involved in the project collaborated in a completely natural way, integrating perfectly and successfully working on all kinds of products for the surface pre-treatment, water treatment, and paint stripping fields,” states Bernasconi. “The constant and spontaneous exchange of experiences has allowed us to work together and create a

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harmonious and functional corporate structure, as well as developing a wide range of products suitable for many industries and for the most diverse needs.” “Proactivity and versatility have allowed us to move towards new fields and they will enable us to plan the future strategies of our new and growing business,” says Bernasconi.

During the development phases that led to the establishment of this new business, Dollmar and Noxorsokem Group were very pleased with the fact that all the players involved in the project collaborated in a completely natural way, integrating perfectly and successfully working on all kinds of products for the surface pre-treatment, water treatment, and paint stripping fields.”

WWW.LESTA.IT

LESTA S.r.l.

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BUSINESS CARDS

JOB OFFER Global leading company in the ﬁeld of zero liquid discharge (ZLD) wastewater treatment for metal ﬁnishing line, with more than 30 years’ experience in design, development, manufacture and installation of wastewater plants, is searching for the following job candidates: CHEMICAL OR MECHANICAL ENGINEERS (or comparable preparation) DESIGNERS (Autocad 2D/3D) QUALITY, SAFETY AND MANUAL OFFICERS SOFTWARE TECHNICIANS, AUTOMATION (Siemens, A.B.) What you need to succeed: - Aged preferably under 35; - Good knowledge of MS Office and order management systems; - Written and spoken english (min. level required: B2); - Availability to travel abroad for medium-term periods; - Candidates coming from Metal Finishing sector appreciated.

Place of work: CIE Milano. Please send detailed CV to silvia.tamburini@cieeng.com and indicate availability for Skype interviews http://www.cieeng.com

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

... On the road to

ipcm

n. 52...

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Gli espositori presenteranno una gamma completa di prodotti, attrezzature e servizi di distribuzione dall’Italia e dall’estero: f Viteria, bulloneria e ﬁssaggi industriali f Fissaggi per costruzioni f Sistemi di assemblaggio e installazione f Tecnologia per produzione di viteria e bulloneria f Servizi di stoccaggio e logistica

Incontrate fornitori e professionisti del settore. Scoprite le ultime tecnologie, ricercate prodotti e servizi.

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SPECIAL ON TRANSPORTATION

FOCUS ON TECHNOLOGY Flawless Finishes for Alloy Wheels: The Secret Is in the Spray Gun

FOCUS ON TECHNOLOGY Fainsa, Where Cutting-Edge Technology Meets Tradition: Double Production Speed and Higher Coating Quality for Public Transport Seats

INNOVATIONS: PRESENT&FUTURE IDROLIN/K DTM: Easy To Use with Good Anti-Corrosion Performance

SUCCESS STORIES EcoInCure: Space-Saving Oven Technology for Electric Cars

HIGHLIGHT OF THE MONTH Future Mobility and Human Needs Inspire BASF’s 2018-19 Automotive Color Trends

BRAND NEW

INNOVATIONS: PRESENT&FUTURE

JackF © Fotolia

Alternative and Innovative Technologies Implemented in Coating Booths for Railway Vehicles

Opening picture: Cevher is one of the most innovative alloy wheel suppliers of European OEMs.

FOCUS ON TECHNOLOGY

SPECI AL ON T R AN SPORTATION

Flawless Finishes for Alloy Wheels: The Secret Is in the Spray Gun Alessia Venturi ipcm®

lthough the reduction of

management costs; and the efficient

Cevher Wheels, a Turkish company

environmental impact and of raw

integration of modern and advanced

producing alloy wheels for cars (ref.

material consumption has been a

systems even in dated equipment,

Opening Photo), managed to achieve

priority for some time now, the main needs

because production devices can be

all these objectives by only updating the

currently expressed by the manufacturing

updated at different stages to cope with

spraying equipment integrated in its

industry include greater operational safety;

costs. In the industrial finishing sector,

already-existing coating system. This was

reduced production spaces, since space

all this must go hand in hand with an

possible thanks to the expertise of Graco in

has increasingly higher purchase and

impeccable finishing quality.

the electrostatic coating field.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The partner of the major European automobile groups

The parts are cured at 180 °C (Fig. 4),

of the primer and the base coat and

cooled, and subjected to quality controls

they are then subjected to the coating

With 1 million and 600 thousand

with the possible sanding of any defects.

cycle from the beginning, i.e. from the

workpieces produced, a turnover of

Then, we apply the liquid base coat – we

pre-treatment stage; finally, two layers

over 70 million Euros in 2017, and an

manage over 15 colours, although the

of clear coat are applied, a powder and

export rate of nearly 100%, Cevher

most used ones are 6 or 7 – and the

a liquid one, for a total of four layers of

Wheels (Izmir, Turkey) is one of the

acrylic clear coat (Fig. 5) with a wet-on-

paint.”

most innovative alloy wheel suppliers

wet process featuring a 12-minute flash

company covers an area

An investment in spraying quality and consumption reduction

of 44,000 m2, of which

From the beginning,

22,000 are covered. It

Cevher has

integrates vertically the

always been at

entire production process

the forefront of

of wheels, from casting to

experimentation

finishing through mould

and willing to

design.

implement new

of European automobile groups, including Volkswagen and FCA. Established in 2002, the

“Cevher’s production process is divided into five phases: melting of primary aluminium, low pressure die casting

technologies, as

proven by its recent

Figure 1: From left to right: Michael Lucas and Erbil Zerenler of Graco, Arda Cilantli of Cevher, Harun Dağteke of Genmar, Miranda Houbrechts of Graco, Alessia Venturi of ipcm and Semih Balkaya of Cevher.

of wheels, thermal

investment in the replacement of all automatic spray guns with Graco’s

treatments, machining, and coating,”

off stage between the two application

Pro XPc Auto

says Cevher coating manager Arda

operations. Polymerisation takes

(Fig. 6) devices. “We have always

Cilantli (Fig. 1). “We are equipped with

place in a hot air oven at 150 °C for

used the electrostatic technology for

3 melting furnaces, 28 low pressure

15 minutes. At the end of the coating

spraying liquid coatings. A year ago, we

presses, a continuous flow heat

cycle, the wheels proceed to the final

approved an investment to replace all

treatment line, 8 machining stations

control and packaging stations. In case

our equipment, especially atomisers and

with 3 lathes each, a mirror polishing

a diamond finish is required, the wheels

control units (Fig. 7),” says Arda Cilantli.

station with 5 lathes featuring an

are mirror polished after the application

“Graco was already our technological

annual capacity of 300,000 wheels,

partner for the supply of both

and a coating line featuring an annual capacity of 2 million wheels (Fig. 2). Our factory also has a metallurgical testing laboratory for dimensional, dynamic, and balancing checks and a laboratory for the quality control of coatings.” For the finishing of alloy wheels, Cevher employs the mixed powderliquid coating systems conventionally used in the wheel sector. “After a 13-stage pre-treatment phase (Fig. 3) with Chemetall chemicals, we apply an epoxy-polyester powder primer.

application and paint feeding

Although the reduction of environmental impact and of raw material consumption has been a priority for some time now, the main needs currently expressed by the manufacturing industry include greater operational safety; reduced production spaces, since space has increasingly higher purchase and management costs; and the efficient integration of modern and advanced systems even in dated equipment, because production devices can be updated at different stages to cope with costs.”

devices. We decided to confirm this choice by opting for the implementation of Pro XPc Auto guns. We also considered Graco’s ProBell® rotating bells, but our coating plant does not allow to use them since it cannot guarantee the maintenance of some necessary parameters, such as air temperature and humidity. “We installed six guns in each of the two liquid coating application

international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52

SPECIAL ON TR ANSPORTAT I ON

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Figure 2: Cevher painting installation has an annual capacity of 2 million wheels.

Figure 3: Wheels with the powder primer applied during the curing stage.

consumption depending on the

booths, mounted on fixed reciprocators same time: we have different spraying programs to be selected by the operator during loading depending on the wheel’s design and size, which require three or four guns at a time. For instance, for 15 and 16” wheels, we use the guns no. 1, 3, and 6, while for 17 and 18” wheels we use the guns no. 2, 4, and 6. The gun no. 5 is normally kept as a back-up.” “Since we have started using the new Pro XPc Auto guns, we have noticed a significant decrease in overspray,

colour used,” states Arda Cilantli. “This also led to an environmental benefit, because we produce less paint sludge and we consume less chemicals for its treatment. Moreover, the application of some metallic shades now achieves a far better quality level, since the guns’ electronic control units enable us to precisely adjust electrostatic properties such as voltage and current intensity. The old equipment had pneumatic controls that did not allow for the fine-tuning of these parameters.”

resulting in a 15%-20% reduction in paint

With 1 million and 600 thousand workpieces produced, a turnover of over 70 million Euros in 2017, and an export rate of nearly 100%, Cevher Wheels (Izmir, Turkey) is one of the most innovative alloy wheel suppliers of European automobile groups, including Volkswagen and FCA. Established in 2002, the company covers an area of 44,000 m2, of which 22,000 are covered. It integrates vertically the entire production process of wheels, from casting to finishing through mould design.”

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Figure 4: Pre- treatment tunnel.

(Fig. 8). We never use all the guns at the

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

Figure 5: Application of the liquid base coat: each booth is equipped with 6 guns mounted on fixed reciprocators.

FOCUS ON TECHNOLOGY

From the beginning, Cevher has always been at the forefront of experimentation and willing to implement new technologies, as proven by its recent investment in the replacement of all automatic spray guns with Graco’s Pro XPc Auto devices.”

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Figure 6: Graco’s ProXPc Auto.

The Graco Pro XPc Auto technology

- their small size and weight allow them to

The electrostatic spray guns Pro XPc Auto

- the possibility to control the guns and

be used in confined spaces and corners;

transfer efficiency and reduced material consumption. A salient feature of these devices is safety.

are versatile, compact, and light, which

the coating parameters with a PLC or a

It is no secret that high voltage inside the

makes them the ideal choice for robots and

control unit provides spraying flexibility and

coating booth may involve risks: that is

process improvement;

why the Pro XPc Auto guns have been

reciprocators with low payloads. They are safe, durable, and designed for efficient integration in various types of coating systems:

- their patent pending charge points enable to maximise profits through high

designed with a 100 kV power supply and a low voltage connection cable.

We create chemistry that makes lines love curves. Coatings give a car more than just long-lasting protection. Brilliant gloss and innovative colors transform contours into dynamics and design into emotion. Lines and curves are united and edges and contours are brought to life. When color and shape come together, and paint evokes passion, it’s because at BASF, we create chemistry. www.basf-coatings.com

SPECIAL ON TR ANSPORTAT I ON

Figure 7: The spray guns electronic control units.

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Figure 8: Application of the acrylic clear coat with Graco’s ProXPc Auto spray guns.

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N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Since Cevher has started using the new Pro XPc Auto guns, they have noticed a significant decrease in overspray, resulting in a 15%-20% reduction in paint consumption depending on the colour used. This also led to an environmental benefit, because they produce less paint sludge and consume less chemicals for its treatment. Moreover, the application of some metallic shades now achieves a far better quality level, since the guns’ electronic control units enable them to precisely adjust electrostatic properties such as voltage and current intensity.”

Their external controller, which generates and manages the voltage, features software that detects the presence of electric arcs and automatically stops the electrostatic charge when a workpiece is too close to the gun.

Perfect finishing quality, reduced maintenance, and ease of use “It was difficult to improve the quality of our coating process, but with our new guns and electronic control units we have achieved a perfect finishing level,” states Arda Cilantli. “Graco’s Pro XPc Auto guns are user friendly and feature a smaller number of constructive components, which results in less frequent and easier maintenance operations, since they are easy to disassemble. These devices are practical and reduce system downtimes. Among their main advantages, however, they ensure significant paint savings, nearly 15% for some colours, and thickness uniformity, thanks to the possibility of performing fine adjustments of the coating parameters, such as air pressure and electrostatics. Therefore, our investment in new spraying equipment supplied by Graco has enabled us to achieve a global improvement of our finishing process.”

Opening photo: Fainsa is a European leader in the production of passenger seats.

FOCUS ON TECHNOLOGY

SPECI AL ON T R AN SPORTATION

Fainsa, Where Cutting-Edge Technology Meets Tradition: Double Production Speed and Higher Coating Quality for Public Transport Seats Barbara Pennati ipcm®

he history of Fainsa (Fabricación

motorcycle accessories in 1935. Since its

seats. In 2015, it became part of the French

Asientos Vehículos Industriales

modest beginnings, Fainsa has recorded

group Compin (ref. Opening photo).

Sa) started in Martorelles, in the

a considerable growth, developing its

The Martorelles-based company currently

northern suburbs of Barcelona (Spain),

technical knowledge and increasingly

covers 24,000 m2 distributed among six

where Aleix Singla Vila opened a small

specialising to establish itself among the

buildings and it produces 150,000 seats per

workshop manufacturing bicycle and

main manufacturers of passenger transport

year, exporting almost 80% of production

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

globally. “Fainsa’s strength and key to success lies in

were equipped merely with two manual powder

its ability to combine the craftsmanship and human

application stations. We needed to invest in order

skills earned in over eighty years with the cutting-edge

to improve our productivity, quality, and consistency

production technologies needed to guarantee the

in terms of coating. We looked for a technological

high quality levels required

partner able to offer us

by its target market – public

a functional solution

transport and, in particular,

that was both advanced

the rail and tram sector”, explains Fainsa general manager Salvatore Esposito (Fig. 1). “A large part of our production is intended for foreign markets, with stringent regulatory requirements. The need to cope with the most diverse technical specifications and the exponential growth

Fainsa’s strength and key to success lies in its ability to combine the craftsmanship and human skills earned in over eighty years with the cuttingedge production technologies needed to guarantee the high quality levels required by its target market – public transport and, in particular, the rail and tram sector.”

and able to integrate with Fainsa’s production equipment, including structures dating back to 1935 and, therefore, with a few limitations in terms of logistics.” Fainsa relied on System Pulver (Sant Just Desvern,

KMU LOFT – because resources are limited

Spain), representing Gema on the Spanish market and offering automated

of our company in the

powder coating solutions

last few years forced us

since 1994 (Fig. 2). Thanks to the integration of a new

Moreover, we have always strived to manage all key

generation automatic powder coating system, the

processes in-house: until one year ago, only the

optimisation of some phases such as the hanging

coating phase was largely outsourced because we

one, and the lengthening of its one-rail conveyor,

to rethink our factory’s capacity and quality levels.

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Figure 1: Salvatore Esposito, the general manager of Fainsa.

www.kmu-loft.it

SPECIAL ON TR ANSPORTAT I ON

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Fainsa managed to achieve an increase

Figure 2: The new powder application booth installed by Gema (Sant Just Desvern, Barcelona, Spain).

Fainsa relied on System Pulver (Sant Just Desvern, Spain), representing Gema on the Spanish market and offering automated powder coating solutions since 1994. Thanks to the integration of a new generation automatic powder coating system, the optimisation of some phases such as the hanging one, and the lengthening of its one-rail conveyor, Fainsa managed to achieve an increase in productivity and an impressive quality level in terms of coating, thickness, and film distension even on the hidden surfaces of its seats.” The need for greater production

in productivity and an impressive quality

versatility is one of the reasons

level in terms of coating, thickness, and film

that led Fainsa to completely

distension even on the hidden surfaces of

automate and insource the

its seats (Fig. 3).

coating process. “The products intended for the public transport

Products and experience behind eighty-three years of history

field are subject to a very high degree of wear, and therefore

At the Martorelles factory, the production

their coating has a purely

process starts with the raw material,

functional purpose. It is essential

especially sheet metal and steel pipes,

to ensure effective corrosion

which is cut, folded, and welded to form

protection, a long service life,

the seat frames (Fig. 4). “Fainsa’s products

and great cleaning ease in case

are divided into two main lines: the seats

of graffiti and vandalism acts,

intended for trains and undergrounds

which are recurrent problems

and those intended for buses,” says

in the sector,” states Salvatore

Salvatore Esposito. “All parts are designed,

Esposito. “For the rail and tram

approved, and treated in-house. We then

sector, however, coatings also

subject our products to strict quality

have an aesthetic function:

controls before sending them to the end

an automotive-level quality is

customers. The in-house management

required, with surfaces free of

of our entire production process is a

any defects and orange peel

significant advantage for us, because it gives us the flexibility to adapt our products to customer needs as much as possible (Fig. 5).”

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Figure 3: Fully coated seat frames waiting to be assembled.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

effects. That is why we only apply high quality polyester or easy-toclean clean polyurethane

powders with anti-graffiti properties. We

FOCUS ON TECHNOLOGY

rely on different paint manufacturers whose expertise is recognised worldwide, including AkzoNobel, Adapta, Tiger Drylac, and Ripol,” says Esposito. “Based on our experience, however, anti-graffiti polyurethane powders are difficultto-manage products, perhaps not yet perfected in terms of formulation. In fact, we find a high variability between different batches as well as problems of adhesion, application and, above all, material recovery, which most manufacturers do not recommend performing.” “We are sure that the coating manufacturers will acquire more and more know-how thanks to the increase in the industrial use of these powders, but for us it was necessary to find a solution to automate our coating process and integrate it within our production flow.

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Figure 4: The automated welding of the seats.

Aluminium Wheel Painting

Excellence in surface finishing For the painting of aluminum wheels, Dürr delivers powerful technologies along the whole process, starting with wheel surface cleaning and chemical conversion for effective corrosion protection, painting and curing, to the purification of air exhaust. Dürr offers their own application technology with specially patented features that fit best with the requirements of quality-oriented aluminum wheel surface painting. www.verind.it

SPECIAL ON TR ANSPORTAT I ON

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Figure 5: Finished seats waiting to be packaged.

We also aimed at reducing the waste generated by our manual stations, where powders were not recovered, and their disposal costs, while further increasing our quality level,” states Esposito.

The investment on the coating line Fainsa worked with Gema to find a solution that could increase the company’s flexibility and capacity, while optimising the application phase, the process costs, and the consumption levels related to the use, in particular, of polyurethane and polyester paints. “Together with Gema, we developed a project that required the increase of the length of the already-existing one-rail conveyor in order to improve the performance of the line in terms of

The need for greater production versatility is one of the reasons that led Fainsa to completely automate and insource the coating process. The products intended for the public transport field are subject to a very high degree of wear, and therefore their coating has a purely functional purpose. It is essential to ensure effective corrosion protection, a long service life, and great cleaning ease in case of graffiti and vandalism acts, which are recurrent problems in the sector. For the rail and tram sector, however, coatings also have an aesthetic function: an automotive-level quality is required, with surfaces free of any defects and orange peel effects.”

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Figure 6: The loading area of the coating plant.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

capacity and speed, as

FOCUS ON TECHNOLOGY

of Gema’s

well as the optimisation

guns and

of the hanging phase

reciprocators,

with specifically

which ensure

designed frames (Fig.

optimal

6),” explains Marc

distribution of

Garriga, the general

the product,”

manager of Coating

says Salvatore

Point. This consulting

Esposito (Fig.

firm supported Fainsa

11). “Fainsa is

during the setting up

an ISO 14000

of the new coating

certified

line (Fig. 7). “We then

company

replaced the two

and it is very

manual stations with

attentive to

Gema MagicCompact

environmental

booth featuring a quick colour change system, an automatic application station equipped with two

issues. The

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OptiCenter

Figure 7: From left to right: Fainsa coating manager Andrés Barba (jokingly nicknamed “the emperor of coatings”), Alessia Venturi (Ipcm), Marc Garriga (Coating Point), and Juan Carlos Gómez (Gema).

recovery system (Fig. 12) allows us to recover the polyester

reciprocators with three guns each (Fig. 8), and two

amount of product applied for

powders, thus reducing waste levels and

manual pre and post-retouching

the same thicknesses – in other

disposal costs and, therefore, achieving

stations (Fig. 9). The booth is

words, greater transfer efficiency.

another important goal. Our working

equipped with optical bars that

The thickness homogeneity

environment has also benefited from this

recognise the workpieces and

achieved by this system is really

because the booth cleaning operations are

automatically activate the guns only

impressive: although manual

easier and faster, as is the colour change process, now requiring about 8 minutes.

to the complex shapes of parts,

Unfortunately, we cannot recover the

immediately ensured a significantly

the application results have greatly

polyurethane powders due to their reactive

lower overspray level and a smaller

improved thanks to the quality

chemical nature that prevents their reuse.”

retouching is always necessary, due

as they pass (Fig. 10).” “The new spray paint booth

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Figure 8: The booth is equipped with two opposing reciprocators with three guns each and two manual stations.

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Figure 9: The pre and post-retouching stations.

international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52

SPECIAL ON TR ANSPORTAT I ON

A future 4.0 for a wellestablished industrial group “The new coating plant has been in operation since August 2017. Although we cannot claim to have solved all the problems related to anti-graffiti powders, Gema’s booth has optimised the consumption levels and improved the thickness uniformity in a relatively short time. This, of course, positively influenced the final quality of parts,” states Marc

Garriga.

The new coating plant has been in operation since August 2017. Although Fainsa cannot claim to have solved all the problems related to anti-graffiti powders, Gema’s booth has optimised the consumption levels and improved the thickness uniformity in a relatively short time. This, of course, positively influenced the final quality of parts.” level guaranteed by Gema. They were able to fulfil our needs by showing commitment, respect of the timeline, and the flexibility

10 1

needed to design a modern coating line in a historic infrastructure like that of Fainsa.”

Figure 10: The optical recognition bar at the entrance of the booth.

“The group management is very pleased with the results obtained by Fainsa and they intend to make further investments to implement these technologies also in other plants, in order

to offer our customers increasingly greater and, above all, constant production and quality levels,” states Salvatore Esposito. © ipcm ®

Together with Gema, Fainsa developed a project that required the increase of the length of the alreadyexisting one-rail conveyor in order to improve the performance of the line in terms of capacity and speed, as well as the optimisation of the hanging phase with specifically designed frames. Then, they replaced the two manual stations with Gema MagicCompact booth featuring a quick colour change system, an automatic application station equipped with two reciprocators with three guns each and two manual pre and postretouching stations. The booth is equipped with optical bars that recognise the workpieces and automatically activate the guns only as they pass.”

11 1

Figure 11: The paint coverage and spreading are optimal even in undercuts and in the most diﬃcult-to-reach points.

“The current line speed is of 2.6 to 4 metres per minute, depending on the type of product. This has enabled us to speed up our production, increase our production capacity, and completely insource our coating operations, but also to manage the production volume of another company within the group, which is based in Llinares (Andalusia, Spain) and previously relied on coating contractors,” says Salvatore Esposito. “This investment has been very important for

12 1

our firm and we could not have achieved our objectives without the support and quality

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

Figure 12: The new Gema OptiCenter.

ÂŠ Grayson Thermal Systems

Opening photo: Grayson Thermal Systems have been designing and manufacturing bespoke heating, cooling and HVAC products for the Coach, Bus and Commercial Vehicle markets for 40 years and have partnered with Sherwin-Williams after trials of INVER brand paint from the water soluble IDROLIN/K DTM range.

INNOVATIONS: PRESENT&FUTURE

SPECI AL ON T R AN SPORTATION

IDROLIN/K DTM: Easy To Use with Good Anti-Corrosion Performance Christian Lucano Sherwin-Williams, Bologna, Italy

christian.lucano@sherwin.com

he technological challenges in the

recent years, one particularly stands

carried out in the past led to formulations

paint industry are increasingly

out fully satisfying the customers:

with those properties, but somehow

focusing on products with high

the development of one component

failing in aesthetic terms. In fact, to ensure

performance in terms of mechanical and

acrylic, water soluble IDROLIN/K DTM

corrosion resistance, it was necessary to

chemical resistance, with good aesthetic

range.

use anti-corrosion pigments, which reduced

properties and, possibly, at reasonable

This is the next generation of the

the brightness on application.

prices. Most part of the research is carried

well-known Idrolin brand, with which

The new IDROLIN/K DTM range performs

out on water based coatings, in which

especially the Italian customers are

well against corrosion, resisting from 300

Sherwin-Williams, with its fifty years of

familiar. The goal is to satisfy the

to 500 hours NSST (Neutral Salt Spray

know-how built up with Inver brand, plays

market demand for a fast, easy to

Test), depending on the substrate, without

a leading role on the market.

apply water soluble product with good

compromising the brightness, which can

Out of the many projects developed in

corrosion resistance. The studies

remain up to 80 gloss at 60Â° (Figs. 1 and 2).

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

2 1

Figures 1 and 2: The results obtained by IDROLIN standard version (left) and IDROLIN/K (right) after 300h of NSST (Neutral Salt Spray Test).

In addition, the new, high performing acrylic resin,

requirement was for easy to use products, typical

which is the backbone of this product, imparts

for single component paints, but with good anti-

excellent adhesion on various substrates, which lets

corrosion performance, needed in the case of a

us classify the products as DTM, or Direct-To-Metal,

global customer which makes steel piping, this

that is products that can be applied directly to metal.

series fully satisfies all the initial requirements.

Good mechanical properties are also retained, as

Even if it was not one of the main requirements,

confirmed by the direct and inverse impact and

this series exceeds the aesthetic expectations as

cylindrical mandrel bending tests. The surface

well.

hardness after full drying of the film is very good

“Grayson Thermal Systems have been designing

and resistance to light is outstanding, like any other

and manufacturing bespoke heating, cooling

acrylic product. The water and chemical resistance

and HVAC products for the Coach, Bus and

are excellent.

Commercial Vehicle markets for 40 years and

Being a water soluble range, the average level of

are now a market leading supplier around the

VOC (Volatile Organic Compounds) is approximately

globe (ref. Opening photo). We decided to

40 g/l.

partner with Sherwin-Williams after trials of INVER

Last but not least, a very appreciated feature is

brand paint from the water soluble IDROLIN/K

that the drip limit of this product range is over

DTM range and the business has already seen

150μm DFT (Dry Film Thickness). This means that

the benefits from its ease of use, corrosion

high thicknesses may be applied without negatively

protection and consistent cosmetic finish”, said

influencing the final appearance of the painted

Stuart Hateley, managing director of Grayson

surface.

Thermal Systems. “Using this product over a

A very important customer in the UK which

standard solvent based paint has also allowed

manufactures cooling, heating and air conditioning

us to reduce our carbon footprint and adhere to

systems pointed out that they have achieved, thanks

our environmental policy, further securing our

to Idrolin/K DTM product range, a measurable

position as an ethical and environmentally aware

technical improvement. Even though the initial

business across our 5 manufacturing facilities”.

SUCCESS STORIES

SPECI AL ON T R AN SPORTATION

lectric, fully networked, highly automated: the new car brand Byton is consistently designed

EcoInCure: Space-Saving Oven Technology for Electric Cars for the mobility of the future. The Chinese start-up also insists on stateof-the-art standards for manufacturing and commissioned Dürr to construct a complete paint shop. Distinguishing features are a 20% reduction in footprint and the use of pioneering technologies. An example of this is the EcoInCure oven, which is ideal for electric vehicles. From October 2019, the new Chinese OEM Future Mobility Corporation (FMC) will produce electric vehicles under the Byton brand at its company site in Nanjing. The new paint shop is initially designed for 150,000 vehicles per year – equivalent to 30 units per hour. Growth has already been factored in, since the capacity can easily be doubled. Electric mobility goes hand in hand

Figure 1: Improved paint quality thanks to EcoInCure by heating the body from the inside.

with modified body concepts that use new materials or combine materials in

from the inside out reduces the risk

with the body. The robots in the

new ways. Conventional ovens reach

of pinholing. In addition, minimized

spray booths are equipped with the

their limits when steel, aluminum, and

flow velocities along the freshly

latest EcoBell 3 atomizer generation.

composite materials are used together.

painted surfaces ensure a completely

The semi-automatic EcoDryX dry

This is because it is vital that all body parts

undisrupted top coat appearance.

separation system, which separates

are heated uniformly, otherwise thermal

Dürr’s scope of delivery for the new

the overspray in the paint booths

stresses occur. For this challenge, Dürr

paint shop for Byton FMC includes

for primer and top coat, requires

developed a fundamentally new concept

the RoDip® rotational dip process

absolutely no water or chemicals.

in vehicle drying with EcoInCure: bodies

for pretreatment and electrocoating

This simple and robust technology

are heated from the inside out by two

– already equipped for 60 units

works on the basis of cardboard

jet nozzles through the opening for the

per hour – as well as all the robotic

filters.

windshield and two nozzles directed into

and application technology for the

In addition, Dürr is designing a

the engine compartment opening (Fig. 1).

sealing and painting processes. The

downstream exhaust air purification

This enables unprecedented uniformity

electrocoating stage uses the energy-

system made up of the highly

of heating. Compared with conventional

saving and fail-safe system EcoDC

efficient Ecopure® KPR VOC

ovens, there is also a significant

MACS (Fig. 2). This technology uses

adsorptive concentration system

improvement in top-coat quality and

its modular anode control to create a

with combined thermal exhaust air

process performance - because heating

voltage profile in the tank that moves

purification using the Ecopure® RTO.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

SUCCESS STORIES

SPECI AL ON T R AN SPORTATION

Figure 2: The fail-safe EcoDC MACS electrocoating solution is based on a voltage profile in the tank that moves with the body.

saving – also thanks to EcoInCure. This is because the oven transports bodies transversely, halving its length compared to conventional systems. In addition, a central high-bay warehouse saves the space required

2 1

for multiple intermediate buffers and enables intelligent material flow

The scope of delivery of the order

exhaust air from the ovens is purified via the

control. All in all, this Eco+Layout

placed at the beginning of 2018 includes

Ecopure® TAR recuperative thermal process,

from Dürr reduces the paint shop’s

material feeding for PVC and paint,

which also provides all the heat for heating the

footprint by 20 percent.

shop ventilation, fire protection for the

oven in an energy-efficient way.

process systems, and a reverse-osmosis

Despite the extensive equipment, the design

For further information:

plant to reduce the water hardness. The

of the plant will be very compact and space

www.durr.com

join us at

hall 12 - booth E05

www.cieeng.com

info@cieeng.com

Opening photo: The 65 colours of BASF’s Automotive Color Trends 2018-19 – Keep it Real.

HIGHLIGHT OF THE MONTH

SPECI AL ON T R AN SPORTATION

Future Mobility and Human Needs Inspire BASF’s 2018-19 Automotive Color Trends Joerg Zumkley BASF Coatings GmbH, Muenster, Germany

joerg.zumkley@basf.com

continues to blur the lines between reality and artificiality is

Dark colours, blue hues and complex eﬀects represent the omnipresence of technology

the driving force behind the BASF’s 2018-19 Automotive Color

Advancements in digitalization make technology become

he need to stay authentic in a world where technology

Trends theme – “Keep it Real” (ref. Opening photo).

less visible and more intertwined with reality. Augmented

As innovations such as artificial intelligence, autonomous driving and

reality applications and smart gadgets that simplify everyday

robotic industrialization take hold, the return to the human element –

life merge the real with the digital world. People seem to

people’s needs and emotions – becomes increasingly important. The

spend more time on online platforms, striving for perfection

designers at BASF’s Coatings division translated these observations into

on social media, than in the real world. This omnipresence

a collection of 65 colours for automotive surfaces.

of technology is reflected in the Automotive Color Trends.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

Shades of grey and blue are the focal

ÂŠ BASF

HIGHLIGHT OF THE MONTH

point of the collection. Achromatic colours are combined with complex effects that add colourful and natural accents and represent the merging of reality and the virtual world. Blue hues â&#x20AC;&#x201C; mirroring the colour of screens and digital light â&#x20AC;&#x201C; appear as strong saturated colours. Natural textures and colour effects symbolize the search for human qualities in a virtual world.

Shifting functions â&#x20AC;&#x201C; new mobility concepts will influence colour choices Car sharing concepts, ride hailing services and autonomous driving will shift a carâ&#x20AC;&#x2122;s function from a personally owned object

Figure 1: The Urbanist.

to a more public mode of transportation.

EMEA â&#x20AC;&#x201C; Life in urban spaces

of creating an atmosphere of comfort and

For cars that are designed for sharing,

In the EMEA region, the use of

luxury, forms and materials are increasingly

colour pallets with a universal appeal will

urban spaces is changing, with real

displaying straight edges.

play a significant role. The trend collection

places becoming more significant in

These trends are reflected in the colour range

shows how elaborate textures and

metropolitan areas. This is reflected in

for EMEA. Grey nuances stand for urbanity.

intricate effects can make each colour truly

innovative design concepts for semi-

Combined with haptic effects, they build on

unique.

public spaces such as shops, museums

the significance of what can be experienced

In addition, BASF addresses future

and restaurants. The product becomes

for real. The off-white â&#x20AC;&#x153;Grand Blancâ&#x20AC;?, with

mobility with the continued development

less important while the space itself

its rough texture and its associations with

of functional colours. Select colours of

turns into an experience. It invites digital

concrete, alludes to life in urban spaces.

the collection feature a coatings system

nomads to sit down and stay a while.

Effect particles included in the clear coat

that mitigates heat build-up on the

At the same time, the question of how

accentuate the special nature of a car as

vehicle surface, which reduces the rise of

to attract attention in the face of so

an emotional product. â&#x20AC;&#x153;The Urbanistâ&#x20AC;?, as a

the temperature inside the car. Further

many virtual offerings arises. What is

dark grey, metallic anthracite, represents the

innovations include colours with state-of-

worth looking up from the smartphone

blending of humans and technology (Fig. 1).

the-art functionality, increasing reflectivity

for? One answer may be architectural

The pronounced metallic effect creates

for enhanced LiDAR detectability, without

elements that are rough and in some

unanticipated reflections and conjures up the

compromising their aesthetic appeal.

cases evoke archaic impressions. Instead

desire for attention.

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SPECIAL ON TR ANSPORTAT I ON

South America – Transformation of classic colour spaces The colours for South America offer a visual connection to the diversity of the region. Two of the most popular colour spaces in the automotive market – black and white – are transformed into elegant, eclectic coatings for cars. Coriolis Force, the region’s key colour, reflects on care and respect of traditional crafts and knowledge handed down over generations. The dark hue exudes a luxurious effect, which is

2 1

created by using a reddish gold flake. Under a strong light source, it creates a

Figure 2: Grey Ambivalence.

genuine aesthetic for the region.

Asia Pacific – Quest for quality in the real life

in North America, Atomium Sky: a deeply saturated blue with a

Colour expertise of the Coatings division

People in the Asia Pacific region

medium coarseness that transitions

The designers of BASF’s Coatings division

have an ambivalent relationship with

to a softer, semi-opaque hue in

observe technological and societal

technology.

longer grazing angles (Fig. 3).

changes and use them as inspiration and

They freely give their personal data

The colour exudes playfulness and

starting point for intensive research into

to companies that make everyday

demonstrates a futuristic spirit

future trends. Every year they translate

life more convenient and embrace

and forward thinking. This is the

their findings and predictions into a

emotional bonds to machines with

second consecutive year that BASF

collection of 65 new colours that reflect

artificial intelligence. At the same

has selected blue as its key colour

on global trends and developments within

time, a desire for human and real-life

in North America, which is a result

the regions of Europe, the Middle East and

contacts and experiences reshapes

of its growing prominence in the

Africa (EMEA), Asia Pacific (AP) and North

public spaces in the cities. Grey

region.

America (NA).

stands for the integration of high performance technology in everyday

Ambivalence, a glaring metallic grey,

life (Fig. 2). It is balanced by a solid flop that connects to the real world.

North America – Expanding colour horizons The dismantling of public heroes makes room for new idols. Flaws are accepted as part of being human and diversity is celebrated. A new enthusiasm for science and especially space travel draws attention to far away worlds. The connection of the real and virtual world as well as the relationship of earth and space is captured in BASF’s key colour

3 1

Figure 3: Atomium Sky.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

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BRAND-NEW

SPECI AL ON T R AN SPORTATION

AkzoNobel and Icelandair Let Fly With Stunning New Livery

celand’s rich and vivid history is being celebrated with colourful new livery launched by Icelandair, which was specially

created using AkzoNobel products. The Icelandic national airline’s new Boeing 757300 looks stunning with its tri-colour red, white and blue fuselage, which represents the colours of Iceland’s flag (Fig. 1). It was developed

to mark the 100th anniversary of Iceland’s independence and sovereignty. Featuring the company’s latest generation base coat/clear coat system and Aerodur 3001/3002 range, the aircraft is also coated with Aeroflex wing coatings and Aerofine interior cabin coatings. One of its first jobs was to fly Iceland

Figure 1: The Icelandic national airline’s new Boeing 757-300 coated using AkzoNobel products.

coatings will continue to provide the kind

these milestones in Iceland’s history,

“We have been partners with Icelandair for

of protection and endurance that has

Iceland’s sovereignty and the Icelandic

many years and were delighted to supply

helped Icelandic culture and heritage to

National team’s debut at the World Cup,

products for their eye-catching new livery,”

thrive for so many years.”

and are thrilled with the result. AkzoNobel

said John Griffin, Director of AkzoNobel’s

Added Icelandair’s Jón Skafti Kristjánsson,

products are used on the entire Icelandair

Aerospace Coatings business. “The design

Director of Marketing: “We wanted to

fleet and we couldn’t be happier with the

looks stunning and our high performance

do something remarkable to celebrate

quality and efficiency of the solutions the

football fans to Russia.

2 1

Figure 2: The Boeing 757 ‘Hekla Aurora’ based on the Northern Lights.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

BRAND-NEW

SPECI AL ON T R AN SPORTATION

The company’s recent acquisition of Disa Technology has also allowed AkzoNobel to expand its product portfolio to include film technology used on aircraft. Added Griffin: “Our emphasis is on producing sustainable, high performance, cost-effective coatings that are easy to use. These qualities have been fundamental to our relationship with Icelandair, which is built on trust, service, quality and reliability.” Icelandair’s new Boeing 757-300 is the carrier’s

3 1

third aircraft to feature special livery. The other

Figure 3: The Boeing 757 ‘Vatnajökull’, representing Europe’s second largest glacier.

two are based on the Northern Lights (Fig. 2) and Europe’s second largest glacier, Vatnajökull (Fig. 3). Both were created with AkzoNobel products.

company supplies. It’s a winning partnership in

waterborne coatings, base coat/clear coat

every sense.”

systems, high solids/low VOC coatings, peelable

AkzoNobel has pioneered and developed

coatings, selectively removable systems and

For further information:

many of the coatings technologies used in

special effects coatings, as well as chrome-free

www.anac.com /

the modern aerospace industry. This includes

systems.

www.akzonobel.com

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BRAND-NEW

SPECI AL ON T R AN SPORTATION

Major Upgrade Using Flexible Equipment

isenmann, the international plant

4.0 production environments. This

out any surface unevenness. “As there

engineering specialist, has been given

underscores the suitability of E-Shuttle

is no need for a solvent-based primer,

overall responsibility for expanding

200 as a component of a smart factory,”

there is a significant improvement in the

the paint shop at BMW Group’s plant in

adds Berger.

paint shop’s eco-efficiency. Furthermore,

Leipzig. Within the scope of the contract,

Eisenmann will also convert an existing

the primerless process is more cost-

Eisenmann will convert the top coat line

top coat line at BMW Group’s Leipzig

effective and cuts the time required to

and perform reengineering work on

plant to a primerless painting process,

paint each body. This makes it possible to

pretreatment and electrocoating.

and reengineer the finishing line. Primer

increase capacity considerably,” explains

This large-scale project includes a new

is conventionally applied to car bodies as

Berger. Installation work will commence

pretreatment/electrocoating system

a second layer. The specially formulated

in December 2018 and the project is

equipped with E-Shuttle 200 conveyors and

water-based base coat, a component of

scheduled to be completed by early 2020.

e-coat dryers. The E-Shuttle 200 conveyor

the integrated paint solution, performs

system moves the car bodies through the

the traditional functions of a primer: to

For futher information:

process tanks on individual shuttles. Its

protect against UV radiation and smooth

www.eisenmann.com

height make it particularly suitable for retrofitting to existing facilities (Fig. 1).

compact design and low

“Furthermore, we recommend E-Shuttle 200 to our customers when high throughputs are required, as is the case here,” explains Thomas Berger, Vice President, Sales, Automotive Systems, at Eisenmann. In addition, the flexible dip-coating conveyor is not only an excellent basis for achieving high finish quality, but also enables a variety of vehicle models to be treated on a single production line. “In light of the trend towards ever-greater customization, E-Shuttle 200 is an outstanding investment in the future. Moreover, the system’s intelligent control unit means that it is easily integrated into Industry

Figure 1: The E-Shuttle 200 conveyor system.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

Opening photo: When designing a large-sized coating booth, as happens to Savim in the field of the railway vehicles, it is no longer suﬃcient to perform a mere mathematical calculation to determine the airflow, air change, and electrical and thermal power values.

INNOVATIONS: PRESENT&FUTURE

SPECI AL ON T R AN SPORTATION

Alternative and Innovative Technologies Implemented in Coating Booths for Railway Vehicles Renzo Scavini Savim Europe Srl, Arbizzano (VR, Italy)

info@savim-europe.com

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

hen designing a largesized coating booth, as

The new air delivery plenum concept creates air intake flows from the booth’s ceiling without

happens to Savim in the

field of the railway vehicles, it is no

generating any interference

longer sufficient to perform a mere

and turbulence among its

mathematical calculation to determine

various segments. The system

the airflow, air change, and electrical

is managed by a PLC that can

and thermal power values (ref.

handle each area and modify

Opening photo). It is necessary to

the operating parameters

analyse each parameter and see

through a point-to-point

how any unnecessary waste can be

process. The PLC also enables

avoided without sacrificing the booth’s

to pre-set the air speed and

efficiency and safety.

air change values also based

In particular, the size and shape

on the different types of

regularity of railway vehicles should

coatings used. The coating

be taken into consideration. For

booth becomes therefore like

obvious reasons of size, these booths are equipped with several identical ventilation and heating devices installed along its length, in order to cover the entire coating

a series of adjacent identical

booths without any separation

Figure 1: The coating booth becomes like a series of adjacent identical booths without any separation between them.

between them (Fig. 1). Each of these booths has an autonomous functioning, identical or different from the

application area. Conventional booths alternately act as a coating booth, a

vehicle in the booth and therefore the

others. The PLC manages the cycle,

flash-off station, and a drying oven. By

lead time, thus increasing the paint shop’s

whereas the operator only gives consent

productivity.

based on his position (Fig. 2).

taking into consideration the size and shape regularity of the structure to be

This enables to reduce the plant’s

Savim made this possible by creating

coated, however, it is possible to create

energy consumption, process times, and

air delivery plenums with a technology

different properly sized segments and

management costs. The expertise of

fine-tuned over the last fifteen years in

to assign them to various operating

Savim and its new heating and air diffusion

the coating of large workpieces and in

phases. This ensures three important

technologies make all this possible. The

the field of composite materials. The air

advantages:

application of new technologies is always

entering the plenums passes through

• Saving electrical and thermal energy.

costly, since new equipment must be

micro-perforated diffusers that evenly

• Simultaneously performing coating

implemented in the booths, but the

distribute it among the filters and

and flash-off operations in different

considerable savings guaranteed make this

introduce it in the booth in a perfectly

areas of the same booth.

a very convenient, profitable, and easily

perpendicular way, from top to bottom.

amortisable investment.

This is especially important when it is

• Reducing the staying time of each

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The air entering the plenums passes through micro-perforated diffusers that evenly distribute it among the filters and introduce it in the booth in a perfectly perpendicular way, from top to bottom. This is especially important when it is also necessary to control the humidity in the booth.” by a micro-flame burner. The exhaust air exhaust chimneys are also used. A control unit continuously monitors the

2 1

operating parameters and air quality

Figure 2: Each of these booths has an autonomous functioning, identical or diﬀerent from the others. The PLC manages the cycle, whereas the operator only gives consent based on his position.

levels. The attainment of the right temperature is almost immediate and manageable with precision, since there are no heavy exchangers with their related thermal flywheel, which also

also necessary to control the humidity in the

lengthens the air heating and cooling

booth. Controlling and managing accurately the

times.

amount of circulating air enables to limit and

These concepts can be applied

maximise the investment and management

successfully not only to large-sized

costs of expensive and costly equipment.

booths, but also to smaller booths and

This also applies to the booth’s air heating

systems for coating components.

equipment: for decades, Savim has used direct

Conventional booths alternately act as a coating booth, a flash-off station, and a drying oven. By taking into consideration the size and shape regularity of the structure to be coated, however, it is possible to create different properly sized segments and to assign them to various operating phases. This ensures three important advantages: saving electrical and thermal energy; simultaneously performing coating and flash-off operations in different areas of the same booth; reducing the staying time of each vehicle in the booth and therefore the lead time, thus increasing the paint shop’s productivity. The expertise of Savim and its new heating and air diffusion technologies make all this possible.”

fire heating units that ensure energy savings, as confirmed by a 30% reduction in consumption costs, as well as constant temperatures in the booth (Fig. 3). Direct fire heating units have a nearly 100% yield. They do not require a conventional combustion chamber with tube bundles

3 1

nor a flue exhaust chimney, replaced

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

Figure 3: Direct fire heating units for Savim’s coating booths.

SUCCESS STORIES

SPECI AL ON T R AN SPORTATION

The World’s Largest Preservation Line in the Ship Building Industry Goes to Finland

in 2014 was a strategically important

go with the Rösler concept was the

of a preservation line at ND

milestone for the Meyer family. It

high productivity and reliability of the

Coatings, a strategic partner of

coincided with substantial investments

preservation line Rösler had supplied

the Meyer Werft shipyard in the German

in state-of-the-art equipment for the

to ND Coatings, the strategic partner of

town of Papenburg, Rösler has now

production of cruise ships. These

the Meyer Werft shipyard in Papenburg

delivered a second line for the Meyer

included a preservation line with leveling

for corrosion protection, insulation and

Werft shipyard in Turku, Finland (Fig. 1).

stations for bulb flat steel, straight

surface treatment (Fig. 2).

This is the largest equipment project ever

flat steel profiles and steel plates, all

This is one of the most modern and

undertaken by Rösler.

designed and built by Rösler. A key

eco-friendly preservation lines in the

The acquisition of the shipyard in Turku

factor in the customer’s decision to

hree years after the commissioning

Figure 1: Three years after the commissioning of a preservation line at ND Coatings, a strategic partner of the Meyer Werft shipyard in the German town of Papenburg, Rösler has now delivered a second line for the Meyer Werft shipyard in Turku, Finland.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

SPECI AL ON T R AN SPOR TAT I ON

SUCCESS STORIES

2 1

Figure 2: A key factor in the customer’s decision to go with the Rösler concept was the high productivity and reliability of the preservation line Rösler had supplied to ND Coatings, the strategic partner of the Meyer Werft shipyard in Papenburg for corrosion protection, insulation and surface treatment.

Fully automatic line including two shot blast machines

the control system automatically determines if the

The 225 meter (740 feet) long shot blast and

with which color they must be painted, or if they

leveling preservation line was completely

must only undergo a partial process. For every

work pieces must be cleaned, shot blasted, leveled,

custom engineered

finished component

to the needs of Meyer

all process parameter

Turku and consists of an inter-linked work piece transport system, pre-heaters, two independent shot blast machines, suitable leveling systems for beams and plates and a paint station with dryer. All system components

The acquisition of the shipyard in Turku in 2014 was a strategically important milestone for the Meyer family. It coincided with substantial investments in state-of-the-art equipment for the production of cruise ships. These included a preservation line with leveling stations for bulb flat steel, straight flat steel profiles and steel plates, all designed and built by Rösler.”

are linked with each

are reported back to the production control system allowing for complete and precise documentation. The steel profiles, which are stored outdoors, are covered with rust or scale from the roll forming process. Depending on the season, they

other and integrated into the production

may also be covered with snow and ice. Seven

control system of the shipyard. Upon arrival

work pieces are combined into a single batch on

of the work pieces at the line entrance,

the transport system and are passed through the

SUCCESS STORIES

The steel plates, stored in a roof-covered outdoor area, can be up to 100 mm (4”) thick, 3,300 mm (130”) wide and 24,000 mm (945”) long. They are picked up by a magnetic portal crane and placed in a centered position on the load station of the roller conveyor, the so-called main transport line. A sensor monitors the entire loading process. In the first stage the steel plates are passed through a blow-off station for the removal of water and other debris followed by a pre-heating step. From there they enter the RRB 35/6-HD roller conveyor shot blast machine at an average speed of 5 m (16 feet) per minute.”

SPECI AL ON T R AN SPORTATION

subsequent batching station with batch

with spray guns from above and below

widths of up to 3,200 mm (126”).

the work pieces. To minimize overspray,

The steel plates, stored in a roof-covered

the spray guns are controlled by a work

outdoor area, can be up to 100 mm (4”)

piece recognition and displacement

thick, 3,300 mm (130”) wide and 24,000

measuring system. The solvent used for

mm (945”) long. They are picked up by

rinsing and cleaning is conditioned and

a magnetic portal crane and placed in a

recovered in a processing plant allowing

centered position on the load station of

the recovery and recycling of 98% of the

the roller conveyor, the so-called main

material.

transport line. A sensor monitors the

The drier was designed to ensure

entire loading process. In the first stage

fast and optimum curing of the paint.

the steel plates are passed through a

It is equipped with gas burners and

blow-off station for the removal of water

recirculation nozzles at the top and

and other debris followed by a pre-heating

bottom of the cabin.

step. From there they enter the RRB 35/6-

In a last step the plates and profiles are

HD roller conveyor shot blast machine

staged at various unload stations for

at an average speed of 5 m (16 feet) per

downstream manufacturing operations

minute. The blast machine is equipped

as prescribed by the production control

with eight (8) high performance turbines,

system.

type Rutten Gamma 400, with an installed drive power of 37 kW each. To minimize

For further information:

the wear rate and facilitate maintenance,

www.rosler.com

the blast chamber, fabricated from manganese steel, is lined with overlapping, easy to replace manganese steel plates.

cleaning station/pre-heater for de-icing

After the removal of residual blast media

– if required - at a speed of 3 m (10 feet)

in a brush- and blow-off station the work

per minute. In a subsequent stage the

pieces undergo a leveling process.

work pieces undergo a blast cleaning

To allow for the channeling of shot

process in a roller conveyor shot

blasted batches of profiles onto the main

blasting machine, type RRB 16/5. Four

transport line for painting, the loading

Gamma 400 G turbines with a drive

of raw steel plates stops automatically,

power of 15 kW each ensure optimum

as soon as a finished batch of profiles is

blasting results. They are mounted

standing by. These batches are passed

on the roof and bottom of the blast

through the various stations, even

chamber made from manganese steel.

permitting the profiles to be pre-heated

Easy to replace, overlapping manganese

and undergoing a secondary blast

steel liners provide additional protection

process.

against premature wear. After travelling

in single file for passing through the

Coating with a minimum of overspray and solvent recovery

subsequent leveling system at a speed

The paint process at the end of the

of 30 m (100 feet) per minute. Faulty

line takes place with solvent-based

profiles are immediately discharged

2-component paint types in two colors,

from the system. The profiles within

which are automatically and instantly

specs are combined into batches in the

mixed as required. The paint is applied

through a blast media brush- and blow-off station the profiles are aligned

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

The paint process at the end of the line takes place with solvent-based 2-component paint types in two colors, which are automatically and instantly mixed as required. The paint is applied with spray guns from above and below the work pieces. To minimize overspray, the spray guns are controlled by a work piece recognition and displacement measuring system. The solvent used for rinsing and cleaning is conditioned and recovered in a processing plant allowing the recovery and recycling of 98% of the material.”

Opening photo: The railway sector requires productivity, cost optimisation, safety, and a highly durable finishes with excellent anti-corrosion performance.

INNOVATIONS: PRESENT&FUTURE

SPECI AL ON T R AN SPORTATION

Wet-on-wet Application in the Transport Sector. Technological Innovation, Automation, and Industry 4.0 Alessandro Soba Verind S.p.a., Rodano, Milan (Italy)

verind@verind.it

Preliminary remarks

friendly technologies are those that can

materials, and design, and on the other

People who have the ability to innovate, to

contribute to building a modern industrial

hand productivity, cost optimisation,

believe in what they do, to have the courage

business able to compete in the global

eco-friendliness, innovation, and safety.

to question themselves, designing systems

market. Today’s main issues in the industry

All of them combined may help to build a

that implement energy efficient and eco-

concern on the one hand shapes, surfaces,

technological vision that can integrate in

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

(Fig. 1) and with systems that may include as

production processes requiring excellent surface finishes with a protective and corrosion protection function. These are the characteristics required by the transport sector, especially in the railway field (ref. Opening photo).

Characteristics required from a modern coating plant A modern coating plant must possess some essential characteristics and ensure the achievement of certain quality and efficiency results, such as: • excellent finishing quality in terms of

People who have the ability to innovate, to believe in what they do, to have the courage to question themselves, designing systems that implement energy efficient and eco-friendly technologies are those that can contribute to building a modern industrial business able to compete in the global market.”

aesthetics;

follows: • electrostatic technology • electronic 2K dosing • automatic colour change • paint recovery • application system supervision • laser positioning.

Process objectives: a contribution in terms of application technologies The design and implementation criteria adopted in industrial sectors such as automotive, aircraft, and energy can be © Dürr

• high productivity and low operating costs; • the protection of the safety

extended to the railway field. Reduced energy consumption and

and health of operators and

environmental impact

respect for the environment;

levels are required

• VOC reduction thanks to

for the production

coating solutions with water-

processes. OEMs’ main

based systems, powder

needs/trends in terms

systems, mixed systems,

of coating quality are as

high solid paints (>70% of

follows:

weight), and the elimination

• premium aesthetic

of one or more layers, e.g.

level, increasingly

though the Direct To Metal

comparable with the

(DTM) technology; • implementation of reliable application equipment and techniques suitable for the coating products currently

automotive one; • extreme mechanical,

chemical, and corrosion resistance based on the

Figure 1: Two robots coating the ceiling of a railway car.

products’ intended use.

available on the market; • high transfer efficiency with the use of LVLP, electrostatic, airless, or air assisted

predictive maintenance, tele-assistance.

In order to meet these needs and control the process application variables, it is possible to

consumption monitoring controls, in

Application and automation technologies for coating railway vehicles and rolling components

particular with the use of 2k paints;

In this industrial sector, anti-corrosion coating

as follows:

systems are normally applied with single

• an electrically and pneumatically driven

technologies; • implementation of dosage, mixing, and

• automation integrated in compliance with the SCADA concept and the

component (1K) and two component (2K)

Industry 4.0 paradigms: reciprocators,

equipment specifically designed for:

integrate a complete line of Dürr equipment operating according to the new flexibility and Industry 4.0 concepts. A typical line includes

EcoPump with the “4 ball” technology (Fig. 2); • dosing equipment with gear pumps;

robots, coating management units,

• underbodies

• LVLP automatic guns;

automatic colour change devices, paint

• rolling components.

• the EcoBell electrostatic technology with

recovery systems; • digitisation and flexibility of the production cycle (smart factory); • smart solutions, remote service,

rotating bells; • automation devices integrated with the

The vehicles’ internal and external coating systems, on the other hand, are applied with robots integrated in the application booths

reciprocators; • electronic dosing systems EcoDose 2K

international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52

SPECIAL ON TR ANSPORTAT I ON

“Coriolis” for 2K and 3K paints and

Particular attention should be paid to variables such as:

coatings (Fig. 3);

• reliability in the dosing and mixing

• a robotic arm (Fig. 4) to ensure finishing quality, reliability,

of coating products (catalyst, paint,

production improvement, and

additives);

process repeatability.

• reliability in the monitoring of pot life with automatic risk

The coating process: objectives and challenges

management actions by the devices; • ability of the equipment to

For a conventional base coat and top coat system, the goal is combining

2 1

resistance with stability and

Figure 2: An EcoPump device with the “4 ball” technology.

(temperature, viscosity,

dosing, mixing, and application support the operators in the reduction of all potential risks and in the performance of a proper process, as well as

The design and implementation criteria adopted in industrial sectors such as automotive, aircraft, and energy can be extended to the railway field. Reduced energy consumption and environmental impact levels are required for the production processes.”

ensuring high quality results.

3 1

Figure 3: EcoDose 2K electronic mixers.

sensitive parameters of coating products

colour gloss properties. The technologies must increasingly

monitor the application KPIs; • ability to monitor all the

mechanical, chemical, and corrosion

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

density, consumption); • ability of the application equipment to guarantee stable and reproducible operations and thus ensure quality consistency.

INNOVATIONS: PRESENT&FUTURE

FATI

srl

CATENE PER TRASPORTATORI CUSCINETTI A SFERA

CATENE AD ALTE PRESTAZIONI HIGH PERFORMANCE CHAINS LEISTUNGSFÄHIGE KETTEN

NOVITÀ NEW NEUHEIT

HPCOAT

4 1

Figure 4: A robotic arm under construction.

Electronic dosing technologies for 2K products Electronic dosing equipment is the industrial response to 2K coating processes in order to guarantee the best automatic dosing and mixing performance for the paints (be they epoxy, polyurethane, high solid, DTM one-layer, or UV products) on

Particolare dei cuscinetti con HPCOAT Detail of bearing with HPCOAT Ausschnitt der Lager mit HPCOAT

different types of surfaces: metal, steel, plastic, wood, glass, marble, composites. Modern electronic dosing devices are suitable for handling water-based and solvent-based 2K coatings manual or automatic application processes. Moreover, they are suitable for integration into an automatic system (Figs. 5 and 6) with the full control of all application process parameters in order to obtain as follows: • flexibility and reliability;

con | with | mit HPCOAT

• higher surface finishing quality; • reduced production costs;

For a conventional base coat + top coat system, the goal is combining mechanical, chemical, and corrosion resistance with stability and colour gloss properties. The dosing, mixing, and application technologies must increasingly support the operators in the reduction of all potential risks and in the performance of a proper process, as well as ensuring high quality results.”

• greater productivity and efficiency.

A tt dopo Aspetto d 2 200 ore in nebbia salina Surface after 200 hours of salt spray test senza | without | ohne Aussehen nach 200 Stunden in Salzsprühtest HPCOAT

Coefficiente Resistenza alla d’attrito corrosione Friction factor Corrosion protection Reibwert Korrosionsfestigkeit Costi di Durata alle alte manutenzione temperature Maintenance costs Life-time at high Wartungskosten temperatures Corrosione Beständigkeit gegen Corrosion hohen Temperaturen Korrosion Autolubrifcazione Abrasione alle Self lubrification alte temperature Selbstschmierung Wear at high Produttività temperatures Productivity Abrieb bei hohen Produktivität Temperaturen

FATI srl

LESS

intended for low or high pressure, conventional spray or AA gun,

Via C. Porta, 14 | 23861 Cesana B.za (LC) | Italy t. +39 031 655688 | f. +39 031 656772 info@fatisrl.com | www.fatisrl.com

SPECIAL ON TR ANSPORTAT I ON

5 1

Figure 5: Integrated controls for manual applications.

to the component A and the component B;

Verind’s dosing system EcoDose

The configuration with a higher technological

2K was specifically developed for

content provides for the measurement of

high quality applications. It features

component flow with the Coriolis technology,

system per channel, with alarm thresholds for

the Direct Injection Technology

because:

complete process control.

(DIT), with two independent

• there are no rotary gears flow meters;

channels with automatic injection.

• there is no integrator mixer (A + B sequential

Both channels – A for the coating and B for the catalyst – work simultaneously for a very precise

• no maintenance is required on the fluid dosing section; • there are two separate cleaning circuits devoted

Automatic coating stations with EcoRP and Ready2Spray robots Robots designed to automate the application of coatings on railway vehicles or rolling stock can be installed: © Dürr

and reliable dosing process.

injection technology);

• there is a temperature and density control

6 1

Figure 6: Integrated controls for automatic applications.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

â&#x20AC;˘ on the floor

robot programs, parameterise the associated

enhanced analysis and diagnostic

â&#x20AC;˘ on the wall

process data, and simulate an entire robotic

functions. EcoScreen 3D-OnSite

â&#x20AC;˘ on the ceiling.

station. The new version of this software

combines all the typical functions

DĂźrrâ&#x20AC;&#x2122;s robots allow for offline coating

of parameterisation, programming,

simulations of cars, locomotives and

simulation, and optimisation of DĂźrrâ&#x20AC;&#x2122;s robots EcoRP. The software is also a

buses. They can be programmed 100% offline thanks to the import of 3D models with a dedicated software and to the automatic calculation of application trajectories. Moreover, it is possible to run offline a verification of the reachability of different surface areas in the framework of the feasibility studies of a coating automation project.

DĂźrrâ&#x20AC;&#x2122;s robots allow for offline coating simulations of cars, locomotives and buses. They can be programmed 100% offline thanks to the import of 3D models with a dedicated software and to the automatic calculation of application trajectories.â&#x20AC;?

part of the smart factory concept that is one of the pillars of the â&#x20AC;&#x153;digital@ DĂ&#x153;RRâ&#x20AC;? strategy. Thanks to its complete simulation functions, EcoScreen 3D-OnSite speeds up the start-up process of systems. It also offers as follows: â&#x20AC;˘ the automatic generation of application trajectories;

EcoScreen 3D-OnSite: increased performance and speed

package can also be used on already-existing

EcoScreen 3D-OnSite is DĂźrrâ&#x20AC;&#x2122;s 3D

systems and it offers additional features

of any other component included

visualisation and programming software.

such as the ability to import models in all

in the installation process (valves,

It was designed to create and process

the main CAD formats, a new 3D library, and

drives, wiring, dosing pumps, etc.).

â&#x20AC;˘ a database manager of spraying parameters; â&#x20AC;˘ perfect integration and management

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international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52

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Opening photo: The DKC Group is a leading manufacturer of cable tray systems, especially in the industrial automation sector.

FOCUS ON TECHNOLOGY

DKC Group: Optimising the Pre-Treatment Process for Easier Plant Management and Constant Quality Barbara Pennati ipcm®

n the age of digitisation, high tech,

quality degree. That is why the DKC Group

different markets through 6 divisions – DKC

and the pursuit of ever-increasing

has recently made significant investments

Europe, DKC Russia, DKC Ukraine, DKC

quality levels, sometimes the ease of

to simplify the management of its coating

Hungary, DKC Romania, and DKC Maghreb –

management of the plants themselves

systems without sacrificing product quality

the Group is a leading manufacturer of cable

can be neglected despite its actually

and process consistency.

tray systems, especially in the industrial

important role in achieving a high final

Established in 1998 and now present on

automation sector (ref. Opening photo).

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

Over the years, it has diversified its

FOCUS ON TECHNOLOGY

treatment and finishing systems

production through the acquisition

(Fig. 4). “Our coating cycle starts

of local companies. Its product

with a pre-treatment phase

range now includes metal cable

including phosphodegreasing,

trays, protection systems for

rinsing with mains water, rinsing

electric cables, mounting modules

with demineralised water,

for photovoltaic panels, carpentry

nanotechnology conversion

components, and air conditioners

application, drying, and coating

for electric boards. In Italy, DKC

(Figs. 5 and 6),” says Oberti.

has production sites in Novi Ligure

“Since the sheets often undergo

(AL), Villanova sull’Arda (PC), Rome,

further processing after coating,

Travagliato (BS), Collegno (TO), and

such as punching or drawing,

Bellinzago Novarese (NO).

it is crucial for us that they are

The Ram Block production unit of

properly treated to ensure

the Bellinzago Novarese factory,

optimum adhesion and flexibility

formerly known as Costel, was the

of the paint film.”

first to modify its coating process with a view to cost efficiency

“However, we had noticed that

and quality improvement and management. “Our unit produces

both aesthetic and qualitative problems. Moreover, our

cabinets, boxes, and pulpits

specifications require a 200

for industrial automation and

hours salt spray resistance value,

low voltage energy distribution

which we could not achieve

processes. We perform in-house

with the chemical process we

every sheet metal processing

used. This also entailed rather

phase, from technical design to

high management costs, mainly

delivery (Figs. 1 and 2),” explains

due to the high replacement

Michele Oberti, the manager of

frequency of the pre-treatment

the Ram Block production unit.

active baths,” states Oberti.

“However, we used to face various

Therefore, DKC developed a new

paint adhesion issues and high

pre-treatment process together

management costs, mainly due

with DN Chemicals, which could

to inadequate pre-treatment.”

adapt to its production needs

Therefore, DKC turned to

and solve its performance, costs,

DN Chemicals Srl, a Milan-based

management, and quality issues.

company specialising in the

“We decided to keep the plant

production and distribution of

installed in 2012 and only modify

industrial chemicals. Together, they

the pre-treatment chemicals.

developed a new pre-treatment

First of all, in order to solve the

process ensuring higher quality

critical issues found by DKC, we

and better plant integration and

integrated a conventional cycle

management (Fig. 3).

featuring a phosphodegreaser

The critical aspects of the pre-treatment process The plant dates back to 2012 and it was supplied by O.M.SA. (Besana in Brianza, MB, Italy), specialising in the design of automatic surface

for carbon steel additivated with surfactant mixtures for higher degreasing power and a final 2 1

passivation stage with Dollcoat

Figure 1 and 2: Cabinets for industrial automation and low voltage energy distribution processes, produced by DKC’s plant in Bellinzago Novarese (Italy).

SA116,” says DN Chemicals technical sales specialist Roberto Rebuffo. “The acidic nature of

international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52

Figure 3: From left to right: Maurizio Bovio from DKC, Roberto Rebuﬀo from DN Chemicals Srl, Alessia Venturi from ipcm, and André Bernasconi from DN Chemicals Srl.

phosphodegreaser able to maintain a constant pH value lower than 4 as well as a final nanotechnology conversion stage with Dollcoat SA111. This product contains silane-based oligomers, whose quantity varies depending on the product to be treated and its intended use. The oligomers’ silanic characteristics allow the product to interact with the coating through the creation of chemical bonds that increase the

3 1

adhesion of paint,” states DN Chemicals sales manager André Bernasconi. “We the material (Fig. 7).”

chose this nanotechnology passivation

adhesion issue without sacrificing quality.

“Based on the improvements obtained

product because DKC’s plant includes

Indeed, since they also treat very glossy

after the adoption of this first process,

no nebulisation system for the last

laminate sheets, it was essential to adopt a

we conducted several tests and created

pre-treatment stage; therefore, the

functional but not too aggressive product,

a tailor-made cycle for DKC. The current

product is recirculated, unlike what

able to preserve the aesthetic properties of

process includes a better performing

the phosphodegreaser solved the coating

4 1

Figure 4: The pre-treatment tunnel supplied by O.M.SA. (Besana in Brianza, MB, Italy).

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

5 1

Figure 5: Components at the entrance to the pre-treatment tunnel.

In the age of digitisation, high tech, and the pursuit of ever-increasing quality levels, sometimes the ease of management of the plants themselves can be neglected despite its actually important role in achieving a high final quality degree. That is why the DKC Group has recently made significant investments to simplify the management of its coating systems without sacrificing product quality and process consistency.”

DKC developed a new pre-treatment process together with DN Chemicals, which could adapt to its production needs and solve its performance, costs, management, and quality issues. They decided to keep the plant installed in 2012 and only modify the pre-treatment chemicals. First of all, in order to solve the critical issues found by DKC, they integrated a conventional cycle featuring a phosphodegreaser for carbon steel additivated with surfactant mixtures for higher degreasing power and a final passivation stage with Dollcoat SA116.”

6 1

Figure 6: A stage of the spray pre-treatment process using DN Chemicals products.

with an always fresh product. The more the oligomers contained in the formulation, the greater the product’s sensitivity to pollution. With Dollcoat SA111, the DN Chemicals’ product featuring the best anti-corrosion properties, the lower content of oligomers enables to replace the passivation bath only once every two months, or when the conductivity of water exceeds 800 μS.” The coating process is performed by applying polyester or epoxy polyester powders in a quick colour change booth supplied by Gema (Fig. 8), equipped with 2 reciprocators with 4 guns each (Fig. 9) and two pre and post-retouching stations. “Our products are generally intended for indoor use, but for several customisation requests calling for higher performance levels we prefer to apply outdoor coatings or a two-coat system with a zinc primer,” explains Michele Oberti. “With the adoption of this pre-treatment process, the salt spray test results achieved by our workpieces range between 250 and 300 hours, which enables us to fulfil DKC’s specifications. Also the film adhesion properties have improved considerably, allowing us to further process our parts without any quality problems,” states Oberti.

7 1

Figure 7: Components at the end of the coating process.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

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

8 1

Figure 8: The quick colour change booth supplied by Gema.

Based on the improvements obtained after the adoption of this first process, DN Chemicals conducted several tests and created a tailor-made cycle for DKC. The current process includes a better performing phosphodegreaser able to maintain a constant pH value lower than 4 as well as a final nanotechnology conversion stage with Dollcoat SA111. This product contains silane-based oligomers, whose quantity varies depending on the product to be treated and its intended use. The oligomers’ silanic characteristics allow the product to interact with the coating through the creation of chemical bonds that increase the adhesion of paint.”

ANTARES S.r.l. Via F.lli Cervi 12/B - 37036 San Martino Buon Albergo (Vr) ITALY T. +39 045 8780567 F. +39 045 994606 email: info@anteresitaly.net WWW.ANTERESITALY.NET

A gradual transformation for higher yield

Towards ever higher production versatility “DKC is constantly growing

The first phase of intervention

and it has managed to expand

required the adoption of a

thanks to the acquisition

process that could minimise

of several local companies,

the problems caused by the

reorganised according to the

previous pre-treatment, in

group’s standards in order to

order to enable DN Chemicals

guarantee constant quality

to design a new optimal cycle

to all our global customers,”

for DKC’s plant configuration.

states Michele Oberti. “The

“The current process with a

pre-treatment process

phosphodegreaser and the

currently performed by our

passivating product Dollcoat

Bellinzago Novarese plant has

SA111 was implemented a year

been adopted also by DKC

and half ago. Since then, it has

Romania, whereas O.M.SA.,

ensured optimal paint adhesion,

which installed the system at

higher final quality levels, and

our premises, subsequently

the achievement of the salt

upgraded also the DKC

spray resistance values required

Hungary factory’s line.”

by our customers and the DKC

“In future, we intend to make

specifications,” explains DKC

further investments in coating.

production technology specialist

Our Bellinzago Novarese plant

Maurizio Bovio.

has 95 employees working

“Since we mainly treat

on two shifts and our paint

carbon steel with our

shop is currently saturated.

phosphodegreasers, our

The current space is limited,

sludge production is quite high

but we could make new

compared to those dealing with

space by fully exploiting the

metals of different nature. In

area available. In this way, we

order to avoid any qualitative

could add a rinsing stage to

problems and based on the

the pre-treatment process,

optimal management parameters

thus making it even more

provided by DN Chemicals, we

functional and suitable for the

replace our active baths around

use of an alkaline pH product

once every three months. This

that, if not rinsed properly,

has ensured higher quality degrees and reduced operating costs and waste,” says Michele Oberti. “This performance improvement went hand in hand

9 1

Figure 9: The automatic coating booth is equipped with 2 reciprocators with 4 guns each and two manual pre and post-retouching stations.

inhibits polymerisation; we could also install a second spray paint booth to speed up the application and colour change operations. Our goal

with an increase in the ease

is to become even more

of management of the plant

competitive on the market, offering our customers

itself, which is a very important factor for us. Our operators can manage the entire production cycle more easily, thus achieving a process consistency level that we could not obtain in the past.”

The coating process is performed by applying polyester or epoxy polyester powders in a quick colour change booth supplied by Gema, equipped with 2 reciprocators with 4 guns each and two pre and post-retouching stations.”

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

maximum customisation levels while ensuring reduced delivery times and a high quality level,” says Michele Oberti.

Opening photo: Imel started to develop i4paintshop at the beginning of 2017 based on the idea of a think tank, which oﬀered to survey the needs of diﬀerent clients and analyse trends and opportunities deriving from the new SW and HW tools related to digitisation.

INNOVATIONS: PRESENT&FUTURE

Imel presents the i4paintshop Platform for 4.0 Management of Coating Plants and the Facilitation of Decision-Making Processes From an interview with Imel Spa general manager Stefano Bianchin

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

delivery of a service component as

mel Spa is a company specialized in the design of coating systems based in Codroipo (UD, Italy).

Always focussing on the continuous improvement of products thanks to its technical expertise, it has recently decided to re-engineer its organisation with the addition of new management personnel in key positions (Fig. 1). Also its R&D, electrical and software design, and service departments have been improved. As for the service department, both its processes and its staff are being reorganised aiming

an added value, when providing products1. “Servitisation” is an integral part of the company’s 4.0-oriented approach. “For Imel, Industry 4.0 is synonymous with demand and opportunity,” says Stefano Bianchin, the general manager of Imel. “Why ‘demand’? Because the most advanced customers increasingly tend to ask for real-time processing of the big data generated by their plants’ PLCs. Their aim is making quick and 1

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at the so-called “servitisation”, i.e. the

Imel Spa is a company specialising in the design of coating systems based in Codroipo (UD, Italy). Always focussing on the continuous improvement of products thanks to its sound technical expertise, it has recently decided to re-engineer its organisation with the addition of new management personnel in key positions.”

Figure 1: IMEL Spa (Codroipo, UD, Italy), a company specialising in the design of coating systems, has decided to re-engineer its organisation with the addition of new management personnel in key positions; also its R&D, electrical and software design, and service departments have been improved.

international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52

Imel started to develop i4paintshop at the beginning of 2017 based on the idea of a think tank, which offered to survey the needs of different clients and analyse trends and opportunities deriving from the new SW and HW tools related to digitisation.”

sound decisions about consumption and cost reduction; global efficiency parameter control and, therefore, shift and production planning; and quality management and improvement through the traceability over time of batch process parameters. Moreover, it is now clear that the concept of competitiveness in the strict sense is not sufficient for customers in order to prevail in the market. The assessment and monitoring of the environmental impact of one’s own production processes is an indirect cost that should be controlled and improved.” “All this is made possible by the i4paintshop platform, which, on the other hand, embodies the concept of “opportunity”, since Imel was able to launch this platform in advance of its competitors, thus presenting itself as the preferred partner of advanced customers,” says Bianchin. Imel started to develop i4paintshop at the beginning of 2017 based on the idea of a think tank, which offered to survey the needs of different clients and analyse trends and opportunities deriving from the new SW and HW tools related to digitisation (ref. Opening photo). “In mid-2017, two teams were created. The first one was devoted to developing the data communication protocol and the platform architecture, including the management and security of data. The second team dealt with the creation of the data processing software and the user interface,” explains Bianchin. “i4paintshop was officially presented during the Paint Expo trade fair held in Karlsruhe (Germany) in April 2018, that is, one year after the start of the

INNOVATIONS: PRESENT&FUTURE

project. Feedback was very positive and Imel immediately started several negotiations.” i4paintshop is for well-structured companies with professionals able to understand the information provided by the platform and

INTERNATIONAL PATENT

translate it into decisions, such as energy engineers, maintenance managers with a predictive maintenance-oriented approach, planning managers, and environmental managers (Fig. 2). The platform can adapt the processes automatically, but the final choice rests with the user, who should progressively switch from an operator to a decision maker. “Given the nature of the product and its end users, i4paintshop is particularly suitable for the automotive industry, but we are also getting excellent feedback from different suppliers intending to implement the Industry 4.0 concepts regardless of their end users. Actually, the first i4 plant was installed at the premises of Global, a leading manufacturer of home radiators. We will complete other two installations within December 2018” states Stefano Bianchin. The creation of the platform i4paintshop went hand in hand with the development of Imel’s

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

new process control software standard. This software package features algorithms that

i4paintshop is for wellstructured companies with professionals able to understand the information provided by the platform and translate it into decisions, such as energy engineers, maintenance managers with a predictive maintenanceoriented approach, planning managers, and environmental managers. The platform can adapt the processes automatically, but the final choice rests with the user, who should progressively switch from an operator to a decision maker.

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

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

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Figure 2: i4paintshop is for well-structured companies with professionals able to understand the information provided by the platform and translate it into decisions.

are necessary to the transfer of process and plant data to the platform. “By discussing the 4.0-oriented customisation level required by the customer since the offer phase, Imel can immediately assess both the costs related to the additional devices to be integrated into the system and the time needed to adapt the standard platform. This enables us to make the platform operational within a month after the system’s start up,” states Bianchin. “With a third-party software, the process would take no less than a year,

with poorer results due to lack of full

The creation of the platform i4paintshop went hand in hand with the development of Imel’s new process control software standard. This software package features algorithms that are necessary to the transfer of process and plant data to the platform.”

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

integration with the system control software and certainly with higher costs linked to the management of additional equipment.” Imel has already defined its next 4.0-oriented steps. “We do not want reveal too much, but we can say that our goal is offering innovative solutions for the whole customer follow up process, starting from the offer phase,” says Bianchin.

Zaniolo CdA - 1.18

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Opening photo: The operator can manage the coating operations also via smartphones and tablets.

INNOVATIONS: PRESENT&FUTURE

The Evolution of Powder Spraying Systems: Digitalisation, Ergonomics, Connectivity From an interview with Massimo Ricci, Zeus Electrostatic System, Argenta (FE, Italy), riccim@zeus-el.it

n international card games, the Joker

spraying systems “J”. These systems are

programs, application parameters, paint

is the card that matches all others – a

fully evolved in terms of materials thanks

consumption data, and so on. They are

symbol of extreme versatility.

to the switch to injection moulded plastic

also extremely easy, ergonomic, and

gun casings, versatile, and able to easily

intuitive to use.

That is why Zeus Electrostatic System chose

connect with the outside world, as well as

Precisely this change in shapes,

to call the latest version of its powder

to provide real-time information on coating

materials, and connectivity resulted in

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

In international card games, the Joker is the card that matches all others – a symbol of extreme versatility. That is why Zeus Electrostatic System chose to call the latest version of its powder spraying systems “J”. These systems are fully evolved in terms of materials thanks to the switch to injection moulded plastic gun casings, versatile, and able to easily connect with the outside world, as well as to provide real-time information on coating programs, application parameters, paint consumption data, and so on. They are also extremely easy, ergonomic, and intuitive to use.”

the first generation of a complete system

the new pump NEA415, with a 4-stroke

composed of a generator, automatic

operating cycle. By next autumn, we will

guns, a powder management unit, and

launch the first machines featuring a

manual equipment with conventional

high-flow dense phase pump for paint

Venturi injectors, following a four-year

feeding and a dense phase pump for

development process that involved a

spraying. The development of our J

team of thirty people and saw various

Series is the result of a large investment

companies in the sector collaborate.

in integration, calling for a complete

However, Zeus’ R&D efforts did not stop

modification of the Zeus equipment’s

at this first goal, but they continued with

electronics, software, design, and

a focus on the Industry 4.0 concepts to

materials. This coordinated project

equip the new J Series with a complete

also enables us to convey the image of

booth management system, able to

a technological company that can be

make all information available on mobile,

a partner, and not just a supplier, for

PC, and remote devices and to provide

coaters. Today, we find ourselves selling

predictive maintenance indications (ref.

much more than the equipment in our

Opening photo). The third development

catalogue: first of all, we sell advice,

phase is currently underway: Zeus is

as well as a solution to any coating

integrating its J Series with the dense

problem.”

phase powder transport technology. “We started by adding high-flow dense

The origin of success

phase pumps developed by Verne

The J Series was designed following an

Technology to the plants’ recovery devices

analysis of the coating market’s needs

and to the powder management units’

for greater integration, automation,

paint loading systems,” says Massimo

and digitisation without neglecting

Ricci, the general manager of Zeus

ergonomics, ease of use, and user

Electrostatic System (Fig. 1). “We are

friendliness. “It was created for fun:

currently integrating our spray guns with

we invented a smart function for our

Figure 1: Massimo Ricci with Alessia Venturi (ipcm).

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Figure 2: Since 2016, the casings of Zeus’ guns have been made of moulded plastics, definitely lighter than processed plastics.

international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52

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Figure 3: The new generator for the manual unit.

guns that made

The development of the J Series is the result of a large investment in integration, calling for a complete modification of the Zeus equipment’s electronics, software, design, and materials. This coordinated project also enables Zeus to convey the image of a technological company that can be a partner, and not just a supplier, for coaters.”

the whole system multi-functional,” explains Ricci. “Then, we started focussing on materials, design, production techniques, and 4.0-oriented connectivity.” Injection moulded gun casings require a higher investment cost compared with processed plastics, but they allow to reduce production costs later on. Moulded plastic is

lighter and, therefore, it enables to create better balanced and more comfortable to use products with a lower molecular weight and a more accurate degree of finish. Indeed, design and finishing are important even for spray guns, not just for the objects they help to coat (Fig. 2). “Zeus certainly invested also on aesthetics, but our guns’ design is primarily functional and not an end in itself,” states Ricci. “The investment for the injection moulding of all our technologies’ components forced us to change all CAD design systems in order to adapt to our suppliers, with which we have built a mutually stimulating relationship and an interface to enhance our R&D activities. Our technological equipment is now complete. The next step will be to reach the foreign

INNOVATIONS: PRESENT&FUTURE

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Figure 4: The Zeus automatic booth.

markets, also because we have invested a lot to obtain the ATEX certification for the European markets. We are currently starting the procedures to obtain the FM certification for the American market.”

jGun: technology at its finest jGun is a concentrate of technology, starting from its materials, its high mechanical and electrical resistance properties, and its low molecular weight not to tire the operator during use. The core of this gun is the high voltage generator, which transfers all its energy to the powder with a high charge efficiency thanks to its high insulation degree (Fig. 3). The automatic jGun represents the latest generation of Zeus’ guns: it can house any type of nozzle. It is available in the conventional short version or in the integrated and connected arm version that can be used with the cleaning systems of Zeus’ booths (Fig. 4). All jGun devices are certified according to the requirements of the ATEX standard.

Injection moulded gun casings require a higher investment cost compared with processed plastics, but they allow to reduce production costs later on. Moulded plastic is lighter and, therefore, it enables to create better balanced and more comfortable to use products with a lower molecular weight and a more accurate degree of finish. Indeed, design and finishing are important even for spray guns, not just for the objects they help to coat.”

HIGH

PERFORMANCE POWDER COATINGS

The control units jGen Digital feature a 485 interface enabling them to connect one each other in order to share settings and programs. The J connectivity does not only involve the J modules, but also other Zeus devices such as reading systems, powder management units, and so on.” Technical characteristics of the control units

allow to better manage the coating

System opened the world of

operations.

Digital feature a 485 interface enabling them to connect one each other in order to share settings and programs (Fig. 5). The J connectivity does not

coating programs, each with different pneumatic and electrostatic settings.

systems, powder management units,

or combined with the Wildcard function

and so on (Fig. 6).

to clean any parts during the colour

In the J machines, all functions take

change operations or to clean the

higher productivity:

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Figure 6: The powder management unit.

N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine

other connected ones. - the P function allows to create up to 50

- the Clean function can be used alone

of the parameters set in a unit in all the