ipcm® n. 54 - November/December 2018 by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

ipcm digital on In this issue :

SPECIAL ON ACE & OFF ROAD VEHICLES

& INTERNATIONAL PAINT&COATING MAGAZINE

ISSN 2280-6083

INDUSTRIAL CLEANING TECHNOLOGIES

www.myipcm.com 2018

9th Year - Bimonthly N° 54 - NOVEMBER/DECEMBER

s.r.l.

CHAINS FOR CONVEYORS

News Chains with 100Cr6 ball bearings for operation at temperatures up to 250Â°C

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M A D E

w .

I N

I T A L Y

CONTENTS NOVEMBER/DECEMBER 2018

FOCUS ON TECHNOLOGY

HIGHLIGHT OF THE MONTH

Mixing it Up: New 2K Coating System for ZIEHL-ABEGG

32 © ipcm ®

Powder-on-Powder Application Without Any Intermediate Gelation Phase: The Technological Innovation That Opens up New Horizons for Powder Coatings

SP EC IA L O N AC E & O FF R O A D V EHIC L E S

SPE C IAL O N AC E & OFF ROAD VEH ICLES

FOCUS ON TECHNOLOGY

42 05 06

FOCUS ON TECHNOLOGY

Berti Macchine Agricole. An Innovative Industrial Solution for the Coating Process of Its New Production Site.

EDITOR’S LETTER ANALYSIS

36 39

Ferrari Costruzioni Meccaniche: A New Tunnel Shot Blasting System for Highly Customisable Agricultural Machinery

SUSTAINABILITY

Eisenmann, a Paint Shop 4.0 Pioneer, Debuts an Integrated, End-to-End Solution for the Paint Shop of the Future

ON THE ROAD TO ipcm® N. 54

Thin Organic Coatings (TOCs)

16 18 22 26

BRAND-NEW SUSTAINABILITY BRAND-NEW HIGHLIGHT OF THE MONTH Colours as an Iconic and Emotional Journey. PPG Presents Human Icon, Its Colour Proposal For 2019

41 52 54

SPE C IAL O N AC E & O F F RO AD VE HIC L E S

Under the Surface: Innovative Pretreatment for the ACE Industry

HIGHLIGHT OF THE MONTH UV curing systems: A Low-Consumption and Sustainable Technology for High Production Rates

BRAND-NEW INNOVATIONS: PRESENT&FUTURE

SUCCESS STORIES

FOCUS ON TECHNOLOGY The Single-Stage Cold Pre-Treatment Technology Improves Production Efficiency and Environmental Sustainability

TECHNOLOGY INNOVATION SERVICE PERFORMANCE

Specialty Powder Coatings In addition to the traditional products, we offer a variety of specialty powder coatings designed to offer a certain

RIPOL Series BT low temperature cure systems

RIPOL Series OGF outgassing-friendly

RIPOL Series BACTERI Ag antimicrobial systems

RIPOL Series ESD antistatic and conductive systems

RIPOL Series TF thin ďŹ lm powder coatings

look, feel or function.

RIPOL Series AG scratch-resistant powder coatings

RIPOL Series PF coil coating & post forming

RIPOL Series HR improved overbaking stability

RIPOL Series MED Marine Equipment

international@ripol.com www.ripol.com

CONTENTS NOVEMBER/DECEMBER 2018

HIGHLIGHT OF THE MONTH

Mixed Powder Today: More Scratch-Resistant Specialist Coatings with Great Flow Properties

Mihail©fotolia

INNOVATIONS: PRESENT&FUTURE

The New Dimension of the Spray Painting Solutions by Venjakob

136 94

ICT - CASE STUDY

Opting for a Modified Alcohol Cleaning Technology for Oil-Hydraulic Components in the Framework of a Smart Factory Project

FOCUS ON TECHNOLOGY Steelpaint: The Industrialisation of a Nanotechnology Pre-Treatment Process for Large-Sized Workpieces Treated in a Static Coating Plant

100 102

112

In the Portuguese Bike Valley, a Cutting-Edge Coating Plant Brings Automotive Technology and Quality to the Service of the Bicycle Industry

INNOVATIONS: PRESENT&FUTURE Times and Methods in Production Processes

118 121 122

MicroCare Corporation Expands at the European Level: Inaugurated a New English Plant for the Mixing and Packaging of Industrial Cleaning Solutions

132 144 150

ICT - CASE STUDY

ICT - HIGHLIGHT OF THE MONTH MAFAC Cleaning Solutions: A New Dimension of Dynamic Cleaning

TRADE FAIRS & CONFERENCES ZOOM ON EVENTS

ICT - INDUSTRY NEWS

An Environmentally Friendly and Low Energy Consumption Cleaning Process for Tailor-Made Oil-Hydraulic Componentsy

SUCCESS STORIES Dürr Builds a Highly Automated Paint Shop with Integrated IIoT Solutions for VinFast

BRAND-NEW FOCUS ON TECHNOLOGY

142

ICT - CASE STUDY

154

ICT - ZOOM ON EVENTS

EDITOR’S LETTER It is time for “Humans 4.0”. Richiedi la versione in italiano a info@ipcm.it

he paradox of the fourth industrial revolution, the era of the Digital Factory, is that human capital will remain a crucial resource to seize its opportunities. With the advent of the concept of Industry 4.0, the dichotomy between man and robot

has been overcome and replaced by the centrality of human resources in the digitisation process. Already in 2017, the World Economic Forum had confirmed the importance of the human factor, highlighting that by 2020 one third of the skills required of employees would include competences that are not considered crucial today. Companies are no longer required only to invest in 4.0-oriented machines. It is imperative to find specialised personnel able to manage them, exploit their full potential, and above all analyse big data – skills without which the Industry 4.0 loses part of its appeal and purpose. The incentives that all European governments have given to companies willing to invest in machines and plants 4.0 have been widely used to renew production lines and create digital, interconnected factories that track production, predict errors, and perform necessary maintenance. Now it is time for these companies to invest in human resources. These include professionals able to solve complex problems and think critically to help organisations adapt quickly to changes; software programmers; data analytic experts and data scientist transforming the collected data into strategic suggestions; and IT security experts to protect networks and expertise. Extremely specialised technical skills will be needed, some of which perhaps do not exist, yet. Graduates in Science, Technology, Engineering, and Mathematic (STEM) subjects and super-experts are the most sought after by global companies, and they will be for many years to come. However, the question is if the current educational offer will be able to meet the demands of the world of work in the next five years. Indeed, after making huge investments in technology, several manufacturing companies are now facing a sense of disorientation among their employees. The older ones feel threatened by digital machines and struggle to adapt to the new production environment; the younger ones do not have the technical skills to manage the new digital factory, yet, and they struggle to find information and training resources. The human factor, therefore, must be enhanced even before technology. There are no technology and innovation, without adequate human resources. The technological changes call for a different education and culture for students and workers. Strengthening the school-work link, as many European countries are doing, is certainly one of the keys to preparing the new generations of engineers to the reality of the digital factory, which develops so quickly that knowledge becomes obsolete within a few years. Plug & play training and the development of professionals ready to enter specific work environments are the solutions to reduce the gap between students’ education and businesses’ needs. The ipcm Academy project, i.e. the professional training courses organised by the ipcm® magazine, is aimed precisely at this. The different modules make up a training course able to refine the professional skills of participants and offer immediate specialisation. ipcm Academy has very interesting development projects in store, in line with the demands of the manufacturing world for 2019 and 2020.

Alessia Venturi Editor-in-chief Direttore Responsabile

2019 will also be the year of ipcm®’s 10th anniversary. Therefore, we end this year full of energies and ready to work! Happy Holidays. We will see you all next year.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

ÂŠ CONDOROIL

Opening photo: Thin Organic Coating (TOC) formulations can have a rapid growth in the immediate future, especially in the treatment of hot galvanised coils.

ANALYSIS

Thin Organic Coatings (TOCs) Marco Zavattoni Condoroil Chemical S.r.l., Casale Litta (Varese) - Italy

marketing@condoroil.it

his article aims at explaining why

In order to let you understand what led us

What are TOCs?

we believe that the so-called Thin

to this prediction, we will start by explaining

As the name suggests, TOCs are formulations

Organic Coating (TOC) formulations

what TOCs are in terms of formulation,

that produce a low-thickness organic

can have a rapid growth in the immediate

where and how they are applied, what their

coating. They are commonly also called

future, especially in the treatment of hot

characteristics are, and what their current

permanent coatings, to differentiate them

galvanised coils (ref. Opening photo).

industrial uses are.

from temporary coatings, or anti-fingerprint

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

Figure 1: The thickness created by TOC is generally about 1 μ. This is the main characteristic that distinguishes them from other formulations, with generally higher thicknesses.

How and where are they applied?

Main features

TOC formulations are

ones are as follows:

employed in various

- corrosion resistance;

industrial sectors, although

- overcoatability;

they are mainly applied on

- foamability;

hot metallised (especially

- anti-fingerprint characteristic;

galvanised and zinc

- aesthetic effects;

aluminised) steel coils, i.e.

- lubrication;

galvalume, for which the

- chemical resistance;

precursors of this product

- temperature resistance;

category were developed

- UV resistance;

in the early 1980s.

- scratch resistance.

TOCs have a wide range of features. The main

Although this phase can be integrated on coil coating

ANALYSIS

lines, these formulations are generally applied at the exit of the galvanising line

coatings, due to one of their characteristics.

with a chemical coater (Fig. 2). Since they

Basically, these formulations contain as follows:

are no-rinse products, after the application

- one or more organic resins;

of the film, a drying phase is needed for

- various functional additives that can be

which hot air, IR, NIR, or induction ovens are used.

organic or inorganic.

The applied product layer can be The thickness of the coating they create is

measured inline through continuous

generally about 1 μ, or anyway within the 0.5-3

flow spot measurements performed

μ range. This is the main characteristic that

with an X-ray gun, by measuring the

distinguishes them from other formulations,

thickness of the wet film, or by dividing the

with generally higher thicknesses (Fig. 1).

instantaneous product consumption value

The selection of the resins is crucial, as they

by the treated area. Depending on the

must ensure perfect adhesion to metal even

resin used, the coating thickness, and the

when charged by the additives dispersed or

required characteristics, it is necessary to

solubilised in them. Such additives, on the

reach a certain PMT value, generally equal

other hand, give the coating the characteristics

to or greater than 70 °C. The temperature

that we will analyse in the following

at which the coil rewinding occurs, on the

paragraphs.

other hand, should not exceed 40 °C.

2 1

Figure 2: The TOC formulations are generally applied at the exit of the galvanising line with a chemical coater.

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

The thickness of the coating they create is generally about 1 μ, or anyway within the 0.5-3 μ range. This is the main characteristic that distinguishes them from other formulations, with generally higher thicknesses. The selection of the resins is crucial, as they must ensure perfect adhesion to metal even when charged by the additives dispersed or solubilised in them.”

The products available on the market have most of the listed properties. Depending on their formulations, they can be more or less suitable to the intended use of a material. In order to quickly highlight the distribution of their various properties, these products are generally provided with a spider web diagram, like the one shown in the Figure 3.

Application examples Production of household 3 1

Figure 3: The distribution of the properties of a product used on home appliances and sandwich panels: 1 - corrosion resistance; 2 - overcoatability; 3 - foamability; 4 - anti-fingerprint characteristic; 5 - lubrication; 6 - chemical resistance; 7 - temperature resistance; 8 - UV resistance.

appliances and equipment in general The use of TOC coated coils enables the manufacturers of appliances, equipment, and structural components not

subjected to strong deformations

4 1

Figure 4: The Condorboard series by CONDOROIL with a blackboard eﬀect.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

ANALYSIS

TOC formulations are employed in various industrial sectors, although they are mainly applied on hot metallised (especially galvanised and zinc aluminised) steel coils, i.e. galvalume, for which the precursors of this product category were developed in the early 1980s. Although this phase can be integrated on coil coating lines, these formulations are generally applied at the exit of the galvanising line with a chemical coater.â&#x20AC;?

to treat metal sheets without lubricants and, therefore, to coat them without any prior pre-treatment cycle. At the same time, TOC coated parts can also be used in hidden areas of household appliances (e.g. washing machine backside) because they have much higher corrosion resistance than traditional HDG coated parts and a much lower cost per unit compared to pre-painted components. Depending on the case, the coatings can be required to have particularly high lubrication, corrosion resistance, or overcoatability properties. Production of sandwich panels TOCs are a valid alternative to back coat paints in the production of sandwich panels. Also in this case, the lubrication and corrosion resistance properties are important, as well as the presence of a foamable deposit. Coil coating Although generally classified as passivating or pre-treatment products, the no-rinse paints applied with a chemical coater as a surface preparation phase prior to coating belong to the general TOC category. In this case, corrosion resistance and overcoatability are the most sought after features. Also the so-called pre-treatment primers, combining the characteristics of a pre-treatment product and a primer in one formulation, belong to the large TOC family. There are many ongoing research projects for the industrialisation of pre-treatment primers, and a few low productivity lines are already using them. Other minor uses Internal components of electronic equipment, profiles, shelves, ventilation channels, etc. are other examples of use of TOC coated sheet metal.

Why TOCs are promising Now that we have presented this technology, let us go back to the initial question: why do we expect a future development of TOC formulations? As is often the case, a simple question calls for a complex and articulate answer. Surely, the main driving force behind the search for new applications, and therefore new formulations, will be the possibility of increasing the profit ÂŠ CONDOROIL

margin of galvanised coils by applying a product that virtually does not affect production costs. This growth factor is further enhanced by a situation of production overcapacity that is limiting the processing margins of companies. This perfectly chimes with a product like TOC, whose potential has only been minimally expressed. Based on what has been illustrated so far, there are currently few formulations with a limited range of properties on the market. These characteristics can however be enhanced and expanded

5 1

with the use of different resins and additives. Close collaboration between sales representatives of metallic materials who know the usersâ&#x20AC;&#x2122; needs, line engineers, and chemists will certainly

Figure 5: Mogalvin is a TOC that gives a galvanised coil a gold-like appearance. It was born from the collaboration between CONDOROIL and the Saudi company Unicoil.

compounds, and the Condorboard series with a blackboard effect (Fig. 4). Condoroil is also proud to present

enable the industry to grow through the

Mogalvin, a special product born from

following actions: - development of increasingly high

with tactile finishes recalling natural

- self-cleaning coatings through the addition

the exclusive collaboration with the Saudi

performance formulations towards specific

of nanoparticles with UV degradation

company Unicoil. This TOC gives the

needs (lubrication, corrosion resistance,

properties;

galvanised coil a gold-like appearance by

aesthetics, etc.); - development of formulations with new specific characteristics; - opening to other sectors than coil (there are already a few applications on wires, bars, and tubes).

- anti-scratch coatings through the addition of ceramic nanoparticles; - conductive coatings through the addition

exploiting the brilliance of the metal itself (Fig. 5). This material is now being used in an important advertising campaign

of graphene or an alternative conductive

launched by Unicoil throughout the

molecule;

Middle East area.

- coatings with particular aesthetic effects.

Conclusions

Here below, you will find some examples of

CONDOROIL has worked a lot on the latter

TOCs have a strong potential for

products with special properties:

in the last few years, developing particularly

development on the market, which

- fluorescent coatings for escape routes;

pleasant products in terms of colours and

has just begun to appreciate some of

- antiseptic coatings through the addition of

finishes. Some examples are the Condorcoat

their features. This article presents the

PC 800 series with wrinkled finishes, the

characteristics of these formulations and

Condorcoat PC 900 series with metallic

highlights the reasons and the markets

effects, the Condorcoat PC 600 series

where their future growth is expected.

bacteriostatic agents; - trackable coatings as a support in the event of disputes;

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

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ÂŠ ST Powder Coatings

Opening photo: Metal sheets coated with the Powder on Powder technology.

HIGHLIGHT OF THE MONTH

Powder-on-Powder Application Without Any Intermediate Gelation Phase: The Technological Innovation That Opens up New Horizons for Powder Coatings Alessio Carlotto ST Powder Coatings, Montecchio Maggiore (Vicenza) - Italy

info@stpowdercoatings.com

he coating industry is certainly

trends, but it also concerns the application

That is why ST Powder Coatings

among the most dynamic and

methods, with the aim of combining

(Montecchio Maggiore, Vicenza, Italy -

ever-evolving sectors. Innovation

quality and advanced technologies with a

Fig. 1), a company specialising in the

does not only involve colours and finishes,

more efficient process in terms of costs

production of powder coatings, has

which go hand in hand with market

and times.

started an intensive R&D program to

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

meet a new market requirement that was

To guarantee maximum performance in the

first imposed in Germany (Fig. 2).

subsequent finishing phase, three hybrid primers

The result was the development of a

have been developed, in three different colours:

powder-on-powder technology enabling to

white (to be used with light-coloured finishes), black

apply a topcoat immediately after primer, without

(for dark-coloured finishes), and grey (for all other

any intermediate gelation stage and with standard

tints). The choice to develop three primers with

application methods. ST Powder Coatings

the same chemical nature but in different colours

presented its Powder on Powder technology

was dictated by the will to minimise all problems ÂŠ ST Powder Coatings

for the first time in May 2018, on the occasion of the XVI Wagner

related to the risk of mixing primers and topcoats,

Symposium

which can

held in Poland

compromise

(ref. Opening

the final

photo). This is

quality level

a revolutionary

(especially for

system, among

light colours):

the first in Italy,

should this

which guarantees

happen, the

a considerable

result would

reduction in the

be however

coating time

guaranteed

and process

by the colour

optimisation.

matching of

One of the main

the primer

issues of powder-

and the

on-powder

topcoat.

systems without

Another factor

an intermediate

that played

gelation stage

a crucial

has always been the application of a finish with the same electrostatic charge of the

role in the

development

Figure 1: ST Powder Coatingsâ&#x20AC;&#x2122; headquarters is located in Montecchio Maggiore (Vicenza, Italy).

of these primers was the environment:

primer, which entails the risk of mixing and distension

they are eco-friendly, since they do not contain zinc

problems. In order to overcome these

or other harmful substances.

problems, it is necessary to reconsider the

The development of specific primers allows to use

application technology used, opting for

finishes that are already present in the ST range,

triboelectric application systems, not widely

without having to resort to specially designed

used, or hybrid systems, i.e. triboelectric and

products. The tests performed did not find any

Corona. ST Powder Coatings has developed

problems of distension of the coatings, which present

a technology that can be applied with the

the same properties of a one-layer system. Currently,

widespread Corona system without any

the finishes suitable for this process can be smooth,

qualitative problems, although without a

glossy, semi glossy, and matte.

primer gelation phase before the topcoat

The Powder on Powder product range has excellent

application.

anti-corrosion qualities: It was subjected to a salt

2 1

Figure 2: A bird’s eye view of the inside of the factory.

spray test for a cycle of 5000 hours

This system also guarantees greater

for a double application process

on sheets pre-treated with zinc

elasticity, which depends on how the

in the available booth. The final

phosphates. This paves the way

primer is applied. ST Powder Coatings’

polymerisation temperature

for the use of powder coatings

engineers recommend to apply

depends on the selected ST topcoat.

in many sectors, even those that

not too high thicknesses to achieve

The powder coatings of the Powder

have always preferred liquid paints,

both greater film elasticity and

on Powder range feature excellent

such as the heavy industry and

improved finish application. Usually,

corrosion resistance and they

corrosion protection ones. For

the recommended total thickness of

contribute to significant savings

optimal results, it is necessary to

the coating is between 100 and 150

in terms of plant management

respect some parameters and

microns.

costs and an increase in hourly

follow the application suggestions,

In terms of application equipment,

productivity. The possibility of using

also with regard to the guns’ voltage.

no system changes are required: it

these products without any special

Generally, the primers can be

is sufficient to adjust the application

arrangements and with commonly

applied under standard voltage

process depending on the system

used technologies makes them

conditions, whereas the topcoats

installed. If there are not two booths

versatile and easy to use in most

require a slightly lower voltage.

on the line, it is possible to provide

industrial sectors.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

BRAND-NEW

inishing Group has manufactured and

The New Headquarters of Finishing Group for the Production of Euromask® Masking Products distributed its Euromask® -branded masking products all over the world for over twenty

years. Created in 1994, this brand includes professional masking systems for any type of surface treatment: powder and liquid coating, electrostatic coating, liquid immersion coating, platinising, galvanic treatments, anodising, oxidation, nickel-plating, galvanising, and so on. Over the years, a production department has been created and gradually expanded. The possibility to manufacture its products in-house has given the firm total flexibility in terms of both products and ability to meet the most diverse customer needs. Finishing Group carries out the whole production process of its hook range and all processing operations on its masks, i.e. cutting, die cutting, rewinding, and so on. The success on the market of these products has led the company to an exponential growth not only at the European level, but also internationally. Finishing Group is now a multinational company with activities

Figure 1: A moment of the inauguration of the new Finishing Group’s headquarters in Lainate (Milan).

world, from Europe to the Americas, from Asia to Africa. Exports account for over 40% of its turnover.

in over 50 of the most important countries in the

Recently, the company has further expanded: on 5 October, it inaugurated its new headquarters in Lainate (Milan): this is the main production site of the whole Euromask® range (Figs. 1 and 2). From here and from three other factories located in Northern Europe, Eastern Europe, and Central America, the masking products of this Italian company are shipped all over the world. Its key to success are speed, flexibility, and professionalism. Here below, you will find a few significant figures: • 85% of orders processed in 24/48 hours; • 60,000,000 ready-for-delivery components; • 3 days for the sampling of out-of-standard masks; • 3-5 days for the sampling of special moulded products. For further information: www.euromask-shop.com

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

2 1

Figure 2: The whole staﬀ of Finishing Group.

BRAND-NEW

Gema Wins BESSER LACKIEREN Supplier Award 2019

ema is the winner of the BESSER LACKIEREN Supplier Award 2019 for the product area “Powder Application Equipment”. This is the result of a survey conducted by the “IMK Institut

für angewandte Marketing- und Kommunikationsforschung GmbH” on behalf of the magazine BESSER LACKIEREN. Participants of the survey were owners/managing directors and paint shop managers of customers based in Switzerland, Germany and Austria. The survey participants assessed their suppliers on the basis of seven criteria: • Product quality; • Price-performance ratio; • Delivery performance; • Support during installation and commissioning; • Partnership strength; • Understanding of current and future market requirements;

Based on the positive scores in all

• Innovation competence.

these categories, Gema was able to prevail over its competitors and was elected best supplier for 2019. Gema achieved particularly positive scores in ‘Product quality’, ‘Delivery performance’ and ‘Support during installation and commissioning’. “Gema’s strategy is largely focused on innovation, quality and customer service, therefore we are particularly proud of this award that is entirely based on customers’ satisfaction indicators. It is an important recognition for our past performance and a great incentive for all our team to continue growing our business with dedication and enthusiasm”, says Claudio Merengo, Gema President Worldwide. For further information: www.gemapowdercoating.com

SUSTAINABILITY

A Second Look at Paint Recycling Mr. Radhakrishnan Regent Paints Inc., New York - USA

huzaifa@regentpaintsusa.com

Â© pngtree.com

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

SUSTAINABILITY

aint recycling is an excellent

since passed similar laws, and more states

coatings; two-component coatings; roof

mechanism for preventing the

are expected to do so in the coming year.

patch and repair materials; and asphalt, tar

land-filling and incineration of

In these states, architectural paints carry an

and bitumen-based products are not part of

unwanted paints that have residual value

additional fee that covers the costs of the

the program. As with architectural coatings,

as paint products, but not in their intended

program. Unused architectural paints are

there are significant environmental benefits

applications. The American Coatings

returned to the more than 1,750 drop-off

to be gained by recycling and/or reusing

Association (ACA) established PaintCare

sites across the nine PaintCare states for

these materials, many of which are

Inc., a non-profit 501(c)(3) organization

free. The paint is sorted and managed for

solvent-based products.

representing paint manufacturers that

reuse, recycling, energy recovery, or safe

One company is taking on the challenge of

operates paint stewardship programs

disposal. In California alone, from July 1,

recycling solvent-based industrial coatings

for architectural paints in U.S. states and

2016-June 30, 2017, PaintCare collected

and paint raw materials that would otherwise

jurisdictions that pass paint stewardship

and processed 3.4M gallons of paint.

end up in waste streams. Regent Paints Inc.

laws. The first paint stewardship law was

PaintCare focuses on architectural paints

is a US-based Division of Matawala Paint

passed in Oregon in 2009 as a three-year

(house paint and primers, stains, sealers,

Industries UAE and the Matawala Group

pilot initiative, with the PaintCare program

and clear coatings), and does not collect or

of Industries, which has manufacturing

in that state made permanent through

process products intended for industrial or

locations in the United Arab Emirates.

legislation in 2013. California, Colorado,

non-architectural use. Paint thinners and

The company accepts materials (both

Connecticut, the District of Columbia, Maine,

solvents; automotive, marine, industrial

solvent- and water-based) from paint/

Minnesota, Rhode Island, and Vermont have

maintenance, and traffic/road marking

coating, resin, and solvent manufacturers

Aluminium Wheel Painting

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

international intern inte rnat ationa ionall PAINT&COATING PA NT& PAINT &CO COATIN COAT ING NG magazine NG maga mag aga gazine zzine ine i - NOVE NOVEMBER/DECEMBER V MBER M /DECCEMBE /DECEMBE MBE BER R 2018 2018 - N. N 54 54

1199

SUSTAINABILITY

across the US and in Canada, Europe,

entire batch. If a mineral spirit paint

primers that can then be provided

and the Middle East and ships them

batch based on a long-oil resin gets

to Regent for sale to its customers.

to its plant in the UAE for reworking.

mixed with methanol, toluene, or any

“When we share our proprietary and

These materials are typically products

other very fast drying solvent, Matawala

unique process for converting waste

generated during production that are

notes that the paint will lose its

into useful products, we are opening

unusable for some reason, whether due

viscosity. Mixing of automotive paints

an avenue and a product line with that

to a major batch failure or because they

with medium oil resins can lead to the

company. In order to be protected,

are even slightly off-spec.

formation of undesirable precipitates.

however, the supplier must agree

“Although these materials are no longer

Depending on their properties, the

to only use the process to produce

fit for sale by the manufacturer, they still

materials end up in bitumen primer

products for Regent Paint and its

have value that we can leverage through

or bitumen emulsion products sold

affiliates and to not share any details

recycling/reworking. The manufacturer

under the brand names TOLOKOTE

of process,” Matawala observes.

benefits because they receive payment

and REGENT. Both are basic,

Matawala Group of Industries is a

for materials that previously they had to

economic products that are marketed

third-generation paint manufacturer

pay to dispose of. Reduction of waste

for infrastructure applications in

that began recycling its own paints

streams benefits the environment,

developing nations, according to

and raw materials as a way to reclaim

and we are able to provide economical

Matawala. TOLOKOTE is produced

the value of off-spec materials. “We

products that offer good performance to

from solvent-based resins, pulp,

have found that recycling oil-based

markets in need of such basic protective

and off-spec paints and is intended

paint is cheaper than fuel blending

coatings,” says Huzaifa Matawala, CEO of

for use on walls and underground

because the value of the ingredients

the Matawala Group of Industries and

concrete as a protective coating to

is better captured, and at the same

Regent Paints Inc.

prevent damage to substrates in hot,

time no power is needed and natural

Water-based paints are sorted by color,

humid, salty climates. It is also used

resource consumption and CO2

combined and filtered, then subjected

for road construction applications.

generation are reduced or avoided.

to further blending and finally packaged.

These products are often formed

In addition, the performance of

For solvent-based products, the

from gelled resin batches that are the

recycled paints in most cases is the

paints are first sorted by the end-use

result of production errors during resin

same or even better than freshly

application: decorative enamels, epoxies,

manufacturing. In the warmer climate

produced batches,” Matawala asserts.

polyurethanes, and other industrial

of the UAE, they often flow more easily

After developing its recycling process,

primers and coatings. The materials are

and can be removed from barrels

the company soon realized that other

then sorted based on the type of resin

naturally. If not, they are gently heated

paint, coating, and resin producers

and solvent used in the formulation.

to reduce the viscosity and then mixed

had similar issues, and that its

Most of the items are mineral spirits-

with other resins/paints and blended

process could be applied to the

based, while most of the resins are

with additives and thinners to obtain

recycling of material from external

soya-based, long/medium oils, according

a homogenous product. All of the

sources as well. “We now offer in

to Matawala. The matt/gloss properties

bitumen coatings are formulated as

addition to the recycled paints, a

of the materials are also determined

black coatings by adding black pigment

virgin line of white and base paints,

using a glossmeter. Density is checked to

in the appropriate dosage levels.

pigments, and specialty ingredients

ascertain the resin content, which varies

For some materials that are not

that can be mixed with the recycled

with every barrel received. Determining

shippable in their current form, Regent

products to improve their properties,”

the compatibility of different inputs is

Paints provides suppliers, under non-

Matawala says. He also notes that

essential prior to blending, as mixing

disclosure agreements, with details

the company hopes to expand its

of incompatible ingredients can lead

of its process for producing reworked

recycling business in the US and all of

to undesired gelling or hardening. For

coating products. Regent shares

North America.

instance, mixing a hardener by mistake

information on segregation, bulking,

with a batch of epoxy or polyurethane

and the use of additives to convert

For further information:

coatings can lead to solidification of the

unusable material into alkyd stains or

www.regentpaintsusa.com

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

Italian Excellence since 1917

Italian colour technology at the service of all industries.

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100% made in Italy

BRAND-NEW

BASF Introduces AUROOM™, a Platform for the Digital Visualization of Automotive Exterior Colours

ith AUROOM, BASF’s Coatings

Working together with almost every

reproductions. For our customers, it

division introduces a digital

car manufacturer on the market, BASF

means the colour decision process will

platform which enables OEM

currently produces over 600 colours

become easier, faster and much more

designers to access a database of

in Europe with new colours constantly

effective. They can also use the data for

photo-realistic virtual car colours (Fig. 1).

being designed. This massive portfolio will

their own brand-specific car configurators

BASF’s virtual colours capture all facets

now be scanned by cameras. The huge

so that car buyers can experience

of automotive coatings including

amount of appearance data generated

automotive colours in their entire variety

lightness flop, colour flop and sparkling.

during the scan is processed using a

which supports their buying decision,”

By mapping these colours on car

sophisticated mathematic model while

said Krzysztof Patryk Stolarzewicz, head

models, OEM designers can virtually

BASF’s colorimetric know-how contributes

of Global Strategic Marketing at BASF’s

paint every colour proposal and gain

to ensure its authenticity. OEMs can then

Coatings division.

realistic impressions of colours and

In the start-up phase, BASF’s virtual colour

effects on a complete car already

solution will first be introduced

in an early design phase.

to OEMs in EMEA. In

AUROOM will be a

addition to the

valuable tool for OEM

digital platform, © BASF

designers to speed up and perfect the overall colour design process as

the customers will have the chance to

experience

they are no longer

the technology

solely dependent on

at AUROOM’s

physical samples that need to

“analog twin” – a specially

be painted and shipped. AUROOM provides further innovative features like real-time side by side comparison of different colour shades of the same colour group to make the right colour

designed showroom at the Figure 1: AUROOM is a digital platform which enables OEM designers to access a database of photo-realistic virtual car colours.

decision easier.

Color Design Studio Europe in Münster, Germany. To demonstrate the colours and effects in the most authentic way possible, BASF also developed special virtual 3-D car shapes. Like BASF’s iconic

“Automotive coatings are highly

access the comprehensive colour data

dome shape, the virtual shapes simulate

complex colours with texture, colour

at the AUROOM platform and render it

various forms of a car body.

position and surface defining the overall

on different 3D shapes provided by the

In order to assess compatibility of colour

impression. To easily understand the

platform or CAD shapes of their own

with the overall design concept, OEM

impact of these colour parameters

models.

designers can choose shapes of different

on a 3-D shape, the digitized colours

“Digitalization is an important topic,

vehicle segments in AUROOM for colour

enable the user to see this on their

especially in the automotive industry. We

visualization.

individual models” said Mark Gutjahr,

have a lot of experience creating colours

head of Automotive Color Design

in our labs and now we are able to digitize

For further information:

EMEA at BASF’s Coatings division.

them and create photo-realistic digital

www.basf-coatings.com

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

* patent pending

BRAND-NEW

TEGO® Dispers 687 – Wetting and Dispersing Additive for Matting Agents in Solventborne Coatings

Light on rejects Light on waste Bright on application

EGO® Dispers 687 is a new dispersant specially developed for the wetting and dispersing of matting agents in solventborne coatings.

TEGO® Dispers 687 helps achieve coating characteristics

such as excellent anti-sedimentation and consistent matte values. Highly recommended for semi-gloss and matte wood coatings, TEGO® Dispers 687 extends the application

The must-have accessory for the Encore manual spray gun range

window by greatly reducing the sedimentation tendency of

The Encore® nLighten™ LED Kit*

matting agents, even when the paint is diluted over a period of time.

Reduce or eliminate rejects or rework

TEGO® Dispers 687 is especially suitable for untreated matting agents that have good transparency but high

Effectively highlight and ﬁx light powder areas on surfaces,

sedimentation tendency. Because of its excellent

deep recesses and cavities – on the ﬂy.

anti-sedimentation property, it allows users to lessen or

Reduce material waste

eliminate the use of anti-sedimentation additives in their formulation – which is advantageous to the development of

Optimum light levels enable precisely targeted powder

highly transparent matte coatings.

application, to reduce waste and save on material costs. Increase efficiency

For further information:

This all-in-one application and inspection tool gives © Evonik

www.coating-additives.com

every operator the power to both spray and inspect at the same time. Improve safety Rated for use in all powder coating environments. For more information please visit www.nordsoncoating.com/nlighten

ics.eu@nordson.com | www.nordson.com/powder Figure 1: TEGO® Dispers 687 is a new dispersant specially developed by Evonik for the wetting and dispersing of matting agents in solventborne coatings.

Performance by design

BRAND-NEW

PHASCOPE® PAINT: The Pen That Measures Coating Thickness

During measurement, a red LED

the PHASCOPE PAINT is equipped with a

Fischer PHASCOPE® family is the new

indicates if tolerance limits are exceeded.

conductivity compensation feature, which

pen-probe. PHASCOPE PAINT reliably

That makes it easy to recognize defects in

ensures accurate measurement results.

measures the thickness of paint layers on

the coating, even for non-technical users.

In addition to spot checks, the

various substrates – quickly and easily.

To simplify analysing the readings,

PHASCOPE PAINT also has a continuous

Small and pen-shaped,

PHASCOPE PAINT uses an intuitive app.

mode for testing large areas, with up to 70

it slips neatly into

The measurements can be visualized

measurements per minute.

your pocket, and it’s

on a smartphone without having to

designed to be simple

first transfer them to a computer. And

Features

to use.

reports can also be created directly on

• Automatically recognizes the substrate

The handy, pen-like

the smartphone. Special feature: the

PHASCOPE® PAINT is

user can quickly insert photos of the

• Broad measurement range (0 – 2500 μm).

test site into the measurement report

• Modes for single-point and continuous

ideal for fast and easy

he latest member of the

thickness measurement

to document potentially damaged

of paint layers on

areas. Then the app does the statistical

ferrous and non-ferrous

evaluation.

metals. Thanks to its

The versatile PHASCOPE PAINT is ideal

broad measuring range

for measuring all thicker paint coatings

material.

(free-running) testing with up to 70 measurements per minute. • An LED on the probe indicates when tolerance limits are breached. • Data analysis with the Fischer app for smartphone or tablet.

up to 2500 μm, it is

• Potentially damaged areas can be

particularly well-suited for very thick coatings.

documented with photos in the reports.

Statistical evaluation of

• Bluetooth connection to mobile devices.

the readings is carried

• Due to its robust housing, even under

out on a smartphone

harsh environmental conditions the gauge

using the intuitive Fischer

remains extremely reliable.

app. Reports can then be sent quickly and easily as

Applications

PDFs.

• Quick and easy coating thickness

Because field testing often involves checking many different kinds of coatings, a flexible instrument is needed. PHASCOPE PAINT relies on the versatile eddy current method.

measurements, equivalent to DIN EN ISO Figure 1: PHASCOPE PAINT developed by Fischer is ideal for fast and easy thickness measurement of paint layers on ferrous and non-ferrous metals.

For example, it can measure paint coatings

2360, ASTM D7091, DIN EN ISO2178 and DIN EN ISO 21968. • Measurement of paints and lacquers on ferrous and non-ferrous metals and analysis of anodized surfaces.

on magnetizable substrates such as steel

• Automotive industry and car-body paint

or iron, as well as on non-magnetic metals

and applicable in industries ranging from

like aluminium, without having to change

automotive to corrosion protection.

• Corrosion protection.

the device or the probe. PHASCOPE PAINT

When handling workpieces of various

• Facade engineering.

can also automatically detect the kind

aluminium alloys, their different

of substrate at hand and selecting the

conductivities can influence the coating

For further information:

appropriate mode.

thickness measurements. This is why

www.fischer-technology.com

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

shops.

BRAND-NEW

Dürr Designs Highly Flexible Assembly Layout for the New Lamborghini Urus

he Urus super SUV from

but also the overall capacity to 7,000

another in a linear conveyor system as it

Lamborghini is manufactured under

vehicles annually. For this strategically

has been the case up to now. They also run

the most modern conditions.

important project for the future of the

without rails, are freely programmable like

The plant at the headquarters of the Italian

brand, Lamborghini entrusted Dürr with

robots, and can be controlled flexibly. This

sports car manufacturer in Sant’Agata

developing new production lines for

means that future model series can also be

Bolognese, which was rebuilt in record

complete vehicle assembly (Fig. 1).

manufactured on existing lines, since they

time, is characterized by highly flexible

This is based on a forward-looking layout in

can be changed over quickly in order to be

assembly lines with newly developed AGVs

which each area can be used flexibly. That

appropriate to new market scenarios and

(Automated Guided Vehicles) and especially

allows the line configuration to be modified

varied production requirements. The AGVs

ergonomic workstations. As the general

at any time following installation, in other

at Lamborghini come in three different

contractor, Dürr was responsible for the

words it remains adaptable to changing

sizes and are suitable for line feeding tasks,

installation of the assembly lines as well

requirements.

the processes in the main line, and for

as for the integration and optimization of

subassembly and powertrain operations.

innovative technologies and processes.

AGV fleet in various sizes

With a view to the market launch of the new

The conveying system with AGVs,

Urus super SUV, Lamborghini modernized

specifically developed by Dürr for the

Ergonomically optimized workstations

its long-established plant within just 18

Urus, guarantees a high degree of

In addition to the AGVs, Dürr installed

months during ongoing production.

flexibility.

further technologies that also meet the

Not only was the production space

The AGVs move individual components

most demanding standards for ergonomics

and bodies separately instead of one after

in the workplace. These include loading

doubled from 80,000 m to 160,000 m , 2

carriers (body on AGV), unloading devices © Dürr Systems AG

(car from AGV), rotating and vertical adjustable carriers for body transport and lifting, as well as slat conveyors with a lifting table for moving the vehicle into an ergonomic position. Overall control of the project on behalf of the Dürr Group rested with CPM, its Italian subsidiary specializing in final assembly. CPM and Lamborghini were already working hand in hand on layout design for conveyor technology, assembly lines, marriage stations, trim lines, and the end-of-line area. CPM was supported by its German colleagues from Dürr Assembly Products, which among other things supplied the x-road roll/brake test stand and adjusted it 1

Figure 1: As the general contractor, Dürr was responsible for the installation of the assembly lines as well as for the integration and optimization of innovative technologies and processes.

precisely to the Urus. For further information: www.durr.com

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

Opening photo: PPG Colorshow 2018 was held on 12 October in the Intesa Sanpaolo skyscraper in Turin to present PPG’s new colour ranges for next year. Human Icon is the new colour project that will certainly have an impact on the colour trends for 2019.

HIGHLIGHT OF THE MONTH

Colours as an Iconic and Emotional Journey. PPG Presents Human Icon, Its Colour Proposal For 2019 Barbara Pennati ipcm®

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

physically; Diversity, referring to creativity

use last generation metallic pigments and

creative process behind the choice

as a means to stand out; and Experience,

very fine synthetic micas to create a “liquid”,

of each shade. PPG Colorshow 2018

referring to the core concept of Human

almost mirror-like appearance. The red,

was held on 12 October in the Intesa

Icon: in a world where everything is

blue, purple, yellow, and orange shades,

Sanpaolo skyscraper in Turin, which, with

readily available, the emotional journey

finally, convey vividness and irony through

its suggestive 360-degree view of the city,

continues to be of primary importance.

tints made more saturated and deeper by

olorshow is a biennial event

Durability, referring to the ability to

shades for sobriety and elegance to the

organised by PPG to present

survive over time, both in memory and

lightest ones for refinement. The “fluid” tints

its new colour ranges and the

perfectly fitted Human Icon, a new tint range that will certainly

a coloured transparent layer containing patented nano

have an impact on the colour

pigments called Andaro® –

trends for 2019 (ref. Opening

ipcm® has already dealt with

photo).

them in its Ferrari report1. The colours created are

Human Icon was developed with

the result of a creative but

the aim of giving its new colours

also technical process. “All

an emotional and sympathetic

128 colours are classified

aspect as well as a unique and

according to their application

iconic appearance. “We live in an

properties, innovation degree,

interconnected world, in highly

formulation, and pigments

technological environments. That

used (Fig. 5). This results in

is why PPG created these new factor in order to stand out and focus back on awareness, quality, and emotional

the most suitable process for

colours, inspired by the human

industrialising our products

Figure 1: PPG Style Centre Manager Daniela Nicolelli during the presentation of the new colour range Human Icon.

experience through tints that

with the utmost confidence. Our technical department, therefore, works jointly with our Style Centre to offer our

can communicate,” explains PPG Style

For PPG, colors are an emotional journey.

customers innovative tints, able to convey

Centre Manager Daniela Nicolelli during

These four themes have helped develop

emotions and at the same time ensure ever

the presentation of the new colour range

seven colour palettes (Techno Attitude,

higher performance levels,” says Rodolfo

(Fig. 1).

Native Soul, Think Pink, Deep Authority,

Saporiti, the Automotive Market Manager

Analysing our environment, PPG

Enchanting Spirit, Nordic Dimension,

and CEO of PPG (Fig. 6).

identified four main themes for its

and Hop Art – Figs. 2, 3 and 4). PPG

creative project: Engagement, referring

experimented with different nuances

to attentive and aware actions;

and effects, ranging from the darkest

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1 “Ferrari: The Italian Automaker Revolutionises the Car Painting Process with a Low Cure Clear Coat System”, ipcm®_International Paint&Coating Magazine no. 51, Vol. IX, 2018, pages 34-48.

2 1

3 1

4 1

Figures 2, 3, and 4: Some of the seven palettes that gather the 128 Human Icon colours.

The Colorshow event was organised by PPG

FCA Head of the Colour & Materials Style

brands of the Group. Our task is to grasp

for FCA - FIAT Chrysler Automobiles, in order

Centre Rossella Guasco (Fig. 7), who attended

and anticipate trends, reinterpreting them

to renew the long-standing collaboration

the event, explained the process behind the

for each brand and car model. That is why

with the automotive Group and pursue PPG’s

creation of the automotive colours designed

we highly value our collaboration with our

mission to support the automotive industry in

for the FCA Group: “Colour is one of the main

suppliers, such as PPG, our exclusive coating

the use of colour as a strategic business lever

protagonists of the work we carry out at the

partner: for years, they have supported

to stand out on the market. “PPG has always

FCA Style Centre, which deals with all the

us in identifying the right colours, effects,

believed in the ability of colour to transform beautiful. That is why we invest in innovation

the world, protect it, and make it more and talent, developing high quality and sustainable solutions helping our automotive customers to maximise performance, enhance the uniqueness of their products, and minimise their environmental impact. With our six manufacturing sites throughout Italy, two of which are dedicated to the production of coatings for the car sector, we develop the creativity of this industry and innovate it, launching new trends and leading the change. Our commitment on the territory is proved, for instance, by our long-standing collaboration with the FCA Group. We have worked with them in Italy and abroad for many years now, through a mutual collaboration aimed at developing new highly impacting and effective colours, such as those presented at PPG Colorshow 2018,” states Rodolfo Saporiti.

5 1

Figure 5: The 128 shades were also analysed at the technical level and they are classified according to their application properties, innovation degree, formulation, and pigments used.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

6 1

Figure 6: From left to right: PPG Style Centre Manager Daniela Nicolelli, PPG Automotive Vice President Roald Johannsen, and PPG Automotive Market Manager Rodolfo Saporiti.

The colours created are the result of a creative but also technical process. All 128 colours are classified according to their application properties, innovation degree, formulation, and pigments used. This results in the most suitable process for industrialising PPG products with the utmost confidence. PPG’s technical department, therefore, works jointly with the Style Centre to offer customers innovative tints, able to convey emotions and at the same time ensure ever higher performance levels.”

7 1

Figure 7: Rossella Guasco, the Head of the Colour & Materials Style Centre of FCA (left), with Daniela Nicolelli.

When a new car model is developed, the first colour proposals are submitted twenty-four months before the launch in order to select about fifteen shades. Then, a small-scale silhouette of the car is presented, in order to have a more precise idea of how these colours will “dress” the shapes and assess any changes or alternatives. When the first bodies are manufactured, a colour test is performed on them to assess the effect on a life-size car as well as the application process in the coating plant.” © ipcm ®

pigments, and technologies for our requirements, which in turn are based

The creation and selection process is long and complex. When a new car model is

on an initial analysis of trends and

developed, the first colour proposals are

scenarios.” The Style Centre may choose a

submitted twenty-four months before

particular tint based on various sources of

the launch in order to select about fifteen

inspiration: images, objects, fashion, or the

shades. Then, a small-scale silhouette of

nature. Also for FCA, the creative process

the car is presented, in order to have a

goes hand in hand with technical analyses

more precise idea of how these colours

to check the applicability of the selected

will “dress” the shapes and assess any

colours.

changes or alternatives. When the first

“Our Style Centre works for seven brands,

bodies are manufactured, a colour test

each with several car models. In general,

is performed on them to assess the

each year we develop about 30 standard

effect on a life-size car as well as the

colours and about 10 tints for special

application process in the coating plant.

series. PPG always selects its colour

For its colour assessment, FCA also uses

proposals based on the products for which

virtual tools and new technologies, such

the coatings are intended and also taking

as panel lights that artificially reproduce

into consideration any potential application

the various times of the day, each with

problems,” says Rossella Guasco.

a different light diffusion pattern. The advanced tools available guarantee an

“The model on which we have experimented and dared the most in

8 1

non-artificial environments with natural

terms of colour is Fiat 500, a timeless car that lends itself to any chromatic interpretation. In addition to experimenting with colours such as candy pink, coral, and

Figures 8 and 9: The exclusive location of PPG Colorshow 2018, overlooking the winter garden and the light artwork created by Migliore+Servetto Architects for the Intesa Sanpaolo skyscraper.

milk-mint green, this car was also among effect. However, whereas

light are also performed. The FCA Style Centre also controls the images used by the configurators available online, in order to offer to the customers a representation that is as close as possible to

the first to offer a matte

accurate analysis, but assessments in

reality.

with brands like this it is important to keep up

After finding out how the

with trends and anticipate

Human Icon project was

them, other brands,

developed, the guests were

such as Maserati, call for

able to actually see the 128

sophisticated colours

selected shades, divided into

with a focus on depth

the seven colour palettes,

and on the final effect.

while tasting an aperitif on an

This proves that the

exclusive terrace overlooking

development and choice

the winter garden and the

of colours is not a trivial

light artwork created by

process, but it requires

Migliore+Servetto Architects

in-depth thought and research.”

9 1

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

for the Intesa Sanpaolo skyscraper (Figs. 8 and 9).

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Opening photo: The increasing global demand for energy-saving fans and rising quality standards have prompted the fan and motor manufacturer to expand its production capacity.

FOCUS ON TECHNOLOGY

Mixing it Up: New 2K Coating System for ZIEHL-ABEGG Mark Dekreon, Sprimag, Kirchheim-Teck – Germany

mark.dekreon@sprimag.de

primag’s new coating system for fan rotor

Fans have an extensive range of

When it comes to these and many other

bodies provides a breath of fresh

application, including in everyday

areas of application, ZIEHL-ABEGG is

air to fan and motor manufacturer

ventilation, automotive engineering and

widely regarded as one of the leading

ZIEHL-ABEGG, because its chain system is

even in machine and system technology,

manufacturers of fans and ventilation

capable of handling even complex requirements.

such as that produced by Sprimag.

systems. The increasing global demand for

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

system that was in every way a perfect fit for the

Sprimag’s new coating system for fan rotor bodies provides a breath of fresh air to fan and motor manufacturer ZIEHL-ABEGG, because its chain system is capable of handling even complex requirements.”

new ZIEHL-ABEGG production hall. As requested by the customer, the coating system’s dry spray station was deliberately positioned facing outwards for the added benefit of easy access for maintenance staff when changing the dry extraction filters for the coating, for instance. A large viewing window at the start of the evaporation zone gives the operator a clear view of the rotor once coated, meaning the quality of

energy-saving fans and rising quality standards have

the coating on the parts can always be inspected

prompted the fan and motor manufacturer to expand

before the parts move on to the two-stage drying

its production capacity by means of a new building

process.

and additional production facilities.

Another requirement of the coating system was

Among the new equipment installed is a Sprimag coating system, which

that it needed to be able to process a wide range of parts that vary greatly in terms of the

has been coating rotor bodies

size and dimensions

of energy-saving fans (EC

bodies. As well

start of 2018 (Fig. 1).

as large rotors

Sprimag rose to

measuring

through close

275 mm in

collaboration with

diameter, the

ZIEHL-ABEGG and

system should

the challenge and,

a series of trials

be capable of coating

in the applications

compact ECblue

center, succeeded in

rotors with a

meeting even the most

diameter of just

complex requirements

146 mm. The system is

of the new facility. “The foundations were laid for

a trusting working relationship from

required to coat a total of 23 different types of part. A number of trial

the very beginning of through an extensive

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

of the rotor

technology1) since the

the project, particularly

Spare Parts for Industrial Plants

Figure 1: A detail of rotor body of energy-saving fans.

series, conducted in Sprimag’s

series of initial trials. It was important to us

in-house applications center, ascertained whether

that the system operated a fully dependable

the SpriMix II 2K paint supply would be suitable

coating method that guarantees us maximum

for ZIEHL-ABEGG’s purposes (Fig. 2). During these

process reliability,” explains Jürgen Rehrauer, Head of Process Planning for EC Fans at ZIEHL-ABEGG. The first challenge to overcome was the spatial requirements, because space was at a premium on this project, especially in terms of height. This gave rise to a compact chain on edge coating

1 EC stands for “electronically commutated”. This type of motor needs less electricity to operate.

The increasing global demand for energy-saving fans and rising quality standards have prompted the fan and motor manufacturer to expand its production capacity by means of a new building and additional production facilities.”

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

coating are coated with precision. Because the

trials in the technical center it was initially established that the existing SpriMixII 2K paint supply had found its limits: The technology was currently set up for significantly higher flow rates, and so needed to be honed into a new solution. Sprimag rose to the challenge and was ultimately able to adjust the mixing technology to also accommodate low flow rates with ease. The coating system is integrated in a

The technology was currently set up for significantly higher flow rates, and so needed to be honed into a new solution. Sprimag rose to the challenge and was ultimately able to adjust the mixing technology to also accommodate low flow rates with ease.”

industry-wide rise in quality standards leaves no room for compromise in this area, we drew on our extensive experience and were able to meet the customer’s exacting requirements for precision coating of rotor bodies. The overall ventilation technology was created in consultation with ZIEHL-ABEGG’s technical plans for the building design. The objective was to ensure that the air needed for the system is not taken from the hall. To achieve this, fresh air is taken from outside and the exhaust air

work stations. Once the shafts have been

from spray booths, paint rooms, evaporation

pressed, the operator places the rotor

zones, dryers and cooling zones is fed into an

working environment with two other

body on the coating machine’s transport

air collection system. The requisite fans and

system. Once the coating process is

automatic throttle valves ensure a smooth

complete, an operator conveys the

connection to the exhaust air system.

parts to the pick-up station, ready for

Sprimag was on hand offering in-depth advice

magnetization. The Sprimag chain on

throughout the entire collaboration. As a result,

edge coating system features a transport

in the space of just two weeks all 22 coating

system that is ideal for conveying heavy

programs were set up and the operating staff

parts weighing over 5 kg. To avoid the need

were trained on coating processes and using

for time-consuming retrofits, a universal

the SpriMix II. This was possible thanks to the

retaining chuck is used here, which is

trials conducted in the applications center at

suitable for the full range of different parts.

the very start of the project, which enabled

The parts are rotated in the spray station

us to adapt our SpriMix II to the customer’s

and coated by a coating robot. The

requirements and gain experience with the

transport cart is connected to the spray

coating system at an early stage in the project.

station by the chain system in operation,

“Thanks to the excellent partnership with

ensuring that parts that require only partial

Sprimag, from the trials to the system design and construction and all the way through to commissioning, we are now in a position to meet ever-growing demand and our own

The first challenge to overcome was the spatial requirements, because space was at a premium on this project, especially in terms of height. As requested by the customer, the coating system’s dry spray station was deliberately positioned facing outwards for the added benefit of easy access for maintenance staff when changing the dry extraction filters for the coating, for instance.”

integral quality standards,” reports Jürgen Rehrauer, who is looking forward to further opportunities to work together.

2 1

Figure 2: The SpriMix II 2K paint supply.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

Sprimag was on hand offering in-depth advice throughout the entire collaboration. As a result, in the space of just two weeks all 22 coating programs were set up and the operating staff were trained on coating processes and using the SpriMix II.”

SUSTAINABILITY

A sustainable alternative to CrVI: Manifest of the Alliance of PVD Providers APP - Alliance of PVD Providers’ oﬀicial notice

he Alliance of PVD Providers (the

process on the pending authorisations

APP) lead and managed by Fipra

The APP calls on the EU institutions to replace a hazardous chemical substance inclused in the REACH Regulation, the hexavalent chromium (CrVI), with the sustainable alternative of PVD, the physical vapor deposition technology. ”

International Ltd. includes IHI Hauzer

Techno Coating B.V., Ionbond Netherlands, B.V., Kolzer SRL, Oerlikon Balzers Coating Germany GmbH and Vergason Technology, Inc. The APP calls on the EU institutions to replace a hazardous chemical substance inclused in the REACH Regulation, the

of the CrVI applications, included the Gerhardi, Lanxess and Hapoc applications, by December 2018. - Reduce authorisation for Gerhardi application to maximum 7 years. This would be in line with the opinions of some ECHA - European Chemicals Agency’s members.

hexavalent chromium (CrVI), with the vapor deposition technology.

On the basis of the above considerations, the

sustainable alternative of PVD, the physical

APP has written the Manifest intitled

CrVI is a carcinogenic substance: in the

“A sustainable alternative to CrVI”4, which

European market it has been banned since

has the aim to show that the current draft

2011. However, despite this and despite

decisions approving the CrVI‘s continued

the existence of sustainable alternative

use are not based on the latest available

technologies, it is still used on an industrial

information, but on the opinion submitted to

scale without providing a precise date for

the European Commission by the European

its final replacement. Indeed, the European

Chemicals Agency in 2005-2006 (RAC and

Commission is planning to extend various pending CrVI authorisations for a very long

SEAC). During this period the PVD technology was still in rapid development and has been

time (12 years). The Committee for Socio-economic Analysis (SEAC) and the Committee for Risk Assessment (RAC) within

greatly developed since then. Figure 1: The PVD technologies provide the same quality of the CrVI, they are cost-eﬀective and available to meet the market demand and they were approved by the automotive industry.

ECHA - European Chemicals Agency have

other ones: • Lanxess: 4-year authorisation for functional plating with decorative character1, whilst maintaining a 7-year authorisation for other

2 Opinion of RAC and SEAC (16 September 2016) on an Application for Authorisation for Chromium trioxide use: Functional chrome plating.

quality, they are cost-effective and available approved by the automotive industry (Fig. 1).

• Gerhardi: 12-year authorisation3 although

The replacement with more environmentally

there were 2 minority positions in RAC and

friendly products must be the main aim of

SEAC in favour of a shorter review period;

REACH.

• Hapoc: RAC and SEAC have not yet issued a recommendation on this application.

The current status quo means the maintenance of a situation that represents a defeat for the

applications2;

1 Opinion of RAC and SEAC (16 September 2016) on an Application for Authorisation for Chromium trioxide use: Functional chrome plating with decorative character.

the PVD technologies, that provide the same to meet the market demand and they were

recommended the European Commission to grant the following authorisations, among

Nowadays the CrVI can be easily replaced with

The APP requests the EU institutions to:

society, since it is a missed opportunity for a

- Clarify and speed-up the decision-making

more sustainable Europe.

3 Opinion of RAC and SEAC (13 March 2017) on an Application for Authorisation for Chromium trioxide, use: Plating on Plastics for Automotive Applications (PoPAA). ECHA/RAC/SEAC: AFA-O0000006558-63-02/F.

4 The manifest can be downloaded from the website: https://fipra.com/wp-content/uploads/2018/10/Nonconfidential-APP-manifest-PVD-a-sustainable-alternative-toCrVI-14092018-final61.pdf

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

HAI UN IMPIANTO DI MOVIMENTAZIONE A CATENA?

SUSTAINABILITY

TRAS-MEC è la prima azienda che mette in sicurezza il tuo impianto e ti garantisce da contratto una produzione senza fermi improvvisi

The current status quo means the maintenance of a situation that represents a defeat for the society, since it is a missed opportunity for a more sustainable Europe. Indeed, both the companies and the NGOs know that the CrVI’s replacement with the PVD technology is the only possible solution.”

Non dovrai più lavorare accontentandoti HM YRE WSPY^MSRI GLI RSR XM WSHHMWǻ Progettazione: Mandaci il tuo progetto e studieremo il tuo trasportatore così che risponda alle caratteristiche che rendono il tuo ciclo produttivo unico.

Indeed, both the companies and the NGOs know that the CrVI’s replacement with the PVD technology is the only possible solution. Inspired by what Erin Brockovich achieved with the CrVI’s elimination

Non avrai più dubbi sulla produzione del tuo materiale

in the United States, the APP was created to achieve a better result.

Produzione: Costruiremo il tuo trasportatore secondo metodi standardizzati sviluppati nel tempo per farti avere un impianto performante.

The APP urges the EU institutions to say yes to the investments in a sustainable and recyclable product, that is suitable to the EU’s ambition to create a non-toxic environment; to say yes to a climate-friendly production process and in line with the Paris Conference’s objectives; lastly, to say yes to a competitive

Non dovrai più preoccuparti del montaggio del convogliatore

EU that has the know-how and the capacities to compete with technological giants in United States, China and elsewhere, rather

Installazione: Con quest’opzione, avrai il tuo convogliatore chiavi in mano montato da un team di tecnici montatori esperti.

than to leave room to other Countries in order to be the first continent to develop new greener technologies (Fig. 2). For any question, please contact Willem Vriesendorp (+32 2 613 2828), Fipra International’s partner on behalf of the Alliance

Non avrai più blocchi di produzione

of PVD Providers. The PVD technologies provide the same quality

Servizio di manutenzione: Con il nostro servizio di manutenzione avrai un’assistenza periodica e continuativa che ti eviterà fermi non programmati, perdite di produzione impreviste.

of the CrVI, they are cost-effective and available to meet the market

demand and they were approved by the automotive industry.

TRAS-MEC è la prima azienda che ha integrato tutti i processi in un unico sistema industriale, per farti lavorare nel modo più performante senza più fermi di produzione che non sono stati programmati. Se vuoi avere più informazioni sul tuo trasportatore scrivi a customercare@tras-mec.it Riceverai in regalo il report “I 5 errori da evitare per mettere in sicurezza il tuo impianto nto ed eliminare per sempre il rischio dei fermi improvvisi” vvisi”

2 1

Figure 2: Europe has the chance to become the first continent to develop ecological solutions alternative to the CrVI: in the image one of the PVD chromium plating machine manufactured by the Italian company Kolzer.

REPORT IIN N RE REGALO! REGALO EGALO! LO

ON THE ROAD TO ipcm

Â®

n. 54

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

SPECIAL ON ACE & OFF ROAD VEHICLES

FOCUS ON TECHNOLOGY

BRAND NEW

INNOVATIONS: PRESENT&FUTURE

FOCUS ON TECHNOLOGY

Berti Macchine Agricole. An Innovative Industrial Solution for the Coating Process of Its New Production Site.

Under the Surface: Innovative Pretreatment for the ACE Industry

zhao jian kang Â© fotolia

Ferrari Costruzioni Meccaniche: A New Tunnel Shot Blasting System for Highly Customisable Agricultural Machinery

Opening photo: In 1972, Berti Macchine Agricole (Caldiero, Verona, Italy) decided to specialise in the production of mulchers, whose range now includes 500 models.

FOCUS ON TECHNOLOGY

S P E C I A L O N AC E & O FF ROAD V EHICLES

Berti Macchine Agricole. An Innovative Industrial Solution for the Coating Process of Its New Production Site. Alessia Venturi ipcm®

he switch from manual-only

of a well-established Italian manufacturer

in all design and development phases,

operations to an automated,

of agricultural machinery for the redesign

they created one of the most advanced

robotised, and digitised process; total

of its coating process by a group of

finishing systems ever installed in the

traceability of the operating process; data

plant engineering firms. Some of the

agricultural machinery sector. This

collection; and diagnostics for preventive

main players in the sector accepted the

new coating plant started in 2018 by

maintenance: these were the requirements

challenge: by effectively collaborating

Berti Macchine Agricole and born from

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

the collaboration among Savim, Futura

The production flow

reversed, our production is now steadier,

Convogliatori Aerei, Gaiotto Automation,

“Our machining and welding operations are

as is the workflow with our contractors.”

and Verind is compact, modern, extremely

entrusted to a few contractors that work

“We order all the productive material

functional, and Industry 4.0-oriented.

almost exclusively for Berti,” says Sales

according to our technical office’s

Manager Filippo Berti (Fig. 1). “Until a few

instructions and all workshops operate

years ago, our work was seasonal: production

with our know-how,” says Filippo Berti. “Our

The story of a company and a family

production flow is order-based: our main

Berti Macchine Agricole was established

issue are delivery times, because the fact

by Livio Berti in Caldiero (Verona) in the

that the European dealers operate with very little stock does not match well with

early 1920s, as an artisan company in the

the requests for 20-day deliveries now Berti Macchine Agricole typical of this market. Indeed, there is was established by Livio Berti in now a trend towards a just-in-time in the production of mulchers (ref. Caldiero (Verona) in the early 1920s, as an production. That is why in 2015 Opening photo), developing them at artisan company in the field of agricultural we decided to start a corporate the technological level for over thirty implements. In 1972, the Berti family decided restructuring project involving years. More than thirty years have to specialise in the production of mulchers, our productive structure, and passed since the creation of the first developing them at the technological level for especially our downstream vineyard and orchard mulcher. One over thirty years. More than thirty years have processes: assembly, coating, of the company’s main objectives passed since the creation of the first vineyard and storage. This investment has always been to build innovative and orchard mulcher. One of the company’s and restructuring plan was mainly machines specially designed for the main objectives has always been to build motivated by our will to switch from professional maintenance and reclaim innovative machines specially designed of urban, agricultural, and forest green for the professional maintenance and an order-based to a continuous-flow production. We currently have six spaces. reclaim of urban, agricultural, assembly lines, which will become nine in Berti now offers a range of 500 products and forest green spaces.” field of agricultural implements. In 1972, the Berti family decided to specialise

for all types of cultivation and ground

January and twelve at the end of 2019, of

conditions, applicable to any tractor or

which five will be devoted to continuous © ipcm ®

excavator. Its complete range of robust and high-

production and seven to special machines.”

performance equipment

“After assembly, we

is divided into two product

also focussed on our

lines intended for two

coating phase.

well-defined market

We already had a

segments. The “agricultural

recently bought plant

line” includes vineyard and

installed in a building

orchard mulchers, mowers,

specifically devoted

in-line mulchers, hedge

to this operation.

mowers, and forestry

However, it was a static

mulchers (with an installed power range from 15 to 300 HP). The “professional line”, on the other hand, includes different

system performing a

manual application

Figure 1: From left to right: Filippo Berti, Berti Macchine Agricole’s owner, Maria Grazia Signorini, Finance Manager and Francesco Attuati, Purchase Manager.

process and using solvent-based paints. Luckily, the corporate growth of

earthmoving devices intended for maintenance and forestation

peaks were concentrated from February to

the last few years enabled us to invest

operations, which are suitable for every

July, while the last months of the year were

in a new, technologically advanced

kind of excavator (with an operating

dedicated to the preparation of the new

automatic system and, at the same time,

weight between 1.5 and 35 tonnes) and

season. By differentiating our target markets

to switch to water-based coatings,”

skid steer.

and also working overseas where seasons are

explains Filippo Berti.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

SP ECIAL ON ACE & OFF RO AD V EH ICLES

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2 1

Figure 2: A bird’s eye view of the new coating plant supplied by Savim (Arbizzano, Verona).

Figure 3: A detail of the plant.

“Using two-component water-soluble coatings

with Savim (Arbizzano, Verona), which

and automation requirements,” says

was a business choice unrelated to any

then recommended all other technological

Attuati. “Inver, our supplier of water-based

regional regulation,” says Purchase Manager

partners for the handling, automation, and

coatings, also greatly supported us in the

Francesco Attuati. “We assessed that the

application aspects, i.e. Futura Convogliatori

design phase. Understanding our coating

market is gradually abandoning conventional

Aerei, Gaiotto Automation, and Verind.

requirements was crucial to design an

solvent-based products in favour of

Under the coordination of Savim, we created

optimal application system. In any case, the

water-based systems with the same

a relationship of mutual esteem with all of

starting point for us was our will to create

performance. Moreover, we are located in an

them.”

a new production structure that was a

urban environment: over the years, the town

“The plant designed by Savim was undoubtedly

linear, streamlined, efficient, automatic, and

of Caldiero has practically developed around

the most suitable to our production needs

completely traceable at all times.”

coatings seemed the most natural choice for us, although there remains a small part of our

our plant. Therefore, switching to water-based

production requiring solvent-based paints. Finally, in our new production area, we also added an automatic warehouse to favour the switch from an order-based to a continuousflow production.”

The origin of the new coating plant 4.0 Since it used to perform only a manual painting process, Berti did not have any knowledge of coating systems. “In order to design the new plant (Fig. 2 and 3) and, above all, understand how our automation, productivity, and surface quality needs could be met, we did some technical research and spoke with people who had already installed a coating system,” says Filippo Berti. “We thus came into contact

4 1

Figure 4: A component at the entrance of the pre-treatment booth.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Characteristics of the coating line

“We opted for the use of a water-based liquid

The system installed by Savim is completely

system with an application and automation system

Industry 4.0-oriented. By interfacing with the

that would allow us to industrialise and automate

automation and application systems, the

a process that used to be completely manual, little

management software package collects and

controllable, and hardly standardisable,” states

checks all operating parameters, applied

Francesco Attuati. “The goal was to improve the

thicknesses, and consumption data. The project

process, increase quality, decrease consumption

also included a thorough study of ergonomics,

and waste, and above all digitise operations as

flexibility, and modularity, so that the new line

much as possible.”

meets every current and long-term future

The products applied by Berti are the © ipcm ®

production need. The maximum capacity of the plant is 4 m in length;

INVERPUR semi-matte two-component anti-corrosion primer

however, two manual booths

based on hydro-soluble

(primer and enamel) have

acrylic resins and the

been devoted to machines

INVERPUR/X SM 2K

with larger dimensions,

two-component

accounting for 15% of the

water-soluble enamel

total production. The plant

based on acrylic resins,

management is based on

both in the company’s

barcodes.

distinctive orange colour.

The chemical pre-treatment

They are supplied by

is performed with a 3-stage

Inver, a brand of the

process (Fig. 4 and 5)

Sherwin-Williams Group.

followed by an intermediate

The primer forms a film

blow off and masking station.

with good salt spray,

Berti coats fully assembled

chemical, and water

machines and, therefore, all

resistance characteristics.

delicate components must

It reduces the enamel

be protected. The coating application station features two dry booths with a floor filtration system, a robotised and a manual one, for both

GANCI | HOOKS

TELAI | RACKS

brilliance very little and

5 1

it is a suitable basecoat

Figure 5: The 3-stage chemical pre-treatment process.

MASCHERATURE | MASKING

for iron, aluminium, and cataphoresis products, as it has excellent adhesion

the primer and enamel application.

and good corrosion protection properties.

Savim chose to integrate these automatic booths

The two-component enamel forms a hard and

with two manual ones (Fig. 6) to coat oversized

elastic film with excellent weathering resistance

workpieces, but also to perform accurate

characteristics and it is suitable for high quality

post-retouching operations on parts where

finishes on metal surfaces of various kinds, such

particular masks may hinder uniform coverage by

as agricultural and earth movement machinery,

the robots and to treat the components that still

machine tools, and industrial vehicles. It is applied

require a solvent-based coating, accounting for

with a viscosity (D4/25 °C) of 50-70” and with a final

15% of production. The robots are equipped with

dry thickness lower than 50-60 μm.

electrostatic guns, whereas the manual booths

“For the design of the paint application and feeding

perform a conventional application operation.

system, we chose to rely on Verind, belonging to

The application process includes a flash-off phase

the Dürr Group, because its equipment range was

between the primer and enamel application

the closest to our needs for 4.0-orientedness,”

stages and a final curing stage in a direct fired

states Filippo Berti. “In order to develop the best

furnace (Fig. 7).

application system, Verind had a preliminary

PER INFORMAZIONI E ORDINI VI INVITIAMO A CONTATTARE: PLEASE CONTACT:

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

www.emptmeyer.it

SP ECIAL ON ACE & OFF RO AD V EH ICLES

coatings through fibre-optic flow metres (Fig. 9). The coating management unit is equipped with three groups of lifts for the 200 kg-drums used for the storage of paints, level sensors, and Dürr circulation pumps for the primer and enamel. The remote coating management unit (Fig. 10) is located about 50 m of pipes away from the booths. Specific loading stations feed directly the process tanks of both the manual application stations and the insulated stations that contain the electrostatically charged pumping systems.” “The application equipment of the primer (Fig. 11) and enamel booths are symmetrical,” says Benevelli. “Each booth features an EcoDose 2K electronic dosing system. The automatic

6 1

stations’ systems are equipped with a remote station, fibre-optic volumetric

Figure 6: One of the two manual booths.

meeting with Inver to share a few

In 2015 Berti decided to start a corporate restructuring project involving the productive structure, and especially the downstream processes: assembly, coating, and storage. This investment and restructuring plan was mainly motivated by the will to switch from an order-based to a continuous-flow production. Berti currently has six assembly lines, which will become nine in January and twelve at the end of 2019, of which five will be devoted to continuous production and seven to special machines.”

technological choices. In fact, our two products could be applied with both the mixed air and low pressure technology: our coating quality depended on this choice.” “Our choice fell on an airless air assisted application for the primer, in order to achieve the right thicknesses and application speed, and for a low pressure application for the enamel, in order to ensure maximum aesthetic quality,” explains Verind Area Sales Manager Giovanni Benevelli (Fig. 8). “Therefore, we developed a flexible and modular system that combines an electrostatic application process with an automatic system for the dosing and mixing of 2K

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Figure 7: The curing stage in the direct fired furnace.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

SP ECIAL ON ACE & OFF RO AD V EH ICLES

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Figure 8: Left to right: Manuel Pesamosca, the Technical Sales Manager of Gaiotto Automation, Francesco Attuati, the Purchase Manager of Berti Spa, Alessandro Soba and Giovanni Benevelli, the Verind Area Sales Managers.

Figure 9: Verind’s EcoDose 2K automatic system for the dosing and mixing of 2K coatings.

Future-ready automation

friendly and offers one point of command

high and low pressure pumps, whereas

Berti’s new industrial coating line includes

through which the operator can easily control

the manual retouching stations feature

four GA25-P six-axis spraying robots provided

the overall state of the machines and the

standard EcoDose 2K systems with high

by Gaiotto (Fig. 12 and 13), installed on a

exchange of data with the other systems

and low pressure pumps. A PLC manages

linear translation axis and complying with

operating within the plant.

an EcoDose 2K for the automatic

current safety regulations, especially the ATEX

“The four robots installed for Berti Macchine

application process of each robot and an

standard for explosive atmospheres. This

Agricole feature all three programming

EcoDose 2K for each manual station.”

robot was specifically designed and developed

logics available: point-to-point, self-learning,

EcoDose is an advanced electronic

for paint spraying applications, with all the

and off-line, which is the main challenge

system for the stoichiometric dosage and

advantages of a system intended for a given

in the field of industrial robotics of the last

mixing of two or more water-based or

type of automation and, above all, with high

decade. In fact, the off-line programming

solvent-based coating products. Its main

mechanical reliability. Its Human-Machine

method enables to create coating programs

technical features are as follows:

Interface (HMI) makes the machine user-

without stopping the line thus reducing

• direct dosing technology with two channels (A and B)

counters, and insulated devices with

• view of actual flow rates, partial consumption for each program, alarms, diagnostics, VOC quantities, and consumption related to each model/colour for every application station • connection to the line master for the automatic management of the style queue and the colour change operations • management of the pot-life and pot-time parameters • information to the operator for predictive maintenance on all application components, in order to avert downtimes.

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N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

Figure 10: The coating management unit for manual station with Dürr pump.

productivity. In the last few years, Gaiotto

FOCUS ON TECHNOLOGY

has focussed a lot on this method, which allows the operators to design the painting programs only based on the geometry of the workpieces, without physically operating on them,” says Manuel Pesamosca, the Technical Sales Manager of Gaiotto Automation. “During commissioning, we realised that the off-line programming method was best suited to Berti’s needs, also because the company has the great advantage of having available all the 3D models of the machines produced. The integrated software package offers a process parameter control system, which makes it ideal for the industrial coating sector since it enables to check and modify the flow rate, the atomisation process, and the spraying fan. These parameters can all be defined directly during off-line programming, complete with simulations aimed at reducing time and waste.”

www.cieeng.com info@cieeng.com

11 1

Figure 11: The feeding system of the primer application booth for manual station with Dürr pump.

www.mstchemicals.com info@mstchemicals.com

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12 1

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Figures 12 and 13: Gaiotto’s GA25-P six-axis spraying robots.

“Gaiotto’s robots, with all their technological

Manager Alessandro Soba. Berti’s main

any deviations from the standard, and make

systems, operate at the core of the coating

objectives for its new Smart Factory were as

them available through a specific line interface

process, interfacing with both Verind’s

follows:

for corrective actions.

application systems and Savim’s plant systems,”

• Implementing a digitised application/

• Integrating the EcoDose 2K electronic system

says Pesamosca. “Together with Verind, we

coating system, managed with integrated

in its remote version with fibre-optic flow

developed an operating interface between the

control and automation systems and

metres, suitable for handling two-component

robots and the spraying equipment to enable

interfaced with robot and manual retouch

water-based epoxy and polyurethane coatings

continuous collection of operational data, error

stations.

applied with an electrostatic process (Fig. 14).

reporting, operating status updating, predictive

• Obtaining the best application and surface

• Remote service, predictive maintenance, and remote assistance.

maintenance, and control over the quantities

finish results with specific integrated

of coating consumed for each program or part

automation, application, and robot

“Berti’s coating process is very complex, with

type. In short, Verind’s system sends all paint

systems for the management of the

a significant number of variables. By focussing

consumption data to the robots and the robots

various 2K products and of the process in

on innovation, we were able to ensure that this

transfer them to Savim’s management software

its entirety.

application management workflow contributes

package, which collects all the data from the

• Monitoring all productivity information and

to reduce production costs per unit while increasing efficiency,” says Giovanni

“We could build a highly

Benevelli.

automation systems.” functional and compact smart

partners involved, which operated

A challenge won and an important industrial result achieved

in synergy since the design phase,”

“The joint and coordinated

says Pesamosca.

work of Savim, Gaiotto, and

architecture only thanks to the close collaboration of all the three

Verind has enabled the

Industry 4.0 principles and proven experience in the ACE sector

development of innovative and industrially sustainable solutions, oriented towards

“Its ability to combine system

eco-friendliness, workplace

engineering, know-how, and

safety, processing cost

innovation was crucial for Verind to meet Berti Macchine Agricole’s industrialisation requirements,” says Verind Industry Sector Sales

14 1

Figure 14: The pumping and recirculation unit of the coating products created by Verind/Dürr.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

reduction, high surface quality, and industrial digitisation, with which we are very pleased,” says Filippo Berti.

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FASTRIP, for the easy, effective and rapid paint stripping of metals.

ALIT Technologies, the chemical paint stripping specialist. Products, machines, processes and consultancy.

www.alit-tech.com San Bonifacio â&#x20AC;&#x201C; Verona - ITALY

BRAND-NEW

S P E C I A L O N AC E & O FF RO AD V EHICLES

oyal DSM, a global science-based

of up to 48% compared to standard

company in Nutrition, Health and

alternatives (Fig. 2).

Sustainable Living, has announced

In addition, because of the faster drying

the launch of a new Hybrane™ product. This

possibilities, our resin shortens the spray

product, Hybrane CY235, will drive standards

booth cycle time by 20%. Under typical

in the ACE, General Industrial and Car

workshop conditions, for example, car

Refinish metal coating industries by enabling

refinishers can paint two extra jobs every

enhanced coatings performance, higher

day, driving throughput. Crucially, these

throughput and reduced energy consumption

operational benefits in no way compromise

(Fig. 1).

the performance of Hybrane CY235, which

Based on DSM’s proprietary technology,

delivers excellent hardness, a high-quality

the new Hybrane CY235 product leverages

appearance with distinctiveness of image,

the high functionality of the Hybrane

and high reactivity without compromising on

molecular structure to deliver unprecedented

pot life.

performance standards. Unlike other high

Ap Heijenk, Industry Manager Industrial

solid acrylic resins, which typically require

Metal & Plastic DSM: “After many months

forced drying conditions at 60°C for 30

of careful experimentation and testing,

minutes, Hybrane CY235 only requires a

involving a cross-functional and cross-site

curing temperature of 40°C. In this way,

collaboration, we’re very proud to launch

Hybrane CY235 can deliver energy savings

Hybrane CY235. This product enables

DSM Drives Performance of Metal Coatings by Expanding Hybrane™ Resins Family

2 1

Figure 2: Unlike other high solid acrylic resins, Hybrane CY235 only requires a curing temperature of 40°C. In this way, it can deliver energy savings of up to 48% compared to standard alternatives.

better coating performance at a lower © DSM Coating Resins

environmental cost. As such, it is clearly aligned with our wider organizational aims of using bright science to enable brighter living.” “Moving forward, we will continue to develop our Hybrane proposition in line with market demands. In particular, we will channel our development efforts to deliver Hybrane products for an even wider range of industries and also extending the application to different substrates like plastic and wood. We’re confident that our Hybrane technology will open up new coating horizons – in terms of sustainability and

processability.”

Figure 1: Hybrane™ CY235, will drive standards in the ACE, General Industrial and Car Refinish metal coating industries by enabling enhanced coatings performance, higher throughput and reduced energy consumption.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

For further information: www.dsm.com/paint

BRAND-NEW

S P E C I A L O N AC E & O FF RO AD V EHICLES

ptiStar® 4.0 ensures excellent

The New Electrostatic App and OptiStar® 4.0: The Benchmark for Efficient Gun Control finishing results and measurable system optimisation actions.

New features, such as the E-App, make

the control module even smarter and allow access to the Smart Factory Automation (Fig. 1).

Smart and flexible The Electrostatic App is an innovative function that enables to control the coating process while improving its flexibility and efficiency. This makes the new command module of OptiStar® 4.0 a pioneer of the Smart Factory Automation on powder coating plants. The app can be used to monitor the application parameters on one or more control modules.

Greater eﬃciency with the Electrostatic App The Electrostatic App offers a completely

Figure 1: The new E-App makes the control module even smarter and allows access to the Smart Factory Automation.

• Services: direct access to the use and

• Application: all the main coating

new range of process control options,

parameters are clearly visible on the

maintenance manuals and to Gema’s

ranging from line management to

device and they can be controlled and

website.

equipment maintenance data. Process

regulated directly from there.

data and relevant application parameters

With the Electrostatic App, the most

• Line management: process productivity

can be seen on a mobile device and they

data can be recovered at any time.

relevant application data and the

can be adjusted and controlled directly

The most important statistics and

most crucial coating parameters are

through it. Calculations and statistics are

calculations of production costs are

immediately available on a mobile

automatically available at any time. This

generated automatically. The maintenance

device. The operator can easily access

saves time and improves the efficiency of

programs can be easily controlled with a

process evaluations and statistics.

the powder application process.

simple “Tap”.

This saves time and makes the coating

The Electrostatic App’s functions

• Settings: this function enables to configure

process even more efficient.

the control module. OptiStar 4.0 can be ®

controlled as a single device or within a

For further information:

With this app’s 4 functions, the coating

group of control units. System information

www.gemapowdercoating.com and

process can be monitored and controlled

and diagnostic data can be easily retrieved

www.youtube.com/watch?time_

though a mobile device:

and sent by e-mail.

continue=12&v=TSFRm5j6Mm4

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

Opening photo: Maintenance of the functional eﬃciency and the permanent corrosion protection of the vehicle surfaces therefore play an integral role in their longevity.

INNOVATIONS: PRESENT&FUTURE

S P E C I A L O N AC E & O FF ROAD V EHICLES

Under the Surface: Innovative Pretreatment for the ACE Industry Thomas Willumeit Chemetall GmbH, Frankfurt am Main - Germany

thomas.willumeit@basf.com

gricultural, construction, and

programs increases the long-term value

infrastructure, construction industry and

earthmoving vehicles operate in the

of the vehicles in terms of quality and

farming. The general trend towards global

most extreme of environments around

sustainability.

urbanization, ever faster growing cities,

the world and must remain functional for the

and increasing demands on infrastructure

entire life of the asset. To achieve operational

Manufacturers of agricultural,

expansion are some of the key drivers for the

longevity the quality of the surface finish of the

construction and earthmoving

global ACE companies.

vehicles plays a key role. Utilizing Chemetall’s

(ACE) machinery make an important

The requirements for corrosion

innovative pretreatment processes and

contribution when it comes to

protection and the appearance of

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

ACE manufacturers and suppliers

ACE vehicles have increased. ACE machinery manufacturers put the

Agricultural, construction, and earthmoving vehicles operate in the most extreme of environments around the world and must remain functional for the entire life of the asset. To achieve operational longevity the quality of the surface finish of the vehicles plays a key role. Utilizing Chemetall’s innovative pretreatment processes and programs increases the long-term value of the vehicles in terms of quality and sustainability.”

quality of their design and surface finishes to the test on a daily basis: Off-road vehicles, construction machinery, industrial machinery, and agricultural equipment must withstand adverse conditions and yet remain functional for years. Maintenance of the functional efficiency and the permanent corrosion protection of the vehicle surfaces therefore play an integral

benefit from Chemetall’s decades long experience in the ACE industry sector and market. As a recent example of the sustainability initiatives, Chemetall collaborated with a large construction equipment manufacturer to provide a tailored pretreatment for their paint system. An audit, Chemetall’s initial step in any process recommendation, identified several areas of potential improvement. One area

photo). Pretreatment technologies

identified was the high number of

therefore must deliver consistently high-quality results on hot-rolled steel,

role in their longevity (ref. Opening

heat exchanger plates that were replaced several times per year in

cold-rolled steel, cast iron, and

a process stage. The use of a CIP-

non-ferrous substrates such

system (Clean-In-Place)

as aluminium- all used in the

for the heat exchangers was

manufacture of these vehicles.

recommended, the aim being to

The pre-treatment of substrates

eliminate the need to replace three

processed into construction

to four heat exchanger plates per

materials plays a key role in corrosion

year. Each exchanger replacement

protection, thus extending substrate

represented a 3,5 – 4 K € cost

life and providing an aesthetic

for the construction equipment

appearance (Fig. 1). Chemetall, the

manufacturer. In addition, the

global Surface Treatment business

CIP-system allows temperature to

unit of BASF’s Coatings division,

be monitored and maintained very

offers tailor-made pre-treatments

closely improving the quality level of

which fulfil all the ACE manufacturer

the pretreated parts. Moreover, the

requirements. As a premium global

Clean-In-Place-program has virtually

supplier, Chemetall assumes the role

eliminated the need for the removal

of a solution-oriented partner for

of the exchangers manually, thereby

customers’ projects who desire to enhance their processes, quality, and safety standards in a sustainable way. For ACE machinery, a high-quality surface finish that meets or even exceeds OEM specifications, is

reducing employee exposure to

very aggressive acidic chemicals

Figure 1: The pre-treatment of substrates processed into construction materials plays a key role in corrosion protection, thus extending substrate life and providing an aesthetic appearance.

(Fig. 3). “The key to successful sustainability analysis is to look beyond the product to the entire process. By looking at a process holistically, far more improvements

becoming more and more important. At the same time, widely differing

In addition to achieving a high-quality surface

can be identified”, says Ron Sattler,

substrates place high demands on

finish, the cost-effectiveness and sustainability

Executive Director of Strategic Accounts at

production processes.

of the pretreatment technologies play an

Chemetall.

To meet the requirements of each

increasingly important role, as the processes

Furthermore, Chemetall also implemented

customer, we must first analyze the

used must not only be more conscious of

automated control and data acquisition

individual customer process and related

environmental concerns, but also more

which allowed the identification of a stage

needs to develop ideal and efficient

economically sustainable to meet future market

that had a serious water leak. Prior to the

technical solutions.

requirements (Fig. 2).

implementation of the system, the leak

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

SP ECIAL ON ACE & OFF RO AD V EH ICLES

had gone unnoticed resulting in excessive

increase safety and reduce costs.

chemical usage and

These technology

heat loss. Chemetall

requirements,

was able to pinpoint

products, and

the root cause area,

operating

allowing a quick and

procedures allow

targeted repair. The

companies to

result was water savings of over 1.900 m3. While the overall financial savings was significant, the true benefit was the

actively contribute

2 1

to a better global

Figure 2: The pre-treatment processes must not only be more conscious of environmental concerns, but also more economically sustainable.

environmental performance. Chemetall’s technologies

conservation of one of

fulfill national regulations and

the world’s most precious resources – water.

Chemetall also implemented automated control and data acquisition which allowed the identification of a stage that had a serious water leak.”

“Our process experts assist customers to improve the reliability of their control and monitoring to insure quality

requirements: The ISO 9001:2008 certified company offers a wide spectrum of tailored products and systems that follow global quality guidelines. Additionally, the

time minimizing waste,” adds Ron

production sites comply with the

Sattler. “We look beyond the chemistry, collaborating closely with our customers

standards are met while at the same

quality standards ISO 14001:2015 certificate. This international

to identify unique opportunities for

standard sets out requirements

improvement to deliver on the promise

for an environmental management

of sustainability.”

system with which an organization

“A deep commitment to innovation

can improve its environmental

and sustainability, together with the

performance, fulfil legal and

customer as partner is the basis for

other obligations, and achieve

continuous improvement and to deliver

environmental goals.

the highest quality and mutual value

Based on customer requirements,

creation,” says Korneel Demeyere,

substrate throughput and existing

Key Account Manager at Chemetall.

plant technology, Chemetall can

With a strong global network and local

recommend to ACE manufacturer

technical representation, tailored and

suppliers coordinated technologies

sustainable solutions can be provided

such as the Oxsilan technology,

which are close to each customer. From

which fits perfectly in a multitude of

a regulation perspective, increasingly

applications. The modular structure

stringent environmental legislation

of this pre-treatment technology

as well as the ever more varied metal

makes it possible to increase

combinations now used create the

process efficiency quality and

need for companies to look beyond

production output in a wide variety

traditional phosphating processes.

of pretreatment systems. Oxsilan

Chemetall has been able to replace zinc

technology offers advantages versus

phosphate process in powder lines with

3 1

lower sludge formation, a major

eco-friendly processes. One goal is the elimination of Nickel salts by introducing globally applicable, environmentally-sound processes to

zinc phosphate including significantly

Figure 3: The Clean-In-Place-program has virtually eliminated the need for the removal of the exchangers manually, thereby reducing employee exposure to very aggressive acidic chemicals.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

improvement considering the time and effort needed for the manual removal of zinc sludge in traditional

INNOVATIONS: PRESENT&FUTURE

Based on customer requirements, substrate throughput and existing plant technology, Chemetall can recommend to ACE manufacturer suppliers coordinated technologies such as the Oxsilan technology, which fits perfectly in a multitude of applications. The modular structure of this pretreatment technology makes it possible to increase process efficiency quality and production output in a wide variety of pretreatment systems.â&#x20AC;? zinc phosphating systems. Due to the absence of Nickel, the environmental impact of a pretreatment line will be decreased. The result is lower use of chemical as well as tremendous savings in water and energy (30 to 65 percent reductions). The sustainability benefit is not always apparent at first as the next example will show. A large global engine manufacturer decided to focus on reducing motorized vehicle traffic around the site to increase personnel safety. Traffic and chemical treatment are not often thought of as being linked, but by understanding sustainability and how all the processes within a facility are tied together even seemingly non-associated goals can be impacted. By making improvements to the effectiveness of a cleaning process Chemetall was able to reduce the amount of chemical required and as such reduced the need for the restocking of the chemical. This lower restocking was so significant it created a reduction in motorized vehicle traffic in the area by 19%. Without an understanding of sustainability and how a process, and not just a product can impact results, a true sustainability solution may have been missed. As global competition increases, and resources become scarcer, it is important to focus on comprehensive sustainable programs. Thus, for BASF, Chemetall and their customers, sustainability is not just a word but rather a mindset that is implemented to customer interactions. Itâ&#x20AC;&#x2122;s a commitment to improve overall process performance by reducing environment impact, lowering manufacturing cost, and improving the human element associated with the process. For the ACE industry, Chemetallâ&#x20AC;&#x2122;s pretreatment technologies offer a multitude of benefits: multi-metal treatment, enhanced quality, significant process cost savings, and world class global support that is aligned with their customers business goals. This is what creates real quality and what Chemetall stands for expect more.

Opening photo: Ferrari Costruzioni Meccaniche was established by Luigi Ferrari as a repairer of agricultural machinery in Guidizzolo (Mantua, Italy), in 1961. The company is now managed by his sons Francesco and Dario and it has specialised in the production of transplanting machines.

FOCUS ON TECHNOLOGY

S P E C I A L O N AC E & O FF ROAD V EHICLES

Ferrari Costruzioni Meccaniche: A New Tunnel Shot Blasting System for Highly Customisable Agricultural Machinery Barbara Pennati ipcm®

n our modern globalised world, we

possible and what process lies behind the

agriculture has always been the basis of

are used to having any product at our

salad head that we effortlessly put in our

our livelihood and, precisely for this reason,

disposal at any time. This is especially

shopping cart. If talking about agriculture,

it has evolved hand in hand with man and

true for food: supermarkets always offer

we are more likely to initially recall concepts

his habits – not just in terms of crops,

a huge selection of products, vegetables,

learned from our history and geography

which now do not know borders, but also

and fruits from all over the world. Although

books rather than thinking of it as an

of technology.

awareness and interest in this subject

integral part of the industrialised societies

Ferrari Costruzioni Meccaniche has

are exponentially increasing, we are often

of the first world. And yet, however far

been one of the players of this evolution

too busy to stop and wonder how this is

apart from the everyday life of most people,

since 1961. Established as a repairer

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

of agricultural machinery in Guidizzolo

technology, which is our core business,

methods are selected depending on the type

(Mantua, Italy) by Luigi Ferrari, the company

makes sure that plants grow before

of plant: the sod system is more expensive,

is now managed by his sons Francesco,

weeds; however, despite the agronomic

but it brings significant benefits with short

and Dario and it has specialised in the

advantages, there was initially no machine

cycle crops, such as salads, whereas seeding

production of transplanting machines

to automate this process, which had to be

boxes are more suitable for longer cycle

(ref. Opening photo). “Ferrari Costruzioni

performed manually,” says Dario Ferrari.

crops, such as tomatoes, which take three to

Meccaniche is located in one of the most

“The systems developed and produced

four months.”

important agricultural areas of Italy: 40% of

by Ferrari Costruzioni Meccaniche can

With the advent of organic agriculture in

lettuce is produced in Guidizzolo,” explains

handle the semi-automatic and automatic

1995-96 and its success on world markets, a

technical director and partner Dario Ferrari

transplantation of plants placed in seed

new need arose: the reduction of chemical

(Fig. 1). “The company has followed the

boxes (Fig. 2) or on sods. These two

impact. Therefore, Ferrari Costruzioni

metamorphoses of the agricultural sector,

Meccaniche started offering a transplanting© ipcm ®

adapting its machinery to the needs arising over the

mulching machine able to lay a polyethylene or

years.”

biodegradable film, fix

With the advent of new

it to the ground, and

agronomic needs and

transplant the plants

the development of

(Fig. 3). By covering the

new technologies, the

soil adjacent to the plant,

quality level required for

this film prevents the

agricultural machinery has

growth of weeds without

increased. That is why,

the use of chemicals. An

in order to offer robust

electronic weeder was

and durable products

also developed: through

to its customers, Ferrari

a viewer, it carries out

Costruzioni Meccaniche

a mechanical weeding

has made some changes

operation at a speed

to its coating plant. One of them involved the mechanical pre-treatment phase, now performed with a tunnel shot blasting

of 4 km/h and without

damaging the plant – a

Figure 1: Technical director Dario Ferrari manages the company established by his father Luigi together with his brother Francesco.

has specialised in the design and production of shot blasting, sand blasting, and shot peening systems for over fifty-five years.

A global presence for every production requirement “Over the years, agricultural production has undergone many changes that have made it necessary to adapt the machinery to ever-new needs. For example, for what concerns sowing, the transplantation

“In 1985, the agricultural business established by

OMSG-Officine Meccaniche a well-established company that

people to perform. machinery repairing

machine supplied by San Giorgio SpA (Villa Cortese, Milan),

job that would require ten

Ferrari Costruzioni Meccaniche covers three buildings on a 15,000 m2 area and it has 102 employees, who manage the entire production process in-house. The production flow starts in the technical office, which designs the machines according to customer specifications. Once the work order has been generated, the various production departments are activated: turning (with 6 turning centres and 2 machining centres), laser cutting, welding (with both robotised and manual welding stations), coating, and assembly (where different specialised teams operate depending on the machine type).”

our father started to convert into a manufacturing company. We have developed different types of machines, but we have specialised in transplanting machines for different crops, especially tomato, brassicaceae, and salads, but also coffee, sugar cane, tobacco, and pineapple,” says Dario Ferrari. “By attending various trade fairs, we have managed to open up to the global market and we now have customers in fifty countries around the world, including USA, Latin America, Canada, South Africa, and China.”

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

SP ECIAL ON ACE & OFF RO AD V EH ICLES

2 1

3 1

Figure 2: An automatic transplanting machine developed for vegetable plants placed in seed boxes.

Figure 3: With the advent of organic agriculture, Ferrari Costruzioni Meccaniche has added to its range a transplanting-mulching machine able to lay a polyethylene or biodegradable film that prevents the growth of weeds without the use of chemicals.

Productive flexibility in the name of quality

stations), coating, and assembly (where

The will to offer tailor-made solutions calls for

different specialised teams operate depending

extreme production flexibility. This has led

Ferrari Costruzioni Meccaniche covers three

on the machine type),” explains Dario Ferrari.

Ferrari Costruzioni Meccaniche to insource

buildings on a 15,000 m area and it has 102

“The process is automated, but not intensively,

most processes, including coating, to which

employees, who manage the entire production

as our key to success is a high customisation

it has devoted an entire building. “The

process in-house. “The production flow starts

level that requires significant artisanal skills.

components we buy are already coated. On

in our technical office, which designs the

We produce about 1,000 machines a year,

the other hand, all products coming out of

machines according to customer specifications.

belonging to different price ranges and very

our turning department can be subjected,

Once the work order has been generated, the

different from each other. This is precisely

depending on the type of workpiece, to a

various production departments are activated

due to the high level of customisation that we

galvanic treatment, carried out by a contractor,

(Figs. 4 and 5): turning (with 6 turning centres

make available to our customers, which have

or to a liquid or powder coating process,

and 2 machining centres), laser cutting, welding

the opportunity to build a system that is truly

performed with the system we have installed at

(with both robotised and manual welding

tailored to their needs.”

our premises,” says Dario Ferrari.

4 1

5 1

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

Figures 4 and 5: Ferrari Costruzioni Meccaniche manages its entire production process in-house. Its production departments include turning, laser cutting, welding, coating, and assembly.

FOCUS ON TECHNOLOGY

“The hydraulic motor cylinders are liquid painted in an offline manual booth, which requires a chemical pre-treatment process; the carpentry parts are powder coated in an inline system, which requires a mechanical pre-treatment operation.” The in-line coating plant, equipped with a one-rail conveyor, dates back to 1998, the year in which the painting process was insourced. Its booth and polymerisation oven have been revamped over the years. Originally, also this plant performed chemical pre-treatment (phospho-pickling, degreasing, rinsing with mains water, and rinsing with demineralised water). However, this did not guarantee the requested quality, resistance, and consistency performance levels. “Our powder coating line treats different types of parts and materials, including white and black sheet metal and tubes. We constantly had significant yield problems in terms of both quality and corrosion resistance. In short, the previously

The paint performs even under high pressure. Surface coating expertise on many levels – that‘s where Rippert has been making a name for itself for over ﬁve decades. We conceived surface coating plants for PILATUS for the ﬁnishing individual components and complete aircraft. We are delighted to accompany a successful company with our ideas and technologies. We make brands shine. Find out more at www.rippert.de

6 1

Figure 6: The TUNNELBLAST 1525/12 tunnel shot blasting system installed in December 2017 by OMSG (Villa Cortese, Milan).

S P E C I A L ON AC E & OF F ROA D V E HI C L E S

Figures 7 and 8: In order to perform a continuous flow process, the tunnel shot blasting system has no closing doors, but it is equipped with vestibules featuring rubber curtains at both the entrance and exit: this reduces the spillage of media and dust from the shot blasting chamber.

7 1

8 1

used pre-treatment cycle guaranteed neither high salt spray resistance values nor result repeatability, which fluctuated depending on the material treated,” says Dario Ferrari. “In order to solve these problems, we would have had to carry out a major tunnel updating and completely reformulate the active baths’ chemicals. That is why we decided to look for a different solution: a technology that could be installed inline and that was able to treat both small and large workpieces without affecting logistics and ensuring a high quality level in terms of both aesthetics and corrosion resistance. We thus came into contact with OMSG, which took us to the factory of one of their customers, a manufacturer of corn heads, to enable us to see its technology applied to a machine in our industry, and then developed the best suited plant for our needs.” The machine installed in December 2017 at the premises of Ferrari Costruzioni Meccaniche is a TUNNELBLAST 1525/12 tunnel shot blasting system (Fig. 6), able to treat workpieces up to 1500 mm in width and 2500 mm in height and equipped with 12 OMSG-patented single-disc turbines, each with a 7,5 Kw power, to guarantee an SA 2½ finishing degree. “The parts to be treated move continuously at a speed of 0.5 metres per minute. This limited speed allows us to obtain the required

FOCUS ON TECHNOLOGY

quality level without using larger media, which could damage the workpieces with their intense action,” explains Ferrari. “One of the requirements of Ferrari Costruzioni Meccaniche was that the shot blasting system could perfectly integrate into the coating plant and work inline and with a continuous flow. We opted for a tunnel shot blasting machine, not hermetic but with vestibules featuring rubber curtains at both the entrance and exit: this reduces the spillage of media and dust from the shot blasting chamber (Figs. 7 and 8),” states Giorgio Pozzi from the technical sales department of OMSG. “The rotation speed of the turbines is adjustable through an inverter. Special valves dose the abrasive, which is then recovered and reconditioned: through a blowing nozzle, the media left on the component are removed by the operator and collected in hoppers placed in the exit area (Fig. 9).” “As well as consistency and salt spray resistance, another problem that we solved thanks to this machine is related to the coating quality of laser cut workpieces,” says Ferrari. “Indeed, laser cutting creates a sharp edge that often causes a ‘tear’ in the paint. In the past, we rounded these edges with a brushing machine combined with an abrasive; now, thanks to our shot blasting plant, this is not necessary anymore.” After pre-treatment (chemical in the case of engine cylinders, mechanical for carpentry components), the workpieces reach the coating process. “The carpentry parts are coated in the inline plant, equipped with a booth featuring 4 reciprocators and 2 guns for manual retouching,

supplied by Wagner (Fig. 10). A one-layer system is applied that employs Sherwin-Williams polyester powders, which are then recovered during spraying through cartridge filters. The subsequent polymerisation phase takes place at 200 °C for 20 minutes (Fig. 11),” says Dario Ferrari. “On the other hand, for the liquid coating of our engine cylinders, we use an offline manual booth applying water-based two-component paints, 9 1

Figure 9: The abrasive can be recovered and reconditioned: through a blowing nozzle, the media left on the component are removed by the operator and collected in hoppers placed in the exit area.

also provided by Sherwin-Williams. The colours used are those typical of the Ferrari Costruzioni Meccaniche brand, i.e. RAL 2002 red and blue.”

HIGH

PERFORMANCE POWDER COATINGS

SP ECIAL ON ACE & OFF RO AD V EH ICLES

The OMSG Group (OMSG + Carlo Banfi), has always committed to offer constant and efficient after-sales assistance. Its customers are categorised according to the machines they have installed, and this allows OMSG to intervene promptly and effectively even in the most remote locations. Moreover, the machines are Industry 4.0-oriented and always provided with a package of devices and services for the management of the process (and of any problems), such as a PLC, an integrated touchscreen, remote assistance, and safety devices.” Our customers are categorised according to the machines they have installed, and this allows us to intervene promptly and effectively even in the most remote locations,” explains Giorgio Pozzi. “Moreover, our machines are Industry

10 1

4.0-oriented and always provided with a package of devices and services for the

Figure 10: The powder coating booth is equipped with 4 reciprocators and 2 guns for manual retouching, supplied by Wagner; it applies Sherwin-Williams polyester powders.

management of the process (and of any problems), such as a PLC, an integrated touchscreen, remote assistance, and safety devices.” “The plant has now reached optimal

A historical business keeping up with the times

conditions, and we can now focus on future improvements. To obtain an even

“Ferrari Costruzioni Meccaniche has

higher salt spray resistance value, we are

operated in the agricultural sector for over

considering the implementation of a primer

fifty years. With time, we have witnessed

application phase. In this way, we will be

and taken part in the succession of different

able to offer our customers increasingly

trends and technologies, always trying to establish ourselves on the national and international markets as a solid and reliable company,” states Dario Ferrari. “Therefore,

11 1

Figure 11: Workpieces entering the polymerisation oven.

products, in terms of both technology and quality,” says Dario Ferrari.

it was extremely important to find the right

advanced and competitive services and

technological partner to obtain increasingly optimal results in line with market needs.” “With the adoption of this machine, we have solved the problems related to consistency and salt spray resistance, managing to guarantee much higher quality and corrosion resistance levels (Fig. 12). We are very pleased of this system, of the results achieved, and of OMSG’s professionalism and technical efficiency,” says Ferrari. “The OMSG Group (OMSG + Carlo Banfi), has always committed to offer constant and efficient after-sales assistance.

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N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

Figure 12: A finished product of Ferrari Costruzioni Meccaniche.

Â®

SUCCESS STORIES

Eisenmann, a Paint Shop 4.0 Pioneer, Debuts an Integrated, End-to-End Solution for the Paint Shop of the Future

Figure 1: Eisenmann pre-assembles paint shop components at its Technology Center in Holzgerlingen near Stuttgart. A prime example is a new paint shop, built for the expanded Mercedes-Benz plant in Kecskemét, Hungary.

lant engineering enterprise

Eisenmann pre-assembles paint shop

be implementing a skidless paint shop in

Eisenmann, headquartered in

components at its Technology Center in

Kecskemét that incorporates a number

southern Germany, has built and

Holzgerlingen near Stuttgart.

of our solutions. With our combination of

pre-installed equipment for a new paint

The approximately 15,000 m2 production

Industry 4.0 technologies, we are making the

shop. The solution is ultimately destined for

halls enable the enterprise to put

vision of a highly flexible and efficient smart

Kecskemét, Hungary, but made its debut in

customer-specific solutions to the test prior

paint shop a reality.”

Holzgerlingen. The event demonstrated the

to delivery – and to cooperate closely with

individual but interconnected production

customers to tailor new technologies to

Highly flexible skidless conveyor

steps based on Eisenmann technologies. For

their needs. A prime example is a new paint

At the heart of this fully integrated,

the first time, these have been implemented

shop, built for the expanded Mercedes-

end-to-end solution is Eisenmann’s VarioLoc

as an end-to-end, highly flexible, skidless

Benz plant in Kecskemét, Hungary (Fig. 1).

conveyors (Fig. 2). They enable skidless

paint shop – underscoring Eisenmann’s ability

As Jörg Robbin, Vice President of Product

movement of vehicle bodies through

to design and build one-stop, future-proof

Development, Automotive Systems at

the paint shop. As Robbin emphasizes,

solutions.

Eisenmann explains: “We are proud to

“Eliminating the need for heavy skids paves

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

SUCCESS STORIES

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Figure 2: At the heart of this fully integrated, end-to-end solution is Eisenmann’s VarioLoc conveyors. They enable skidless movement of vehicle bodies through the paint shop.

Smart, energy-eﬃcient dryers State-of-the-art dryers play a pivotal role in ensuring high paint quality at OEMs and their suppliers. The corresponding processes require considerable energy input – meaning efficiency gains translate into huge savings. “Our Smart Oven represents a milestone in vehicle body drying (Fig. 4). This new solution evenly delivers heat to the chassis, yet requires significantly less energy. This, in turn, reduces resources consumed by the paint shop, and slashes harmful emissions. Users benefit in the long term from an improved ecological footprint and higher coating

2 1

quality,” Robbin states. The Smart Oven

the way for greater flexibility in terms of cycle times, throughput, resources, and

At the heart of this fully integrated, end-to-end solution is Eisenmann’s VarioLoc conveyors. They enable skidless movement of vehicle bodies through the paint shop. VarioLoc conveyors with the car bodies move along a rail installed in the floor. The drives are independent, and speed can be adjusted according to each process step. As a result, cycle times and throughput can be managed flexibly and optimized.”

vehicle architectures.” VarioLoc conveyors with the car bodies move along a rail installed in the floor (Fig. 3). The drives are independent, and speed can be adjusted according to each process step. As a result, cycle times and optimized. Moreover, the modular system can be relocated to a new site, and easily extended without major modifications – as all VarioLocs are of identical design,

throughput can be managed flexibly and

and comprise highly standardized components. This enables responsiveness to fluctuating workloads, and quick and simple changeovers between vehicle models during ongoing production, without specially trained staff. In conventional paint shops, by contrast, it would be necessary to purchase entirely new skids, or to make significant alterations to existing ones. Figure 3: VarioLoc conveyors with the car bodies move along a rail installed in the floor. Cycle times and throughput can be managed flexibly and optimized.

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international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

SUCCESS STORIES

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Figure 4: Smart, energy-eﬃcient dryers: This new solution evenly delivers heat to the chassis, yet requires significantly less energy.

is among the solutions leveraged in the Kecskemét paint shop. The Smart Oven can make the most of its strengths when deployed in conjunction with VarioLoc skidless conveyors. In the past, the hefty skids carrying the vehicle bodies through the dryer had to be heated up and cooled down with each cycle. And for a skid that tips the scales at 200 kg that is a huge amount of energy. By taking the skids out of the picture, VarioLoc reduces energy consumption for drying alone by up to 13 percent – and that is just part of the potential 37 percent savings that can be achieved annually with the Smart Oven. This total includes efficiency gains through preheated combustion air and reduced pressure loss (16 percent) and through load-dependent operation (8 percent).

Mercedes-Benz applies a primerless top coat to its vehicle bodies. Eliminating the solventbased primer means greater eco-friendliness and lower operating costs. What’s more, Eisenmann’s application systems are a precise fit for the twolayer base coat. And for the Kecskemét paint shop, the company is providing the entire paint supply system and a top coat line, comprising six spray booths with 36 paint application and 24 handling robots.”

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

Intelligent conveyor solution for pretreatment The scope of supply for the Kecskemét paint shop includes a pretreatment and electrocoating line featuring the E-Shuttle 200 conveyor (Fig. 5). The VarioLocs transfer the car bodies to the individual shuttles, and these then move them through the electrodeposition (ED) tank. A variety of car models can be processed on a single line. An intelligent shuttle control unit, connected via bus with the PLC, enables each shuttle to respond autonomously to changes in the process. In addition, it is possible to capture and store data on the exact position of each vehicle body at any time. This ensures complete

Eisenmann’s modular E-Cube solution removes paint overspray mechanically, and is sustainable and energy-efficient. It offers diverse advantages over conventional wet scrubbers. E-Cube saves energy, and does not require water, chemicals or other additives. It boasts an exceptionally high removal rate, and is user-friendly.”

Figure 5: The VarioLocs transfer the car bodies to the individual shuttles of the E-Shuttle 200 system, and these then move them through the electrodeposition tank.

SUCCESS STORIES

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We create chemistry that makes lines love curves. Coatings give a car more than just long-lasting protection. Brilliant gloss and innovative colors transform contours into dynamics and design into emotion. Lines and curves are united and edges and contours are brought to life. When color and shape come together, and paint evokes passion, it’s because at BASF, we create chemistry. www.basf-coatings.com international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

visibility, and can be used for subsequent analysis to improve production and

SUCCESS STORIES

In addition, Eisenmann’s modular E-Cube solution removes paint overspray

increase flexibility. The

mechanically, and is

result is better paint quality

sustainable and

and a higher first-run rate.

energy-efficient (Fig. 7).

As Jörg Robbin points out,

It offers diverse

“Bearing in mind the trend

advantages over

toward mass customization

conventional wet

in the automotive industry,

scrubbers. E-Cube saves

E-Shuttle 200 is a smart

energy, and does not

investment. The system’s

require water, chemicals

intelligent control unit

or other additives.

enables easy, seamless

It boasts an exceptionally

integration into connected

high removal rate,

manufacturing environments. And that underscores E-Shuttle 200’s future-proof design and suitability for the smart factory.”

and is user-friendly.

6 1

The filtration modules

Figure 6: Eisenmann is providing application systems, which are a precise fit for the primerless top coating process.

Paint application and overspray removal Mercedes-Benz applies a primerless top coat to its vehicle bodies. Eliminating the solventbased primer means greater ecofriendliness and lower operating costs. What’s more, Eisenmann’s application systems are a precise

(cubes) are controlled and monitored via a touch panel, and can be replaced while the spray booth is in operation.

The skidless paint shop for the Kecskemét plant highlights Eisenmann’s role as a Paint Shop 4.0 pioneer. The enterprise has combined multiple state-of-the-art technologies to enable flexible, sustainable and energy-efficient car production – independent of chassis or engine type, and capable of being modified in line with changing demand.”

Furthermore, disposal of the solid matter trapped in the filters is convenient and simple. Outstanding flexibility in automotive paint shops The skidless paint shop for the Kecskemét plant highlights Eisenmann’s role as a Paint Shop 4.0 pioneer.

And for the Kecskemét paint

The enterprise has combined

fit for the two-layer base coat. shop, the company is providing the entire paint supply system

multiple state-of-the-art technologies to enable flexible,

and a top coat line, comprising

sustainable and energy-efficient

six spray booths with 36 paint

car production – independent

application and 24 handling

of chassis or engine type, and

robots (Fig. 6). The latter open

capable of being modified in

the car doors and hoods, allowing

line with changing demand.

automated application of paint

The solution will be

to the interior. VarioBell v.2

pre-assembled in Holzgerlingen

high-speed rotary atomizers

by the end of the year, then

and the VarioCharger v.2 paint

transported to Kecskemét and

metering system minimize paint loss. Eisenmann is also supplying application equipment for sealing and damping materials.

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Figure 7: Eisenmann’s modular E-Cube solution removes paint overspray mechanically, and is sustainable and energy-eﬃcient.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

installed. The first chassis are expected to roll off the line by the early 2020s.

we keep an eye on your AUTOMATION needs.

vertical & horizontal axis reciprocators | color centers dimensional detection systems | control panels | accessories

www.reind.it

Opening photo: UV Ray’s UV curing systems are distinguished by the low amount of energy needed during the work cycle, resulting in lower consumption and greater safety for the environment.

HIGHLIGHT OF THE MONTH

UV curing systems: A Low-Consumption and Sustainable Technology for High Production Rates Stefano Maiano UV Ray, Cornaredo (MI) – Italy

s.maiano@uvray.it

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

2014 UV Ray has been active also in the

iven the growing demand from several industries for efficient but sustainable solutions, UV Ray’s

UV curing systems are currently one of the most innovative and concrete responses for the spray painting, printing, and coating markets. Compared with conventional systems, the UV Ray products are distinguished by the low amount of energy needed during the work cycle, resulting in lower consumption and greater safety for the environment (ref. Opening photo).

UV Ray has designed and manufactured UV curing systems for over twenty years. Based in Cornaredo (Milan), the company, established by Alberto Maiano and now managed by him and his son Stefano, has numerous distributors worldwide: in Europe, in the Americas, in South Africa, in China, and in India. Mainly specialising in the printing and coating sectors, since

UV Ray has designed and manufactured UV curing systems systems for over twenty years. Based in Cornaredo (Milan), the company, established by Alberto Maiano and now managed by him and his son Stefano, has numerous distributors worldwide: in Europe, in the Americas, in South Africa, in China, and in India. Mainly specialising in the printing and coating sectors, since 2014 UV Ray has been active also in the painting industry, now accounting for 20% of its core business. In particular, the firm is present in the plastic, metal, and wood painting field for different industries, especially automotive and cosmetics.”

painting industry, now accounting for 20% of its core business. In particular, the firm is present in the plastic, metal, and wood painting field for different industries, especially automotive and cosmetics (Figs. 1 and 2). UV Ray’s systems are patented for the curing of liquid paints and they stand out for their high curing efficiency, as well as significant energy savings for the hot air renewal in the chamber. With their lean but solid mechanical design, UV Ray’s products are particularly convenient with high volume productions, as they can operate without interruptions at high rates, and they show greater reliability in the long term. Thanks to the low operating temperatures required, the work environment is easily accessible, thus simplifying any maintenance and repair operations.

The next generation of powder coating! A revolutionary solution for your coating requirements.

IPS coating center • Color change at the push of a button • Maximum coating quality • High-performance & fully automated system

go.wagner-group.com/ips

Figures 1 and 2: Spray painting of packages for cosmetics with UV Ray’s Magnum long-arc UV reflector.

The units can be isolated to solve any problems without having to stop the entire line. Thanks to innovative design and engineering, also the cost of spare parts is lower. All UV Ray systems feature an interface and UV sensors in the booth to monitor the production process remotely and safely.

All UV Ray systems feature an interface and UV sensors in the booth to monitor the production process remotely and safely. They also integrate a UV reflector in borosilicate with a multilayer treatment, which ensures greater reflection of ultraviolet rays on the substrate thus preventing the infrared rays from reflecting on it.”

2 1

They also integrate a UV reflector in

life precisely thanks to the low operative

borosilicate with a multilayer treatment,

temperature needed.

which ensures greater reflection of

UV Ray’s next projects will focus on the

ultraviolet rays on the substrate thus

development and manufacture of a

preventing the infrared rays from reflecting

system for the treatment of extruded

on it. This results in low temperature

metal pipes and on cooperation with

printed materials, very high efficiency, and

various paint manufacturers to patent a

therefore savings in the cooling process of

system suitable for the powder coatings

the lamp, which in turn has a longer service

curing.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

P O W E R F U L

I N

V E R T I C A L

T L E S S

I N

H O R I Z O N T A L

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

I T A LY

B A R C E L O N A S A N T A

S P A I N

C A T A R I N A

F L O R I D A

U S A

B R A Z I L

Opening photo: Cavalca liquid and powder coats workpieces with any weight and size.

FOCUS ON TECHNOLOGY

The Single-Stage Cold Pre-Treatment Technology Improves Production Efficiency and Environmental Sustainability Monica Fumagalli ipcm®

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

n any Italian industrial sector, it is not

industrial coating, proving that our operations

uncommon to meet small or medium-sized

are fully eco-friendly. The “secret” is to invest in

companies that manage their production

proven processes in terms of economic savings

Experience, flexibility, and delivery speed: Cavalca Verniciature’s cornerstones

activities by making eco-sustainable choices for

and lower energy consumption. For example,

As well as its forty-year experience in coating

ethical reasons, despite the limited resources

when we decided to automate our powder

transport vehicles, Cavalca Verniciature’s

for updating their plants and

strengths include a

although the sporadic careful

manufacturing flexibility

and effective environmental

Cavalca Verniciature has opted for Chemtec Toran 3® for the preliminary treatment to the application of powders. In order to speed up the production phases, especially the cleaning ones. Certain types of workpieces, especially the large-sized and complex-shaped ones, required long cleaning times and complicated handling operations, resulting in higher production costs. Chemtec has solved these two problems while making the cleaning of the most complex parts in a uniform and optimal, but also eco-friendly way.”

controls by the responsible bodies may be an incentive to act oppositely. At the centre of the Emilia Romagna region, in Bagnolo in Piano (Reggio Emilia - Italy), we have met a company that has turned its environmental strategy into a winning strategy: Cavalca Verniciature, Carrozzeria Cavalca, established

every type of workpiece, with any size and weight, with a fast and efficient service guaranteed by its speed in terms of both production and delivery. “Our main target market is the local one,” says Cavalca. “The speed of production flow management and product delivery is crucial to counteract competition. That is why we are equipped

the business evolution of

level such as that it can treat

to handle both large orders

in the 1960s for the repair of

and small quantities, and

motor vehicles.

especially large-sized objects:

In 2007, the firm converted into

at the moment, we have a

a powder and liquid coating

modern powder coating plant

contractor specialising in metal

that can process components

(especially steel and aluminium)

up to 13.20 meters in length,

components mainly intended

3.20 meters in height, and

for the ACE and machine tools

3.20 meters in width. The

sectors (ref. Opening photo).

versatility of our machines also

“We mainly treat medium

enables us to better manage

and large-sized carpentry

the most urgent work, in order

components and complementary

to deliver in a very short time.”

small parts using two coating one,” says Riccardo Cavalca,

Liquid and powder coating processes

the owner of the firm with his

Surface treatments are

lines, i.e. a liquid and a powder

son Gabriele (Fig. 1). “Despite the complexity of the treated materials, we have never stopped focussing on the quality of our production processes, on the

performed on the two

coating lines through manual

Figure 1: From right to left: Chemtec owner Carlo Guidetti, Gabriele Cavalca from Cavalca Verniciature, Alessia Venturi from ipcm®, and Chemtec Product Manager Tommaso Giovenzana.

safety of our employees and

operations (Fig. 2). “As for liquid coating, we do not have an actual continuous line: we have arranged the different

of the environment in which they operate,

coating line about one year ago, we opted for

stations in both our buildings in order to

and of course on our end products’ quality.

an innovative solution: a single-stage cold pre-

make the air drying phase, performed after

We have been ISO 9001 certified for several

treatment system called Toran 3 and supplied

application with heat exchangers, more

years. Cavalca Verniciature is also one of the

by Chemtec (Corbetta, Milan), which is an effective

flexible. If necessary and at the specific

very few Italian companies with the ISO 14001

eco-friendly alternative to phosphodegreasing or

request of the customers, the parts can be

environmental certification in the field of

to phosphating followed by passivation.”

subjected to an initial sand blasting treatment

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

2 1

Figure 2: The manual application of powder coatings.

to remove oxidation and calamine residues remaining on their surfaces after machining, thus achieving a roughness degree equal to Sa 2 ½ - Sa 3 (Fig. 3). Sand blasting is generally the preliminary treatment for components requiring marine-level treatments (C5-MH): these are special workpieces intended for areas with high salinity, e.g. offshore, or regions characterised by very aggressive atmospheric phenomena. That is why the coating system includes several layers of both the base coat and the top coat, so as to apply an average paint thickness of at least 320 microns. Besides these systems, we also apply intumescent paints, high solid © ipcm ®

coatings for lower environmental impact, and polyurethane and epoxy paints.” “For our powder line, we use epoxy-polyester paint products applied in two layers, a zinc-based primer and a top coat, with an intermediate polymerisation phase (Fig. 4). Powder coating,” says Cavalca “ensures numerous advantages compared with the conventional one, including lower costs, because the process is faster, and lower disposal costs.

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Figure 3: The automatic shot blasting system.

FOCUS ON TECHNOLOGY

Toran 3® is a degreasing process suitable for any type of material, which requires only one cold phase and can be integrated on already existing cleaning lines. In the low-pressure spray application tunnel, the contact time between the chemical product and the part surface ranges from 1 to 3 minutes, depending on the contamination level and the pre-set process time.” Moreover, in terms of eco-friendliness, powders greatly reduce pollution and avoid the use of solvents. With the modern technologies implemented, we have reached high quality levels even with powder coatings in terms of both aesthetics and corrosion protection. Indeed, we have achieved extraordinary results, with workpieces showing a salt spray resistance value of over 2000 hours.” The company has opted for Chemtec Toran 3® for the preliminary treatment to the application of powders. “About one year ago, we assessed that in order to be even more competitive we had to further speed up our production phases, especially the cleaning ones,” states Cavalca. “Certain types of workpieces, especially the large-sized and complex-shaped ones, required long cleaning times and complicated handling operations, resulting in higher production costs. Chemtec has solved these two problems while making sure that we clean even the most complex parts in a

uniform and optimal, but also eco-friendly way.”

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Figure 4: A detail of the result of a powder application process.

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Figure 5: The pre-treatment tunnel with Chemtec’s Toran 3®.

Figure 6: The inside of the pre-treatment tunnel.

Toran 3®: a single-stage multi-metal process

bars. These are mounted on a compressed

“At the end of the process, after drying,”

air piston-driven cart that performs an

says Guidetti, “the parts are clean and

“Toran 3® is a degreasing process

oscillating movement inside the cleaning

coated with an organic polymer with a

suitable for any type of material, which

chamber: on the one hand, this guarantees

thickness of about 300 nm, ensuring both

requires only one cold phase and

more homogeneous and uniform cleaning

temporary protection, as the surfaces do

can be integrated on already existing

results and, on the other, it reduces the

not oxidise if left inside the tunnel, and

cleaning lines,” says Chemtec owner

volume of the plant (Fig. 8).

excellent paint adhesion. At the same

spray application tunnel, the contact time between the chemical product

Carlo Guidetti. “In the low-pressure

and the part surface ranges from 1 to 3 minutes, depending on the contamination level and the pre-set process time (Fig. 5 and 6). This is followed by a 5-minute dripping and oven drying phase. The standard drying time is 10 minutes at 130-140 °C: for Cavalca, the temperature is 180 °C, due to the particular shape and size of the workpieces.” The dripping phase is one of the most problematic: if the part has a particularly complex shape, the product risks not to drain properly, so that a manual intervention is needed (Fig. 7). The pre-treatment tunnel features tilting nebulisation

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Figure 7: An example of components with a complex shape.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

8 1

Figure 8: Workpieces entering the pre-treatment tunnel.

At the end of the process, after drying the parts are clean and coated with an organic polymer with a thickness of about 300 nm, ensuring both temporary protection, as the surfaces do not oxidise if left inside the tunnel, and excellent paint adhesion. At the same time, this polymer is able to absorb any oily contaminants, turning these pollutants into active components that do not have to be disposed of. This eliminates the rinsing phase, since the process does not require the use of water, but rather of non-hazardous and non-toxic organic fluids.” time, this polymer is able to absorb any oily

maintenance, limiting the operations to the

contaminants, turning these pollutants into

cleaning of the filter, which is sometimes

active components that do not have to be

clogged up by metal micro-particles removed

disposed of. This eliminates the rinsing phase,

in the cleaning phase. In one year, we have

since the process does not require the use of

never emptied the tank or cleaned the nozzles.

water, but rather of non-hazardous and

A further benefit is that the cleaning product

non-toxic organic fluids.”

always maintains excellent performance and

“In this way, the product has a substantially

consistent process quality levels, so that we do

unlimited service life,” says Cavalca. “We

not need to perform daily or monthly analyses:

do not need to replace the cleaning agent,

quarterly analyses, on the other hand, are

but only replenish it. This also minimises

carried out by Chemtec’s staff.”

The consistency of the chemical’s characteristics, which remain unchanged over time, ensures good powder film adhesion and result repeatability while improving the corrosion resistance of the coating system. Before implementing Toran 3®, Cavalca Verniciature performed some tests: they achieved a 700-hour salt spray resistance value with the epoxy-polyester powders that they usually employ, which is an excellent result for products intended to be exposed in very harsh environments.” 9A 1

Figure 9A: The results of the SEM analysis: a Q-Panel degreased with a solvent.

usually employ, which is an excellent result for products intended to be exposed in very

“After the implementation of Toran 3 , ®

harsh environments (Fig. 9a, 9b,

Toran 3®’s advantages

and 9c). “The last and the most important

we have found significant benefits in

advantages are the greater

several areas,” states Cavalca. “First of

healthiness of our working

all, we have achieved the goal that had

environment and the lower

led us to install a new pre-treatment

impact of our production activity

system: greater speed and ease of

on the environment. Indeed,

management of the production flow.

the product used is VOC-free

The single-stage cleaning process

and classified as non-hazardous

now ensures that we always achieve

for man and the environment according to current European

the delivery speed that is one of our strengths, enabling us to be competitive

9B 1

regulations. Moreover, there is

also and above all in terms of costs.

no waste presenting a high risk

The small footprint of the single-stage

of water contamination and our

chamber also allows us to save useful space for faster and easier handling of

Figure 9B: A Q-Panel treated with Toran 3®.

characteristics, which remain unchanged over time, ensures good powder film adhesion and result

“The consistency of the chemical’s

reduced. Chemtec’s solution has fully met all our expectations.”

larger workpieces.

The cleaning agent has a substantially unlimited service life. It is no longer necessary to replace it, but only replenish it. This also minimises maintenance, limiting the operations to the cleaning of the filter, which is sometimes clogged up by metal micro-particles removed in the cleaning phase.”

energy consumption has been

repeatability while improving the corrosion resistance of the coating system. Before implementing Toran 3®, we performed some tests: we achieved a 700-hour salt spray resistance value with the epoxy-polyester powders that we

Figure 9C: A Q-Panel treated with Toran 3® and polluted with 2% of oil: micro-drops of oil trapped in the polymer can be clearly seen.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

9C 1

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Opening photo: The Venjakob’s Technical Center.

HIGHLIGHT OF THE MONTH

The New Dimension of the Spray Painting Solutions by Venjakob From an interview with Christian Nüßer, CEO of Venjakob Maschinenbau GmbH & Co.

he evolution of a company from locksmith’s shop to international manufacturer of painting systems

specific for wood to global player in the field of surface treatments and finishes of wood, metal and plastic: this is the life’s course of Venjakob Maschinenbau, one of the German historical and still familyowned companies, which set the standards in efficient and reliable finishing technology (Fig. 1). We have interviewed Christian Nüβer (Fig. 2), the third generation of the family at the head of the company, to listen from his voice the past, present and especially the future of this global player.

ipcm®: Can you outline a short history

The evolution of a company from locksmith’s shop to international manufacturer of painting systems specific for wood to global player in the field of surface treatments and finishes of wood, metal and plastic: this is the life’s course of Venjakob Maschinenbau, one of the German historical and still family-owned companies, which set the standards in efficient and reliable finishing technology.”

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

of Venjakob since its foundation? Christian Nüßer: Venjakob was founded in 1963 by Heinrich and Anneliese Venjakob and started business as locksmith’s shop. In 1964 the small enterprise designed and manufactured its first staining machine. This machine was the entry into the market of surface technology. In 1976, when the founders’ daughter, Elisabeth and her husband Otto Nüßer joined the company, Venjakob became an internationally operating enterprise. The company expanded, submitted and registered patents and established sales representatives around the world. At the

beginning, Venjakob was focussing on the wood and furniture industry. This might be due to the location in East-Westphalia (Germany) where most of

HIGHLIGHT OF THE MONTH

With a Venjakob coating solution, you can apply various liquid media (paint, glue, sol-gel…) on various kinds of workpieces (Fig. 5). Nearly on all

the kitchen and furniture

materials and shapes.

manufacturers were

Furthermore, Venjakob

located, too.

offers the corresponding

In 1993 Venjakob entered

automation/handling

the non-wooden market.

technology to make the

Then, in 2004, the product

customers workflow as

portfolio was expanded Meckeler and renaming the manufacturer of

effective as possible.

by taking over Pflock &

ipcm®: Which are

Figure 1: The Venjakob’s headquarters.

the most important

exhaust-air purification

markets and main

plants into Venjakob Umwelttechnik GmbH & Co. KG. Another proof for Venjakobs’ international success are own sales offices in Canada, India, Spain and since 2008 the takeover of Nutro Inc. Nutro is a well-known US manufacturer for customized finishing solutions, located in Strongsville, Ohio. Over decades in cross-industrial branches, Venjakob sets standards in efficient and reliable finishing technology. Venjakob, still family owned, in third generation, takes care of its very experienced team. More than 300

target industries for the company? CN:

The company expanded, submitted and registered patents and established sales representatives around the world. At the beginning, Venjakob was focussing on the wood and furniture industry. This might be due to the location in East-Westphalia (Germany) where most of the kitchen and furniture manufacturers were located, too.”

- Wood and furniture industry; - Steel & Pipe industry; - Building components (fiber cement boards, façade panels, acoustic ceiling panels, insulating material). ipcm®: Can you describe for our readers Venjakob’s key values and vision? CN: Highest possible quality and maximum customer satisfaction - in order to achieve this goal, we rely on the well-founded © Venjakob Maschinenbau GmbH & Co. KG

employees are developing customized

- Automotive industry (interior/exterior);

solutions, offering a fast and reliable service or are making sure that Industry 4.0, IOT, Predictive Analytics and other key words for industrial automation are lived and not only empty slogans (Figs. 3 and 4).

expertise of our employees. Competent and technically specialized staff develop and implement on time individual problem solutions for our customers from the most different branches. Equally important to us is the use of natural resources, in accordance with our responsibility to present and future

ipcm : Which is Venjakob’s main focus

generations.

and core business?

The quality work of Venjakob is reflected in

CN: Spray coating technology is the core

extensive consultation talks and underpinned

business, but it is accompanied by the entire

in test series in our own technical center,

range of products, which are needed to set

completed by punctual assembly, and

up a complete finishing line.

commissioning (ref. Opening photo).

This includes cleaning devices, surface

Nevertheless, you will also receive quality

pre-treatment and activating units as well as various kinds of application technologies, drying systems also as industrial automation and exhaust air purification plants.

and competence through our extensive

2 1

stock of spare parts, our fast and

Figure 2: Christian Nüßer, CEO of Venjakob Maschinenbau GmbH & Co. KG.

experienced service staff and the qualified training for your staff.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

Spray coating technology is the core business but it is accompanied by the entire range of products, which are needed to set up a complete finishing line. This includes cleaning devices, surface pretreatment and activating units as well as various kinds of application technologies, drying systems also as industrial automation and exhaust air purification plants.”

3 1

Figure 3: The oﬃces of the headquarters in Rheda (Germany).

The basis of our common actions in our company are satisfied customers. With the

the environmental aspects in the design

developments let our customer produce

and development of environmentally

energy-efficiently, environmentally friendly

friendly machines, but also in production

and economically. In addition, the modular

and infrastructure, for the protection of the

design of our systems makes your

environment and our employees.

investment future-proof. Secure these

Numerous, partly patented product

added values.

In 1993 Venjakob entered the non-wooden market. Then, in 2004, the product portfolio was expanded by taking over Pflock & Meckeler and renaming the manufacturer of exhaust-air purification plants into Venjakob Umwelttechnik GmbH & Co. KG. ”

supply of high-quality machines, we fulfill their requirements in every aspect. The original claim of ISO 9001 to deliver consistent quality is not enough for us alone. With the help of our consistently applied, continuous improvement process (CIP), we constantly increase the quality of our products and services for the benefit of our customers. Our products and processes are constantly evolving to conserve resources and further reduce negative impacts on the environment. Venjakob not only considers

4 1

Figure 4: The Venjakob’s lab.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

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Figure 5: Application onto a glass workpiece.

ipcm®: Which is Venjakob’s best technology? Can you describe its advantages and key strengths? CN: High-performance painting in a new dimension. Based on our decades of know-how in the realization of highperformance spray painting systems, the flexibility of this new generation is impressive (Fig. 6). Here is a summary of the plant benefits and features: - Investment security through modularity; - Paint compatibility; - Systematic paint recovery; - Low production idling; - Short paint change times; - Perfect painting result; - Resource-saving, economical and ecological. The modular system offers long-term consideration of all production requirements. At the time of acquisition, the machine concept realized all variants from “lot size 1” to “high volume series” in the high-end sector.

6 1

Figure 6: VEN SPRAY VARIO oﬀers the flexibility of an industrial spray coating robot and the high output of an automatic surface spray coating machine.

Competent and technically specialized staff develop and implement on time individual problem solutions for the customers from the most different branches. Equally important is the use of natural resources, in accordance with the responsibility to present and future generations.”

With a glance to the future, Venjakob is working on self-learning machines as well as on some visualization projects (plant visualization, VR /AR). Together with well-known universities in Germany it is developing systems for descriptive, diagnostic, predictive and prescriptive analytic software.”

Several plants, operating with RFID technology

companies like Dürr, Festo or Homag, Venjakob

are successfully implemented in the market.

is involved in the further development of the

Furthermore, Venjakob is a tapio-partner.

project and the possibilities this platform offers.

Tapio is intended to help the wood industry to

With a glance to the future, Venjakob is working

evolve into the digital future itself. With tapio

on self-learning machines as well as on some

machinery manufacturers, toolmakers and

visualization projects (plant visualization, VR /

material producers use the same technology

AR). Together with well-known universities

platform. In that way, digital solutions for

in Germany we are developing systems

common customers of every size are being

for descriptive, diagnostic, predictive and

discovered. Tapio itself is neutral within this

prescriptive analytic software.

network and considers itself to be a supporter.

Right now, we are testing a new visual service

By being a partner of this platform from the

module which we are going to present at the

very beginning, among many other re-known

upcoming Ligna in May 2019.

At any time, the modular principle enables

ipcm®: Do you have any kind of

the implementation of changed framework

cooperation with foreign companies who

conditions by upgrading new modules, making your investment future-proof. ipcm : Today the keyword is Industry 4.0: ®

What is Venjakob’s strategy and approach? CN: Industry 4.0 is a living project at Venjakob for many years. With a huge team of programmers, Venjakob is able to face the future and its upcoming tasks.

Venjakob not only considers the environmental aspects in the design and development of environmentally friendly machines, but also in production and infrastructure, for the protection of the environment and employees.”

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

shares your values and technological strengths? CN: We have been developing cooperation’s globally with paint suppliers, manufactures of 2K mixing systems and painting equipment. Furthermore, we are in a very close contact with our global sales network, reflecting us their view on prospective customers’ needs and expectations.

Opening photo: Metal oﬃce furniture has long become more than mere functional products: filing cabinets, desks, lights and oﬃce chairs are increasingly becoming designer items.

INNOVATIONS: PRESENT&FUTURE

Mixed Powder Today: More Scratch-Resistant Specialist Coatings with Great Flow Properties Peter Christl IGP Pulvertechnik AG, Wil - Switzerland

peter.christl@igp-powder.com

fter the emergence and

blends of epoxy and polyester resins

colloquially also referred to as “mixed

establishment of duroplastic

would appear in the late 1960s, forming a

powder”, permitted the creation of

coating powders based on

new class of powder coatings called hybrid

powder coating formulations that would

epoxy resins at the beginning of the

powder coatings.

be more reactive and less prone to

1960s, it was not long until the first

For the first time, this coating system,

yellowing.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

These systems replace a hardener with

such as surface variety, resistance to

production of “white goods” to

a further resin component from the

mechanical and chemical influences

radiators, fences, lights, shelves, metal

polyester resin family in mixing ratios

and weather stability was well achieved

furniture and coatings for glass and

of epoxy to polyester resins from 50:50

with these polyester powders at an

ceramic flower pots.

to 30:70.

acceptable price.

This core positioning in mass markets

Reducing the usually rather yellowish

As a result of an amendment to the

with very high sales potentials

epoxy resins in the coating recipes also

labelling requirements for powder

consequently attracted a large

first enabled the creation of pure white

coatings containing TGIC, the situation

number of established and new

shades such as Signal White (RAL 9003)

changed slightly and successor products

powder coating manufacturers.

or Traffic White (RAL 9016).

with the same or at least similarly good

The competition characterised by

The Achilles’ heel of the epoxy systems,

properties could be found within a very

partly self-destructive price declines

i.e. their extremely poor resistance

short space of time.

that emerged after the saturation

to UV radiation from natural daylight,

phase both made these markets

could also be reduced by admixing

increasingly lose their attractiveness and gave hybrid powders the tainted

polyester resins. The only clear advantage of epoxy systems that remains in most cases is their higher resistance to chemicals such as acids and alkaline solutions and their barrier function for superior corrosion protection. However, the innovative class of hybrid powder coatings was soon overshadowed by another novelty, pure polyester powders, which could be interlinked with the newly developed hardener triglycidyl isocyanurate (TGIC).

After the emergence and establishment of duroplastic coating powders based on epoxy resins at the beginning of the 1960s, it was not long until the first blends of epoxy and polyester resins would appear in the late 1960s, forming a new class of powder coatings called hybrid powder coatings.”

reputation of being cheap products. Representatives of the powder coating industry could be accused of having created a pricing situation in which the large-scale production of these products serves the sole purpose of maximising the utilisation of their own production capacity and deterring competitors. From a business point of view, it seems that this field has reached the point of exhaustion, and from a technical point of view, no further

From the early 1970s onwards, such

innovative developments seem

systems enabled a breakthrough in segments such as façade applications,

Over time, hybrid powder coatings

to make sense in such a pricing

which by their very nature place high

thus positioned themselves in a very

environment.

demands on weather stability.

extensive range of applications across

But there was no reason to hide the

all areas of industrial production

Does this mean the end of “mixed

overall performance of these powder

of consumer and capital goods.

powders”? What options are there for

coatings either: the compromise

Applications extend from traditional

coating manufacturers to differentiate

between typical coating requirements

mechanical engineering and the mass

the performance of their products

For the first time, this coating system, colloquially also referred to as “mixed powder”, permitted the creation of powder coating formulations that would be more reactive and less prone to yellowing.” from the competition? What package should manufacturers offer to place hybrid powder coatings in targeted applications where their performance has not been sufficient so far or where the needs of customers and users have not been met?

The flow properties of conventional powder coatings with a smooth finish are limited, resulting in characteristic powder coating surfaces which look like “orange peel skin”. A more scratchresistant variant of such surfaces has so far usually been associated with a visible deterioration of the already limited flow.”

There are several promising approaches addressing these issues, which have already been successfully

powder coatings with a smooth finish

implemented in products.

are limited, resulting in characteristic

These include the combination of

powder coating surfaces which look

surfaces with anti-graffiti properties,

like “orange peel skin”.

for instance, which permit the easy and

A more scratch-resistant variant

nearly residue-free removal of such

of such surfaces has so far usually

acts of vandalism.

been associated with a visible

Modern hybrid powder coatings

deterioration of the already limited

also offer exceptional resistance to

flow.

chemicals. Some of them even exceed

With the new silk matt product

the performance of pure epoxy

3902 from the proven

systems.

low-temperature series 39, IGP

Another additional benefit, namely the

now provides a solution which, with

functionalisation of powder coatings as antimicrobial surfaces, is primarily aimed at the medtech and ventilation technology market, but can also be implemented in the field of municipal

Figure 1: The highly resistant surface is recommended

for the high-quality furniture industry.

its unique combination of good flow characteristics and cross-linking temperatures of 10 minutes at 160°C combined with significantly improved scratch resistance, offers

furnishing or generally in areas where

a high degree of resistance to

there is a high level of public footfall.

scratching. Scratch resistance is assessed

At the peak of current research and development is the creation of highly scratch-resistant surfaces. The combination of hard-wearing and smooth surfaces in easy-to-process powder coatings perfects the close alliance between form and function. The flow properties of conventional

Representatives of the powder coating industry could be accused of having created a pricing situation in which the large-scale production of these products serves the sole purpose of maximising the utilisation of their own production capacity and deterring competitors.”

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

by means of the “Martindale” test method. During this test, an abrasive object with a defined weight is applied to the test surface and rubbed across the surface in cycles in accordance with standard DIN CEN/TS 16611 “Furniture

INNOVATIONS: PRESENT&FUTURE

Users of metal furniture expect them to be not just beautiful but also hard-wearing, a requirement which has so far seldom been met. With the new combination of flow and resistance, this need is now optimally met from a technical point of view, while at the same time processing is more efficient due to the low cross-linking temperatures.” – Assessment of the surface resistance to microscratching”. The impact is assessed both visually and especially by measuring the residual gloss, i.e. the difference between the level of gloss measured before and after the surface has been exposed to scratching. Compared to conventional powder coatings, but also compared to many liquid coatings, 3902 performs extraordinarily well in these tests. Residual gloss values after a stress test load of up to 70% attest that this surface is highly resistant and therefore of great utility to the consumer. With such a performance profile, this surface is recommended for the high-quality furniture industry (Fig. 1). Metal office furniture has long become more than mere functional products. Filing cabinets, desks, lights and office chairs are increasingly becoming designer items reflecting the style and taste of their users and adding to their well-being (ref. Opening photo). Users expect them to be not just beautiful but also hard-wearing, a requirement which has so far seldom been met. With the new combination of flow and resistance, this need is now optimally met from a technical point of view, while at the same time processing is more efficient due to the low cross-linking temperatures. This and other developments have the potential of taking “mixed powders” out of their dusty low-cost corners and actively sending them back into the ring to fight for high-quality coating systems.

+49 89 13928723

Opening photo: Steelpaint’s new extremely flexible coating line to powder paint large workpieces.

FOCUS ON TECHNOLOGY

Steelpaint: The Industrialisation of a Nanotechnology Pre-Treatment Process for Large-Sized Workpieces Treated in a Static Coating Plant Ilaria Paolomelo ipcm®

or almost twenty years now, we have

technical characteristics and advantages in

with an equipment that constantly

been reading articles and technical

terms of surface performance and above

provides the bars with fresh product, thus

reports about the application of

all corrosion resistance. We also know their

minimising consumption and maximising

nanotechnology-based surface conversion

best application methods: they are typically

the treatment quality and uniformity levels.

products for the pre-treatment of ferrous

sprayed, but they can also be applied by

However, we always read about applications

metal prior to coating. We know all their

immersion or, even better, by nebulisation

in continuous-flow plants and automatic

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Figure 1: Products intended for the building sector and treated by Steelpaint.

Thanks to the collaboration with DN Chemicals, the recently established company combining the experience of Dollmar and NoxorSokem in the pre-treatment sector, Steelpaint has industrialised a flexible pre-treatment cycle that includes a nanotechnology conversion phase, performed in a specially equipped static cleaning booth.”

tunnels in which the workpieces are hung

of the many coating contractors working for

“Thanks to my previous work experience,

onto equally automatic conveyors.

the building industry (Fig. 1). Steelpaint still

Steelpaint could design on its own a new

Nonetheless, in the last few months, we

focusses on the construction sector, but it

extremely flexible coating line to powder

have gotten to know Steelpaint Srl, a

decided to diversify its activity by opening

paint large workpieces weighing up to 4000

contractor specialising in the treatment of

up to other industrial sectors, especially

kg (ref. Opening photo),” states Steelpaint

heavy and large-sized carpentry parts with

heavy metal carpentry.

Technical Director Alessio Di Mattia.

a static plant. Thanks to its collaboration © ipcm ®

with DN Chemicals, the recently established company combining the experience of Dollmar and NoxorSokem in the pre-treatment sector, this firm has industrialised a flexible pre-treatment cycle that includes a nanotechnology conversion phase, performed in a specially equipped static cleaning booth. In the last two years, Steelpaint has established itself in the field of industrial coating and sand blasting of materials for the building and architecture sector. Located in Castellalto (TE), in Central Italy, it is a young company with nonetheless many years of experience in the field of contracting coating and sand blasting. Indeed, it inherited the know-how of a well-known company in the Abruzzo region, closed after the period of recession that hit the construction sector in particular, but also had an impact on some

2 1

Figure 2: The manual one-rail overhead conveyor enables to handle the workpieces through the four treatment booths composing the plant.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

The pre-treatment phase “Depending on the surface contamination degree, we assess if a workpiece can be sent directly to the chemical pre-treatment station or if it must undergo a mechanical pre-treatment phase in the sand blasting booth. After sand blasting, the part undergoes the chemical pre-treatment cycle, divided into two stages: spray degreasing, performed with a pressure washer, and an innovative surface conversion process, with the nebulisation of active chemicals on the component’s surface inside the dedicated booth (Fig. 3). A few years ago, in fact, we automated this phase by installing a 500-cubic metre industrial nebulisation booth, on whose

3 1

roof we have mounted a few nebulisation

“The plant consists of four opposing

pre-treatment phase and the oxidation

treatment booths devoted to sand

process developed by Steelpaint itself,

blasting, chemical pre-treatment,

allowing to obtain a particular COR-TEN

powder application, and

effect on steel without applying any

drying/polymerisation. The parts are

powder coating,” explains DN Chemicals

handled through a manual one-rail

Sales Manager André Bernasconi.

Figure 3: The chemical pre-treatment booth.

overhead conveyor: the operator moves the load bars in each of the treatment booths, depending on the finishing cycle required (Fig. 2).” “One of the cornerstones of our corporate philosophy is precisely production flexibility. A flexible and versatile production, in fact, enables us to perfectly meet the demands of a constantly changing market and the needs of our customers,” says Di Mattia. In order to offer high quality products and increasingly innovative services, the firm has always cooperated with reliable and forward-looking partners, including DN Chemicals. “We supply Steelpaint with the products needed for the different chemical treatments to which they subject their coated structural steel. These include, in particular, the

Steelpaint now has a complex but flexible pre-treatment process that includes numerous stages: manual alkaline degreasing and spray rinse, phospho-pickling product application, second rinse, and nebulisation of the nanotechnological product that doubles the corrosion resistance of our products. The cycle ends with a drying phase in a static oven that also acts as a powder polymerisation oven.”

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

4 1

Figure 4: Nebulisation bars have been mounted on the roof of the pre-treatment booth to apply Dollcoat SA 115 after the use of DOLLACID ZN 539.

FOCUS ON TECHNOLOGY

bars that apply the Dollcoat SA 115 product after the use of DOLLACID ZN 539 (Fig. 4),” says Di Mattia. DOLLACID ZN 539 is a specific phospho-pickling product for galvanised steel, with a detergent and deoxidising power. Dollcoat SA 115, on the other hand, is a nanotechnological chemical with excellent performance levels, which has obtained several quality certifications from important national institutes. If applied on steel, it guarantees as follows: • improved passivation of metal; • better adhesion of powder coatings; • excellent pre-treatment flexibility; • excellent thermal resistance; • excellent barrier effect against water and oxygen; • no drop effect on the treated workpiece; • high salt spray resistance (over 500 hours without the use of a primer).

5 1

Figure 5: The static oven devoted to the drying and polymerisation of the powder coating.

Application Pump with SIT technology Improve your coating line's automation and achieve a more uniform finishing quality

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Industry 4.0 Ready

www.gemapowdercoating.com

It requires the operator to have special skills and be able to control the oxidation process and not to stop the chemical reaction too early or too late. Also in this case, we decided to rely on the experience of DN Chemicals,” says Alessio di Mattia. “In order to obtain a COR-TEN finish, we use acidic chemicals that are usually designed for other surface treatments, such as the pre-treatment of aluminium. In this way, we can oxidise steel thus obtaining the desired aesthetic effect, although this is a ‘non-standard’ application.”

Future projects “In order to show our commitment to high quality and perfectly meet the

6 1

needs of our customers, we intend to

Figure 6: The powders are applied with the dense phase technology through a Gema manual pump.

further expand our surface treatment range. The expansion of our paintshop is certainly among our future projects. In order to be even more competitive, we are planning to install a new liquid

“We now have a complex but flexible pre-treatment process that includes numerous stages: manual alkaline degreasing and spray

coating line. Finally, a few months ago, we started using Plascoat thermoplastic powder coatings, guaranteeing excellent results in terms of both quality, as they ensure greater paint yield, and resistance.”

In order to obtain a COR-TEN finish, Steelpaint uses acidic chemicals that are usually designed for other surface treatments, such as the pre-treatment of aluminium. In this way, they can oxidise steel thus obtaining the desired aesthetic effect, although this is a ‘non-standard’ application.”

rinse, phospho-pickling product application, second rinse, and nebulisation of the nanotechnological product that doubles the corrosion resistance of our products. The cycle ends with a drying phase in a static oven that also acts as a powder polymerisation oven (Fig. 5),” says Di Mattia. After pre-treatment, the components enter the static booth devoted to coating. The powder coating products, supplied almost entirely by Europolveri, are applied with the dense phase technology through a Gema manual pump (Fig. 6).

A chemical treatment producing a COR-TEN eﬀect: a Steelpaint specialty “We have recently added the COR-TEN effect (Fig. 7) to the range of surface treatments that we offer to our clients. Creating the oxidised appearance typical of weathering steel without applying powder coatings but rather through a chemical reaction is not easy.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

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Figure 7: The COR-TEN finish created by Steelpaint using DN Chemicals products.

WASHING

COATING

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

GRT Superior Series

RT srl (Modena, Italy) is a company

recovered powder. It is equipped with

weighing system to monitor and store

specialising in the design,

an integrated sieving system in its base,

powder consumption data. In fact, a load

production, and installation of

easily opened to facilitate cleaning

cell positioned directly beneath the powder

automatic booths and powder coating

and inspection. The new GRT powder

pack enables to control and register the

systems. In a market where it is difficult

management system called “Tidy Center”

powder consumption data for each batch.

to emerge, GRT focuses exclusively

is the ideal solution to perform quick

By connecting the GRT powder management

on the high quality and reliability of its

colour change operations without any

unit to its company network, a customer

products. All the components of its plants

coating leakage. Indeed, thanks to the

can monitor this figure along with various

are produced with the use of the most

dense phase transfer pumps, the paints

other processing data, such as the conveyor

modern equipment and following strict

are automatically, directly sent from their

operating and idle times, the amount and

quality and safety procedures, and they

pack to the airtight container both at

time of colour change operations, and so

are guaranteed and certified according

the beginning and during the coating,

on. All these data are directly sent to the

to the EC Directive and ATEX Directive

thus creating an optimal mix of fresh

company management system, helping to

2014/34/EU.

and recovered powder. A second dense

keep the costs of each coated batch under

The Superior series booth, installed by

phase pump handles the recovery and

control.

several leading companies in the field of

transport of the used powder directly

powder coating, is completely automatic

from the cyclone to the work container.

For further information:

and it represents GRT’s top of the range

Finally, the plant is equipped with a

www.grtsrl.com

required to guarantee compliance with ATEX regulations for fire safety and

system. It is equipped with all the devices

prevention (Fig. 1). The new booth installed by Eredi Piana di Piana Carlo & C. (Martinengo, Bergamo) belongs to the Superior series and it includes all the devices required for compliance with the ATEX regulations for fire safety and prevention. Built completely in PVC and with a capacity of 20,000 m³, it is made according to the most modern and advanced standards and it is completely automatic. The automation system includes two reciprocators with motorised bases and three guns each, as well as optical bars for shape recognition that automatically control the positioning of axes and the switching on and off of guns as the workpieces passes through. The GRT Superior series cyclone with a dense phase recovery pump guarantees high recovery efficiency and it is equipped with a recirculation system for the

100

Figure 1: The Superior series booth by GRT is completely automatic and equipped with all the devices required to guarantee compliance with ATEX regulations for fire safety and prevention.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

BRAND-NEW

The New Kawasaki 2019 Ninja H2 Will Feature a “Self-healing Paint”

PAINTING ROBOTS & SYSTEM INTEGRATOR We are able to provide the full range of articulated and cartesian robots for every painting need! LeBot MV A5-A6: 5 and 6 axis articulated robot with self-learning, point to point and 3D offline programming, also available in chariot, carriage and carousel configuration with 3D Lesta shape acquisition system.

awasaki’s new highly durable paint features a special coat that allows scratches to repair themselves, enabling the paint to maintain its high-quality finish.

Kawasaki is the first motorcycle manufacturer offering self-healing paint from the factory. The company hasn’t revealed how its proprietary system works but has stated on its website:b“Soft and hard segments in the coat work together like a chemical spring, creating a trampoline effect that absorbs impacts”.

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

Even though it’ll be a few years before we know how Kawasaki’s formulation holds up, the motorcycle manufacturer already pointed out some limitations of this self-healing paint. “In some cases, it takes about one week for recovery. The paint will not recover in the case of scratches caused by a coin or key, or zip fasteners”, stated Kawasaki. For further information:

www.kawasaki.com

LeBot IA6: articulated 6-axis industrial robots with jointed-arm kinematics for all point-to-point and continuous-path tasks, controlled by our LeCRob K-Manager software. LeBot IA6 robots can work with 3D Lesta shape system. aacquisition ac qu tem.

WWW.LESTA.IT

Figure 1: The new Kawasaki Ninja H2 features a special coat that allows scratches to repair themselves, enabling the paint to maintain its high-quality finish.

LESTA S.r.l.

Via D. Chiesa, 42 - 20020 Dairago (MI) - Italy +39 0331.430817 +39 0331.1581053 0331.158 info@lesta.it

102

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

In the Portuguese Bike Valley, a Cutting-Edge Coating Plant Brings Automotive Technology and Quality to the Service of the Bicycle Industry Barbara Pennati ipcm®

ikes are one of the most widespread

that has brought together different firms

For its cutting-edge project, it chose

means of transport in the world. Their

specialising in the production of cycles and

Solintellysys (Águeda, Portugal), specialising

history dates back to three centuries

motorcycles for over ninety years. This is in fact

in the design and production of surface

ago: people have been using them for their

a joint venture among three bicycle component

treatment and coating plants (Fig. 1), as its

daily activities since 1818, when the first 13

manufacturers: Rodi, Miranda, and Ciclo-Fapril.

technological partner. © ipcm ®

kilometres were travelled by the world of sport and

Extreme process flexibility

by many movies and now a

The production area

part of the national identity

of Triangle’s covers

of several countries,

about 20,000 m²,

bikes are a symbol of

where fully automated

freedom, simplicity, and

hydroforming,

slow rhythms, as well as

robotic welding, heat

the response adopted by

treatment, superficial

many nations to address

preparation, coating,

on two wheels. Celebrated

environmental issues. Artisanship has been central to the long and peculiar history of this means of transport, but

and decal processes

are performed on

Figure 1: A bird’s eye view of the paint application station of the brand new system installed by Solintellysys.

nonetheless it has gone

aluminium frames for high-end bicycles. For this project, Solintellysys designed

hand in hand with the technological evolution

a complete surface treatment line, including

that has always distinguished it. Triangle’s –

the T6 heat treatment furnaces – this is a

Cycling Equipments SA has embraced these values by combining tradition and innovation: indeed, it has recently inaugurated the first completely automated system in the world for the production of aluminium bicycle frames (ref. Opening photo). The company was established in 2015 in Águeda (Portugal), in the renowned Bike Valley – an industrial area

Triangle’s – Cycling Equipments SA has recently inaugurated the first completely automated system in the world for the production of aluminium bicycle frames by combining tradition and innovation.”

fundamental phase in the frame hardening process, i.e. the last production phase before surface preparation prior to finishing (Fig. 2). One of the most technologically advanced aspects of the project was the integration of all the coating and decoration phases into a clean room, which allows to completely insulate the process from

Opening photo: Cycling Equipments SA produces aluminium frames for high-end bicycles.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

103

Solintellysys designed a complete surface treatment line, including the T6 heat treatment furnaces – this is a fundamental phase in the frame hardening process, i.e. the last production phase before surface preparation prior to finishing.”

This layout gives Triangle’s full production flexibility. In fact, not all workpieces undergo the same

2 1

production process: some frames

Figure 2: The furnaces for the heat treatment of frames before the finishing phase.

are subjects to (mechanical or chemical) pre-treatment and then they are stored; others immediately

any external contamination and thus

into two zones: the chemical pre-treatment

reach the coating department,”

station and the clean room where coating is

explains Solintellysys Ibérica Sales

performed. Each surface treatment station

Manager Luís Rodrigues (Fig. 4).

plant that was arranged in two buildings:

is linked to a separate one-rail conveyor – 4

After hydroforming and welding, all the

some machines were installed in the

circuits in total, designed and installed by

frames undergo a T6 heat treatment,

robotic welding department, the others in

Futura Convogliatori Aerei (Robecco Pavese,

which takes place in 4 furnaces that

the actual paintshop. This, in turn, is divided

Italy).

can be activated as needed, to increase

guarantee premium-quality coatings (Fig. 3). “We supplied a very complex treatment

3 1

Figure 3: Chemical pre-treatment, coating, and final decoration are performed in an insulated, air-conditioned, fully dust-free area.

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FOCUS ON TECHNOLOGY

One of the most technologically advanced aspects of the project was the integration of all the coating and decoration phases into a clean room, which allows to completely insulate the process from any external contamination and thus guarantee premium-quality coatings.” © ipcm ®

AUTOMATIC POWDER COATING BOOTHS

4 1

Figure 4: From left to right: Sara Candeias (Solintellysys), Alessia Venturi (ipcm), Luís Rodrigues (Solintellysys), Luis Pedro (Ibérica Sales Manager at Triangle’s), and Catarina Pinheiro (Solintellysys).

their hardness and resistance. Then they may be subjected to mechanical deoxidation through a shotblasting process using stainless steel abrasive (Fig. 5) or they may directly reach the multi-metal chemical pre-treatment station, ensuring a salt spray resistance value of 1,200 hours. Each of the two process is linked to a dedicated one-rail conveyor. The loading and unloading stations of the pre-treatment tunnel are located in the welding

This layout gives Triangle’s full production flexibility. In fact, not all workpieces undergo the same production process: some frames are subjects to (mechanical or chemical) pre-treatment and then they are stored; others immediately reach the coating department.”

department (Fig. 6), whereas the actual tunnel constitutes the first operational area of the paintshop (Fig. 7). Chemetall provides the pre-treatment chemicals. The cycle includes 6 stages as follows:

G RT

5 1

6 1

Figure 5: The shotblasting plant.

Figure 6: The loading station.

Tailor-made, advanced technology

“In order to ensure optimal air

cleaning with demineralised water, acid conversion, and cleaning with

At the end of the chemical pre-treatment

contamination, the paintshop was

demineralised water. “The tunnel is

process, the bicycle frames can proceed

created inside a pressurised clean

equipped with automatic controls

on the same circuit and return to the

room with controlled humidity and

that enable to monitor the process

welding department to be stored or they

temperature,” states Rodrigues. “The

steps and tank levels. The different

can be unloaded, arranged on special

coating process includes the wet-on-

pre-treatment stages are activated

trolleys, and enter the clean room to be

wet application of a primer, a base coat,

progressively, as the workpiece

coated and decorated (Fig. 8).

and a clear coat, with a 15-minute flash-

2 rinses, cleaning with mains water,

quality and total absence of external

passes. This ensures optimal energy on the specifications, the products undergo a mechanical or chemical

savings,” says Rodrigues. Depending

pre-treatment process, or both.

The coating process includes the wet-on-wet application of a primer, a base coat, and a clear coat, with a 15-minute flashoff between each stage. All the coating stages are robotised and they are each performed in a dedicated booth. Only the base coat booth is equipped with a manual post-retouching station.”

7 1

Figure 7: The pre-treatment tunnel in the dust-free area.

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off between each stage. All the coating

FOCUS ON TECHNOLOGY

used in the automotive sector,

stages are robotised and they are each

in order to guarantee superior

performed in a dedicated booth.

quality. This is an evolution of the

Only the base coat booth is equipped

ready2_spray robot, developed by

with a manual post-retouching station

KUKA and Dürr’s joint venture (Fig.

(Fig. 9).”

12), ideal for industrial applications

“The coating and curing station is linked

where a very high coating quality is

to the third one-rail conveyor. Each

required,” explains Luís Rodrigues.

booth has its own coating management

“Actually, the standard dimensions

unit. A neutral area among the three

of ready2_spray were not suited

booths avoids paint contamination

to the requirements of Triangle’s,

as the component passes from one

which needed a larger robot.

application station to another, thanks

Therefore, Solintellysys developed

to the air pressurisation differential,”

the communication protocol that

says Rodrigues (Fig. 10).

enabled to integrate a bigger KUKA

The coating application is completely

robot with the EcoBell 2 atomiser

automated with the use of KUKA

(Fig. 13).”

robots equipped with Dürr EcoBell 2 atomisers (Fig. 11). “For this project, we opted for a technology and an application process that are usually

“After coating, the frames enter a

8 1

special curing oven with 2 plenum

Figure 8: Frames placed on trolleys, ready to be coated.

chambers for the insufflation of air from below and a top suction system.

FISMET SERVICE S.r.l.

This system helps to maintain

without sacrificing production

a uniform temperature, and

versatility.

therefore a consistent curing

“Aluminium welding could seem a

quality level,” says Rodrigues (Fig.

simple process, but several pitfalls

14). The last phase of the surface

may actually affect its final result.

finishing process is the manual

One of the most critical aspects

application of decorative decals:

is the need to perfectly weld the

this is done again in the clean

various components of a frame: if

room, with the frames hung on a

this is not done perfectly, there is

special conveyor (Fig. 15).

a high risk that the frame collapses due to the infiltration of corrosion.

A combination of technological progress and territorial development

Triangle’s has managed to master this skill and it is now among the leading experts in the field”, explains Luís Rodrigues. “It was

The project of Triangle’s to

therefore necessary to develop an

automate its production of

automatic process that guaranteed

bicycle aluminium frames fits into

the same care and attention to

the context of Portugal 2020, a cooperation agreement between Portugal and the European Commission for the granting

detail of a craft process. This is

9 1

also one of the reasons why the

Figure 9: The manual retouching station.

human factor remains crucial even in automated processes: it

of funds to promote economic,

guarantees more accurate controls

social, and territorial development.

and higher final quality.”

Started in June 2015 and ended in May 2017, this futuristic project required a total investment of more than 14 million Euros. The goal was to fully automate a mostly manual process and to reach a quality level equal to

“Solintellysys’ expertise is highly varied and stems from our direct experiences in the most diverse industrial sectors. Thanks to the knowledge acquired, we have been able to develop together with Triangle’s a system that enabled the company to achieve

that of the automotive industry,

For this project, Triangle’s opted for a technology and an application process that are usually used in the automotive sector, in order to guarantee superior quality. This is an evolution of the ready2_spray robot, developed by KUKA and Dürr’s joint venture.”

11 1

10 1

Figure 10: One of the coating management units.

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Figure 11: The base coat application booth with two KUKA robots.

FOCUS ON TECHNOLOGY

FATI

srl

CATENE PER TRASPORTATORI CUSCINETTI A SFERA

CATENE AD ALTE PRESTAZIONI HIGH PERFORMANCE CHAINS LEISTUNGSFÄHIGE KETTEN

NOVITÀ NEW NEUHEIT

HPCOAT

12 1

Figure 12: All the automatic booths are equipped with KUKA robots and Dürr atomisers.

con | with | mit HPCOAT

13 1

Figure 13: Dürr EcoBell 2 atomiser.

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

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

FATI srl

LESS

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

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

The layout of the plant was also developed to ensure energy efficiency and maximum flexibility: with a simple control panel, the operators can define the route of each frame and the process phases to be activated based on customer specifications and needs.”

14 1

Figure 14: The interior of the curing oven.

each frame and the process phases to be

exporters of bikes, confirming the role

levels. The layout of the plant was also

activated based on customer specifications

of Portugal as a centre of technological

developed to ensure energy efficiency and

and needs,” says Rodrigues. These factors

excellence in the sector, as well as

maximum flexibility: with a simple control

have contributed to make Triangle’s and its

the third bicycle producing country in

panel, the operators can define the route of

partners some of the major producers and

Europe.

optimal quality as well as customisation

Aluminium welding could seem a simple process, but several pitfalls may actually affect its final result. One of the most critical aspects is the need to perfectly weld the various components of a frame: if this is not done perfectly, there is a high risk that the frame collapses due to the infiltration of corrosion. Triangle’s has managed to master this skill and it is now among the leading experts in the field.”

110

15 1

Figure 15: Also the final decoration of the frames is carried out in the clean room.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

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% Âą 1%, at environment temperature of 20 Â°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

Â© HangOn

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INNOVATIONS: PRESENT&FUTURE

Times and Methods in Production Processes Adriano Antonelli Ibix Srl, Santa Maria in Fabriago (Ravenna) – Italy

adriano.antonelli@tecnosupply.com

that is recognisable and appreciated

fter several consecutive quarters with GDP steadily growing in the Eurozone and in Italy, in the

last few months the market has become stagnant again. There were many factors: American duties, which curb direct and indirect exports to the US; the Brexit deal, whose conditions and the economic effects have not been clarified, yet; widespread political instability; and the global economic slowdown. Unfortunately, some economic policies, such as US duties, severely penalise the countries with a vocation for export, Italy included. Once

Unfortunately, some economic policies, such as US duties, severely penalise the countries with a vocation for export, Italy included. Once again, therefore, innovative strategies are needed to be competitive and it is necessary to create new opportunities to expand and spread one’s own products.”

again, therefore, innovative strategies are it is necessary to create new opportunities to expand and

fair, the important event dedicated to agricultural machinery, was an important showcase. Its international level always ensures an exposure degree that can help boost the sales of the exhibiting companies. For the visitors of this trade fair, one of the first factors assessed by coating professionals is the attention paid to each component of machines. Their technological level is indeed enhanced by their design, and shapes and finishes are comparable to those of luxury car bodies. In this article, we will deal with why the quality level of surface

needed to be competitive and

internationally. That is why the EIMA trade

treatment, performed not only for aesthetic but

spread one’s own products. A

above all for corrosion

sound national economic system

resistance reasons, must

and, above all, the possibility

necessarily match with

to network thus become the

the effectiveness of the

minimum and necessary

industrial coating process.

prerequisites for penetrating

Let us now focus on the

distant and complex markets.

protection of parts that do

At the same time, an increase in

not need to be painted.

shares in international markets

This is an important

is the key to increasing domestic

operation, in order not to

demand, which remains weak.

jeopardise the efficiency

In Italy, some industries have

of subsequent processes,

reached excellence levels

such as assembly – an

recognised all over the world.

assembly line cannot be

In these sectors, technology, design, and mechanics merge to create a product

Figure 1: Masks for blind holes.

stopped because of a pin that does not screw in easily. Workpieces must

Opening photo: Many ready-to-use products from the Hang-On range have guaranteed the achievement of production goals in terms of time and methods, of management of the masking devices before and after use, and therefore of results.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

113

The possibility of visually distinguishing and selecting them is therefore of the essence. Another important aspect is pre-treatment, because some masks must be applied before this phase. In the case of sand blasting or shot blasting processes, they must be scratch resistant and able to prevent the media to enter the holes and cavities of the treated product; if this happens, these particles become a non-conformity for the coated workpiece. Other times, such as with phosphodegreasing, masks must be waterproof: otherwise, functional parts of the machine could be damaged. Finally, many components in this sector are treated with a cataphoresis process to guarantee corrosion protection: in this case, the use of watertight masks is essential. Many ready-to-use products from the Hang-On range have guaranteed the achievement of production goals in terms of time

and methods, of management of the masking devices before and

2 1

Figure 2: The GAP caps protect pins up to 50 mm and with variable lengths.

therefore exit the coating department in optimal conditions. For this to be possible, they must be carefully protected everywhere needed. For this purpose, masking speed, “infiltration” prevention, ease in the protection insertion, and the possibility to remove the component and recover the device for later use are key factors. Sometimes, one component may require the insertion of 50-60 masking devices, some of which are similar to each other.

Workpieces must therefore exit the coating department in optimal conditions. For this to be possible, they must be carefully protected everywhere needed. For this purpose, masking speed, “infiltration” prevention, ease in the protection insertion, and the possibility to remove the component and recover the device for later use are key factors.”

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3 1

Figure 3: Magnetic silicone has the power to attach itself to ferrous material.

INNOVATIONS: PRESENT&FUTURE

Paint stripping Many ready-to-use products from the Hang-On range have guaranteed the achievement of production goals in terms of time and methods, of management of the masking devices before and after use, and therefore of results.” after use, and therefore of results (ref.

mask without air resistance. The GAQ caps,

Opening photo). The silicone range is

thanks to their particular configuration,

certainly among these high performance

significantly reduce the time required for this

products. The masks are coloured, and the

operation.

shade is guaranteed for each lot. The M4

In general, HangOn (distributed by Ibix) can

size of each configuration is white, so that

produce specially moulded products for any

the operator can recognise it easily and

out-of-standard request. By taking problems,

quickly. Colours can however be changed

tolerances, frictions, treatment processes,

and customised, in order to match a specific

etc. into consideration, it can design and

product with a given tint. Here below, you

manufacture products for any special need.

will find a few examples of these devices.

However, in the field of agricultural and earth

The GDM caps allow a through hole to be

moving machinery, components present many

sealed hermetically: the cylinder terminal

areas to be masked that have completely

part perfectly matches the countersunk

different characteristics, so that each type

shape of nuts. Currently, GDM caps up to

of mask is required in very small amounts.

83 mm are available. These caps are hollow

Producing a mould for each of them would

to allow easier insertion.

be excessively expensive. A quicker and

The QB caps are screwed caps for blind

more flexible solution that does not request

holes, i.e. parts where depth is minimal

minimum quantities are assembled masks.

and where it is necessary to close the hole

These also enable to mix different material,

hermetically and guarantee the mask stays

thus creating masks that are firm on the

still even during the movement of the

outside and soft on the inside. The materials

component (Fig. 1).

that can be employed are as follows:

With bushings and large through holes, good

• solid silicone, 1 to 6 mm. Solid silicone has

results have been obtained with expanded

the same characteristics as the silicone (caps

silicone. The SP expanded silicone tube,

and tops) used in coating plants. These

which can be cut to size, expands into the

sheets can be die-cut to size. They can be

hole creating a mask that prevents any

glued on top of one another to increase

shading and build up effects. The maximum

thickness. Extraction handles can be applied.

diameter is 60 mm.

The material can be cleaned like a conical

Again with large holes, the GBH cap masks

cap.

holes up to 110 mm.

… and always close to you

Worldwide leading and innovative technologies

guarantee the best solutions for our customers around the globe. PaintExpo 17. - 20. April 2018 Halle 2, Stand 2512

• Expanded silicone, 2 to 20 mm. The

With large-sized through holes, the

material looks like a sponge. It has a silicone

cylindrical GDM H caps are suitable for

nature, and therefore it is resistant to high

lengths up to 83 mm. They enable to mask

temperatures and it can be cleaned. Its

the components appropriately and above all

softness allows to insert the cap easily and

to protect the holes during sand blasting.

ensures efficient grip. If needed, it can be

As regards pins, we offer a few out-of- standard

glued to solid silicone.

caps, such as the GAP and GAQ ones,

worldwide

• EPDM, 1 to 6 mm. This material is hard and

protecting pins up to 50 mm and with variable

resistant to the abrasion of mechanical

lengths (Fig. 2). The GAP caps feature a

pre-treatments. It is resistant to a maximum

ventilation valve to insert and remove the

temperature of 170 °C.

• Magnetic silicone, 1 to 2 mm. It has a magnetic

technical departments designs some

power that allows it to

alternatives and

attach to ferrous materials

then prototypes are

(Fig. 3). This prevents

provided to check

continuous disposal of tape.

protection coverage

It is resistant to a maximum

and efficiency.

temperature of 250 °C,

Properly arranging

it can be easily cleaned,

a mask ensures that

and it can be glued to the

there are no errors

materials mentioned above.

and exposed parts.

• MDF. Compared with the

The cost of the initial

other materials, this has

investment, obviously

a few limitations. It can

higher than that of

be inserted before the

polyester tape for

chemical pre-treatment

powders or crepe

phase, but not the

paper for liquids, is

mechanical one, because it

entirely amortised, also

impregnates with water. It

considering the ease of

is less flexible and therefore

removal at the end of

more difficult to clean.

the process.

However, it is cheaper and it

This also minimises any

is resistant up to 200 °C,

potential interpretation

and therefore it can

errors by the operator,

also be used for powder

who may mask some

applications.

wrong areas.

• Cork, 2 to 25 mm. Compressed cork is an

The flexibility of

economic material designed

these masks lies

for liquid applications

above all in quantity.

(Fig. 4). It is resistant up to 150 °C and it can be glued to other materials. In this type of masks, magnets can be added to improve

Without minimum

4 1

quantities, HangOn/

Figure 4: Compressed cork is an economic material designed for liquid applications. It is resistant up to 150 °C and it can be glued to other materials.

Tecno Supply can produce exactly the number of items you need. Should

stability and grip. It is also starting from the workpiece to be

your technical department change some

protected, the acceptable tolerance

workpiece dimensions, a new mask

The wide range of materials and possibilities

rates, the hanging method, the required

could be produced, since there are no

offered enables to always obtain the

masking easiness, the classification

fixed costs. Even in the event of damage

right mask depending on the times and

method, the durability required, the

or wear of some items, they could be

production methods. Masks are designed

budget, etc. The HangOn/Tecno Supply

replaced without any additional cost.

possible to add caps for better grip.

In the field of agricultural and earth moving machinery, components present many areas to be masked that have completely different characteristics, so that each type of mask is required in very small amounts. Producing a mould for each of them would be excessively expensive. A quicker and more flexible solution that does not request minimum quantities are assembled masks.

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SUCCESS STORIES

Dürr Builds a Highly Automated Paint Shop with Integrated IIoT Solutions for VinFast

tart-ups from outside the automotive

achieve this ambitious investment objective

costs, not least since it only needs two

sector are entering the automotive

in the area of the paint shop, VinFast

levels and no so-called penthouse. The

market more and more frequently.

commissioned Dürr to handle this project.

compact design enabled the concreted

VinFast is a subsidiary of VinGroup and is the

“Our paint shop will be the biggest in Vietnam,

area to be reduced by approx. 15,000 m2.

first volume automotive manufacturer from

and highly automated through the integration

This corresponds to a saving of more

Vietnam with a particular ambition: a smart

of numerous IIoT applications. This makes

than 20% compared with a conventional

factory where 250,000 cars per year in the

it the benchmark for outstanding quality

concept.

first phase, initially with conventional drives

combined with the lowest operating costs, the

VinFast’s requirement of maximum

and in the future also with electric drives, will

highest ecological standards, and a high level of

automation of production processes

roll off the production line. The paint shop

occupational safety,” explains James Deluca,

and logistics is met with IIoT-capable

in the factory in Haiphong, that has been

CEO of VinFast Trading and Production Company.

machines from end to end. They are

is currently being installed by Dürr.

comprehensively controlled,

ordered in the first quarter of 2018,

monitored, and supervised

It is highly automated and features

in real time using control

integrated Industrial Internet of

technology from Dürr. This

Things (IIoT) technology. In addition,

makes it possible to test

an innovative layout concept permits

and optimize the overall

a building design that dramatically

equipment efficiency (OEE), for

reduces the space required and

example.

costs involved. the largest non-state owned listed

Flexible technology for future targets

company in Vietnam with a market

Just how precisely the paint

capitalization of approximately

shop technology meets the

VND 340 trillion (USD 14.6 billion)

requirements of VinFast while

as of July 31, 2018. The strategy of

remaining flexible for changes

VinFast is a start-up of the VinGroup,

VinGroup is to become the leading Vietnam and the region. The VinFast brand is the Group’s first foray into the mobility market, which offers

in the future is demonstrated

technology-industry company in

by the oven. ThebEcoInCure

Figure 1: The EcoInCure oven achieves the best possible quality when it comes to the top coat appearance thanks to its heating process from the inside out and optimized air flow.

enormous growth potential due to

oven achieves the best possible quality when it comes to the top coat appearance thanks to its heating process from the

Southeast Asia.

Patented layout concept for a lean building

Each body gets a digital quality certificate

VinFast intends to establish itself with various

The VinGroup constructed the building for

for the drying process. The data from

models delivering best-in-class quality and

the paint shop based on the patented layout

the IIoT-capable oven is collected and

produced in a factory equipped with

concept developed by Dürr in a record time

evaluated by the control technology for

state-of-the-art technology that enables

of just short of eight months. The layout

this. In addition,bEcoInCure’s innovative,

transparent, lean processes. In order to

minimizes the investment and operating

space-saving transverse mode of operation

the strong increase in demand for vehicles in

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N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

inside out and optimized air flow (Fig. 1).

SUCCESS STORIES

in combination with a central high-bay

range of sensors, they are prepared for

because the smaller tank capacity

warehouse makes it ideal for the compact

the requirements of an Industry 4.0

means that RoDip速 uses less energy,

building concept.

environment. The robots supply

less water, and fewer chemicals than

The principle of heating from the inside

real-time data that is analyzed and

other technical solutions.

is particularly beneficial for bodies with

evaluated using the latest software

different material thicknesses (a perfect

products from D端rr.

dry paint overspray separation is a

example is electric vehicles with their

In addition to the EcoInCure

multi-stage, easy-to-handle filter system

reinforced frame on the underbody).

innovations and seven-axis robots

that comprises filter trolleys with six

The innovative EcoInCure drying method

described, D端rr will also be installing

filter boxes each and downstream

significantly reduces thermal component

further technical highlights in the

pocket filters as the second filter stage.

stresses compared with conventional

VinFast paint shop:

The semi-automatic separation system

ovens. VinFast is therefore well prepared

- RoDip rotational dip process:

sets the standard for high separation

速

- EcoDry X dry separation: EcoDry X for

technically for the future expansion of the

the efficient RoDip rotational dip

model range to include electric vehicles.

process will be used at VinFast

With all of these state-of-the-art

The new VinFast paint shop will also be

throughout the PT/EC (pre-treatment

technologies, the new paint shop for

equipped with the latest generation of

and electro coating) area. The

VinFast is geared towards the strategic

the fully automaticbEcopaintbrobot. This

rotational movement of the bodies

goals of the start-up: highest quality

includes the extremely mobile painting

does away with the need for entry

standards at the lowest operating costs,

robots with seven-axis kinematics, which

and exit inclines at the immersion

low environmental impact, and high

do not need a rail. This saves space and

tank, thereby making the tanks more

health protection and occupational safety

investment costs. Equipped with a whole

compact. This reduces the unit costs,

with high future security.

capacity and low filter costs.

The Millennium Event The Aluspecialists’ Meeting

11th ALUMINIUM TWO THOUSAND WORLD CONGRESS BHR Treviso Hotel

9 – 13 APRIL 2019 Treviso, Italy

WHERE INNOVATION MEETS BUSINESS REGISTER AS SPEAKER, DELEGATE, EXHIBITOR Topics of the conference include (but are not limited to): Markets & Strategies - Alloys Billets & Related Equipment - Rolling Technology - Architecture & Special Uses - Transport & Automotive Industry – Extrusion • Process Sustainability • Process Management • Process Monitoring • Plant & Process • Process Simulation • Product Quality • Alloys • Dies • New Processes – Anodizing – Coating - Nano Technologies – Automation - Measuring, Testing & Quality Techniques Advanced Applications & Research - Environmental Protection & Recycling - Casting & Die Casting • Process Management • Process Quality • Process Monitoring • Process Innovation • Process Simulation - New Alloys

For Information: Interall Srl, Via G. Marinuzzi 38, 41122 Modena, +39059282390 info@interall.it – aluminium2000@interall.it – www.aluminium2000.com

TRADE FAIRS & CONFERENCES

DECEMBER 2018 COATING JAPAN

BUILD ASIA

Tokyo, Japan December 05-07, 2018 www.coating-japan.jp/en/

Karachi, Pakistan December 15-17, 2018 www.buildasia.net

ipcm

media partner

METAL JAPAN

Tokyo, Japan December 05-07, 2018 www.metal-japan.jp/en

JANUARY 2019 BOUW&RENO

IPCC 2019

AQUA-THERM MOSCOW

AGROMASHEXPO

STEEL FAB

IMTEX

AHR EXPO

OPTI

Tehran, Iran January 23-26, 2019 www.ipcc.ir

Antwerp, Belgium January 12-20, 2019 www.bouwreno.be

Moscow, Russia January 12-15, 2019 www.aquatherm-moscow.ru

Budapest, Hungary January 23-26, 2019 www.agromashexpo.hu

Sharjah, UAE January 14-17, 2019 www.steelfabme.com

Bangalore, India January 24 -30, 2019 www.imtex.in

Atlanta, USA January 14-16, 2019 www.ahrexpo.com

Munich, Germany January 25-27, 2019 www.opti.de

BAU

Munich, Germany January 14-19, 2019 www.bau-muenchen.com

HVACR SAUDI

ipcm

distribution

AUTOZUM

Salzburg, Austria January 16-19, 2019 www.autozum.at

Riyadh, Saudi Arabia January 28-30, 2019 www.hvacrexposaudi.com

INTERPLASTICA

ipcm

distribution

IFEX

Greater Noida, India January 18-20, 2019 www.ifexindia.com

Moscow, Russia January 29 - February 1, 2019 www.interplastica.de

ASTEC

Tokyo, Japan January 30 - February 1, 2019 www.astecexpo.jp

CONSTRUCTION & ARCHITECTURE SHOW Krasnoyarsk, Russia January 22-25, 2019 www.krasfair.ru/en/events/build_en/

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

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ZOOM ON EVENTS

Titan’s 10th Technical Day: A Focus on the State of the Art of Powder Coatings

Figure 1: The tenth Technical Day organised by Industrias Titan was dedicated to the current technological level of powder systems. © ipcm ®

or the tenth meeting of the round of

the second report, titled “The new

Technical Days it is holding, powder

sublimation system Eazy Vacuum (wood

coating manufacturer Industrias

effect) for steel/aluminium”. He described

Titan has organised an event on the

the advantages of the new sublimation

current technological level of powder

technology Eazy Vacuum, developed to

systems on October 27 in Madrid (Fig. 1).

improve the application quality and the

The introduction of José Manuel Azpeitia

service life of products while reducing

(Fig. 2), the Director of the Powder

process and labour costs.

Coating Division of Titan, was followed by

The morning session continued with the

several reports that compared different

speech delivered by Carlos Avendaño, the

powder technologies currently used on

Quality Manager of the Gonvarri Group, a

various substrates and materials.

leading company in the steel processing

Antonio Maeso from Ldo CC. Quimicas

sector. He presented the characteristics

spoke about coating quality in the

required for a steel galvanising

architectural field, comparing the

process to achieve high quality and

powder coating of aluminium profiles for architecture in the geographical areas using QUALICOAT or AAMA certifications. Davide Agostini from Miroglio presented

122

2 1

Figure 2: José Manuel Azpeitia, the Director of the Powder Coating Division of Titan.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

excellent performance levels, from the steelworking of the component to the corrosion protection of the galvanising process.

ZOOM ON EVENTS

3 1

Figure 3: The event ended with a round table discussion moderated by José Manuel Azpeitia and involving José Antonio Arrieta (Titan), Elena Montesino (MARSAN Group), and Diogo Barreto (Lacoviana).

After the coffee break, José Antonio Arrieta, the Technical Manager of the Powder Coating Division of Titan, presented his report comparing pre-anodising + powder with powder + powder systems (Seaside) in order to determine which one offers the best corrosion resistance results. After illustrating the results of the Toyota tests carried out on super-durable powder coatings (200 hours/10 years Qualicoat), José Manuel Azpeitia concluded the event as the moderator of the round table discussion involving Elena Montesino from the MARSAN Group, specialising in the surface treatment of automotive components, and Diogo Barreto, the Production Manager of Lacoviana, a Portuguese company specialising in aluminium finishes (Fig. 3). By presenting their own practical experience, these users offered to the vast audience present an overview of the state of the art of the powder coating sector. For further information: www.titanpowdercoatings.com

ZOOM ON EVENTS

ECCA Conference – “Pre-Painted Metal: The Future of Construction”

n October 17, 2018, on the

substrate and of an optimal geometric

Alubel Spa Sales Manager Davide

occasion of the 53rd edition of

shape and the use of corrosion inhibitors.

Lorusso presented the advantages of

SAIE, the trade fair dedicated

Rossi also highlighted the importance of

pre-painted metal for roofing, including

to the technologies for construction and

coating and above all of duplex systems, i.e.

durability, lightness, impermeability,

built environment 4.0, ipcm® held the

the combination of hot-dip galvanising and

chemical resistance, and environmental

conference “Pre-Painted Metal:

painting, to further prevent corrosion.

sustainability. Thanks to these quality and eco-friendliness benefits, pre-painted

The Future of Construction” organised in European Coil Coating Association ECCA

metal is going to play an increasingly

collaboration with the Italian branch of the

important role in the civil and

Italia. Indeed, this association was created

commercial building sector: this

in 1967 in Brussels precisely with the

was the main theme addressed by

aim of promoting and spreading culture

ipcm®_International Paint&Coating

on pre-painted metal.

Magazine Editor-in-Chief Alessia

This innovative material is mainly used in

Venturi, who also showed some

the construction and architectural sector,

projects realised all over the world,

it is produced through a coil coating

including the famous Ferrari World

process, and it offers high environmental,

in Abu Dhabi.Finally, Prof. Stefano

economic, and quality benefits. With

Rossi concluded the conference

the aim of pursuing the association’s mission, ECCA Italia annually organises meetings and conferences to present the latest technical innovations to the main

talking about the influence that Figure 1: From left to right, Davide Lorusso from Alubel, Antonio Bonoli from Marcegaglia, Alessia Venturi from ipcm®, and Prof. Stefano Rossi from the University of Trento.

colours, finishes, and pigments can have on the thermal behaviour of buildings. Then, an interesting debate was started on the need

material producers to end users, including

to inform the building and town

players of the coil coating sector, from raw designers and architects.

planning commissions of public bodies on the endless application possibilities

“Pre-painted metal: the future of construction”

of pre-painted metal as an innovative, lightweight, and sustainable material that

The conference opened with a greeting

can replace traditional materials such as

from ECCA Italia President Antonio

brick roofing.

Bonoli, the Coil Coating Lines Operation

In addition to this meeting, ECCA

Manager of Marcegaglia (Fig. 1).

participated in the SAIE trade fair with

The meeting then continued with a series

a stand, in which the numerous visitors

of technical reports.

were able to see some pre-painted

Prof. Stefano Rossi from the Department

metal roofing samples, as well as a video

of Industrial Engineering of the University

presentation on the most important

of Trento presented the main corrosive

projects made with this material

phenomena that degrade the properties

worldwide (Fig. 2).

of metal and how to fight them in order to protect the materials used. This include the choice of a more resistant

124

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Figure 2: The ECCA booth at SAIE 2018.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

For further information: www.prepaintedmetal.eu

ZOOM ON EVENTS

PCI’s POWDER COATING 2019 Heads to Orlando

the basics of powder coating operations,

facets of powder coating that I will

is pleased to announce the PCI

led by PCI member company experts in a

utilize in my career.” The event will

POWDER COATING 2019 Technical

non-commercial setting (Fig. 1). The Custom

include social activities and ample

Conference & Tabletop Exhibition will be

Coater Forum is the only industry event

networking time with tabletop

held April 1-4, at the Renaissance Orlando

designed specifically for custom coaters,

exhibitors and speakers.

he Powder Coating Institute (PCI)

Figure 1: Attendees learn about the latest in industry technology from powder coating experts.

with a focus on

The tabletop display area will feature

business processes

powder coating manufacturers,

and technologies

powder coating application

that can improve

equipment companies, systems

custom coater

houses, chemical suppliers and

operations.

various services that support the

Workshop and

powder coating industry. A current

Forum attendees

list of exhibitors can be found at

will enjoy a discount

conference.powdercoating.org/

when registering

exhibitors.html.

for the technical

Don’t miss this unique opportunity

conference and

to learn from the best in the powder

exhibition as well.

coating industry. Save the week of

The PCI Technical

April 1-4, 2019 and plan to join PCI

Conference and

in Orlando, FL for PCI’s POWDER

Tabletop Exhibition

COATING 2019 Technical Conference.

will follow the Powder Coating 101 Workshop and Custom

For further information:

excited about the location selected for

Coater Forum on Wednesday, April 3 through

conference.powdercoating.org

PCI’s Powder Coating 2019,” states PCI’s

Thursday, April 4

Executive Director, Trena Benson. “Following

(Fig. 2).

the very positive comments about Powder

Complete with

Coating 2018 and the increased attendance,

general sessions and

we are enthusiastic about getting to work on

concurrent technical

PCI’s next technical conference. Continuing

programming,

to deliver outstanding education to the

attendees will have

powder coating industry is a top priority for

access to a variety

us.” Orlando is an easy fly-in destination with

of powder coating

service from across the USA and around the

information as well as

world and the hotel is ideally located near

personal interaction

many theme parks and restaurants.

with suppliers. A

The four-day event will kick off with PCI’s

recent conference

popular Powder Coating 101: Basic Essentials

attendee remarks:

Workshop and PCI’s Custom Coater Forum,

“There was a great

to be held April 1 & 2. The workshop includes

variety of sessions

a comprehensive agenda that covers all

addressing the many

at SeaWorld® in Orlando, FL. “We are very

2 1

Figure 2: The Tabletop Exhibition oﬀers the opportunity to meet with suppliers face-to-face.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

125

ZOOM ON EVENTS

MADE expo 2019: Interiors and Finishes

ADE expo Milan stands out for

The journey then continues through the

value of investments in properties

being a showcase of the best

exhibition pavilions which will present a

dedicated to hospitality will exceed

of Made in Italy and not only in

wide range of interior finishes ranging

the remarkable threshold of €3 billion

architecture and interior design.

from entrance doors to interior doors,

to reach 3.2 billion next year (source:

Within the multi-specialized MADE

handles, partitions, floors, walls and a

Scenari immobiliari).

expo, the Interiors and Finishes section

wide selection of finishing products for

In order to develop Italy’s potential in

represents the place to discover new

architecture, consolidating the logic of

the hotel and hospitality sector and fully

fashions and products for interior

the event to represent a single place

seize the opportunities that will derive

architecture through trends, materials

in which to find the widest and most

from the growth of quality tourism, the

and aesthetic and technological

integrated range of solutions possible.

redevelopment of structures that can

solutions presented by companies that

Within a project, the choice of finishes

offer a contribution in terms of design

represent the most advanced products

and architectural features for interiors

but also sustainability can therefore be

on the market.

is a fundamental element in defining

of great value.

Considering the developments in living

and renewing the identity of the

MADE expo will tackle this topic with a

styles this is a rapidly evolving area

environments, the experience of those

series of events that will embrace market

that entails serious changes in what

who live there and optimizing the use of

perspectives, trends/architecture and

is expected from new materials in

space; for this reason, it is particularly

aspects of management in collaboration

terms of aesthetics, performance and

relevant for example in the hotel and

with Confindustria Alberghi, Hotel

sustainability, distribution methods and

catering sector. This is why the next

Rewind, ELLE DECOR and other sector

new business spaces.

edition of MADE expo will pay particular

associations and businesses.

In order to highlight the importance

attention to hospitality, a sector that is

of finishes in architecture and interior

enjoying a particularly positive moment.

For further information:

design and create a centre of attention

In actual fact, at the end of 2018 the

www.madeexpo.it

interior finishes to designers and decorators, MADE expo 2019 will host an exclusive exhibition event created in collaboration with the internationally renowned magazine ELLE DECOR and designed by the Calvi Brambilla studio. The journey/installation focuses on excellence in terms of finishes and coatings giving life to evocative settings. The interpretation of traditional and innovative materials and products turns the spotlight onto finishes in an emotional journey into decoration.

126

Pic.: MADE expo 2019 will take place from March 13 to March 16 at Fiera Milano (Rho, MI).

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

13/16 INTERNATIONAL TRADE SHOW FIERA MARCH FOR AR C H IT E C T U R E A ND MILANO RHO 2019 THE CONSTRUCTION INDUSTRY ITALY

PICK NEW IDEAS MADE IN MILAN madeexpo.it THE LEADING TRADE SHOW IN ITALY TO DESIGN, BUILD & RENOVATE. CONSTRUCTION AND MATERIALS, BUILDING ENVELOPE & WINDOWS, INTERIORS AND FINISHES, SOFTWARE & TECNOLOGIES. Promoted by

Partner

ZOOM ON EVENTS

PaintExpo 2020 with Strong Demand for Booth Locations

ust a few months after the

visitors came from countries other

many other companies: 304 companies

seventh edition of the world’s

than Germany. Most of the visitors

from 19 countries have already made

leading trade fair for industrial

brought concrete tasks and projects

firm bookings for their booth floor space

coating technologies closed – which

along with them. “We participate at

at the world’s leading trade fair in 2020,

achieved new record-breaking

numerous trade fairs – in Asia and

and they enjoyed a full range of options

numbers with regard to exhibitors,

America too – but where the quality

in selecting their booth locations.

visitors and internationalism – firm

of the exhibitors and visitors are

The list includes nearly all of the national

bookings for booth floor space

concerned, as well as product quality

and international market and technology

at PaintExpo 2020 have already

and coverage, PaintExpo is the global

leaders from the various exhibition

been submitted by 304 companies

leader. That’s why we’ll exhibit in

segments.

from 19 countries. At a current

At a current level of

level of 124,000 square feet, net

124,000 square feet, net

exhibition floor space already

exhibition floor space

amounts to more than 74% of the

already amounts to more

level reached at the last event.

than 74% of the level

This is a strong indication that the

reached at the event in

upcoming PaintExpo will once

2018. The strong demand

again be larger than ever before.

for booth floor space long

For the eighth time, PaintExpo

before the event opens

will showcase innovations,

2020 again,” explains Frank Berg,

once more underscores the outstanding

applications, future technologies

Managing Director of Caldan Service

position enjoyed by PaintExpo as a

and trends covering all aspects

GmbH. Professor Dr. Nils A. Reinke,

global industry meet.

of coating from the 21st through

CEO of Winterthur Instruments AG in

the 24th of April, 2020. It presents

Switzerland, has already made firm

the full spectrum of international

plans to participate as well: “We’ve

Focus on Future-Oriented Coating

product and service offerings

been exhibiting at PaintExpo ever

Jürgen Haußmann, managing

in the field of industrial coating

since our company was founded

director of trade fair promoters

technology throughout the

seven years ago, and participation

FairFair GmbH, is convinced

entire value creation chain.

at the trade fair has had a significant

that PaintExpo will continue to

This internationally unique

impact on the development of our

experience strong development

concentration of companies from

business. It provides us with an ideal

where visitor numbers are concerned

industrial coating technology is

platform for the presentation of our

as well: “Even if requirements and

the basis for the event’s strong

products. Aside from this, we gain

developments differ in the various

ability to attract users from job-

a great deal of input for the further

user sectors and countries – as key

shop coaters and companies

development of our products thanks

technologies, painting and coating

with in-house painting operations

to the broad spectrum of visitors.”

are an important success factor.”

from around the globe. 11,790

A look at the exhibitor list, which is

And it’s correspondingly important

expert visitors from 88 countries

already full of world-class enterprises

for companies with in-house painting

travelled to Karlsruhe in 2018

17 months before the trade fair

operations and coating job-shops

(representing a 12% increase).

opens, makes it apparent that these

to prepare themselves for new

More than one third of the

assessments coincide with those of

requirements. In addition to ever

128

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

ZOOM ON EVENTS

Figure 1: The next edition of PaintExpo will take place from the 21st through the 24th of April, 2020 in Karlsruhe, Germany.

stricter customer demands for

be presented with correspondingly

and conveyor technology, cleaning

quality, economy and flexibility, this

adapted product, process and

and pre-treatment, drying and

also involves more efficient use of

problem solutions thanks to the

curing, environmental technology,

materials and resources, as well

unique, future-oriented offerings

pneumatics, compressed air

as sustainability. Additional issues

shown by the exhibitors,” says Jürgen

supply and exhaust purification,

include advancing digitalisation and

Haußmann with confidence already

water treatment, recycling and

networking of production processes,

today.

disposal, accessories, masking,

the use of new materials and material

The exhibition programme of

measuring and test technology,

combinations, and the trend towards

the world’s leading trade fair for

quality assurance, identification,

individualisation.

industrial coatings technology

paint stripping, job-shop coating,

“Regardless of whether coatings

covers coating equipment for liquid,

services, packaging and technical

for metal, plastic, wood or wooden

powder, UV, immersion and coil

literature.

materials, glass, composites or other

processes, paints and enamels for all

materials are involved, visitors to the

processes, application systems, spray

For further information:

upcoming PaintExpo will once again

guns and atomisers, automation

www.paintexpo.com

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

129

WELCOME TO THE INDUSTRY’S LEADING TRADE SHOW NUREMBERG // GERMANY European Coatings Show: 19 – 21 March 2019 European Coatings Show Conference: 18 –19 March 2019

Most recently over 1,100 international exhibitors and over 30,000 visitors Accompanied by Europe’s largest and most important industry conference w Plan your visit online: european-coatings-show.com/shownavigator Organisation: NürnbergMesse european-coatings-show.com

Organiser: Vincentz Network european-coatings.com

Supplemento a IPCM nÂ° 54 - November/December 2018

INDUSTRIAL CLEANING TECHNOLOGIES

ICT digital on

www.myipcm.com

ÂŽ

Automatic sealed ultrasonic cleaning machine 2S 90/24-P-F PCT AC Our machine requires only 5 kW about 20% of the normal power requested by type Ib machines)

The future of green technology 1HZ JHQHUDWLRQ VROYHQWV with ORZ-boiling point (19-50Â°C) QRQ Ă DPPDEle DQG HQYLURQPHQWDOly friendly

MEG S.r.l. Via Rometta, 13/G - S. Martino di Lupari (PD) - Italy Phone +39 049 9461165 - Fax +39 049 9461133 e-mail megpd@tin.it â&#x20AC;&#x201C; www.meg.it

PRECISION CLEANING

ICT - INDUSTRY NEWS

ÂŠ acp systems AG

Partial or Full-Surface Inline Removal of Filmic Contamination ilmic contamination is becoming ever-more important in the component

Dry and environmentally friendly cleaning process With the quattroClean technology

manufacturing industry. No

from acp systems AG, a proven

wonder, because the quality of

solution is now available for

manufacturing processes such

components made of practically

as bonding, sealing, welding

any technical material. The

and coating depends to a large

environmentally-friendly process

extent on surface cleanliness.

works with liquid carbon dioxide,

With its environmentally friendly

which has a virtually unlimited shelf

quattroClean snow jet technology,

life and is generated as a by-product

acp systems AG offers a proven

from chemical processes as well as

solution for the partial and

energy generation from biomass.

full-surface cleaning of parts made

In the cleaning process, carbon

from any technical material.

dioxide is fed through the

In addition, the scalable and

non-wearing two-component ring

inline-capable cleaning step is a dry

nozzle of the quattroClean system,

process that leaves no residues

expanding as it exits to form fine CO2

from the medium itself.

snow (Fig. 2).

This is then bundled by a jacketed jet While component cleaning used to

of compressed air and accelerated

be mainly concerned with removing

to supersonic speed. The patented

particulate contamination, today

technology ensures uniform cleaning

filmic residues are increasingly

results - even with large-surface

becoming the focus of attention in

applications using several nozzles.

industries such as the automotive

When the easily-focused jet of

and associated supplier

snow and compressed air impacts

industries, medical equipment, aviation, precision engineering, micromechanics and mechanical engineering. This is due to new and modified manufacturing, joining and coating processes. Filmic

on the surface to be cleaned at a

temperature of minus 78.5Â°C, a

Figure 1: Filmic contamination (here an anti-corrosion oil), which impairs quality in subsequent processes such as welding or bonding, is removed reliably in an inline process with the quattroClean system.

contamination, such as residues of

combination of thermal, mechanical, sublimation and solvent effects take place. Thanks to these four mechanisms of action, the quattroClean system reliably

processing and preserving media,

for the subsequent process need to

removes filmic contaminants such as residues

separating agents, silicon and other

be cleaned, e.g. where sealants and

of cooling lubricants, machining oils, separating

auxiliary manufacturing materials,

adhesives are applied or for welding,

agents and silicon. The quattroClean cleaning

as well as fingerprints, can impair

bonding, coating or assembly

process also reproducibly removes particulate

quality (Fig. 1). Added to this, often

steps â&#x20AC;&#x201C; with a requirement for a

contamination. The cleaning process is so

only those areas of the component

production-integrated process wherever

gentle on materials that it can even be used to

that are relevant to cleanliness

possible.

clean delicate and finely-structured surfaces.

132

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

ICT - INDUSTRY NEWS

Through pilot tests in the acp systems technical center, the process parameters, such as volume flows for compressed air and carbon dioxide, jet zone and jet time, are precisely tailored to the respective application. The parameters also account for material properties and contamination requiring removal and can be filed as part-specific © acp systems AG

cleaning programs in the system control.

The system can be integrated into production lines and networked production environments

Figure 2: The technology with its non-wearing two-component ring nozzle ensures a consistently high and homogeneous cleaning performance - even for large-surface applications with several nozzles.

KMU LOFT – because resources are limited

Tailored to the respective cleanliness and cycle time specifications, acp systems develops customized, manual, partially and

2 1

fully automated plant concepts based on standard modules - both as stand-alone solutions as well as for integration into production lines and networked

During the cleaning step, the crystalline carbon

production facilities (Fig. 3).

dioxide is completely converted into a gaseous

The latter is made possible by the system’s

state, meaning that the cleaned material dries

Industry 4.0 capability. The system can be easily

instantly. Detached impurities are removed from

integrated into and controlled by higher-level

the component surface by the aerodynamic

master computers via standardized interfaces.

force of the compressed air and transported

To ensure full documentation and traceability, all

away together with the sublimated carbon

process parameters are automatically recorded and

dioxide by a suction unit integrated into the

transferred to the host computer.

cleaning module. For further information:

Partial or full-surface cleaning

www.acp-systems.com

The scalable quattroClean process component geometries to enable partial or full-surface cleaning.

can be easily adapted to different

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Compared to classic wet chemical cleaning methods, the system requires significantly less production space and investment and operating costs are lower.

Figure 3: The industry 4.0-capable quattroClean system enables the production-integrated, partial or total removal of filmic contamination with consistent results.

• soluzioni economicamente all’avan-guardia nella riduzione degli scarichi e nel recupero delle risorse 3 1

www.kmu-loft.it

ICT - INDUSTRY NEWS

Kemet Adds FPI to Range

he perfect non-destructive-test (NDT)

provide a small footprint. The FPI systems are

mass production with dipping

solution for inspection of components,

durable, safe, ergonomic and user-friendly.

penetrant application, “Dust Storm”

Liquid Penetrant Testing, or Fluorescent

A variety of systems are available, from

developer chamber and integrated

Penetrant Inspection (FPI), is commonly used in

flexible manual roll track spray lines with

pre and post wash. Further options

the aerospace and medical industries. Precision

a small footprint, to fully automated roll

include material handling and

surface finishing leaders, Kemet, now offers

conveyor immersion lines for high capacity,

batch traceability via a data log, fully

FPI systems with control that ensures repeatability, process safety and traceability of each

automated penetrant and developer Figure 1: The Fluorescent Penetrant Inspection (FPI) is commonly used in the aerospace and medical industries.

advanced process

batch within the set parameters (Fig. 1). The systems are

spray, basket rotation, basket trolleys and automatic loading/unloading conveyors (Fig. 3). These FPI systems complement Kemet’s existing Ultrasonic Cleaning programme which incorporates a broad range of aqueous cleaning solutions to suit all types of components and budgets.

designed and built to meet the ASTM

the aerospace and medical industries. Kemet offers a range of standard systems

www.kemet.co.uk Figure 2: The FPI systems by Kemet oﬀer flexibility to combine automated and manual operation.

common to both

For further information:

E1417 FPI standard

as well as the flexibility to combine automated and manual operation to provide streamlined, maintainable NDT inspection, with water handling and

2 1

extraction systems as options, to generate cost savings on process chemicals, labour and energy consumption (Fig. 2). These can be supplied as fully automated

integrated waste

systems for airframe components, turbine blades, and medical implants as well as smaller manual systems for less critical parts. An intelligent combination of automation and manual handling can reduce labour requirements, while an adjustable layout can

134

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

3 1

Figure 3: Further options include material handling and batch traceability via a data log, fully automated penetrant and developer spray, basket rotation, basket trolleys and automatic loading/unloading conveyors.

ICT - CASE STUDY

Opting for a Modified Alcohol Cleaning Technology for Oil-Hydraulic Components in the Framework of a Smart Factory Project © ipcm ®

Monica Fumagalli ipcm®

Opening photo: Some of the oil-hydraulic components produced by HBS.

he report on the future of jobs in the

concept of work, the creation of new job

In this article, we present a case study on

new digital age presented during the

opportunities, but also the loss of 5 million

HBS (Monzambano, Mantua, Italy), a company

World Economic Forum 2016 in Davos

jobs. After almost three years, it is perhaps still

specialising in the production of oil-hydraulic

(Switzerland)1 illustrated the future prospects

early to draw conclusions on this revolution

valves and components for every use, from

of the fourth industrial revolution, more

well under way that has involved all industrial

transport to earth-moving vehicles, from

commonly called “Industry 4.0”. The report

sectors; however, we can continue to record

building to agriculture, from ecology to

stated that the following five years would

on the pages of our magazines the ways in

industrial plants. Present worldwide with

have seen a profound transformation of the

which several companies from the world of

production facilities in China and Brazil,

surface treatments are dealing with this radical

plus one under design in India and two

change.

soon-to-open ones in the United States and

1 The complete report can be downloaded at the following link: www3.weforum.org/docs/WEF_FOJ_Executive_Summary_Jobs.pdf

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machinery and equipment often operating in harsh conditions (ref. Opening photo). Therefore, we looked for a supplier able to offer a system solution that would make our cleaning cycle fast, easy to manage, and with a low environmental impact: we found this partner in IFP Europe (Galliera Veneta, Padua, Italy). This firm fully understood the principles that had inspired us and followed them to optimise our production flow through the integration of production units, the interconnection among operators, machines, and devices, and the implementation of eco-friendly solutions.”

From design to end products: quality means perfect synergy with customers

Figure 1: The two cleaning systems installed by IFP Europe.

The entire production cycle, except for heat and surface treatments, takes place inside the Monzambano factory, covering

Russia, this company is gradually adapting

of about 3 components per day.

a 12,000 m2 area and consisting of two

its production process to the Industry 4.0

“With such a massive production, the

production units, to which a new structure

parameters in order to offer high quality

first goal to adapt our company structure

of about 7.500 m2 will be added in the next

products in terms of both performance and

to the Industry 4.0 principles was

two years. “Our R&D department starts

innovation capacity.

streamlining our production process. One

designing a component based on the

“HBS was established in 1967,” says CEO Ezio

of the main bottlenecks was the cleaning

suggestions of a customer, on a new need

Bompieri at the beginning of our meeting,

phase, a crucial step to guarantee the

detected by our sales network, or on an

“as a machining contractor. Since 1980, it

correct functioning and long service life

innovative product that our technical team

has integrated its production activity with

of our products, which are intended for

the design of solutions meeting the different needs of its

We therefore create the prototype to be tested in

customers. In 1995, it started

our 500 m2 lab, equipped

manufacturing an entire range

with test benches for

of HBS branded products,

destructive and durability

then integrating its production

tests. The prototype is

of valves and oil-hydraulic

approved after performing

components with that of

functional tests on the

hydraulic swivel joints and, since

customer’s machine. At that

2009, of slip rings.” The HBS

point, the component can

standard product range now

be industrialised.”

includes 3600 components in

The production process is

addition to the special products

standardised and starts with

manufactured as a contractor.

the receipt of bars of steel,

Every year, HBS puts around 600 new products on the market, with a very high average

2 1

Figure 2: The cleaning machine for small components.

constituting 90% of the company’s products, and aluminium. This is followed

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

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ICT - CASE STUDY

3 1

Figure 3: The IFP Europe cleaning plant for large components.

Therefore, we

since HBS is about to get the ISO 14001

had to perform a

environmental certification, we reduced our

manual blow off

production’s impact on the environment

operation on every

and solved the problem of water and sludge

part to remove

disposal, which, with the previous plant, had

any residues, thus

a significant impact due to the costs for the

wasting time and

elimination of hazardous waste.

employing labour

Now, no waste water to be disposed of

in hazardous

comes from our cleaning phase, because

operations for

the plant has a self-purification system

health and safety.”

that activates after the process, separating

The critical issues resolved

the dry residue (e.g. chips) from the oil contained in the cleaning chemical and the alcohol to be recirculated.

In 2013, HBS

Thanks to this system, we perform a

contacted the

replenishing process once a year, contrary to

by operations performed with machining

technical staff of IFP Europe to install the

what happened previously with weekly tank

centres and lathes, a first cleaning process

first cleaning machine, followed by the

checks, continuous addition of additives to

for the removal of any scraps and emulsions

larger one in 2017 after checking the

keep the cleaning result optimal, and tank

left on the surfaces, thermal and superficial

efficiency of the first plant. “The two systems

emptying operations two times a month

treatments, and for some products a final

use the same technology,” states Bompieri

resulting in an enormous consumption of

cleaning phase. The cleaning process occurs in

(Figs. 2 and 3).

water.”

two IFP modified alcohol systems, a smaller one

“Thanks to this solution, we streamlined our

for small workpieces and a larger one for

production flow, reducing our cleaning time

large-sized components (Fig. 1).

from about 30 to 20 minutes.

The cycle and structure of the two IFP cleaning plants

We also solved the issue of workpieces left

Both systems consist of a single-stage chamber.

The previous cleaning process

oxidising in the air: the modified alcohol

The chamber of the smaller machine is

“Before installing the IFP plants,” says

process does not require any drying phase,

equipped with 2 small baskets (40x30x20 cm),

Bompieri, “we cleaned our components in a

so that after cleaning the components are

whereas that of the larger one hosts two 2

conventional ultrasound system, with different

ready for the next phases without needing

baskets with a dimension of 120x80x45 cm,

cycles depending on the type of material and

any blow off operation. Last but not least,

component to be treated. If we had to treat both steel and aluminium parts, we had to set two different cycles not to pollute water, using

cell’s volume based on the average specific

different degreasing additives and applying an

weight of its treated

anti-rust protection on steel products, as they

products, so it can

oxidise quickly if washed with water and left to

always work at full load

air dry for too long.

for maximum energy

“In addition to this critical issue, since that

efficiency.

was a static plant, machining scraps often

“In order to meet our

remained in the hollow areas of workpieces.

lean production and

Despite the powerful action of ultrasound,

Industry 4.0 needs,

the internal cleaning of parts has always been

we developed an ad

one of our biggest problems, because such

hoc system for the

residues in the inside of the most complex-shaped products risked compromising the result of subsequent stages.

138

4 1

Figure 4: The baskets holding the workpieces to be cleaned.

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

handling of containers,” explains Bompieri (Fig. 4). “It is no longer

necessary to transfer parts from the

ICT - CASE STUDY

production chain containers to those of the cleaning system, because the baskets used during machining are also suitable for our cleaning plant. IFP’s machines are equipped with a roller conveyor on which the baskets are arranged (Fig. 5). They have been specially designed to guarantee an unattended working time of at least 2 hours.” After the baskets have entered the plant (Fig. 6), the system closes automatically to allow the chamber to be flooded with modified alcohols that heat up under vacuum conditions, at a temperature of about 70 °C. Inside the baskets, the components are subjected to a tilting movement and they are cleaned with ultrasound, favouring the removal of

5 1

Figure 5: The roller conveyor installed at the entrance of the two cleaning machines guarantees an unattended working time of at least 2 hours.

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

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

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

ICT - CASE STUDY

6 1

7 1

Figure 6: A detail of the opening compartment of the cleaning system.

Figure 7: Residues from a few precision finishing treatments, such as lapping and grinding, may remain on the surfaces of some components.

contaminants even from the most

systems in our heat treatment and

Conclusions

difficult-to-reach areas.

finishing department. These systems

“Much has been done in the

At the end of the cycle, vacuum

would be specifically designed for

Industry 4.0-oriented updating of

pumps empty the chamber

our needs and installed near the

our company, but a lot can still be

creating a vortex and dragging all

machines in order to eliminate any

done,” states Bompieri. “We intend

the removed residues.

travel time between departments.

to interconnect our suppliers and

The parts are unloaded from the

Also in this case, we intend to rely on

customers to HBS’ internal network

cleaning plant and, after cooling for

the expertise of IFP Europe, which

by 2020. That is why we are already

a few minutes, they are sent to the

has shown an excellent reliability

selecting suppliers like IFP Europe,

subsequent heat treatment and

degree in terms of both technology

which designs systems already

finishing stages. From there, a few

and service.”

prepared for this purpose. We also

parts come back to undergo a last

More generally, HBS’ Smart Factory

intend to improve our product range

cleaning treatment.

project also aims at creating a

by adding to our solenoid valve

paperless production process. “We

design and manufacturing activity

envision a factory where paper will

(started this year) a production of

A cleaning process for a Smart Factory

no longer be used. The automation

lever-operated valves. We aim at

“One of the problems we still

of our processes will start from

offering to our customers complete

have to solve are the travel times

the design operations of our R&D

kits for setting up their machinery,

of those components returning

department, up to our shipping

from distribution components to

to the cleaning plants after the

phases. This will be made possible

control and management systems.

thermal and finishing treatments.

by 85 touch screen stations through

Thanks to IFP’s cleaning technology,

This is a necessary step in order to

which the operators will be able

we will able to manage also this new

remove any oil traces from some

to follow the process phases and

type of production, with the certainty

of those phases, such as lapping

update their progress. This project

to reach such a cleanliness degree

and grinding, which leave residues

will start in January and it will be the

to guarantee optimal quality and

that could compromise the sliding

prerequisite for starting a robotised

functional performance. Moreover,

and functioning of valves (Fig. 7).

handling program that will replace

we will be ready for the integration of

Therefore, we are considering

the forklifts led by operators with

any new production units required by

installing a few small cleaning

small automatic trains.”

our Smart Factory project.”

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ICT - HIGHLIGHT OF THE MONTH

MicroCare Corporation Expands at the European Level: Inaugurated a New English Plant for the Mixing and Packaging of Industrial Cleaning Solutions MihailÂŠfotolia

Ilaria Paolomelo ipcmÂŽ

Opening photo: One of the two divisions of the MicroCare new English factory will manufacture critical cleaning fluids for PCBs.

hen cleaning printed electronic

Registration, Evaluation, Authorisation,

of the REACH regulation, MicroCare, an

components, an effective

and restriction of Chemicals (REACH)

American leading manufacturer of cleaning,

cleaning process is crucial to

regulation, which affects the chemicals

coating, and lubrication solutions, has further

meet both the growing market demand

used in all main industrial processes

strengthened its presence in Europe with

for reliability and the increasingly stringent

and by most companies all over Europe.

a new plant in England, near Birmingham.

European regulations. These include the

Precisely to meet the requirements

Whereas its headquarters and customer

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ICT - HIGHLIGHT OF THE MONTH

service office will remain in Brussels, the new English factory will handle the mixing and packaging of chemicals. “The new plant consists of two divisions, one of which is totally dedicated to cleaning printed circuit boards (PCBs, ref. Opening photo). In fact, after soldering, electronic boards often need thorough cleaning in order to remove any residues of fluxes, soldering pastes, or other contaminants. Currently, the cleaning of these electronic components is a true challenge, because modern PCBs are much smaller and more complex than ever before. This calls for the use of advanced cleaning technologies. In this framework, MicroCare offers a wide range of special fluids that can reach even the most hidden, narrow slots and guarantee a deep, accurate cleaning process, thus averting some of the most common problems such as dendritic

Figure 1: MicroCare COO Thomas Tattersall with ipcm® Editor-in-Chief Alessia Venturi.

growth and corrosion,” states MicroCare Chief Operating Officer Thomas Tattersall

processes. Indeed, the use of this product

glues and inks used during production. Another

(Fig. 1).

in standard vapour degreasers instead

typical application for Tergo™ is cleaning

“Tergo™ Chlorine-Free Cleaning Fluid,

of other water or hydrocarbon cleaning

medical devices to remove oils and particulates

launched on the European market about

processes reduces both the dangers to the

prior to sterilization. Finally, our fluid is also

eighteen months ago, stands out among

health of workers and the environment.

used in the aerospace industry, where it is

our special fluids. This is a new, unique

This also reduces process costs. Depending

essential to remove any contamination that

chlorine-free formulation that removes

on the size of the machine and the

could lead to poor performance,” says the COO.

even the most difficult contaminants quickly

components to be treated, a very short

“Tergo™ and all other fluids in our range

and effectively.

cycle of 8 to 10 minutes can be achieved,”

are a great help in the cleaning of critical

This cleaning agent can replace

says Tattersall.

components and they are a safe, reliable choice

water-based processes and it is compatible

“Tergo™ is also suitable for cleaning medical

complying with all European regulations.”

with conventional vapour degreasing

devices, which may contain residues of

says Tattersall.

DRY CLEANING

with

to perfect

advanced clean production

PAINTING ! Cleaning with CO2 - snow jet www.acp-V\VWHPV.com Phone: +49 7156 48014-0

ICT - CASE STUDY

An Environmentally Friendly and Low Energy Consumption Cleaning Process for Tailor-Made Oil-Hydraulic Components © Power Hydraulik

Barbara Pennati ipcm®

Opening photo: Power Hydraulik has been active in the hydraulic sector for over twenty years, operating in diﬀerent industries such as food, oil & gas, earth moving machines, amusement, subsea, and machine tools.

il hydraulics is among the most

quality standards, because the success

in San Martino Buon Albergo (Verona, Italy)

versatile industrial processes,

of an application is strictly linked to the

in 1993, the company is now managed

able to meet the needs of various

quality of every system component. Power

by Claudio and Lorenzo Merzari and has

sectors and to handle considerable power

Hydraulik has been operating in this

about thirty employees who take care of

ranges. It therefore requires very high

industry for over twenty years. Established

the entire production cycle.

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The service life of oil-hydraulic components is closely linked to their cleanliness degree. Indeed, cleanliness is decisive not only for the components themselves, but also for hydraulic oils: these are filtered and cleaned, and they must not be exposed to any contaminants present on the workpieces in order to remain clean and ensure optimal operation. With the aim of offering a competitive, functional, and high quality product, Power Hydraulik turned to STS (Ravenna, Italy), a company specialising in the design and production of industrial cleaning plants, to install a machine for cleaning components and hydraulic blocks in various sizes and materials.

Figure 1: Hydraulic blocks ready to be cleaned.

“Power Hydraulik designs oil-hydraulic

Another field in which our skills are often

plants and systems for different industrial

applied is subsea engineering, for which we

sectors, including food, oil & gas, earth

produce equipment specifically designed

moving machines, amusement, and

for underwater machines, used for

machine tools (ref. Opening photo).

example for laying submarine pipelines.”

Indeed, oil-hydraulics can be applied in

Power Hydraulik deals with the whole

numerous fields, even the most particular

production process, from design to

ones such as subsea, where applications

installation at the customer premises.

are used in submerged marine

The firm stands out for its ability to

environments,” explains Carlo Dal Forno

meet every specific need, placing itself

from the technical sales department of

as a technological partner able to offer

Power Hydraulik. “We operate on the

customised solutions in a sector where

Italian market, but we also collaborate

mass-produced series generally prevail.

with international companies. Despite

“Every element we produce is ‘out of

boasting a capillary presence in many

standard’, that is, it is developed based

industrial sectors, one of our main target

on customer specifications,” says Carlo

markets is that of amusement parks, for

Dal Forno. “This is one of the strengths of

which we manufacture special cylinders

Power Hydraulik, which places itself as an

for handle safety fasteners and motion

‘artisan’ company able to offer targeted

control systems, calling for great accuracy

solutions for the production of

in terms of both design and assembly.

small-medium volume batches.”

2 1

Figure 2: STS’ AQUAROLL® E30 system installed at the premises of Power Hydraulik about one year ago.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

145

ICT - CASE STUDY

Figure 3: The single-stage cleaning cycle includes spray cleaning, ultrasonic cleaning, spray rinsing, ultrasonic rinsing, drying, and vacuum drying.

3 1

Energy and production eﬃciency

types of parts and materials.”

The cleaning cycle is a single-stage

Collaborating actively with STS, the firm carried

process lasting about 20 minutes and

Before installing this automatic machine,

out different cleaning tests that eventually

it includes spray cleaning, ultrasonic

Power Hydraulik cleaned its products

led to the installation of the AQUAROLL® E30

cleaning, spray rinsing, ultrasonic rinsing,

manually, which however did not

system about one year ago (Fig. 2).

drying, and vacuum drying (Fig. 3).

“One of our flagship products are hydraulic blocks, which are systems for

guarantee any quality consistency.

creating complex hydraulic circuits by gathering various devices in one block (Fig. 1),” explains Power Hydraulik owner Claudio Merzari. “These blocks feature deep, small, often interconnected holes that need to be perfectly cleaned from emulsions and cutting oil residues from the previous machining operations.” “Moreover, since we do not manufacture standard components, our production includes both smaller and lighter workpieces and components weighing 100 kg, available in various materials such as aluminium, cast iron, and steel. We therefore needed a cleaning machine able to achieve our required quality level, but also flexible enough to treat different

146

4 1

Figure 4: During cleaning, water is constantly renewed through the closing and opening of a valve.

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ICT - CASE STUDY

5 1

Figure 5: The machine can load up to two stackable baskets for small workpieces or one basket with an anterior dimension of 30 cm in the case of larger-sized parts.

During cleaning, water is constantly renewed through the closing and opening of a valve (Fig. 4). The cleaning programs are pre-set and selectable by the operators according to the type of workpiece to be treated. The machine can load up to two stackable baskets for small workpieces or one basket with an anterior dimension of 30 cm in the case of larger-sized parts (Fig. 5). The process occurs at 60/70 °C, a temperature suitable for cleaning both aluminium, which could blacken at higher temperatures, and cast iron and steel. The baskets can be rotated, tilted, or kept still according to requirements. “The system we have installed for Power Hydraulik was designed to guarantee maximum production flexibility. It cleans parts in various sizes and alloys, always ensuring result repeatability,” states STS Technical Manager Mauro Ballo. “It uses environmentally friendly and VOC-free water-based detergents, so that it is not necessary to connect it to any suction system. This allows the machine to be easily and quickly reinstalled in any production area.” “Our cleaning plant also guarantees very low consumption of water because it performs closed-loop operations, recovering water through a filter that recovers and recirculates the vapours. Energy consumption is also very low as the tanks are insulated: even when the machine is idle, the thermal loss in the tanks does not exceed 8 °C,” says Ballo. “Finally, the system employs products based on bicarbonate that, being a salt, reduces their evaporation, thus helping minimise environmental and energy impact.”

ICT - CASE STUDY

About 90% of Power Hydraulik’s

“Power Hydraulik has always

products are subjected to cleaning,

evolved in terms of production

“We do not manufacture

now performed by the STS system.

and design. This has allowed us to

mass-produced components: our

“In the past, we only used a manual

count some very important global

target clients are businesses needing

system that however did not achieve

players among our customers.

products with unique characteristics.

the required results, especially

Thanks to the high quality level

Therefore, we often handle smaller

in terms of repeatability,” says

guaranteed by our cleaning

volume orders. This is our strength, as

Claudio Merzari. “Thanks to this

process, we now manufacture

well as the distinctive feature that has

new machine, we have halved our

products with an added value that

enabled us to establish ourselves in a

cleaning times and achieved excellent

has turned out to be a great calling

very competitive and highly professional

quality consistency for all types of

card for several projects,” states

market,” states Claudio Merzari. “That

workpieces (Fig. 6). This is crucial

Merzari. “In future, we intend to

is why it was important for us to find

for us, because oil-hydraulics often

continue to experiment with the

a technological partner that was

apply to increasingly sophisticated

cleaning phase, collaborating with

professional and reliable, but also able

(also in terms of electronics) pumps

STS to develop the best method

to meet our need for flexibility and

and valves, which require extreme

to offer a more and more versatile

production versatility. We found this

cleanliness of all components before

service and increasingly competitive

partner in STS.”

assembly.”

products.”

Italian-made solutions for global markets

6 1

Figure 6: The installation of this automatic cleaning machine has reduced the cleaning times and improved quality consistency for all types of components.

148

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

efficacia, ecologia e sicurezza

effective, ecological and safe

sistema di lavaggio rotazionale rotational washing system Asciugatura rotazionale sottovuoto

Lavaggio rotazionale ad immersione

Lavaggio rotazionale spray Asciugatura rotazionale ad aria calda

Immissione rotazionale di aria Immissione rotazionale di aria

Risciacquo rotazionale spray

EE 30 R

EE 40 S

Risciacquo rotazionale ad immersione

EE 60 R

soluzioni ecologiche per il lavaggio e trattamento delle superfici ecological solutions for washing and treatment of surfaces STS Srl - Via Galvani, 8 - 48123 Ravenna RA (Italia) Tel. +39 0544 456731 - Fax +39 0544 456733 w e b : w w w. s t s i t a l y. i t e m a i l : s t s @ s t s i t a l y. i t Customer Care STS: tel. +39 0544 456732 email: info.sts@stsitaly.it

ICT - HIGHLIGHT OF THE MONTH

MAFAC Cleaning Solutions: A New Dimension of Dynamic Cleaning Bettina Kern bettina.kern@mafac.de

MAFAC – E. Schwarz GmbH & Co. KG, Alpirsbach - Germany

Opening photo: MAFAC PURA completes MAFAC’s product range downwards. The single-tank machine with spray cleaning is suitable for quick and easy component cleaning.

ince their entry into the aqueous parts

receptacle system is a crucial component

and time, clean component surfaces well and,

cleaning market, MAFAC cleaning

of this corporate success. It is based on the

at the same time, efficiently. In continuing

machines have set global standards

understanding that cleaning with motion

the development of this kinematic system

in terms of cleaning quality, efficiency and

is more efficient. Consequently, all MAFAC

approach, MAFAC now presents a new cleaning

application diversity. The patented process

machines work systematically with targeted

process, the MAFAC vector kinematics - a new

technology of counter- or co-rotating

turbulences. The combination of mechanical

dimension of dynamic cleaning - and a new

movements of spraying system and basket

components, temperature, cleaning additives

machine: the MAFAC PURA.

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N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

Figure 1: In cleaning processes with a rigid nozzle system, the partial regions which are not exposed (red) outweigh those which are optimally exposed (green).

ICT - HIGHLIGHT OF THE MONTH

Figure 2: Thanks to angular variance, the MAFAC vector kinematics leads to a significantly better exposure of the components. Optimally (green) and partially (yellow) exposed regions clearly outweigh unreached locations (red).

MAFAC vector kinematics more movement and focused turbulences

Innovative technology for more flexibility In particular, manufacturers of complex workpieces with geometries and

With the MAFAC vector kinematics process, there is even more

surfaces that can be reached in

movement to clean and dry

different ways benefit from

components. In contrast to the

this innovative process. The

process in a rigid nozzle system,

various angles of impact

the workpieces are not hit

lead to significantly less

at a specific angle (Figs. 1

spray shadows, so that excessive cleaning of easily

permits optimal angular

accessible component

variance on the surfaces of

regions with valuable

and 2). The new method

the components (Fig. 3).

resources is avoided. The complete cleaning

The nozzle tube performs a rocking movement about

process is more efficient

its own axis through 35° to

and economical, which is

either side, while the basket

particularly advantageous in view of the requirements

receptacle system rotates

for constantly improving

synchronously at an optimally

cleanliness and increasingly

adapted speed. The maviatic

tighter budgets. In the future, users

controller of the machines calculates

will also be able to react with significantly

the movement of the basket rotation beforehand, whereby co- and counter-rotation are both possible. This coordinated interaction

greater flexibility to a wide range of parts

3 1

or to changes in the part program: thanks to the high angle variance, a large variety of

of nozzle tube and basket movements leads to a targeted and, depending on the part geometry, up to 60 % higher application on the component surfaces.

Figure 3: The new MAFAC vector kinematics permits a wide range of diﬀerent angles for the application onto the component surfaces.

significantly different workpiece batches can be processed - from standard operation to sophisticated and varied angular application

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

151

ICT - HIGHLIGHT OF THE MONTH

(Figs. 4a and 4b). The new MAFAC vector

programming have been reduced to

of individual workpieces. An optional

kinematics permits an effective execution

the essentials. Since the patented and

coalescence oil separator and high-quality

of many cleaning tasks.

proven MAFAC process technology with

main-stream filtration ensure long and

counter- or co-rotating basket-nozzle

stable bath service lives. Another benefit:

rotation is the indispensable core of the

the voltage range of the machine is

Stefan Schaal, Head of Development

machine, MAFAC PURA works specifically

suitable for worldwide use. The modern

and Design at MAFAC, is convinced of

with turbulences, thus achieving a safe

machine design, where MAFAC focuses

the pioneering importance of vector

and effective cleaning of the component

on the use of new materials, presents a

kinematics: “With the vector-kinematic

surfaces. The parts are dried via a hot-air

visually appealing appearance within the

movement of the nozzle and spraying

impulse blower system.

production process.

Pioneering technology

system, we have succeeded in taking a first

“With the MAFAC PURA we round off

step into a new

our product

dimension of

range in the

dynamic cleaning.

lower range

The process

and specifically

permits its users to

address those

achieve the speed,

who are

quality and

entering the

cost-effectiveness

field of aqueous

that will be

parts cleaning,

required in

have little

industrial parts cleaning in the future”. In its current form, the new technology is

4A 1

experience or

4B 1

are operating

Figures 4a and 4b: Workpieces with complex geometries such as drilled holes and undercuts, in particular, benefit from the targeted turbulences of MAFAC vector kinematics.

a promising start

within a tight budget,” Peter Ruoff, Head of Marketing

further developments. “The innovation

High-quality technology for a small budget

approaches of vector kinematics are

In addition to powerful technology,

manifold. We are still at the beginning, and

the jubilee machine impresses with its

Available from stock

are moving into an exciting time.”

functionality and simplicity. The MAFAC

In this context, MAFAC also decided for

PURA standard selection program has

the first time to use the “machine to go

been designed such that it is easy for

principle”. The MAFAC PURA is built in

that offers great potential for numerous

Small and Fine: The Jubilee Machine MAFAC PURA

and Sales at MAFAC explains the machine concept.

anyone to operate. This enables the

batches of 10 and is therefore immediately

To mark its 50th anniversary, MAFAC

customer to start up the system on his

available from stock. “The purchase shall

is launching a new machine onto the

or her own. MAFAC telephone support

not be preceded by test cleaning. For

market: the MAFAC PURA, a powerful

or a service technician will be available if

the simple applications for which MAFAC

entry-level model for rapid, thorough

required. The equipment also supports

PURA has been designed, we rely on

cleaning (ref. Opening photo).

uncomplicated handling of the machine

our experience. It influenced product

The spray cleaning machine of compact

in other ways: the starter kit with basket

development fully in a standardized way,

design with single bath technology is

and cleaner makes it easy to get started.

so that no individual adjustments are

intended to be used as an all-round

The small basket size (471x321x200 mm)

necessary”, explains Peter Ruoff.

parts washer for decentralised use.

permits small batches to be processed, or

This makes “Plug and Play” possible for the

Accordingly, its structure and its

allows an intermediate and final cleaning

user.

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N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

ICT - ZOOM ON EVENTS

DeburringEXPO 2019 - Strong Demand for Booth Floor Space

oughly one year before

experience at the trade for as well: “We were

surface finishes, DeburringEXPO provides

DeburringEXPO opens its doors

able to establish contact with numerous tier

a representative overview of the relevant

for the third time, more than

2 and 3 companies and smaller businesses

systems, processes, tools and equipment,

70 companies have already made firm

from the automotive and aviation industries

as well as measuring, test and analysis

bookings for their booth floor space. This is

at DeburringEXPO, as well as from the fields

systems. The exhibition portfolio covers

a strong indication of growth for the trade

of hydraulics and pneumatics, with whom

processing of workpieces and components

fair for deburring technology and precision

we weren’t previously familiar – not only with

made of practically all technical materials

surface finishing, which will be held in

companies from Germany, but from many

and from nearly all industry sectors. “At the

Karlsruhe from the 8th through the 10th of

other countries as well such as Italy, France,

upcoming trade fair, even more attention

October, 2019.

Belgium, Sweden, Denmark, the USA, India

will be focused on the deburring of sheet

Even greater attention will be focused at

and Brazil. Participation at the trade fair

metal components than at previous

the upcoming event on the optimisation

has paid off for us and we’ll be back again

events, in particular lasered parts and

of deburring processes for sheet-metal

in two years,” reports Keisuke Kaga, Head

stampings, flame-cut and fine-blanked

components and additively manufactured

of Europe Sales at Sugino Machine Limited

parts, as well as additively manufactured

parts, as well as parts cleaning after

from Japan.

workpieces. Furthermore, we’ll also place

deburring. Added value will be provided by

Numerous other exhibitors at the last

more emphasis on parts cleaning after the

the DeburringEXPO expert forum which is

trade fair for deburring technology and

deburring process”, adds Hartmut Herdin.

in great demand as a source of knowledge

precision surface finishing arrived at this

Further issues covered by the exhibition

and will offer simultaneously interpreted

conclusion as well, and have thus already

portfolio include training and technical

(German<> English), highly practical

made firm bookings for their booth floor

literature.

presentations.

space at DeburringEXPO 2019. “Thanks

DeburringEXPO’s exhibition spectrum,

to a high exhibitor return rate, frequently

which is consistently aligned to deburring,

associated with increased booth size, as

Knowledge as Added Value – Bilingual Expert Forum

rounding and the production of precision

well as new exhibiting companies who have

Offerings presented by the exhibitors will

surface finishes, deals with processes which

already decided in favour of participating

be rounded out by the integrated 3-day

are becoming more and more important

at the upcoming event, the exhibitor list

expert forum at DeburringEXPO, which

in parts manufacturing: despite all of the

already included more than 70 companies

has established itself as a highly popular

optimisation measures implemented prior

in mid-October 2018,” says Hartmut Herdin,

source of knowledge. With simultaneously

to workpiece processing, residues remain

managing director of trade fair promoters

interpreted (German <> English)

which have to be removed for high quality

fairXperts GmbH & Co. KG. These currently

presentations, it provides visitors with the

downstream processes, and in order to

registered exhibitors will occupy nearly

opportunity of expanding their knowledge

assure flawless functioning.

70% of all exhibition floor space rented

in the fields of deburring and rounding, as

After only two events, the trade fair for

out in 2017, which is a good indication

well as the production of precision surface

deburring technologies and precision

that exhibition offerings will once again be

finishes. Beyond this, examples based on

surface finishing has already established

significantly increased.

actual practice and benchmark solutions

itself as an international information and

provide ideas and stimulation for the

of decision-making authority, 94% of whom

A Single Trade Fair for All Materials and All Industry Sectors

are involved in company decision-making

As a technology platform for deburring,

For further information:

processes, but rather by the exhibitors’

rounding and the production of precision

www.deburring-expo.de

procurement platform in this area. This is not only confirmed by the visitors’ high levels

154

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

optimisation of processes at one’s own company.

ICT - ZOOM ON EVENTS

Milan Hosts Second Successful Fastener Fair Italy. Dates Set For 2020 Show

total of 2700 managers, engineers and

attending the show. Department heads and

opportunities in the Italian market for the

buyers visited the highly successful

senior managers totalled 17% of attendees,

fastener and fixings industry. And with Milan

Fastener Fair Italy 2018, which took

while a further 11% were engineers and

such a dynamic business centre, it is the ideal

place at the Mico Milano Congressi on

technicians.

host city for Fastener Fair Italy.”

September 26-27. This was the second of these

The most strongly represented industry

events to take place in Italy.

sectors were the automotive industry,

Popular seminars

The number of suppliers of fastener and fixing

construction, mechanical engineering,

Adding a further important dimension to

products and systems taking part in the show

hardware / do-it yourself retailing, electrical

Fastener Fair Italy was an accompanying

was 210, filling the venue’s South Hall. While

products / domestic appliances, aerospace,

programme of technical seminars. These

22% of exhibitors were foreign companies

agricultural / off highway machinery and

proved highly popular, attracting a total of 175

representing 13 countries, participation by

furniture manufacturing.

delegates over the two days. Three sessions

Italian firms increased compared to the 2016

Exhibitors were delighted to welcome high

were devised by Show Partner Fasten.it

show, confirming that Fastener Fair Italy is

calibre Italian and international visitors,

(www.fasten.it), providing insights into issues

now established as the reference point for the

including the science-based technology

currently affecting the fasteners market.

market in this country. Among foreign nations

company 3M Italia, multinational corporation

These included seminars curated by A.I.F.M.

strongly represented were Germany, Turkey,

ABB S.p.A., world’s leading chemical company

Associazione Italiana Finiture dei Metalli,

the UK, Spain, while companies from Slovenia,

BASF, top global engineering companies

E.C.A.P. European Consortium of Anchors

Denmark, India, France and the USA also took

Ansaldo Energia, HILTI Corporation, Altran

Producers and Kistler Group. Also, selected

part.

Technologies.

exhibitors took to the big stage with their most

Leading industry associations supported

Among automotive companies represented

innovative ideas and solutions – the experts

the event and welcomed delegations on

by visitors were Ducati Motor Holding, LISI

from Coventya Group, Atotech Group, Frontline

their stands: the Italian Union of Fastener

Automotive, IVECO S.p.A. Buyers from the

Consulting and Filtereco Filtration Technologies

Manufacturers U.P.I.V.E.B., the Italian Union of

well-known appliance manufacturers Electrolux

presented the latest solutions to the issues

Fastener Distributors U.D.I.B. and the Italian

and De’Longhi attended the fair, as did

concerning fastener and fixing sector and

Association of Metal Finishing A.I.F.M.

technical specialists from IKEA Components.

related industries.

The mix of visitors to the show reflected the

In addition, there were visitors from

diversity of markets served by the fastener

the multinational steel manufacturers

More stand space in 2020

and fixing industry. Majority of visitors were

ArcelorMittal and Aferpi Steel Company. Local

Dates have now been set for the next Fastener

either wholesalers (24%) or distributors (42%),

and international representatives of leading

Fair Italy. The third show in the series will take

all playing a vital role in the supply chain to

fastener distributors and manufacturers,

place on November 11-12, 2020. The venue will

resellers and end-users. Around 20% were

including Würth, Fontana Gruppo, Stamperia

be Fiera Milano City and there has already been

end-users themselves. Fastener and fixings

Carcano Giuseppe, F.lli Mauri, A. Agrati S.p.A.

very strong demand for stand space. Following

manufacturers accounted for 34% of those

and many others.

the success of the show, some 50 companies

attending.

Commenting on the success of the event,

have confirmed their participation in Fastener

A significant number of visitors –28% –were

Olivia Griscelli, Exhibition Director at

Fair Italy 2020, with around 1,900 m² already

foreign, representing 62 countries.

organisers Mack Brooks Exhibitions said:

booked. In response, this next exhibition will

“We were especially pleased to receive very

occupy a large Pavilion 3 to provide additional

favourable feedback from exhibitors on the

stand space.

High visitor quality Visitor quality was also noteworthy, with

quality of visitors to this show. It was also good

managing directors, partners and board

to see such strong international participation.

For further information:

members accounting for 38% of those

This strengthens our belief in the many

www.fastenerfairitalia.com

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

155

ICT - ZOOM ON EVENTS

he 16th parts2clean proved to be a complete success.

From 23 - 25 October

parts2clean 2018: First-class Contacts, Projects and Contracts

2018 the 240 exhibitors at parts2clean transformed Halls 3 and 5 of the Stuttgart Exhibition Grounds into an international hub for the industrial components and surface cleaning sectors. Companies from 16 countries exhibited at the event, including 26% from outside the host nation Germany. Approximately 4,500 trade visitors from 42 countries attended, a response that underlines the consistently sound performance of this international flagship event. Some 21% of the trade visitors came from outside

Figure 1: From 23 - 25 October 2018 the 240 exhibitors at parts2clean transformed Halls 3 and 5 of the Stuttgart Exhibition Grounds into an international hub for the industrial components and surface cleaning sectors.

Germany, including 76% from member nations of the EU and a further

contacts made at our stand was slightly

important role played by industrial parts

18% from non-EU European countries.

down on the previous year, but quality

and surface cleaning in maintaining

Germany, of course, accounted for the

clearly made up for quantity. In the past,

quality standards in diverse stages of

largest contingent of visitors. This year the

some of the discussions at the stand

production. This was made evident not

biggest groups of visitors from outside the

tended to be a bit cursory, but this year

only by the extraordinarily high proportion

host nation came from Austria, followed by

we were able to talk in more depth. These

of professionals who attended the event

Switzerland, France, the Czech Republic,

discussions led to concrete projects,

(99%), but also by the decision-making

Italy and the Netherlands.

dates for visits and even some tests of our

competence of the visitors within their

“We are entirely satisfied with the results

cleaning technology. We will definitely be

companies. One in two visitors came

of parts2clean 2018”, says Olaf Daebler,

exhibiting at parts2clean 2019.”

from management and 85% of all visitors

Global Director parts2clean at Deutsche

stated that they played a role in their

of the quality of the visitors.” This view

Decision-makers welcome this platform for information and acquisitions

was shared by Jens Emmerich, Product

The 16th parts2clean clearly showed

them came with clear ideas on acquisition

Manager for R&D, Surface Technology

that more companies from different

and investment, a figure that was slightly

at BCD Chemie GmbH: “The number of

sectors are beginning to recognize the

higher than at last year’s trade show.

Messe AG, adding: “Many exhibitors noted a further improvement in terms

156

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

company’s investment decisions. It was also clear that the visitors to parts2clean were keen to invest. No fewer than 82% of

ICT - ZOOM ON EVENTS

Marketing & Sales and a member of senior

“We have been exhibiting successfully at

had an investment budget of over 100,000

management at MAFAC – E. Schwarz

parts2clean for many years and 2018 was

euros at their disposal. In other words,

GmbH & Co., enthused about an order

another success. This trade fair only attracts

many of the trade visitors arrived at the

for the company’s latest cleaning system:

serious trade visitors interested in concrete

International Trade Fair for Industrial Parts

“parts2clean 2018 proved better for us

business and it gives us the time to discuss

and Surface Cleaning with clear intentions

than last year’s event, not simply because

their requirements and specific objectives

and concrete projects in mind.

we concluded a direct sale of a cleaning

with them in detail. parts2clean is always

Consequently, the exhibiting companies

system at our stand, but also due to the

a great opportunity to meet first-class

were able to report some excellent

number of enquiries received from new

contacts and convert them into potential

contacts, new projects and even contracts

contacts. The conversations with trade

new customers, as well as nurture existing

negotiated at the trade fair. “We could

visitors revealed that the trend towards

customer contacts and business partners.”

convert high-calibre contacts into potential

increased industrial cleanliness continues

Elia Bosco, Sales, Everest Elektromekanik

new customers at this year’s parts2clean

unabated. The main focus of interest is in

Makine Ve Sistemleri Sanayi ve Tic Ltd.

and were able to conclude a big order

the removal of particulates, residues and

Sti., Turkey, also considers parts2clean an

almost on the spot. That is relatively

film-like contaminants.”

ideal platform for initiating new business:

rare at a capital goods fairs such as

This positive experience was echoed by

“parts2clean offers an excellent opportunity

parts2clean,” explained Carola Maurer,

Raffaela Tessari, Sales and Customer

to promote our products and new

Market Development Assistant, Hobart

Care with the Italian manufacturer of

developments among the right audience.

GmbH. Similarly, Peter Ruoff, Head of

cleaning plant and systems, NOVATEC S.r.l.:

The quality of the international professional

Some 41% of these potential investors

2 1

Figure 2: Companies from 16 countries exhibited at the event. The team of ICT_ Industrial Cleaning Technologies were also present with the latest issues of the magazines.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54

157

ICT - ZOOM ON EVENTS

visitors is outstanding and we will

The outcome of this year’s parts2clean

their specific needs, for example with

definitely exhibit again at next year’s

justifies our decision to exhibit at this

respect to both the partial or complete

parts2clean.”

trade fair every year.”

removal of residual, film-like

The manufacturers of cleaning plant

contamination of surfaces, as

Focus on trends and future requirements

with their trade fair participation.

A tour of parts2clean showed that this

AG, reported: “Compared to last

Suppliers of equipment from other

flagship event is not solely focused on

year, the number of leads was up by

areas of industrial cleaning were

current needs and demand for clean

about 30 %. These were primarily

also impressed. For example, Sandra

industrial components and surfaces. As

contacts from the automobile and

Gruber, from Sales & Marketing at

parts2clean organizer Daebler pointed

components industries, aerospace and

SensAction AG, said: “The number of

out: “We established that digitization and

electronics. The most frequent issue

visitors at our stand was similar to last

automation are making rapid inroads

was the partial removal of film-like

year, but the quality of the contacts

into industrial components and surface

contaminates, a challenge for which

made was higher. We are therefore

cleaning.” The organizers responded,

many companies do not yet have an

expecting good post-fair business.”

therefore, by including new display

adequate solution.”

Hans-Jürgen Oberdiek, Sales Marketing

formats, special presentations and

Manager, Carl Zeiss Microscopy GmbH,

various exhibits covering these

was also optimistic: “The visitors

future-focused areas. “This year, by

A cross-section of sectors and materials

approached us with a quite diverse

exhibiting combined preliminary solvent

The cleaning of industrial parts and

range of interests and requirements,

treatment and plasma technology, as

surfaces involves an extremely broad

which really underlines the growing

well as our digitization solutions, we

range of tasks and requirements,

importance of clean parts and surfaces

addressed the core needs of many users.

and this diversity is matched by the

within an increasing number of

We received an excellent response from

number of sectors from which the

sectors. Accordingly, we were able to

the visitors, particularly from customers

professional visitors at parts2clean

make a large number of new contacts

and existing business partners with

came. The sector with the biggest

at parts2clean, and this could generate

high expectations and requirements in

contingent of visitors this year was

more orders.”

specific areas such as film-like residual

the automobile industry with approx.

Florian Weber, Sales Director of

contamination or the digitization of

42%, followed by mechanical and plant

Weber Ultrasonics AG, had the same

cleaning processes. We were able to give

engineering, metalworking and metal

experience: “Yet again, we are very

them a clearer idea about the direction

processing, electrical engineering and

pleased with this trade fair. The

that this sector is taking”, said Rainer

electronics, precision engineering,

number of trade visitors and the

Straub, Board of Management, Vice

optics, pharmaceuticals, chemicals and

quality of the contacts was excellent.

President Sales & Customer Service,

production technology. The verdict

parts2clean is the only trade fair in

Ecoclean GmbH. His comments were

of the visitors at parts2clean was

this sector and we will be back next

echoed by Andreas Rosenbusch, Business

positive. An overwhelming majority

year.” Likewise, Tobias Jessberger,

Development Manager at Stäubli Tec-

stated that the event covered almost

managing director of Dr. Jessberger

Systems GmbH Robotics: “parts2clean

every aspect. Nine out of ten visitors

GmbH, reported: “Due to the

has signposted the role of Industrie 4.0

are confident that they will again

extremely high quality of the contacts

in the cleaning of industrial parts and

attend the International Trade Fair for

and the international outreach of

surfaces. The digitization of cleaning

Industrial Parts and Surface Cleaning

the trade show, parts2clean has a

plant and processes, as well as the

in the future. The next parts2clean will

firm place in our trade fair schedule.”

acquisition, evaluation and use of data

take place from 22-24 October 2019 at

Anja Wächter, managing director of

are huge topics that will assume greater

the Stuttgart Exhibition Grounds.

Metallform Wächter GmbH, came to

significance and for which we can offer

the same conclusion: “Our trade fair

an array of solutions.” However, many

For further information:

participation has again paid off - 100%.

sectors are still seeking a solution to

www.parts2clean.de

were not the only exhibitors to

158

N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine

Karl-Hein Menauer, Senior Manager Sales & Technologie at acp systems

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