ipcm 46 Magazine (July/August 2017) - English Version by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

ISSN 2280-6083

ipcm digital on In this issue :

SPECIAL AUTOMOTIVE

INDUSTRIAL CLEANING TECHNOLOGIES

www.myipcm.com 2017

8th Year - Bimonthly N° 46 - JULY/AUGUST

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

DISCOVER OUR SOLUTIONS

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Poliefun Dipartimento di Chimica, Materiali e Ingegneria Chimica “Giulio Natta” Dipartimento di Meccanica / Politecnico di Milano Piazza Leonardo da Vinci 32 / 20133 Milano Segreteria organizzativa smooth / via bono cairoli 30 / 20127 Milano segreteria@poliefun.org / telefono 02 89054867

www.poliefun.org

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CONTENTS JULY/AUGUST 2017

SP ECIAL AU TOMOTIVE

Sustainable and Cost-Effective: New Paint Mist Separation System at JLG’s Tianjin Site

FOCUS ON TECHNOLOGY

Green Factory 4.0 for the Production of the New Alfa Romeo Top Range Cars: the Evolution of FCA Cassino Plant

SUCCESS STORIES

SP ECIAL AU TOMOTIVE

S P E CI A L AUTOMO TI VE

44 05 06 12

FOCUS ON TECHNOLOGY

Smart Factory at 2,400 m of Height: the New Audi Plant in San José Chiapa, Mexico

BRAND-NEW

18 22

HIGHLIGHT OF THE MONTH

History Is Us: OMSG Acquires the brand Carlo Banfi

110 114

EDITORIAL

FOCUS ON TECHNOLOGY

Maserati Levante: a Top Tailor-Made Coating Process, from Cataphoresis to Enamelling

BRAND-NEW

117

BUSINESS CARDS

REACH: Updating the List of Substances Subject to Authorisation

S PE C I AL AUTOMOTI VE

BRAND-NEW BUSINESS TRAINING Customer Satisfaction Analysis & Management – Part 3

STANDARD & LEGISLATION - UCIF Informs

118

TRADE FAIRS & CONFERENCES

120 ZOOM ON EVENTS

www.mascom.it

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PURAL® FOR ANODIZING LINES 50% WATER SAVING ACID DESMUTTING RINSE ANODIZING

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Reusing water quality • SO4 < 150 mg/l • Al3+ < 0,5 mg/l • Cond. ≤ 400 μS

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CONTENTS JULY/AUGUST 2017

S P E CI A L AUTOMO TI VE

Smart Paintshop - The Paintshop of the Future

102

FOCUS ON TECHNOLOGY

Coating Waste Water Treatment: a Value Added to the Well-known Quality of OZ Racing Alloy Wheels

INNOVATIONS: PRESENT&FUTURE

SP ECIAL AU TOMOTIVE

128 126 136

ICT - CASE STUDY

Miroglio & C.: Maximum Cleaning Quality of Automotive Components with Modified Alcohol

ICT - INDUSTRY NEWS

146

Metro and Municipal Railway of Paris: VACUDEST® Provides Clean Water for Train Maintenance

ICT - CASE STUDY Fast and Cost-Effective Finishing of Aluminium Die-Castings

ICT - CASE STUDY The Targeted Cleaning of Cast Iron Turbines and the Constant Checks Make the Difference in the Automotive Sector

142

ICT - SUCCESS STORIES

150

ICT - CASE STUDY Efficient Cleaning Solution for Use in Transmission Remanufacturing: Advances in Speed, Efficiency and Sustainability Yield Improved Replacement Transmissions

154

ICT - TECHNOLOGY OVERVIEW The Increasingly Specialized and Exacting Science of Parts Cleaning in the Automotive Industry

158 ICT - BUSINESS CARDS 160 ICT - ZOOM ON EVENTS

15 -17.11. 2 017

SHANGHAI

JOIN THE SHOW WHERE THE FINISHING COMMUNITY MEETS

Shanghai New International Expo Centre (SNIEC)

Statistics on SFCHINA2016, Guangzhou

Mechanical Finishing; Pre-treatment Technologies & Plating Process; Raw Materials & Equipment for Electroplating; Paint & Powder Coating Applications (include Coating Equipment & Accessories); Functional Coating Products; Environmental, Safety & Protection; Inspection, Measuring & Test Equipment, etc.

EXHIBITOR

THREE Exhibit Zones Hall E1

ZONE

Electroplating & Finishing Technology

ZONE

Overseas

Hong Kong & Taiwan Regions

Domestic China

Total

No. of Companies Represented

193

275

No. of New Exhibitors

Regions / Countries Represented

ZONE

Environmental, Safety & Protection

w ww.sfchina.net

19 9,896

Total No. of Domestic China Visitors

1,150

Total No. of Overseas Visitors (Including Hong Kong & Taiwan Regions) Total No. of Visitors

Hall E2

Coating Applications & Coating Products

Hall E1

NEW

VISITOR

Scope of Exhibits

11,046

SPONSORING EXHIBITORS Co-located Show

The 22nd China Int'l Exhibition for Coatings, Printing Inks & Adhesives Follow Us

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EDITORIAL

The Factory of the Future is already here.

Alessia Venturi Editor-in-chief Direttore Responsabile

few common development topics and trends have been emerging for some time in every industrial segment: use of lightweight materials, resource efficiency, production automation and digitisation as a new industrial paradigm 4.0, carbon footprint reduction, and cost saving. The car industry, however, has grasped and realised these concepts like no other. The combination of different materials in the design of new generation cars entails increasingly challenging technological issues for OEMs and their suppliers of surface treatment plants and products. In the last few years, in order to meet the need for weight and consumption reduction, aluminium has been increasingly employed in the construction of bodies, in higher or lower percentages depending on the car segment. Nonetheless, the common goal of all OEMs is the construction of aluminium-only bodies in the near future. This change in materials makes the already existing pre-treatment and cataphoresis plants obsolete, since the new metal mix requires extreme flexibility and accuracy of treatment so that all surfaces, regardless of their nature, achieve the same characteristics of corrosion resistance, coating adhesion, and uniform look. That is why the new coating lines intended for the automotive sector implement body handling technologies that enable to choose from different treatment sequences, or even skip some process stages, depending on the type of vehicle being produced. This results in high productivity, low consumption and costs, and higher treatment quality. Digitisation and man-machine interaction have reached such levels that it is possible to design paintshops that are fully managed and constantly monitored through wearable devices, such as smartphones or augmented reality glasses; where the application of the Internet of Things enables systems and devices to communicate with the operators and self-learn from them the best â&#x20AC;&#x153;behavioursâ&#x20AC;? to achieve maximum efficiency; where half the resources are consumed; and where flexibility is such that it becomes mass customisation. The industrial revolution of the auto industry also involves chemistry. Pre-treatment products are selective and give high corrosion resistance properties to various types of substrates. Soundproofing materials are water-based and increasingly light to help reduce the weight of cars. Coatings ensure more and more varied, customisable and pleasing aesthetic and tactile effects. New generation clearcoats are able to orientate the metallic basecoat particles to give the special effects a new dimension. You will find all this and much more in the explosive ipcmÂŽ issue you are about to read, which includes one of the best feature stories on the automotive industry of the last few years: we have crossed the world to find prestigious examples that the new digital production paradigms are already a reality. Finally, in the last part of the magazine, you will find a feature story on the latest and most effective technologies for washing and cleaning mechanical components, because nothing is left to chance in the automotive industry.

international PAINT&COATING magazine - JULY/AUGUST 2017 - N. 46

BRAND-NEW

n important recognition for the company located in Montecchio Maggiore that has been selected by Banco BPM-Akros to take part in Elite, the London Stock Exchange Group’s international program dedicated to the most ambitious companies, with a solid business model and a clear growth strategy. St Powder Coatings join the club together with other 22 Italian companies representing different sectors and coming from 6 different Italian regions, bringing to 582 the total number of ELITE companies in 26 different countries. The ELITE Project was founded in 2012 on the Italian Stock Exchange with the goal of supporting small and medium-sized Italian companies in the process of growth and opening up to foreign markets. It was born from the collaboration with both national and European institutional and corporate partners, among which: The Ministry of Economy and Finance, Abi, Confindustria, Bocconi University Milan and Academy of London Stock Exchange Group. ELITE Project is reserved for selected and highly potential companies: this confirms the solidity of the business model and strategy developed by the St Powder Coatings Group. As a matter of fact, in order to participate the ELITE Project, companies must meet the key requirements including strong growth orientation, an operating result as a percentage of revenue greater than 5%, the latest balance sheet registered in profit and a minimum turnover of 10 million Euro. Conditions, fully respected by St Powder

St Powder Coatings Join the Club of Excellent Italian Companies

1 Figure 1: Marco Zadra, C.E.O. of St Powder Coatings S.p.A.

Coatings, which closed the 2015-2016 fiscal year with a turnover of over 30 million Euros, an Ebitda of 18% and a net profit of Euro 2.3 million. Since years now, the company is working hard and significantly on a growth and internationalization plan that has led it to export almost 50% of its sales. From this point of view, accessing the ELITE Project is a further step forward because, since the beginning, it is part of a dedicated environment that gives access to numerous networking opportunities as well as an integrated service platform consisting of industrial, financial and organizational skills that can contribute to the company’s managerial and organizational development.

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

St Powder Coatings, with the ELITE accreditation, will be able to exhibit its quality seal that once again qualifies it as an excellent company in the international landscape of powder coatings. These are the words of Marco Zadra, C.E.O. of St Powder Coatings S.p.A. during the Gala dinner at Borsa Italiana headquarters (Fig. 1): “We are pleased that the efforts made in these years have been awarded by Borsa Italiana: the admission to ELITE Project is for us a stimulus to continue the work done until now towards a continuous customer service improvement”. For further information: www.stpowdercoatings.com and www.elite-growth.com

BRAND-NEW

Evonik Bundles its Expertise in Crosslinking Technology

epoxy and polyurethane applications under one roof now – be it basic amines, isocyanate monomers, polyisocyanates or formulated epoxy hardeners”, Dr. Claus Rettig, Chairman of the Board of Management, Evonik Resource Efficiency GmbH (Fig. 1). “Apart from the organizational change, safety and meeting the needs of our customers continues to remain our first priority”, Min Chong, head of the new Business Line Crosslinkers (Fig. 2). “We see ourselves as a partner; interested in developing next-generation product solutions together with our customers. A broad technology platform serves as the basis for further growth and successful collaboration.” The Business Line has a total of about 1.000 employees worldwide. Production facilities in Europe, North America, and Asia ensure optimal proximity to markets and customers and open up attractive growth opportunities. The Crosslinkers portfolio contains strong brands: Amicure®, Ancamide®, Ancamine®, Ancarez®, Ancatherm®, Anquamine®, Anquawhite®, Curezol®, Dicyanex®, Eplink™, Epodil®, Hybridur®, Imicure®, Nourybond®, Sunmide®, VESTAGON®, VESTAMIN®, VESTANAT®, VESTASOL®. For further information: www.evonik.com/crosslinkers © Evonik

vonik Industries AG will combine its isophorone chemistry and epoxy curing agents business in the new Crosslinkers Business Line effective July 1, 2017. The newly formed Business Line, headed by Min Chong, will be part of the Resource Efficiency Segment. With the acquisition of the Air Product’s epoxy curing agents business and Evonik’s long-time experience in isophorone chemistry, Evonik has a very broad technology platform and expertise in crosslinker technology. The new Crosslinkers Business Line offers a broad range of products and competences for coatings and adhesives, civil engineering as well as for highperformance elastomers and composites. Evonik is the pioneer in isophorone chemistry and covers the entire value chain: isophorone, diamine, as well as di-isocyanate and polyisocyanate. Additionally the product portfolio contains a full tool box of amine curing agents for ambient and heat cure applications. The products are mainly used in industrial applications due to the mechanical strength, durability, chemical resistance and excellent adhesion properties. “Combining both businesses to one new unit gives Evonik the chance to offer a variety of products for

1 Figure 1: Claus Rettig, Chairman of the Board of Management Evonik Resource Efﬁciency GmbH

2 Figure 2: Min Chong, Head of the Business Line Crosslinkers Evonik Resource Efﬁciency GmbH.

BRAND-NEW

rsonsisi presents its new range of polyester coatings Top Quality Collection J 20.20, with Qualicoat Class 1 certification, which anticipates colour trends for the furniture, design and architecture sectors, with a special collection of 35 iconic colours featuring striking nuances. The new Top Quality Collection J 20.20 meets the highest decorative standards thanks to its outstanding mechanical characteristics, aesthetic appeal and its excellent resistance to corrosion and exposure in outdoor environments, guaranteed by Qualicoat Class 1 certification.

Top Quality Collection J 20.20, the New Collection of Powder Coatings by Arsonsisi, Anticipates Forthcoming Trends in Design, Drawing Inspiration from Iconic Colours

2 Figure 2: Detail of some products with the Water shade.

of paint and a more even and consistent finish The collection, created with the than traditional finishes. cooperation of colour specialists, is The chosen names highlight the iconic nature divided into 7 elements: Water, Metals, of colour, enhanced with a striking nuance Flora, Space, Snow, Precious and Soil (Fig. 1). Each element comprises 5 iconic colours that all match and are intended to remain timeless for a long period, since they can be perfectly incorporated into any context. The focus is on pastel colours, soft textured finishes and bonderized 3 metals, thus ensuring the best possible application Figure 3: Roof structure with the Metals theme’s colours.

1 Figure 1: The colour card of the new Top Quality Collection J 20.20 by Arsonsisi.

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

BRAND-NEW

Figure 4: Modern furniture with the Precious tone.

found in the most extreme conditions, from lichens in the cold countries of the north to cactuses growing in arid areas (Fig. 5). Elegant and delicate shades of white and grey for Snow recall lands that emerge from melting glaciers or the peaks of the Dolomites and create light effects reflected by ice crystals (Fig. 6). The colours of bonderized metals for Space are more striking. They go beyond infinite boundaries to galaxies, stars and planets to meet new glowing shades and nuances (Fig. 7). The journey ends by returning to Soil, with its reassuring sense of solidity and security and the colours of natural soils that acquire dominant colours that are very different yet always match perfectly (Fig. 8). The Top Quality Collection J 20.20 can be used in a wide range of

capable of stirring the imagination and inspiring the creativity of designers. This exciting journey among colours, starting with the deep blue of the ocean depths, crosses the waters of the Black Sea, flows through mountain waterfalls and streams, challenges the Bering Sea currents and recalls important explorations in the Atlantic while giving the element of Water unexpected nuances and reflections (Fig. 2). The colours used for Metals and Precious preserve a touch of nostalgia, with traces revived in the present. Contemporary design contexts are perfectly enhanced

with the elegant and versatile crinkled and marbled effects of rust, copper and iron, whereas precious stones and metals in attractive and evocative bonderized colours are ideal for timeless projects (Figs. 3 and 4). For Flora and Snow, the force of nature reigns. For the former element, the iconic colours are the evergreens also

7 Figure 7: The Space nuance. © Arsonsisi

Figure 6: Metal furniture with the Snow shade.

5 Figure 5: Detail of the structure with Flora effect.

8 Figure 8: The natural soils of the Soil theme.

industrial applications thanks to the quality of coatings - with Qualicoat Class 1 certification for outdoor use - and to versatile colours: panels, aluminium profiles, doors, gates, lighting technology products, furnishing accessories and garden furniture. For further information: www.arsonsisi.com

international PAINT&COATING magazine - JULY/AUGUST 2017 - N. 46

BRAND-NEW

Automated Painting Solution for General Industry: Dürr and Kuka Introduce Jointly Developed Robot System with all its different components, is completed and pre-commissioned at Dürr. It is thus ready for use (“ready2spray”), can be quickly installed at the customer’s site, and ensures efficient processes and a consistently high-quality paint finish. The ready2spray robot enables the application of solvent- and water-based one- and two-component paints. It can be equipped with matching dosing pumps, paint pressure regulators and color changers. Depending on requirements, it comes with automated spray guns (air-atomizing or airless) from the EcoGun range or with electrostatic high-speed rotating atomizers from the EcoBell range, both by Dürr. Dürr is the world leader in automotive painting and car body sealing through its painting and sealing robots as well as its application technology. As in the

growing need for fully automated paint application of the highest quality. The new painting robot system offers a perfect complement to Dürr’s product portfolio in the form of a compact painting robot for customers in general industry. The new solution is a true innovation in this market segment.” Stefan Lampa, CEO of Kuka Roboter GmbH says: “Its perfectly matched and tried-and-tested components are a unique selling point. They have been merged and integrated into an automated painting solution, which is currently unique in the market.” The painting robot system consists of a small six-axis robot equipped with stateof-the-art paint application technology. This technology is available in different configurations, tailored to each individual customer project. The system,

Figure 1: Equipped with application technology, ready to spray: While the robot comes from Kuka, Dürr provides the paint application technology.

ürr and Kuka, both leading manufacturers in the fields of production and automation technology, have joined forces: together they have developed an integrated solution for automated paint application in the form of a compact robot for general industry. While the robot comes from Kuka, Dürr provides the paint application technology (Figs. 1 and 2). Pre-installed and ready-to-spray, the robot contains fully compatible, tried-andtested components and offers a unique combination in the market. It is perfectly suited to the requirements of general industry. Areas of application include the painting of wood, plastics, glass and metal. Dr. Hans Schumacher (Fig. 3), Board Spokesman of Dürr Systems AG, says: “General industry has also seen a

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

Figure 2: The ready2spray robot enables the application of solventand water-based one- and two-component paints. It can be equipped with Dürr products.

BRAND-NEW

Figure 3: From the left: Stefan Lampa, CEO of Kuka Roboter GmbH, with Dr. Hans Schumacher, Board Spokesman of Dürr Systems AG.

automotive industry, Dürr also covers the entire spectrum of paint application in the industrial sector. Customers receive all components from a single source. These include the four product categories of pump and fluid-handling equipment, conventional application technology (spray guns), two-component systems as well as solutions for electrostatic application. To expand its portfolio for general industry, Dürr acquired two spray gun application specialists in June 2014: EST+ from the Czech Republic and German company Bertsch & Fratscher. This enables Dürr to offer the right equipment for any area of application. The EcoBell high-speed rotating atomizers are also ideally suited to industry, thanks to their variable spray jet. With its small dimensions and

pre-installed application technology, the ready2spray solution in the form of the compact industrial robot is an innovation in industrial painting. Its integrated concept also includes the motion control of the robot and the process control for the applications, housed together in one control cabinet. Furthermore, the new painting system is fully Industry 4.0-ready. The cooperation agreement covers aspects such as development, mass production, marketing strategy as well as delivery and after-sales processes. The sales concept allows both Kuka and Dürr to offer the robot on the market. The jointly defined target markets for sales and marketing activities comprise general industry in the fields of wood, ceramics, glass, plastics and metal. In the beginning, the new Dürr and Kuka robot system will be sold mainly in Europe, China and North America. Customers will be able to order it from

Dürr as well as Kuka and also configure it in the Dürr webshop. “Dürr also offers a large version for general industry using its own painting robots, which have been tried-andtested in the automotive industry. This is an automated system for painting larger workpieces. We can thus cover the entire range of customer requirements”, says Dr. Schumacher. Dürr has been sourcing mechanical systems for industrial robots from Kuka for a number of years and equipping these with its own application and robot technology for sealing in automotive production. For paint applications in the automotive industry, Dürr will continue to exclusively offer robots developed and produced in-house. Kuka does not operate in this field. For further information: www.durr.com, www.kuka.com

international PAINT&COATING magazine - JULY/AUGUST 2017 - N. 46

HIGHLIGHT OF THE MONTH

History Is Us: OMSG Acquires the brand Carlo Banfi © ipcm ®

Alessia Venturi ipcm®

n June 15, 2017, OMSG operations has become – Officine Meccaniche increasingly high and the San Giorgio – acquired market has firmly oriented the brand Carlo Banfi. Both towards automatic global leaders in the production systems, so much so that of shot blasting machines, OMSG had dismissed that these two companies together line of business already have 135 years of experience in the nineties. Now, our in this field and they have top technologies are roller installed about 9000 plants conveyor shot blasting in 100 different countries, machines for sheets, including Angola, Burkina Faso, profiles and pipes (Fig. 2) Ghana and the nations of South and tunnel plants where America. the workpieces are 1 “Officine Meccaniche San handled by a double hoist Giorgio was established in San or a two-rail conveyor Figure 1: The entrance to OMSG factory. Giorgio su Legnano (Italy, and sent through a shot Fig. 1) in 1961,” says Enzo blasting tunnel (Fig. 3). Dell’Orto, the owner of OMSG These systems are to be assembled, now account for 40% of our and the son of one of the founders. conventionally found in sand blasting production. Luckily for us, mechanical “A few months afterwards, my father paid and coating lines where an overhead pre-treatment is now a requirement in off the other partners and acquired the conveyor takes the parts from the most of today’s specifications. Moreover, full ownership of the company. After a shot blasting stage to the subsequent the treatment and disposal of the waste transfer in Legnano, he set its permanent surface treatment steps. However, also water from chemical pre-treatment plants and current headquarters in Villa Cortese our automatic hanger, hook and hoist are quite expensive, so end-users prefer in 1974. In the eighties, OMSG also shot blasting systems, technologically dry pre-treatment processes. Finally, bought a second factory in Dairago, now simple but very large-sized, are still very the impact of labour costs on manual used for raw material storage and for the important for us.” revamping of our equipment. In 1991, The beneﬁts of this we established OMSG Deutschland acquisition in Metzingen and our French branch, which was later closed and finally On June 15, 2017, OMSG – Officine “Acquiring the brand Carlo reopened in 2011 with the name of Banfi means to expand our Meccaniche San Giorgio – acquired the OMSG France.” position on the market by brand Carlo Banfi. Both global leaders in “In the last few years, the shot absorbing its customers the production of shot blasting machines, blasting market has been shifting through the after-sales and these two companies together have 135 its focus from foundry and forge to spare part services. This years of experience in this field and they carpentry,” adds Dell’Orto. “Metal will give us the chance to have installed about 9000 plants in 100 carpentry components, simple or get acquainted with such different countries.”

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

In the last few years, the shot blasting market has been shifting its focus from foundry and forge to carpentry. Metal carpentry components, simple or assembled, now account for 40% of OMSG’s production. The mechanical pre-treatment is now a requirement in most of today’s specifications.”

clients and then to loyalise them. Another great advantage is the opportunity to improve our presence and know-how in the product sectors where Carlo Banfi was much more popular and specialised, including metal wire and bars, coils, shot blasting machines for ferrous metal foundry, and sandblasters for railway wagons and for treating the inside of boilers, cylinders and tanks. OMSG, on the other hand, is well-known in other fields, such as commercial sheets and profiles, welded metal components for agricultural and earthmoving machinery, and aluminium treatment systems, for example for the automotive industry,” states Enzo dell’Orto during the press conference held in Villa Cortese on June 11 to communicate the acquisition to the market. “The growth that will come from this acquisition will enable us to gain new sales areas and significantly increase our presence on the global market. In the past, having a small company was a big advantage because it was synonymous with flexibility. Now, small dimensions prevent from entering the strategic markets towards which the business is heading. The multinational companies of the shot blasting industry

2 Figure 2: Enzo Dell’Orto and a continuous ﬂow shot blasting system ready for ﬁnal testing.

international PAINT&COATING magazine - JULY/AUGUST 2017 - N. 46

3 Figure 3: A large automatic tunnel shot blasting system under construction.

Another great advantage is the opportunity to improve the presence and know-how in the product sectors where Carlo Banfi was much more popular and specialised, including metal wire and bars, coils, shot blasting machines for ferrous metal foundry, and sandblasters for railway wagons and for treating the inside of boilers, cylinders and tanks.”

have an enormous potential in the foreign markets, especially outside Europe, because they have a better organised structure and more branches and the end customers have more confidence in their ability to provide a good after-sales service. Therefore, we now hope to grow and become much more competitive with our flexibility, expertise and experience.” “Following this acquisition, we will use the OMSG brand in the sectors where we are already well-known and specialised, but we will keep using the Carlo Banfi brand in the aforementioned strategic industries. For instance, next year we will attend the Wire&Tube trade fair in Düsseldorf with the Carlo Banfi brand, precisely because it is more known and established than the OMSG one.”

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

The strengths of the new industrial group “The OMSG group includes the headquarters located in via Pacinotti, Villa Cortese; Carlo Banfi; and the two branches OMSG Deutschland, operating since 1991, and OMSG France, since 2011. We have a strong presence, therefore, on the whole European market – not just France and Germany, where we are the major nonGerman plant manufacturer, but also in Spain, Poland, Russia and North Europe. With the acquisition of Carlo Banfi, we also hope to find new strategic distributors that can help us enter other new markets,” says Enzo Dell’Orto. “Until December, we will be very busy with the brand integration activities, but as of next year we will think about our next steps: the market is evolving very quickly.”

SUCCESS STORIES

Sustainable and Cost-Effective: New Paint Mist Separation System at JLG’s Tianjin Site

Opening photo: The innovative edrizzi® system is based on a handy cube made of corrugated cardboard, which can be cost-effectively disposed of at incineration plants and very compactly transported and stored, since the boxes can be disassembled.

ounded in 1969, the American company JLG Industries Inc. specializes in the production of work platforms and is the world’s largest developer and manufacturer in this field. During painting, large amounts of paint mist are generated, which was placing an increasing strain on the exhaust systems of the painting booths. Looking for an economical and sustainable solution, the JLG site in Tianjin, China (Fig. 1), decided to equip its exhaust air systems with filtration solutions from Freudenberg Filtration Technologies: A system based on edrizzi® paint mist separators and Viledon® compact pocket filters. Freudenberg Filtration Technologies has been distributing the edrizzi® system since April 2016 to the worldwide automotive industry, in many countries to all surface material processing industries.

Initial situation – Low service life and a high amount of paint sludge A strong orange paint finish gives JLG lifting platforms and articulated telescopic booms their distinctive appearance. However, large amounts of overspray and paint sludge were being produced in the two coating booths (primer and topcoat) of the Chinese site in Tianjin. Even with efficient painting processes, up to 35 percent of the paint failed to reach the surface, more than 100 kilograms of paint sludge accumulated per cabin and day. The consequence was clogged filters and reduced exhaust air volumes. Filters had to be changed frequently, the paint sludge disposal was time-consuming and expensive. JLG were therefore looking for a reliable solution to filter their exhaust air, collect the excess paint and prevent paint accumulations in shafts and fans.

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

The solution – A system of edrizzi® paint mist separators and Viledon® pocket ﬁlters Freudenberg Filtration Technologies presented an efficient solution for dry separation due to the edrizzi® paint mist separators, which convince with high absorption capacity, economic efficiency and sustainability. The system is based on a handy cube made of corrugated cardboard, which can be cost-effectively disposed of at incineration plants in most cases and is very compactly transported and stored, since the boxes can be disassembled (ref. Opening photo). It has the capacity to absorb up to 100 kilograms of paint per square meter at a nominal volume flow rate of 2,000 to 3,000 m3 per hour (Fig. 2). As usual when using floor extraction, the new system was assembled just under the grid

SUCCESS STORIES

1 Figure 1: Freudenberg Filtration Technologies equipped the exhaust air filtration system at the Chinese JLG site in Tianjin with an economical dry separation system with edrizzi® paint mist separators and Viledon® pocket filters to reach an extended filter lifetime, while reducing time, labor and costs involved in changing and disposal.

gratings, which allows the edrizzi boxes to be easily accessed from below, regardless of the painting area. For the initial treatment, edrizzi® Vario medium paint mist separators are used. The post-filtration of the exhaust air takes place via moisture-resistant Viledon® Compact pocket filters made from synthetic-organic fibers. To increase performance, the system was converted to edrizzi® Vario S fine modules after a test phase. In addition, three Viledon® WinAir 50 pocket filters ensure clean air within the VOC system.

Table 1: Technical data of the reconstruction Location

JLG Industries Inc., Tianjin (China)

Installation

September 2016

Filtration solution

Paint mist separation: 72 edrizzi® Vario S fine Post-filtration: 72 Viledon® Compact pocket filters Exhaust air: 3 Viledon® WinAir 50 pocket filters

Absorption performance

100 kg/m² at a nominal air flow rate of 2,000 to 3,000 m³/h

Service life

On 26 working days per month and a two-shift working model, Viledon® pocket filters and the edrizzi® system are changed 3.9 times per month on average in the primer booth and 2.7 times per month in the topcoat booth

Cost savings

More than 40% of cost savings due to the system based on edrizzi® paint mist separation with two-stage Viledon® post filtration

Customer beneﬁt – An economic, clean and energysaving painting system

Compared to the previous system, the JLG site now saves more than 40 percent of the costs for the exhaust air filtration of its paint booths. Higher absorption capacities ensure longer filter life and a considerably more economical dry separation system. Thanks to the modular design, the exchange and disposal of individual filters and paint mist separators requires considerably less time and effort. Switching to the Freudenberg Filtration Technologies system with edrizzi® has not only reduced overall costs, but also increased the sustainability of production process at the site (Table 1).

Figure 2: The 36 edrizzi® boxes, used in the primer booth, collect more than 100 kilograms of paint in two shifts daily.

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

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

Visit us at the international trade fair EMO from18th to 23rd September 2017: Hall 7, Booth B51 H2O GmbH | info@h2o-de.com | www.h2o-de.com

BRAND-NEW

1 Figure 1: Roger Stonecipher is the new President of the Pangborn Group.

“Not many companies have been around since 1873. Obviously, they have been doing something right, by providing customers with reliable and innovative surface preparation solutions globally. I’m honored © Pangborn Group

he Pangborn Group, a global leader in surface preparation solutions, is pleased to introduce Roger Stonecipher as their new President, effective immediately (Fig. 1). As President, Stonecipher will have responsibility for the company’s operating units worldwide (Fig. 2). He will report directly to Doug Basler, Chairman of United Generations, LLC, the family-owned holding company of the Pangborn Group. Stonecipher, 52, is a 29-year veteran of the manufacturing industry. He ran various global divisions of Tyco Electronics over a 21-year career, and went on to become CEO of two other companies. Roger was most recently Executive Vice President of Zeus Industrial Products, Inc., a familyowned global supplier of industrial fluoropolymers, located in Orangeburg, SC. “Roger is an accomplished leader, with a successful track record of running global manufacturing organizations,” said Doug Basler, Chairman of UG, LLC. “He brings a great mix of leadership, financial know-how, operations and product management experience, as well as, sales and marketing talent to his new position at The Pangborn Group. Roger has the unique experience of running both a family-owned business, as well as a publically traded business, and understands there can be differences. Roger is also very personable and we feel is a great fit for our family culture.” “I couldn’t be more excited about joining The Pangborn Group,” said Stonecipher.

The Pangborn Group Selects Roger Stonecipher as New President

2 Figure 2: The Pangborn Group’s headquarters.

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and grateful to Doug and the United Generations team for this opportunity to lead this exceptional group of talented professionals. I look forward to continuing the tradition of taking care of our customers in each of our regions, while driving one, global, Pangborn team.” Roger graduated with a Bachelor of Science in Civil Engineering from the University of Louisiana. He also earned his MBA from Oklahoma City University and a Master’s Degree in Industrial Engineering from Purdue University. Roger, along with his wife, Karen, and their four children will soon be relocating to the Atlanta metro area from Charleston, South Carolina. For further information: www.pangborngroup.com

BRAND-NEW

Dürr Receives Ford Motor Company´s World Excellence Award for Second Year in Succession

he Ford Motor Company has honored Dürr with a World Excellence Award for outstanding suppliers for the second year in succession. Dürr received the award in the “Gold Award” category for its work on upgrading and expanding the Ford Motor Company´s paint shop in Valencia, Spain and for jointly developing environment-friendly and flexible production concepts with the Ford Motor Company. Bruno Welsch, President and CEO of Dürr North America, accepted the award from Hau Thai-Tang, Ford Group Vice President Global Purchasing (Fig. 1), and said: “Our goal is to improve our customers’ production efficiency by means of innovative technologies and services. We are delighted that we have once again been able to demonstrate this expertise at Ford. The World Excellence Award will spur us on to perform outstandingly for Ford in future projects, too.” In total, the Ford Motor Company presented World Excellence Awards to 54 suppliers. The award ceremony took place on May 17 at the Henry Ford Museum in Dearborn, Michigan. For further information: www.durr.com

1 Figure 1: Bruno Welsch (center, President & CEO Dürr Systems, Inc.) with Hau Thai-Tang (left, Ford Group Vice President Global Purchasing) and Raj Nair (Ford Executive Vice President and Chief Technical Ofﬁcer Global Product Development).

BRAND-NEW

temp-gard basic - Control and Optimization of Your Curing Process

1 Figure 1: The new temp-gard basic by BYK-Gardner.

YK-Gardner – producer of complete QC solutions for measuring colour, appearance, and physical properties in the automotive, paint and plastic industries – is expanding the oven temperature recorder family: new temp-gard basic with 6 probes, robust thermal barrier and temp-chart lite software for easy Pass/Fail data analysis (Fig. 1). In order to cure coated objects industrial baking ovens are used. The painted product is sent through the oven in a continuous process. The logger of the temp-gard system accompanies the object on its way through the oven protected by a thermal barrier and without the need of a trailing cable. Meanwhile the logger measures and records object and air temperature.

Afterwards the temperature profile is downloaded to the temp-chart lite software for a fast and easy evaluation of the oven conditions.

The logger – heart of the product Due to the small logger with large colour LCD display measurement parameters can be set and measurement data can be monitored directly on the logger. USB interfaces ensure quick and easy data transfer to the PC for in field as well as in plant location. The six temperature probe connections allow you detailed control of the process. For the various substrates, different high-quality thermo-elements of type „K” are available.

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

The thermal barrier – stay cool at any required cure temperature Our thermal barrier is compact and light weight with thermal characteristics suitable for all common coatings – waterborne, solventborne or powder.

temp-chart lite – document, analyse and optimize your cure process Organizers facilitate the setup of measurement parameters and the sample identification. Based on the baking condition of your coating system, Pass/Fail analysis is indicated by a Cure Index and exceeding critical temperature limits will be highlighted. Thus your oven is always running efficiently. For further information: www.byk.com/en/instruments

BRAND-NEW

AkzoNobel Adds New Design App to Growing Selection of Digital Tools for Customers

he Design app allows users to develop a bespoke technical specification in a matter of minutes by offering a choice of filters at each stage of the decision process. These filters range from type of construction material, geographical location of project and durability requirements, to liquid and powder coating options, colour choices and finished look. A powerful tool which can increase customer efficiency, the new app is the latest addition to the rapidly growing selection of innovative digital solutions provided by AkzoNobel across its businesses. “We realize it is time-consuming going through colour cards, and then checking that products meet the necessary requirements of durability, toughness and weathering,” explained Russell Deane, AkzoNobel’s Global Specification Manager for the powder coatings architectural segment.

“Our new app short-circuits the whole process, but without any compromises to the level of detail that a specification can demand. And it can be done from anywhere in the world, whether you’re on the road, out in the field, or in your client’s office.” Users can find full data sheets, test reports and property characteristics for each paint range and finish. The app also lets users check real-life examples of projects where their selected products have been used. As well as showcasing the company’s complete range of colours and finishes – including metallic – the app also allows users to colour match. Simply upload a photograph of your chosen colour (the blue of a swimming pool for example) and the app instantly searches for the closest matches. Chosen colours can then be built into a personalized colour card. For further information: www.akzonobel.com

FA ACTORY PLANNING BODY SHOP CONVEYORS AND FINALL ASSEMBLY LINES COMPLETE PAINT SHOPS APPLICATION TECHNO OLOGY ENVIRONMENTAL TECHN NOLOGY PRODUCTION CONTROL SYSTEMS

End-to-end solutions – from body shop to coating and final assembly. www.eisenmann.com

BUSINESS CARDS

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

... On the road to

ipcm

Â®

n. 46...

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BRAND NEW

FOCUS ON TECHNOLOGY Green Factory 4.0 for the Production of the New Alfa Romeo Top Range Cars: The Evolution of FCA Cassino Plant

42 44

BRAND NEW

FOCUS ON TECHNOLOGY Smart Factory at 2,400 m of Height: the New Audi Plant in San José Chiapa, Mexico

58 60

BRAND NEW

FOCUS ON TECHNOLOGY Maserati Levante: a Top Tailor-Made Coating Process, from Cataphoresis to Enamelling

HIGHLIGHT OF THE MONTH More Than Just Paint

INNOVATIONS: PRESENT&FUTURE Smart Paintshop - The Paintshop of the Future

FOCUS ON TECHNOLOGY Ronal Querétaro: Smart Technologies for the Coating of Diamond-Cut Alloy Wheels

FOCUS ON TECHNOLOGY An Italian Technology to Coat Bumper Components for the Hyundai Group

102

FOCUS ON TECHNOLOGY Coating Waste Water Treatment: a Value Added to the Well-known Quality of OZ Racing Alloy Wheels

S PECI AL AUTOMOTIVE

BRAND-NEW

SPECI AL AUTOMOTIVE

High-quality Surfaces in Automotive Interiors

This technology enables the efficient production of coated components with tremendous design freedom in regard to appearance and haptics. Today plastics dominate the automotive interior. Components are typically injectionmolded from a thermoplastic and then, in a second step, coated on a coating line at a different location to create the desired appearance and haptic properties.

One mold for colour, surface and feel The DirectCoating process produces a component in just one step (Fig. 1). After production in the injection mold, the plastic substrate is then transferred to a second, minimally larger cavity, into which the coating system is injected via a reaction injection molding (RIM) mixing head. This creates a polyurethane (PU)-coated

ÂŠ Covestro

onsumers appreciate a personalized vehicle interior with a premium feel and appealing design. The automotive industry and its suppliers are therefore focused on design freedom, but also want to reduce the energy consumption, logistics effort and costs associated with the production of the components. The solution for all these desires is DirectCoating.

Figure 1: The DirectCoating process produces coated, injection-molded parts for the automotive interior in just one step.

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

BRAND-NEW

SPECI AL AUTOMOTIVE

Precise coating ﬁlling simulation

2 Figure 2: The injected coating can also reproduce contours such as sharp or rounded edges and raised surfaces because it accurately depicts the mold surface.

component with outstanding properties that requires virtually no post-processing. “Compared with the conventional process, the integrated process offers substantial savings potential with respect to logistics effort, energy consumption and space requirements,” said automotive coatings expert Dr. Jan Weikard. “All you need is an injection molding machine and a RIM system.”

Virtually unlimited design freedom The component itself can be transparent, translucent or opaque. Its surface can be coated in various colors, decorated with a matte or high-gloss finish or protected with scratch-resistant functional coatings.

demonstrates the wide range of colours, surface structures and tactile properties that can be reproduced on the same component from a single mold using DirectCoating. Located in the driver’s direct field of vision, the steering wheel cover meets the most demanding appearance requirements. The raw materials for PU layers applied by DirectCoating cannot contain any solvents, not even water. The process therefore requires low-viscosity raw materials that display sufficient flow at 50 to 90 degrees Celsius to quickly fill the cavity. Aliphatic polyisocyanates are particularly well-suited materials, as are polyester and polyether diols and polyols as well as polycarbonate diols as the polyol components. Characteristics such as elasticity, weathering resistance, self-healing and scratch resistance can be defined by the appropriate selection of raw materials.

There are also various haptic and surface structuring options. This is another advantage the DirectCoating process has over spray coating. The injected coating can also reproduce contours such as sharp or rounded edges and raised surfaces because it accurately depicts the mold surface (Fig. 2). Ultrafine grain patterns with a sharp contrast between high-gloss and matte areas are one possible variant.

Various surfaces on a single component One example is the prototype of a redesigned steering wheel cover that Covestro presented the European Coatings Show 2017. This development

Mold filling with the polyurethane coating can be computed in advance using a material data set created by Covestro for Moldflow® simulation software. The simulation model considers various parameters so that problems such as air pockets can be prevented. Trials with the model have now reached the stage where Covestro is offering its customers and their mold makers the project service of computing the ideal sprue and vent design for the coating component. Critical to the continued success of the technology are customized materials, optimum combination of the thermoplastic with the PU raw materials, special formulation expertise with solvent-free coatings, effective use of simulation and testing methods, and solid processing know-how. DirectCoating technology then has good chances of becoming established in the automotive industry. For further information: www.covestro.com

international PAINT&COATING magazine - JULY/AUGUST 2017 - N. 46

BRAND-NEW

SPECI AL AUTOMOTIVE

Clariant Dives Deep into the Ocean to Forecast Trend Automotive Colours for 2019

Figure 1: SHINY MULTITUDES.

Fancy Flexibility: SHINY MULTITUDES

A sense of Curiosity: EXPLORER BY NATURE

Some colours are like a common denominator, something everybody can live with even when they come in multitudes. They bring a sense of optimism into our technology- and efficiency-focused lifestyle, but do not attract attention. Because of their simple effects, they require only little maintenance and remain beautiful even at low light (Fig. 1).

The car is becoming »smart«, and the consequences on how we travel will be as revolutionary as the transition from mobile phones to smartphones. So there are lots of surprises ahead, and it can be thrilling to discover. The intrinsic optimism of such drivers is represented by the choice of bright chromatic colours, too (Fig. 3).

A taste for Tradition: SOLITARY ELEGANCE These colours provide a car with a touch of timelessness. They are decent and low-key, yet the effects appear valuable, but unintrusive. This is why such colours stand for traditional and rock solid values like respect and appreciation, but also for sustainability and a careful use of resources (Fig. 2).

lariant, a world leader in specialty chemicals, suggests a sea of underwater-inspired shades to bring more colour to our roads in 2019 in its new global Automotive Trendbook. The “Marine Magic” collection of automotive styling shades is based on Clariant’s colour know-how and observations of social trends, topics and industry developments. Clariant’s biennial global Automotive Trendbook presents the colour areas that will play a role in the automotive industry in the future. It includes analysis of colour popularity and offers innovative solutions based on its organic pigments. Clariant is one of only a few pigment producers worldwide spearheading colour trend forecasting for the automotive industry. For the year 2019, Clariant explores the mesmerizing colours of the oceans and reefs, and the strikingly coloured and camouflaged “outfits” of marine life. It delves into the infinite variety of hues and nuances found in the depths, and thinks about what meaning they convey above the water. The result is a presentation of four colour families which are likely to attract different types of personalities and mindsets.

Figure 2: SOLITARY ELEGANCE.

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Eager for Excellence: LOOK AT ME! Some people are definitive individualists. They enjoy power and speed and show this in their choice of exclusive and outstanding car colours. Individualists are by no means egotists. However, they operate their lives and machines at the limits, paving the way for those to follow (Fig. 4). Clariant communicates the trends using colour samples coated with original paint and through meaningful imagery. In the new Automotive Trendbook 2019, Clariant

BRAND-NEW © Clariant

SPECI AL AUTOMOTIVE

Figure 3: EXPLORER BY NATURE.

comments: “We have observed a global colour megatrend towards achromatic car colours since the beginning of the millenium. Now, it’s time for the chromatic shades to stand out and add more colour. Clariant’s biennial Automotive Trendbook is a highly appreciated source of inspiration for the

automotive industry, from paint and coatings manufacturers, and designers and trend analysts for automotive colours, to the OEMs and their designers. We are looking forward to sharing this journey into Marine Magic with them.” For further information: www.clariant.com © Clariant

displays a wide variety of future shades, made possible by the use of Clariant Hostaperm® and Novoperm® grades with new opaque, sparkling effect pigments and tinted clear technology. Bernhard Stengel-Rutkowski, Senior Global Technical Marketing Manager at Clariant,

Figure 4: LOOK AT ME.

Opening photo: Alfa Romeo’s Giulia Quadrifoglio Verde: the most powerful Alfa Romeo classic car ever.

FOCUS ON TECHNOLOGY

SPECI AL AUTOMOTIVE

Green Factory 4.0 for the Production of the New Alfa Romeo Top Range Cars: the Evolution of FCA Cassino Plant Alessia Venturi and Monica Fumagalli ipcm®

“T

he challenge was to turn the FCA Cassino plant, near embodies the will of the group, and above all of its CEO Sergio Frosinone, which has been used since 2016 exclusively Marchionne, to win new markets and fight its ever-stronger for the production of Alfa Romeo Giulia (ref. Opening competitors with more and more ambitious economic and picture) and Stelvio (Fig. 1) cars, into a premium factory,” states financial targets in mind. Since when the 2014-2018 industrial plan Concetta Ragosta, the WCM coordinator of FCA Cassino. “After fortywas presented, the group has focused on this plant to relaunch four years of production activity and over seven million vehicles Alfa Romeo, a prestigious and historical brand of the group. produced in eighteen models, our In 2014, the FCA board set mission was to upgrade our plant for out two major projects: one the production of premium cars.” The challenge was to turn the FCA concerned the Mirafiori plant Within the FCA group, the Cassino with the production of Levante, Cassino plant, near Frosinone, which plant, located in Piedimonte San the new Maserati SUV (see has been used since 2016 exclusively for Germano, near Frosinone (Italy), page 60 of this magazine, Ed.), the production of Alfa Romeo Giulia and is undoubtedly the one that best the other involved the Cassino Stelvio cars, into a premium factory.”

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

1 Figure 1: Alfa Romeo Stelvio, an SUV with a new and original design combining the comfort and ﬂexibility of its category with the pleasure to drive and the sport-level performance that only an Alfa Romeo car can offer.

upgraded by implementing an innovative plan plant for the production of Giulia, a manufactured here since 2010.” that involved the sheet metal working, coating new premium sedan, and the new Alfa The factory covers a 2 million m2 area and churns out 1,000 vehicles a day with over and assembly departments. Renovating the Romeo Stelvio SUV. These two car 4,300 employees and 1,400 robots working coating department was the main challenge, models are built on a modular platform on 2 shifts. The site has been wholly due to the need to reduce energy consumption named “Giorgio”, a highly efficient and eliminate waste from the paint platform for the assembly shop to comply with the strict of rear-wheel or four-wheel The site has been wholly upgraded environmental requirements drive models, which enables a (Fig. 3). significant reduction in the weight by implementing an innovative plan that of the vehicles to the benefit of involved the sheet metal working, coating and The relaunching plan for performance, along with lower assembly departments. Renovating the coating FCA’s cars pollutant emissions. department was the main challenge.” FCA needed to meet two “Right from the onset,” explains Costanzo Marchitti (Fig. 2), the requirements for the coating process of Giulia and Stelvio: Manufacturing Engineering production of premium car Paint of FCA Cassino, “the two models and flexibility in the programmes were characterised treatment of bodies that contain by three common elements: aluminium parts, a material premium quality level; full that, along with the use of automation of the plant, with carbon fibre components in zero logistics in the paint shop the assembly phase, make based on the Industry 4.0 Alfa Giulia the lightest sedan principles; and green awareness, in its segment. “Before thanks to which every process starting upgrading our coating is environment friendly. At the department,” says Marchitti, Cassino site, the upgrading “several feasibility studies phase of the plants took two 2 were carried out on the existing years: during this time the factory plants to asses if they were fit never stopped production of Figure 2: Costanzo Marchitti (centre) with Pasquale Incarnato (right) and for the production of the new Giulietta cars, which have been Giovanni Ferrari (left). international PAINT&COATING magazine - JULY/AUGUST 2017 - N. 46

SPECIAL AUTOMOTIV E

3 Figure 3: A side view of the V1 coating unit including pre-treatment, cataphoresis and primer application.

FCA planned a substantial investment and installed a new pre-treatment, cataphoresis, sealing and primer application line, as well as retooling the base and clearcoat application lines.”

premium range. The first one focused on production capacity: our already existing plants had a production capacity of 60 car models/hour, meeting the needs set by the new plan, but were not fit for the required expansion to 74 cars/hour. Another study considered the size of the new bodies compared with our pretreatment and cataphoresis tanks: with some modifications, the 4 plant could have been made fit for the Giulia bodies, but not for Figure 4: The coating process includes the following stages: the Stelvio’s ones. The last critical pre-treatment, cataphoresis, sealing, application of a primer on the aspect was the treatment of the interior and exterior, application of a basecoat and clearcoat on the exterior. body aluminium parts: aluminium poses a major challenge in terms of pre-treatment, as it needs to be treated differently than steel. Giulia, which has 45% of aluminium parts (Fig. 4), could have been produced on the old plant after some modifications, but the FCA management required a pre-treatment and cataphoresis line able to handle 100% aluminium bodies, this being the future trend of the automotive industry. Our conventional overhead conveyor system was not fit for the process, as it could not exclude some pretreatment steps.

After carrying out several industrial benchmark studies on our competitors’ premium cars, we concluded that our devices were not up to the best in class systems due to the obsolescence of the plants. We therefore planned a substantial investment and installed a new pre-treatment, cataphoresis, sealing and primer application line, as well as retooling our base and clearcoat application lines, which resulted in the current layout.” The partner chosen for the implementation of the new plants was Eisenmann, a German engineering company based in Böblingen, near Stuttgart, and one of the leading suppliers of coating lines for the automotive industry. At the Cassino plant, Eisenmann installed its E-Shuttle 200 system, which rotates by 360 degrees to transport bodies to the pre-treatment and cataphoresis baths (Fig. 5), reducing energy and material consumption and, above all, the space requirements of the line. “The integration of this system had already been considered by FCA and included in our roadmap back in 2012. Thanks to the tests carried out back then on several vehicles to assess its technology

FCA needed to meet two requirements: production of premium car models and flexibility in the treatment of bodies that contain aluminium parts.”

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

5 Figure 5: A body entering the pre-treatment tunnel.

At the Cassino plant, Eisenmann installed its E-Shuttle system, which rotates by 360 degrees to transport bodies to the pre-treatment and cataphoresis baths, reducing energy and material consumption and, above all, the space requirements of the line.”

FOCUS ON TECHNOLOGY

6 Figure 6: Eisenmann’s E-Cube dry overspray ﬁltration system: the roller shutter door enables to replace each module individually.

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efficiency, in 2014, when the need arose, we were ready to install it at both the Mirafiori and Cassino plants.” The primer application line is one of the first industrial examples of the application of Eisenmann’s E-Cube system to dry overspray filtration, a technology launched in 2010 that needs no use of water, chemicals or other additives but uses cubeshaped filtering modules (Fig. 6), which are easily replaceable by operators, and require less space and fewer resources.

SPECIAL AUTOMOTIV E

Verind dealt with the tooling of the primer application booth and the retooling of both the base and clearcoat application booths and the new sealing line.” new sealing line. The upgrading work included the installation of 10 primer application robots with EcoBell 3 atomisers and the replacement of the spray guns for the application of the first basecoat layer with EcoBell 3 (Fig. 7) atomisers, thus implementing a Bell-Bell process. Dürr also supplied and installed a highly advanced sealing line that is fully automated (Fig. 8), with dedicated robots and special application systems to carry out all sealing processes: UBC (underbody coating), UBS (underbody sealing), sealing of the seams and housing guides inside the bodies, and LASD application.

Figure 7: The primer application line is equipped with 10 Dürr robots with EcoBell3 atomisers.

Verind, an Italian company belonging to the Dürr group that works with all FCA plants all over the world, dealt with the tooling of the primer application booth and the retooling of both the base and clearcoat application booths and the

The primer application line is one of the first industrial examples of the application of Eisenmann’s E-Cube system to dry overspray filtration, a technology that needs no use of water, chemicals or other additives but uses cube-shaped filtering modules, which are easily replaceable by operators, and require less space and fewer resource.”

Figure 8: The robotic sealing station.

9 Figure 9: The transfer line between cataphoresis ﬁnal inspection area and automatic underbody sealing area.

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

FCA Cassino: a World Class Sustainable Plant In this two-year period of major changes, the Cassino plant has entirely upgraded its systems to aim at higher quality while adopting a premium attitude, a totally new approach to work. “We try to reach our ambitious goals by implementing the World Class Manufacturing (WCM) principles, a rigorous and integrated production strategy adopted in all the FCA plants in the world, which involves all production areas and aims at eliminating waste and

The upgrading work included the installation of 10 primer application robots with EcoBell 3 atomisers and the replacement of the spray guns for the application of the first basecoat layer with EcoBell 3 atomisers, thus implementing a Bell-Bell process.”

Old photo from the Fiera Milano archive. An Arsonsisi stand featuring specialty coatings for civil and military aviation.

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Arsonsisi provides complete solutions to meet the requirements of the entire painting cycle for any type of product, with its industrial liquid paints, powder coatings and electro-deposition paints. Everything is strictly designed and made in Italy.

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SPECIAL AUTOMOTIV E

Figure 10: The body immersion and rotation sequence in the cataphoresis bath.

“As an example, we have totally revised our organisational standards and the way in which we train our staff: at the core of the new approach, there are the workers and the team leaders, which are the main focus for the activities 11 carried out by all the others, from Figure 11: Bodies entering the polymerisation ovens. the managers to the supervisors. increase productivity, quality and safety This change was made through a training in a systematic and organised way. It is a programme on the WCM method, focusing continuous improvement process in which on work as “craft”, behaviour, and employee engagement plays a key role, as leadership.” workers are the starting point and not an “Thanks to this arrival point,” explains Concetta Ragosta. new attitude and the sustainability goals achieved, such as zero emission of CO2, zero waste and zero waste water, our plant was denominated FCA has totally a World Class Sustainable Plant within the FCA world,” adds Ragosta. revised its organisational

standards: at the core of the new approach, there are the workers and the team leaders, which are the main focus for the activities carried out by all the others, from the managers to the supervisors.”

Sheet metal working and pretreatment: a “light” revolution The factory currently includes two sheet metal working and assembly lines: the already existing one for the production of Giulietta and the new one for the Giulia and Stelvio models. There is one paint shop for

N. 46 - JULY/AUGUST 2017 - international PAINT&COATING magazine

The E-Shuttle 200 was designed by Eisenmann to enable the rotation of the holding fixtures, which ensures total flexibility in the handling of the bodies. Each shuttle is fitted with 2 programmable axes according to the needs (horizontal and rotary) and one control unit. The combined action of lifting and 360-degree rotary motion allows the vehicle bodies to be vertically immersed in the bath.” all the car models produced, but it is split in two production units: V1, which has undergone the main revamping works and includes the pre-treatment, cataphoresis, sealing, and primer application lines, as well as all the related ovens, and V2, with the underbody revision, coating and final revision lines. “The use of new aluminium and carbon fibre materials for a lighter car body,” explains Costanzo Marchitti, “required the implementation of new sheet metal working technologies, for example replacing conventional soldering with laser brazing for a seamless welding of aluminium roof and doors. Other innovative techniques have also been introduced, such as the self-piercing

FOCUS ON TECHNOLOGY

the conventional method, the E-Shuttle 200 system ensures better results while requiring much smaller immersion tanks since it uses no entry and exit ramps. This results in reduced water and energy consumption due to the lower running temperature.” “The E-Shuttle 200 was designed by Eisenmann to enable the rotation of the holding fixtures, which ensures total flexibility in the handling of the bodies (Fig. 10),” explains Giovanni Ferrari from Eisenmann Italia. “Each shuttle is fitted with 2 programmable

riveting technology for joining steel and aluminium components, originally conceived for the aerospace industry, and a special gluing process for the carbon fibre roof of the top-of-the line Giulia Quadrifoglio.” From the sheet metal working station, the car bodies are taken to the 11-stage pre-treatment unit and then to the cataphoresis one (Fig. 9). “One of the main innovations implemented was the E-Shuttle technology for the transport and immersion of bodies in pre-treatment and cataphoresis baths” says Marchitti. “Compared with

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Figure 12: A sealing robot in action.

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SPECIAL AUTOMOTIV E

Figure 13: The manual sealing station.

Figure 14: The primer application line.

axes according to the needs (horizontal and rotary) and one Another characteristic of the control unit. The combined action of Eisenmann pre-treatment and lifting and 360-degree rotary motion cataphoresis line is its curved allows the vehicle bodies to be layout, preferred to the conventional vertically immersed in the bath. The linear one to save space and money. system offers faster immersion and The entry and exit sides are very draining steps compared with the near to each other, which allows for conventional oscillating conveyor the shuttle’s fast return to its initial systems, with better results.” position and results in the need for a “The rotary system contributes lower number of shuttles and fewer to improving quality, as vehicles steel structures.” are moved in such a wat that all the air contained in the body is removed,” adds Pasquale Incarnato, the Paint Area Professional Maintenance Manager. Another characteristic of the Eisenmann pre-treatment and cataphoresis line is its curved layout, preferred to the conventional linear one to save space and money. The entry and exit sides are very near 15 to each other, which Figure 15: The “cubic” modules of the E-Cube dry overspray ﬁltration system. allows for the shuttle’s

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fast return to its initial position and results in the need for a lower number of shuttles and fewer steel structures. “This solution, designed in collaboration with Eisenmann, allowed for fast installation, reducing its implementation phase to only six weeks. Moreover, in order to be ready for the production of 100% aluminium bodies in the future, this system enables us to exclude every non-dedicated treatment for this material type. Other advantages were a 16% saving of the material in the tank, the elimination of cataphoresis defects such as holes, drips and dirt, and easy future expansion of the system,” adds Incarnato. After the cataphoresis process, the bodies are taken to the curing oven (Fig. 11) and, © Eisenmann

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Another peculiar feature of the production of the Giulia and Stelvio cars compared with competitors is that the carbon component finishing process is carried out in-house, in the same paint booth used for the bodies, save for the clear resin type, which is specifically suitable for carbon parts.” © ipcm ®

16 Figure 16: A detail of the interior of a ﬁltration module. © ipcm ®

after surface sanding, they are sent to the sealing line, which is fitted with robotised cells (Fig. 12), a little manual sealing line (Fig. 13) and an underbody sealing station. For reasons of flexibility and production costs, FCA decided to replace the sound-damping mats that specialised workers used to manually glue inside the vehicle body with new, special LASD products. The Cassino plant chose waterbased products that require the use of special equipment: in order to meet this new requirement, Dürr set up special robotised cells for the application of LASD products, developing a special technology for the application nozzles. After sealing, the bodies are sent to the primer application booth (Fig. 14).

New technologies for zero water consumption “The new E-Cube dry technology (Fig. 15) has replaced the conventional water-based method of recovering overspray to a large extent,” explains Giovanni Ferrari. “This high capacity separation system recovers

17 Figure 17: Each module is equipped with a control touch screen to simplify its replacement.

overspray in the primer application booths without the use of any chemical additive. Air pressure directs the overspray particles through a filter system to cartridges, or E-Cubes (Fig. 16), that can be replaced without stopping production (Fig. 17). The cube design means reduced space requirements for the storage of the separation modules.” “Cassino is the first car assembly plant in the world to use this technology,” states Marchitti. “The saving achieved with this system amounts to 20% of the coating product; this being a dry filter system, we were able to reduce water consumption and totally eliminate the need for chemicals, aligning our factory with the World Class environmental performance levels.” Verind dealt with the primer application and mixing operations, for which it supplied 10 robots assembled in their “tower” version (Fig. 18). “These robots are fitted with the new EcoBell3 rotary atomisers,” says Marchitti, “especially designed for the application of 1K or 2K solvent or water-

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Figure 18: New robots installed in the primer application station in their “tower” version.

After the drying of the primer coated bodies and the surface inspection, the vehicles are collected in a storage buffer before being fed to the second coating unit.

A more performing ﬁnishing process

with the rotary atomisers already installed on the station applying the first basecoat layer; this enabled to implement the new Bell-Bell electrostatic application process (Fig. 20). The plant was completed with a special station for the two-colour wet-on-wet application operations. “As regards the products used, we have replaced clear resin with another more performing resin provided by BASF (Fig. 21), our long-time supplier,” states Marchitti. “We use the classical

The basecoat application line, installed by Dürr in 2007, was upgraded with new devices. The automatic spray guns (EcoGun2 type) of the second basecoat layer application station were replaced

based coatings on the bodies’ exterior and interior, also in combination on a single area by using a dual shaping air system and a dynamic system for high voltage generation and management. This product allows us to achieve the best quality results, with minimum air consumption and optimised product use.” For the new sealing and primer application stations, a new storage and feeding system had to be set up, featuring sealant and coating management units as well as EcoPump HPE electrical pumps (Fig. 19).

Figure 19: The primer storage and feeding system with EcoPump HPE electrical pumps.

Figure 20: The basecoat application station.

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Figure 21: The clearcoat application on a body.

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body coating system in the ten colours offered by Alfa Romeo, while the white pearl and Alfa red colours require the use of a three-layer system and therefore two passages in the finishing line.” Another peculiar feature of the production of the Giulia and Stelvio cars compared with competitors is that the carbon component finishing process is carried out in-house, in the same paint booth used for the bodies (although on two different skids) and with the same products (Fig. 22), save for the clear resin type, which is specifically suitable for carbon parts. “With this system, we found the solution to two

The results achieved at FCA Cassino plant can be summed up as follows: - aesthetic performance of the finishes up to the best in class levels; - 15% reduction of coating costs; - reduced consumption of materials leading to fewer emissions; - removal of ergonomics and management issues typical of obsolete plants.”

problems: colour matching, as the vehicle components are coated in the same booth, and component handling, since the carbon parts are handled together with the bodies.” The last stages include roof panel sealing and hood positioning on the body before final assembly (Fig. 23).

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Industry 4.0 at the Cassino plant

Cassino is a truly digitised factory 4.0, featuring high brightness screens along the production line and eBoard touch screens enabling the team leaders to control the manufacturing cycle. The production team leaders themselves chose the digital solutions and devices that were most suitable to meet the requirements for higher efficiency and control, providing the line staff with a smartphone and a smartwatch in order to streamline the processes and improve the production flow and the workplace ergonomics.

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22 Figure 22: The carbon components are coated in the same paint booth used to apply the basecoat and the clearcoat on the bodies (although on two different skids): this eliminates any colour matching issue.

summed up as follows: - aesthetic performance of the finishes up to the best in class levels; - 15% reduction of coating costs thanks to the saving of materials and resources © ipcm ®

The operators receive the list of the operations to be performed on a body from the MES (Manufacturing Execution System, FCA’s information system). After completing their tasks, they send confirmation through their smartwatch, the operation is recorded as concluded, and the products can reach the next step. In case an operation cannot be carried out for any reason, the operators use their device to warn the team leader in charge. The digitisation of the production flow improves the products’ quality level through data analysis and fast warning of problems, as well as enabling to solve any issue in a timely way and to standardise the production processes also with the aim of implementing them in all other plants.

but also to fewer touch-up operations; - reduced consumption of products and materials leading to fewer emissions; - removal of ergonomics and management issues typical of obsolete plants. “Eco-sustainability is one of the aspects on which FCA has focused,” adds Concetta Ragosta, “and this has become another area of excellence of the Cassino plant, with three key points. Since 2000, all production waste and by-products have been 100% recovered or recycled; water consumption has been reduced to zero through onsite rainwater recovery and reuse, along with the adoption of innovative technologies in the paint shop and other areas; CO2 emissions have been reduced, with 100% of electricity used in our industrial processes coming from renewable sources, like solar panels.”

Conclusions In the light of the technological innovations implemented in this factory, the results achieved can be

23 Figure 23: Finished bodies ready to reach the assembly line.

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Henkel Partners with Fiat Chrysler to Save Weight and Improve Process and Material Performance on Alfa Romeo’s Giulia

the opportunity to use lighter metal enkel and Fiat Chrysler new metal treatment systems applied structures, but they are themselves Automobiles (FCA) are set to to the new Giulia, created through close using materials that are lighter than discuss their close cooperation cooperation between body engineering, previous generations of treatment in the development of ground-breaking process & materials engineering, and products. Processes and procedures new treatment processes applied to the the process material supplier. They shed are changing significantly as new latest version of the Alfa Romeo Giulia light on a holistic approach involving materials and application technologies (Fig. 1). Both companies shared the state-of-the-art multi-metal pretreatment are launched. podium at Surcar 2017, the international technology as well as acoustic, structural, meeting on sealing & automotive body coating finishing that has technologies taken place in in the body Cannes, France, and paint on June 29-30. shop. FCA and Henkel The new Giulia worked together has a body for almost three that is 90 kg years to develop lighter than a and tailor Henkel comparable materials and all-steel body. systems for This was FCA’s specific achieved by needs. Weight the use of reduction in car light metals in bodies is causing combination significant with new changes to process 1 the processes materials and applied in application Figure 1: The new Alfa Romeo Giulia manufactured by the FCA’s factory in Cassino (Italy): the car body is body and paint technologies. treated with the Henkel’s products. shops. Lighter To reduce car bodies weight At Surcar, Roberto Selvestrel from manufactured from mixed steel and and improve performance, FCA is using lighter metals like aluminium are FCA Materials Engineering Paint and Aluminum to account for 45% of car body Manfred Holzmueller, Sales Director requiring new approaches to surface weight. It has adopted a ground-breaking Transplant OEM Business at Henkel, treatments. The new processes are acoustic package to enhance passenger providing car makers not only with discussed results achieved by using comfort while saving more weight.

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BRAND-NEW

Pretreatment processes The Bonderite two-step metal pretreatment process was developed by Henkel for multi-metal bodies with very high aluminium contents (up to 80%), providing superior corrosion performance while reducing investment- and processing costs. The dip-coating process uses zinc phosphate in the first step to treat the steel, followed by aluminium treatment in the post rinse. “Aluminium can be eaten up by the acids normally used to phosphate steel, so there is a need to find a balance in the treatment process,” says Holzmueller. “Corrosion performance is equal to tricationic Zn-Phosphate, but the Bonderite process generates 30 – 50% less sludge, consumes fewer chemicals, and creates less surface roughness that demands rework. Lower operating temperature also saves energy.”

Keeping the noise out The Alfa Romeo Giulia also benefits from Henkel Teroson high expansion pillar fillers. These are moldings made from a special foamable elastomer that are inserted into cavities in the car body – in the A-pillars for example – during assembly in the body shop. When the body passes through the e-coat oven, the high temperatures cause the moldings to expand to up to ten times their original volume, completely filling and sealing the cavity. This prevents any air entering into the cavity while the vehicle is in motion, and eliminates any wind noise that would otherwise result. A second Teroson product applied to the car body, Teroson AL7154, is a liquid spray-applied acrylic waterborne sound deadener (LASD) developed by Henkel to reduce noise generation in the passenger compartment caused by vibration of the body shell. During extensive tests at FCA, this product showed by far the highest loss factor (a measure of the damping properties) of all candidate materials. The total weight of Teroson AL7154 on the Giulia is over 10% less than standard bitumen pads that would have provided a lower level of acoustic insulation. A further advantage of this new LASD is that it can be applied robotically, without the need for

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any human intervention at all. This has important implications, not only in terms of costs, but also in terms of health and safety. The Alfa Romeo Giulia was the first new car to benefit from the use of Teroson AL7154. Two other vehicles made by FCA on the same line in Cassino, Italy – the company’s first SUV, the Stelvio, as well as the existing Giulietta (in a running change) – have also since adopted the product. Also developed for fully robotic application on the Giulia is Teroson PV3414, a new interior and exterior seam sealer concept that replaces two different sealers – one for exterior seams, one for interiors, and both applied manually. It enables higher application speed, better sealing, better appearance, less dripping and significantly less manual touch-up work. Alfa Romeo is also the first adopter of this system, which is based on a PVC plastisol. According to Holzmueller: “The new Cassino paint shop is providing FCA with a step-change in quality for its vehicles. The company now uses the most modern paint shop technology for the production of high class vehicles. We believe that the innovative spirit at Henkel is clearly on show in the new Giulia. We are facilitating weight reduction through the use of lighter metals, and we are helping our customer cut costs and improve sustainability by using fully automated application systems and reducing waste by avoiding sludge and overspray in its the processes. Furthermore, we are reducing the need for cleaning and maintenance. FCA has taken a major step forward with the simultaneous implementation of numerous new technologies and processes for the new Alfa Romeo Giulia. Very close and intensive cooperation between our two companies was essential, and I am happy that it has resulted in such a beautiful new car!” Henkel and FCA’s presentation, “Reducing Applied Weight While Improving Performance”, has taken place June 29th at 10:30 in the Hôtel Majestic Barrière Cannes. Presenters were: Manfred Holzmueller, Sales Director Transplant OEM Business at Henkel and Roberto Selvestrel, EMEA Region, Materials Engineering Paint at FCA. For further information: www.bonderite-mpt.com

Opening picture: Audi Q5 First Drive in Mexico. Colour: Florett silver

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Smart Factory at 2,400 m of Height: the New Audi Plant in San José Chiapa, Mexico Alessia Venturi ipcm®

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“This plant is the first example of Audi Smart Factory,” says Hubert Waltl, the chairman of the Mexican division’s board. “It was in fact built based on totally virtual simulations, which have enabled us to optimise the entire process chain, and also reduce manufacturing times. The most advanced technologies have been used to create a plant that will be totally waste water free.” Audi Mexico’s long-term target is to achieve an auto manufacturing process with no CO2 emissions nor waste water. This goal will be achieved thanks also to the sustainability of its coating system.

For the paintshop, which is notoriously the step of the whole automotive production process that uses most energy, Audi has turned to German supplier Dürr. The latter, as the General Contractor, has built one of the world’s most environmentally friendly paintshops, thanks to the use of minimum amounts of water, energy and materials. This is based on the Eco+Paintshop concept, which ensures that all processes and interfaces are efficient, from pre-treatment to cataphoresis and from the spray paint booths with their application systems to the ovens.

Paintshop in short:

The second-generation Audi Q5 crossover is built at 2,400 metres above sea level. Elevation is not the only peculiar feature of this plant, which also stands out for technological innovation, the efficient use of resources, and the advanced Environmental Management System.”

Model built: Audi Q5 Start of production: 2016 Bodies/hour: 30 (which can be doubled to 60). Technologies in short: Eco+Paintshop Ecopaint RoDip 10 EcoRS16 sealing robots 36 EcoRP L133 coating robots EcoDryScrubber.

he second-generation Audi Q5 crossover is built at 2,400 metres above sea level in the new Audi production site of San José Chiapa, in the state of Puebla, Mexico. All second-generation Audi Q5 models sold all over the world – save for India and China, which have dedicated production sites – are manufactured here (Ref. opening photo). Elevation is not the only peculiar feature of this plant, which also stands out for technological innovation, the efficient use of resources, and the advanced Environmental Management System. “This factory is a milestone in our company’s history, in addition to being one of the most modern of the whole American continent,” states Rupert Stadler, the chairman of the Ingolstadt company’s board, during the inauguration of the site, in mid 2016 (Fig. 1). The new factory, built from a greenfield in only three years and a half and with an investment of over 1 billion euro, covers a 400 hectare area, has a production capacity of 150,000 models a year and has over 5,000 employees.

1 Figure 1: Aerial view of the Audi site in San José Chiapa, Puebla, Mexico. It is located at 2,400 meters above sea level and is the most modern plant in the Audi world.

international PAINT&COATING magazine - JULY/AUGUST 2017 - N. 46

Audi implements the same quality standards all over the world. For the San José Chiapa plant, it has invested in the employees’ training by opening a training centre near the plant and sending around 700 employees to the Ingolstadt parent company for specific training programmes. It has also chosen to rely on advanced and proven technologies for all the production steps, from moulding and sheet metal working to assembly and coating. 2 “Audi has its own premium quality standard that we implement in Figure 2: Q5 Coating Head Carsten Mohr. every new plant of the company, wherever it is located”, explains Carsten Mohr, the Q5 Coating Head in San José Chiapa (Fig. 2). “That is Dürr has built one of the world’s most why the company has chosen to use proven and guaranteed technologies environmentally friendly paintshops, and processes. For the new Mexican thanks to the use of minimum amounts factory, we have taken the plant of water, energy and materials. This is recently opened in Hungary as a based on the Eco+Paintshop concept, model, and have further enhanced the which ensures that all processes and paintshop performances thanks to a interfaces are efficient.” system using the latest technologies and ensuring that the environmental impact and use of resources are among the lowest in the world in the automotive sector.” “The coating process we use for the Q5 models is the traditional Audi one, enabling us to achieve the top coat premium quality that sets us apart from our competitors: pre-treatment and cataphoresis, sealing, primer application on 3 interiors and exteriors, and basecoat and Figure 3: A few ﬁnished bodies

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clearcoat application (Fig. 3). We have in-depth knowledge of the materials with which the Q5 is built and know how to handle them. Most importantly, 70% of these materials is sourced from Mexico or the NAFTA regions (North American Free Trade Agreement) and our aim is to increase such share,” says Mohr. “In the first months of the ramp up step of the coating line, we used materials sourced from Europe, the same employed at our Ingolstadt plants. However, after our quality release, we have started to use materials locally produced by our traditional partners, such as BASF, PPG, Axalta and Hemmelrath, which have manufacturing sites in North Mexico or the USA. This was one of the keys to the success and rapidity of our ramp up step: there were no unpleasant surprises,” Carsten Mohr states. “The other factor behind our success was certainly the line itself. We have chosen to turn to Dürr because we know their technologies very well: they had already been approved for the new paintshops of Ingolstadt and Hungary, and therefore we have decided to implement the same know-how and experience here in Mexico.” Audi’s coating line uses water-based primers and basecoats, while the clearcoat is a two-component high-solid product. “Unlike our competitors, we apply the whole coating © ipcm ®

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Figure 4: The coating process includes the following stages: pre-treatment, cataphoresis, sealing, and interior and exterior application of a primer, a basecoat and a clearcoat.

system, i.e. primer, basecoat and clearcoat, to the car body interiors as well (Fig. 4). Our colour range includes 15 shades, but we are so flexible that we can apply any colour required by the clients, including any special or customised ones (Fig. 5).”

Audi has its own premium quality standard that it implements in every new plant of the company, wherever it is located. That is why the company has chosen to use proven and guaranteed technologies and processes.”

L’eccellenza in campo ingegneristico e l’ampia linea di prodotti Dürr mettono a fuoco tutti gli aspetti coerenti con un modello di business rappresenta il ecosostenibile e consapevole. Il nostro livello massimo di qualità e consente di ridurre notevolmente energia, materiale e costi unitari.

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Figure 5: The company’s colour range includes 15 shades, but it is possible to apply any colour required by the clients.

tank (Figs. 7 and 8). Less water, chemicals and energy need to be used for bath conditioning because of the smaller volumes of these shortened dip tanks. The Audi plant uses the RoDip M system, which is efficiently driven by a couple of chains. The system is fitted with a chain drive on both sides of tank (Fig. 9). The chain pulls the body rotation carrier through the process line, and allows for both rotary and traverse motions. RoDip contributes to reducing unit costs (up to -16%) and also ensures better protection of the bodies from corrosion because the coat

film is much more uniform, thanks to optimised immersion, flooding and draining. The efficiency of the cleaning and pre-treatment steps is also enhanced through combined linear and rotary motions of the car bodies.

Unlike its competitors, Audi applies the whole coating system, i.e. primer, basecoat and clearcoat, to the car body interiors as well.”

Dürr paid attention to sustainability right from the early steps of the coating process. All the systems installed on the plant meet the Eco+Efficiency concept’s requirements, i.e. the ongoing development of solutions that can improve performance and efficiency, as well as higher flexibility, optimised use of energy and space saving. Audi Mexico has chosen the Ecopaint RoDip rotational dip coating system for pre-treatment and cataphoresis (Fig. 6). RoDip eliminates entry and exit inclines as the car body is completely rotated in the immersion

Figure 7: Another body being rotated with the Ecopaint RoDip system in the cataphoresis tank.

The plant’s highlights

Figure 6: A body being rotated with the Ecopaint RoDip system in the cataphoresis tank.

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Figure 8: A body exiting the cataphoresis tank.

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Figure 9: The RoDip M system’s rendering with its mechanical drive system highlighted.

Audi’s colour range includes 15 shades, but the company is so flexible that it can apply any colour required by the clients, including any special or customised ones.” 9

flexible EcoSupply P system and of “pigs” (pipeline inspection gauges, Fig. 13). With the “pigging” process, the paint is pushed through the pipe, leaving no residues. This procedure is particularly material efficient and saves money. In addition to its 36 coating robots, Audi also uses 24 handling robots to hold the doors and hoods open during interior coating (Fig. 14). Overspray is “separated” via the booth’s dry separation system EcoDryScrubber. It uses limestone powder and needs no water nor chemicals. Therefore, it can be powered by up to 90% recirculated air with up to 60% energy savings, as less air conditioning is needed. The in-line ovens are conceived for complex car body structures with a considerable amount of aluminium, and they are designed to have low exhaust air temperatures. The exhaust air streams from all ovens is purified by the integrated Ecopure TAR post-combustion system, recovering heat to be used for thermal heating. The highly efficient Ecopure TAR exhaust air purification system also cleans the remaining exhaust air from the spray booths, already reduced

Fitted with EcoBell3 high speed rotary atomisers, 36 EcoRP L133 robots are responsible for the fully automated interior and exterior coating in the primer and topcoat line (Fig. 10). The basecoat colour change operation takes less than 10 seconds in the push-out mode, with these atomisers combined with the colour change device EcoLCC2.

Figure 10: The primer application stage on the outside of a body.

During the push-out process, the paint valve is closed before the end of the coating phase and the paint material in the colour hose is pushed towards the atomiser with solvent (Fig. 11). Paint loss during the colour change operation is between 10 and 15 ml (Fig. 12). Audi uses a proven circulation and feeding technology for standard colours, while special shades can be applied with the use of the

Audi Mexico has chosen the Ecopaint RoDip rotational dip coating system for pretreatment and cataphoresis.”

11 Figure 11: A feeding pump of the coating management unit.

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Figure 13: A feeding tank containing a special colour.

Figure 12: A segment of the large-sized coating management unit.

by the EcoDryScrubber system. Thanks to the air recirculation and the dry separation of overspray, the exhaust air to be conveyed to the purification system is efficiently filtered and characterised by high solvent concentration. This enables the use of a very compact air purification system, with a resulting drop of investment costs for the exhaust air system by 60%. With this combination, the power consumption for the exhaust air purification is reduced by up to 80% and solvent emissions drop by 90%.

San José Chiapa is the plant at the highest elevation of all Audi group’s sites. The same is true for the paintshop, covering a surface of 100,000 m2 and developed on five levels, for a total of 23 metres of height. “Most operators work on the floor level (0 m), which houses the sealing line with the PVC application unit (Fig. 15) and the touch-up area, and at 9 m of height, where the spray paint booths are installed,” Tanja Mehes cleaning specialist of Audi Mexico explains during our visit to the plant (Fig. 16). “The conveyor system is installed at 0, 4.5, 9 and 12 metres (Fig. 17), and the offices are housed on the 4.5 metre level. To the right of the entrance, the floor level houses the pre-treatment and cataphoresis line, the quality control lab and the sealing line; to the left, there are the touch-up stations, the PVC feeding pumps (Fig. 18), the paintshop and the waste water treatment system.” “Following sheet metal working, the car bodies are directly sent to the first station of the pre-treatment and cataphoresis © ipcm ®

A layout developed on several levels

14 Figure 14: In addition to its 36 coating robots, Audi also uses 24 handling robots to hold the doors and hoods open during interior coating.

15 Figure 15: The manual PVC application unit.

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line. Here, the doors, hoods and boots are checked to ensure they are open and secured (Fig. 19); then, through another skid, the bodies are fastened to the RoDip system’s shuttles (Fig. 20),” explains Miguel Angel García, a pre-treatment and cataphoresis specialist at Audi Mexico. “The line includes two parallel circuits:

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the tunnel of the left is used After leaving the prefor pre-treatment, the one treatment tunnel, the on the right for cataphoresis. RoDip shuttles enter a Our current output, still in the buffer. If the car bodies ramp up phase, amounts to are left in front of the 30 bodies/hour, but the line cataphoresis tank for is designed to treat up to 60 a sufficient time to bodies/hour.” be dried, a spraying “There are twelve steps. The nozzle damps them first three stages provide for into make the surface depth cleaning. The first one, more conductive for in particular, uses degreasing cataphoresis. This may agents to wash away any happen, for example, grease as well as welding in case of long plant 16 and sheet metal working downtimes or on residues,” García adds. “The Sundays, when the Figure 16: Standing, from left to right: Franziska Habelt, Bernardo Mercado three degreasing steps are plant is shut down (Communication/Press), Nico Stephan, Juan Pablo Navarro (Communication followed by two rinses with for technical cleaning Vicepresident production and logistic). Below, from left to right: Alessia Venturi and Tanja Mehes. mains water, a phosphating and preventive treatment, two further rinses, maintenance. a passivation treatment with a sealing Ingolstadt plant, here the whole pre-treatment “We are achieving excellent values product, two rinses, and a final cleaning process is carried out through immersion, not in terms of residual particles after stage with demineralised water. Unlike the spraying (Fig. 21).” pre-treatment, near to zero,” says

energy resources used by Audi Mexico to manufacture the new Audi Q5

Electricity: 72 megawatts, i.e. the power needed to supply 96,000 homes at the same time.

Gas: 4,200 m³/h, i.e. enough to feed 7,800 radiators simultaneously.

Compressed air: 20,000 m³/h, i.e. the air needed to inflate the tires of nearly 72,000 Audi Q5 every hour.

Drinking water: 130 m³/h, i.e. 650 19-litre carafes per hour.

Industrial water: 130 m³/h, i.e. 650 19-litre carafes per hour.

Cooling water (26° C): 2,000 m³/h, i.e. the amount needed to fill 19 olympic-size swimming pools a day.

Cold water (14° C): 2,700 m³/h, i.e. the amount needed to fill 1 olympic-size swimming per hour.

Hot water (90° C): 291 m³/h, i.e. the amount needed to fill 3 olympic-size swimming pools a day.

Waste water treatment: 1,800 m³/day, i.e. the amount needed to fill 180 tubes per day.

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Miguel García. “Every day, we monitor the process parameters to maintain our pre-set quality level. We have also been much appreciated for the top uniformity of our cataphoretic coating, with a roughness level that perfectly complies with the certification requirements. Admitted values are included in the range between 17 and 30 μm: our value is 22 μm. This result is possible because each floating module of our cataphoresis tank has a different voltage, which gradually increases as the car bodies are fed along the line to improve thickness and coating uniformity; thanks to the constant control of the process parameters, such as pH, conductivity and pigment/paste ratio; and, last but not least, because the RoDip technology by Dürr is much more effective than our old overhead conveyor (Fig. 22).”

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17 Figure 17: A descender moves the bodies from one level to another.

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Figure 18: The PVC feeding pumps.

5 robotised and 2 manual application stations. The first ones apply PVC even on difficult-to-reach parts and the critical areas for which clients require high finishing precision and accuracy. The last robotic station carries out high precision applications on visible parts.” “The clean room includes 3 spray paint

booths. Each booth has two robotic stations, one for interiors and one for exteriors. Moreover, the primer and basecoat spray booths are fitted with an innovative body cleaning system (Fig. 24) that does not use conventional emu feathers,“ Tanja Mehes of Audi Mexico adds.

“The PVC application and masking line’s task is to seal the car body openings from where the cataphoretic coating flows and, at the same time, protect the cars from dust and water,” explains Nico Stephan, a PVC specialist. “10 EcoRS16 robots by Dürr are used to seal the underbodies and welding joints (Fig. 23). There are

Figure 19: After sheet metal working, the bodies are checked before pre-treatment.

20 Figure 20: After the inspections, the bodies are fastened to the RoDip system’s shuttles.

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Audi has been much appreciated for the top uniformity of its cataphoretic coating. This result is possible because each floating module of the cataphoresis tank has a different voltage, which gradually increases as the car bodies are fed along the line to improve thickness and coating uniformity.”

FOCUS ON TECHNOLOGY

Figure 21: To the right, the exterior of the pre-treatment plant.

Figure 22: The control stage after cataphoresis.

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

VERTICAL and HORIZONTAL Coating Lines for Aluminum Pro¿les.

SP E C IA L A U TOMO TIV E

23 Figure 23:The robotic application of PVC.

The Audi Group With its brands Audi, Ducati e Lamborghini, the Audi group is one of the most successful car and motorcycle manufacturers in the premium segment. It is present in more than 100 markets worldwide and has 16 production sites in 12 countries.

AUDI AG has several 100% owned branches, including Audi Sport GmbH (Neckarsulm, Germany), Automobili Lamborghini S.p.A. (Sant’Agata Bolognese, Italy) and Ducati Motor Holding S.p.A. (Bologna, Italy).

In 2016, the Audi group delivered approximately 1,868 million Audi cars to its customers, as well as 3,457 million Lamborghini sports cars and 55,451 million Ducati motorcycles. In the same year, with a turnover of 59,300 million Euros, the group achieved a 3,100 million Euro EBIT. Currently, the group has about 88,000 employees worldwide, of which over 60,000 only in Germany. Audi is now focusing on new products and sustainable technologies for the future of mobility.

FOCUS ON TECHNOLOGY

INTERNATIONAL PATENT

24 Figure 24: The brushes clean the bodies with synthetic feathers soaked in a liquid that incorporates dust and removes it.

“The brushing robots clean the car bodies with synthetic feathers soaked in a liquid that incorporates dust and removes it. The primer application on interiors and exteriors is followed by a stage in the primer oven; then, the bodies are fed to a second brushing line and to the basecoat application booth. Finally, they are fed to a flash-off oven and to the clearcoat application booth with a zigzag motion.” “All booths are equipped with the EcoDryScrubber dry separation system with limestone powder. Hoppers with conveyor belts are placed under them. The airflow from the booths moves downwards, carrying the paint overspray that mixes with limestone powders and hardens, becoming a reusable material. This is the first EcoDryScrubber system installed by Dürr in Mexico” Tanja Mehes states. Audi Mexico’s coating line also includes 5 spot touch-up stations for any possible defects, 5 polishing stations and 2 finishing stations that can accommodate 30 bodies each.

Smart Factory, Sustainable Factory When Mexico and San José Chiapa opened their doors to Audi, the company was charged with great responsibility towards environment and the sustainable development of the region. Being able to rely on the most advanced production and coating technologies means to limit water consumption, save and recover energy, and significantly reduce waste production. Moreover, the gas, water and compressed air distribution networks are designed to reduce leaks to a minimum. Thanks to that, Audi Mexico is now a strategic partner of the Puebla region.

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

NITROTHERM The performance is 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

BRAND-NEW

SPECI AL AUTOMOTIVE

Chemetall Presented at SURCAR 2017 on the Evolution of Thin-Film Pre-treatment Technology and its Benefits in Automotive Surface Treatment

paint adhesion for the growing mix of metals used on car bodies (Fig. 1). The session took place the first day of the event. It was also represented by Jean-Marc Kopp and Patrick Vejrich of Chemetall. There were two additional presentations during the conference

provided by BASF Coatings’ Automotive group - Individual Colors (IC Colors) co-presented by Stefan Sickert and 2K Clearcoat co-presented by William Kosteniuk. For further information: www.chemetall.com

hemetall Surface Treatment and Automotive business units were proud partners of SURCAR. SURCAR 2017 took place from June 29 to June 30 2017 in Cannes, France. The conference featured the topics Industry 4.0, new technology, personalized cars and opportunities in the ever changing automotive industry. In addition, the event focused on developments, changes and results from new technology and market trends, smart factory, and strategic issues for the coatings industry. Dr. Dietmar Chmielewski, of Chemetall Surface Treatment, presented on the evolution of thinfilm pre-treatment technology and its benefits. Chemetall’s metal pretreatment technology Oxsilan® provides long-term protection against corrosion and ensures optimal

1 Figure 1: Chemetall’s metal pretreatment technology Oxsilan® provides long-term protection against corrosion and ensures optimal paint adhesion.

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BRAND-NEW

S P E C I A L A U TOMOT I V E

Merck and Industry Partners Create New Automotive Coating Effects

erck, a leading science and technology company, announced the outcome of a successful collaboration with Daimler AG, the coating specialist PPG Industries and the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA). The joint efforts have yielded a special clearcoat for generating new effect dimensions that Daimler AG is currently testing and was presented for the first time at SURCAR 2017, the International Conference on Automotive Body Finishing in Cannes, France.

Crucial: the interface between the clearcoat and the basecoat

The Xirallic® effect pigment makes the difference in the product manufactured by PPG. The pigment surface is modified using innovative curing, a process developed by the Fraunhofer IPA and Daimler AG and jointly submitted for a patent. Thanks to customized additives in the clearcoat, after the clearcoat is applied to the body the particles specifically orient themselves toward the interface to the basecoat. This new development can significantly intensify the effect on existing OEM basecoats, making it possible to create completely new color tones. By selectively combining a series basecoat with a shiny, matte, or “stratifying” clearcoat, different color effects can be realized for vehicles. A show car exhibited this novel effect for the first time at SURCAR on June 29 and 30 in Cannes (Fig. 1). For further information: www.merckgroup.com

Figure 1: The show car exhibited the novel Merck’s effect at the SURCAR Congress.

Foto di apertura: ?????????? © FCA

Opening photo: Levante is the Maserati of SUVs, a perfect combination between on-road and off-road performance.

FOCUS ON TECHNOLOGY

SPECI AL AUTOMOTIVE

Maserati Levante: a Top Tailor-Made Coating Process, from Cataphoresis to Enamelling Alessia Venturi and Monica Fumagalli ipcm®

evante, the Maserati of SUVs: elegance, power, originality. Levante is the quintessence of Maserati’s soul and a perfect example of the Italian design excellence. The new SUV has an exclusive and innovative style; it is a sporty and highly performing car, providing at the same time excellent off road capabilities. It also features the most innovative suspension

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system of the moment, with air-ride suspensions that in off-road position raise the vehicle by 40 mm, while when exceeding 180 km/h lower by 40 mm turning the SUV into a true racing car. Levante’s concept was born from the will to link a sports car brand like Maserati to an SUV, in line with the great success of the sedans Maserati Quattroporte and Ghibli, both produced in

FOCUS ON TECHNOLOGY

by Dürr, which enables the treatment the conventional use of bells and spray the former Bertone factory of Grugliasco, of zinc-coated, galvanised sheet and guns, and a basecoat/clearcoat line near Turin. Based on the company plans, aluminium, or fully aluminium bodies was reconverted into a primer line. The the same site should have been dedicated (Fig. 2). With EcoPaint RoDip E, installation and renovation works on the to the Levante production, but following a the bodies are transported through the coating lines were carried out by Olpidürr rise in the output volume of the two sedans, process by means of freely which have met with great market programmable, independently success, the new production line powered smart transport units was instead installed at the Mirafiori Levante is the quintessence of (Fig. 3). Each shuttle has a plant. conveying drive for the transport The first Levante models were Maserati’s soul and a perfect example of of bodies along the line and a produced by the Turin plant in early the Italian design excellence.” separate drive for rotation. The 2016 and production capacity steadily transport unit is controlled via an increased until reaching an average accurate path positioning system, of 140 cars a day – about 34,000 a while a WLAN signal is used to year – with further growth potential. communicate with control units. “The US and Canadian markets account for 30% of Levante sales, Body preparation: 35% is accounted for by China and different materials, the remaining 35% by the rest of the different sequences, world, mainly Europe, but also Middle one system East,” says Paolo Ollino, Head of “The fundamental prerequisite Vehicle Line Manufacturing Maserati of the new pre-treatment and (Fig. 1). “The current product is a cataphoresis line was maximum high-performance premium car, 5 flexibility, essential for the m long and weighing almost 2 tons, treatment of bodies of different fitted with the Ferrari V6 engine for a size and different materials on total power of 430 hp for the gasoline the same line,” explains Roberta engine and 275 hp for the diesel Pecoraro, Head of Paint Methods, engine. Its colour range includes 11 Material and Automation Dpt in tints – pastel shades and metallised Manufacturing Engineering Paint colours, all applied in a conventional 1 of FCA (Fig. 4). “The large size of system – and the pearl white colour, the Levante body might have been applied in a three-layer system. Figure 1: Paolo Ollino, Head of Vehicle Line Manufacturing a problem even for a large plant Traditionally, Maserati always focused Maserati. like Mirafiori. Moreover, the new its attention on performances, project required the production driving pleasure, exclusivity and of a premium car model with top coating Spa, an Italian company of the Dürr group quality, aspects that our typical clients have quality to meet market requirements. and a world leader in designing and building always greatly appreciated. The Maserati’s Finally yet importantly, the moving parts coating lines for the automotive industry. philosophy is to add new contents every of Levante – the bonnet, the 4 doors and Mirafiori was one of the first plants in the year to keep the product up-to-date.” the boot – are made of aluminium (Fig. 5): world to use the EcoPaint RoDip E system The engineering project for the installation the project needed to include of the new line started in 2015 a properly fitted plant for the and it was completed in about a treatment of bodies made with year. Among other things, a new The first Levante models were high percentages of aluminium advanced plant for pre-treatment or fully made of aluminium. and cataphoresis was introduced, produced by the Turin plant in early 2016 the enamel application process and production capacity steadily increased The electrical EcoPaint RoDip system by Dürr meets all these was updated with the adoption until reaching an average of 140 cars a day requirements.” of a bell/bell process instead of with further growth potential.” international PAINT&COATING magazine - JULY/AUGUST 2017 - N. 46

SPECIAL AUTOMOTIV E

2 Figure 2: Bodies reaching the sheet metal working station.

means of PLC-controlled pumps to ensure the right liquid concentration inside the tanks. The aluminium parts, on the other hand, are subjected to a surface conversion process in a dedicated pretreatment area.

“The initial 3-stage degreasing process includes a flooding step with a jet sprayed from the exterior to the interior of the bodies by means of high capacity nozzles, a spraying step with high pressure nozzles that spray a degreasing fluid at 55°C (Fig. 6), and a final immersion step, where the nozzles are positioned at the tank bottom to agitate the bath and further enhance the removal of residues from the bodies. For the degreasing, we use one alkaline product heated at 55°C and supplied 3 by Henkel, which also provides the other preFigure 3: The rendering of the RoDip E system, using smart electric treatment products.” shuttles.

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The coating cycle starts with a conventional pre-treatment line including 10 stages as follows: 3 degreasing steps, rinsing, activation for the phosphating process, tricationic phosphating for galvanised sheet metal, two cleaning steps, aluminium conversion through dipping, and a final washing step. “A Two Step cycle was chosen for the surface treatment of Levante,” states Fabrizio Santarelli, the Manufacturing Engineering Specialist of FCA. “The zinc coated parts are treated with a conventional selective phosphating process that does not damage aluminium. The product used is made of four components that are dosed by

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FOCUS ON TECHNOLOGY

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5 Figure 5: This picture clearly shows the aluminium parts of Levanteâ&#x20AC;&#x2122;s body.

6 Figure 6: The initial body degreasing process includes three stages.

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SPECIAL AUTOMOTIV E

Figure 7: A bird’s eye view of the pre-treatment and cataphoresis line equipped with Dürr’s EcoPaint RoDip E system.

For the cataphoresis process, Mirafiori is the second plant in Europe to use ENVIRO-PRIME® EPIC, a last generation water-based technology by PPG that offers improved penetrating power, making it easier to reach the required thicknesses in cavities, as well as improved brilliance, spreading rate and corrosion resistance. It does not contain tin or any other heavy metals and it has a very low VOC content. Cataphoresis is followed by rinsing and ultra-filtration processes to remove the paint in excess that has not electro-deposited, a cleaning stage with demineralised © ipcm ®

Mirafiori is the second plant in Europe to use ENVIRO-PRIME® EPIC, a last generation water-based technology by PPG that offers improved penetrating power, making it easier to reach the required thicknesses in cavities, as well as improved brilliance, spreading rate and corrosion resistance.”

Figure 8: The chain with the smart carriers handling the bodies along the pre-treatment and cataphoresis line.

water, and a drying stage in the oven. Permanence in the conventional hot air oven with methane heating units amounts to 37 minutes. The plant’s takt time is 2 minutes (30 bodies/hour, Fig. 7). The true innovation of this pre-treatment and cataphoresis line is the body conveyor system by means of smart shuttles designed by Dürr, which currently offers the highest possible production flexibility. With this system, the degreasing phase can be excluded when the line is

Figure 9: The body is immersed vertically in the cataphoresis tank and then completely rotated.

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SPECIAL AUTOMOTIV E

Figure 10: Each carrier has two motors, one for the transport and the other for the rotation of the bodies.

The smart shuttles designed by Dürr currently offers the highest possible production flexibility. This system offers a dedicated cataphoresis sequence for any type of body.” © ipcm ®

used for the treatment of non-premium vehicles, with the possibility in future to eliminate the phosphating process in favour of direct aluminium conversion, when only fully aluminium bodies will be treated; it also offers a dedicated cataphoresis sequence for any type of body (Fig. 8).

Figure 11: The control panel of the electriﬁcation curve.

RoDip E: the highest possible treatment ﬂexibility “The RoDip E system installed here has 2 loops,” explains Maurizio La Rosa, the Project Manager of Dürr. “The first one runs along the pre-treatment tanks and the other along the cataphoresis tanks, for a total path of 450 m that enables the bodies to rotate by 360° inside the baths (Fig. 9). While the pre-treatment cycle is the same for all car models, for the cataphoresis process different programmes can be selected depending on the body, the only difference being the size of the surface to be treated. Based on this parameter, which is taken from the bar code on the bodies, it is possible to set the characteristics of the electrification curve. The electrically driven RoDip E system (Fig. 10) detects the car body loaded and allows for its treatment with a dedicated sequence independently from the other bodies

12 Figure 12: A body exiting the cataphoresis tank after being completely rotated to deposit a highly uniform cataphoretic layer.

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to be treated: the single pair of cells is electrified (Fig. 11), thus preventing waste and excessive product being deposited on the body. While Rodip M has a mechanical transport system with a chain linked to one motor, RoDip E is fitted with carriers, each with two motors, one for the transport and the other for the rotation of the bodies. For every unit, the type of transport and/or rotary movements can be selected.” Thanks to the 360° rotation of the body, which remains in the bath for 3 minutes, the same contact time is granted for the whole surface, resulting in highly homogenous cataphoretic thicknesses (Fig. 12). “The system allows for the continuous control of the coating temperature, which is kept lower than overheating levels,” adds La Rosa, “and for the continuous removal of the acids released in the cell, which is thus kept clean for a longer service life (Fig. 13).” “An important advantage of this plant is the reduced size of the process tanks for the body rotation compared with conventional overhead conveyor systems,” adds Mario Viano, the Sales Key Accounts manager of Olpidürr.

FOCUS ON TECHNOLOGY

The electrically driven RoDip E system detects the car body loaded and allows for its treatment with a dedicated sequence independently from the other bodies to be treated: the single pair of cells is electrified, thus preventing waste and excessive product being deposited on the body.”

13 Figure 13: The ultraﬁltration module of the cataphoresis plant.

SPECIAL AUTOMOTIV E

14 Figure 14: The tanks of the cataphoresis line are much smaller thanks to the use of the RoDip system.

“There is no need for ramps at the entrance and exit of the tank as the body is positioned vertically. This represents an advantage mainly for factories like Mirafiori, where the new plant had to be installed in an already existing area.” The volume of the cataphoresis tank is 180 m3, compared with the 330 m3 of the tank previously installed by Dürr (Fig. 14).

RoDip E is fitted with carriers, each with two motors, one for the transport and the other for the rotation of the bodies.”

Figure 16: The primer inspection line.

Figure 15: The primer application line.

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“In terms of energy savings,” says Fabrizio Santarelli, “we have recorded 20% lower consumption compared with the previous plant, and above all these savings do not depend on the model produced.” The premium quality of a product is also achieved through constant monitoring of production and operating parameters.

FOCUS ON TECHNOLOGY

Figure 17: The basecoat application on the interior of a Levante car.

Sealing and coating for premium cars

“The use of mobile control devices has strongly simplified and speeded up the work for operators, who have to keep a 450 m long line under control,” says Santarelli. “The system software also enables us to monitor the production trends of the other plants of the group, in order to make comparative studies among the various production lines.”

The Mirafiori coating line is fully run by a software programme with the web operator system developed by Dürr, which enables the plant operators to continuously control each process thanks to the use of tablets connected to the central system by means of Wi-Fi stations distributed through the plant.

Figure 18: The transfer from the interior coating station to the exterior coating one. They perform a bell/bell process.

19 Figure 19: The basecoat application on the exterior of a Levante car.

“The sealing of the Levante bodies is a manual process excluding the conventional seam system in favour of a sealant application system that ensures full edge cleanness and lends a more linear design to the car as a whole,” explains Fabio Negri, the Head of Coating Department at FCA. “In addition to the sealant, we add sounddampening sheets (IFF) then make further applications of adhesive to seal any possible gaps on the car body: in this way, we provide full protection from air and water penetration and insulation against external noises.” The body is then fed to the primer application line. “In this section, we have converted the old enamel application line into a new automated primer application line (Fig. 15) for the exterior of the bodies,” adds Roberta Pecoraro. “This is followed by a primer cross-linking stage in the oven and an inspection stage on the first layer applied (Fig. 16). The updating process of the plants for the production of a premium car like Levante also included the enamel application line (Figg. 17 and 18). Here it was decided,

international PAINT&COATING magazine - JULY/AUGUST 2017 - N. 46

SPECIAL AUTOMOTIV E

Figure 20: The two-component clearcoat application.

Figure 21: The ﬁnal release.

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FOCUS ON TECHNOLOGY

22 Figure 22: A ﬁnished car ready for the application of the protective cloth.

first of all, to shift from a bell/spray gun process to a bell/bell process with electrostatic rotary atomisers: with this system, application is more precise and there are fewer residues on the body and reduced overspray, to the advantage of the environment and product consumption (Fig. 19).” For the primer application, two new EcoSupply P systems have been integrated to handle special colours (low runner). They operate in a simple way: a product feeding unit, a starting station (near the feeding unit), a destination station (next to the applicator), a special piping system linking the two stations, and a pig located inside the pipe that allows for both the product delivery to the station (“Push Out” function) and the product recovery at the end of the coating process (“Recovery” function). Everything is controlled by a new software system that fully manages all the plant’s operating cycles and programmes. “With an eye to premium quality, we have then changed the type of clearcoat used: we have opted for a two-component product instead of a one-component paint to ensure improved and more durable scratch resistance, gloss and

The EcoPaint RoDip E system does not offer the performance degree of a mechanically driven system, which is more suitable for mass production, but it ensures a more tailored treatment of the bodies already in the first stages of the surface treatment.”

G RT

SPECIAL AUTOMOTIV E

23 © FCA

Figure 23: A Levante car ﬁnished with the pearl white three-layer coating system.

aesthetics (Fig. 20). All coatings are water-based, save for the clearcoat that is solvent-based,” states Pecoraro. “The enamel application process includes the application of a basecoat on both interiors and exteriors, followed by a forced flash-off stage at 90°C for 5 minutes, the application of a clearcoat on both interiors and exteriors, a reticulation stage for 20 minutes at 140°C and the final release (Fig. 21). In case a threelayer system has to be applied, after release the body is conveyed off the line for a roughening operation. It is then carried back to the spray paint booth where it is coated with two further layers (metallic basecoat and clearcoat, which enhances colour depth).”

From premium to tailor-made cars: the next future Along with performance, design and finishes, what makes a premium car exclusive is its limited production (Fig. 22). “The EcoPaint RoDip E system is especially suitable for this kind of production,” states La Rosa from Olpidürr. “In terms of productivity, it does not offer the performance degree of a mechanically driven system, which is more suitable for mass production, but it ensures a more tailored treatment of the bodies already in the first stages of the surface treatment. In the premium car segment, the current trend is towards the full personalisation of vehicles, and this means paying maximum attention to every detail that may satisfy the client (Fig. 23).”

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“Personalisation is a very important and attractive aspect for Maserati’s clients and it involves substantially the choice of colours,” states Paolo Ollino. “We currently rely on our suppliers to meet this requirement, but in future we might also decide to use our lines for the coating of a limited number of bodies with personalised colours.”

Â© Mankiewicz

Opening photo: An aesthetical interior plays an important part in the decision of all potential buyers.

HIGHLIGHT OF THE MONTH

More Than Just Paint Interview with Carsten Bernau Sales Director Automotive at Mankiewicz, Hamburg, Germany

automotive@mankiewicz.com

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SPECI AL AUTOMOTIVE

HIGHLIGHT OF THE MONTH

ankiewicz Coatings is a leading manufacturer of paint systems. We conducted an interview with Mankiewicz’s Sales Director Automotive Carsten Bernau to learn about new paint trends and requirements (Fig. 1). About Carsten Bernau: 57 years old, studied business economics in Berlin and Vienna, specializing in foreign trade. After graduation he worked as a sales representative for a chemical company for ten years and then started working at Mankiewicz, first in the general industry, later in the automotive sector. He has been the director of the automotive department for more than 20 years and is a member of the management board. When did Mankiewicz enter the automotive market and what has changed since then?

We have been busy in the automotive sector for over 25 years now. In the beginning the focus was on the interior. At the time, functionality was more important than design issues. Accordingly, the paint was comparatively “hard” and applied in high film thicknesses up to 100 μm. This only changed in the middle of the 1990s with the development of new, much more elastic binding agents for appealing textures and haptics. The film thickness was reduced: in the car interior it is only 20 to 30 μm nowadays. At that time, colour design and haptics were first combined. The scope of design for the car interior became more varied – as did the demands of the customers (Ref. opening photo). Today, cars are not merely sold for their technical performance; an aesthetic interior is essential, too. Appealing surfaces are mostly achieved with customized paint

systems. Today´s paint systems are much more resistant to mechanical and chemical influences. What does the Mankiewicz product portfolio comprise? We mainly produce two-component polyurethane-based paints: the ALEXIT paint systems. In the automotive interior we use socalled décor haptic paints to enhance plastic surfaces optically and haptically and to align them with other materials like leather or fabric. Plastic parts are coated with metallic paints to substitute metal components and surfaces. We also offer individual concepts like laseretchable paint systems for a day-night design in the automotive interior. The symbols on the keys are etched out with a laser beam, thus becoming visible later. In the exterior we use polyurethane-based or UV-curing high-gloss paints in colour shade piano black. UV-curing

SPECIAL AUTOMOTIV E

60 percent of the automotive business is done in this market. The Chinese market with its huge demand and unrealized potential is another important target for the Mankiewicz group. The US market is, too. For a long time the domestic and © Mankiewicz

systems offer very good mechanical and chemical resistance values, thus reducing slight scratches on the highgloss surfaces to a minimum. We also offer mat exterior décor paint systems which improve the scratch and light resistance values. Our NEXTEL paint systems offer suede-like, non-glare surfaces to replace textiles. Easy-toclean paints round off the portfolio. What are the demands on the automotive interior and exterior fittings? Interior fittings have to be resistant to heat and humidity in order to avoid hydrolysis damage. The paints have to be resistant to hand lotions, mechanical influences and ageing. In contrast, exterior paint systems have to be resistant to light as well as climatic and mechanical influences like stone-chipping. They have to survive automated carwash systems, bird droppings and insect removers without damage. Is it correct that your focus will be more on the exterior sector in future? That´s correct. We are very experienced in the coating of plastics. It was obvious for us to make use of this know-how in the exterior sector as well. The growth potential for us is huge. We have gained lots of experience in the coating of plastic components like radiator grills, license plate brackets and bumper parts. What are your key markets? The domestic market – Europe – is still our major target. Quality enhancement by means of paint is very well accepted and we know the demands very well.

1 Figure 1: Carsten Bernau, Mankiewicz’s Sales Director Automotive.

Japanese car manufacturers were one step ahead in this market, but nowadays the Europeans are gaining more and more ground. Mankiewicz is already present in the USA and we will certainly expand the market presence of the Mankiewicz group. How big is your automotive team? Apart from the production department,

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approximately 200 employees work in the automotive sales, laboratory and applications engineering departments – the automotive department is one of the company´s biggest sectors. What do you think are the future paint trends in the automotive market? At the moment mat paints with smooth or textured surfaces and appealing haptics are in vogue. This is contrasted by the trend to use metallic colour shades and metallic paints in the car interior – as a special visual feature. Paint is increasingly used as a replacement for galvanized surfaces. Playing with colours and textures sometimes leads to unusual designs. For example, we now paint parts in bright colours which traditionally used to be dark. Naturally, these surfaces are much more prone to contamination, which makes the development of easy-toclean surfaces very interesting. They look like regular paint surfaces, but are less prone to soiling and much easier to clean. In future the issue of “black panel systems” will gain in importance, too: the touch screens in the cars will have to blend in harmoniously with the surroundings. Therefore, the surfaces around the display will also be designed as a black panel. Doubtless, autonomous driving is a general future trend of the automotive industry. In spite or, perhaps, because of that the car interior design will remain very important.

Opening photo: Geico’s focus on research and innovation has enabled to reduce the energy consumption of a car coating plant from 900 kWh/job to 270 kWh/job 3 years ahead of the initial forecast.

INNOVATIONS: PRESENT&FUTURE

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Smart Paintshop - The Paintshop of the Future Alessia Venturi ipcm®

mart Paintshop is the project that will revolutionise the car coating concept (ref. opening photo). Presented by Geico in a world premiere at the last Surcar Congress in Cannes, on June 30, it is a new type of system that will bring the car coating process in the Industry 4.0 era. The most significant features of Smart Paintshop include body geolocalisation, safety sensors to prevent malfunctions,

applied Internet of Things that analyses and improves the paintshop in real time, wearable technology for perfect manmachine interaction, augmented reality, an innovative system for managing energy consumption, and flexibility – all managed in cloud with J-Suite, the “avatar” of the whole plant. This is a total revolution: it impacts efficiency, safety, quality, save costing, and ecofriendliness. Moreover, its concept can be applied to any greenfield or brownfield project.

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With the optimisation of man-machine interaction and of production procedures achieved through Smart Paintshop, Geico will also be able to provide a new paintshop in record time, ten to fifteen months for very complex systems. Such goal was really unthinkable only a short while ago.

Smart Paintshop Geico’s new concept is an integrated solution system including six strategic aspects: 1. Smart Design – All Geico’s lean and

adaptable in-house processes developed with the aim of significantly reducing the delivery times of coating plants. 2. Internet Of Things (IOT) System – All systems required by the plant to analyse, learn, communicate with the operators and assimilate from them how to be more efficient. 3. Production Flexibility – The technologies enabling the system to adapt to the ever changing production needs (mass customisation). 4. Smart Plant Management – The tools enabling the man-machine collaboration, constantly monitoring the plant’s operation and warning of possible anomalies that could compromise it in the future. 5. Smart Energy Management System – The technologies that control energy consumption, as well as enabling the system to adapt such consumption to its production capacity. 6. J-Suite – It is the operating brain of the plant, its virtual version (avatar), able to manage all its functions at best. It collects and analyses information from sensors and wearable devices and, by processing this huge amount of data, it “learns” the best modes of behaviour in different situations, thus improving the system’s performance and efficiency over time.

Smart Design

1 Figure 1: The body geolocalisation system.

analysis. The integration of the different design tools enables to pursue strategic objectives, such as: • Overall paintshop delivery (between 12 and 15 months); • Cost reduction; • Simplification of the final result analysis; • Generation and aggregation of information and data about the plant; • Possibility of having a faster feedback from Geico during the proposal period.

IOT System

The Internet Of Things is a possible evolution of the use of the Web: “things” acquire intelligence and identity thanks to their ability to communicate data about themselves and access aggregated information from others.

Within the Smart Paintshop concept, this translates in the possibility to geolocalise car bodies inside the plant (Fig. 1), use smart skids able to predict malfunctions, implement an innovative automatic quality control system with man-machine interaction thanks to augmented reality. With the in-plant body geolocalisation system in the GPS Indoor mode, an OEM will be able to: • Locate each body inside the plant; • Analyse the process flow; • Integrate more flexible and efficient solutions in terms of plant layout and operations; • Integrate innovative features. One of the main advantages of the body geolocalisation system is that no cables are

It involves different aspects of the engineering process, from design and simulation to cost

INNOVATIONS: PRESENT&FUTURE

2 Figure 2: The automatic defect control system.

3 Figure 3: ELENE system’s operation diagram.

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4 Figure 4: The J-HIVE spray paint booth.

autonomously correct the flaw or predict malfunctioning (using data analysis). Last but not least, the implementation of the IOT System in a paintshop reduces maintenance time as it allows for predictive maintenance.

requirements. By using this approach, energy, costs and emissions are greatly reduced. In the future, information will be communicated by the sensors on the car body, thus enabling the elaboration of different production scenarios. 2. J-Hive: it is an eight-sided cell designed for painting both the interior and exterior of a body in one station (Fig. 4). The J-Hive booth has a compact footprint, a tailor-made layout (octagonal frame), high efficiency (as the seventh axis allows for the elimination of the painting area of the trolley), and it reduces investment and operating costs. 3. Smart Conveyor: an Automatic Guided Vehicle (AGV) for handling car bodies and skids inside the plant (Fig. 5). The advantages of this system are a smart and flexible transportation of car bodies and materials, an efficient and flexible production, the reduction of investment and management costs, a simpler and faster installation and commissioning, and easy implementation for brownfield projects.

required. This reduces the installation time for the areas where the geolocalisation equipment is implemented. In addition, the model information is uploaded directly on the car body and not on the equipment for a more precise and reliable information. The Smart Process Module 5 allows for ready-touse process modules Figure 5: Simulated use of Smart Conveyor. equipped with sensors able to monitor and Production Flexibility Smart Plant Management predict the equipment operation thus Production flexibility in the Smart Managing a plant in a smart way means to avoiding future breakdowns. Again, by Paintshop will be achieved using three new take advantage of man-machine and machineusing Smart Process Module the installation technologies: machine interaction to constantly monitor time required will be shorter while virtual 1. ELENE (ELastic commissioning of the plant will be possible ENergy Ecology – thanks to the Plug and Play mode. Fig. 3): the booth’s On the quality control side, an Advanced ventilation and Analysis Detection System using specific its operation are scanning tools will allow for human adjusted according eye-like identification of topography to the active length flaws (Fig. 2), real time analysis, and the actually required possibility to find defects between 0.2 and 0.3 mm. The system can work with for the production two cameras, a scanning area of 500 mm in progress, with a resolution of 0.1 mm/pixel and a while the oven’s high frequency scanning pattern with 30 ventilation and its 6 frames per second. The future evolution length are adjusted of this Advanced Analysis system will based on the Figure 6: An example of a wearable device working with augmented be its upstream integration in order to current production reality.

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INNOVATIONS: PRESENT&FUTURE

the processes while optimising them. The Smart Plant Management concept includes as follows: Smart Supply Management (a tag system for unloading and uploading warehouse/stock data); J-Doc (content management software for technical data about plants, machines, and components + other integrations implemented on PLC systems – Fig. 6); and wearable systems using augmented reality for enhanced man-machine cooperation and safety. The Smart Plant Management allows for real time information for the operators’ training and the client’s plant management, as well as real time manmachine communication in order for easier manual operations and maintenance interventions. In the near future, the interface will be able to collect documentation, start-up process data, and information about engineering

and operative aspects of the plant, which are now available on different devices. The J-Suite will become a hub for the management of integrated tools such as J-Doc.

Smart Energy Management System The energy management system will collect data on energy consumption and use them to adjust the plant and pursue cost efficiency. Two different technologies fall within the Smart Energy Management System: J-Power, a software programme for the simulation of scenarios on energy requirements and alternative resource availabilities on specific locations; and VOC Intelligent Sensing Oven, a sensor system for the control of the solvent level in the oven: it supplies fresh air to the oven only when it is necessary with a reduction of energy consumption due to the lower amount of fresh air to be treated. The Smart Energy Management System

enables the real time displaying of the energy consumptions and costs, the identification of any significant difference between the actual and the theoretical consumptions, and the elaboration of consumption statistics on the different plant lines. In the future, the J-Power software and the VOC Sensing Oven will be integrated into the Smart Process Module in the wireless mode for a constant feedback to the customer, aimed at facilitating any plants updates or investments.

J-Suite J-Suite is the “avatar”, the “brain” of all the plant. It is a Manufacturing Operations Management (MOM) software which gives the possibility of not only fully integrating with the clients’ system but also of digitalizing manufacturing operations in order to improve efficiency, flexibility and time-to-market.

Dynamic contour detection - sophisticated coating solution - High level automation of the application process - Automated recognition of complex geometries for both the front and rear of the object - Optimized coating quality - Powder savings and reduction in overspray - Drastic reduction of the manual coating operation - Automated programming of U-axes. No time consuming axes adjustments

www.gemapowdercoating.com

Opening photo: A detail of the new coating line devoted to diamond cut wheels.

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Ronal Querétaro: Smart Technologies for the Coating of Diamond-Cut Alloy Wheels Alessia Venturi ipcm®

onal, Speedline Corse, and Speedline Truck are the wheel brands the Ronal group, headquartered in Härkingen, Switzerland, manufactures and sells all over the world. The company is among the world leaders for OEM products and accessories for cars and commercial vehicles and it is the only integrated supplier of alloy and forged wheels. The company produces over 20 million wheels a year in 11 plants located in 3 continents. Thanks to its presence in Eastern Europe, NAFTA

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countries and Asia, the Ronal group is one of the few true global players. It is one of the main suppliers of technologically advanced wheels, thanks to its vertical integration strategy in all production steps – manufacturing, in-house production of tools, and construction of the end products. Established 17 years ago in Mexico, in the last few years Ronal Querétaro Sa. de Cv. has been steadily growing as for both volumes and production facilities. Its current capacity amounts to

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2.1 million wheels a year, 50% of which are diamond cut wheels (Ref. opening photo). “We can supply wheels ranging from 15 to 22 inch size. The premium range accounts for 50% of our market, the remaining 50% belonging to volume market,” explains Carlos Sánchez, the Head of Production and Deputy General Manager of Ronal Querétaro (Fig. 1). “Our clients include the three large European OEMs (Volkswagen, BMW and Daimler) and the three large US OEMs (Ford, FCA and General Motors), and we have also started to work with the Asian market: we are now providing some of our products to Toyota and Nissan and have started collaboration with Kia. We export 70% of our production, of which 80% to the USA and 20% to Brazil. We also export a small share of our products to Europe, mainly to service parks, and the remaining 30% goes to local car assemblers.”

One of Ronal Querétaro’s important investments, made last year, was the new coating line that is used for the application of the clearcoat.”

last coating step after machining: it is an advanced line in the wheel sector due to both its compact size and its very high automation degree (Fig. 2)”. The line installed at Ronal Querétaro is the result of collaboration between the Italian firms Olpidürr and Verind, both belonging to the German group Dürr, which supplied the coating line and the water treatment line, respectively.

The line layout

Along with the market demands of automotive OEMs, alloy wheel suppliers have to face increasing requests for improved processes, higher productivity, and quality and cost optimisation. The new coating lines fitted with specific equipment and devices are the best solution to reach high automation degrees. The robots used for handling wheels on the line and the numerous separate loops “Our plant currently employs of conveyors synchronised 700 people. We work on 4 over the entire process are shifts in the foundry shop 1 the precondition to meet to cover 24/7 production, the highest production while the machining and Figure 1: Carlos Sanchez. demands. paint shops work 6 days In the planning phase, Dürr out of 7, as Sundays are focuses on providing easy access to every “One of our most important investments, dedicated to preventive maintenance section of the coating line and the ability to made last year, was the new coating line and technical clean-up operations,” adds monitor each application stage. Whenever that is used for the application of the Carlos Sánchez. “Our company has been possible, a single floor solution is adopted clearcoat,” explains Sánchez. “This line steadily growing and in the last few years with all process equipment at ground provides for the treatment of all diamondwe have strongly invested to improve level. In case of limited space available for cut products that need to undergo the and update our production facilities. the installation of the new The largest investments are coating line, Dürr is able being made in the machining to supply space-saving department, which is our The line installed at Ronal Querétaro is the layouts and goes beyond bottleneck. As an example, the standard solutions to in the current year we will result of collaboration between the Italian firms develop highly tailored be increasing by 10% our Olpidürr and Verind, both belonging to the German systems upon demand. production capacity in the group Dürr, which supplied the coating line and the Olpidürr has designed the diamond-cutting department.” water treatment line, respectively.” international PAINT&COATING magazine - JULY/AUGUST 2017 - N. 46

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Figure 2: The new line is at the forefront for compactness and automation.

In order to prevent overspray, the conveyor system is split into separated loops. Several 6-axis robots fitted with 2 or 3 light weight grippers developed by Dürr to increase the operational payload and reduce inertia provide for the transfer between every synchronised conveyor upstream and downstream (Figs. 5, 6 and 7). The line has three spray paint booths. One is for the application of the powder basecoat or transparent layer (Fig. 8); the other two are water veil painting booths equipped with an air recycling system and devoted to the application of © ipcm ®

line installed at Ronal Querétaro to operate with any coating system used by the client, starting with the conventional three-layer one, modifying the path followed by the wheels through the coating plant and managing to occupy a very limited space, since there were no other available areas in the factory. That is why a three-floor layout has been conceived: the pre-treatment and coating application stations are on the ground floor; the drying and polimerisation ovens on the first one (Fig. 3); and the heat generators on the second one. The overhead conveyor and the robotic handling stations enable to transfer the wheels from one level to another (Fig. 4).

Figure 3: The plant features a three-level layout, with the drying and polimerisation ovens on the ﬁrst ﬂoor.

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KSL, a liquid product that offers additional corrosion protection and is exclusively used for one client, and of the clearcoat (Fig. 9). Since solvent-based coatings are used, the exhaust air from the booths and the ovens is sent to a regenerative thermal oxidiser supplied by Olpidürr. This features specific technical solutions to avoid condensation of the high boiling solvents used in the coatings intended for the wheel industry. “The automation degree of the line is very high and the production control system is very advanced,” says Carlos Sánchez, “Only 8 people are needed for the line control: one or two operators for loading and unloading operations, one responsible for each of the three paint booths, a supervisor and an assistant. The whole production flow is managed by a software programme developed

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by Dürr: production data, temperatures, time and operational parameters of all the process steps are constantly displayed. When loading the wheels on the line, the workpiece code and the lot size can be entered in the control panel, and the entire plant will run based on a pre-set sequence (Fig. 10).” In case of necessity, Ronal can even ask Olpidürr’s engineers for remote assistance thanks to the hardware devices installed and to the software programme developed by Olpidürr’s automation and supervision specialist team, which also directly deals with the programming of the handling robots.

5 Figure 5: The robot for the automatic handling of the wheels from one level to another.

The general production process at the factory “Aluminium ingots are melt through low pressure injection with permanent moulds, after which all the products undergo X-ray

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Figure 6: Another phase of the automatic placement of the wheels.

inspection: all the wheels not complying with the client specifications are separated,” adds Luis Maldonado, the Head of Infrastructure of the Querétaro and San Luis de Potosí plants (Fig. 11). “Approved wheels undergo a boring process to remove injection cones. We use two different alloys, silicon 7 and silicon 11. Depending on the alloy type used, the wheels are subjected to thermal treatment or are directly machined. The machining shop is equipped with a

4-axis lathe, a 2-axis lathe and a milling machine. After machining, the wheels are hung onto a conveyor system that transports them to a cleaning station to remove any residue of coolant, having to undergo a helium leak test (air with 10% of helium). Afterwards the wheels are manually prepared for subsequent coating, through a grinding process that removes burrs and surface defects. This production step is being currently

Olpidürr has designed the line installed at Ronal Querétaro to operate with any coating system used by the client, starting with the conventional three-layer one, modifying the path followed by the wheels through the coating plant and managing to occupy a very limited space.”

Figure 7: The robot picks the wheels up from the vertical pre-treatment ring and places them on the ground conveyor reaching the paintshop.

Figure 8: The powder application booth.

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9 Figure 9: The clearcoat is applied in a water veil painting booth.

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the basecoat and the clearcoat (which can be opaque, semi opaque or glossy) with wet-onwet technology. After the polimerisation stage, all wheels undergo quality inspection. At this point they are ready for packaging; the wheels that need diamond cutting are fed to the wheel machining area. Diamond-cut wheels are then sent to the new fully automated coating line by Dürr (Fig. 12). © ipcm ®

optimised to make it fully automated. which account for 50% of production, and “At this point all alloy wheels are sent to the other applying 7 different colours. After the coating process on a pre-existing line,” curing, the wheels that need finishing are fed states Maldonado, “where they undergo to a finishing booth and then are sent to the in-depth cleaning through a 10-stage preliquid coating application system that applies treatment cycle that includes two alkaline degreasing processes, two rinsing steps with mains water, two acid etching processes, two rinsing steps with mains water, SAM (Self Assembled Monolayer) phosphating, and then two rinses with demineralised water. All process chemicals are supplied by Chemetall. Drying and the application of an acrylic powder primer are then carried out. The line is equipped with two automated 10 self-cleaning powder spray booths, one dedicated to grey primers, Figure 10: The control panel located in the loading area.

The coating process for diamond wheels “The clear coating line for diamond wheels designed by Olpidürr requires the same pre-treatment carried out for the first wheel coating stage (Fig. 13),” explains Juan Meza, the Senior Paintshop

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Figure 11: From right to left, Luis Maldonado, Juan Meza and Alessia Venturi from ipcm®.

Manager of Ronal Querétaro. “The wheels have to undergo another full pre-treatment as during diamondcutting we use cutting solutions that contain mineral, organic or synthetic oils. Moreover, the wheels are contaminated with lubricant oils from machinery and a second cleaning operation is therefore essential to guarantee quality and ensure top corrosion resistance. The pretreatment tunnel is self-checking: all the operational parameters, from pH concentrations to water conductivity, are constantly automatically monitored (Fig. 14).” “After drying, the wheels can be subjected to two different cycles

according on the client’s demands: application of a powder primer (Figs 15 and 16) and a liquid clearcoat, or application of KSL (a liquid corrosion protection product), a powder primer and a liquid clearcoat (Fig. 17),” says Meza. “The cycle ends with the final

Since March 2016 the new coating line has had a positive and fast production ramp up: during its first month it operated with a waste rate of 25%, now reduced to 5%.”

Figure 12: The loading area.

13 Figure 13: Wheels exiting the pre-treatment tunnel and reaching the drying oven on the upper ﬂoor.

inspection of 100% of the coated wheels, and compliant wheels are sent to the warehouse. The Olpidürr line is technically solid, efficient, accurate and “clean”. Since March 2016 we have had a positive and fast production ramp up: during the first month of operation, the coating line operated with a waste rate of 25%, now reduced to 5%, which 95% is caused not by the coating but from previous processes (Fig. 18). “Olpidürr has implemented one of the most advanced technologies on this line: each wheel model has its own coating sequence. Control panels fully display the different stages and the system constantly monitors the

Olpidürr has implemented one of the most advanced technologies on this line: each wheel model has its own coating sequence. Control panels fully display the different stages and the system constantly monitors the coating process.”

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coating process. A warning system enables us to track any “off-standard” event occurred, for example a malfunctioning burner, and to effectively trace the source of malfunctioning. Product traceability is guaranteed thanks to the use of bar codes that enable us to view the production records of the last three months, and all previous data is automatically filed in the system. This means we are able to track any production lot and know when it was coated, the sequence used, the volume of coated wheels, and the coating parameters applied. Moreover, the management system communicates the production output for every shift.”

The line is fitted with a plant for the treatment of primary and waste water commissioned by Olpidürr to Verind, a company of the Dürr group.”

Figure 15: The powder basecoat application.

Primary water and waste water treatment

Figure 14: The large-sized pre-treatment tunnel.

The line is fitted with a plant for the treatment of primary and waste water commissioned by Olpidürr to Verind (Rodano, Milan, Italy), a company of the Dürr group. The system includes a reverse osmosis system, a demineralisation plant and a chemical-physical system (Fig. 19). Reverse osmosis Starting from industrial water, this plant supplies demineralised water with less than 10 mS conductivity, which is used in the various production processes. The system, with a production capacity of up to 3 m3/h, is fitted with 4” reverse osmosis membranes; the devices are located on a self-supporting skid, automatically running 24 hours/day.

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16 Figure 16: The powder coating management unit.

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17 Figure 17: The clearcoat application.

Ionic exchange resin plant WWT (Waste Water Treatment) This plant treats the water used for cleaning the All the eluates from the wheel coating wheels after phosphating. The system uses ionic line, exhausted baths, eluates from resin exchange resins, and water regeneration and is continuously purified reverse osmosis and then recirculated to the For the treatment of the concentrates are production lines. The system properly stored in spray booth’s wastewater at installed is duplex: when the special tanks, and from Ronal Querétaro, Olpidürr running cycle of resins from here they are sent to –as prime contractor of the the first section is exhausted, the chemical-physical project – provided for two their regeneration is carried waste water treatment Skimmerflot 8000 flotation out automatically and the plant. sludge removers, supplied second section is activated. The plant treatment and installed by Water In order to prevent bacteria capacity is 4 m3/h, with Energy.” a totally automated formation inside the process. The treatment cleaning tanks, waste water line includes: undergoes a disinfection/debacterisation process after treatment. The acid and alkaline eluates - a reaction, neutralisation and flocculation section with the dosing of chemical resulting from resin regeneration are sent to the additives for precipitation of all existing WWT plant. pollutants; This system can treat a volume of up to 4 m3/h. Its columns have a diameter of 600 mm and a - a sedimentation section with a lamellar capacity of 300 l of resins each. An activated decanter; carbon filter is installed as a protection of the - a filtering section with sand for discharge; resins entering the treatment process. - a sludge thickening and dehydration section.

guarantee the best solutions for our customers around the globe.

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Figure 18: “The Olpidürr line is technically solid, efﬁcient, accurate and “clean”,” says Juan Meza di Ronal.

The treatment of the spray booths’ waste water

Figure 19: The primary and waste water treatment plant was supplied by Verind (Rodano, Milan, Italy).

- removal of paint overspray from water; - significant reduction in the booth For the treatment of the spray booth’s maintenance, pump cleaning, and water wastewater at Ronal Querétaro, veil and abatement system costs, as the Olpidürr –as prime contractor of the water veils, the booster pumps, the booths’ project – provided for two Skimmerflot rear and all the parts in contact with sludge 8000 flotation sludge removers, remain clean; supplied and installed by Water Energy - sludge already stored in big bags (80% (San Pietro in Casale, Bologna, Italy, sludge recovery effectiveness) and made Fig. 20). Each plant has a ready for disposal, with treatment capacity of up sludge humidity of less to 8,000 l/hour, is made than 40%; in AISI304 stainless steel - cleaner booths with and is able to reduce water replacement sludge concentration only once a year; in wastewater by - sludge denaturation recirculating the liquid (reduced tackiness of with specific denaturants. paint to prevent it from The flotation plant sticking to the plant); operates through the - sludge flocculation molecular separation of and flotation water and the specific (denatured sludge sludge to be treated, that floats on water; enabling the latter to aggregation of surface and be removed denatured paint in by means of a sludge and the form of flakes that supernatant pumping/ float on water to allow 20 catchment system. Air is for sludge separation injected at the entrance and removal without Figure 20: For the treatment of the spray booth’s waste water, Olpidürr provided for two of the Skimmerflot plants any sedimentation in Skimmerﬂot 8000 ﬂotation sludge removers, supplied and installed by Water Energy to enhance pollutant the booths’ tank). (San Pietro in Casale, Bologna, Italy). © ipcm ®

separation and sludge floating, and prevent sludge from accumulating in the booth sections where water flow is weak. Further micronisation of dissolved air also takes place on the plants’ bottom. Water Energy also supplies all tailored and tested chemicals that are necessary for effective plant running. It is thus possible to achieve:

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Opening photo: A complete front bumper with the components produced and painted by KFTS.

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An Italian Technology to Coat Bumper Components for the Hyundai Group Francesco Stucchi ipcm®

he largest Korean investments in Europe are currently made in the Eastern Countries. That is the case of KFTS, the Slovak branch of Korea Fuel-Tech Corporation, a manufacturer of components for the automotive industry and in particular for fuel distribution systems based in South Korea. The parent company was founded in 1996; currently, the group has offices in

China, India, Poland and Slovakia. As it expanded towards Eastern Europe, it progressively specialised in the production of plastic components and bumper accessories. KFTP and KFTS, the Polish and Slovak branches respectively, now specialise precisely in the injection moulding and coating of plastic components for the automotive sector and they are among the main suppliers of the

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Hyundai group. KFTP was established first, in 2007; it currently has two factories in Zabrze and Zory. KFTS, the most recent branch, was established in 2014 in Rajec, under the guidance of Seiduk Kim and Joon Hee Kim. KFTS is a young, expanding business specialising in the production of plastic components for the bumpers of KIA cars (ref. Opening photo), a brand of the Hyundai group.

Coating plastics: the importance of plant design

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sector. Moreover, we had to rely on a company capable of designing a plant in full compliance with the Slovak Nowadays, plastic is one environmental and safety of the materials most regulations, which in many used for the production of ways are more complex and automotive components. strict than the European Most of these items require standards.” coating, but the chemical The coating line (Fig. 2) and physical characteristics for KFTS’ plastic of plastic itself tend to make components was this a complicated process. designed and installed In order to ensure perfect by QPD Quality Painting finishes on plastic parts, a Development, a Polish firm needs skilled operators, 1 company headquartered properly prepared surfaces, in Chorzów but with Italian and precise and carefully Figure 1: From left to right: Jana Schvarcová, Marián C˘ern˘ansky´, Seiduk Kim, Lorenzo know-how. “KFTS’ coating adjusted equipment, del Passo, and Alessia Venturi. process includes the especially in the coating application of three paint application and film drying layers in three consecutive booths,” stages, during which it is crucial to says Joanna Wlosek, QPD owner prevent the material from attracting together with Georgios Bousios. “Only KFTP and KFTS now specialise dust or other contaminants. That is one robot was installed in the primer where plant design comes into play. precisely in the injection moulding and and clearcoat application booths. “Our competitive advantage is the will coating of plastic components for the This was a cost-effective solution to constantly improve our processes automotive sector and they are among the to meet the customer’s capacity and find innovative solutions to main suppliers of the Hyundai group.” requirements while respecting the the technical challenges posed by budget set for this our customers,” investment. However, states KFTS general the system was manager Seiduk Kim conceived to enable (Fig 1). “Whereas a capacity increases many entrepreneurs at a later time with that have invested the installation of in Eastern European additional robots in countries have the basecoat and preferred to import clearcoat booths. Korean technologies The spray paint in their production booths have an facilities, KFTS chose air recirculation to rely on an Italian system to optimise technology. This was the costs related especially true for to air preparation coating, which is a and, in particular, critical production to maintaining the phase because it must temperature and meet the stringent 2 humidity levels.” quality requirements “The line operation is of the automotive Figure 2: A bird’s eye view of the coating system.

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SPECIAL AUTOMOTIV E

Figure 3: The loading and unloading areas are adjacent.

fully automatic. Only the material loading and unloading are performed by operators (Fig. 3), whereas the control and adjustment of the process parameters, as well as the coating application, are automatic,” adds Bousios. “Such line automation ensures constant temperature and humidity in the booths and the flash-off stations.”

Plant layout KFTS mainly produces components in polypropylene and, in a much smaller percentage, in ABS. The injection moulding (Fig. 4) and coating areas are located in two adjacent buildings: the workpieces are taken from the moulding stations to the coating line through carts. Here, after manual loading, the frames reach the pre-treatment station, where the operators thoroughly clean all surfaces with a manual process using isopropyl alcohol and ionising guns (Fig. 5). The pre-treatment area has been designed for the implementation at a later time of a CO2 cleaning robot. This is followed by a flaming station and by the three automatic booths for the

Figure 4: Just a few of the many moulding presses.

In order to ensure perfect finishes on plastic parts, a firm needs skilled operators, properly prepared surfaces, and precise and carefully adjusted equipment, especially in the coating application and film drying stages, during which it is crucial to prevent the material from attracting dust or other contaminants. That is where plant design comes into play.”

application of the primer, the enamel and the clearcoat (Figs. 6, 7 and 8) through ABB robots and DeVilbiss pneumatic guns (Fig. 9). “The plant is equipped with four filtration units: the inlet air is heated and then sent to all areas of the line,” explains Marián C˘ern˘ansky´, the Paint Line Deputy Manager of KFTS. “Each spray paint booth

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has an air recirculation system with filters and exchangers that cleanse air from dirt and overspray and recirculate it to the booth itself. Only 5% of the air used comes from our regenerative thermal oxidiser (RTO, Fig. 10).” “The primer application booth is equipped with a fool proof security system that uses a camera installed in the passage area from one booth to another to check if the primer has been applied correctly based on the workpieces’ colour,” adds C˘ern˘ansky´. “After flash-off, the parts go through the bell curing oven ensuring air recirculation and optimum heat distribution (Fig. 11).” The system is also fitted with a separate coating management unit (Fig. 12), although some paint preparation stations have been located before each booth for the most used colours. The line has a takt time of 90 seconds and it is highly automated: only 10 people are needed to operate it. Installed in September 2016, it currently works on one shift producing about 2,500-3,000 components per day, with an expected increase in 2018.

FOCUS ON TECHNOLOGY

One of the safest coating lines in Slovakia

“The Slovak safety regulations are stricter than the European ones,” says Georgios Bousios from QPD. “Initially, we had designed this line in compliance with the European standards; however, we had to redesign some parts in order to meet the Slovak requirements.” “We use a two-component solvent-based coating system supplied by the German company Peter Lacke,” adds Marián C˘ern˘ansky´. “In order to ensure compliance with the strict Slovak safety regulations, QPD added a further two-stage firefighting system in addition to the conventional fire prevention equipment: when a booth’s temperature reaches the maximum safety threshold, two automatic shutters isolate it. If needed, an automatic fire extinguisher system with carbon dioxide is activated.”

5 Figure 5: The ionisation station.

SPECIAL AUTOMOTIV E

Figure 6: The primer application booth.

Figure 7: The enamel application booth.

A treatment plant for the booths’ waste water

waste water, specifically a flotation sludge remover, was a strategic choice. For this part of the plant, QPD relied on the technology of Water Energy (San Pietro in Casale, Bologna, Italy), opting for a Skimmerflot 15000 system able to treat up to 15,000 l/h (Fig. 13). “KFTS’ three spray paint booths produce an overspray of about 30 kg of paint per day. Skimmerflot performs a chemicalmechanical process,” explains Lorenzo

KFTS’ coating system was also equipped with an advanced treatment system for the waste water from the booths’ overspray capture veils. The three spray paint booths have a significant flow rate, about 10 m3/min. In order to ensure constant circulation of clean water and avoid wasting resources, the installation of a treatment plant for the booths’

Dal Passo, manager at Water Energy Central Europe, Water Energy’s Polish branch. “The coating is subjected to flotation and then separated from water in the sludge remover. Technically, through flotation the denatured paint is aggregated in flakes floating on the water level, thus enabling the sludge to be removed without any sedimentation in the booth’s tank. Once the water has been drawn from the collection hole, we

Figure 8: The clearcoat application booth.

Figure 9: A detail of the paint application with a DeVilbiss pneumatic gun.

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FOCUS ON TECHNOLOGY

10 Figure 10: The regenerative thermal oxidiser (RTO) installed by Broﬁnd.

The Slovak safety regulations are stricter than the European ones. Initially, QPD had designed this line in compliance with the European standards; however, it had to redesign some parts in order to meet the Slovak requirements.”

11 Figure 11: The inside of the bell curing oven.

SPECIAL AUTOMOTIV E

Figure 12: The coating management unit.

Figure 13: Water Energy’s Skimmerﬂot sludge remover with a ﬂow rate of 15,000 litres/hour.

inject a flocculant able to aggregate the coating particles in a pre-set contact time and make The three spray paint booths them float on water. In the recirculation circuit, have a significant flow rate, we dose a coagulant able to separate the paint about 10 m3/min. In order to from water. The latter returns to the booths’ ensure constant circulation of overspray capture veils, while the mechanically clean water and avoid wasting separated coating is collected in big bags to be resources, the installation of a disposed of.” treatment plant for the booths’ “For the purposes of the sludge removal waste water, specifically a process, the control of the pH value is crucial, flotation sludge remover, was a since it must be kept constantly neutral to strategic choice: QPD relied on ensure good flocculation efficiency,” adds the technology of Water Energy Dal Passo. “The machine is fully automatic. (Italy), opting for a Skimmerflot Level sensors control the recirculation and 15000 system able to treat up to mixing of the chemicals based on the process 15,000 l/h.” parameters, and the operator intervenes only in the event of a problem. Finally, we installed a softener in the booths’ water cooling system to prevent any limestone formations in the circuit.” “Thanks to this flotation waste water treatment system, we have reduced the costs for the booths’ maintenance and the cleaning of pumps, water veils and abatement systems,” explains Marián C˘ern˘ansky´. “Sludge no longer soils the water veils, the pumps, the back 14 of the booths and all the parts in contact with it. The sludge residues Figure 14: The sludge, with a humidity of less than 40%, is are also directly put into big bags transferred directly to big bags to be disposed of.

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and ready for disposal, with a humidity of less than 40% (Fig. 14). In general, the Skimmerflot system ensures an 80% sludge recovery efficiency; we expect to have to replace the booths’ water only once a year.”

Conclusions “We are very pleased with the coating line installed by QPD,” states Seiduk Kim. “I already knew its owner, Georgios Bousios, and I was very confident about his engineering skills. Like all new lines, it required some time for the set up, but now, six months after the beginning of operations and with the staff technology training made by QPD, we are pleased with the coating quality and the production capacity achieved. Within two years, we plan to produce on three shifts with this line. In order to do this, we will add a second robot in all our application booths, which are already fit for such integration. However, we will be able to achieve a significant productivity increase only by investing in a second finishing line. We have already allocated enough space to accommodate it in our Rajec plant.” © ipcm ®

Opening photo: OZ has manufactured alloy wheels for racing cars and motorcycles since 1971.

FOCUS ON TECHNOLOGY

SPECI AL AUTOMOTIVE

Coating Waste Water Treatment: a Value Added to the Well-Known Quality of OZ Racing Alloy Wheels Monica Fumagalli ipcm®

Z Racing is a well-established Italian brand, known and appreciated by all car and motorcycle lovers. The company, which is headquartered in San Martino di Lupari, near Padua, is in fact one of the world top suppliers of alloy wheels for racing cars and motorcycles as well as the related aftermarket (ref. Opening photo).

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It is also the proof that craftsmanship and attention to details, two factors behind a successful product, can be integrated in advanced and innovative industrial systems. “The more functional the systems and devices installed in our plant,” says Armando Gabbiadini, the coating department head at OZ Spa, “the higher the

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possibility to ensure high quality for our wheels and the clients’ satisfaction, once the vehicle has been equipped with our products. The more the equipment installed meets the company requirements for a safe working environment, respecting the health of operators and the environment, the more we are stimulated to carry out our tasks in

FOCUS ON TECHNOLOGY

OZ Sp a

such that in a short time the small firm became the best possible way to keep up the OZ brand well known for its high quality products; in 1978, name (Fig. 1).” it became a joint stock company and opened Craftsmanship and quality, which have always its current plant (Fig. 2). In 1984, the OZ Racing characterised the production activity of OZ, division was created for the production of racing as well as reduced environmental impact, wheels, especially for the Formula 1 cars: the first are the requisites that drive this company’s vehicle to be fitted with these wheels was continuous search for improvement and are the Alfa Romeo Euroracing F1, which among the main reasons behind the was equipped with magnesium implementation of always new and aluminium alloy wheels systems. “In particular, the designed by Eng. Claudio finishing treatments carried Bernoni, the current out in our industry are CEO and President undoubtedly among of OZ S.p.A. Since those with the then, the company’s highest impact on the history has been environment,” adds invariably linked Gabbiadini. “Last year, to the great names our company decided of the car and to invest in a plant for motorcycle racing treating the waste water world.” from our powder and Today the OZ plant liquid coating application covers a total surface area of booths, the goal being to reduce 100,000 m2 (of which energy consumption 75,000 roofed) and and improve the Figure 1: An OZ wheel is synonymous with quality. has more than 180 management of the employees; it offers whole department in a range of 35 alloy wheel models, which mainly terms of maintenance.” Chemtec, a company differ as for the type and vehicle range for which based in Corbetta, near Milan, was chosen by OZ they are intended, with a total production volume to design and install a waste water purification of about 100,000 wheels a year. plant to meet these precise requirements. “The racing sector, our core business, accounts for The OZ legend a small percentage of our turnover, the remaining “Our company was set up in 1971 by Silvano part being accounted for by the aftermarket,” says Oselladore and Pietro Zen: the initial letters of Bordignon. “Most of our products are destined to their surnames were taken to create the acronym the foreign market, mainly Germany and Japan, that identifies the OZ home to our two company,” explains largest commercial Martina Bordignon, The more functional the systems branches, then Communication the USA and and devices installed in the OZ plant, Manager at the Scandinavian the higher the possibility to ensure Veneto company. countries. In line high quality for wheels and the clients’ “Both fond of cars and with our corporate satisfaction, once the vehicle has been competitions, at the policy, due to the equipped with these products.” time they took part in strong desire of a local rally with a Mini Cooper model fitted with our President, the OZ Racing wheels are entirely alloy wheels made by them. The market then produced in Italy, helping make the “Made in Italy” did not offer what they required: a lighter wheel brand universally known in the automotive and than those used at the time. Their success was motorcycle world.”

SPECIAL AUTOMOTIV E

2 Figure 2: The headquarters of San Martino di Lupari (Padua), where the OZ Racing wheels are produced.

Racing alloy wheels: a matter of style OZ operates on the spare parts market for cars and motorcycles with 4 brands: OZ Racing, a light and performing wheel inspired by the racing world technology; X Line, a range fit for any vehicle type; MSW, the first brand marketed by OZ in the 1980s; and Sparco Wheels, a range of wheels born from the collaboration between OZ and Sparco, an Italian company that produces and markets components and technical wear for automotive competitions. “Attention to innovation in terms of both design and production technology is very important for us,” states Bordignon, “because it enables us offer always new and original solutions to our clients. From the lightest wheels to those with the

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OZ decided to invest in a plant for treating the waste water from the powder and liquid coating application booths, the goal being to reduce energy consumption and improve the management of the whole department in terms of maintenance.”

brightest colours, creativity in this sector is essential to get the best results in terms of technical performance and aesthetics. Our product underwent a major evolution as for the materials used as well: the alloy types used for the OZ wheels are the result of our long experience in the racing world.

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The same technologies and know-how are also implemented in the production of wheels for the aftermarket, for which one of the lightest aluminium alloys is used, with a specific weight of 2.7 g/ cm3. Magnesium alloys are instead used for the some racing wheels, depending on the championship of belonging, this being the lightest material among structural metals: it has a specific weight of 1.74 g/cm3, 35% less than aluminium. Magnesium alloys are therefore characterised by top lightness, resistance to impact and vibrations and they are not subject to stretching.” OZ carries out strict control tests on its products: all its wheels are certified and approved by TÜV and by several Italian and international certification bodies. “Our company carries out a further test,”

FOCUS ON TECHNOLOGY

SINCE 1958

Automatic washing cell Cella di lavaggio automatica

3 Figure 3: The application of the liquid coating with a robot.

OZ’s product underwent a major evolution as for the materials used as well: the alloy types used for the OZ wheels are the result of our long experience in the racing world .”

explains Bordignon, “that is not required from the suppliers of wheels for the aftermarket, but that guarantees the high quality and performance of our products. This is the LBF test, where wheels of any type and size undergo extreme stress tests by simulating a 35,000 km long race on the famous Nürburgring track and their reactions are carefully monitored.”

for ALL type of surfaces

per TUTTI i tipi di superﬁci

4 Figure 4: The application of the powder clearcoat.

info@eurotherm.eu T + 39 011 98 23 500 F + 39 011 98 23 560 Via Pisa, 78 - 10088 Volpiano (TO) Italy EUROTHERM SpA

EUROTHERM SAS

EUROTHERM GmbH

eurotherm.eu

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A production system inspired by the Toyota model

Tailor-made ﬁnishing: the Personal Colour programme by OZ The paintshop is equipped with a monorail floor conveyor that continuously transports the wheels to the two water veil spray booths – one equipped with a robot installed by CMA Robotics of Pradamano, Udine, Italy

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Since 2002, OZ has implemented Toyota’s “Lean” approach, i.e. the so-called “just in time” production system. “The Lean system,” says Bordignon, “turns the production cycle into a continuous flow. It also finds and eliminates any waste and introduces the “one piece at a time” concept, which streamlines production and complies with the craftsmanship attitude of our brand. Our focus on each production detail is the technological and stylistic aspect that makes us stand out in the racing world and the one on which the OZ Racing brand’s success is based. For the production flow management, on the other hand, we have implemented the Kanban system, which enables us to gradually replace spares as they run out, thus avoiding high stocks and the related costs.” The production cycle, which is entirely carried out at the Padua plant, starts with reception of materials, which are subjected to two different treatment types: casting and forging. After casting, the ingots are processed in melting furnaces and then undergo a low pressure treatment using in-house produced moulds, from which wheels are obtained. As for the machining of forged wheels, which have higher performing features, the department receives the alloy billets on which further operations are carried out to remove the material in excess from the wheels’ spokes to make them as light as possible. Every wheel is then subjected to heat treatment and coating, after which the wheels are ready for packaging and shipment.

For several years OZ has been offering a programme called “Personal Colours” that provides its clients with a wide range of colours to choose the ideal one for matching the wheel with the car.”

5 Figure 5: The visual inspection after coating.

(Fig. 3), the other fitted with two automatic electrostatic guns supplied by Wagner Spa – and then to the automatic powder application plant (Fig. 4). “Our coating system,” explains coating department head Armando Gabbiadini, “includes a powder primer, a basecoat in several colours, and a liquid or powder acrylic clearcoat. All our coating products are supplied by Inver-Valspar and the German company Lankwitzer. A few months ago, we completed the replacement of solvent-based coatings with water-

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based products, in compliance with the company’s environmental policy. The coating application is followed by a flash-off process at room temperature for the clear liquid basecoats, and then the wheels are fed to the oven at 180 °C for 20 minutes. The average production capacity is 120 wheels/hour.” “For several years,” states Bordignon, “OZ has been offering a programme called “Personal Colours” that provides our clients with a wide range of colours to choose the ideal one for matching the wheel with the car. We offer 10 different shades for the aftermarket sector, on three models of the i-Tech series, our top-of-the-range cast wheels. Also due to the large variety of models and colours offered, producing an alloy wheel for the aftermarket is not, as one may assume, a highly industrialised process: visual inspections and manual operations are still indispensable to obtain perfect finishes and ensure high quality (Fig. 5).” Quality is also guaranteed through rigorous coating tests. Along with adhesion and 1,000-hour salt spray tests, the wheels undergo other checks such as the CASS test, which measures their corrosion resistance inside a room saturated with a copper-saline-acetic solution for 240 hours, and the QUV test, which simulates the weather effects during the passage from night to day and in which the wheels are exposed for a long period (up to 700 hours) to UV rays in a dark environment with high temperatures, with humidity conditions that lead to dew formation.

A bottleneck in the coating phase: the removal of sludge Until last year, the most critical aspect of the coating phase was the sludge removal operation, carried out manually in the static tank gathering all booths’ waste water. Besides the waste of water resources, the two main issues were

FOCUS ON TECHNOLOGY

6 Figure 6: The waste water treatment plant installed by Chemtec.

the need to frequently interrupt the coating cycle for the daily cleaning of the tank and the risk that the overspray particles accumulated, thus jeopardising the application results. The problem was solved with the installation of a purification system consisting of an automatic dirt separator that removes any trace of sludge and recirculates the clean water to the coating plant. “Chemtec has developed a custom-made system for OZ based on the production volumes of its paintshop,” says Carlo Guidetti, the owner of the Milan-based company, which specialises in the production of chemicals for the industrial surface treatment sector and which has been designing water treatment systems operating in both continuous and batch

7 Figure 7: The puriﬁed water tank.

SPECIAL AUTOMOTIV E

mode since 2014. “The system installed works in continuous mode to purify the waste water coming from the paintshop with a chemical-physical process. It removes sludge through a scraper that pushes such residues in a container specifically designed for the collection and drying of sludge, thus ensuring the water recirculated to the plant is perfectly clean (Fig. 6).”

the waste water treatment system. Here, flocculant is added to start the flocculation process, resulting in the formation of a largesize molecule whose electrostatic charge attracts the deactivated coating particles to obtain a light and non-hydrosoluble molecule that goes back to the surface (Fig. 7). These inert molecules are gathered by the scraper and pushed into the sludge container (Figs. 8 and 9). The products’ feeding and dosing occur in an automatic and timed manner through adjustable

dosing pumps. We also offer other chemicals for the control of the foam generated in the tank, of the particles’ microlife, and of the aqueous solution’s pH value.”

Eco-friendliness: a common goal

“Chemtec’s plant has three main advantages,” states Gabbiadini. “First of all, the coating system is more efficient: it The synergy between the performs better thanks to the reduction of puriﬁcation plant and the overspray and it is more flexible because eco-friendly chemicals: we no longer need to stop it a peculiarity of Chemtec for our cleaning operations, The combination of the so that it is always ready to purification plant installed with operate. Secondly, we have the chemicals used is crucial to reduced water consumption: the efficiency of the waste water water is constantly recycled treatment system designed and it does not need to be by Chemtec. “We have been replaced, also resulting in formulating and producing cost savings. Finally, the eco-friendly chemicals for management of the plant several years,” adds Guidetti. has been improved thanks “The creation of a new division to Chemtec’s assistance devoted to the waste water for both the plant and the treatment processes has chemical products, but also 8 enabled us to design a plant to the significant reduction in that operates in harmony with the amount of sludge to be Figure 8: The scraper collects the inert molecules and pushes them into the the chemicals supplied, thus disposed of by a specialised sludge container. offering an eco-friendly process company. and a more efficient and flexible “One of the most important management of the plant.” aspects for us was the “We supplied OZ with the reduction of our polluting coagulants needed to make emissions,” adds Gabbiadini. the paint inert,” says Adolfo “Chemtec shares our same environmental vocation: Palmanti, the Product Manager of Chemtec. “Although waterprecisely thanks to this common goal, we have based coatings are now being both strived to achieve used, these products still such satisfying results. contain a few non-hydrosoluble The collaboration of their components. When the paint staff has contributed to comes into contact with the the improvement of the water veil of the booth, it is efficiency of our production deactivated and turned into flow, helping to maintain the nanometre-sized colloidal 9 high quality level that has particles. These micro particles characterised the OZ wheels are pumped from the collection Figure 9: The sludge container is replaced every two weeks and disposed of every six months. for over forty years.” tank under the coating plant to

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BRAND-NEW

he 2K Smart from WAGNER (Fig. 1) is an electronically controlled mixing and dosing system. Depending on the material, stroke sensors, gear or Coriolis flow meters are generally used for the flow measurement, which is necessary to ensure a high-quality finish. In the case of mixing systems with automatic hardening control, the market offers mainly gear or mass flow meters (Coriolis). Yet these are not ideal, especially when highly viscous materials with a high solids content are involved. This is because higher wear results from the material contact during the flow measurement. In addition, the metering system requires constant cleaning. For this reason, WAGNER now offers an optional stroke sensor for its new 2K Smart multi-colour mixing system. This sensor has already proven itself in the TwinControl mixing and dosing system. “The stroke sensor calculates the flow rate via the stroke on the pump. That means it doesn’t come into contact with the material. This entails reduced wear and cleaning costs as a result,” explains Carsten Ludwig, Senior Product Manager Liquid at WAGNER.

That’s huge. In addition, the process is more reliable because mixing errors are avoided and exact mixing ratios are always achieved,” says Carsten Ludwig. When compared to other 3K mixing systems on the market, the 2K Smart stands out with its excellent price/performance ratio. “With the 2K Smart, we’re offering an attractive multi-colour 2/3K mixing system for everyday wet coating applications.”

The system is delivered fully assembled The 2K Smart can be adapted to numerous applications. For example, a version is available for processing acid-hardening paint systems. It is also optimised for integration in automatic systems. Using an online configurator, the WAGNER sales partner can optimise the mixing system to suit the customer’s needs - it is then delivered fully assembled and just needs to be put into operation. “Our equipment is designed to make things as easy as possible for our customers. With the 2K Smart, we’ve succeeded in doing this in every respect,” says Carsten Ludwig.

Affordable 3K mixing system for wet coatings

For further information: www.wagner-group.com

In addition to being used as a 2K mixing system, the 2K Smart can also be configured as a 3K mixing system. The third component is also dosed automatically. For example, this means the material can be diluted automatically. “The user thus saves about half an hour per 30-litre container.

Figure 1: WAGNER 2K Smart.

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New 2K Smart: Flow Measurement Via Stroke Sensor

BRAND-NEW

Plastic Nanotechnology: Spain at the Forefront of Research and Development of New Graphene-based Materials

he public-private collaboration between Spanish companies, technology centres and research organizations has enabled the implementation of a new research initiative in the field of graphene for the development of new industrial applications with high added value and advanced properties. The project GRAPHOS is led by the company of specialty chemicals CROMOGENIA and has the participation of ANTEX, ARZUBIALDE, BECSA, ELIX POLYMERS, MAIER, NANOINNOVA and POLYMEC. It kicks off with the ambitious aim of achieving the incorporation of graphene

and carbonaceous nanostructures in a broad range of polymeric matrixes. In this way, it is expected to achieve the integration in different products with advanced functionalities and improved physical-mechanical properties. In particular, the project GRAPHOS focuses its activity on automotive, plastics, paints, inks and coatings, construction, textile and electronics industries. In this way, four out of the eight large sectors where developments in graphene and carbonaceous nanostructures are expected to have a higher impact: energy aerospace, automotive, biomedicine, coatings, composites,

sensors, electronics and defence. The consortium GRAPHOS covers the value chain from production and functionalization of graphenes and carbonaceous nanostructures to the integration in final product of acrylics, polyester, polyurethane, polypropylenes, SBS, SAN and ABS. The project is funded by the programme CIEN, co-funded with ERDF funds with a budget of EUR 7,200,022.00 million and a grant of EUR 5,400,016.50 million in a period of four years. For further information: www.aimplas.net

Alit Technologies Srl Via Francesco Perlini, sn â&#x20AC;˘ 37047 San Bonifacio (VR) www.alit-tech.com â&#x20AC;˘ info@alit-tech.com

BRAND-NEW

Heat Protection Range for Temperature Profiling in Paint Operations: Robust Results Ensured he new DATAPAQ EasyTrack3 temperature profiling system from Fluke Process Instruments addresses the needs of any paint or powder coating operation. A comprehensive range of thermal barriers protects the data logger with its non-volatile memory in infrared and convection ovens. The light-weight aluminum standard barrier shields the electronics for up to 2 hours at 200°C. Thermal protection 1 is ensured by high-performance Figure 1: The DATAPAQ EasyTrack3 program comprises equipment for temperature proﬁling in PTFE and Dacromet coating, microporous insulation IR and convection ovens, and low-clearance mesh belt ovens. and a heat sink. The DATAPAQ EasyTrack3 the barrier provides protection combined) over its entire operating Professional System for a full 13 min at 200°C or for temperature range. The robust, triedextends protection to 3 hours, allowing 30 min at 100°C. The logger and-tested system ensures successful users to monitor up to three cure operating temperature is 85°C. It measurements day after day. processes consecutively. automatically switches off, should A thermal barrier for high-temperature it ever heat above that point - for PTFE and Dacromet coating withstands For further information: instance due to unscheduled line 400°C for up to 90 min. www.flukeprocessinstruments.de stops. This prevents faulty data Lastly, the manufacturer has also collection. designed a low-height barrier for The profiler provides a profiling typical mesh belt cure lines measurement accuracy of ±1.6°C where oven clearance is significantly (logger and thermocouple accuracy restricted. At merely 31 mm high,

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BRAND-NEW

New App to Quantify Sustainability of Coil Coatings

eckers Group, leading worldwide supplier of coil coatings, just launched a tool to quantify the sustainability of its coating products. The ”Beckers SI” app is designed for architects, designers, building planners and steel makers: individuals or companies who are involved in the planning or construction of a building and aim to work with green materials without compromising on the design. For different applications such as roofing or façade systems, the “Beckers SI” app shows users the collective impact of the materials used to make the coating as well as the value certain functions add to a construction.

This enables them to make an educated decision and can also be rewarded by green building rating schemes such as LEED and BREEAM. “At Beckers, we strongly believe in providing solutions that meet today’s needs without compromising those of future generations. The ‘Beckers SI’ app offers an easy way to find more sustainable coil coating materials and shows clearly that our coatings can do much more than decorate,” says Bernd Vogel, Chief Technology Officer of Beckers. Nicklas Augustsson, Beckers’ Global Sustainability Director adds: “With the “Beckers SI” app we lead the way towards

a more sustainable building design. We show which of our coatings are produced with sustainable raw materials and highlight functions that fully support green building trends.” The “Beckers SI” app is based on the “Beckers Sustainability Index” and part of the company’s digital sustainability reporting. Together with it Beckers also published its yearly sustainability report as well as a short explanation video (Beckers SI Video: beckers.link/BSI-Video; Beckers Sustainability Report: beckers.link/ SR16; App Store: beckers.link/BSI-AppStore; Google Play: beckers.link/BSI-GooglePlay). For further information: beckers-group.com

Of course you can paint 400 horses. Surface coating expertise on many levels – that‘s where Rippert has been making a name for itself for over ﬁve decades. We conceived a surface coating plant for the CLAAS Group for the ﬁnishing of chassis. We are delighted to accompany a successful company with our ideas and technologies. We make brands shine. Find out more at www.rippert.de

BUSINESS TRAINING

Customer Satisfaction Analysis & Management – Part 3 Felice Ambrosino consultant

simeida@tin.it

The importance of assessment It should be now clear that any company wanting to grow, increase its competitiveness and achieve a stable profit must fully meet its customers’ needs. However, this is not enough. In a free market, especially if clients are few, a firm also needs to beware of its

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competitors, which will try to attract its customers by promising higher satisfaction and therefore making them feel less pleased with its offer. In order to minimise the risk to lose them, it is crucial to strive to constantly increase their satisfaction. The Japanese philosophy of Kaizen, which has had and is

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still having great success, is precisely based on a continuous improvement approach. In other words, a company should stop focusing on sales and start promoting the know-how or the service characterising its products, considering that “a firm’s success can be assessed based on the quality of its service,

BUSINESS TRAINING

How can you improve something if you cannot assess it? How can you set a reference parameter? And how can you quantify your improvement if you have not defined a starting point?”

but the quality of its service can be assessed based on its clients’ satisfaction (Various authors, Customer Satisfaction Management, Il Sole 24 Ore). And yet, how can you improve something if you cannot assess it? How can you set a reference parameter? And how can you quantify your improvement if you have not defined a starting point? That is why the Customer Satisfaction assessment plays such a crucial role and why it should be the core of any business’ strategy.

A method to assess Customer Satisfaction There exist different methods to assess Customer Satisfaction. Many authors suggest their own approach and indices, focusing more on some aspects of Customer Satisfaction or on some kinds of business than on others. For the purposes of this article, it will suffice to describe one of these methods, which I consider the simplest and therefore the most reliable one. It is based on the assessment of the difference between the value of the clients’ expectations and the perceived value of the purchased good/service. The customers should be asked a few questions aimed at assessing the extent and the mathematical sign of such difference (+1, 0, -1, or even +2, +1, 0, -1, -2); the different factors affecting their expectations should be previously segmented and subsegmented in order to obtain clear and targeted answers. The more positive the difference, the more pleased the clients; however, generally speaking, the customers’ answers will refer to three grades of satisfaction based on two performance levels: the “desired” and the “suitable” one (Raimondi, Customer Satisfaction, ISEDI).

Desired level

Over-satisfied

Tolerance area

Satisfied

Suitable level

Dissatisfied

The method is based on the assessment of the difference between the value of the clients’ expectations and the perceived value of the purchased good/service.”

In the tolerance area, the clients have not been provided with their desired performance, but they still consider the supplier’s performance acceptable. Customers should also be asked about the importance they attribute to the aspects that have pleased them (or not). A scale of importance can be defined by assigning a score to each “step” (e.g. from 1, not important, to 5, determining, with the intermediate levels being 2, not very important, 3, important, 4, very important). For instance, some customers could say they were not much pleased with the “Technical sheets’ clarity” performance, which they consider highly important (a score of 4 on a 1 to 5 scale): this performance will therefore have a value of -4 (= -1 x 4) and it will surely require an improvement. The importance attributed to each factor by the clients can also be further analysed, for example to find out any problem currently arising in their procedures, their trends and habits, the seriousness and frequency of their issues, and so on. Of course, each aspect will have to be assigned a weighted score. The results of this analysis can be integrated with a “Satisfaction/Importance” matrix to highlight the firm’s strengths and weaknesses (G.C. Pacenti, Business Marketing, Il Sole 24 Ore).

Clearly, the more factors are added to the box containing the important characteristics for which customers are unsatisfied, the more the company will need to reassess its design, production, selling, delivery, and assistance processes. Clients should also be asked to compare each performance with that of the company’s main competitors in order to understand where the firm is positioned on the market in its customers’ eyes – which is the only point of view that matters. Other precious data can be obtained by asking the same questions to the management: their answers, compared to those given by the clients, will shed some light on the self-assessment capacity of the company and on its self-awareness in terms of strengths and weaknesses. The analysis of this information and the use of critical area maps and index tables will enable to draft a Customer Satisfaction report, i.e. the main document needed for the creation of a Customer Satisfaction Management programme. (to be continued on the next issue of ipcm®)

The analysis of this information and the use of critical area maps and index tables will enable to draft a Customer Satisfaction report, i.e. the main document needed for the creation of a Customer Satisfaction Management programme.”

Satisfied customer

Dissatisfied customer

Important performance/ characteristic

The main focus of continuous improvement activities.

The most critical area to retain customers. The company’s approach should be reassessed also based on the importance of the clients. The whole firm should strive to improve their satisfaction.

Unimportant performance/ characteristic

A safe situation, but the company should make sure it is not wasting any resources that could be employed in other ways.

A case-by-case approach is needed based on the degree of tolerance and the importance of the client, the number of competitors in the area, etc.

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STANDARD & LEGISLATION - UCIF Informs

REACH: Updating the List of Substances Subject to Authorisation Marcello Zinno

he European Commission has published an update of Annex XIV of the REACH Regulation, containing the list of substances subject to authorisation. The update includes the addition of twelve new substances, of which eight are classified as toxic for reproduction, two have carcinogenic and PBT/vPvB properties, and two are endocrine disruptors. The SVHC included in Annex XIV are now 43. Such substances listed in Annex XIV of the REACH Regulation cannot be placed on the market nor used after a certain date, unless permission is granted for a specific use provided that it occurs in safe conditions.

info@ucif.net

UCIF-Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

However, other substances are not officially included in the REACH list, yet, but they are kept under observation. One of them is titanium dioxide, a chemical compound in the form of a colourless, whitish crystalline powder. Its chemical formula is TiO2 and, in nature, it has five different crystalline forms: rutile, anatase, brookite, and the two high-pressure polymorphs (due to meteorites’ impact) akaogiite and TiO2 II, which can be coloured due to the presence of impurities in the crystal. This substance is mainly used as a white pigment in paints, plastics and construction cement as well as an opacifier for coloured coatings; that

is why it is commonly called “titanium white”.

production and/or use of this substance to assess the impact of its possible classification as a group 2 carcinogen.

On June 9, the Risk Assessment Committee (RAC) of the European Chemicals Agency (ECHA) has expressed its opinion on the proposal to classify titanium dioxide as a 1B carcinogen, presented France in May 2016. The RAC concluded that the available scientific evidence is insufficient to classify titanium dioxide as a 1B carcinogen, but it agreed on considering it as suspected of causing cancer by inhalation (group 2). Such classification will have a definitely smaller impact than that originally required by France. However, investigations will be needed in the different industrial chains involved in

The RAC’s opinion will be officialised by ECHA in September, discussed in political terms by CARACAL (the competent authorities for REACH and CLP), and finally sent to the European Commission for the final decision, which will only have effect after the publication in the Official Journal of the EU.

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TRADE FAIRS & CONFERENCES

AUGUST 2017 AUTOEXPO AFRICA

INDUSMACH AFRICA

Dar-es-Salaam, Tanzania August 16-18, 2017 www.expogr.com/tanzania/autoexpo/index.php

Dar-es-Salaam, Tanzania August 22-24, 2017 www.expogr.com/tanzania/indexpo/

GLOBAL AUTOMOTIVE LIGHTWEIGHT MATERIALS SUMMIT

INACOATING INDONESIA

Detroit, USA August 22-24, 2017 www.global-automotive-lightweight-materials-detroit.com

Jakarta, Indonesia August 23-25, 2017 www.inacoating-exhibition.net

SEPTEMBER 2017 GLOBAL COATINGS INNOVATION SUMMIT Berlin, Germany September 11-12, 2017 curtiswyss.com/events/events/30

EMO HANNOVER

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media partner

Hanover, Germany September 18-23, 2017 www.emo-hannover.de

CONSTRUCTION INDONESIA

COMPOSITES EUROPE

Jakarta, Indonesia September 13-16, 2017 constructionindo.com

Stuttgart, Germany September 19-21, 2017 www.composites-europe.com

ASIA PACIFIC COATINGS SHOW

CMTS

Jakarta, Indonesia September 13-15, 2017 www.coatings-group.com/apcs/jakarta/cfp

Mississauga, Canada September 25-28, 2017 cmts.ca/

IAA CARS

POWDER COATING & CURING PROCESSES SEMINAR

Frankfurt, Germany September 14-24, 2017 www.iaa.de

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TRADE FAIRS & CONFERENCE

POWTECH

Montreal, Canada September 18-21, 2017 www.shotpeening.org

Nuremberg, Germany September 26-28, 2017 www.powtech.de/en

OCTOBER 2017 Barcelona, Spain October 02-06, 2017 www.eurosurfas.com

EXPOQUIMIA Barcelona, Spain October 02-06, 2017 www.expoquimia.com

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ABRAFATI

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media partner

São Paulo, Brazil October 03-05, 2017 www.abrafati2017.com.br/en/

ALUMINIUM-21/ SURFACE TREATMENT&FINISHING Moscow, Russia October 03-05, 2017 www.eng.apral.org

POWDER COATING SUMMIT

MEDTEC EUROPE IRELAND

Columbus - OH, USA October 03-04, 2017 www.powdersummit.com

Galway, Ireland October 04-05, 2017 www.medteceurope.com/ireland/

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media partner

Atlanta - GA, USA September 26-27, 2017 www.ccaiweb.com/events/EventDetails.aspx?id=886647&group=

ICSP 13

EUROSURFAS

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OCTOBER 2017 CIS COATINGS AND RAW MATERIALS MARKETS

IPC - PAINTS & COATING EXPO Karachi, Pakistan October 13-15, 2017 www.ipcexpo.net

Sochi, Russia October 04-06, 2017 www.lkmconf.com/en/

ALUEXPO

RADTECH EUROPE

Istanbul, Turkey October 05-07, 2017 www.aluexpo.com/index.php?en

Prague, Czech Republic October 17-19, 2017 www.radtech2017.com

INTERNATIONAL PAINT, RESIN, COATING & COMPOSITES FAIR

ARAB COATING EXPO Cairo, Egypt October 19-22, 2017 arabcoatingexpo.com

Tehran, Iran October 06-09, 2017 www.ipcc.ir/index.php/en

DEBURRING EXPO Karlsruhe, Germany October 10-12, 2017 www.deburring-expo.de

MANUFUTURE

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Tallinn, Estonia October 24-25, 2017 manufuture2017.eu

ARCHITECT@WORK ITALY

PARTS2CLEAN

Rome, Italy October 11-12, 2017 www.architectatwork.it

Stuttgart, Germany October 24-26, 2017 www.parts2clean.de

EGYPTIAN COATINGS SHOW

EXPO COATING

Cairo, Egypt October 11-12, 2017 coatings-group.com/mecs/cairo/

Moscow, Russia October 24-26, 2017 www.expocoating-moscow.ru/?lang=en-GB

MTA HANOI

KOREA METAL WEEK

Hanoi, Vietnam October 11-13, 2017 www.mtahanoi.com/home/

Goyang, South Korea October 24-27, 2017 www.korea-metal.com/en

PAINTEXPO EURASIA

ALUMINUM USA

Istanbul, Turkey October 12-14, 2017 www.paintexpo.com.tr

Nashville - TN, USA October 25-26, 2017 www.aluminum-us.com

ipcm

media partner

ipcm

media partner

ipcm

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NOVEMBER 2017 1,*(5,$

&216758&7,21 %8,/',1* (;+,%,7,21

NIGERIA BUILDEXPO

ECOMONDO

Lagos, Nigeria November 02-04, 2017 www.nigeriabuildexpo.net

Rimini, Italy November 07-10, 2017 en.ecomondo.com

FABTECH USA

BLECHEXPO

Chicago, USA November 06-09, 2017 www.fabtechexpo.com

Stuttgart, Germany November 07-10, 2017 www.blechexpo-messe.de/en/blechexpo/

BATIMAT

MAROC INDUSTRIE EXPO

Paris, France November 06-10, 2017 www.batimat.com

Casablanca, Morocco November 08-11, 2017 www.midest-maroc.com

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A More International Metef 2017 by Mario Conserva President of the METEF exhibition (Verona, June 21-24, 2017)

“T

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and return to the top of global rankings, companies which do not consider Industry 4.0 to be a little slogan but a great objective which has been achieved. Over 400 great quality exhibitors, a framework of side events rich in contents and so tightly packed with appointments that it would be impossible to mention them all; worth remembering, for their international relevance, the panel on the future of aluminium by Assomet-Centroal and AFFG, the Opening Conference by the FARO Club regarding the automotive industry, the Aluminium 2000-Iceb Congress, the Italy-India Forum on trade between the two countries, the NADCA Convention on die casting. We might be emerging from the crisis, this is a phase where such events as Metef turn out to be particularly useful to encourage development where it is most needed: in the country’s economic system”. Among the exhibitors they were numerous companies from the surface treatments industry (Figs. 2 to 8). The ipcm Magazine was a media partner of this event, Ed. For more information: www.metef.com © Metef

innovative metals, casting foundry, die casting, extrusion, rolling – by enhancing trends particularly favourable for development, especially in very dynamic transversal macro-areas, such as automotive

and digitization (Fig. 1). Innovation is the leading theme for a show that for twenty years has been a witness to the excellence of the aluminium world and of the connected manufacturing industry; companies which in this edition won the Metef Innovation Prize are the essence of an industry which has been able to change in just a few years © ipcm ®

he eagerly awaited eleventh edition of Metef just ended in Verona; a great interest was clearly visible, business linked to the aluminium and foundry worlds is brisk, the dominant theme recorded was that of an more international character. There was a 25% increase in the number of foreign operators and visitors with respect to the previous edition; a leading role was played by commercial delegations coming from countries with solid industrial traditions, such as, the United States, Germany, Austria, Russia, and by markets where technical and production capacity is developing fast, such as India, Iran, Iraq, Poland, the Czech Republic, Slovenia, 1 Hungary, Serbia, Turkey, Ukraine, Mexico. The presence of great primary metal producer should be underlined: Europe with HYDRO, the Gulf, present with EGA and with the top management of the Gulf Aluminium Council, Russia with RUSAL, India with VEDANTA and Iran. Metef 2017 grasped the inversion in trend of the entire industry – aluminium and

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ZOOM ON EVENTS

The First Edition of Lamiera in Milan was a Great Success: 23,579 Registered Visits

for the exhibition were already sold-out. reat success for LAMIERA, the PRODURRE, in cooperation with the Ministry For this reason, for 2019, LAMIERA will have international biennial exhibition of Economic Development and ICE-Italian an additional pavilion besides the two halls focused on the metal forming Trade Agency, which materialised in more that were completely booked for the edition machine tool industry and on all innovative than 1,600 meetings at the exhibitors’ stands. that has just ended. technologies related to the sector. Promoted by UCIMU-SISTEMI PER The registered number of visiting operators The trade show took place at fieramilano PRODURRE, the Italian machine tools, robots attests to the growth of this exhibition, which Rho from 17 to 20 May 2017. and automation systems manufacturers’ considerably benefitted from its location and For its debut in Milan, the event had all association, and organised by CEU-CENTRO date change. The total visits were 23,579, i.e. its exhibition area sold-out, registering ESPOSIZIONI UCIMU, the trade show - a 15% more than in the previous edition. a presence of exhibiting companies, an reference point for Industry 4.0 - showed exhibition surface area and the best international product a number of visitors above offering of the sector. expectations. Great interest was generated In particular, the exhibition area by the special initiative of the two pavilions set up for the LAMIERALIVING, a display trade show (halls 13 and 15) was area presenting more than increased by 21% compared with 40 design objects, icons of the 2016 edition. the Made in Italy worldwide, The total surface area was 40,000 which had won the prestigious square meter. “ADI Compasso d’oro” As far as exhibitors are concerned, international Award and were over 480 exhibiting companies totally or partially made using participated in LAMIERA, i.e. metal forming machines and 25% more than in the previous technologies (Fig. 1). 1 edition. Among the attending “The results we had - pointed companies 27% were from abroad. out Massimo Carboniero, Figure 1: One of the products displayed at the LAMIERALIVING Area. In the spotlight there were: President of UCIMU-SISTEMI sheet metal forming machines, PER PRODURRE - are an Visitors from abroad made up a percentage bar-, tube-, section-working machines, excellent basis for the next edition of of 9%, thus almost twice as many as those presses, blanking and punching machines, LAMIERA, which will take place from 15 to attending the 2016 edition. Numerous laser, robots, automation, Industry 4.0, 18 May 2019 at fieramilano Rho. Our next operators came from Switzerland, Germany, moulds and dies, heat treatments, surface target is to further increase the international Spain, France, Poland, Serbia, Croatia, treatment and finishing, wires and metal character of the event thanks to a specific Slovenia, Russia, Japan, India and Great carpentry. promotion programme addressed to foreign Britain. The exhibiting companies have been really operators. The fact that LAMIERA will again In addition, there were 110 buyers belonging interested in the event, as evidenced by be held every two years will help to ensure a to 13 delegations of foreign operators coming the numerous applications to take part higher presence of innovations and novelties from Algeria, Brazil, Canada, China, Germany, in this trade show. Some applications on show: a good part of them, related to the India, Iran, Morocco, Mexico, Poland, were received even few days before the technologies of Industry 4.0, should be in the Russia, Serbia and Turkey, invited within the beginning of LAMIERA and the organisers process of being fully consolidated in 2019”. initiative promoted by UCIMU-SISTEMI PER could not accept them, as the halls reserved For more information: www.lamiera.net

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HANNOVER MESSE - “More Attendees, More Solutions, More International!”

“M

MESSE 2017 has been nothing short of ore attendees, more solutions, outstanding.” more international – that Of the show’s 225,000 attendees (up from aptly sums up HANNOVER 217,000 in 2015 as the most recent comparable MESSE 2017,” commented Dr. Jochen Köckler, event), more than 75,000 came from abroad. Member of the Managing Board at Deutsche “This is an unprecedented figure in the 70-year Messe. “Over the five days, Hannover has history of HANNOVER MESSE,” commented served as a global hub for all things related Köckler, adding: “This impressively proves that to Industrie 4.0. Every sector involved in the decision-makers from around the world rely on digitalization of industry was on hand to HANNOVER MESSE as their definitive source showcase its answers to the key question faced by industrial enterprises everywhere: How can I best get my company into shape for the digital future? HANNOVER MESSE has resoundingly underscored its value as a prime source of orientation for decision-makers from around the globe,” he added. The show’s chosen lead theme of “Integrated Industry – Creating Value” put a major spotlight on the benefits of Industrie 4.0 and the role of humans in 1 tomorrow’s integrated factories (Fig. 1). As this year’s featured Partner Country, Poland Figure 1: The show put a major spotlight on the called added attention to the need for close beneﬁts of Industrie 4.0 and the role of humans in cooperation throughout Europe, while tomorrow’s integrated factories. impressing attending professionals with its of Industrie 4.0 orientation and solutions.” The credentials as an innovative partner to global largest number of foreign visitors came from industry. China (9,000), followed by the Netherlands In his summation of the event, Thilo (6,200), India (5,300) and Poland, whose 5,000 Brodtmann, Managing Director of the German visitors set a new Partner Country record. Engineering Federation (VDMA), said: The long-term impact of Partner Country “HANNOVER MESSE 2017 has served as an participation was underscored by an impressive unsurpassed showcase for the mechanical 3,000 visitors from the U.S. as last year’s engineering sector. Industry 4.0 is now well Partner Country. past the trial stage, and is already generating “In close collaboration with our exhibitors, we real benefits in application. The show clearly succeeded in making this year’s lead theme reflected the industry’s buoyant mood – a tangible in the truest sense of the word,” mood powered by having exactly what it remarked Köckler. “With an array of more than takes to get the job done for the benefit of 500 application scenarios, the show gave real people everywhere. And when it comes to shape to the promise that digitalization holds international competition, we are definitely for industry and the energy sector.” among the frontrunners. In short, HANNOVER

HANNOVER MESSE 2018 features CeMAT and IAMD Beginning in 2018, the annual Industrial Automation (IA) show will merge with the biennial Motion, Drive & Automation (MDA) – both representing leading fairs staged under the HANNOVER MESSE umbrella. IA and MDA will then take place jointly under the new name of “Integrated Automation, Motion & Drives” (IAMD) – reflecting the entire spectrum of industrial automation, power transmission and fluid power at HANNOVER MESSE. Beginning in 2018, CeMAT, the world’s leading intralogistics trade fair, will be staged every two years in parallel with HANNOVER MESSE. “Production and logistics processes are in the process of becoming intelligently integrated, enabling even more efficient, flexible production processes. At CeMAT we will be making this integration tangible and will demonstrate the resulting potential,” said Köckler. Additional display sectors at CeMAT include logistics solutions for retailing and logistics services. “Efficient logistics processes are of critical importance to the business success of online retailers or bricks-and-mortar retailers. At CeMAT they’ll find the right logistics systems for omni or cross-channel solutions,” reported Köckler. CeMAT and HANNOVER MESSE will be a strong duo next year, providing a unique platform for international decision-makers from industry and logistics. The next HANNOVER MESSE will run from 23 to 27 April 2018, with Mexico as its official Partner Country. For more information: www.hannovermesse.de

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Master’s Degree in Color Technology for the Automotive Sector organized by the University of Alicante

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he University of Alicante (Spain) organized the “Master’s Degree in Color Technology for the Automotive Sector”, from September 2017 to July 2018. Color Technology focuses on the study of theories and techniques related to the design, manufacture and measurement of colored materials. A wide range of different industrial sectors are involved in color technology (colorants, coatings, textiles, ceramics, plastics, printing, multimedia, etc.). Unfortunately, in many cases, color experts within these sectors have not received any specific training in color science. Therefore, their knowledge about colors, which is critical to developing their work, has been obtained through practical, possibly self-taught, experience. For this reason, companies involved in these productive sectors often invest considerable resources in specific color training to improve their employees’ skills. In the same way, the limited number of graduates who do have advanced color training are highly sought after by many companies. Over recent decades, color measurement and color quality control of gonioapparent materials have become key areas for the automotive industry and also for other sectors such as cosmetics, coatings, plastics, printing, textiles, architecture, etc. Therefore, it is necessary to count on in-depth knowledge of complex instrumentation techniques and visual evaluation procedures as regards differences in color and texture (sparkle and graininess); and even color

formulation with solid and special effect pigments. In response to this socioeconomic demand, the Color and Vision Group of the Department of Optics, Pharmacology and Anatomy at the University of Alicante, in collaboration with other academic institutions (UGR, UPC, and CSIC) and different companies (AUDI, SEAT, BASF Coatings, BYKGardner, Mercedes Benz, Opel, Toyota Motor Europe, PPG, Merck, Valspar, Plastic Omnium, NubiolaFerro, etc), is offering the Master’s Degree in Color Technology for the Automotive Sector (acronym: ColTAS) as a postgraduate course with 60 ECTS or credits.

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The purpose of the ColTAS Master is to provide comprehensive training in the multidisciplinary study of Color Science and Technology from a global perspective. Students will examine the physicochemical and visual laws and solve real or simulated problems that often arise when using special effect pigments in different industrial sectors, particularly within the automotive sector. This course includes an industry-based internship of up to 300 hours and provides a great opportunity to achieve basic and advanced color control skills at an industrial level, particularly in the automotive sector, but also in other industries using special-effect pigments as cosmetics, plastics, inks, etc. For further information: web.ua.es/en/gvc

Supplemento a IPCM n° 46 - July/August 2017

INDUSTRIAL CLEANING TECHNOLOGIES

ICT digital on

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ICT - INDUSTRY NEWS

he absolute necessity for clean components in the automotive industry requires reliable cleaning technologies. With longstanding experience in this field, the manufacturer BvL Oberflächentechnik produces suitable cleaning systems which are always tailored to the special customer requirements.

Clean and Burr-free for the Automotive Industry Parallel cleaning of workpiece holders While the component is deburred, the empty workpiece holders in this special application move through a washing unit integrated into the high pressure system. This positions the deburred component on the cleaned workpiece holder, preventing renewed soiling through residue.

Thorough cleaning with fast cycles The NiagaraDFS basket washing system is the answer to especially high cleanliness requirements (Fig. 1). The flood/spray system with revolving wheel technology ensures thorough all-round cleaning through rotation of the parts baskets or parts carriers around the horizontal axis. The inline material flow concept shortens ancillary times to a minimum, significantly reducing cycle times and increasing capacity.

Deburring system in application BvL also offers expertise in the field of deburring: For the cleaning of gearbox parts for a large German automotive manufacturer, the Slovenian company

Cleaning systems integrated into production

1 Figure 1: NiagaraDFS basket washing system with cycled continuous process for optimising cycle times.

LTH Castings invested in the Geyser high pressure deburring system with an integrated industrial robot (Fig. 2). The Geyser reliably removes swarf and burrs with a high pressure water jet through multiple rotating nozzles or single lances which are directed specifically at the critical areas of the component (Fig. 3). Short cycle times make the system particularly efficient and suitable for series production.

Because of its compact design in container form, the high pressure deburring system can be ideally integrated into the production process. BvL offers all required systems from a single source: from pre-cleaning, deburring and fine cleaning to drying and cooling. The machines and components made of high quality stainless steel are perfectly matched and can be individually adapted: the high pressure deburring system from LTH Castings was also combined with a pre-cleaning unit and a final fine cleaning stage. For further information: www.bvl-group.de

Figure 2: Geyser high pressure deburring system combined with precleaning and ﬁne cleaning.

Figure 3: Spray-water protected robot technology for maximum ﬂexibility.

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ICT - INDUSTRY NEWS

Dürr Ecoclean Supplied its 100th EcoCFlex to a South German Automotive Manufacturer

he first EcoCFlex machine for cleaning and deburring engine components went into service at the BMW Group in 2005. Eleven years later, when the company was celebrating the 100th anniversary of its foundation, BMW ordered the 100th cleaning machine of this type as part of a major order. Representing the third generation of Dürr Ecoclean’s flexible robotized cells, this anniversary specimen was launched in production at the Steyr (Austria) engine plant in early May 2017 along with two other EcoCFlex 3L systems. These cleaning machines are adapted

to BMW’s latest specifications for technical cleanliness, replacing the transfer systems previously employed on a production line for petrol engines. Along with the special painting specified to suit the occasion, the BMW Group opted to order the new EcoCFlex 3L systems with handling technology comprising the Scara manipulator developed by Dürr Ecoclean. This rugged robot was purpose-designed for use in cleaning machines and convinces, among other features, with its innovative control approach. Instead

of the separate robot control unit commonly adopted, the EcoCFlex 3L relies on just one single CNC controller to operate both the Scara manipulator and the cleaning machine. This simplifies and accelerates programming, service and maintenance of the overall installation. However, the EcoCFlex 3L sets new standards not only for cleaning quality and ease of operation, but also in terms of energy efficiency. For further information: www.durr-ecoclean.com

PURE EFFICIENCY NO MATTER HOW DEMANDING YOUR CLEANING REQUIREMENTS ARE, THE SONOPOWER 3S SERIES MEETS ALL EXPECTATIONS.

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ICT - CASE STUDY

Miroglio & C.: Maximum Cleaning Quality of Automotive Components with Modified Alcohol Luca Antolini ipcm®

Opening photo: Steel components manufactured by Miroglio & C. after cleaning and drying.

he rule that a non-polar contaminant, e.g. mineral oils, is best removed with a solvent whereas a polar contaminant, e.g. emulsions and solid particles, can be effectively removed with a water-based detergent solution is still valid. Yet, the case of Miroglio & C., an

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engineering company based in Turin (Italy) and specialising in automotive components, has proven that a versatile product and an accurate cleaning system enable to remove both types of contaminants with a solvent (a modified alcohol) while meeting the strict requirements posed by the automotive

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industry and its suppliers, as well as working safely and in compliance with the applicable regulations. The cleanliness specifications of steel and aluminium components for engines, gearboxes and transmissions for the automotive sector are very strict in terms

aqueous detergent solutions with a process that uses a modified alcohol produced by SAFECHEM Europe GmbH (Düsseldorf, Germany), DOWCLENETM* Modified Alcohol, and is performed in a vacuum ultrasonic cleaning plant supplied by IFP Europe (Cittadella, Padua, Italy). This combination has enabled the company to dramatically improve the cleanliness degree of its parts and create a safe, lean and fully monitored process.

Precision is in Miroglio’s DNA

The company was established by Giuseppe Miroglio in Turin in 1898. In the first decades of 1900, it grew thanks to his sons Lorenzo and Eusebio, producing tower clocks. After WWII, the firm progressively specialised in a few industrial productions for the automotive sector, thus becoming a well-established company of the Turin area. Its customers include FCA, Magna Powertrain, Ferrari, CNH Industrial and FPT Powertrain Technologies. Currently, its range includes over 800 products; each month, it treats more than 300

of weight, size and amount of contaminant particles. Indeed, mechanical manufacturing processes deposit different kinds of contaminants on parts, such as chips, fine dust, oil, emulsions and lubricants. In these cases, flexibility and effectiveness are essential characteristics for the cleaning systems and products, in order to achieve the required results while avoiding burdensome manual or retouching 1 operations. This is the context in which Figure 1: Components produced by Miroglio & C. Miroglio & C. operates as a Tier 1 automotive supplier producing mechanical components for engines Miroglio & C. has proven and gearboxes as well as active aerodynamic parts for car bodies. that a versatile product This company’s production processes and an accurate cleaning are very complex and include thermal system enable to remove and special treatments performed by both types of contaminants a few contractors; however, they all (polar and non-polar) with a have a common requirement: The high solvent (a modified alcohol) cleanliness degree of surfaces while meeting the strict (Ref. opening photo). requirements posed by the Miroglio has recently decided to replace automotive industry and its its static cleaning cycle based on suppliers.”

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2 Figure 2: A part of the production area.

3 Figure 3: The interior of a water jet-cutting machine.

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4 Figure 4: The interior of one of Miroglio & C.’s labs.

different parts, such as oil pressure valves, injector cases, cold formed products, integral traction components, steering components, camshaft terminals and threaded shafts (Fig. 1). Miroglio & C.’s expertise comes with a deep knowledge of materials and processes. The

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Miroglio & C. has recently decided to replace its static cleaning cycle based on aqueous detergent solutions with a process that uses a modified alcohol produced by SAFECHEM Europe GmbH, DOWCLENETM* Modified Alcohol, and is performed in a vacuum ultrasonic cleaning plant supplied by IFP Europe.”

company can treat aluminium and any grade of steel, especially noble metals, offering a complete service that includes hot and cold forming, machining, grinding, surface treatments, heat treatments and assembly.

Exports account for 50% of its turnover, of which 5% is invested in the updating of its machinery and the training of its 80 employees. Its factory covers a 10,000 m2 area and includes three plants, hosting 25 CNC production systems and 3 laboratories for dimensional controls, material analyses and cleanliness tests (Fig. 2, 3 and 4). “We specialise in machining processes based on the drawings provided by our customers and already checked for feasibility: in fact, such operations account for 100% of our production. However, we often offer also a consultancy service for the choice of the most suitable material or the fine-tuning of the manufacturing process,” says Miroglio & C.’s owner Luca Grigoli, (Fig. 5). “This is possible thanks to our deep knowledge of noble metals, particularly difficult to treat and requiring advanced technologies, and to our ability to analyse a project and realise it with maximum efficiency and quality.”

5 Figure 5: From left to right: Arianna Bertaina, BRENNTAG Spa; Luca Grigoli, Miroglio & C.; Massimo Bove, SAFECHEM Europe; Alessia Venturi, ipcm®.

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Cleaning: Flexibility, precision, and effectiveness Miroglio & C. treats its raw materials starting from either bars or hot and cold formed workpieces. Its machines mainly perform chip removal processes using both neat oils and emulsions. “We are currently switching to the exclusive use of neat oil to cool and lubricate our plants: As a consequence, our cleaning process will need to become even more effective.” Although not every product manufactured by Miroglio & C. requires to be cleaned after machining, the cleaning step can be performed in different moments of the production cycle, between two operations or as the final stage. “We normally carry out a final cleaning operation on our parts to remove oil and chips,” says Grigoli, “but some components

may require an interoperational cleaning step, for instance those that are subjected to nitriding. Before this operation, performed by a contractor, the workpieces are cleaned with the same cycle we use for the final cleaning stage. We always carry out a fine cleaning process, for both interoperational and final operations.” The cleaning processes performed here are as complex as the manufacturing ones. “Some workpieces can be placed in fixed positions within our baskets in order to prevent any damage. In other cases, we have built special housings to fix and protect them even more effectively. Other parts, finally, can be simply cleaned in bulk.” The cleaning phase plays a crucial role for Miroglio & C. due to several reasons. “The removal of machining chips is important, but our processes create such residues in

COMPLEX CLEANING REQUIREMENTS – SAFECHEM offers customised cleaning solutions SAFECHEM offers complete solutions for high quality parts cleaning in line with ecological, social, and economic requirements. Comprehensive services and individual chemical-technical consulting help for an optimised cleaning process.

NECESSITÀ COMPLESSE DI LAVAGGIO – SAFECHEM offre soluzioni di lavaggio su misura SAFECHEM offre soluzioni complete per lavaggio ad alte prestazioni di componenti che soddisfano i requisiti ambientali, sociali ed economici. Una vasta gamma di servizi e consulenza personalizzata tecnico-chimica per un processo di lavaggio ottimizzato.

SAFECHEM Europe GmbH Phone: +49 211 4389-300 service@safechem-europe.com www.safechem-europe.com

very small amounts. Since we perform precision machining operations, we should rather talk about fine dust,” says Luca Grigoli. “The removal of oil and emulsions is the second reason why we need a very thorough cleaning process. On the one hand, some workpieces require a heat treatment and therefore we must eliminate any trace of oil, which could not be removed if it dried on the surfaces. On the other hand, we need to follow our quality philosophy and at the same time meet the cleanliness requirements of the automotive industry, sometimes corresponding, for instance, to the standard VDA 19.” For all these reasons, Miroglio & C. has chosen to replace its old ultrasonic cleaning system using water and

6 Figure 6: IFP Europe’s cleaning system fed with SAFECHEM’s DOWCLENETM* 1601 Modiﬁed Alcohol.

operation carried out to protect the parts in a uniform and controlled manner,” states Grigoli. The loading is automatic: A roller conveyor and a piston move the baskets inside the

detergent as well as fixed baskets, which was not flexible and effective enough, with a new modified alcoholbased process performed in a vacuum ultrasonic cleaning machine with moving baskets. “Our previous system was static: The components were placed in the baskets by a manipulator and then immersed in tanks with water, detergent and ultrasonic. However, it was not possible to perform any movement of the basket to increase the process effectiveness.” That is why the company started looking for another solution to overcome all these critical issues. Eventually, they opted for the use of a cleaning solvent, i.e. SAFECHEM’s DOWCLENETM* 1601 Modified Alcohol, supplied by BRENNTAG Spa; they also found that the most suitable system was a vacuum ultrasonic cleaning system built by IFP Europe (Fig. 6). “It consists of one treatment chamber performing four stages: Three cleaning ones and one for the application of a protective oil - a crucial, unique

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Figure 7: The automatic loading system with a roller conveyor and a piston for feeding the baskets.

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treatment chamber (Fig. 7). Then, the operator selects the right sequence. “The versatility of this solution enables us to adjust different parameters to control each step of the cycle, such as processing time and basket movements – rotation, tilting or stillness. However, the most important aspect lies in the cleaning “mechanics”: We can choose an ultrasonic, kinetic or spray process. There are numerous possible combinations. The drying stage is performed under vacuum in the machine. For most of our parts, the ultrasonic stage is the most important one, together with the basket’s tilting and rotary movements that are crucial to prevent any shadow effect on the surfaces, which make ultrasonic ineffective,” adds Grigoli.

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In addition to using DOWCLENETM* DOWCLENE 1601 1601, Miroglio & C. also relies on other services offered by SAFECHEM for the is characterised by a twomanagement of the cleaning process. component molecule with “They use the SAFE-TAINER™ System excellent chemical and for the supply and collection of solvents, thermal stability and high with the aim of protecting both the removal capacity with operators and the environment. This both oils and emulsions. system consists of specially designed, Its success is precisely extremely robust palletised steel due to the wide range of containers with containment bars. This contaminants that it can prevents the solvents from coming remove compared with into contact with the operators. All other solvents.” the operations are automatic, even during the stocking All the cleaning stages phase. With SAFEuse the same product: TAINER™, we offer TM* 1 DOWCLENE 1601 by the possibility to SAFECHEM (Fig. 8). It is a manage chemical high performance modified risk with a closed alcohol solvent used as an loop that integrates alternative to chlorinated the hermetic one solvents, hydrocarbons and of the machine in water-based products. Its all handling stages, lipophilic and hydrophilic from decanting to properties enable it to disposal,” states effectively remove any oil Bove. and grease traces as well as “Safety and ecopolar contaminants such as friendliness are emulsions. It is also used core aspects for 8 us,” says Grigoli. in difficult applications, “That is why, e.g. with expensive high Figure 8: SAFE-TAINER™, a steel container speciﬁcally designed for handling when we opted precision mechanical chemicals such as DOWCLENE™* 1601 and included in the services provided by TM* for the use of a components. DOWCLENE SAFECHEM. last generation 1601 can be distilled, it solvent, we is not corrosive and it decided to implement a vacuum plant evaporates quickly without leaving any and emulsions in the same machine in full compliance with all the safety residue. with the same quality results (Fig. 9 TM* regulations and with a professional “DOWCLENE 1601,” says Massimo and 10). “The cleanliness degree that Bove, the Sales Manager Italy of chemical risk management system.” we can now achieve is incomparable SAFECHEM Europe GmbH, “is the best The SAFECHEM MAXICHECK™ DCL-1N with the previous one. Moreover, performing modified alcohol for this Test Kit also enables Miroglio & C. to we currently clean up to 16 baskets application. It is characterised by a fully monitor its solvent status. “The per hour, more quickly than before two-component molecule with excellent analysis is carried out on-site by an and with a fully automatic process. operator to monitor the pH value and Depending on the cycle, the cleaning 1 ICT no. 11, March 2017, pages 40-44, “VIS Hydraulics acid content. Of course, it cannot time ranges between 15 and 20 seeks maximum quality with the modiﬁed alcohol replace any lab analyses, such as the minutes,” says Grigoli. technology”. chemical and thermal stability and high removal capacity with both oils and emulsions. Its success is precisely due to the wide range of contaminants that it can remove compared with other solvents.” Grigoli adds: “Moreover, our solvent consumption is very limited, since the deterioration rate of this product is very low. The odour detection threshold is very low, too.” With the new IFP cleaning system and the DOWCLENETM* 1601 solvent, Miroglio & C. can now remove oils

TM*

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Conclusions “The new cleaning plant has been operating on two shifts with the new DOWCLENETM* 1601 solution since 2014. Until now, our laboratory tests have not detected any significant worsening of the solutions’ parameters and we have never had to replace any whole bath,” states Grigoli. “We are very pleased with the cleanliness degree we have achieved, as proved by the analyses performed on our parts both in-house and by specialised laboratories. We have fully achieved our goal of meeting the increasingly stringent quality requirements of the automotive industry.”

9 Figure 9: Parts waiting to be cleaned.

Trademark of SAFECHEM

CHEMAWARE™ services that we offer to optimise cleaning processes, but it enables to constantly monitor the quality of the results as well as the process chemicals,” says Bove. “For the full management of its chemical cleaning process, Miroglio & C. relies on all the CHEMAWARE™ services provided by SAFECHEM Europe and distributed by BRENNTAG Spa,” says BRENNTAG Account Manager Arianna Bertaina, “such as our recurrent CHEMAWARETM Solvent Analyses and the CHEMAWARETM Solvent Training, which provided the operators involved with adequate training on every process aspect, from the solvent’s properties to the process technologies used.”

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TM*

Trademark of The Dow Chemical Company

The new cleaning plant has been operating on two shifts with the new DOWCLENETM* 1601 solution since 2014. Until now, Miroglio & C. laboratory tests have not detected any significant worsening of the solutions’ parameters and we have never had to replace any whole bath, fully achieving its goal of meeting the increasingly stringent quality requirements of the automotive industry.”

10 Figure 10: Cleaned parts after the cleaning and drying process performed with the DOWCLENETM* 1601 Modiﬁed Alcohol.

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IL LAVAGGIO DEL FUTURO… ADESSO

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The Targeted Cleaning of Cast Iron Turbines and the Constant Checks Make the Difference in the Automotive Sector Monica Fumagalli ipcm®

Opening photo: A cast iron turbine processed by RCM and cleaned in the Dollmar Meccanica system.

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office, which after examining it creates a detailed and fully transparent APQP (Advanced Product Quality Planning). We want our clients to clearly understand the production flow conceived for their components. If the plan is approved, we realise a prototype and some pre-production items to make sure the process meets all the functional and technical requirements. Afterwards, the component can be mass produced and we can agree a delivery date with the customer.” The production cycle starts with the unloading of the workpieces coming from the foundry. Then, the logistics operators distribute them among the various machining departments, depending on the customer. There are numerous high-precision CNC machining and turning centres devoted to cast iron, steel, stainless steel, aluminium and magnesium components (Fig. 2). At the end of the entire production cycle strict sealing tests and the components assembly have been running, when requested by the customers (Fig. 3 and 4).” © ipcm ®

the production of prototypes and foundry moulds, and Edil Tacconi, producing and selling materials for the construction sector.” The RCM’s factory occupies an area of 13,000 m2 covered and it is divided into nine warehouses, of which five are devoted to machining processes; the others to loading and unloading, assembly, testing and maintenance operations of components. The RCM’s turnover reaches the 20 M€ with 120 employees, whereas the group’s one reaches the 100 M€ with a total of 700 employees. “We deal with the products requiring precision machining processes,” says Vocca, “such as, for example, the aluminium bedplates intended for the Maserati and a few Ferrari cars. Other types of components generally processed by RCM are cylinder heads, turbines, suction manifolds, car and motorcycle chassis, wheel hubs, differentials, gearboxes, gearbox lids and gear housings (Fig. 1). “The customer provides our sales office with the design of the component. The sales office forwards it to our technical

he increasingly strict requirements of the automotive industry are not limited to the aesthetic performance of coatings and machining processes, but are more and more related to the cleaning of components that will be mounted on the finished products. This is a new challenge for the OEMs, constantly striving for the best possible quality results. RCM Spa (Valsamoggia of Monteveglio, Bologna) is among the most well established Italian companies specialising in the production of mechanical parts for prestigious car and motorcycle brands. “RCM was established in 1973,” says Quality Manager Gaetano Vocca. “Its competitive advantages are quality and service to its customers, including major firms such as CNH, Daimler, Ducati, Ferrari, BMW, Magneti Marelli, Maserati, New Holland and VM Motori. In 2007, we joined the Fonderie Officine Meccaniche Tacconi group, focused on casting of components in cast iron alloy and, since 2005, steel. The group also includes Sirfit, focused on machining processes, with its production site in Sibiu, Romania, Tekno K2, specialising in

1 Figure 1: Finished cylinder heads.

2 Figure 2: The machining area.

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The cleaning stage as the core of the production cycle

Figure 4: Some packed workpieces ready for shipment.

Dollmar Meccanica, a company based in Caleppio di Settala (Milan, Italy) that designs and manufactures cleaning plants using aqueous solutions for the surface treatment field. At the end of 2015, we asked them to revamp the system due a change in the shape of our turbines.”

Cleaning is an extremely delicate operation, but crucial to the quality of products. “RCM is equipped with 19 cleaning systems, including interoperational cleaning machines,” states Vocca. “One of the issues we have recently solved was the final cleaning of cast iron turbines (ref. Opening photo). They consist of two parts of plates that create the reverse impression onto the moulding sand and of two cores cast together, which is then broken to extract the workpiece. Especially for components with this particular structure, it is possible that some sand particles remain inside the part and are dragged along the production line up to the machining station and, after manual deburring, to the cleaning one. 5 For this type of parts, for several years we have been using a Figure 5: Dollmar Meccanica’s carousel cleaning system. cleaning machine supplied by

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Cleaning cast iron: a carousel system for a targeted operation The cleaning plant was installed in 2011 to treat cast iron turbines, characterised by strict requirements including a residual particle size below 600 microns. It is a carousel system working at a rate of 90 seconds/ workpiece and equipped with 15 stations (Fig. 5). “The request for such a high cleaning performance,” adds Gianfranco Fiori from Dollmar Meccanica, “led us to design a special system with focused jets at pre-set pressures. Moreover, any plant using baskets would © ipcm ®

Figure 3: A detail of the warehouse.

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not have been suited to this production rate, while the weight of the workpieces, between 15 and 20 kg, would have complicated the rotation of parts during the hydrokinetic cleaning cycle. In agreement with RCM, therefore, we opted for a carousel system that can even handle components with that size and weight (Fig. 6).” The solution adopted is based on the use of water and detergent due to the characteristics of cast iron. Vocca says: “RCM chose a water and detergentbased technology because both chips and residues of lubricating oil need to be removed from the cast iron surfaces while at the same time protecting them against corrosion. Indeed, when coming into contact with an aqueous element, this material can oxidise quickly. We needed a chemical solution able to ensure high levels of cleansing and passivation, if dosed in the right percentages, without leaving any trace on the components.” The system includes the following stages: general cleaning of the workpiece; targeted cleaning with nozzles hitting the critical areas of the turbine, such as the threaded blind holes on the component; flushing; blow-off; hot air drying; cooling; and unloading. “The main issue arising during cleaning,” says Vocca, “is due to the particular shape of the spiral inside the turbine, whose end part is closed: without any hole, water accumulates at the base of the spiral, jeopardising the effectiveness of the targeted cleaning phase. Dollmar Meccanica solved the problem with an internal flushing system consisting of two pads equipped with nozzles that block the side parts of the spiral. When the pad creates a barrier, the nozzles enter the spiral and perform a high pressure cleaning operation; since the holes are closed, the spiral fills with water and the liquid flows toward the only way out, that is, the holes on one of the two sides.”

Improved cleaning quality following the modiﬁcation of a product About one year and a half ago, RCM asked Dollmar Meccanica’s engineers to adapt its cleaning plant to the new performance needs arising from the changes occurred in the product treated. “Their turbines,” says Fiori, “no longer had the characteristics for which our cleaning machine had been designed, but they had changed: for instance, the holes were placed in a different spot compared with the previous layout. Therefore, we revamped the flushing and

ICT - CASE STUDY Figure 6: A detail of the entrance of the cleaning machine.

the components exiting the cleaning chamber, we have required Dollmar Meccanica to create a compliance test area and delimit it with walls (Fig. 7). If the clean workpiece passes the visual inspection and a recently added check on all threaded parts, a sealing test is performed (Fig. 8). After the Data Matrix code marking, used to trace the products’ manufacturing data, the components are packaged and sent to the warehouse.

An ongoing collaboration

blow-off systems to further improve the cleaning results of the system. This was possible also thanks to the collaboration of RCM, whose operators, during the four years of plant operation, had been able to observe and assess the plant, thus identifying the technical aspects that could be improved.” “After each cleaning cycle,” says Vocca, “an operator performs the specific checks with suitable tools in order to guarantee the further absence of residues on the surface or inside the spiral. In order to avoid any environmental contamination of

8 Figure 8: A turbine leaving the cleaning plant and waiting to be visually inspected by the operator.

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“The cooperation capacity of all parties involved determines the success of a product,” states Gaetano Vocca while explaining that the search for ever more effective cleaning solutions now characterises the activity of every OEM company. “Production conditions are getting stricter due to the ever evolving cleanliness requirements, with tolerances as low as 200 microns in the automotive industry. RCM aims at giving its cleaning systems the same importance of any machine tool, increasing the number of our interoperational cleaning plants, which contribute to optimal results, and 7 cooperating even more closely with cleaning Figure 7: The carousel cleaning system and, on the left, the isolated test chamber. solution specialists such as Dollmar Meccanica.”

The cooperation capacity of all parties involved determines the success of a product. RCM aims at giving its cleaning systems the same importance of any machine tool, increasing the number of our interoperational cleaning plants, which contribute to optimal results, and cooperating even more closely with cleaning solution specialists such as Dollmar Meccanica.”

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Metro and Municipal Railway of Paris: VACUDEST® Provides Clean Water for Train Maintenance Peter Demarez H2O GmbH, Steinen, Germany

info@h2o-de.com

Opening photo: Every year, more than 3 billion passengers are travelling in and around Paris with trains and buses from RATP (Régie Autonome des Transport Parisiens).

very year, more than 3 billion passengers are travelling in and around Paris with trains and buses from RATP - the “Régie Autonome des Transport Parisiens” (Ref. opening photo). This major public transport company in Paris operates divisions like the Paris Metro

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System, parts of the RER (trains of the Réseau express régional d’Île-deFrance), a huge bus system and several tram lines. All the trains and busses have to be maintained in certain time intervals. The technical revision of the trains is

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organised in different workshops in and around Paris. In the maintenance process, a lot of washing waters (i.e. from parts cleaning) and emulsions (cutting- and drilling-emulsions) are produced. Because of environmental laws, these waters may not be disposed of into the public sewer system,

Highpressure competence

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Piller deburring and cleaning systems for industrial part cleaning

Figure 1: Amortisation of the investment in the VACUDEST® system compared with the conventional treatments.

Treatment concept with VACUDEST® Clearcat vacuum distillation system The different types of polluted process waters are collected in a 10m3 storage tank prior to being fed into the VACUDEST®. This size of the tank gives the possibility to compensate fluctuating process water flows because of unsteady maintenance activities in the work shop. After separation

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but have to be destructed by specialised companies, creating high cost. Due RATP’s environmental policy, the transport operator tried to find an environment friendly, cost effective, 1 simple and reliable treatment system for the emulsions and washing waters. After careful analyses of different technologies, RATP decided for a process based on the H2O VACUDEST®-technology. This process allows zero liquid discharge since the distillate can be recycled. Thus fresh water resources can be saved and fresh water treatment cost reduced to a minimum.

High-pressure deburring systems

Cleaning systems

P Precision i i deburring services

2 Figure 2: Activepowerclean heat exchanger.

www.piller-online.com

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Each heat exchange process has to follow unchangeable physical laws. One of them is the effect that the power input into a vacuum distillation system is increasing at high evaporation rates due to scaling on the inner heat exchanger surface. To reduce this effect, H2O GmbH developed the Activepowerclean-technology. The heat exchanger of the vacuum distillation system is cleaned during operation continuously by means of small ceramic grinding balls (Fig. 2). Since 1998, the approved APCsystem is available for middlerange and large VACUDEST®systems. In the new VACUDEST®

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Figure 3: Vacutouch Control System.

of floating oils by a skimmer, the emulsion is fed into VACUDEST®unit. This vacuum distillation system produces purified process water, which can be either re-used in the washing process or disposed of into the public sewer. The project in Paris includes a VACUDEST® M 1,500 Clearcat-System for treatment of up to 1.250 m3 of waste water. Because of the patented Clearcat technology, the treatment of water containing hydrocarbons is much more efficient compared to conventional evaporator combined with residual oil absorbers for distillate post treatment. The innovative Clearcat technology produces crystal clear distillate, virtually free of oils, heavy metals and salts without any post treatment. Thus space required, investment and operation cost are lower (Fig. 1).

Activepowerclean (APC): A milestone to reduce energy consumption

4 Figure 4: VACUDEST M 1,500 Clearcat for the treatment of degreasing rinsing water.

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series, the Activepowerclean-heat exchanger was generously enlarged and fluid dynamic parameters have been improved, thus chemical cleaning is reduced and energy consumption is reduced by 15 %. In addition the Activepowerclean grinding balls act like boiling stones and thus reduce foam formation drastically.

The new VACUDESTÂ® Vacutouch control panel For the VACUDESTÂ® generation H2O has developed a new, innovative control system (Fig. 3). The new PLC control system guarantees uncomplicated handling via process visualisation and user guidance. Due to features like Profibus and Ethernet connection, the VACUDESTÂ® can be integrated flexibly in superordinated control systems or can be operated via remote access.

Advantage of Vacutouch: - Complete transparency of plant performance due to extensive log book functions - Optimized program functions like automatic adaption to fluctuation process water qualities - Test run procedure, monitoring and displaying of maintenance schedules and many others - Remote service possibilities enabling fast H2O service support - Alarm signal transmission via SMTP to superordinated systems - Online program updates guarantee an upto-date VACUDESTÂ®.

Project management In a team with engineers from H2O, RATP and a plant manufacturer the

complete system was designed according to the special requirements of RATP. Total project management and project execution was to the full satisfaction of RATP.

Installations all over the Ile of France Because of all the good experience with the first installation - a VACUDESTÂ® M 1,500 in Sucy En Brie - four more installations have been realized in the meantime (Fig. 4). Systems with a capacity of 200 to 350 litres per hour make sure, that yearly 6.000 m3 of emulsions and washing water are processed by VACUDESTÂ®-technology: An ecologically friendly process water treatment system for an environmental friendly public transport company!

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ICT - CASE STUDY

Fast and Cost-Effective Finishing of Aluminium Die-Castings Manuela Casali marketing-it@rosler.com

Rösler Italiana Srl, Concorezzo (Milan), Italy

Opening photo: To prevent any damage to the delicate work pieces during the separation cycle the multi-deck vibratory screening unit contains two steps with minimal drop heights.

hen it comes to high volume production of complex aluminium die-castings, Kovolis Hedvikov a.s. is a sought after partner by numerous car manufacturers and their suppliers. To expand its capacity and achieve more flexibility in the overall manufacturing process this company purchased a new vibratory finishing system that can handle a wide work piece spectrum and was custom engineered to fit into the available space at the customer’s premises. The die-casting company Kovolis Hedvikov a.s., founded in 1816 as an ironworking operation, has a long and eventful history. Since 1945 the company focus has been entirely on aluminum die-casting. Today, Kovolis produces components from nine different

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aluminium alloys weighing between 200 grams (7 ounces) and 8 kg (18 lbs.) with different casting technologies like vacuum investment casting and rheocasting. Their product range includes brakes, power steering systems, turbo chargers and compressors for air conditioning systems. Their customers are renowned car manufacturers and tier-1 suppliers who also employ Kovolis as an important partner for product development. In addition, the company provides services for machining, heat treatment and surface finishing.

Fast and gentle surface ﬁnishing Jiri Buzek, manager of foundry III at Kovolis, explains the need for a new vibratory finishing system as follows: “Our product portfolio underwent a drastic change in the

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past years. The trend goes more and more to larger and more delicate components, which require a vibratory finishing step after punch deburring for their downstream handling. Our existing finishing system was not designed for this and had also reached the end of its productive service life.” The new system had not only to cope with larger work pieces, but the finishing process also had to be a lot gentler. Additional customer requirements were high equipment uptimes and cost efficiency. And, above all else, the new finishing system had to be integrated into the existing manufacturing operation, utilizing the existing work piece loading device and hot air belt drier. The planning engineers at Kovolis submitted these specifications to two German equipment suppliers. The foundry manager continues:

ICT - CASE STUDY

Fully automatic feeding of the work pieces every 30 seconds The new finishing system consists of a linear continuous feed machine, type R 550/4600 DA, with a usable length of 4.6 meters (15 feet, Fig. 1). The functions of the existing work piece loading system and hot air belt drier were integrated into the overall system controls. “Rösler met all our technical requirements and provided valuable support in optimizing our finishing process,” explains Mr.

Buzek. About 30 different work pieces with a maximum diameter of 300 mm (12 inches) are currently processed in the R 550/4600 DA. Since it can handle parts with diameters of up to 400 mm (16 inches), this machine offers a high degree of flexibility for the future. Moreover, the system for automatic work piece loading can be easily adapted to a new work piece loading system, which may be installed later on. Depending on their individual design the castings are fed into the © Rösler Oberﬂächentechnik GmbH

“We decided to go with the Rösler continuous feed vibratory finishing system, because it offers ample capacity, and Rösler met all our special technical requirements. Of course, the fact that our company has had excellent experience with other equipment from the same supplier certainly helped.” Important was also that besides the equipment Rösler can also supply all compounds and finishing media the customer needs. This allows the perfect adaptation of the finishing process to the customer’s work pieces.

1 Figure 1: The R 550/4600 DA continuous feed ﬁnishing machine handles about 30 different die-castings with a maximum diameter of 300 mm (12 inches).

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finishing system at cycle times between 30 surface, the separation unit is equipped takes place fully automatically. While with a spray-rinse station. After the work and 60 seconds. The single curve U-shaped in competitive centrifugal systems the cross section of the processing channel pieces have passed through the hot air peeling knife is constantly rotating with belt drier, they go straight to packaging or the drum, the Z 1000 is equipped with guarantees the optimum movement of machining. the media and work pieces through the a stationary peeling knife. During the peeling cycle machine (Fig. 2). the knife This unique design pneumatically and the use of high moves to the performance plastic inner wall of media, type RKM, the slowly produces perfect rotating drum finishing results and removes within a maximum the sludge processing time of without eight minutes. The placing any processing time additional can be adjusted by load on simple inclination the drum of the processing bearings. bowl. Compared Upon to systems with a completion separate vibratory of the peeling discharge channel cycle the the work pieces are inside of travelling through the drum is the machine at a cleaned by a constant speed. spray rinse This prevents any 2 system. This jams, which could prevents cause nicking or, Figure 2: The single curve U-shaped cross section of the processing channel guarantees the optimum any sludge even, deformation movement of the media and work pieces through the machine. of the work pieces. deposits, which during subsequent Dual stage separation with rinsing station peeling cycles might lead to an imbalance Cleaning of the process water with an automatic centrifuge causing premature wear of the drum To prevent any damage to the delicate bearings. Mr. Buzek concludes: “In work pieces during the separation cycle, In addition to the R 550/4600 DA finishing the past we cleaned our process water the multi-deck vibratory screening machine the customer also purchased a chemically or with a semi-automatic unit contains two steps with minimal fully automatic centrifuge, type Z 1000 for centrifuge. This was highly labour drop heights (Ref. opening photo). The cleaning of the process water. Besides intensive and costly. With respect to undersize media classification system is the new finishing system this unit also process water-cleaning Rösler provided equipped with an adjustable bar screen, handles all existing rotary vibrators. us again with the optimum solution. We which allows Kovolis to decide at which With a centrifugal force of up to 2,000 g are certain that with the new equipment dimensions undersize media must be the centrifuge removes solid particles we will not only improve the quality of our discharged. Since the finished die-castings bigger than 2 μm from the process water. finishing operation but, at the same time, Discharge of the sludge weighing up to do not undergo a separate cleaning step will become more cost efficient.” for removal of media fines from their 30 kg (66 lbs.) from the rotating drum

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UNITECH SRL

Vigonza (PD) - ITALY - TEL. +39 049 628961

ICT - CASE STUDY

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Efficient Cleaning Solution for Use in Transmission Remanufacturing: Advances in Speed, Efficiency and Sustainability Yield Improved Replacement Transmissions Doris Schulz SCHULZ. PRESSE. TEXT., Korntal, Germany

ds@pressetextschulz.de

y changing over from an aqueous cleaning process with numerous manual interventions to fully automatic cleaning in three enclosed systems using a nonhalogenated hydrocarbon, British transmission remanufacturer ATP Industries Group not only managed to boost product quality. The switch also yielded substantial improvements in cost efficiency, working conditions and sustainability. Rebuilding vehicle components such as transmissions is an activity that saves raw materials, energy and costs. This is the remit of ATP Industries Group Ltd., an enterprise founded by Alan Smart in 1969. Based in Cannock Wood in the English county of Staffordshire, the company has evolved into Europe’s largest independent remanufacturer of automatic and manual transmissions, transfer boxes and other mechanical and mechatronic drivetrain components for cars and off-highway vehicles. “Our customers include vehicle manufacturers such as Ford, Fiat-Chrysler, Volvo, Aston Martin, Land Rover and JCB, to whom we supply products and services into 35 countries worldwide out of our headquarters plant and subsidiary sites in the U.S. and China,” reports Mark Bowen, Sales Director at ATP Group. The quality of the product, rebuilt to the most exacting global standards, is an

important success factor. Addressing this requirement, ATP has developed solutions including, e.g., a highly sophisticated, technically demanding test rig for precise validation and calibration of the electronic, hydraulic, mechanical and software functions of dual clutch transmissions. In recognition of this innovation, ATP was honoured with Britain’s most prestigious industry award, the Queen’s Award for Enterprises – Innovation Category, in 2016 (Fig. 1).

Part cleanliness – indispensable for high product quality In line with the quality standard, all components of a reconditioned unit must be like new and in some instances better than new, both technically and visually (ref. Opening photo). To achieve this objective, the incoming transmissions and components are initially cleaned and disassembled by hand. Next, the individual parts made of aluminium, steel, cast iron, plastics and other materials were pre-cleaned with brushes and a solvent at dedicated cleaning stations in order to remove oils, greases, carbon deposits and road dirt. Any foreign matter still adhering to the parts was removed in simple, semi-automatic washers

using an aqueous medium, and then the parts were dried manually with compressed air. This was, for one thing, a very time and labourconsuming workflow. Moreover, around 20% of all cleaned parts were rejected as not clean enough by Quality Control and had to pass through the cleaning process again. On the other hand, the cleaning method gave rise to an unwholesome work environment with elevated air humidity, airborne oil particles, and high noise levels. Operators in these areas had to wear ear protectors. “About three years ago, we therefore consulted various cleaning equipment manufacturers to learn about alternatives. Dürr Ecoclean UK presented us with a very attractive solution at the time but it exceeded our budget. As for the other vendors, their systems called for investments that were out of all proportion to the achievable improvement. For a while, therefore, we simply continued to work as before”, recalls Adrian Aston, Technical Director at ATP.

Convincing test results and machine concept Last year, prompted by brisk growth in demand and the company’s own rising quality requirements, ATP’s management approached Dürr Ecoclean again and carried out a series

Opening photo: In line with the quality standard, all components of a reconditioned unit must be like new and in some instances better than new, both technically and visually.

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of initial cleaning trials at the U.K. proceeds and cannot settle in the work test center. This was rounded out by chamber. “We check our cleaning further testing with genuine parts at quality by gravimetric tests once per the Filderstadt test facility in Germany. week. With the EcoCCore, we have “The results were so impressive that been achieving approx. 30% better we ordered two EcoCCore type cleaning results on a consistent basis”, Adrian systems right away”, Adrian Aston Aston recounts. adds. The innovative solvent-based A third cleaning system for mechatronic parts cleaning system that can work with hydrocarbons and modified alcohols “This huge quality gain prompted us 1 is run with a non-halogenated to adopt automatic cleaning also for hydrocarbon at ATP. Operating under the mechatronic components, which Figure 1: ATP was honoured with the Queen’s Award full vacuum, it features a built-in were still being cleaned manually”, for Enterprises – Innovation Category, in 2016. A royal the Technical Director continues. The distilling system plus full-flow and representative presented Britain’s most prestigious industry award to the company founder and chairman Alan Smart. company therefore invested in an bypass filtration for continuous solvent EcoCBase machine which is likewise reconditioning, thus providing a long equipped with two fluid tanks plus ultrasonic solvent life and low consumption. Its extensive common practice, but is directed straight into cleaning and operates with a hydrocarbon standard equipment package includes two the distillation unit. This design minimizes oil cleaning medium as well. The work chamber is flood tanks for the coarse and fine cleaning deposits in the flood tank while counteracting designed for cleaning baskets measuring up to treatment as well as heat recuperation. the accumulation of oil in the solvent. 530 x 320 x 200 mm (L x W x H). The throughput Moreover, the machines feature ultrasonic Signiﬁcant quality improvement of this machine amounts to 35 – 40 baskets per devices in addition to the standard injection through full process automation shift. flood wash system. Ultrasound and filtration Following disassembly, the transmission parts can be used simultaneously, and the volumetric are arranged in a defined position in cleaning Optimization in every respect flow rate is frequency-controlled. Particles baskets measuring up to 670 x 480 x 400 mm The improved cleaning results not only helped are thus discharged concurrently as cleaning ATP to further optimize product quality, which (L x W x H), adapted to the size of the work has already generated additional business. chamber. These baskets are conveyed to the machines in the cleaning section where an The company also reports substantial gains operator selects the appropriate cleaning in productivity and cost-efficiency. Likewise, program (Fig. 2). At present, ATP uses 9 the new cleaning process is top notch in terms of sustainability. The water consumption of different programs with process parameters set to match the respective transmission type, the old cleaning systems amounted to around material, and degree of contamination. 100,000 liters per year, a volume that is now The cleaning cycle takes between 6 and 14 saved. This is in addition to the savings on cleaning chemicals. “Payback on the new minutes to complete. “We clean 65 baskets per shift in each system, with just one lady operator machines will occur much sooner than we had calculated. In addition, we benefit from in attendance. Before, we needed between a much more pleasant and cleaner work 8 and 10 operators to clean these parts”, the Technical Director reports. environment. Our clients and ourselves have 2 To achieve the required cleaning result in gotten so used to this situation that we are such a short time, the EcoCCore is equipped already in discussions with Ecoclean about the Figure 2: Following disassembly, the transmission parts are arranged in a deﬁ ned purchase of a fourth system – for cleaning the with innovative process technology such position in cleaning baskets, then the as, e.g., advance steam degreasing. With complete transmissions prior to disassembly baskets are conveyed to the machines in the so that here, too, visible cleanliness will be this technology, the oil-containing solvent is cleaning section where an operator selects the not passed into the flood tank, contrary to achieved”, Adrian Aston concludes. appropriate cleaning program.

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parts2clean La più importante Fiera Internazionale nel settore della pulizia industriale di pezzi e superfici

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ICT - TECHNOLOGY OVERVIEW

The Increasingly Specialized and Exacting Science of Parts Cleaning in the Automotive Industry Doris Schulz ds@pressetextschulz.de

SCHULZ. PRESSE. TEXT., Korntal, Germany

Opening photo: The key to reliable, efﬁcient cleaning processes is to use the right combination of chemicals, equipment and processes for the component, contamination type and required cleanliness outcome.

here are a number of major trends sweeping the automotive industry at the moment. Emission reduction, electric propulsion, lightweight construction and connectivity are just a few of them. And they all have implications for parts cleaning. Recent cases of manipulation of emission readings in diesel-powered vehicles have

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reignited the debate surrounding the future of internal combustion engines in general and diesel engines in particular. The writing is on the wall: the future belongs to electrification – whether in the form of plug-in hybrids, range extender vehicles or fully electric cars powered by batteries or fuel cells. But it is equally clear that internal combustion engines

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will continue to be the predominant method of propulsion for the next 10 to 20 years. Consequently, automakers are hedging their bets, pushing ahead with the development of lower-emission, higher-efficiency petrol and diesel motors alongside their alternative drive programs. Examples of the former include engine displacement downsizing, forced

induction, high-efficiency, intelligent gearboxes, more effective control systems, and a whole host of other optimizations affecting various engine auxiliaries. These factors mean that vehicle components will become increasingly sensitive to contamination, thereby driving up technical cleanliness requirements for a growing number of parts – all amid mounting cost pressures on the international market. The proliferation of model variants and the shortening of product life cycles will add further challenges. All of these trends call for parts and surface cleaning solutions that consistently perform to very high standards of particulate and film-residue cleanliness while at the same time delivering a maximum of cost-efficiency.

ICT - TECHNOLOGY OVERVIEW

efficiency gains in robot cells lies in optimizing performance parameters. Reducing the cleaning pressure is an example of this. Robot cells are increasingly also being used for cleaning large engines, such as those used in construction and agricultural machinery (Fig. 2).

Optimized cleaning process design

Wet chemical cleaning is used on an increasingly large number of vehicle parts – and not just engine and transmission components. In other words, the proportion of parts requiring compliance with stringent cleanliness specifications is growing constantly. Depending on their type, composition and various other characteristics, Faster and more cost-effective parts can be either cleaned singly or in robot cells batches. 1 In-line robot cells are commonly used for High parts cleanliness standards are the cleaning and high-pressure deburring the norm in the automotive industry. Figure 1: This robot cell features a SCARA of engine and transmission parts because Meeting them reliably and costmanipulator that is specially designed for use of their superior versatility. The latest effectively hinges on having the right in parts cleaning systems and a single CNC controller for the manipulator and cleaning innovations and refinements in this chemicals, plant and processes for the system. area yield efficiency gains and shorter cleaning job at hand. These factors, in processing times, combined turn, depend very much on with improved cleaning quality the nature of the items to be and cell availability. For cleaned in terms of materials example, there are now robot and material combinations, cells on the market in which dimensions and geometry, SCARA manipulators specially the nature and quantity of the developed for harsh cleaning contamination, the cleaning plant conditions are used throughput, the required instead of the usual six-axis level of processing flexibility articulated-arm robots (Fig. 1). and, of course, the applicable Moreover, manipulators and specifications for particulate cleaning plants share the and film-residue cleanliness same CNC controller instead of (Ref. Opening photo). When it comes to choosing the having separate controllers – an cleaning chemicals, the maxim enhancement that simplifies “like dissolves like” is a good and streamlines programming, 2 rule of thumb. The cleaning operation, maintenance, and action of the chemicals is robot set-up after workpiece Figure 2: This robot cell was specially developed for cleaning large engine parts, such as engine blocks for construction machinery. in most cases supported by changes. Additional scope for

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one or more of several physical processes of varying intensity, such as spraying, pressure flooding, or ultrasonic cleaning. There are a number of systems available which can be integrated into production lines. Options here include conveyorized cleaning systems, single and multi-chamber systems and multi-tank systems. The choice depends on the nature of the cleaning task. Choosing a modular system with a range of connection options is worthwhile because it ensures adaptability to specific requirements, scalability and integrability.

Self-monitoring and regulating cleaning processes Process parameters such as cleaner concentration, immersion bath contamination levels and filter condition (in the case of aqueous cleaning processes, for example) can be continuously captured and monitored using automated measuring and analysis systems. As well as accurately tracking and documenting these critical states during cleaning, measuring and analysis systems can automatically initiate cleaner top-ups as and when required (Fig. 3).

parts2clean – leading international trade fair for industrial parts and surface cleaning What are the quality-related, time-saving and cost-reduction benefits of parts cleaning in the automotive industry? What are auto manufacturers’ options for cleaning components of varying types reliably and cost-effectively? What are the best ways of monitoring parts cleaning processes and testing cleaning outcomes? Answers to these and many more questions on parts cleaning in the automotive industry will be available at the upcoming parts2clean show. The leading international trade fair for industrial parts and surface

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3 Figure 3: This online measuring system continuously monitors cleaner concentration during production and automatically triggers cleaner top-ups as and when required.

Dry and partial parts cleaning The ongoing trend towards lightweighting, which involves aluminium, composites, new material combinations and the like, has important consequences in terms of cleaning requirements. For instance, certain material combinations may not

cleaning will be held from 24 to 26 October 2017 at the Stuttgart Exhibition Center in Germany. It will feature a wealth of information on cleaning systems, alternative cleaning technologies, cleaning media, quality assurance and testing methods, cleaning and transport containers, process media disposal and reconditioning, handling and automation systems, services, R&D, consulting and technical literature. As well as exhibits and displays, the lineup includes guided tours and the parts2clean Expert Forum with its three-day program of simultaneously interpreted (German <> English) lectures. For more information: www.parts2clean.de

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be amenable to wet chemical cleaning. In some cases, defined cleanliness requirements apply only to certain areas of a part – e.g. surfaces that are to be adhesively bonded, welded or sealed. And certain components need to be cleaned after they are installed. In these cases, alternative, waterless, processes such as CO2 snow cleaning, ionized compressed air cleaning, laser ablation and plasma cleaning may be the answer (Figs. 4 and 5). These dry technologies are easy to automate and integrate into production lines. They also have the advantage that the relevant surfaces can be cleaned on a just-in-time basis, thereby eliminating the need for measures and processes to keep the parts clean after cleaning and during transport.

Cleanliness inspection: the more frequent, the better In the automotive industry, inspection of parts for particulate cleanliness is prescribed by standards (in Germany: VDA volume 19, part 1; internationally: ISO

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The main difficulty is that, for many film-residue cleanliness scenarios, there are still no suitable testing methods available. Various solutions for detecting film residues, such as test inks, contact angle measurement, fluorescence spectroscopy, are used. However, these methods yield only qualitative or semiquantitative (comparative) results. There is a relatively new measurement method in which film-residue contamination is extracted from the part surface by means of vacuum desorption. With this method, it is possible to qualitatively detect and quantitatively determine film contamination on the entire surface of individual parts, assemblies and batches of parts, irrespective of part geometry. Manufacturers, industry associations and research institutes are currently developing technologies, recommendations and written standards aimed at improving the industry’s ability to define quantifiable film contamination tolerances and test for compliance with the same. © Dr. Escherich

Film-residue cleanliness is a different story. Increasingly, automotive manufacturers and subcontractors are targeting film-residue contaminants like grease and 4 oil, cooling lubricants and Figure 4: Dry processes such as CO2 snow cleaning are the answer when release agents. it comes to preparing deﬁned areas of parts, such as contact surfaces This makes for adhesive bonding, welding, soldering or sealing. sense, given that processes 16232) and is a routine, integral part of quality such as adhesive bonding, welding, management. The key trend here is that auto soldering, coating and hardening require manufacturers are mandating inspections surfaces to be “free of oil and grease on more and more parts and at increasingly residues”. The first step is to specify regular intervals. To meet these challenges, quantifiable cleanliness standards manufacturers of testing systems are and tolerances, which, it turns out, developing solutions that can be implemented is a lot more difficult for film-residue in-line and are therefore simpler and faster to contamination than it is for particulate use. contamination.

5 Figure 5: This unit is used for the non-contact cleaning of installed parts. The speciﬁc arrangement of the rotating air nozzles enables the compressed-air jet to remove loose particles from even the most challenging geometries.

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New Cleaning Challenges to Be Addressed at parts2clean 2017

t’s the same for the car industry, the highly automated cleaning processes and already booked their space by mid-June 2017 are nearly all the major market players component supply industry, medical integration in smart-factory environments, technology, mechanical engineering, and technology leaders represented in each exhibitors at parts2clean will be presenting aviation, precision engineering and of show’s display categories. “We are very intelligent automation concepts and solutions pleased about the industry’s enthusiastic microengineering, optics, electronics and many for adaptive cleaning processes. These response”, notes Daebler. “Moving the show other sectors of modern industry: The purpose include systems that allow continuous in-line back to its autumn timeslot was definitely the of industrial parts cleaning is to ensure the monitoring of the cleaning baths, with fully right decision.” necessary degree of cleanliness required for automatic dosage of additional cleaning agent, At the Stuttgart venue, trade visitors can learn subsequent processing operations, or for the continuous acquisition and documentation of all about the latest trends and innovations long-term, trouble-free functioning of the given all process parameters, and in-line inspection in industrial parts and surface cleaning for a part or component. of the resulting cleanliness. high-tech world. This includes, for example, As such, properly cleaned parts bring added Know-how on every value to the industrial manufacturing conceivable aspect of parts process. Global trends such as and surface cleaning electromobility, lightweight construction, “Adding value to the exhibition lineup Industry 4.0, sustainability, smaller will be a three-day parts2clean Industry production runs due to increasing Forum, which is an invaluable source customization, and the onward march of of information for visitors about the globalization are posing new challenges latest trends and innovations,” remarks for businesses all over the world – Daebler. Distinguished guest speakers including those specializing in industrial from industry and the worlds of R&D and parts and surface cleaning. All these scientific research will be highlighting issues will feature prominently at the next 1 new developments, talking about the best parts2clean, which runs from 24 to 26 ways to optimize processes and costs October in Stuttgart (Fig. 1). Figure 1: The next parts2clean’s event will take place from and assure quality, and sharing examples “The exhibitors at parts2clean will be 24 to 26 October in Stuttgart (Germany). of best practice with their audiences. presenting cleaning solutions that deliver All presentations will be simultaneously consistent results economically and cleaning plants that have been designed from efficiently, enabling manufacturers to meet translated (German ‹ › English). the outset to be adaptable - easily and without the requisite standards for the cleanliness of major investment - so as to stay in stride with industrial parts – not only for now, but also Guided Tours – the quickest way to the best-ﬁt solutions changing needs. Possible scenarios here would for the long term,” says Olaf Daebler, Global Guided Tours to selected exhibitor stands be handling different kinds of parts, meeting Director for parts2clean at Deutsche Messe. enable visitors to focus on specific areas various cleanliness standards or utilizing The products and systems on display at the 15th of interest in industrial parts and surface different processes. Leading International Trade Fair for Industrial cleaning, and to gather relevant information in Also on display are innovative cleaning Parts and Surface Cleaning help users of a time-efficient and concise way. The tours will technologies for use in fine and ultra-fine industrial cleaning technology to maintain their take place twice throughout the show, in two cleaning processes, which make it possible competitive edge in the marketplace – as a languages (English and German). to quickly and economically achieve very brief glance at the lineup of exhibitors makes For more information: high degrees of cleanliness. Responding clear. www.parts2clean.de to the growing industry demands for more Among the 200-plus companies that had

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EMO Hannover 2017 - Preview Provides a Foretaste of the World’s Premier Trade Fair for the Metalworking Sector

Besides Frank-Walter Steinmeier, Lower ermany’s President Frank-Walter Saxony’s Prime Minister Stephan Weil and Steinmeier will in September CECIMO’s President Luigi Galdabini will also be ceremonially opening the be speaking. After this, the President will be EMO Hannover 2017. “We are absolutely taking an exhaustive tour of the fair. delighted that our head of state will be “We shall be demonstrating to the President honouring the EMO Hannover with his the performative and innovative capabilities presence, and thus unequivocally affirming of our sector, and the range of solutions we the high level of perceived importance offer in the environment of digitisation,” accorded to the nation’s industrial added Carl Martin Welcker. sector,” says Carl Martin Welcker, General Commissioner of the EMO Hannover, commenting on the EMO Preview 2017. Following a four-year pause, the world’s premier trade fair for the metalworking sector will once again be opening its doors in Hanover, from 18 to 23 September 2017 (Fig. 1). With its motto of Connecting systems for intelligent production, it will be spotlighting the issues of digitisation and networking for production 1 operations. At the beginning of June 2017, more Figure 1: EMO Hannover 2017 will take place from 18 to 23 than 2,050 firms from 45 countries had September 2017 at the Hanover fair ground. signed up. There are more than 1,400 exhibitors from Europe alone. EMO Hannover 2017 – the The number of Asian participants has world’s premier trade fair for increased from 21 to 25 per cent. the metalworking sector “This means the current registration status is significantly above the comparable figure From 18 to 23 September 2017, for the previous event,” explains Welcker. international manufacturers of production There are plenty of indications that the technology will be spotlighting “Connecting EMO Hannover 2017 is heading for a record systems for intelligent production” at the participation level. EMO Hannover 2017. The world’s premier The opening ceremony is scheduled to last trade fair for the metalworking industry about an hour on 18 September. will be showcasing the entire bandwidth of

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today’s most sophisticated metalworking technology, which is the heart of every industrial production process. The fair will be presenting the latest machines, plus efficient technical solutions, productsupportive services, sustainability in the production process, and much, much more. The principal focus of the EMO Hannover is on metal-cutting and forming machine tools, production systems, high-precision tools, automated material flows, computer technology, industrial electronics and accessories. The trade visitors to the EMO come from all major sectors of industry, such as machinery and plant manufacturers, the automotive industry and its component suppliers, the aerospace sector, precision mechanics and optics, shipbuilding, medical technology, tool and die manufacture, steel and lightweight construction. The EMO Hannover is the world’s most important international meeting point for production technology specialists from all over the planet. In 2013, the fair attracted more than 2,130 exhibitors, and around 143,000 trade visitors from more than 100 different countries. EMO is a registered trademark of the European Committee for Cooperation of the Machine Tool Industry CECIMO. For more information: www.emo-hannover.de

INFO: VDW – Generalkommissariat EMO Hannover 2017 Verein Deutscher Werkzeugmaschinenfabriken e.V. Corneliusstraße 4 · 60325 Frankfurt am Main · GERMANY Tel.: +49 69 756081-0 · Fax: +49 69 756081-74 emo@vdw.de · www.emo-hannover.de

Informazioni e biglietti: Hannover Fairs International GmbH – Branch Italy Via Paleocapa 1 · IT-20121 Milano Tel.: +39 02 70 63 3 29 2 · Fax: +39 02 70 63 3 41 2 E-Mail: info@hfitaly.com

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ore and more attention is being focused on deburring, rounding and surface finishing due to highly demanding specifications with regard to tolerances and surface quality for the production of precision components. With exhibitor bookings already at the 125 mark as of 15 June 2017, DeburringEXPO will present the world’s most comprehensive offerings in its respective field covering innovations, further developments and time-tested solutions. The 2nd trade fair for deburring technology and precision surface finishing will offer valuable know how, not least of all at the bilingual expert forum. The event will take place at the Karlsruhe Exhibition Centre (Germany) from the 10th through the 12th of October 2017. Regardless of the fact that surface finishing requirements for precision components vary depending on product, application and industry sector, they’re resulting in new challenges for manufacturing companies. For example, burr-free components and workpieces with defined edges and roundings have to be produced with ever greater levels of precision. Surface finishes which minimise friction, wear and noise, and which increase performance and extend service life, are also in demand. Manufacturing steps for precise shaping are required as well, and in this respect machining and surface finishing are converging to an ever greater extent. As the procurement and communication platform for deburring, rounding and the production of precision surface finishes, DeburringEXPO presents

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1 Figure 1: The second edition of DeburringEXPO (Karlsruhe - Germany, from 10th to 12nd October 2017) will be expected signiﬁcantly larger and more international than the premiere event in 2015.

innovative and advanced products, processes and services, in order to be able to fulfil these growing requirements efficiently and reliably. “As of the 15th of June, 125 companies from 14 countries had already booked booth floor space for DeburringEXPO, including numerous market and technology leaders. We’re expecting 150 exhibitors, many of whom will take advantage of the trade fair in order to unveil new solutions”, reports Hartmut Herdin, managing director of event promoters fairXperts GmbH & Co. KG. The 2nd trade fair for deburring technology and precision surface finishing will thus be significantly larger and more international than the premiere event in 2015 (Fig. 1).

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Cross-Industry and Cross-Technology Exhibition Portfolio Whether the automotive industry, automation technology, drive and transmission technology, aerospace, machinery manufacturing, medical engineering, sanitary applications, the clock making industry or tool and mould making are concerned, the exhibition programme offered by DeburringEXPO covers the entire spectrum of deburring, rounding and the production of precision surface finishes. In addition to a representative overview of the various processes, equipment, and tooling as well as testing, measuring

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internal and external surfaces in a single process. Defined surface characteristics can be achieved reproducibly within very short cycle times. In particular for demanding materials, the PECM process permits burr-free production of three-dimensional shapes, contours and structures with very high levels of precision and surface finishing quality. As compared with conventional processes, machining is more accurate with regard to component dimensions and tolerances, and it doesn’t result in any thermal influences. Abrasive flow machining (AFM) is used primarily for processing difficult to access workpiece areas and internal surfaces of highquality components made of metal and ceramics, for which conventional procedures do not provide the targeted results. DeburringEXPO will also present various solutions for deburring and processing injection moulded, press formed

and machined plastic parts. These include, for example, cryogenic deburring which is conducted with liquid nitrogen in combination with plastic pellets at temperatures of down to minus 150° C, as well as deburring with carbon dioxide ice (dry ice). The removal of internal and external burrs from parts made of thermoplastics – even at difficult to access locations – is made possible by special systems for thermal deburring.

The Expert Forum – Added Value for Visitors and Exhibitors A three-day, integrated expert forum rounds out the offerings presented by DeburringEXPO. All presentations will be simultaneously interpreted (German ‹ › English). The speakers will provide information on the fundamentals as well as expert knowledge concerning innovative deburring technologies and precision surface finishing with the help of practical examples and benchmark solutions. For more information: www.deburring-expo.com © EMAG ECM GmbH

and analysis methods, the trade fair also makes it possible to gather targeted information concerning trends and current developments. For example, barrel finishing solutions for individual part processing will be exhibited which can be easily integrated into automated production lines and permit highly accurate, reliable deburring, edge rounding, smoothing, grinding and polishing of high-quality, geometrically complex components, synchronised to manufacturing cycle time. In the field of ECM deburring, newly developed generators are making it possible to obtain Ra values of 0.1 μm and better, depending on initial condition (Fig. 2). Beyond this, they also prevent so-called stray machining which may lead to worse machining results at peripheral areas. Furthermore, a new ECM process has been specially developed for, amongst other applications, surface finishing of 3D printed, metallic components. This makes it possible to improve both micro and macrostructures on

Figure 2: The ECM deburring of a metallic workpiece.

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