ipcm® 48 Magazine (November/Dicember 2017) by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

ISSN 2280-6083

ipcm digital on In this issue :

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SPECIAL ACE

INDUSTRIAL CLEANING TECHNOLOGIES

2017

8th Year - Bimonthly

INTERNATIONAL PAINT&COATING MAGAZINE

N° 48 - NOVEMBER/DECEMBER

For over 150 years, we have developed paints and coatings that enhance the appearance and durability of our customers’ products. With a broad range of liquid and powder coatings, designed to meet the needs of a wide array of industries, you can trust Sherwin-Williams to be your coatings solutions partner.

Inver and Syntha Pulvin are brands of The Sherwin-Williams Company

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CONTENTS NOVEMBER/DECEMBER 2017

SP ECIAL ACE

HIGHLIGHT OF THE MONTH

Innovative Industrial Choices for SDF. Eco-coating Technologies for High Productivity Lines Integrated into a Low Environmental Impact Plant

FOCUS ON TECHNOLOGY

125 years of Dörken

SPE C IAL AC E

SP ECIAL ACE

INNOVATIONS

34 05 06 16 20 21 68

FOCUS ON TECHNOLOGY

Electrocoat for the Agriculture, Construction and Earth Moving (ACE) and Home Appliance Markets from Axalta

EDITORIAL

BRAND-NEW

S PE CI A L ACE

BRAND-NEW

KingAgro: Innovation in Agriculture Thanks to Carbon Fibres. An Innovative Coating Plant for Carbon Fibre Spray Booms

HIGHLIGHT OF THE MONTH Industrias TITAN: Technological Research Behind 100 Years of History

BRAND-NEW BUSINESS CARDS

FOCUS ON TECHNOLOGY Pre-treatment as a Key to the Qualitative Improvement of Finishes and as the Success Factor of a Corporate Relaunch

94 96

BRAND-NEW FOCUS ON TECHNOLOGY Cutting-edge Coating Technology for Medium and Large-sized Carpentry Components. Industry 4.0 Principles for Increased Plant Versatility and Performance.

102 BRAND-NEW

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CONTENTS NOVEMBER/DECEMBER 2017

FOCUS ON TECHNOLOGY

Descendant of Titans

SUCCESS STORIES

John Deere Factory in Mannheim Installs Graco 2KS Paint Supply System

FOCUS ON TECHNOLOGY

A Spray Paint Booth with a Quick Colour Change System: Helping Contractors Increase Productivity

107 STANDARD & LEGISLATION - UCIF Informs Treating the Surfaces of Pressure Equipment

108 TRADE FAIRS & CONFERENCES

110

ICT - CASE STUDY

ZOOM ON EVENTS

130

120 ICT - INDUSTRY NEWS 122 ICT - SUCCESS STORIES Ecoclean Implements Energy Efficiency Gains in an Automotive Production Plant

124 ICT - HIGHLIGHT OF THE MONTH Weber Ultrasonics: Thinking Solutions 4.0

All Machining and Cleaning Products for Mechanical Components from One Source: the Success Story of Copra Minuterie Metalliche di Precisione

128 ICT - TECHNOLOGY OVERVIEW Cleaning Braking System Parts: Burr and Chip-free Workpieces in Short Cycle Times

130 ICT - CASE STUDY All Machining and Cleaning Products for Mechanical Components from One Source: the Success Story of Copra Minuterie Metalliche di Precisione

136 ICT - ZOOM ON EVENTS

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the Power of Colour P O W D E R

C O A T I N G S

TECHNOLOGY INNOVATION SERVICE PERFORMANCE

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EDITORIAL

n this year-end issue of ipcm®, more than ever before, we deal with the pre-treatment process and its importance to obtain high-quality products. If the preparation of a surface to be painted is not perfectly suited to the intended use of the object and to the coating quality level required, the film will tend to peel off, chalk, and lose gloss and colour while corrosion will start, regardless of the system applied. Whether a liquid or a powder coating is used, and even if the best products are chosen, a poor pre-treatment always results in a poor final quality level and in low corrosion resistance. As is well known, in the last few years the quality level required by coating specifications has been steadily increasing. Customers in the fields of architecture and aluminium, for instance, are no longer satisfied with five-year or ten-year guarantees: they are starting to demand twenty-year durability and gloss retention guarantees. Some of them even require an insurance, as if they were the only party involved in a process that is actually the result of a joint effort: it works like a classical orchestra, where each instrument has a role and must play in harmony with others. The pre-treatment cycle, the application system, the coating product, the polymerisation curve, and even the line operator are all are factors that must be perfectly adjusted according to the required quality level. A powder manufacturer has recently shared this thought with me: over the years, powder coatings have evolved in terms of quality and technology much more than application systems. It is very common, as well as easier, to blame the paint product for both poor yield and poor quality. Yet, there are so many companies that, maybe also due to the financial difficulties of the last few years, insist on applying metallic, special-effect or Qualicoat Class 3 coatings with systems that are outdated, have no flexibility, and do not allow to adjust any painting parameters. The operator’s professionalism plays a key role, too: proper training is crucial, not only in terms of theoretical notions but also of ability to identify any defects and put them in relation to coating and pre-treatment parameters. This issue ipcm® contains a special focus on the innovations in the field of agricultural and construction machinery finishing as well as a special insert on the workpiece cleaning and preparation processes. However, we have also collected in it the experiences of many coaters that have focussed on automation, Industry 4.0-oriented application systems, and increased pretreatment effectiveness to relaunch their businesses and dramatically improve their coating quality level. Finally, we thought we would give a gift to all of our readers: you will find a brochure attached to this issue, collecting all the major trade fairs in the coating industry as well as in any sector in which surface treatments play a key role for the production processes. This is an indispensable information and planning tool to get the most out of 2018!

Alessia Venturi Editor-in-chief Direttore Responsabile

I wish you a happy reading and I take this opportunity to wish you Merry Christmas on behalf of the whole editorial staff of ipcm®.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2017 - N. 48

BRAND-NEW

HMG Paints Begins Graphene Coatings Tests

©HMG

MG Paints has partnered with Applied Graphene Materials (AGM) to develop and commercialise Graphene (Fig. 1) containing coatings for a variety of industries. Graphene, discovered at The University of Manchester in 2004, is primed to revolutionise the materials world, and the two companies are progressing the formulation and application in protective coatings. Following an initial stage of controlled environment testing (Fig. 2), which produced some extremely positive results, the two companies are now testing their product in a real world environment. Tests will focus on the application of Graphene based coatings

©HMG

Figure 2: Testing at HMG lab.

1 Figure 1: Graphene’s molecular structure.

in both the Commercial Vehicle and Construction Equipment markets in partnership with a leading UK be-spoke commercial vehicle body builder. “We’re delighted with how our initial testing has gone and have now progressed to life trials in the environments they’d ultimately be used in” said Jonathan Falder, Head Technician of the HMG Graphene Project. “We’ve found AGM’s Graphene dispersions to integrate well using conventional processes and seen some significant performance gains from our own testing of commercial products. We are moving onto full scale trials and commercial launch as we believe that these benefits can add real value to our customers.”

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Combining the coatings experience of HMG with the ultra-dispersible form of Graphene and product integration expertise of Applied Graphene Materials, both companies believe that the newly developed products create higher value materials which possess specifically enhanced characteristics for a number of coatings applications across a variety of industries. For further information: www.hmgpaint.com and www.appliedgraphenematerials.com

BRAND-NEW

Jotun Group Partners with Datacolor® for Fast and Accurate Colour Formulation

otun selects the powerful and accurate Datacolor Match Pigment Software in all production facilities worldwide. Datacolor®, a global leader in colour management solutions and colour communication technology, was awarded to provide colour matching solution to Jotun’s all 38 production facilities worldwide. For colour professionals in paints, pigments and plastics, Datacolor’s Match Pigment software offers superior firstshot matches with powerful tools to optimize the cost and quality of recipes. As one of the world’s leading manufacturers of paint, coatings and powder coatings, the Jotun Group’s products are held to the highest standards, and this starts with the colour formulation. It is critical for Jotun, that their new formulation software delivers fast, accurate colour matching, minimizes batch corrections, and is also backwards compatible with their existing instruments. To ensure consistency and streamline colour process, Jotun also requires a centralized solution that will enable all sites to use the same database. “Datacolor was superior in current available functionality of Match Pigment software and superior in responses to Jotun’s specific requirements,” said Dr. Sebastian Schäfer, Jotun Project Manager Colour Matching.

“After 3 years of deep technical evaluation, we can say that Datacolor is offering the best software and instruments for our needs. Besides, Datacolor provides an excellent worldwide support, and has proven to be a reliable partner.” Key benefits Jotun is able to realize with the Match Pigment software: • Providing excellent correction results, also with Jotun legacy databases; • Optimizing formulas for cost and quality requirements; • Improving efficiency with centralized colour management; • Streamlining production with one complete solution for every step of the colour process. “We provide colour matching services to many decorative paint manufacturers, where time and matching quality is crucial.” said Rik Mertens, Global Application manager Datacolor, “we worked very close with the R&D department of Jotun to make sure the new functionality was meeting their needs. Datacolor colour matching algorithms provided reliable prediction of difficult shades resulting in formulas with small colour differences (Delta E), low metamerism and correct contrast ratio values.” For further information: www.jotun.com

BRAND-NEW

AkzoNobel’s Collection Futura 2018-2021

1 Figure 1: The range of special ﬁnishes for use on architectural metal components includes products which are innovative, sustainable and always on trend.

rchitects, designers and developers have an exciting new source of inspiration to draw from following the launch of Collection Futura 2018-2021 by AkzoNobel’s Interpon powder coatings brand. Full of the latest material and design trends, the collection – which is updated every four years – features an extensive range of highly durable and

sustainable colours and finishes developed together with trend experts PeclersParis. It is based on several globally-identified trends for 2018-2021: Glam City, Time Out, Treasured Light and Wild Nature. “Our colour expertise and continued development of durable and sustainable solutions drives the creation of our Collection

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

Futura,” explained Jean-Paul Moonen, AkzoNobel’s Powder Coatings Global Segment for Architecture. “The new collection includes a range of special finishes for use on exterior architectural metal components; products which are innovative, sustainable and always on trend (Fig. 1).”

BRAND-NEW

Wild Nature explores more primitive, wild expressions of nature and features earthy browns, peaty khakis, anthracite greys and charcoal blacks (Figs. 3 and 4). Continued Moonen: “The new range of finishes will enable customers to achieve just the right effect in any environment while helping them contribute to the future of green building and sustainable development.” He added that the company’s Interpon powder coatings have achieved a third party Environmental Product Declaration (EPD) certification, which includes a lifecycle analysis of the raw materials used in the product itself, the manufacture of the product, its shipment and application.

Figure 2: Treasured Light offers sensual and more reﬁned versions of metallic brilliance including brass, pink gold, pale copper and silver.

Each theme in the collection includes a unique range of colours, textures and effects that reflect the design and societal trends seen throughout the world. Innovation is also highly visible through two completely new finishes: silky texture and cotton. Glam City includes modernist influences and baroque trends with intense, dark tones centered on reds, blues and greens. Time Out provides inspiration for soothing living spaces, with light tones based on coloured whites and soft neutrals. Treasured Light offers sensual and more refined versions of metallic brilliance including brass, pink gold, pale copper and silver (Fig. 2).

Figure 3: Wild Nature represents a new approach to “green” trends exploring a more primitive, wild expression of nature.

4 Figure 4: Wild Nature features earthy browns, peaty khakis, anthracite greys and charcoal blacks.

It’s now 20 years since AkzoNobel launched the first special finishes collection for the powder coatings market worldwide. This is also the 15th year that the company has worked with Peclers to create a new trend collection for architects and designers as the global leader in powder coatings. In addition, AkzoNobel was the first powder coatings producer to launch the fine texture Sablé finishes, which have since become a major success in the powder coatings industry. For further information: www.akzonobel.com

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2017 - N. 48

BRAND-NEW

Smart solutions for Paint Shop 4.0 at the Eisenmann Technology Days

on guided tours, guests were given an insight into Eisenmann’s vision of the paint shop of the future: the optimal link-up of flexible hardware with intelligent software, complemented with innovative digital services. One of the product-independent solutions presented here was the E-PASS for automated software creation and virtual commissioning. It enables intensive testing of all the system software in advance, freeing up time and minimizing risks. Data-based services for smooth and fast customer

service were also in the spotlight. E-MES, the production control system from Eisenmann software company Enisco, represents a high level of transparency in production processes and the analysis of large amounts of data. Solutions for efficient painting, cleaning, caulking, sealing and adhering were to be found in the Smart Application Solutions area of the Center. The Smart Paint Shop Solutions island sparked great interest with technologies that offer maximum

aint Shop 4.0 – digital, smart, efficient: This was the main theme throughout the Eisenmann Technology days 2017 in Holzgerlingen. Around 1,000 visitors, mainly car manufacturers and suppliers from around the world, gathered at the systems manufacturer’s Technology Center over these three days to learn more about innovative solutions for surface treatments. In discussions with experts at numerous booths and exhibits and

1 Figure 1: Eisenmann presented its solutions for surface treatments at Eisenmann Technology days 2017.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

ÂŠ Eisenmann

BRAND-NEW

2 Figure 2: Innovative production methods consists of automated software creation and virtual commissioning.

flexibility and efficiency with minimal total cost of ownership. VarioLoc, the skidless paint shop transport system for car chassis, and Smart Oven, an energy-saving dryer concept, are revolutionizing the domain of paint shops. Combined with the VarioInspect light tunnel for surface inspection, the intelligent E-MES production control system and digital service solutions, it is now possible to create a tailormade, highly efficient, flexible Smart Paint Shop in line with Industry 4.0. A new concept for chassis storage with the working title VarioStore drew a lot of attention from the visitors. The Eisenmann conveyor technology experts presented this clever solution with driverless transport devices. This means car manufacturers can dispense with buffering in heavy, expensive high-bay warehouses and make flexible use of free space instead, such as on hall roofs. The system can be built and expanded costeffectively. For further information: www.eisenmann.com

Opening photo: 750 customers and business partners participated to Dörken’s 125th anniversary evening celebration under a marquee.

HIGHLIGHT OF THE MONTH

125 years of Dörken Interview to Dr. Martin Welp Dörken MKS-Systeme GmbH & Co. KG

mks@doerken.de

splendid event crowned the ‘125 Years of Dörken’ anniversary year (ref. Opening photo). On the 29th of September 2017, Ewald Dörken AG, Herdecke celebrated its company birthday along with around 750 customers and business partners. The 30th of September was then all about saying thank you to the employees, who have played a key part in the development of the business. The 29th of September 2017 began with an official part of the programme for customers and partners of the business with special

sector get-togethers of the individual business units, presentations and talks. Dörken MKS-Systeme GmbH & Co. KG, for example, invited 150 customers from all over the world to the ‘Dörken Days’ on the top floor of the Dortmund ‘U’. However, the breathtaking views over the city distracted only briefly from the presentations. Member of Board Dr. Martin Welp (Fig. 1) opened the event with a look back and a look ahead to the 125th anniversary. Arndt Kirchhoff, Vice President of the VDA – Verband der Automobilindustrie e. V. (German Automotive Industry Association) – followed with a talk on developments in his

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

industry. Technical innovations were presented by the Head of Technology Management, Christian Rabe. The President of the Doerken Corporation gave a presentation on market trends in the USA and the expertise of the local team. Onnen von Bredow, as Head of Asia Pacific at Dörken MKS, gave an insight into the Asian culture and local market structure. Andrej von Hofmann, General Manager of Dörken MKS Systems Shanghai, talked about the market situation in China. Finally, Dr. Gerhard Reusmann, Board of Dörken MKS, gave an overview of the Dörken MKS product portfolio and the products’ particular attributes.

HIGHLIGHT OF THE MONTH

At the celebratory evening function, the speeches were then kept consciously brief. 15 minutes was all that Karl E. Dörken (Fig. 2), Partner and Member of the Supervisory Board of Ewald Dörken AG, needed to quickly run through the 125 years of the company’s history. Just a further five minutes was needed by Executive Director Thorsten Koch (Fig. 3) for his look into the future and at the challenges that will face the business over the coming years. Then the exclusive show dinner began, during which the five operating companies of the Dörken Group were cleverly portrayed in dance, acrobatics, performance and music. The climax of the evening, however, was the appearance of Jan Delay and his band Disko No. 1, who really got the tent rocking. After them, the party started with DJ Munich. The 30th of September was then a day of saying thank you to the staff of the Dörken Group. A family day on the factory grounds offered lots of fun and information for all Dörken employees and their families. In the evening there was then a celebration in the marquee with 1,350 employees and their partners, who were able to enjoy the same show programme as the customers the evening before.

ipcm®: How is Dörken organized? MW: The heart of the company is in Germany. We have a headquarter model which means we are producing and developing technologies in our facility in Germany. We have a strong presence of tech centres in the region dealing with application, sampling, consulting. We have branches and tech centres in China, Korea and USA as well, but research and development takes place centrally. In India, we have sales technicians who are supporting the region of Chennai and Delhi. In Europe, Italy is one of our strongest markets because it has an efficient, professional, and globally expanding screw manufacturing industry. Nonetheless, I am sure that in 10 years from now we will have the same setup and type of organization that we currently have in Germany also in other countries.

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ipcm®: What is Dörken current market strategy? MW: Becoming the corrosion experts on a global level. We come from the production of zinc flakes technology but we have expanded our portfolio to electroplating and e-coat for bulk process, which is a very innovative technology. We are currently introducing a new product for coil coating, as well, and we are focusing on the construction industry with a white rust protection technology. With all these ® ipcm was invited to the different technologies, we want 1 celebration and had the occasion to offer expert advice about to interview Dr. Martin Welp, corrosion protection and deliver Figure 1: Dr. Martin Welp, Board of Member of Board of Dörken reliable and efficient solutions to Dörken MKS-Systeme GmbH & Co. KG. MKS-Systeme GmbH & Co. KG, the metal industry. on the company’s present and Our main market is definitely future technological challenges. the automotive flanked by wind energy and railway, which are segments where solutions for a higher “In the last 10 years we have been able to globalize corrosion protection are in great demand. Another the company” Martin Welp started. “We have interesting market is the construction industry where strong organizations in China and USA; we are Dörken is not yet known: that is why we are working present with sales technicians in nearly every on social media, internet, and magazines to get more country where automotive is taking place. We have recognition. 200 licensees globally that means applicators who are applying our products all over the world. We ipcm®: What do you mean by construction industry? MW: Construction is building and infrastructures: are mostly supplying the automotive industry but our coating and protection technology is expanding we’re expanding also to other industries, like wind to large parts, like the ones that are used in the energy, construction, railway.”

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are as harmless as possible. Our electroplating product line, for instance, works with no nickel, no cobalt while CrVI has never been used in our products.

to coat parts of many different sizes, from 3 mm diameter. The only critical aspect with bigger parts is that you will see some touch marks upon them after baking and this the ambit where we are competing against existing processes. Bigger parts can be hanged but hanging is very expensive. Our system is efficient because is a bulk process and is highly effective because we can combine active corrosion protection with zinc flake technology underneath with the barrier protection delivered by e-coat.

ipcm®: How is the market reacting to Dörken KTL System? 2 MW: There is a ipcm®: What is the secret behind a huge interest in Figure 2: Karl E. Dörken, Partner and Member of the Supervisory Board the market. Lots company that is on the market for 125 of Ewald Dörken AG. of sampling is years? taking place for MW: Thinking different, fresh, new, construction industry. The origin of our serial productions. We are working for the and out of the box. In addition, it is business is the protection of small parts like automotive, bicycles, motor bikes industries the empowerment of people and the fasteners, screws and springs but the reality creation of a very young and fresh team of things is that with our technology we with decision power over projects and can protect everything that goes outside. developments. The big difference between Dörken’s The Dörken’s secret is technology and a traditional corrosion ipcm®: How do you see Dörken in the to think different, fresh, new, protection coating is that we do not deliver next 100 years? and out of the box. In addition, MW: Hopefully as a global player by a simple barrier protection but an active it is the empowerment of protection, a sacrificial protection with all means, as strong in China as we are people and the creation of a very thin coating layers. This allows us to in the US and in Germany. I strongly very young and fresh team believe in the quality of production in deliver a very efficient corrosion protection with decision power over one place but in the future, everything where the preservation of geometry, projects and developments.” fitting and tolerances is strategic. This is will have a much bigger footprint than something that you cannot do with a thick today. but these markets layer of barrier protection. In addition, the are mature and very latest generation of our products is able slowly reacting, so to minimize white rust corrosion coupled I think it will take with a very long lasting finish, which is another 5 years for particularly important in the construction our KTL System to industry. be an established ® process in the market. ipcm : What is Dörken’s focus in the R&D? MW: Dörken is strongly driven by sustainability. The nature of our business ipcm®: For which itself is to create sustainability by kind of parts is the preventing corrosion. Since we are using KTL bulk system best much less material than any other coating, suited? 3 we are sustainable, lightweight and not MW: There are no utilizing too much of whatever heavy best parts: with this metal. We are using only products that system, we are able Figure 3: Thorsten Koch, Executive Director of Ewald Dörken AG.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

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

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

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

BRAND-NEW

Sherwin-Williams Now a Major Player in Europe Now, six months later, many Valspar businesses, functions and regions have already been successfully integrated into Sherwin-Williams especially in Europe, the Middle East and India. Early actions have been to further boost our powder capabilities, to bring new technologies from North America to enhance the existing Inver range of well-known technologies such as Acrilinver®, Epoxinver® and Inverplast®, but mainly to promote in Europe and Asia the high performance waterborne technology known in the Italian market with the brands Inverpur®, Idroxinver®, Idrayon®, etc. © Sherwin-William s

Figure 1: Sherwin-Williams has ofﬁcially acquired Valspar and consequently the Inver Group.

n June 2017, Sherwin-Williams officially acquired Valspar and consequently the Inver Group that had been part of the American company since 2013 (Fig. 1). This amalgamation of 2 great companies has created the largest Coatings company in the world with approximately 14 billion euros annual sales. With a broader portfolio of products, a wider footprint of operations and a significantly enhanced R&D organisation, Sherwin-Williams is now even better placed to serve customers around the globe (Fig. 2).

2 Figure 2: Inver’s plant in Minerbio (BO), Italy.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

BRAND-NEW

In November 2017, The Syntha Pulvin® brand has been launched at the Batimat exhibition in Paris. Syntha Pulvin® is the premier architectural powder coatings brand in Europe, setting the industry standard in terms of innovation, quality and service (Fig. 3). The brand was first introduced in the early 70’s. The first powder coated building was in London in 1972. Since then we have continuously worked to improve quality standards and to keep Syntha Pulvin® at the highest level in terms of performance and service. By combining the two companies, Sherwin-Williams is now the technology leader in Europe for waterborne coatings used in the general industrial and heavy machinery segments, is one of the biggest powder producers and has a high market recognition with liquid and e-coat technologies. Furthermore, the focus is on key segments including General Finishing, Heavy Machinery, Architectural and Transportation. All of this, matched with a real local presence, 7 major production plants, 20 tinting & blending facilities and more than 50 distributors across Europe, allows Sherwin-Williams to be a true coatings solutions partner.

Figure 3: Syntha Pulvin® is the premier architectural powder coatings brand in Europe.

BRAND-NEW

M.I. DUE: Celebrating its 45 Years of Plant Engineering Activity in Great Style

1 Figure 1: Carlo Andrea Casiraghi.

Established in 1972 by Carlo Andrea Casiraghi (Fig. 1) in a small building located in Triuggio (Brianza), it soon grew and moved to the neighbouring city of Besana Brianza. The headquarters are still here, including several production plants and the multi-storey office building raising in the beautiful Valle del Lambro Park. The continuous technological upgrade of its equipment, the experience gained in decades of

which are performed by its technical teams. This quality-oriented approach has enabled M.I. DUE to become one of the leading providers of highly automated coating systems for the cosmetic 2 packaging field, with hundreds of Figure 2: Almost 80 employees, partners and friends attended the machines already evening event. installed around the world. The important anniversary of the company activity, and its ability to meet customer was celebrated on Friday 17 November requests make M.I. DUE an advanced with a dinner organised at the restaurant partner for its sector, in Italy and abroad. Cenacolo dei Pittori in Besana Brianza, a High efficiency and reliability characterise all their systems. M.I. DUE is one of the few plant engineering companies to follow the development of new systems from design to construction, which take place in an in-house workshop equipped with cutting-edge 3 machining and welding centres, up to installation Figure 3: Carlo Casiraghi with the drawing gifted by his employees. and start-up, © M.I. DUE Srl

lmost half a century of activity. This is the important milestone achieved in November by M.I. DUE Srl (Besana Brianza, Monza, Italy), a company specialising in the custom engineering, design and construction of surface treatment plants for plastics, metal, glass, Zamak and aluminium.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

well-known venue and meeting place for artists. Eighty people participated: employees, suppliers, partners, but mostly friends (Fig. 2). “I wanted to surround myself only with the people that I carry in my heart to celebrate this achievement for my company and for my life as an entrepreneur,” said Carlo Casiraghi. “It was not easy to bring the company where it is now: there were some difficult moments, but it has always overcome any problem more determined than ever, and I with it. Being a good entrepreneur means sacrificing a lot, taking risks, and feeling very lonely. However, although I have already been doing it for forty-five

BRAND-NEW

4 Figure 4: The handcrafted Tree of Life decorating the tables.

years, I still have twenty projects to complete. Therefore, I intend to keep working for at least another twenty years.” During the evening, ended with the cake cutting, M.I. DUE’s employees presented a beautiful gift to Carlo Casiraghi: a charcoal drawing of the whole company staff (Fig. 3). For the decorative table setting, crafted by the employees, the Tree of Life (Fig. 4) theme was chosen, the symbol of Milan’s Expo 2015 but also of a full and intense life built on solid bases – a very powerful symbol to wish M.I. DUE many more years of success. For further information: www.midue.it

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N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

... On the road to

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n. 48...

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INNOVATIONS: PRESENT&FUTURE

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BRAND NEW

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SUCCESS STORIES

Innovative Industrial Choices for SDF. Eco-coating Technologies for High Productivity Lines Integrated into a Low Environmental Impact Plant

Electrocoat for the Agriculture, Construction and Earth Moving (ACE) and Home Appliance Markets from Axalta

KingAgro: Innovation in Agriculture Thanks to Carbon Fibres. An Innovative Coating Plant for Carbon Fibre Spray Booms

Pre-treating Large-Sized Workpieces: Shotblasting for Hookloaders, Tippers and Bodyworks in General to Increase Their Long-Term Corrosion Resistance

John Deere Factory in Mannheim Installs Graco 2KS Paint Supply System

Descendant of Titans

Â© SDF Spa

Sandvik Paint Plant Conveyor

Opening photo: A VIRTUS series’ tractor manufactured in the SDF’s plant in Treviglio (Bergamo, Italy).

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Innovative Industrial Choices for SDF. Eco-coating Technologies for High Productivity Lines Integrated into a Low Environmental Impact Plant Alessia Venturi and Barbara Pennati ipcm®

current trend in the finishing industry is the development of innovative and industrially sustainable solutions especially focused on: • Industry 4.0; • Eco-friendliness and safety of the working environment; • Lower energy and processing costs; • High quality of the applied films; • High performance coating application cycles; • Proper integration of plants into latest generation processes.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

In particular, nowadays, no new coating plant can be designed without considering the Industry 4.0 principles: digitisation of production, interconnection among machines, and the possibility to collect and process all system data automatically are just a few of the requirements imposed to the manufacturers of coating plants, machines and devices. SDF Spa (Treviglio, Bergamo, Italy) made one of latest Industry 4.0-oriented plant investments in the Agricultural Construction Equipment (ACE) sector early in 2017. This was aimed at installing a new high-

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distributing its products with the brands stages that were previously outsourced, efficiency, fully automatic coating line SAME, DEUTZ-FAHR, Lamborghini such as the assembly of tractor’s front with application systems borrowed from Trattori, Hürlimann, and Grégoire (Ref. axle. “Our Treviglio plant handles the the automotive industry. opening photo). This aptitude for highest production volumes of the Group Verind is a company of the international innovation has recently translated into and it is the most complete one in terms Dürr group, which designs innovative of production process. technology solutions by Here, we machine integrating expertise, some transmission industrial system components, weld engineering, and cabin frames, produce equipment and eco6-cylinder engines coating technologies; and spare parts following its corporate and have several philosophy, it supplied assembly departments SDF with an innovative for transmissions, automatic application cabins, front axles, system 4.0, perfectly and of course the integrated with the process whole tractors,” and ideal for the complex says Massimiliano components treated. Tempesta, SDF’s “In order to develop Group Industrial such a high-productivity 1 Treviglio Plant and automation coating Manager system, we had to consider Figure 1: From left to right: SDF Manufacturing Engineering – New Project, Achille (Fig. 1). a mix of significant Giussani, SDF Group Industrial Treviglio Plant Manager, Massimiliano Tempesta, and The machining variables such as ecology, SDF Plant Treviglio Head of Manufacturing Engineering Gianluca Schiavulli. department has investment costs, undergone profound production efficiency, changes, as well as the assembly the renewal project that has involved plant complexity, coating performance, process, whose transformation process the headquarters as well as the facility predictive maintenance, safety of the is still ongoing. “We have completely of the Group with the highest production working environment, product quality, reconsidered our tractor assembly volumes, precisely located in Treviglio, and product complexity in terms of both system,” states Tempesta. “In the past, where everything started. The project shape and material,” says Alessandro we had three conventional assembly named “Project One” has set up an Soba, the Industry Sales Manager of lines. The coating systems were located intervention programme in different Verind. “Not to mention that we also at their centre without any logistic production phases, with an investment wanted to offer SDF a digitised global optimisation. Moreover, the length of over 20 million Euros and the service.” and arrangement of the assembly insourcing of some manufacturing lines before and after the Project One: creation, painting stations had been development and designed for a product that implementation was significantly different Since the beginning, the SDF Group Nowadays, no new coating plant from the current one: much has always been characterised by a can be designed without considering more assembly operations particular propensity to technological the Industry 4.0 principles: digitisation were needed before painting innovation. Established in 1927 for the of production, interconnection among and much less of them were development of one of the first diesel machines, and the possibility to collect required in the subsequent tractors in the world, the company and process all system data automatically stages. The technological has continued to evolve to become are just a few of the requirements imposed transformation of our tractors a leading manufacturer of tractors, to the manufacturers of coating plants, called for a total change. harvesting machines and diesel engines, machines and devices.”

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2017 - N. 48

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The Treviglio plant handles the highest production volumes of the Group and it is the most complete one in terms of production process.”

recent machine, dating back to the late 1980s, had been integrated with a topcoat application robot; the primer was applied in a semi-automatic booth with a reciprocator that, however, did not ensure satisfactory coverage of the workpieces. On the other two lines, the primer was applied manually and the topcoat with a reciprocator; however, several manual touch-up operations – almost a repainting operation, indeed – were needed.”

2 Figure 2: The new assembly line.

In the framework of the Project One, at the beginning of 2017 we started one tractor assembly line; in January 2018, we will also start a second line and we will dismantle the old one (Fig. 2).”

SDF Spa made one of latest Industry 4.0-oriented plant investments in the Agricultural Construction Equipment (ACE) sector early in 2017. This was aimed at installing a new high-efficiency, fully automatic coating line with application systems borrowed from the automotive industry.”

The new coating plant: from the 1980s to the Industry 4.0 The new coating plant designed by Eisenmann is equipped with an automatic application system developed and supplied by Verind.

The most significant part of the investment project, however, has concerned the tractor body coating phase. Once in full operation, the new systems’ production capacity will be enough for both assembly lines. “We needed to change our entire coating process, which was performed by three outdated systems that had too many

limits in terms of expansion as well as environmental and quality improvement. In particular, we did not have any space to improve the pre-treatment stage with the installation of a multi-stage tunnel,” says Massimiliano Tempesta. “Automation was also lacking. The most

3 Figure 3: A bird’s eye view of the new coating plant.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

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4 Figure 4: A tractor body at the entrance of the pre-treatment tunnel.

VERNICIATURA, SIGILLATURA, INCOLLAGGIO Soluzioni per applicazione materiale 2K – EcoDose 2K

www.verind.it

The technological transformation of the tractors called for a total change. In the framework of the Project One, at the beginning of 2017 SDF started one tractor assembly line; in January 2018, it will also start a second line and it will dismantle the old one. The most significant part of the investment project, however, has concerned the tractor body coating phase. Once in full operation, the new systems’ production capacity will be enough for both assembly lines.”

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

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Figure 5: The only remaining manual workstation is the one devoted to masking operations.

The new system has two main features: a 5-stage pretreatment tunnel, which has considerably increased the corrosion resistance and the quality level of SDF tractors, and the automation of all coating processes. A robotic blow-off station has been added to eliminate the manual drying operation.”

protect the surface areas that must not be coated or wetted during pretreatment (Fig. 5). “We have designed and installed an automation, 2K coating pumping/ dispensing, and application system that has met SDF’s needs for greater application efficiency and productivity optimisation. We have transferred

It has already been started and it will reach full operation by early 2018. The plant engineering choices were based on the criteria of productivity increase, eco-friendliness, quality improvement, and integrated automation (Fig. 3). The new system has two main features: a 5-stage pretreatment tunnel (Fig. 4), which has considerably increased the corrosion resistance and the quality level of SDF tractors, and the automation of all coating processes. A robotic blow-off station has been added to eliminate the manual drying operation: the only manual station left is the one devoted to the masking operations needed to

Figure 6: The coating management unit.

7 Figure 7: The electronic dosing device EcoDose 2K supplied by Verind.

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this technology from the automotive sector to the industrial coating one,” says Marco Assorgia, Technical Sales Engineer at Verind. “Moreover, in order to meet the thickness and cycle time requirement, 2K water-soluble primers and topcoats are applied with the electrostatic technology. This optimises transfer efficiency and reduces overspray.” “Together with SDF’s management, we have also decided to interconnect the automation systems of all robotic stations, following the Industry 4.0 principles,” says Alessandro Soba. “The collection of process data on the consumption of paints and washing products during the colour change operations on all units, including the

The collection of process data on the consumption of paints and washing products during the colour change operations on all units, including the manual touchup one, and the monitoring of the temperatures, pressures and levels of the coating management unit ensure a clear view of the application process.”

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The SDF’s product range is highly varied. It produces about seventy tractors per day that belong to over twenty different families. Each family, in turn, is greatly varied in terms of options available. It is therefore very difficult to handle all coating processes with a robotic system. However, thanks to the possibility to program the robots offline based on the 3D drawings made by the design department, the quality of the coating process has greatly improved despite such diversity. We now operate with about forty different programs selected by the robots depending on the order of production.”

manual touch-up one, and the monitoring of the temperatures, pressures and levels of the coating management unit ensure a clear view of the application process.” Verind has developed its application systems with this in mind, in terms of both process flow and robotics. The features chosen were as follows: • An automatic coating management unit with an EcoPump system with the “4 Ball” technology (Fig. 6); • Automatic filling of process tanks from the paint manufacturer’s drum; • An insulation system designed for Dürr’s 100 kV and 500 μA electrostatic generators; • Continuous measurement of the tank levels and of the temperatures and operating pressures of paints and catalysts; • A modular automatic colour change device with a recirculation system; • A 2K coating dosing and flow control system with a Dürr gear dosing pump; • Hollow-wrist robots that can be programmed offline; • Application technology with Dürr Twin Gun devices and an automatic control system of the atomisation parameters;

• An automatic gun cleaning system; • An electronic dosing equipment EcoDose 2K for the manual touch-up workstation, able to collect consumption data and equipped with a Direct Injection Technology (DIT) system with A and B channels (Fig. 7).

Figure 8: CMA robots’ control modules.

Each booth is equipped with two opposing robots provided by CMA (Pradamano, Udine, Italy), each featuring two Dürr automatic guns and their related electronic dosing equipment (Fig. 8). This enables to separately control their flow, air pressure and other parameters for proper paint application. The blow-off

Figure 9: In its Treviglio factory, SDF manufactures 70 tractors per day belonging to 20 different product families.

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FOCUS ON TECHNOLOGY

10 Figure 10: Manual touch-up operations.

station is equipped with two robots with a centrifugal turbine blow-off system and special nozzles recovered from the old plant. “Our product range is highly varied. We produce about seventy tractors per day that belong to over twenty different families (Fig. 9). Each family, in turn, is greatly varied in terms of options available. It is therefore very difficult to handle all coating processes with a robotic system,” explains Massimiliano Tempesta. “Especially for some products, we still need a manual touch-up stage (Fig. 10). However, thanks to the possibility to program our robots offline based on the 3D drawings made by our design department, the quality of our coating process has greatly improved despite such diversity. We now operate with about forty different programs selected by the robots depending on the order of production.”

The application process is developed for the largest-sized tractor body currently produced. At moment, this equals to 50/52 m2 of surface to be covered; the dosing and dispensing system must therefore ensure adequate thicknesses (50 to 70 microns) in a 5-minute cycle time.”

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Figure 11: The application of a light coloured primer enables to check that the topcoat layer is applied uniformly.

Beckers Industrial Coatings has followed the implementation of the new plant since the beginning, designing a highly performing painting cycle based on the new operating parameters and with high quality standards. The primer has been specially developed to allow adhesion to all types of support in use and it can be recoated with the required topcoat in very short time. The epoxy primer and the polyurethane topcoat are

Since the factory is located in the city centre, the plant design also focussed on eco-friendliness factors. Although water-based, low solvent-content products had long been used, the new E-Cube dry filtration systems installed by Eisenmann on the primer application booth and Edrizzi’s filtration system mounted on the topcoat application one now enable SDF to effectively reduce overspray.”

both water-based two-component products and perfectly in line with the environmental choice adopted by SDF since many years. Two colours are mainly used: SDF black and a grey for a tractor produced for a third party. The primer is light coloured for improved quality, since it enables

The application process

Figure 12: The topcoat application stage.

13 Figure 13: The drying oven.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

The main challenge posed by this project was working in a factory with limited spaces and in full operation, as SDF has never been able to stop production. At the same time, it did not have the opportunity to build a new facility to start the new plants or move the existing machining departments. Therefore, it had to rearrange the different areas, making spaces to gradually install the assembly lines. Although the cycle time has not changed with the new plant, the coating process is now independent from the assembly line thanks to the presence of small storage buffers; when the system will be fully operating, this will enable SDF to exploit even breaks to increase the productivity.”

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the flash-off stages required by a two-component product. Now that we use a two-component primer, we have doubled our salt spray resistance results. Since the factory is located in the city centre, the plant design also focussed on eco-friendliness factors. Although

to check the dark coloured topcoat coverage (Figs. 11 and 12). The wet-on-wet application is followed by a 30-minute flash-off stage and a 45-minute drying one at 80 °C (Fig. 13). “The application process is developed for the largestsized tractor body currently produced. At moment, this equals to 50/52 m2 of surface to be covered; the dosing and dispensing system must therefore ensure adequate thicknesses (50 to 70 microns) in a 5-minute cycle time,” says Alessandro Soba from Verind (Fig. 14). 14 Verind’s Technical Sales Engineer Marco Assorgia Figure 14: A coated tractor body. states: “That is why the twin gun technology has been “There was an important adopted, which divides the product volume improvement also in terms of to be applied between two atomisers primer,” says Gianluca Schiavulli, (Fig. 15), thus reducing the atomisation air the Plant Treviglio Head of pressures. Moreover, the compressed air Manufacturing Engineering - SDF. “In consumption of the coating management the past, we used a one-component unit has been optimised with “4 ball” primer because the old systems did technology pumps featuring opposing not offer enough space to perform horizontal pistons.”

15 Figure 15: The twin gun technology enables to divide the product volume to be applied between two atomisers.

16 Figure 16: The primer application booth is equipped with Eisenmann’s E-Cube ﬁltration systems.

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SP ECIAL ACE

17 Figure 17: The AGV module for the handling of tractors on the assembly line and during transfers.

water-based, low solvent-content products had long been used, the new E-Cube dry filtration systems installed by Eisenmann on the automated primer and topcoat booths and Edrizzi’s filtration system mounted on the touch-up booth now enable us to effectively reduce overspray (Fig. 16). However, since we are very attentive to all environmental aspects, we have also installed an afterburner to ensure the complete abatement of emissions.”

Conclusions “The main challenge posed by this project was working in a factory with limited spaces and in full operation, as we have never been able to stop production. At the same time, we did not have the opportunity to build a new facility to start the new plants or move the existing machining departments. Therefore, we had to rearrange the different areas, making spaces to gradually install the assembly lines,” says Gianluca Schiavulli. “Although our cycle time has not changed with the new plant, the coating process is now independent from the assembly line

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thanks to the presence of small storage buffers; when the system will be fully operating, this will enable us to exploit even breaks to increase our productivity.” Also the adoption of integrated AGV systems has contributed to this result. “These are automated trolleys that move by following a magnetic field generated by two underground cables. The magnetic field powers the trolleys and creates the guiding system. Every tractor placed on an AGV moves along the assembly line at the ideal speed for the performance of operations, and more quickly during transfers (Fig. 17).”

Opening photo: Axalta E-Coat bath at Grimme plant in Damme, Belgium.

INNOVATIONS: PRESENT&FUTURE

SPECIAL ACE

Electrocoat for the Agriculture, Construction and Earth Moving (ACE) and Home Appliance Markets from Axalta Carlos Rodriguez Santamarta and Werner Lehnard Axalta Coating Systems – Köln, Germany

carlos.rodriguez-santamarta@axaltacs.com, werner.lehnard@axaltacs.com

oday’s ultra-competitive agriculture, construction and earth moving (ACE) and home appliance markets demand coatings expertise in quality, productivity and environmental responsibility. Advanced e-coat products have been successfully meeting or exceeding stringent manufacturer and regulatory requirements for more than 40 years. E-coats are applied not just to tractors, heavy equipment and appliances, but also

to other metal fabricated products, including automobile bodies and parts, electrical switch gear and radiators. Axalta Coating Systems, a leading global supplier of liquid and powder coatings, has many years experience and a good reputation for its AquaEC e-coat technology. The products support users by helping to increase business profitability and to reduce the process costs while still achieving a world-class performance.

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E-coat has a number of advantages that have contributed to it being so widely used. First, it is suitable for use on a very wide range of metal materials. The application process is relatively quick and clean – no overspray and no droplet - and deposits a very uniform coating thickness without any porosity. And the application process is usually automated, which means reduced labour costs compared to other coating processes coupled with easy control

INNOVATIONS: PRESENT&FUTURE

of the coating’s composition. Thanks to e-coat’s excellent throwing power, complex geometries can easily be coated, on outside surfaces but particularly in the inside cavities that may be hard to reach using a traditional spray process. The e-coat process also offers highly efficient utilisation of the coating material itself, which can result in lower costs compared to other processes. Lastly, modern electrophoretic paint products are significantly more environmentally responsible than many other painting technologies as they tend to be low VOC, lead- and tin-free, as well as being Hazardous Air Pollutant (HAP)-free and listed in the International Material Data System.

The global ACE market uses an estimated US$1.5 billion worth of coatings every year1 and ACE manufacturers place demands on suppliers to provide increased coating performance as well as a strong 1

IRFAB

aesthetic appearance. Changing climate conditions mean that ACE equipment is often exposed to a wide range of temperatures, humidity and sunlight. With such harsh environments to consider, many ACE manufacturers have

created their own detailed performance level specifications; high on their list of priorities are excellent colour and gloss retention combined with a high degree of edge protection and corrosion resistance. The home appliance market, whilst larger, is not dissimilar, though with differing drivers and challenges. The industry is estimated to be worth US$22.5 billion according to the US-based Association of Home Appliance Manufacturers (AHAM), and demand is expected to grow 3.2% per year according to research by the Freedonia Group Inc. The reason for this growth includes the rise in major appliance purchases thanks to special textured or fingerprint-resistant coatings and unusual and unique colours.

Selecting the right coating

ACE and home appliance markets

Today’s ultra-competitive agriculture, construction and earth moving (ACE) and home appliance markets demand coatings expertise in quality, productivity and environmental responsibility.”

1 Figure 1: AquaEC 5000 is a product family of single layer cathodic e-coat primers designed to provide exceptional protection and top-of-the-range performance.

ACE and home appliances manufacturers consider four main properties when they select a coating: quality, protection, sustainability and value. To achieve the required standards, twolayer systems are becoming increasingly popular. However,

as financial constraints mean total application costs are carefully scrutinised, a global coating manufacturer like Axalta needs to offer high-quality coatings while reducing the overall costs in order to meet ACE and home appliances manufacturers’ needs.

SP ECIAL ACE

One-layer system case study: Grimme

Grimme is a global player in the ACE market and a world leader in harvesting technology. With a portfolio of over 150 different machines for potato, beet and vegetable 2 harvesting, Grimme offers the widest Figure 2: AquaEC 3000 is a range of two component waterborne epoxy-based primers that are particularly valuable when corrosion on parts with sharp edges is an issue. One-layer and most extensive systems product range Axalta’s AquaEC in this segment. 5000 is a product family of single layer Grimme chose Axalta’s one-layer cationic cathodic e-coat primers designed to The global ACE e-coat system, which is based on acrylic provide exceptional protection and top-oftechnology. This coating is applied in a market uses an estimated the-range performance. Based on highly single paint line and offers good corrosion US$1.5 billion worth of UV-resistant acrylic resins, AquaEC 5000 protection for the main machine body and coatings every year and has been specially developed to provide for its component parts (ref. Opening photo). ACE manufacturers place excellent coverage on the first run. One of the principal reasons Grimme chose demands on suppliers to AquaEC 5000 is mainly used as a topcoat this particular system was its cost efficiency provide increased coating and its long-term weathering resistance, compared to two-layer systems. performance as well as a mechanical properties and powerful strong aesthetic appearance.” Two-layer systems corrosion protection makes this range AquaEC 3000 from Axalta is a range of ideally suited for bulk coating of outdoor Liquid direct to metal (DTM) two component waterborne epoxy-based equipment like agriculture machinery, Direct to metal (DTM) is a technology primers that are particularly valuable fork lifts and cranes. It is also widely that, in addition to satisfactory UV when corrosion on parts with sharp edges used in the manufacture of domestic resistance, provides good functional is an issue. It offers excellent mechanical appliances, windows, door fittings and properties, such as corrosion protection properties, good chemical resistance and steel furniture. AquaEC 5000 displays and edge coverage, as well as good superior corrosion resistance. It can be good colour control and high coating aesthetic properties, colour and gloss. applied on a variety of substrates and will efficiency. The superior UV resistance It is a good system to balance costs produce a smooth surface finish thanks of AquaEC 5000 is comparable to a 2K with performance as only one layer is to its wide application window and high polyurethane topcoat. AquaEC 5000 is available in many colours applied. contamination resistance. With to provide versatility for garden furniture, AquaEC 3000 normal film tickness leisure equipment, fences and motor Powder of between 20 μm and 25 μm can be accessories. And as with all Axalta’s Powder technology is best suited for single achieved and high film thicknesses of e-coats, AquaEC 5100, AquaEC 5500 layer systems when standard functionality more than 35 μm can also be produced. and AquaEC 5700 are environmentallyis needed. One-layer powder systems can Another advantage is its great throwing responsible, low-VOC and HAPS also provide better corrosion protection power, so difficult-to-reach areas are compliant thanks to their lead-free, waterand edge coverage than one-layer liquid easy to coat, which helps with complex based formulations (Fig. 1). systems. configurations.

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INNOVATIONS: PRESENT&FUTURE

ACE and home appliances manufacturers consider four main properties when they select a coating: quality, protection, sustainability and value.”

AquaEC 3000 is available in a number of specifications for the automotive, ACE and appliances sectors and is used by many automotive parts and construction equipment manufacturers, as well as by light vehicle OEMs, on axles for example. AquaEC 3000 is environmentally responsible as it is lead- and tin-free, and it is REACH and HAPS compliant (Fig. 2). The two main two-layer technologies are determined by the type of primer used: e-coat primers or spray liquid primers. E-coat primers When e-coat is used as a primer in two-layer systems, it provides outstanding functional properties. The corrosion resistance achieved with an e-coat primer is virtually incomparable to any other coating system. And, as it is a dip technology, the levels of edge protection are very high, which is particularly important with substrates of complex geometries. There are two main e-coat systems depending on the level of functional protection required: Cathodic Electrocoat – epoxy technology Cationic epoxy systems are the highest-performing e-coat systems in terms of corrosion resistance and edge coverage. And they are also the top performing coating systems in the ACE segment for functional protection. Axalta’s AquaEC 3000, a tin-free e-coat with low bake curing conditions (150oC) and outstanding functional performance, is a well-established product in the ACE market.

Direct to metal (DTM) is a technology that, in addition to satisfactory UV resistance, provides good functional properties, such as corrosion protection and edge coverage, as well as good aesthetic properties, colour and gloss. It is a good system to balance costs with performance as only one layer is applied.”

SP ECIAL ACE

Anodic Electrocoat – polyester technology When systems with lesser performance in terms of corrosion resistance and edge coverage are required, the anionic system using polyester chemistry is a valid option. Axalta’s AquaEC A400 and AquaEC A600 are anionic polyester systems that are both well-respected in the ACE segment. Using an e-coat system as a primer in two-layer systems offers one of the best options for functional performance in the ACE segment. Two-layer system – e-coat primer - case study: Amazonen-Werke Amazonen Werke is a global player and the market leader of spreaders and crop protection technology. It specialises in fertiliser spreaders, seed drills, active (rotary cultivators and rotary harrows) and passive soil cultivation (disc cultivators and harrows), precision air seeders and crop protection sprayers. In addition, Amazonen Werke provides the machinery and equipment for park and green field maintenance and for municipal services. Amazonen-Werke uses AquaEC 3000, a 2K system that uses an epoxy e-coat primer, and Stollaqua D7500, a water dip-coat, both from Axalta. The combination of a CED (e-coat) anti-corrosion system and the acryl modified dip-coat results in a system that offers premium corrosion protection with good weather resilience. The main reason AmazonenWerke chose a dip-coat system rather than a conventional spray system was because it guaranteed an even coating across the whole geometry of the pieces, which are often very complex. Spray liquid primers The use of spray liquid systems as primers is widely used across the ACE segment.

While the level of functional properties achieved by spray liquid primers is satisfactory, it is remarkably lower than when an e-coat is used as the first layer. However, depending on the specifications required by the ACE manufacturer, spray liquid primers can fulfil the corrosion requirements very adequately, as well as providing good edge coverage when complex geometries are involved. The advantage of using liquid primer technology in a two-layer system is that the application lines are relatively simple, which helps to keep the investment costs down. Spray liquid primers are significantly lower in cost than using e-coat primer technology, while the coatings consumption cost is similar for both e-coat and liquid primer technology, though understandably slightly higher than in one-layer systems.

Spray topcoat – waterborne Using the most advanced waterborne technology provides similar aesthetic performance to classic solventborne topcoats, and can deliver superior results in terms of colour and outdoor exposure. Axalta’s polyurethane topcoat PercoHyd 755 and polyester topcoat Stollaqua D7500 offer two different options depending on the performance required.

Powder topcoat The third topcoat option for e-coat primed substrates is powder, which is easy to use and offers a wide variety of qualities - from polyester to acrylics. Powder also has the flexibility to deliver almost anything, from an attractive finish to UV resistance in the case of polyesters such as E-coat, liquid and powder: there are Axalta’s Alesta AP, Alesta IP or many different coating options available Alesta AG, as well as outstanding outdoor performance in the case for the ACE market. Both the one- and of super-durable polyesters, two-layer systems offer combinations like Axalta’s Alesta SD. Acrylic that can meet the sectors’ needs powders also offer an additional and specifications for performance, high-performance topcoat corrosion protection and gloss and option. colour retention.”

Conclusion Topcoats over e-coat primers There are three topcoat choices to overcoat an e-coat primer: two liquid and one powder. Spray topcoat - solventborne Applying a solventborne liquid topcoat over e-coat primers provides excellent colour and gloss retention and also very good outdoor resistance when using urethane chemistry. When lower levels of aesthetics and UV resistance are appropriate, alkyd liquid systems can be considered as an alternative topcoat. Axalta’s most popular products in its polyurethane product range for ACE topcoats are PercoTop 9675 and PercoTop 771.

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E-coat, liquid and powder: there are many different coating options available for the ACE and home appliance markets. Both the one- and two-layer systems offer combinations that can meet the sectors’ needs and specifications for performance, corrosion protection and gloss and colour retention. However, as these markets becomes more demanding, coatings manufacturers like Axalta must work ever more closely with their customers to create specific solutions that address both practical and financial demands by continually developing high-quality, cost-effective technologies.

Openinig photo: Carbon ﬁbre spray booms manufactured by King Agro and ﬁtted on a boomer.

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SPECIAL ACE

KingAgro: Innovation in Agriculture Thanks to Carbon Fibres. An Innovative Coating Plant for Carbon Fibre Spray Booms Alessia Venturi ipcm®

nnovation and development in the agricultural sector are currently made possible by the use of carbon fibres as an alternative building material to steel. Carbon fibres were first used in the military and aerospace industry, but, as their cost diminished, new possible applications were found in several sectors. In the field of machines and agricultural tools such as tractor-mounted extensible spray booms,

carbon fibres’ properties enable to increase productivity and process quality. Indeed, they ensure a longer working radius, weight reduction, greater control of the equipment, and less impact on soil compaction (ref. Opening photo). Building carbon fibre components requires a profound knowledge of this material, high technical skills, and advanced production technologies. Carbon fibres

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also pose great challenges in terms of coating. Cabycal is a highly innovative engineering firm based in Alaquás (Valencia, Spain) that designs, develops and builds surface treatment and coating plants and lines for the industrial and automotive sectors all over the world. It has recently installed a liquid coating line for large components made of carbon fibre material near Valencia (Fig. 1).

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KingAgro: sea experience at the service of agriculture

quality and reliability of its products are the result of a corporate philosophy based on innovation, KingAgro opened a new manufacturing facility in technical rigour, quality control and detail care. Picassent early in 2017 for the production and finishing The production of the booms starts with precision of revolutionary carbon fibre spray booms. The new moulds created with a 5-axis CNC plotter. The factory required an Kevlar and carbon investment of 8 million fibres are cut to precise Euros. It will cooperate measures and shapes with the KingAgro Innovation and development with a CNC cutter before plant of Campana, the rolling phase in a in the agricultural sector are Argentina. The facility controlled and dustcurrently made possible by the use covers an area of free environment. The of carbon fibres as an alternative 2 5,500 m and employs building material to steel. Building carbon composite about 100 people. It is components are carbon fibre components requires equipped with all the polymerised with a profound knowledge of this latest manufacturing material, high technical skills, and high temperatures technologies and it will advanced production technologies. and pressures up produce up to 1,800 to 5 atmospheres. Carbon fibres also pose great carbon fibre spray Machining, coating and challenges in terms of coating.” booms every year final assembly complete (Fig. 2). the production cycle of the spray booms, which are KingAgro has over twenty-five years of experience in then ready to be installed on sprinklers. the use of carbon fibres because it was established as KingAgro’s president Guillermo Mariani has KingMarine, a firm specialising in the application of this stated: “Our goal is to change the paradigm of material to the high performance nautical industry. The steel in agricultural machinery. We believe that

1 Figure 1: An exterior view of the new pressurised and dust-free coating plant.

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Figure 2: A carbon ﬁbre spray boom.

The King Agro’s goal is to change the paradigm of steel in agricultural machinery. Its staff believes that carbon fibre spray booms are just the beginning of a trend that will offer innumerable advantages linked to increased productivity, lower costs and reduced soil compaction.”

The new King Agro’s Spanish facility is equipped with all the latest manufacturing technologies and it will produce up to 1,800 carbon fibre spray booms every year.”

Figure 3: A carbon ﬁbre boom on the two-rail conveyor (Futura Convogliatori Aerei).

carbon fibre spray booms are just the beginning of a trend that will offer innumerable advantages linked to increased productivity, lower costs and reduced soil compaction.” KingAgro’s carbon fibre spray booms are six times stronger and over five times lighter than their steel equivalents. Highly durable and resistant to fatigue and corrosion levels that affect spray booms in steel and especially aluminium, they offer a longer service life and lower operating costs. The material’s light weight allows overall sprayer weight to be reduced, resulting not only in less soil compaction but also in lower fuel consumption. Moreover, the low inertia of carbon fibre booms has benefits on the machines’ performance, because it provides workflow optimisation and better control of the booms themselves, thus increasing crop coverage and reducing spray drift (Fig. 3).

“Each year, KingAgro invests 75% of operating profits in the research and development of new processes and products. Our commitment to continuously improve our vacuum, resin infusion, rolling, autoclave, robotic machining, water jet cutting, and coating processes increases the quality of our products. The market is responding very well to carbon composites thanks to the direct improvements they ensure,” says Guillermo Ponzinibbio, KingAgro’s European COO (Fig. 4). KingAgro’s coating process consists in the manual application of a two-component solvent-based system including a

Figure 4: KingAgro’s European COO Guillermo Ponzinibbio on the left, with Sergio Mateo from Cabycal.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

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transparent primer and a UV protection transparent topcoat. This was exclusively developed by PPG to enhance the carbon fibres’ technical characteristics and protect them from aging. KingAgro manages to obtain high quality finishes in a controlled environment thanks to the line that Cabycal developed and installed after careful analysis of the needs and peculiarities of the carbon composite material (Fig. 5).

KingAgro’s coating process consists in the manual application of a two-component solvent-based system including a transparent primer and a UV protection transparent topcoat. This was exclusively developed by PPG to enhance the carbon fibres’ technical characteristics and protect them from aging.”

Figure 5: The mixer for two-component coatings (Graco).

info @ abl-technic.de www.abl-technic.de 6 Figure 6: The booth with the sanding stations.

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LONDON | UK

o t t a f n e B NEW FETTER LANE

7 Figure 7: The IR polymerisation oven.

The strengths of this coating system With a total length of 65.5 metres, a maximum height of 7.5 metres, and an internal width of the cleaning and coating booths of 3.3 metres, this system features a 120 metre long mixed conveyor with 10 metre long loading bars. The conveyors features a manual loop for loading and unloading the pieces and an automatic power&free loop for the treatment process, with automatic devices for the feeding of the parts at pre-determined time intervals. With a power of 170 kW, a 125,000 m3/h moving air flow, the system can treat up to 10 metre long extensible booms weighing up to 100 kg. “Our spray booms are made up of a mixture of carbon fibre, Kevlar and epoxy resins. Once the components have been pressed, cut and machined, we sand them. At this point, the finishing process begins,” says Guillermo Ponzinibbio. “We have worked for two years with Emilio Ferrando, Managing Director of Cabycal, to fine-tune this fivestation system.”

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KingAgro manages to obtain high quality finishes in a controlled environment thanks to the line that Cabycal developed and installed after careful analysis of the needs and peculiarities of the carbon composite material.”

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e n o d l l e W MOOR PLACE

8 Figure 8: The detection of the products’ temperature inside the oven.

Cabycal built a plant where many operations are necessarily manual, due to the shape and size of components, but that is equipped with the most sophisticated automatic control systems of the parameters, the process conditions and the functioning of the entire line through a Siemens PLC.”

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“The surface treatment process of the booms is divided into 5 stages. The cycle starts with the manual sanding for the sanding of the machined carbon fibre components (Fig. 6). The second stage is a manual high-pressure cleaning station to remove dirt and residues from the surface. In the third stage, the pieces go through a drying oven at 45°C with an automatic high-energy blowing to dry off water drops. The high-energy drying oven also pre-heats the workpieces before the manual electrostatic application of the paint. The fourth stage is the application of the protective paint to the carbon fibre in a manual booth with controlled temperature at 21°C and 60% humidity via an air treatment unit. The last automatic stage is the curing of the pieces in an oven (Fig. 7) with IR lamps and recirculated air at 120°C , a small cooling section, the quality control station (thickness and curing conditions, (Fig. 8), and the unloading station,” states Sergio Mateo Teruel, the Project Manager of Cabycal. “We designed the air recirculation system of the coating booth very carefully. The air is always maintained at a

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F.lli Calvi 2G, 24122 Bergamo (BG) TIGER Drylac ITALIA s.r.l., Via Bergamo(BG) ofﬁce.it@tiger-coatings.com | www.tiger-coatings.com

controlled temperature, in line with the parameters required by the process and in particular to maintain the viscosity of the coating product. The air suction and filtration systems were adjusted to eliminate any type of residue and to keep solvent emissions below the limits imposed by the Spanish law. The infrared polymerisation oven is equipped with high energy-efficiency lamps (72 kW dedicated power). The timed IR lamps and the related workpiece temperature control with IR sensors improve the efficiency of the polymerisation stage.” “Cabycal built a plant where many operations are necessarily manual, due to the shape and size of components, but that is equipped with the most sophisticated automatic control systems of the parameters, the process conditions and the functioning of the entire line through a Siemens PLC (Fig. 9),” says Patricia del Rio Arauzo, the Communication Manager of the Spanish plant engineering company. “The coating process is programmed on a tablet by choosing among different treatment programs

depending on the number of paint layers to be applied and the drying and polymerisation conditions (time, IR ray intensity, and so on). An alarm system with a timer warns the operator when the polymerisation cycle is over, enabling him to immediately remove the workpiece from the oven and perform the quality control operations.”

A line ready for the expected increase in productivity

9 Figure 9: The plant is equipped with the most sophisticated control systems of the parameters, the process conditions and the functioning of the entire line through a Siemens PLC.

“The takt time of the line is 22 minutes. Each load bar can carry up to two workpieces at a time, depending on their size,” says Ponzinibbio (Fig. 10). “The line was inaugurated in March and started operating in April. It was designed for a capacity of 5 coated booms per day. We are currently working at 50% of its capacity. This means we will be able to smoothly handle the expected increase in the demand for this high-tech agricultural equipment.”

The line was inaugurated in March and started operating in April. It was designed for a capacity of 5 coated booms per day. King Agro is currently working at 50% of its capacity. This means it will be able to smoothly handle the expected increase in the demand for this high-tech agricultural equipment.”

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10 Figure 10: Each load bar can carry up to two workpieces at a time.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

BRAND-NEW

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Mankiewicz at Agritechnica: Agricultural Machinery & Equipment applies High Build Monolyer. In terms of sustainability and environmental protection, these 2K systems have a lower VOC content than conventional systems and so fulfil the requirements of renowned manufacturers.

Time to shine When an especially glossy surface is called for, such as those you see on buses, trucks and trailers, then a two-coat system from Mankiewicz, comprised of primer and topcoat, is the most suitable solution, especially for plastic surfaces as well as aluminium and steel. This coating system is available as water-based or high-solid composition and can be applied wet-inwet. The excellent filling properties of both water-based and high-solid primers not only provide a good foundation for the topcoat, but also permit savings in terms of time and

materials. High stability of colour and gloss levels in all weather conditions and good cleaning properties are basic requirements for the paints used on commercial vehicles, with the aim of retaining the highest possible value for the coated vehicle, even after years of service.

Bottom line There is one thing Mankiewicz systems all have in common: optimized processes by reducing the coating layers, which also provides savings in terms of time taken, manual effort and energy expended. The good corrosion resistance and high-gloss properties of the paint underscore the worth of the machine in a very ‘obvious’ way. For further information: www.mankiewicz.com © Mankiewicz

ankiewicz, global paint manufacturer, was among the exhibitors of Agritechnica (12 to 18 November 2017), with a focus on values protection, direct-to-metal and upgrading the appearance. At its booth the paint manufacturer presented its coating systems with selected exhibits. Reliable and rugged machines are essential for working on the fields or building sites. Adverse weather conditions not only leave visible traces, they may also prove detrimental for the mechanical properties of components, rendering the machines unserviceable. The coating protects the machines so they continue sporting their glossy appearance even after years of extremely harsh working conditions without it costing the manufacturers a king’s ransom. Hamburg paint manufacturer Mankiewicz is ready with the perfect solution (Fig. 1).

Time is money The maxim for the coatings on construction and agricultural machines is ‘as much as needed, but as little as possible’. For this task Mankiewicz uses the one-coat system ALEXIT® Monolyer. Applied directly onto chemically pre-treated steel, the direct-tometal system enables a quick turnaround and spares the manufacturer both time and money. The 2K system also provides excellent corrosion protection properties and has very good resistance to commonly encountered fluids, such as AdBlue diesel additive. In cases of mechanically treated, sandblasted surfaces, when it is necessary to compensate for the unevenness that results from a fabrication process, thereby calling for a thicker coating, Mankiewicz

1 Figure 1: The coating protects the machines so they continue sporting their glossy appearance even after years of extremely harsh working conditions.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

BRAND-NEW

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ÂŠ AGTOS GmbH

Economical Blasting Technology for High Demands ore and more emphasis is placed on surfaces. Economic concepts for the blasting of heavily stressed surfaces are required. For the first time AGTOS has presented, at the trade fair Agritechnica, 12-18 November 2017 in Hanover, everything about the wheel blasting technology. The manufacturer provides almost all types of shot blasting machines. The robust design with good maintenance possibilities characterizes the machines (Fig. 1). In addition, used blasting machines are offered, which can be modernized in a technically 1 perfect condition and tailored to customer requirements. Figure 1: Continuous overhead rail shot blast machine for the blasting of welded construction before the powder A comprehensive service coating. program completes the service spectrum. the advantages of the tried and tested AGTOS shot blasting machines. High performance, economical operation and good accessibility in the As an exhibit, an AGTOS high-performance turbine was on display. It stood as an example for a whole series of smaller event of maintenance are the most important criteria here. and larger sizes and versions. Interested visitors were shown For further information: www.agtos.de

Opening photo: Tipping body ﬁt for the quick-change system ready for delivery.

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Pre-treating Large-Sized Workpieces: Shotblasting for Hookloaders, Tippers and Bodyworks in General to Increase Their Long-Term Corrosion Resistance Barbara Pennati ipcm®

truck equipped with the quick-change system may be used combined with different types of bodyworks (such as tipping bodies, tanks, flatbeds, hooklifting systems and so on) that can be removed from the lorry on which they are mounted. With a few simple operations, these structures can be detached from the chassis in order to let another one be installed. In this way, the same lorry can be fitted with

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

different equipment, for instance depending on the season. Obviously, these structures require a significant surface protection degree to offer a long service life despite the severe operating conditions. And, as is well known, the better the preparation of the surface – which must be degreased and free from any oxidation and machining residue – the more effective and high performing the coating system (ref. Opening photo).

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KMU LOFT – because resources are limited

years, we have made a leap forward in terms of Pris-Mag (Cambiago, Milan, Italy), a global leader production, reaching an export share of almost 50%. in the production of hook-lifts and quick-change This was possible thanks to the integration of our systems, has experienced a dramatic rise in its hookloaders with our clients’ demands for quick-change system, a coatings with higher mechanical-hydraulic device resistance performance. Pris-Mag (Cambiago, that is mounted on the This has led the company lorry itself and that enables to invest in an automatic Milan, Italy), a global leader to detach any kind of turbine shotblasting in the production of hook-lifts bodyworks from its chassis. system able to ensure an and quick-change systems, This makes the lorry a SA 21/2 finishing degree in has experienced a dramatic compliance with the current multi-functional means of rise in its clients’ demands for international standards. transport, thus reducing coatings with higher resistance Designed and built by downtime and increasing performance. This has led OMSG - Officine Meccaniche flexibility,” says Chiara Sala, the company to invest in an San Giorgio (Villa Cortese, the founder’s daughter. automatic turbine shotblasting Milan, Italy), it is one of the “Pris-Mag is therefore system able to ensure an SA 2½ largest hook shotblasting able to provide complete finishing degree in compliance machines operating in Italy bodywork solutions, with the current international (Fig. 1). adapting various structures standards.” to its quick-change system.” Pris-Mag: from a local business to an This productive improvement has made Pris-Mag an international leader internationally renowned manufacturer, in particular Alessandro Sala, who is still managing this in the northern European countries. Due to their industrial vehicle bodywork business together with climatic and environmental conditions, however, these his children, established the company in 1975. markets require higher quality and outdoor resistance After specialising in the production of hook-lifts standards than the Italian one, which can be only met and gaining several clients with a high quality antiin its area, at the beginning corrosion coating system. of the 2000s Pris-Mag “We were aware of our managed to give added corrosion protection limits value to a product it had and we knew that we were been manufacturing for not able to meet the needs thirty years, i.e. its quickof countries where ice, snow change system, and meet and salt are a daily issue. the users’ needs for multiOur structures were solid functional lorries thanks and well manufactured with to structures that can be first quality raw materials, easily detached from chassis but we could not guarantee frames. The international their long-term resistance patents protecting these in such harsh and cold unique applications and environments,” states Chiara the approval of the Italian Sala. “When a big Swedish Ministry of Transport, as well company turned to us for as its uniqueness on the the provision of a number Italian market, make Prisof hook-lifts, we decided 1 Mag an industry leader even that it was time to invest on foreign markets (Fig. 2). on the factor that my father Figure 1: The huge shotblasting machine “In the last seven-eight has always considered as provided by OMSG.

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was a vertical system,” explains Enzo Dell’Orto, the CEO of OMSG (Fig. 4). “The shotblasting machine installed is a one-hoist system with a hook maximum capacity of 6 tons. It can treat parts with a diameter up to 4 m and a height up to 12.5 m. It is equipped with 13 variable power wheels patented by OMSG. It meets all the customer’s requirements, ensuring a final finishing degree equal to SA 21/2.” “With such complex workpieces,” says Dell’Orto, “in agreement with our supplier we had to design a special PLC-managed hoist (Fig. 5) able to keep containers and chassis in a fixed position for a pre-set time. In this way, OMSG has managed to solve the shotblasting homogeneity issue that is very common with such large-sized parts. Of course, as well as staying in pre-set positions, the hook can rotate and move inside the chamber to subject the surfaces to the action of metal abrasives, which are launched by the turbines mounted on the sides of the machine (Fig. 6). “This is an OMSG standard hook shotblasting system with manganese

the key to obtain higher quality products: the surface preparation and treatment processes before assembling and painting. Until that moment, we pre-treated our workpieces with a manual sandblasting operation that did not ensure optimal cleanliness and roughness values in terms of long-term corrosion resistance,” says Chiara Sala. “That is why we installed an automatic turbine shotblasting machine (Fig. 3).” To achieve its goal, Pris-Mag relied on OMSG - Officine Meccaniche San Giorgio SpA, a company specialising in the design and construction of shotblasting, automatic sandblasting and shot-peening systems.

Figure 2: The container building phase.

3 Figure 3: The shotblasting machine can also treat semi-trailer containers.

When a big Swedish company turned to Pris-Mag for the provision of a number of hook-lifts the company decided to invest on the factor that founder Alessandro Sala has always considered as the key to obtain higher quality products: the surface preparation and treatment processes.”

A “big” challenge Pris-Mag builds hook-lift systems of various sizes, the biggest one also fit for application on semitrailers. “The main challenge was designing a shotblasting machine able to treat such large workpieces in the limited space available. A horizontal plant would have covered a considerable portion of the production area, so the only viable alternative

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

4 Figure 4: A container waiting to be shotblasted.

Figure 5: The touch screen shotblasting machine.

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The coating process has benefited from the investment made on the pre-treatment phase in terms of both quality and yield. The cycle, developed by Alcea, includes the application of four layers: two layers of epoxy primer and two layers of two-component epoxy enamel.”

6 Figure 6: A large container being placed inside the shotblasting machine.

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application of four layers: two layers of epoxy primer and two layers of two-component epoxy enamel. Generally, Pris-Mag chooses the coating system to be applied on its products, although some customers specify thickness and gloss values. The coating application is now performed manually in an oven chamber (Fig. 8). Our next investment to further improve our products’ corrosion protection performance will be aimed at automating this surface treatment stage (Fig. 9).”

Effective collaboration

7 Figure 7: The inside of the shotblasting chamber.

The coating cycle “Our coating process has benefited from the investment made on the pre-treatment phase in terms of both quality and yield,” explains Chiara Sala. “Our cycle, developed by Alcea (Senago, Milan, Italy), includes the

“OMSG addressed our demands professionally and enthusiastically, completely customising its plant for us. The installation times proved to be quite long because of the size of the plant, which even required us to raise the height of our factory’s roof to make room for the shotblasting machine. Thanks to the collaboration of OMSG, however, we managed to make the quality leap needed to enter even the most demanding markets,” states Chiara Sala.

steel and nickel/chrome cast iron linings and special wear-resistant rubber protections for the shotblasting chamber. However, it also stands out from any other standard plant because it is 12.5 m high – 20 m if we also consider the recovery hoppers that collect the abrasives and send them to the base of the elevator through screw conveyors (Fig. 7).” “Another critical issue was the assembly phase. All OMSG machines are assembled and electronically, electrically and mechanically tested at our premises. In this case, however, we did not have enough space to assemble the shotblasting plant in our factory. Therefore, we only mounted the hoppers and pre-assembled some components, while everything else was done on site. Height was actually one of the biggest problems: at a height of 20 meters, even solving the simplest issues can be complicated and timeconsuming,” states Enzo Dell’Orto. “The complexity of this project has certainly been a challenge in terms of design and logistics, but this vertical plant has entered the history of OMSG as the largest hook machine we have ever built and among the largest ones operating in Italy.”

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8 Figure 8: The large oven chamber has three workstations.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

Figure 9: A shotblasted frame ready to be coated.

Opening photo: To meet stringent quality standards and increase process reliability, the John Deere factory in Mannheim has invested in a new Graco paint supply system.

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John Deere Factory in Mannheim Installs Graco 2KS Paint Supply System Marc Gijbels Graco Distribution BVBA, Maasmechelen - Belgium

marc.gijbels@graco.com

he familiar and striking colour combination of dark green with yellow wheel rims makes John Deere’s agricultural machinery easily recognizable at a distance. But they are not the only colours

used. These vehicles can also be painted in orange – favoured by cities and towns – or in special colours like yellow and white to meet specific customer requirements. The John Deere factory in Mannheim, Germany

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

turns out over 20 different models in numerous versions and configurations at a rate of 200 machines per day. After zinc phosphate treatment, the drives, frames and small parts are given a prime layer

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of epoxy-based cathodic electrodeposition (CED) coating, after which the top coat is applied. A 2K PUR high solids coating is used, applied on a production line both by robots and manually.

Highest quality standards

The surface quality requirements for the machines are now nearly as high as in the automotive industry. To meet these high standards even more comprehensively, in late 2016 the John Deere factory in Mannheim decided to invest in a new paint system (ref. Opening photo). Their goals were to boost process reliability and reduce maintenance. Their current Graco equipment had been in constant use since 2005, and although the Graco machines had performed excellently, they were beginning to show signs of wear and tear. John Deere managers, along with paint suppliers

Gross & Perthun, took advantage of last year’s PaintExpo to get quotations for more modern systems. In the end they gave the nod for the conversion to L&S Oberflächentechnik, a system provider for surface and application technology, material provision and automation.

Installation over three weeks During the one-week company break at the Mannheim factory in October 2016 and in the two weeks afterwards, L&S installed 12 new Graco 2KS systems (Fig. 1). The 2KS mixing and dispensing system is suitable for manual and automatic applications and can process up to 30 stock coatings and four hardeners. It works with both high and low pressure and allows sequential and dynamic dispensing. It also has a programmable rinsing sequence and extended reporting functionality to save and manage all of the system’s process and operating parameters. This makes it easier, for example, to record costs and ensure compliance with quality requirements for each individual component. The Graco 2KS provides maximum accuracy for the mixing ratio and feedback on critical process variables, and it has built-in system safety. In addition to the 12 stationary units installed in the factory, a mobile Graco ProMix II (Fig. 2) model enables John Deere to cope with any unexpected outage. This unit is designed exclusively for manual applications, can process up to three tints, and is equipped with USB reporting capability. It means that in the event of an outage, normal operations can be resumed in the shortest possible time, without interrupting the production flow any longer than necessary.

Figure 1: Graco 2KS systems.

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and rinsing concept, leading to enormous savings on materials (Fig. 3). Bad mixes are now impossible, eliminating the need for rework. The volume of costly compressed air has also been reduced considerably. The Merkur pumps in the central paint supply system, also made by Graco, have also been updated. There are five pump stations on the solo cabin and three pump stations on the mobile 2K system. The gun rinsing stations were also updated, and new gun rinsing stations were integrated for the application equipment to ensure monitored, error-free and safe rinsing. In future, L&S Oberflächentechnik will take over technical service in Mannheim.

Number of systems reduced from 16 to 12 Incorporating tinting in the new supply system allowed the number of units to be reduced from 16 to 12. Where previously only one stock coating and one hardener could be processed, it is now possible to run up to 30 stock coatings. This makes it easier to apply the paint, the mixing is better and the coating is cleaner. The systems also support remote queries

The benefits of the new technology are readily apparent: while the old system needed maintenance on at least a monthly basis, this has now dropped to once every three months. The mixing chamber is no longer necessary because the new devices have a completely different injection and rinsing concept, leading to enormous savings on materials.”

and can therefore be accessed from a PC, so they can be managed directly by L&S in eastern Westphalia or by paint manufacturer Gross & Perthun in Mannheim. This system integration also clears the way for Industry 4.0 in paint shops. In addition, it is now possible to measure paint quantities and application times, which boosts cost-effectiveness and quality and enables targeted training of new employees.

Figure 2: Graco ProMix II allows a more functional managing of any unexpected outage.

Maintenance intervals signiﬁcantly extended The benefits of the new technology are readily apparent: while the old system needed maintenance on at least a monthly basis, this has now dropped to once every three months. The mixing chamber is no longer necessary because the new devices have a completely different injection

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

3 Figure 3: Innovative injection and rinsing devices can lead to savings on materials.

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Descendant of Titans Merja Jakobsson MJ Content, Finland

merja.jakobsson@mjcontent.ďŹ

ÂŠ SKS Toijala Works

Opening photo: TW LogStackers are used under very challenging circumstances and their life cycle is exceptionally long.

TD12 KURO, launched two years ago, is the first log stacker designed and produced entirely by SKS Toijala Works Oy. The company started the contract manufacturing of log stackers for Kalmar in 2003 and

acquired its log stacker business ten years later. It was then that the brand name was changed and a new generation of titans, TW LogStackers, was born (ref. Opening photo). SKS Toijala Works has a long history of

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

contract manufacturing also for other large companies, including John Deere, Metso Minerals, Sandvik and Tana. It goes without saying that the high quality of products is of utmost importance for all these partners.

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CONVEY YOUR SUCCESS

The life cycle of the log stackers is exceptionally high

of the bunch and excels on the lumber yards. Its lift capacity is 8-12 tons and it can stack the logs to a Cellulose and paper factories and large sawmills height of up to 7.9 meters (Fig. 2). all favor the biggest one Logistics is the key of the bunch, RTD3126, for the whole lumber which has a lift capacity handling process. Leaving of 31 tons. RTD3126 can SKS Toijala Works has a long valuable lumber to decay unload a truck in one in piles is not an option. history of contract manufacturing take and lift the load to a From the perspective also for other large companies, height of 7.9 meters of the users, the most including John Deere, Metso (Fig. 1). important features of a Minerals, Sandvik and Tana. It The sawmill powerhouse log stacker are reliability, goes without saying that the high RTD1723 is good at dependability and quality of products is of utmost unloading trucks and economic efficiency. importance for all these partners.” working on sorting lines. “There are 8,760 hours It can easily transport and in a year and these lift the round logs to the saw table or to a storage machines are in use an average of 4,000-6,000 hours, at a height of 7.2 meters. The RTD1723 log stacker sometimes even 8,000 hours a year. The engine is has a lift capacity of 17 tons. practically running all the time,” says Juha Manninen, The new RTD12 KURO is the smallest log stacker Product Manager of TW Log Stackers.

INTERNAL HANDLING SYSTEM IMPIANTI MOVIMENTAZIONE INTERNA

Figure 1: The lift capacity of the biggest one of the bunch, RTD3126, is 31 tons and it can lift the whole load from a truck to a height of 7.9 meters in one take.

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

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The Combi alone would be enough for the frame, but with big parts Toijala likes to use a primer since this makes it easier to spot potential defects in the surface. It also allows for a more even spray coating of the top coat.”

“I have been here for ten years and we have never had any major problems with the coating process. This is a good and well-functioning system. At times there have been a few smaller problems, but almost every time the culprit has been pre-treatment. It is extremely important to ensure cleanliness before the coating 2 process,” Seppo Oksa emphasizes. “It is good for the product that we can do the painting ourselves. Figure 2: The new RTD12 KURO is the smallest log stacker of the bunch and We paint big, heavy and complex parts, which come with their own excels on the lumber yards. challenges for the treatment,” Oksa explains. The frames are painted using a “Our log stackers are used under 2-layer epoxy-polyurethane paint very challenging circumstances system. TEKNOPLAST PRIMER 7 and their life cycle is exceptionally functions as primer and TEKNODUR long. We want to lead the way COMBI 3430 as top coat. in terms of technology. The “The Combi alone would be enough durability of our machines is for the frame, but with big parts we the result of a long product like to use a primer since this makes development,” Manninen it easier to spot potential defects in 3 emphasizes. “A happy customer the surface. It also allows for a more is the best-selling point and also even spray coating of the top coat,” Figure 3: All the main components of the log stackers, the boom, the grapple and the frame, are painted in Toijala using Teknos’ the best reference,” Manninen says Seppo Oksa (Fig. 4). polyurethane paint system. adds.

A dependable paint system is key All the main components of the log stackers, the boom, the grapple and the frame, are painted in Toijala using Teknos’ polyurethane paint system (Fig. 3). The cabins are coated with INFRALIT powder coating by a subcontractor. The foreman of the paint shop, Seppo Oksa, has long experience of Teknos’ paint systems.

Logistics is the key for the whole lumber handling process. Leaving valuable lumber to decay in piles is not an option. From the perspective of the users, the most important features of a log stacker are reliability, dependability and economic efficiency.”

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

4 Figure 4: A dependable paint system is key.

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SUCCESS STORIES

SPECIAL ACE

ÂŠ Amber Industries Ltd

Opening photo: Sandvik manufactures mobile crushing and screening equipment that are used within the mining and quarrying industries worldwide.

Sandvik Paint Plant Conveyor Julian Martin Amber Industries Ltd, Chadderton, United Kingdom

julian.martin@amber-industries.ltd.uk

or nearly 150 years, the name Sandvik has been synonymous with quality having annual sales of 89 Billion SEK and 47,000 employees worldwide. Sandvikâ&#x20AC;&#x2122;s Construction and Mining factory in Ballygawley, County Tyrone (Northern Ireland) is now the centre

of excellence for the manufacture of mobile crushing and screening equipment that are used within the mining and quarrying industries worldwide (ref. Opening photo). With the planned expansion of the current manufacturing facility at Ballygawley, Sandvik recognised that there was a

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

requirement for a new finishing plant that would include shot blast booths, paint booths, ovens and an automated conveyor system in order to streamline this part of the production process and cope with the constant increasing demand of machines. Working closely with the engineers at

SUCCESS STORIES © Amber Industries Ltd

SPECIAL ACE

Sandvik and other associated major contractors, Amber Industries Ltd developed a turnkey solution and was subsequently awarded the contract for the new conveyor system utilising our standard Autotrack 500M Power & Free overhead conveyor (Fig. 1). The brief given by Sandvik was that the conveyor system had to handle all derivatives of crusher and screening components ranging up to 3000 kg in weight and having a length of some 8000 mm. A major requirement of the conveyor system had to be a means of easily loading and unloading of these long and heavy components and once safely loaded would be automatically transported through various items of plant and equipment, at times having to be stationary whilst in other areas of the process the product was continuously moving (Fig. 2). In order to achieve all of Sandvik’s requirements, the system was designed with 2 9000 mm long drop sections, one sited at the loading area and one sited at the unload area. The load station having a stationary empty flight bar assembly in position that allows the operator to lower the flight bar down on the drop section carriage accommodating the conveyor track to an ergonomically suitable loading height.

Figure 1: The Autotrack 500M Power & Free overhead conveyor installed by Amber Industries Ltd at the Sandvik factory.

2 Figure 2: A major requirement of the conveyor system had to be a means of easily loading and unloading of the long and heavy components.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2017 - N. 48

SUCCESS STORIES

Flight bar and product are then transferred from the faster moving delivery chain onto a slower moving process chain where the product travels continuously at a given pitch through a primer booth and then through a green cure oven for a stipulated period of time and temperature. After green cure and flash off, the top coat is then applied through a second powder coating booth and then the product travels through the main curing oven for final curing at a temperature of 220 degrees centigrade for a stipulated time period (Fig. 4). As part of the system the conveyor is fitted with a production stop facility that has a traffic light type signal that shows if the conveyor has been stopped for production purposes or as an emergency stop. This facility allows operators to stop the process conveyor, whilst still allowing the delivery conveyor (fast chain) to continue to operate which in effect still maintains unloading operations without having to stop the whole of the plant. Unloading of product as with the loading is undertaken via a second 9000 mm long drop section allowing operators to lower the stationary finished painted product down to a suitable unload height, upon removal of product the empty flight bar rises back to high level and is transported back to the load drop section, check gates are fitted at the drop sections to ensure safe removal of product. Major benefits of the drop sections ensured that lowering of the © Amber Industries Ltd

SPECIAL ACE

3 Figure 3: The master ﬂight bar for attaching the 3000 kg.

Several dedicated SWL points were fitted to the master flight bar for attaching the 3000 kg product (Fig. 3). The whole assembly then rises back to high level and the unpainted component is discharged into the delivery conveyor system where it waits at a stationary position prior to entry of a shot blast booth. As the overall paint plant facility has automatic opening doors within certain parts of the plant, the electronic controls on the conveyor system have to be synchronised with these elements to avoid crash conditions when opening and closing. Upon receipt of a clear signal, the unit then moves into the shot blast booth and once again comes to a halt for the manual shot blasting procedure. This process then continues through to a blow down booth for the removal of any remaining shot that may be present.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

4 Figure 4: One of the two booths for the coating application.

SUCCESS STORIES © Amber Industries Ltd

product could be achieved within a small area compared to that of a conventional conveyor rise and fall. The fact that the stationary flight bar can be lowered down to suitable load and unload heights are found to be beneficial to operatives as this accommodates for the various sizes of products to be handled. Using state of the art electronics enables the integration of the conveyor system to work in conjunction with other plant and equipment ensuring correct product movement and timings as and when required (Fig. 5). The master control is installed with a remote access facility allowing Amber Industries ltd software engineers to access the system from its manufacturing facility at Oldham, Lanc’s (United Kingdom).

SPECIAL ACE

5 Figure 5: The conveyor system works in conjunction with other plant and equipment ensuring correct product movement and timings as and when required.

L’innovazione al servizio del Cliente.

La divisione METALLURGY produce e commercializza specialità chimiche per il trattamento superﬁ ciale dei metalli. In particolare offriamo sgrassanti per l’industria e detergenti, interoperazionali, disossidanti, decapanti, fosfatanti, fosfosgrassanti, prodotti per la conversione dell’alluminio (ossidazione anodica, cromatanti, fosfocromatanti, trattamenti di conversione esente cromo) svernicianti, coagulanti ed ausiliari di lavorazione. La divisione si occupa anche di prodotti per il trattamento di acciaio inox, traﬁ latura e brillantatura. Proponiamo inoltre, per la preparazione alla verniciatura, una serie di prodotti innovativi a basso impatto ambientale esenti da cromo, fosfati e metalli pesanti.

Tecnologia e prodotti per il trattamento superﬁ ciale dei metalli Per maggiori informazioni: Tel. +39.0321789760 salesmet@macdermid.com • www.macdermid.com MacDermid Enthone Italiana Via Vigevano 61 - 28069 San Martino di Trecate (NO)

BRAND-NEW

Cortec® Releases Non-Toxic Corrosion Inhibiting Graffiti Remover in a Recyclable EcoAir® Spray Can

1 Figure 1: Cortec® EcoAir® Grafﬁti Remover can be used to remove grafﬁti, ink and paint from different surfaces.

andalism of public or private property with graffiti is an unfortunate problem that degrades businesses, neighborhoods, and municipalities. Bridges, walls, fences, dumpsters, train cars, road signs, and other structures are all targets of graffiti.

Graffiti degrades and damages the value and appearance of property and local environments (Fig. 1). Methods for timely removal are important to preserving a positive atmosphere. Sometimes they are critical to discouraging further crime associated with graffiti markings.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

One unique tool for graffiti removal has been released by Cortec® Corporation as EcoAir® Graffiti Remover Enhanced with Nano VpCI® Technology. EcoAir® Graffiti Remover is a semi-viscous liquid used to remove graffiti, inks, and paints from metal, concrete, and wood. The liquid contains

BRAND-NEW

a corrosion inhibiting compound to prevent flash rusting and discoloration of metal surfaces after graffiti removal. The property owner or maintenance worker can carry a can of EcoAir® Graffiti Remover to the site of vandalism and spray it in an even layer over the graffiti in order to clean the markings off the surface. Bag-on-valve EcoAir® spray can technology allows the graffiti remover to be sprayed 6-8 inches (15-20 cm) from the surface in any position, even upside down, making it easier to apply in difficult to reach areas. EcoAir® Graffiti Remover has an exceptionally smooth flowing gel that helps achieve complete coverage for vertical surfaces or surfaces of varying geometry. After the product is sprayed on the surface and allowed to penetrate graffiti or unwanted markings for 3 to 30 minutes (depending on the strength of the graffiti), the surface can be scraped clean while rinsing with water. The corrosion inhibitors contained in the product help protect any metal that might be vulnerable to flash rust or discoloration as the graffiti is cleaned off the surface. EcoAir® Graffiti Remover can be used to remove graffiti from many different locations: - walls - equipment - metal - concrete - wood EcoAir® Graffiti Remover has a relatively low level of toxicity and does not rely on some of the typical chemicals used for stripping such as methylene chloride, chlorinated solvents, methanol, toluene, and acetone. Unlike methylene chloride based products that evaporate quickly, EcoAir® Graffiti Remover is a non-drying gel that remains on the surface to soften, penetrate, and remove unsightly markings. It has a low odor and is free of ketones, chromates, and phenols. Because it is packaged in an environmentally-friendly EcoAir® bag-onvalve spray can, it dispenses the product by compressed air without the use of CFC or HCFC propellants that would affect the ozone layer. The steel can is recyclable (always verify local regulations). EcoAir® Graffiti Remover is another example of Cortec’s creativity in adding value to conventional products. The corrosion inhibitor adds a unique dimension of protection for metal surfaces defaced with graffiti; while the EcoAir® spray can technology cuts down on the release of harmful propellants into the atmosphere, all in the process of removing unsightly graffiti. For further information: http://www.cortecvci.com

BRAND-NEW

byko-spectra pro Light Booth: See Things the Right Way

ÂŠ BYK-Gardner

YK-Gardner, worldwide partner of the automotive, paint and plastic industries for quality control of colour, appearance and physical properties, is introducing the new byko-spectra pro. No other light booth came ever closer to natural daylight. Thanks to the combination of LEDs and filtered halogen lamps byko-spectra pro offers the best D65 on the market (Fig. 1). Visual perception is highly subjective as it is influenced by our individual colour preferences depending on our personal experience. Consistent colour is a key factor in our purchasing decision, as we associate it with high quality. To optimize the colour consistency, standardized test procedure including a neutral surrounding and defined illumination is needed. The real challenge is to simulate natural daylight which is defined by CIE D65 and D75 illuminants. The daylight-technology used in the byko-spectra pro guarantees accurate colour rendering which fulfills the highest class A according to CIE (CIE Publication 51). Highlights: - D65 and D75 light illumination with additional LED correction - Enhanced long-term stability of daylight source - Evaluation of colour changes between daylight to incandescent to fluorescent light with 8 different illuminations: D65, D75, A, HZ, CWF, TL84, U30 and UV - Adjustable light level for optimum viewing of any colour â&#x20AC;&#x201C; from bright to dark - Internal daylight colour temperature recalibration - Standardized and efficient colour evaluation with automatic sequence mode - Traceable factory certificate guarantees precision and accuracy of 1 all lamps. For further information: Figure 1: The new byko-spectra pro introduced by BYK-Gardner. www.byk.com

Opening photo: A bird’s eye view of the Industrias TITAN plant of El Prat de Llobregat, Barcelona, Spain.

HIGHLIGHT OF THE MONTH

Industrias TITAN: Technological Research Behind 100 Years of History From an interview with José Manuel Azpeitia Powder Coating Division General Director of Industrias TITAN SA

rgracia@titanlux.es

ndustrias TITAN SA (ref. Opening photo) was established in 1917 by Don Joaquin Folch i Girona and it is currently led by the fourth generation of the family. TITAN is now one of the longestlived industrial companies of Spain. In latest October it turned 100 years of history and on 14 April 2018 will celebrate its anniversary in Barcelona. In this century of history, this firm has never ceased to evolve and be highly innovative, initially in the field of

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

decorative and building paints and then also in the industrial coating sector. Here, it has focussed on low environmental impact products with high solid, low VOC content liquid paints and, since 2004, with powder coatings, too. These paved the way for the conquest of a new, growing market. “TITAN has always been a technological market leader, but the crisis of the last ten years has hit one of our core businesses, the building one,” says José Manuel Azpeitia, the

TITAN has always been a technological market leader, but the crisis of the last ten years has hit one of our core businesses, the building one. On the other hand, the strong growth of the powder industry in the last twelve years has enabled it to expand even in this last decade.”

Powder Coating Division General Director (Fig. 1). “On the other hand, the strong growth of the powder industry in the last twelve years has enabled us to expand even in this last decade.” “Our current goal is to open up new horizons on the global market, both with a new managerial structure and through significant investments in R&D to launch high-tech products,” states Azpeitia. “The export share of powder coatings is now between 20% and 25%, but we want to increase it. That is why we are focussing on new hyper-durable products able to guarantee an aging resistance of over 20 years, on special products for sublimation and in particular for wood effects, and on metallic finishes. Another important factor for the market of this millennium is the ability to create tailormade coatings, customising them based on the characteristics of the customers’ application systems.”

Increasing the resistance of powder products Improving one’s own products in terms of technology and not only of special effects and finishes is a necessary step to meet the needs of a constantly evolving market, demanding ever-increasing quality and durability levels. “TITAN offers a very wide range of colours in all the trendiest effects: metallic, matte, textured, and anodised.

HIGHLIGHT OF THE MONTH

1 Figure 1: José Manuel Azpeitia.

The latter have been our subject of study for several years, although market demand has not exploded, yet. However, this is just a small part of our research activity,” says Azpeitia. “The true focus of our R&D department is further increasing our products’ resistance and high quality level.” “I think it is better to invest in the R&D of products with a solid future and a good industrialisation potential. TITÁN’s laboratory is studying various combinations of resins and pigments in order to formulate products with higher and higher outdoor durability. As for sublimation coatings, the goal is to exceed an outdoor resistance value of 10 years without any issue in colour and gloss retention,” says José Manuel Azpeitia. “Our hyper-durable coatings, on the other hand, have an aging resistance greater than 20 years; we want to obtain the Qualicoat

Class 3 and AMAA 2605 certifications for them. All our new products have a very balanced formulation, without any foreign elements in their chemical compositions. However, our most ambitious research project, conducted with a resin manufacturer and a graphene oxide producer, aims at formulating an exclusive resin that improves the corrosion resistance of powder coatings. In fact, graphene is able to generate an anti-porous barrier that prevents the passage of oxygen.” Hyper-durable coatings and the use of graphene in powders were also the two main topics of the IX Technical Day organised by Industrias TITAN in Madrid on 26 October, titled “What is the contribution of TITAN Powder to the new challenges of the powder

TITAN is focusing on new hyper-durable products able to guarantee an aging resistance of over 20 years, on special products for sublimation and in particular for wood effects, and on metallic finishes. Another important factor for the market of this millennium is the ability to create tailor-made coatings, customising them based on the characteristics of the customers’ application systems.” international PAINT&COATING magazine - NOVEMBER/DECEMBER 2017 - N. 48

The TITAN’s secret is the ability to reinvent itself even when market conditions are not favourable, focussing on long-term innovations and preparing for the future insourcing and professionalisation trends. Secondly, the pursuit of customers’ loyalty by putting at their disposal products that fully meet their needs.”

TITAN’s laboratory is studying various combinations of resins and pigments in order to formulate products with higher and higher outdoor durability. As for sublimation coatings, the goal is to reach an outdoor resistance value of 10 years without any issue in colour and gloss retention.”

customers with high volumes of purchase and that receive the best technical support from us: TITAN is with them in any innovation, research, fine-tuning, or optimisation project.” “Industrias TITAN has been able to be competitive and successful for 100 years,” says Azpeitia. “Its secret? First of all, the ability to reinvent itself even when market conditions are not favourable, focussing on long-term innovations and preparing for the future insourcing and professionalisation trends. Secondly, the pursuit of customers’ loyalty by putting at their disposal products that fully meet their needs.”

3 Figure 3: The speaker’s table at the panel discussion that followed the technical presentations.

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Cuba, North Africa and Germany. We have realised that it is very important 2 to work directly with our clients, Figure 2: A break time during the IX Technical Day organised by TITAN. especially in terms of technical assistance, rather coating industry?”. The event saw the than opening more and more distribution participation of a hundred professionals centres. This does not mean that we exclude in the field (Fig. 2) and gave rise to an the possibility of working with distributors, interesting debate on the paint durability but what is really important for us is getting issue (Fig. 3). into the most demanding markets with high quality products,” states Azpeitia. A growing foreign market “Our current market consists of very loyal TITÁN’s propensity to innovation has led it to be one of the world’s leading players through direct export. “We have a very important customer in Mexico in the field of architecture and we also distribute our products in Colombia,

SUCCESS STORIES

Beijing Benz Automotive Expanding Production Capacities with Sustainable Paint Shop from Dürr

1 Figure 1: 15 robots of the type EcoRS 16 and EcoRS30 L16 from Dürr in use at seam sealing and insulation application.

he new paint shop of Beijing Benz Automotive Co, Ltd. (BBAC) meets the highest standards for environmentally friendly production and air pollution control. The compact system design, the resource-efficient painting technology,

and efficient exhaust air purification all contribute to this. What is notable about the major project, where Dürr was the general contractor, is also the speed of commissioning: the entire paint shop was launched in September 2017 four weeks earlier than originally planned.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

China is increasingly reconciling economic dynamism and environmental protection. Its aim in doing so is to improve the air quality in major cities with low-emission production processes. This is also true of Beijing, the location of BBAC’s recently commissioned paint shop. That is why the German-Chinese

SUCCESS STORIES

the initial fill and during operation. BBAC is automotive joint venture focused on two Energy savings of up to 60% The technology is also designed for also using an environmentally friendly solution environmental issues from the beginning: sustainability in the PT/ED phase. The in the spray booths with water-based paints high energy efficiency during production and RoDip rotational system used during applied by painting robots using the EcoBell2 efficient exhaust air purification. pre-treatment and cathodic dip-coating high-speed rotating atomizers (Fig. 1). With In the new paint shop, which has an hourly eliminates entry and exit inclines as the its flexible spray jet setting, the EcoBell2 throughput of 30 vehicles, BBAC is using car bodies are introduced at a steep angle can handle different painting tasks with the the Integrated Paint Process (IP2) which has and rotated through 360°. This enables best quality and – thanks to the high degree been tried and tested at Mercedes-Benz. shorter dip tanks, which need less water of transfer efficiency during application – This process eliminates the application and and energy as well as fewer chemicals for economically. Any paint overspray is separated baking of the primer, since it is integrated in a resource saving manner. The dry into the base coat. This reduces separation system EcoDryScrubber emissions and energy consumption binds the overspray with limestone significantly. It also makes for a The new paint shop of Beijing Benz powder in a process involving no more compact system design, since water or chemicals. This means that the entire primer line including the Automotive Co, Ltd. (BBAC) meets the the painting booth can be operated associated oven is not needed. highest standards for environmentally with 80% recirculated air, which in This saves infrastructure space and friendly production and air pollution control. turn lowers air conditioning costs already lowers energy consumption The compact system design, the resourceand offers energy savings of up to and CO2 emissions during the efficient painting technology, and efficient construction phase. exhaust air purification all contribute to this.” 60%.

SUCCESS STORIES

2 Figure 2: Ergonomic and friendly workplaces for the ﬁnal vehicle inspection after top coat application.

Heating ovens with exhaust air BBAC is also setting standards when it comes to emission control. The painting booth is equipped with Dürr’s compact exhaust air purification system for removing the solvents (VOC) from the exhaust air. Due to the booth air recirculation, the exhaust air requiring abatement is already concentrated. The Ecopure(R) KPR VOC concentrator system, combined with a downstream thermal oxidizer, the Ecopure(R) TAR, allows for highly efficient VOC removal. This combination reduces the size of the thermal oxidizer by 80% compared to conventional VOC abatement systems connected to spray booths without air

The Ecopure(R) KPR VOC concentrator system, combined with a downstream thermal oxidizer, the Ecopure(R) TAR, allows for highly efficient VOC removal. This combination reduces the size of the thermal oxidizer by 80% compared to conventional VOC abatement systems connected to spray booths without air recirculation.”

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

recirculation. The exhaust air from the ovens is abated by the Ecopure(R) TAR, an integral afterburning system with heat recovery, and is then reused for heating the oven. The new paint shop is the second contract from BBAC. Dürr constructed a first paint shop in Beijing in fall 2015, just three miles away from the new one. The lessons learned during this project, the synergies in planning and execution, and largely identical project teams on both sides ensured such a smooth process that the start of production for the second project was achieved much earlier than planned (Fig. 2). For further information: www.durr.com

Zaniolo CdA - 1.17

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

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

QUALITÀ QUALITY

RISPOSTE ANSWERS

A M B I E N T E _ UN ASPETTO CHE NON METTIAMO C O N S TA N T R E S P E C T F O R _ THE ENVIRONMENT

M A I F R A PA R E N T E S I

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

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

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

A Spray Paint Booth with a Quick Colour Change System: Helping Contractors Increase Productivity Monica Fumagalli ipcm® nvesting in their businesses Verniciatura F.lli Sasso’s ﬁfty years of business and in technological innovation Like many medium-sized contractors even when demand falls and the “A coating contractor,” says Giovanni that have recently undergone a period market tapers off, but also making Sasso, one of the firm’s founders, of production decline, Verniciatura proportionate investments to their “must be able to provide its customers Sasso has now resumed working at full structure and solidity as well as in with a complete service, without capacity, also thanks to the installation of line with the quality required by their excluding any kind of treatment, not an automatic spray paint booth, about a customers. This is the secret of many even those with the smallest lots. year and a half ago. The objectives of this Therefore, it also must equip itself with companies that have managed to investment were as follows: a versatile application system. Finally, overcome the global market crisis and - higher quality yield; even become stronger, ready to meet it must not be afraid of economic - lower paint consumption; fluctuations: it should always be growing demand and ever-increasing - higher productivity.” ready to invest and adapt quality requirements. One of them is Verniciatura Fratelli to ever-evolving regulations and market trends.” This Sasso, based in Oggiona statement summarises the Santo Stefano (Varese, Italy). corporate philosophy that Established in 1967 by Giovanni and Antonio has characterised the first fifty years of business of Sasso, the company Verniciatura F.lli Sasso. “In half initially specialised in contracting liquid coating a century, we have developed in-depth knowledge not only operations, in particular on components for weighing of application technologies scales and slicers and other and systems, but also of the mechanical elements. Since most appropriate production 1978, however, it has been approach. This has enabled specialising in powder us to overcome the most 1 coating processes with epoxy, critical moments: the full polyester and epoxy polyester satisfaction of our customers Figure 1: The new spray paint booth installed by GRT. products. It treats different and our ability to find the best types and sizes of workpieces, solutions in terms of both installation of an automatic spray paint booth, from small metal to textile quality and cost-effectiveness about a year and a half ago. The objectives of machine components (ref. Opening photo). are a winning combination for us. About two this investment were as follows: Like many medium-sized contractors that have years ago, when there was no sign of recovery - higher quality yield; recently undergone a period of production yet, we decided to invest in the replacement - lower paint consumption; decline, Verniciatura Sasso has now resumed of our outdated spray paint booth with a new - higher productivity (Fig. 1). working at full capacity, also thanks to the generation one.” © ipcm ®

Opening photo: Some ﬁre extinguishers coated by Verniciatura F.lli Sasso.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2017 - N. 48

2 Figure 2: The outside of the pre-treatment tunnel.

In half a century, Verniciatura Sasso has developed in-depth knowledge not only of application technologies and systems, but also of the most appropriate production approach. This has enabled it to overcome the most critical moments: the full satisfaction of its customers and its ability to find the best solutions in terms of both quality and cost-effectiveness are a winning combination.”

The pre-treatment process (Fig. 2) is a 4-stage conventional treatment (degreasing, phosphating, rinse, and final rinse in demineralised water) followed by the application phase. The new coating booth was installed by GRT (Modena, Italy), a company designing, producing and installing automatic booths and powder coating systems with components certified according to the EC Directive and the ATEX Directive 2014/34/EU. “Their respect of the most recent legal requirements on safety, the great value for money, and the use of Gema’s trusted equipment, exclusively employed by GRT for its booths, were decisive factors for our choice,” states Valentina Sasso, who manages the company with her father and her brothers Silvano and Claudio.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

The new booth with 6 automatic horizontal guns was then integrated into the already existing coating system and equipped with two stations for manual touch-up operations before and after application, featuring one spraying gun each (Fig. 3).

Main features of the GRT booth “The booth belongs to the Superior series,” says Massimo Zangari, one of the owners of GRT, “and has all the tools needed to comply with the ATEX regulations for fire safety and prevention. Built to the most modern and advanced standards, it is fully automatic and features sandwich panels in plastic and antistatic material; these prevent the powders from depositing on the walls (Fig. 4). The rounded shape of the booth also facilitates colour change and cleaning

FOCUS ON TECHNOLOGY

The respect of the most recent legal requirements on safety, the great value for money, and the use of Gema’s trusted equipment, exclusively employed by GRT for its booths, were decisive factors for the choice of its equipment. The new booth with 6 automatic horizontal guns was then integrated into the already existing coating system and equipped with two stations for manual touch-up operations before and after application, featuring one spraying gun each.”

3 Figure 3: Three out of the six application guns in operation.

G RT

The booth belongs to the Superior series and has all the tools needed to comply with the ATEX regulations for fire safety and prevention. Built to the most modern and advanced standards, it is fully automatic and features sandwich panels in plastic and antistatic material; these prevent the powders from depositing on the walls.”

4 Figure 4: Components exiting the booth.

operations. Its bottom houses a suction and blowing system for automatic cleaning.” “The high level of automation and versatility of this machine has enabled it to integrate into an already existing plant and be adapted to our one-coat application operations on workpieces up to 250 x 100 x 100 cm. It has also enabled us to significantly simplify process management and reduce manual labour during the preparation phase,” says Silvano Sasso. The tasks previously performed by the operators have been eliminated thanks to the automatic selection of programs enabled by dimensional detection optical barriers. “The dimensional detection system,” states Zangari from GRT, “makes the movement of axes completely automatic and optimises the corona spraying of powders, thus enabling a considerable saving of product. It also adjusts the speed of the self-supporting vertical reciprocators, synchronising it with that of the conveyor and thereby ensuring the number of passages required for a uniform coating is reached. The booth is also equipped with a start/stop detection system that stops the guns if there are no workpieces and starts them when a part moves through the machine.” Also thanks to this system, a 15% increase in the amount of paint saved has been obtained compared with the previous booth.

FOCUS ON TECHNOLOGY

ÂŠ ipcm ÂŽ

The GRT powder management unit is the core of the automatic multifunctional system, designed to eliminate human intervention (Fig. 5). It is composed as follows: - a gun power feeding system; - two fluidised powder tanks; - an air storage buffer for cleaning the dip and recovery tubes; - a connection for the fluidisation of the powder tanks; - a vibratory table for the powder tanks or boxes; - a capacitive probe for level control; - a PLC with a touch screen panel to display and store the amount of m2 coated daily; - a weighting integrated system and powder consumption storage and management.

5 Figure 5: The GRT powder management unit.

www.defil.it

“For a coating contractor like us, treating several batches of different components on a daily basis, the speed of the colour change operation is a crucial factor,” says Claudio Sasso (Fig. 6). “We currently perform about six colour changes per hour, that is, one every ten minutes. It is a very quick operation thanks to GRT’s devices, exploited at best thanks to our team’s skills acquired over the years. Also the programming of the shades to be applied ensures that parts are not contaminated during coating.” The filtration and suction unit consists of a fan, a soundproof engine (<80 dB), and highly efficient cartridges with an automatic integrated backpressure cleaning system. The dispersed powder is then collected by an easily movable container, which can be fitted with an automatic unloading system at any time. “The suction performance is excellent,” says Claudio Sasso. “The applied layers are never contaminated and our operators could even work without any protection equipment, if it was

The booth is also equipped with a start/ stop detection system that stops the guns if there are no workpieces and starts them when a part moves through the machine. Also thanks to this system, a 15% increase in the amount of paint saved has been obtained compared with the previous booth.”

Conclusions

The suction performance is excellent. The applied layers are never contaminated and the operators could even work without any protection equipment, if it was allowed. Another important aspect in the choice of this booth was its powder recovery performance, equal to about 97%.”

“The main advantages we have found after installing the new GRT booth,” states Silvano Sasso, “are lower powder consumption and higher level of automation for easier operations and better quality results. We have reached a paradox: some of our about sixty clients now are surprised that the coating quality of their workpieces is too high!”

Quick colour change and powder recovery

6 Figure 6: From left to right: Claudio Sasso, Silvano Sasso, Valentina Sasso, and Giovanni Sasso.

allowed. Another important aspect in our choice of this booth was its powder recovery performance, equal to about 97%.” “The cyclone from GRT’s Superior series has a dense phase recovery pump,” says Zangari from GRT. “It features a high recovery efficiency degree and a recirculation system for the recovered powder. It has an integrated sieve in its bottom, easily opened to perform cleaning and inspection tasks.”

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The main advantages Verniciatura Sasso found after installing the new GRT booth are lower powder consumption and higher level of automation for easier operations and better quality results. It has reached a paradox: some of about sixty clients now are surprised that the coating quality of their workpieces is too high!”

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Powder coating lines since 1976. V E R O N A

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Opening photo: The new pre-treatment tunnel.

FOCUS ON TECHNOLOGY

Pre-treatment as a Key to the Qualitative Improvement of Finishes and as the Success Factor of a Corporate Relaunch Barbara Pennati ipcm®

he pre-treatment of metal surfaces prior to coating is often regarded as a necessary evil. This leads to underestimate its importance for the final quality of finishes and the durability of components. If a surface is not perfectly

prepared up to the standard required for its intended use, the coating will tend to peel off and lose gloss and colour while corrosion will start, regardless of the system applied. That is why the powder coating contractor DT Colors has far-sightedly invested in the quality of

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its pre-treatment process. This has led the company, which had recently experienced economic difficulties, to reinvent itself and stand out on the market as a dynamic and growing business able to offer high quality products.

FOCUS ON TECHNOLOGY

“DT Colors raised from the ashes of Industria Galvanica Dalla Torre Ermanno & Figli, a company that ceased its activity following the crisis of the regional chair market. In 2008, we were faced with a significant reduction in the orders from this sector and we were forced to change our strategy,” explains Lorenzo Dalla Torre, Partner, Project Manager and R&D of DT Colors (Fig. 1). “Two companies that are now actively cooperating originated from Industria Galvanica Dalla Torre, which had been operating since 1928: Surface Design, specialising in galvanic treatments, and DT Colors, which inherited Industria Galvanica’s coating division.” With a strategy aimed at increasing the quality of its application processes, DT Colors has relied on the expertise of Kemmex, a company specialising in the production and distribution of chemicals for metal pre-treatment and wastewater treatment processes. In particular, it decided to focus on the workpiece preparation phase, looking for the best pre-treatment method that could help it enter new markets with high quality standards. The company restructuring process started with a focus on team engagement and with several commercial relaunch activities in its area, then went on with a technological innovation process.

The ﬁrst phase of relaunch: teamwork and ability to evolve In the first phase, pushed by the new commercial approach and by the team engagement,

The pre-treatment of metal surfaces prior to coating is often regarded as a necessary evil. This leads to underestimate its importance for the final quality of finishes and the durability of components. If a surface is not perfectly prepared up to the standard required for its intended use, the coating will tend to peel off and lose gloss and colour while corrosion will start, regardless of the system applied.”

DT Colors made the first changes to the coating plant, in order to increase the quality of the pre-treatment stage (ref. Opening photo). “We already had a plant in line with the required qualitative standards and able to apply two-layer powder systems, thanks to the presence of six spray paint booths and two ovens. We have exploited its potential by focusing on coatings intended for outdoor use,

including systems requiring a zinc primer as the first layer, two-layer systems to be applied on high-quality indoor products, and processes combining galvanic and powder coating thanks to the cooperation with Surface Design,” states Dalla Torre. “For its new pre-treatment cycle, DT Colors started experimenting with a multi-metal nanotechnology system requiring no changes in the existing line,” says Gianni Zilli, Director of Kemmex. “Another crucial step to improve its quality level was the addition of rinsing stages with demineralised water.” The implementation of new services, the customer care and the adoption of high quality powders and a multi-metal onestage pre-treatment nanotechnology systems have promptly brought positive results to DT Colors, relaunching the company as a reliable coating contractor.

The second phase of transformation: Preparation is everything

“Given the success of this first investment, the second phase focused even more on improving our surface preparation process. Inspired by the motto ‘Preparation is everything’, we acquired a new pre-treatment tunnel enabling us to perform a multi-stage cycle,” says Lorenzo Dalla Torre. “In this way, we can adapt our preparation process to the 1 type of surface to be treated Figure 1: Lorenzo Dalla Torre, left, with Luciano Bertoldo, DT Colors’ Plant Manager and Gianni (Fig. 2).” Zilli from Kemmex, right.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2017 - N. 48

That is why the powder coating contractor DT Colors has far-sightedly invested in the quality of its pretreatment process. This has led the company, which had recently experienced economic difficulties, to reinvent itself and stand out on the market as a dynamic and growing business able to offer high quality products.”

2 Figure 2: Workpieces inside the pre-treatment tunnel.

“The new pre-treatment tunnel features an initial degreasing and decontamination stage that is performed on all materials. It is followed by several rinses with demineralised water to ensure that the parts are perfectly clean before moving them forward to the following treatments. Then, the specific cycle start, as we “turn on” or “off” some tanks depending on the substrate. Carbon steel and galvanised steel undergo an acid-based nanotechnology conversion process whereas aluminium is subjected to a fluorozirconate treatment. Each process applies a slight colouration to simplify the quality and uniformity checks (Fig. 4),” states Gianni Zilli from Kemmex. © ipcm ®

Also in this case, DT Colors relied on the expertise of Kemmex and especially of Gianni Zilli, who designed the pretreatment cycle. The new 60-metre long tunnel, acquired based on such process, precisely enables to select different pre-treatment steps depending on the material to be treated (Fig. 3).

With a strategy aimed at increasing the quality of its application processes, DT Colors has relied on the expertise of Kemmex, a company specialising in the production and distribution of chemicals for metal pre-treatment and waste water treatment processes. In particular, it decided to focus on the workpiece preparation phase, looking for the best pre-treatment method that could help it enter new markets with high quality standards.”

3 Figure 3: The tunnel is divided into two parts. The connecting area is devoted to visual inspections.

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FOCUS ON TECHNOLOGY

For its new pre-treatment cycle, DT Colors started experimenting with a multi-metal nanotechnology system requiring no changes in the existing line. Another crucial step to improve its quality level was the addition of rinsing stages with demineralised water.” Innovative aspects of the pre-treatment cycle DT Colors’ chemical pre-treatment cycle employs two innovative and highly performing products developed by the laboratories of Kemmex for use in both modern systems and conventional tunnels. The first product is a degreasing

additive based on vegetable extracts from the SG/NS BIO series: it ensures the elimination of surfactants during the purification stage and the reduction of risks, of water consumption and of maintenance operations needed. For the treatment of iron and steel, DT Colors uses a zirconium salt nanometric conversion product from the DEXBOND SZR EH series. It also works at room temperature (±20°C) without foaming, completely removing the conversion sludge while improving the quality level of the pre-treatment cycle. “Thanks to this multi-metal process developed by Kemmex based on our quality requirements, in particular for use in our tunnel without any plant modifications, we can now perform highly performing treatments while reducing our disposal costs and environmental impact. Moreover, the possibility to differentiate

our pre-treatment cycles enables us to also coat materials that we could not treat with our old plant, aluminium in particular. This important innovation paved the way for markets other than the furniture one, such as the medical one and the naval and outdoor furnishing sectors, where high durability coatings are required. We can even offer custom services for design companies requiring special- effect colour ranges,” says Dalla Torre. “In our lab, we have focussed on modern, nanotechnological and high performance pre-treatment cycles that could also be used on already existing plants, without forcing the companies that want to increase their products’ quality to make significant investments to adapt their lines to the new chemicals,” says Gianni Zilli. “A key to guarantee their performance is the addition of rinsing stages with demineralised water.”

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4 Figure 4: The pre-treatment processes apply a slight colouration to simplify the quality and uniformity checks.

The coating process DT Colors specialises in two-layer coating systems and combined finishes that include the application of a galvanic and a powder coating or a galvanic and a transparent cataphoretic coating. “We only use high quality epoxy and polyester powders. We choose the paint supplier based on our customers’ requests, but we have a particularly good partnership with Inver,” says Dalla Torre. “One of our most popular coating systems is intended for outdoor and naval use and it includes a zinc salt primer and a polyester topcoat. Another very common two-layer system to protect high quality indoor components includes the application

FOCUS ON TECHNOLOGY

Also for the second phase, DT Colors totally relied on the expertise of Kemmex, who designed the pre-treatment cycle. The new 60-metre long tunnel, acquired based on such process, precisely enables to select different pre-treatment steps depending on the material to be treated.”

of a galvanic and a powder coating: a metallic basecoat and a protective transparent topcoat that can be satinised, matte, or glossy. Finally, our target markets often require the application of a transparent pigmented coating known as chrome gel, allowing to obtain different colours on substrates with a galvanic build-up, in polished aluminium, and in chrome,” says Lorenzo Dalla Torre. “The starting point, however, is always a degreased and uniform surface ensuring good adhesion of the coating film.”

Conclusions “After about one year, I can safely say that this investment has largely contributed to relaunch our company after the crisis that had led to an important downsizing of the original business. We have focussed on the pursuit of an ever-increasing quality level, also thanks to the daily collaboration of Kemmex. The development of an advanced and highly effective pre-treatment cycle has enabled us to improve the characteristics of our products in terms of aesthetics, but above all of durability and resistance. We can only be pleased with our choice, and we certainly recommend it to any company intending to increase the quality of its finishes,” states Lorenzo Dalla Torre.

The development of an advanced and highly effective pre-treatment cycle has enabled DT Colors to improve the characteristics of its products in terms of aesthetics, but above all of durability and resistance.”

INTERNATIONAL PATENT

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

NITROTHERM The performance is 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

DSM Invests €15 million to Expand Capacity at Coating Resins Plant in Meppen, Germany

segment in recent years with the growth due, in part to the market shift from epoxy-based packaging coatings towards new BPA-free solutions. In particular, the investment will enable greater supply flexibility, the ability to meet growing demand and improved stock management. The investment underlines DSM’s commitment to the sustainability and innovation of the coatings industry and strenghtens its long-term position as a leader in the market.

oyal DSM, a global science company active in health, nutrition and materials, announced it has invested €15 million for the expansion of its Coating Resins plant in Meppen, Germany (Fig. 1). The facility is specialized in the production of liquid polyesters and other specialty resins. With this expansion, DSM Coating Resins reinforces its position in the can and coil coatings segment and ensures it remains fit for growth in the BPA-free market. The capacity expansion follows strong growth in the can and coil coatings

Royal DSM is a global science-based company active in health, nutrition and materials. By connecting its unique competences in life sciences and materials sciences DSM is driving economic prosperity, environmental progress and social advances to create sustainable value for all stakeholders simultaneously. DSM delivers innovative solutions that nourish, protect and improve performance in global markets such as food and dietary supplements, personal care, feed, medical devices, automotive, paints, electrical and electronics, life protection, alternative energy and bio-based materials. DSM and its associated companies deliver annual net sales of about €10 billion with approximately 25,000 employees. The company is listed on Euronext Amsterdam. For further information: www.dsm.com/paint

Figure 1: The DSM’s plant in Meppen, Germany.

DSM – Bright Science. Brighter Living.™

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

Opening photo: The booth 4.0 designed and installed by Zeus Electrostatic Systems.

FOCUS ON TECHNOLOGY

Cutting-edge Coating Technology for Medium and Large-sized Carpentry Components. Industry 4.0 Principles for Increased Plant Versatility and Performance. Barbara Pennati ipcmÂŽ

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FOCUS ON TECHNOLOGY

to lay the groundwork for the next machine,” says Paolo Patuzzo. “Looking he coating industry is complex step: “Once the static plant was in at how the market and its demands and requires robust, reliable full operation, we focussed on the were evolving, we believed that this and efficient equipment. In this replacement of our in-line system. We plant would have ensured a competitive increasingly competitive and difficult kept only its pre-treatment tunnel, advantage by enabling us to process market, however, many companies which performs a three-stage multimedium and large-sized components performing coating tasks also seek metal process (phosphodegreasing, as well as applying increasingly more a partner that can help them reduce rinsing with mains costs, stay competitive, water, and rinsing with and improve quality. For a semi-demineralised firm dealing with carpentry water); it uses components of different Dollmar products and shapes and sizes, from the it features a small smallest dimensions to several nebulisation plant for meters in lenght, it is important the nanotechnology to rely on production systems conversion product, that can cope with the needs entirely designed and of different customers while built by our family,” ensuring adequate quality and states Paolo Patuzzo. durability levels for all types of products. Arcobaleno Arcobaleno Verniciatura was Verniciatura 2.0: established following the 1 the new coating acquisition of Verniciatura plant F.lli Piccoli by Marzio Patuzzo, Figure 1: From left to right Matteo Giordano Cuman, Guerra Srl’s Commercial “We started a project now managing the company Division, Marzio Patuzzo, his sons Paolo and Valerio, and Massimo Ricci called Arcobaleno with his sons Paolo and from Zeus. Verniciatura 2.0 for the Valerio. Precisely aiming upgrade of the old plant, which, albeit colours.” “The manual sliding static at continuous technological and applying powders, had been designed plant is 7 m long. It has lowered our qualitative improvement, it has made for liquid coatings,” says Valerio costs, increased our flexibility and some important investments on its Patuzzo. “That is why, a few years ago, enabled us to acquire new clients who coating plant in collaboration with we conducted a market research with Zeus Electrostatic Systems (Argenta, the intention of changing our drying FE, Italy), a company specialising in the and polymerisation ovens, spray paint production of powder coating plants In this increasingly booth, and overhead conveyor.” and equipment (Fig. 1). This upgrade “The first booth we installed on project has enabled Arcobaleno competitive and difficult the advice of the plant’s designer Verniciatura to be among the Northern market many companies immediately gave us problems: there Italian leaders in the surface treatment performing coating tasks were several critical issues in the of large-sized components for different seek a partner that can powder application process due to sectors, including furniture, design and help them reduce costs, the over-sized suction system, which industry. stay competitive, and compromised our quality standards,” “In 1997, when Arcobaleno Verniciatura improve quality.” says Paolo Patuzzo. The Patuzzo was established, the original business family turned to Zeus Electrostatic had already switched from liquid to Systems in order to find a solution. “We powder coatings and it was equipped already knew Zeus and its distributor are still among our main customers,” with two in-line systems and a static in Lombardy, Guerra Srl (Zelo Buon adds Valerio Patuzzo (Fig. 2). plant. After dismantling one of the two Persico, LO, Italy), because we had Thanks to this first upgrade phase, in-line systems, the first investment already purchased from them the Arcobaleno Verniciatura was able we made in 2007 involved the static

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2017 - N. 48

Zeus3 is a booth 4.0 with a quick colour change system, two manual touch-up stations, and conventional Venturi pumps for feeding the paint. It integrates the Industry 4.0 principles to offer functions such as workpiece recognition, production data transmission, and remote machine monitoring.”

2 Figure 2: Besides the in-line system, the factory is equipped with a static plant to treat largesized components.

The project called Arcobaleno Verniciatura 2.0 was started for the upgrade of the old plant, which, albeit applying powders, had been designed for liquid coatings.”

monitoring. This enables both the user and Zeus itself to intervene promptly in case of technical problems,” states Massimo Ricci, the CEO of Zeus. “The booth is © ipcm ®

powder management unit and the cyclone linked to the new booth. In order to optimise our resources, at the same time, we devoted the old booth to the application of only one colour,” explains Patuzzo. “Given Arcobaleno Verniciatura’s needs, we offered them Zeus3, a booth 4.0 with a quick colour change system, two manual touch-up stations, and conventional Venturi pumps for feeding the paint (ref. Opening photo). It integrates the Industry 4.0 principles to offer functions such as workpiece recognition, production data transmission, and remote machine

made of dielectric material, fast to clean and efficient in terms of powder recovery. Compared to conventional metal booths, plastic does not allow the powder to accumulate on the walls, thus ensuring maximum efficiency of the recovery system and greatly facilitating the cleaning operations,” adds Ricci. “This booth was designed for companies performing several colour change operations per shift.

3 Figure 3: The Venturi-effect micro-hole cleaning system keeps the booth ﬂoor clean avoiding any accumulation of powder.

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FOCUS ON TECHNOLOGY

4 Figure 4: The powder application stage.

This booth was designed for companies performing several colour change operations per shift. Its Venturi-effect micro-hole cleaning system keeps the floor clean avoiding any accumulation of powder Suction is intense but delicate on workpieces.”

Its Venturi-effect micro-hole cleaning system keeps the floor clean avoiding any accumulation of powder (Fig. 3). Suction is intense but delicate on workpieces: its intensity reduces powder leaks and ensures a healthy work environment. However, at the same time, the airflow analysis shows a well-distributed suction action, so as not to compromise the coating results (Fig. 4). Finally, this is a very versatile booth because it can have 1 to 4 slots for automatic guns as well as 1 or 2 manual touch-up stations with a variable size from 1000 to 2000 mm, depending on the requirements (Fig. 5).” “We perform up to 15 colour change operations, working on one turn. Our new Zeus3 booth enables us to switch from black to white in 15 minutes. We no longer have any qualitative yield problem and we can control the reciprocators’ operation and the status of production orders in real time,” says Paolo Patuzzo.

Proven results

5 Figure 5: The control modules of the 6 automatic guns and of the manual one.

Our new Zeus3 booth enables us to switch from black to white in 15 minutes. We no longer have any qualitative yield problem and we can control the reciprocators’ operation and the status of production orders in real time.”

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“After installing the new booth in August, we have lowered our consumption of raw materials by 30% , while applying the same thicknesses,” states Paolo Patuzzo. “By combining the expertise of another company with our own skills, we have obtained a versatile, highly performing and qualitatively impeccable system that has enabled us to acquire several important customers from which we received positive feedback.” “In the future, we intend to also update our pre-treatment tunnel and to test the dense phase powder transport technology together with Zeus. Finally, we will carry on our project related to the application of wood-effect coatings with the powder-on-powder technique, for which we have developed an exclusive system that we may launch on the industrial market,” states Valerio Patuzzo.

WASHING

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IMPREGNATION

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

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

BRAND-NEW

Cooperation With Automotive Manufacturer BELGEE Strengthens BASF’s Coatings Business in Eastern Europe

BELAZ. The cooperation is the result of an ith the opening of With the opening of the production intense preparation. “In the end, we were BELGEE’s new automotive plant, BELGEE starts the line production able to convince BELGEE with the quality of production plant in Belarus at its Belarusian site which has a our products and our technological knowon November 17/18, the cooperation capacity of 60,000 car bodies a year – how”, stated Ravil Bayazitov, Local Account between BASF and the Chinesewith optional expansion. Top-ranking Manager, Automotive OEM Coatings, BASF Belarusian joint venture has reached politicians from Belarus and China Wostok. “The successful international another milestone. At the plant near joined the official opening ceremony. collaboration between all the teams from Minsk, Belarus, SUVs for the Russian, Germany, Russia and China was also a Belarusian, Ukrainian and Kazakh For further information: key to success”, emphasized Markus market will be produced (Fig. 1). www.basf-coatings.com Staubermann, technical project manager. BASF’s Coatings division supplies the respective coatings products for the car body as well as for the plastic parts. BASF is single supplier for all coatings layers – comprising e-coat, primer, basecoat and clearcoat. “We are proud that we won BELGEE as new customer for our comprehensive layer portfolio and that we can further strengthen our position on the Eastern European market”, explained Monika Pander, Account Manager New Business Development, Automotive OEM Coatings, at BASF. BELGEE is one of the rising stars in the automotive industry. The joint venture was founded by Geely, one 1 of the leading Chinese car producers, and Belarusian Figure 1: At the plant near Minsk, Belarus, SUVs for the Russian, Belarusian, Ukrainian and Kazakh market will be automotive manufacturer produced.

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BRAND-NEW

Systematic Optimization of the Painting Process by Freudenberg

1 Figure 1: Viledon® ﬁlterCair modules: service packages individually tailored to your needs.

“W

e see it as our task to optimize the entire painting process at our customers’ plants in both qualitative and economic terms”, observed Jürgen Becker, Market Segment Manager for Surface treatment at Freudenberg Filtration Technologies. For this purpose, the company has compiled a service portfolio that specifically addresses the individual requirements of its customers (Fig. 1). Freudenberg’s filter management system is known as Viledon® filterCair. It

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consists of tailor-made service packages, which ensure pure air and flawlessly brilliant results in painting processes. For many years, leading automotive manufacturers and their suppliers have put their trust in the expertise of qualified filterCair service technicians and engineers. Within the framework of service contracts, Freudenberg experts work with the company’s customers as partners, consultants and problem solvers, ensuring completely stable onsite painting processes.

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In a recent innovation, Freudenberg is now offering its expertise in process analysis and optimization beyond the scope of fixed, permanent service contracts - regardless of whether the customer’s paint plant uses Viledon® filters or not. “We analyse all the factors that influence the painting operation. In the process, we provide professional and objective advice, irrespective of the filter products used and the interests of the paint plant manufacturer”, Becker explained.

BRAND-NEW

Expertise and experience bundled together in modules Customers can choose between seven service modules. Michael Steuer, Regional Manager Viledon® filterCair, explained the offer: “We have individually compiled the contents of the service modules based on our experience. It goes without saying that customers can freely combine the individual modules according to their specific requirements, for large-scale painting systems as well as for repair cabins.” In the basic module, Freudenberg Filtration Technologies’ service technicians systematically assess quality-reducing contamination in the painting process, measuring among other things dust and particle content, down draughts and relative humidity. The “Basic + Dirt in Paint” module extends these checks to include paint damage analysis. These are carried out both onsite and in the laboratory, where Freudenberg specialists investigate the cause of the problem by means of electron and infrared microscopy, for example. Paint damage is often attributable to fibers and fluff that can become detached from the textile materials used in the process, such as robot protective sleeves, painting overalls, polishing pads or cleaning cloths, for example. That is why there is a separate filterCair service module for analyses of these operating materials. Other performance packages are devoted specifically to the flow conditions in the paint shop as well as to the topics of compressed air and paint drying. “With our holistic approach, we first improve the paint results, which means preventing paint defects. Secondly, we ensure that our customers save time and money thanks to efficient processes, which would for example otherwise be necessary for post-polishing or repainting, which is even more costly”, said Becker, summarizing the advantages of the modular Viledon® filterCair service package. Steuer added: “We provide our customers with a comprehensive, user-friendly interactive report that can be used for auditing purposes. It also indicates individual optimization potentials and recommendations for action for the various painting problems, and can be carried forward for future measures.” For further information: www.freudenberg-filter.com

STANDARD & LEGISLATION - UCIF Informs

Treating the Surfaces of Pressure Equipment Marcello Zinno UCIF - Italian Surface Treatment Equipment Manufacturers’ Association, Milan

info@ucif.net

he training day organised by UCIF for the Pressure Equipment field on October 11 was highly successful. The UCC Association, a member of ANIMA formed by boiler and, in general, pressure equipment manufacturers, had asked to study processes and materials for the treatment of its products’ surfaces. Industrial boilers, heat exchangers, cooling towers, interconnecting piping, and pipes in general require the application of highly anti-corrosive coatings – depending on their type of environment (marine, desert, offshore/onshore…), paint (epoxy, acrylic, phenolic, inorganic zinc…), coating tests (thicknesses, tear tests, batch controls…) and applicable regulations – as well as other protective systems (zinc plating, metallisation…). This inter-association event enabled the development of integrated knowledge and an exchange of experiences among apparently different sectors that, however, cannot operate separately. UCIF requested the prestigious support of Poliefun-Politecnico di Milano to conceive and organise this training day with nine reports from major players of the finishing sector, market experts and university professors. They dealt with several issues such as corrosion protection, performance and chemical composition of coatings, shot blasting and mass finishing processes, surface coating in terms of systems as well as application technology, and surface preparation and treatment. The focus was on the products of interest for the UCC member companies. The casual lunch break offered a further chance of discussion among the participants and the speakers, enabling to delve into many aspects of such a complex matter. UCIF is particularly proud of this constructive training day, which enabled several players of the finishing world and numerous users of these technologies to meet – an impossible result to achieve without the support of a category association.

Bring more colour to your product Reduce downtime and save powder with Spectrum® HD Powder Feed Centre Clean operating environment and automated colour change Significant powder savings with high level of process control High finish quality with integrated ultrasonic sieve for fresh and recovered powders Unmatched powder application efficiency delivered by Encore® HD spray systems For a new fast colour change system or easy integration with your existing cyclone booth, get in contact with Nordson for more information. ics.eu@nordson.com www.nordson.com/hdlv

TRADE FAIRS & CONFERENCES

DECEMBER 2017 SURTECH MIDDLE EAST

WELDING AND CUTTING MIDDLE EAST

Dubai, UAE December 04-06, 2017 www.surtechme.com

Dubai, UAE December 17-19, 2017 www.weldingcuttingmiddleeast.com

MODERN ALUMINIUM STRUCTURES IN TRANSPORT

WIRE AND CABLE ARABIA

Moscow, Russia December 05-07, 2017 www.eng.apral.org

Dubai, UAE December 17-19, 2017 wirecablearabia.com

TUBE MIDDLE EAST

METAL MIDDLE EAST

Dubai, UAE December 17-19, 2017 www.tube-arabia.net/index.html

Dubai, UAE December 17-19, 2017 metalmiddleeast.com

JANUARY 2018 INDUSTRIAL BUILDING

Krasnoyarsk, Russia January 23-26, 2018 www.krasfair.ru/en/events/build_en/

COMPLAST VIETNAM

TECHSTROY EXPO. ROADS

Ho Chi Minh, Vietnam January 10-12, 2018 complastexpo.in/vietnam/

Krasnoyarsk, Russia January 23-26, 2018 www.krasfair.ru/en/events/techstroyexpo_en/

OPTI Munich, Germany January 12-14, 2018 www.opti.de/en/

TRADE & CONFERENCE STEEL FAIRS FAB

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CONSTRUCTION & ARCHITECTURE

Essen, Germany January 10-12, 2018 www.messe-essen.de

ARCHITECT@WORK United Kingdom London, UK January 24-25, 2018 www.architect-at-work.co.uk

PULVERSYMPOSIUM DRESDEN

Sharjah, UAE January 15-18, 2018 www.steelfabme.com

Dresden, Germany January 25-26, 2018 pulversymposium-dresden.de/index.htm

EUROGUSS

IMTEX

Nuremberg, Germany January 16-18, 2018 www.euroguss.de/en

Bangalore, India January 25-30, 2018 www.imtex.in

NEPCON JAPAN

BUDMA

Tokyo, Japan January 17-19, 2018 www.nepconjapan.jp/en/About/ICP/

Poznan, Poland January 30 - February 02, 2018 www.budma.pl/en/

PAKISTAN COATING SHOW

ABIMAD

Lahore, Pakistan January 18-20, 2018 www.pcs-online.pk

São Paulo, Brazil January 30 - February 02, 2018 www.abimad.com.br/abimad2017.php

NORTEC

FIERA AGRICOLA

Hamburg, Germany January 23-26, 2018 nortec-hamburg.de/en/

Verona, Italy January 31 - February 03, 2018 www.ﬁeragricola.it/en

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La ďŹ era leader mondiale per le tecnologie di verniciatura industriale Worldâ&#x20AC;&#x2DC;s Leading Trade Fair for Industrial Coating Technology

17 - 20 April 2018 Exhibition Centre Karlsruhe, Germany

www.paintexpo.com In collaborazione con: In cooperation with:

Agenzia per Italia, Spagna e Portogallo: Agency for Italy, Spain and Portugal: EOS Mktg&Communication Srl Tel +39 0362 503215 info@eosmarketing.it

ZOOM ON EVENTS

ÂŠ AluďŹ nish

Prague hosted the Fourth Edition of the Alufinish International Sales Meeting

1 Figure 1: The International Sales Meeting held at the Corinthia Hotel of Prague, Czech Republic.

he fourth International Sales Meeting organised by Alufinish GmbH & Co. KG was held at the Corinthia Hotel of Prague, Czech Republic, from 25 to 27 October 2017 (Fig. 1). Established as a small family business, Alufinish has now more than 70 partners from 50 countries around the world,

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which participated in this three-day meeting organised in the beautiful setting of the Czech capital. Several important topics for the aluminium finishing industry were addressed during the event, such as the decorative electrolytic and organic colouring processes for

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the anodising market, the new neutral etching system, and the ENVIROX ZOX process. On Thursday, 26, after a brief technical introduction to aluminium surface treatments from Thomas Sondermann, issues such as the REACH and biocide

regulation, the ENVIROX ZOX process, and the Cr-free application process of a big Belgian client were treated. In the afternoon, after a brief presentation on a Cr-free product used on a vertical plant in the United States, the Alufinish representatives had the opportunity to visit the Intebo factory close to Prague. On Friday, 27, the main topic was anodising, in particular electrolytic colours. Edgar Rissmann spoke about the Easy-Seal process and Michael Oswald from the German company Alutecta GmbH & Co. KG presented their new grey colouring procedure GRANODAL®. Some success stories on alkaline resistance values of pH 12.5 to 13.5 for automotive components were presented, and the

ZOOM ON EVENTS

problem of the presence of white spots on electrolytically coloured aluminium profiles on an anodising line in Russia was discussed. Alufinish also took advantage of the magnificent setting of this event to organise a Thursday dinner at the Kolkovna pub, a characteristic venue where the guests had the opportunity to taste some typical food (Fig. 2). On Friday, a guided hike was organised to Vys˘ehrad and the meeting was concluded with a dinner on a picturesque boat on the Vltava river.

Figure 2: The participants of the Aluﬁnish International Sales Meeting visiting Prague’s Old Town.

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.

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2017 Innovation Day: Technology Meets Humanity

1 Figure 1: The headquarters of Geico.

he seventh Innovation Day was held in Milan on November 7, 2017. Geico, an international leader in the design and construction of turnkey automated car coating plants, organises this two-year event to present the status of its projects, its technological and cultural strategies, and its future projects to lending and financial institutions (Fig. 1). During this meeting, the innovations brought by Geico in the last few year were discussed: these excellent technological solutions culminated in the environmental sustainability project related to the Energy Independence Day and in the Smart Paintshop project, aimed at bringing the coating sector and the Industry 4.0 together. The first part of the meeting was devoted to environmental sustainability and corporate social responsibility. During 2017, in fact, the company has achieved the goal of reducing its energy consumption for coating car body from 900 kWh to 270 kWh set for the Energy Independence Day of 2020. The goal has been reached three years earlier. This is an outstanding achievement, the result of high level engineering innovation, continuous technological research, and

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environmental ethics. The second important result announced was related to youth employment and to Geico’s projects called J-Next and Gate Bridge of Pardis Foundation. Both of them embody the deep sense of social responsibility; the first one inside the company the second in the companies of the local community. The second part of the meeting was devoted to technological innovation. Francesco Beraldi, one of Italy’s leading IT experts, the President of Alkemy Tech, O2E and Seolab, a member of the BoD of Talent Garden, ICT Sud and Alkemy SpA, and a partner of Superpartes, introduced the topic. He explained to the guests how digital evolution has enabled to enter the Industry 4.0 era by presenting Smart Paintshop, a project that will revolutionise the car coating systems. This evolution in terms of efficiency, safety, quality, cost saving, and eco-friendliness offers solutions to geolocalise car bodies, safety sensors to prevent malfunctions, Internet of Things solutions to analyse and improve any coating stage in real time, wearable technology for a perfect human-machine

interaction, augmented reality, and an innovative system for managing energy consumption. All of this is managed in a cloud environment with J-Suite. Later, the participants to the event could discover all the innovations that have led the company into the Industry 4.0 era through the technological stations set up at the Pardis Innovation Centre, the research and development centre of Geico (Fig. 2). Ali Reza Arabnia, the President and CEO of Geico, stated: “The era of Industry 4.0 has begun. And we are ready. Machines will not replace humans as many people say. Our idea of Industry 4.0 is actually a new revolution, a cultural opportunity that questions the bases of the automotive industry and that will enable us to achieve now unthinkable goals.”

ZOOM ON EVENTS

2 Figure 2: Geico’s R&D Pardis Innovation Centre.

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1 Figure 1: Paolo Rami.

n 2017, Ipcm_Academy, the training branch of the ipcm®_International Paint&Coating Magazine, has organised a number of training courses for the players of the coating industry, including coating operators, department managers, members of the sales-technical staff of paint manufacturers, and quality control managers. Each year, the main objective of Ipcm_Academy is offering training courses aimed at informing and updating the participants on topics of great interest to anyone dealing with machines and coatings, such as process and application innovations, while providing them with methods and tools for quality control. The courses, divided into two sessions, take place in Milan at the premises of

Ipcm_Academy: Informed and Updated to Maintain Excellence!

2 Figure 2: Gianmaria Gasperini during a lesson.

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Innovhub SSI, Oil & Grease Division, and in Rome at the University of Rome Tor Vergata, in collaboration with the professors Paolo Rami (Fig. 1) and Gianmaria Gasperini (Fig. 2). The sessions deal with the following topics: • Corrosion and corrosion protection • Pre-treatment processes prior to coating • Powder coating application • Liquid coating application • Coating control techniques • Advanced controls on painted surfaces. The lessons consists of a theoretical part in which specific issues are analysed in depth and a practical part with demonstrations and laboratory exercises. The modules on quality

ZOOM ON EVENTS

control are carried out in collaboration with BYK Gardner and X-Rite, two leading companies in the production of colour and look control equipment. They help the participants to understand the basic concepts of advanced controls on coated surfaces and to properly assess colours. Finally, again in the framework of the advanced quality control module, the students can examine the issue of accelerated corrosion controls, including the ACET method, and learn to fill out the control modules correctly. At the end of the course, each participant receives a certificate of participation.

A few years ago, the module “Zinc for steel corrosion protection” was added with the aim of analysing the problems related to steel corrosion and the behaviour of zinc. It is addressed to those who intend to use this element to protect their products, use components, structures, and objects that are already protected with zinc, or perform maintenance and repair operations on zinc-plated structures.

designs and carries out customised business training courses aimed at enhancing, developing and improving the employees’ productivity, ability to work in groups, and use of work tools. Pleased with the results achieved over the years, Ipcm_Academy will continue its training activities next year. The program of the first 2018 session to be held in Milan is already available.

Ipcm_Academy, aware of the specific needs of each company and of the importance of a well-trained staff, also

For further information and registration: corsi@ipcm.it; www.myipcm.com

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

ZOOM ON EVENTS

PCI Announces POWDER COATING 2018 to Be Held in Indianapolis

he Powder Coating Following the technical Institute (PCI) is conference, PCI’s pleased to announce popular Powder Coating the PCI POWDER COATING 101: Basic Essentials 2018 Technical Conference & Workshop will be Tabletop Exhibition will be held offered on Wednesday March 12-15, at the JW Marriott afternoon, March 14 and in downtown Indianapolis, IN. Thursday, March 15. PCI’s Executive Director Trena The workshop includes a Benson remarks, “We are comprehensive agenda excited to be headed back to that covers all the basics Indy for the POWDER COATING of powder coating 1 2018 Technical Conference. operations conducted This event is the best place for by PCI member company Figure 1: Attendees get the most current powder coating information from powder coating end users and experts. industry professionals. suppliers to learn, network, Don’t miss this unique and support the entire powder opportunity to learn from will have access to a variety of powder coating coating industry (Fig. 1).” the best in the powder coating industry. information as well as personal interaction The four-day event will kick off with Representatives from OEMs and custom with suppliers. The tabletop display area will the Technical Conference and Tabletop coaters who apply powder coating and feature powder coating manufacturers, powder Exhibition on Monday & Tuesday, March other industrial finishes will attend this coating application equipment, system houses, 12 & 13, closing on the morning of March event. chemical suppliers and various services that 14. Complete with general sessions and For more information: support the powder coating industry (Fig. 2). concurrent technical program, attendees www.powdercoating.org

Figure 2: The Tabletop Exhibition allows attendees to make valuable contacts and meet industry suppliers.

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Supplemento a IPCM n° 48 - November/December 2017

INDUSTRIAL CLEANING TECHNOLOGIES

ICT digital on

www.myipcm.com

INTERNATIONAL PAINT&COATING MAGAZINE

IL LAVAGGIO DEL FUTURO… ADESSO

IL MASSIMO DELLA TECNOLOGIA ANCHE NEI MODELLI DI BASE The best technology also in the basic models

KP.EASY

L AVAT R I C I S O T T O V U O T O A LC O L I M O D I F I C AT I . I D R O C A R B U R I

www.ifpsrl.com

I F P E u r o p e S r l V i a l e d e l l ’ I n d u s t r i a , 11 - 3 5 013 C i t t a d e l l a ( P D ) I t a l i a Te l . + 3 9 0 4 9 . 5 9 9 6 8 8 3 Fa x + 3 9 0 4 9 . 5 9 9 6 8 8 4 i n fo @ i f p s r l . c o m

ICT - INDUSTRY NEWS

or the first time Pero AG showed at the parts2clean 2017 trade fair the new plant Pero T50 for parts cleaning using a tunnel process (Fig. 1). Thanks to spraying water based media a large throughput is reached. The construction supports reliable drying results and offers operators advantages in handling. For the automation of the workpiece feeding and the logistical integration of solvent plants into a manufacturing environment Pero presented a newly developed charging unit. It is designed for common workpiece carriers similar to size 530 x 320 x 200 mm and is built particularly compact (Fig. 2). A real eyecatcher at the trade fair stand was an additively manufactured 3D model of the Pero Competence Centre (Fig. 3). The exhibit often initiated a discussion about the methods of cleaning projects. It crystallized that an optimally tested cleaning process secures procurement decisions. In the real Pero Competence Centre in Königsbrunn near Augsburg Operator Days for parts cleaning will be held on 18th and 19th April 2018. For further information: www.pero.ag

Pero AG: Presentation of New Tunnel Plant

2 Figure 2: The new compact automatic charging unit for the Pero R1 goes along with a conclusive safety concept.

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Figure 3: The possibilities of process technology in the Pero Competence Centre were conveyed by an additively manufactured 3D model.

ICT - INDUSTRY NEWS

Masterclass in Streamlining & Integrating Precision Cleaning with Material Handling of Vacuum Parts

hen a UK manufacturing company approached Layton Technologies with a desire to replace their various existing cleaning & drying systems which utilised both aqueous and solvent chemistries, some of which were unreliable, beyond their useful life or required continual remedial maintenance to keep the plant operational, Layton were able to identify some key objectives for their proposed replacement system. It was a significant capital expenditure for the company and they wanted to ensure the longevity of their investment. The new system would need to meet their specific and stringent precision process cleaning requirements to a high cleanliness specification typical of the vacuum industry and allow them to implement some process improvements whilst still having sufficient flexibility to ensure that they could respond to any new manufacturing demands. They identified that they would need a quality constructed system together with robust and intelligent programme control.

with

After carefully investigating all possible suppliers they chose Layton Technologies, another UK based company, who demonstrated an in-depth project understanding from the outset. There was a large variation in the size and geometry of components to be cleaned and the contaminants to be removed were identified as water-soluble machining fluids and tapping oils along with machining particulates. Layton was ultimately able to provide a large 5 stage aqueous cleaning line which was critical to the project. This variety of components necessitated that tank volumes needed to be in excess of 3000 litres as ideal to cope with the present and projected throughput requirements. Each stage of the system was specifically designed with a variety of options which included ultrasonic agitation, heating, weir overflows, sub-surface sprays and cascading rinses. The final stage of the system was a forced warm air dryer. The entire system is PLC controlled, configured to use in tandem with a

DRY CLEANING

to perfect advanced clean production

PAINTING ! Cleaning with CO2 - snow jet www.acp-micron.com www.acp-micron.co.uk Phone: +49 7156 48014-0

materials handling system that the customer supplied and also has the option to retro-fit items which may need to be added at a later date. With over 20 yearsâ&#x20AC;&#x2122; experience with both cleaning and drying technologies, Layton completed the project on time and within budget. The system has subsequently demonstrated excellent results and improved processes and the customer has the added peace of mind with the Layton Technologies unique 5-year parts and labour warranty option. For further information: www.laytontechnologies.com

ICT - SUCCESS STORIES

Ecoclean Implements Energy Efficiency Gains in an Automotive Production Plant

models (Fig. 1). At the Steyr engine plant, 30 first-generation units of this flexible cleaning machine are in use. Now as before, their cleaning performance is beyond reproach. However, in terms of energy efficiency – a parameter closely monitored by the BMW Group – the systems are no longer up to today’s standards. Their water consumption in particular has proved too high. BMW Steyr therefore contacted the equipment manufacturer, inquiring if and how the machines could be energetically optimized.

1 Figure 1: Energy efﬁciency measures yielded an approx. 30 percent reduction in the electric power and water consumption of an EcoCFlex Classic robot cell that had been in service for several years.

t the BWM Group’s engine plant in Steyr (Austria), in a reference project accompanied by the Technical University of Vienna, Ecoclean Monschau has significantly raised the energy efficiency of a flexible EcoCFlex Classic robot cell that had been in service for several years. The system’s electric power and water consumption were each cut by around 30 percent. These energy efficiency measures are now intended to be implemented on another 95 systems of the same type installed at various sites throughout Europe and Asia.

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At the BWM Group’s engine plant in Steyr (Austria), Ecoclean Monschau has significantly raised the energy efficiency of a flexible EcoCFlex Classic robot cell. The system’s electric power and water consumption were each cut by around 30 percent.” 2

The BMW Group has been using EcoCFlex Classic robot cells made by Ecoclean Monschau for around 12 years in several of their factories to debur and clean engine parts such as, e.g., cylinder heads for diverse car

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

Figure 2: Due to the integration of a variablefrequency drive unit, the booster pump is now controlled as a function of demand so that the unit uses much less energy.

ICT - SUCCESS STORIES

Potential analysis revealed saving options

Small measures, large effect: 30 percent savings

An independently validated reference project

Ecoclean has developed a potential analysis especially for this type of task. In their investigation, the equipment maker’s service staff will focus on factors such as the water consumption, cleaning agent input, electricity demand of power drawing equipment, and the consumption of compressed air. Flow measurements revealed that large quantities of vapour were extracted from the cleaning cell, causing the machine’s elevated water consumption. Furthermore, the analysis identified a major electricity saving potential in operation of the feed pumps.

One measure taken to reduce the water consumption involved changes on the air control dampers. Moreover, the flow velocities inside the system were adapted via a modified fan control regime, resulting in substantially less vapour getting discharged. In the case of the booster pump, a variable-frequency drive unit now provides demand-based control and hence, energy savings (Fig. 2). Thanks to these relatively minor improvement measures the system’s overall electric power consumption was cut by around 30 percent. Savings of the same magnitude were achieved at the level of the water consumption, and are additionally reflected in a reduced need for cleaning chemicals.

The measures were initially carried out on a system installed in the Steyr/Austria-based engine plant. For an objective evaluation of results, the Technical University of Vienna accompanied the reference project with extensive pre- and post-optimization measurements. Depending on the availability of national or regional programs, the unbiased attestation of this successful efficiency improvement may support applications for public funding. For further information: www.ecoclean-group.net

With Rising Momentum www.ecoclean-group.net

Industrial parts cleaning and surface processing. Re-experience Ecoclean.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2017 - N. 48

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Weber Ultrasonics: Thinking Solutions 4.0 Alessia Venturi ipcm®

leaning systems manufacturers and operators are facing an array of new challenges: from the growing demands with regard to particulate and film-based cleanliness, through to the changed requirements brought about by the trend towards miniaturisation, all the way up to electromobility and innovative materials for lightweight construction solutions. Furthermore, integration of cleaning processes in Industry 4.0 manufacturing and the provision of an end-to-end process documentation are increasingly required. On top of this, the component cleaning step within the manufacturing process must be fast and cost effective in order to remain competitive in the global market. All this can only be realised in everyday manufacturing processes with highly flexible and economical cleaning solutions that are optimally equipped to suit any application. This is where the role of ultrasound is becoming increasingly important. During the last p2c exhibition in Stuttgart, from 24 to 26 October, Weber Ultrasonics AG, true to its motto “Thinking Solutions 4.0”, introduced its new SonoPower 3S 4th Generation: the new generator series, now available as single, dual or multi-frequency generator. Visitors of the exhibition could see the new generator, which features 25 to 132 kHz frequencies, power classes up to 3000 watts and it is Industry 4.0-ready, live at Weber’s booth (ref. Opening photo). On October 24, the German manufacturer organised a “Technics & Meet & Talk & Eat” event to introduce its pioneering new development. Selected guests were invited to experience a very special culinary journey: flying food by famous chef Frank Öhler at the Speisemeisterei, Schloss Hohenheim, Stuttgart (Fig. 1). The Speisemeisterei restaurant stands for the “fine things in life” and combines respect for food and ingredients with indulgence and pleasure. As part of an evening, the company presented its new market strategy, its brand-new image and the technical features and application potential of the SonoPower 3S. “In the last 12 months many things have changed at Weber Ultrasonics” started off Oliver Rahlwes, Weber’s CEO (Fig. 2), during the short talk that forerun the event. “We have combined innovation, passion for the ultrasonic technology, and application knowledge to get closer and closer to our customers by developing Opening photo: Weber Ultrasonics’ booth at the last p2c exhibition in Stuttgart.

new pioneering products and new applications, for example in cutting, welding, and deburring. In addition, we have improved our marketing strategies and our brand image. In October, we launched our new global website, which is a key tool to get close to the customers, allowing them to get information and technical details in real time. We have been taking part in many exhibitions in Europe and we took part in our first exhibition in Asia this year. Different magazines have portrayed relevant stories of companies successfully using our ultrasonic devices and this is very important to show the customers that we have good solutions for many different applications and that many cleaning, welding, and cutting machines are powered by Weber Ultrasonics”.

ICT - HIGHLIGHT OF THE MONTH

Figure 1: Guest at the Speisemeisterei, Schloss Hohenheim, Stuttgart.

SonoPower 3S 4TH Generation – Industry 4.0 ready

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Technical features The excellent cleaning quality is secured by the new patented functions SonoBoost-Sweep, SonoPower-Modulation and SonoScan that generate the strongest, most homogeneous sound field. These functions significantly improve quality, increase speed of the cleaning process and boost capacity. Cleaning times and results are directly dependent on cavitation effects. The SonoBoost-Sweep and SonoPower-Modulation technologies

2 Figure 2: From the left: Oliver Rahlwes, CEO; Britton Diver, General Manager Americas; Nathalie Etienne, President; Luca Garrone, Sales Manager Italy, Spain and Portugal, and Udo Brenner, Sales Director.

Figure 3: The SonoPower 3S generator.

N. 48 - NOVEMBER/DECEMBER 2017 - international PAINT&COATING magazine

The evening event organised by Weber Ultrasonics went on with an in-depth analysis of the new generator and its application in the cleaning field. “In developing this new generator we thought about the challenges that the industrial parts cleaning field is currently facing” explained Dr. Oksana Lutz. “We wanted to develop an ultrasonic technology which could give optimum cleaning results. Therefore, we figured out three key points: Quality of the cleaning, flexibility, and automation. We wanted to deliver to our customers a smarter solution able to generate a strong and homogeneous sound field suited for different cleaning tasks”. The SonoPower S3 generator (Fig. 3) is available with one, two or multiple frequencies, which can be switched according to the cleaning process needed. - The SonoPower 3s Single: A wide range of frequencies is available in the single frequency model. Starting at 25 khz for removal of coarse contamination to 132 khz for gentle cleaning of sensitive parts. - The SonoPower 3s Dual: The increasingly stringent demands for parts cleanliness are often met with two-phase cleaning processes. The SonoPower 3S dual-

frequency model combines common frequency pairs to handle demanding jobs. With one space-saving device, it is possible to realise the potential of two generators. - The SonoPower 3s Multi: High flexibility, thanks to three frequencies. With the multi-frequency model, it is possible to clean a variety of components with the most suitable frequency for each workpiece with different degrees of contamination. Different frequencies can be used at different stages of cleaning such as preliminary and fine cleaning all within one process.

ICT - HIGHLIGHT OF THE MONTH

ensure cavitation quality previously believed to be impossible. SonoBoost-Sweep varies the system’s working frequency and prevents standing waves from occurring. In contrast to conventional processing, SonoBoost-Sweep uses an asymmetric variation pattern which is significantly more effective. Parallel to frequency modulation, the SonoPower-Modulation increases the amplitude. The result is a sound field with unmatched homogeneity and power. The interaction of the two technologies achieves maximum power output and perfect cleaning results in very little time. The third function is SonoScan: Without any power output, the software quickly and reliably determines the correct working frequency for the transducer. The frequency is continuously monitored during the cleaning process and adjusted automatically. This function ensures that work is always done with the most efficient power even under varying operational conditions. It is important to guarantee stable cleaning results. The generator is equipped with a digital control interface and it can be easily be integrated in the control systems of automated production lines.

Designed for Industry 4.0 The ultrasound-specific process parameters are precisely controlled and documented during cleaning by means of an optional PROFINET interface integrated in the generator. This makes the SonoPower 3S compatible with Industry 4.0 applications.

Application examples Among the companies that already benefits of the SonoPower S3 generator there is a cleaning company in the United States that, thanks to the generator’s high power, could reduce the number of the generators in use to provide the same power now provided by SonoPower 3S alone. Another example is a customer in Europe, Adunatech1, which has chosen the SonoPower 3S to equip its Tech Center due to its flexibility in frequencies. More and more customer’s feedbacks are yet to come!

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1 See ICT Industrial Cleaning Technologies n. 12, October 2017 edition (supplement to ipcm® Vol. VIII, n. 46 July / August edition) pags. 24 to 27

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ICT - TECHNOLOGY OVERVIEW

Cleaning Braking System Parts: Burr and Chip-free Workpieces in Short Cycle Times Piller Entgrattechnik GmbH Ditzingen-Heimerdingen - Germany

post@piller-online.com

a processing time of ten seconds per housing was required at the beginning of the project. These fist-sized components are the core of a car brake system, and therefore no burrs nor manufacturing residues can be tolerated on their surfaces. The aluminium formed parts have a complex shape with numerous grooves, fits and threaded holes, as well as several oblique oil channels across different cylinders. In addition, they undergo machining operations such as precision turning and reaming, which further increase the requirements imposed to the cleaning process.

Ideal also for rotationally symmetrical components

Opening photo: The new high-pressure water jet system enables the manufacturers of brake cylinder housings to safely obtain burr and chip-free workpieces while increasing throughput.

he production of brake cylinder housings requires completely burr and chip-free workpieces to be obtained in order to meet the high quality requirements of customers. A specifically adapted system technology has made this possible.

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A manufacturer of passenger car brake cylinder housings wanted to improve its process in order to make it burr and chipfree as well as achieving maximum process reliability and flexibility. The company also needed short cycle times to be obtained:

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A standard system was not an option for this application because it would have not met the cycle time requirements. Moreover, the customer intended to use the machine also to treat rotationally symmetrical components. Finally, the optimal component placement had to be determined beforehand in order to ensure consistency. Piller Entgrattechnik decided to specially redesign its proven VectorJet IV system for this task. The result was a multiaxial high-pressure water jet plant comparable to a machining centre and equipped with different high-pressure tools in order to solve any burr and chip issue (ref. Opening photo).

ICT - TECHNOLOGY OVERVIEW

A specially adapted plant Two components are processed simultaneously in order to ensure short cycle times. Each part has its own controlled rotation axis. While two workpieces undergo the high pressure machining treatment, two finished parts can be removed from their fixtures and two new ones can be loaded. The non-productive times are therefore reduced to zero and the high-pressure pump is fully exploited. The operator has the opportunity to adapt and optimise the process at any time, like on a machining centre. This is crucial, in case the geometry of the components changes or individual process steps need to be adjusted. In this way, the system can also be used with other rotationally symmetrical components.

For its application, the manufacturer of brake cylinder housings has deliberately chosen an automated high-pressure solution. This enables the company to perform a safe, burr and chip-free process even on complex components, combining high output and flexibility in one plant.”

Processes designed to be energy-efﬁcient The whole design of this compact plant (process area, high-pressure generation, tank and bath maintenance, and filtration

system) was based on Piller’s VectorJet IV system concept. This also resulted in very quick installation and commissioning operations. In order to reduce the energy costs of the system, special attention was paid to the high pressure process. The highpressure injection devices and the spray program were designed so that the smallest possible amount of water is needed to remove contaminants. For its application, this manufacturer of brake cylinder housings has deliberately chosen an automated high-pressure solution. This enables the company to perform a safe, burr and chip-free process even on complex components, combining high output and flexibility in one plant.

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