ipcm n. 79 | January-February 2023

The smart journal for surface treatments

ipcm digital on

® Special issue on ARCHITECTURE & DESIGN

INTERNATIONAL PAINT&COATING MAGAZINE

ISSN 2280-6083

www.myipcm.com 2023

14th Year - Bimonthly

N° 79 - JANUARY/FEBRUARY

A NEW FOCUS ON INNOVATION www.adaptacolor.com

MARCH 15-16, 2023 FORUM COPENHAGEN DENMARK

Welcome to Scandinavian Coating 2023 – The premier surface treatment exhibition in Scandinavia

Following the positive response last last time and thanks to the increasing international interest in the event, Scandinavian Coating will once again be organized in Denmark. We welcome back all professionals from the surface treatment industry to Copenhagen 2023!

EXHIBITION Scandinavian Coating has established itself as the premier meeting place and exhibition for the entire surface treatment industry in Scandinavia. Over the years the event has become more international with participants from 15 countries. The exhibition with some 80 exhibitors shows the very latest product news and all sorts of equipment and services needed for the treatment of wood, plastic and metal.

CONFERENCE Apart from the highly important exhibition, Scandinavian Coating offers a high quality two-day conference program with educational and interesting seminars that reflects the latest developments in the industry.

Free admission to the exhibition and the conference.

Register at www.scandinaviancoating.com

T H E P R E M I E R S U R FA C E T R E AT M E N T E X H I B I T I O N I N S C A N D I N AV I A

COOL POWDER LOW CURING TEMPERATURE POWDER COATINGS STARTING FROM 140°C ENERGY COSTS REDUCED UP TO 20-30%* * Compared to the standard 170/180°C. The estimation considers a reduction in energy costs up to 5-10% for each 10°C lowering of the curing temperature, a value influenced by different factors, for example the type of oven that is used.

www.stpowdercoatings.com

CONTENTS JANUARY/FEBRUARY 2023

© Plasmatreat Gmbh

14

© Sprech

ADVANCEMENTS

The Plasma Technology from Plasmatreat Optimises Additive Manufacturing

© Blackfin®

40

05 06 18 20 22

34

FOCUS ON TECHNOLOGY

A New Automatic Powder Coating Plant for SPRECH, a Leader in Metal and Solar Canopies: Efficiency and Quality for End Customers

© SAT

FOCUS ON TECHNOLOGY

A New Booth Water Treatment Plant for Titanium Eyewear Industry Leader Blackfin®: Reduced Maintenance, Improved Coating Quality, and Greater Process Efficiency

EDITOR’S LETTER

26

ASK JOE POWDER

BRAND NEW

28

HOW IT’S COATED

SUCCESS STORIES Hammonds Upgrades Automatic Paint Line

BRAND NEW SUCCESS STORIES How the Contract Coater Brandt Also Successfully Coats Non-Metallic Workpieces

31 46

50

The “Ask an Expert” Column

Gold-Based Passive Heating for Eyewear

FOCUS ON TECHNOLOGY

Aluminium Anodizing in Ireland: AMS Architectural & Metal Systems Ltd Chooses an Italian Partner for the Installation of Its First Anodizing Line

58

BRAND NEW

60

FOCUS ON TECHNOLOGY

68

BRAND NEW

WHERE WE HAVE BEEN ADVANCEMENTS Independent, Continuous Quality Assurance Based on an Optimised Incentive Structure

GPS Enhanced its Powder Coating Performance with Self-Made Plant Design and Seamless Integration of the Conveyor

E S T. 1 9 5 2

MK34” - PVD 2.0: THE NEW ERA OF PVD COATING GREEN COATING TECHNOLOGY Kolzer ® MK34” the new era of vacuum coating machines.

PVD 2.0 technology allows extremely dense and homogeneous decorative/ technical coatings, with reduced production times, positions the new PVD at maximum performance technical and aesthetic and offer sustainable technology with extremely low production costs.

Quality, 70 years of manufacturing experience, assistance 24/7, make Kolzer ® your ideal partner.

www.kolzer.com

CONTENTS JANUARY/FEBRUARY 2023

© SMW

72

© Total Finishing Systems

FOCUS ON TECHNOLOGY

A New Powder Coating Plant Installed in Europe’s Largest Bicycle Factory

© Venjakob

92

88

HIGHLIGHT OF THE MONTH

Meeting Each and Every Finishing Requirement: The Mission of Total Finishing Systems

© ipcm

SUCCESS STORIES

Coating System with the Latest Control Technology. Nickname: All-rounder

70

HOW IT’S COATED

78

HIGHLIGHT OF THE MONTH

The Specialty Materials of Arkema Protect the Iconic Logo of NASA as It Blast Off to Space

AVIN Developed New Dialysis Cells to Reduce Energy Consumption

84

106

ADVANCEMENTS CONDOROIL’s Low-Temperature Application Formulations Limit Energy Consumptionand Protect the Environment

96

ADVANCEMENTS

98

ADVANCEMENTS

Complete Solutions for Composites

Spray Sa DDF4 Pumps

ART WITHIN SURFACES

The Lightness of Colour in Le Rond’s Solo Exhibition

102

SPECIALIZED TRAINING

108

STANDARD &LEGISLATION

110

ipcm® Academy Updated its 2023 Training Programme

The Value of Time

MEETING THE INDUSTRY

CLEAN IT. COAT IT. CURE IT. CUSTOM BUILT Engineered finishing systems: Blast, Pretreatment, Conveyors, Booths, applicators, robotics, and ovens.

Total Finishing Systems is a leading designer and integrator of high-quality and complex industrial finishing systems. Whether you need an in-depth process analysis or require finishing equipment and components, our equipment exceeds expectations and our innovation and automation is industry leading.

INCREASE YOUR PRODUCTIVITY by automating your finishing

SELF-LEARNING ROBOT

1 OPERATOR REQUIRED

EUROPEAN ASSISTANCE

info@Lesta.it www.Lesta.it Lesta srl

Lesta srl

Lesta

Lesta Srl Milan

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

Alessia Venturi

H

ow much is the market actually willing to innovate?

On the one hand, it is true that investments have never been as numerous and substantial as they have been in recent years, not least because of the numerous incentives given by virtually all European governments for business digitalisation.

Yet the doubt is legitimate, especially after perceiving discouragement in numerous companies, beneath the enthusiasm for a market demand that has been strong for two years now and is going to remain strong for at least the first half of 2023, despite rumours of an impending crisis.

The observations we gathered during our traditional end-of-year meetings with some of the players in the surface treatment industry can be traced back to two trends: a lack of attention to what is new – as in, truly new – on the market, due to excessive focus on achieving the lowest possible price; and a lack of willingness to assess any proposed solutions on a technical bases and in detail, due to superficiality often leading one to trust any claim without verifying it before investing.

The first trend is frightening: if the market is not interested in testing or even inquiring about innovative products that are the result of careful and continuous research and development, the companies that do such research, investing high percentages of their turnover, will sooner or later stop doing so, discouraged by too little demand for their solutions’ potential.

The second trend is certainly the result of a lack of industrial culture in this sector but, at the same time, I think it can also be traced to the fact that, in general, people’s attention threshold is getting lower and lower. For most of us, everyday life has become an endless scrolling of pages, images, and brief information, for which neither great concentration nor much time is required.

Paradoxically, this attitude is also reflected in work activities. Abandoning a webinar after only a few minutes of listening or refusing to read the clauses of a contract because they are too long is behaviour that is considered (fortunately by very few) almost justified by lack of time.

My wish for this new year is that end users, especially those working in strategic industries such as the metal architecture and design ones – to which this issue is dedicated and which impact many aspects of social life, from urban planning to landscaping, from sustainability to the liveability of spaces, up to aesthetics – stop focusing on the here and now, but rather go back to having a more far-reaching vision, to being curious and ready to experiment, and to showing a more attentive and structured approach to new proposals.

Only in this way will we be able to nurture innovation, breathe life into research, support and reward companies that offer refined products and services, and above all contribute to the growth of the sector.

For our part, we start this new year by welcoming ipcm’s first US client, a confirmation of our interest and willingness to invest in expanding in that market, as a means of promotion not only for European companies in the Unites States, but also for American companies in their own market.

Editor-in-chief Direttore Responsabile

international PAINT&COATING magazine - JANUARY/FEBRUARY 2023 - N. 79

05

BRAND-NEW

The New Additive TEGO® Powder Aid D01 Improves Powder Coating Formulations TEGO® Powder Aid D01 reduces the melt viscosity of powder coating formulations and supports gloss development and DOI.

T

he Coating Additives business line

To avoid this, the low melt viscosity is

to powder coating formulations without

of Evonik has developed a new

particularly important: homogenisation of

containing surface-active waxes. As a result,

multifunctional polymer additive for

the ingredients and levelling of the surface is

overcoating is also possible without any

powder coating formulations: TEGO® Powder

improved. “TEGO® Powder Aid D01 prevents

problems.

Aid D01 makes the formulation easier to

pinholes by increasing the degassing

“TEGO® Powder Aid D01 is a new addition to

disperse during extrusion by promoting

threshold and enables the application of

the additive portfolio from Evonik´s Coating

pigment wetting and effectively reducing melt

thicker coating films,” has added Resch.

Additives Business Line, intended to be

viscosity.

Powder coatings containing TEGO Powder

extruded into powder coating formulations,”

The lower melt viscosity also leads to better

Aid D01 also show comparable resistance

has concluded Resch.

degassing, which aids flow and levelling as the

to weathering, making this additive suitable

formulation cures and prevents pinholes in

for use in exterior applications. So-called

the coating. Thus, the new additive optimises

overbake yellowing, even at elevated

gloss development and ensures better

temperatures, is manageable. The new

For further information:

DOI (Distinctness of Image) on the coating

additive imparts these positive properties

www.coating-additives.com

®

surface.

Another plus point of TEGO® Powder Aid D01 is its particularly versatile applicability in formulations with inorganic fillers and pigments, along with organic pigments including carbon black.

“Our new product thus offers a wide range of benefits for formulators who desire one multifunctional additive for various powder coating systems,” has stated Maximilian Morin, head of the Industrial & Transportation Coatings market segment.

“TEGO® Powder Aid D01 generates a large effect in small amounts and acts as a synergist with other additives.”

TEGO® Powder Aid D01 also plays to its strengths in HAA curing systems for powder coatings with water being formed as a byproduct.

“The challenge during crosslinking is, that the water needs to escape from the system.

This can result in pinholes or small craters in the film,” has explained Bernhard Resch, Scientist in Market Segment Industrial &

© Evonik

Transportation Coatings.

06

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

Application of TEGO Powder Aid.

BRAND-NEW

ECKART Launched Pigments for NIR Detection and Automatic Sorting ECKART has enriched its portfolio of sustainable product innovations with NIR Silver, a pigment solution to support recycling processes.

T

he automatic plastic sorting systems in recycling plants work with

combination with post-consumer resins, NIR Silver offers the packaging

NIR sensors that do not always correctly identify certain colorants

industry an interesting opportunity to further strengthen its efforts

such as conventional silver shades. ECKART has then developed

regarding sustainability.

NIR Silver, a pigment solution that is tailored to the needs of automatic

With NIR Silver, ECKART provides the industry with another pigment

sorting.

solution on how to best reduce its environmental footprint – an

NIR spectroscopy uses the wavelength signature of specific polymers

additional building block in the growing sustainability portfolio of the

to distinguish between them. NIR Silver optimally reflects these specific

effect pigment manufacturer.

wavelengths and thus supports the sorting of plastics.

The pigments are easy to process in all conventional plastics and provide impressive silver metallic effects. Particularly effective in

For further information: www.eckart.net

© ECKART

international PAINT&COATING magazine - JANUARY/FEBRUARY 2023 - N. 79

07

BRAND-NEW

Introducing PANTONE 18-1750 Viva Magenta, the Color of the Year 2023 Vibrating with vim and vigour, a shade rooted in nature descending from the red family demonstrating a new signal of strength.

P

antone’s Color of The Year, Viva

statement. PANTONE 18-1750 Viva Magenta

it is an animated red that encourages

Magenta 18-1750, vibrates with vim and

welcomes anyone and everyone with the same

experimentation and self-expression without

vigour. It is a shade rooted in nature

verve for life and rebellious spirit.

restraint; an electrifying, boundaryless shade

descending from the red family and expressive

It is a colour that is audacious, full of wit and

that is manifestly “out there” and is a stand-out

of a new signal of strength. Viva Magenta is

inclusive of all.

statement. Audacious, witty and inclusive of

brave and fearless, and a pulsating colour

Tapping into the experimental spirit of Viva

all, PANTONE 18-1750 Viva Magenta welcomes

whose exuberance promotes a joyous and

Magenta, Pantone explores the dynamic

anyone and everyone with the same rebellious

optimistic celebration, writing a new narrative.

between Artificial Intelligence and human

spirit.

This year’s Color of The Year is powerful

creativity to create “The Magentaverse”

A nuanced crimson red tone that presents a

and empowering. It is a new animated

available to the public for the first time.

balance between warm and cool, PANTONE

red that revels in pure joy, encouraging

PANTONE 18-1750 Viva Magenta writes a

18-1750 Viva Magenta is also a hybrid colour,

experimentation and self-expression without

new narrative. Brave and fearless, a pulsating

one that comfortably straddles the physical

restraint, an electrifying, and a boundaryless

colour whose exuberance promotes

and virtual, evocative of our multi-dimensional

shade that is manifesting as a stand-out

optimism and joy. Powerful and empowering,

world. Assertive but not aggressive, it is a carmine red that does not boldly dominate but instead takes a “fist in a velvet glove” approach.

Exuding dynamism, PANTONE 18-1750 Viva Magenta is a transformative red tone capable of driving design to create a more positive future.

“In this age of technology, we look to draw inspiration from nature and what is real.

PANTONE 18-1750 Viva Magenta descends from the red family, and is inspired by the red of cochineal, one of the most precious dyes belonging to the natural dye family as well as one of the strongest and brightest the world has known. Rooted in the primordial, PANTONE 18-1750 Viva Magenta reconnects us to original matter. Invoking the forces of nature, PANTONE 18-1750 Viva Magenta galvanizes our spirit, helping us to build our inner strength,” has explained Leatrice Eiseman, the executive director of Pantone Color Institute.

For further information: © Pantone

08

www.pantone.com

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

Ravarini Castoldi & C. srl ELETTROSPRAY® via E. De Nicola, 18 - I-20090 Cesano Boscone (MI) Italy - tel.+39 0255210608 www.ravarinicastoldi.it - dive@ravarinicastoldi.it

BRAND-NEW

KANSAI HELIOS Strengthen its Position in Europe with Two Acquisitions KANSAI HELIOS has expanded its portfolio of powder and liquid coatings thanks to two strategic acquisitions.

K

ANSAI HELIOS has announced that it has signed a share purchase

Beckers in the Railway Coatings segment, such as recipes and railway

agreement to acquire CWS Lackfabrik GmbH, a manufacturer

homologations and customer database (excluding customers from India

of powder coatings and liquid and solid synthetic resins

and China).

headquartered in Düren (Germany). After the fulfilment of closing

KANSAI HELIOS develops, manufactures and distributes industrial

conditions, it will become the new owner of CWS and its subsidiaries

coatings solutions, chemicals for bleaching and cleaning, materials

in Germany, U.S.A, Denmark and Poland. In addition, the company

for sticking and sealing, high-quality resins, architectural paints and

also acquired the Railway Coatings business of Becker Industrie

refinishing coatings.

SAS, establishing KANSAI HELIOS France SAS. The asset purchase

With these agreements, the company is significantly expanding its

agreement was signed on December 9th, 2022. After completion of

strategic position in the powder coating segment, gaining additional

closing conditions, KANSAI HELIOS will acquire all business assets of

know-how and distribution channels, as well as an increased production

© KANSAI HELIOS

10

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

and storage capacity that will further strengthen its presence in Europe.

Founded in 1864, CWS is a family-owned company with around

Get more from water

250 employees specialised in the development, production and marketing of technically sophisticated and customised powder coatings, with a turnover of around €100 million and a production volume of approx. 18,000 tons of powder coatings.

“This acquisition is a milestone in line with the ESG and growth strategy of KANSAI HELIOS. With CWS we have found a perfect complement and extension of our own competences, in powder coatings and synthetic resins as well as the existing liquid coating business, which strengthens our system supplier strategy, because we not only share the same philosophy, but also the same values.

I am convinced that this step will lead us from good to great,” has stated Bastian Krauss, the executive director of the KANSAI HELIOS Group.

The Beckers Group provides, among other products, a wide range of industrial coatings designed to protect railway vehicles and ensure cost-efficiency, long life durability, quality and environmental protection. In addition to the proven solvent-borne range, the company also offers a full waterborne range. Those product range and technologies will be transferred to KANSAI HELIOS and integrated to the existing portfolio.

“For KANSAI HELIOS the Railway Coatings development and production has always been of great importance and we have

Turn key solutions for industrial wastewater treatment Design and manufacturing of plants and chemicals for industrial wastewater treatment Chemical-physical plants Sludge treatment and compactor systems Ion exchange demineralization systems and reverse osmosis systems Oil separators Filtering systems Batch type systems Flotation units Chemicals and spare parts for water treatment Technical service, support and maintenance of wastewater treatment plants

achieved a strong market position in recent years, being the largest producer of Railway Coatings in Europe with important brands such as Wefa, Rembrandtin and Helios. Since quality, efficiency, and the broad range of colour shades, but also highly advanced system solutions have been convincing rail vehicle manufacturers in more than 40 countries worldwide for decades, this purchase rounds off the field perfectly. This business acquisition is a further step of KANSAI HELIOS in the Railway Coatings segment, following our most recent asset acquisition and establishment of KANSAI HELIOS Wefa in Essen, Germany,” has added Jost. “The Beckers Railway Coatings team is excellent and we are delighted that they have chosen the KANSAI HELIOS team to continue to serve their valued existing and new customers in France and around the world.”

For further information: www.kansai-helios.eu

Beware of imitations, buy the original!

info@waterenergy.it

www.waterenergy.it

BRAND-NEW

AkzoNobel Unveils a New Capability for Bonded Metallic Powder Coatings to Meet Rising Demand in North Africa AkzoNobel Powder Coatings has unveiled a new manufacturing facility in Egypt that will enable it to locally produce and deliver bonded metallic powder coatings to customers in North Africa.

A

new production capability that will enable AkzoNobel Powder

the commercial director for South and East Europe of AkzoNobel

Coatings to locally produce and deliver bonded metallic powder

Powder Coatings.

coatings to customers in North Africa is now available in its

Limoncuoğlu has also added that he is pleased that the introduction

manufacturing facility in Egypt.

of the new bonding line fulfils a long-held ambition: “Significantly

The increased demand for bonded products is being driven by the

expanding our local production capabilities and the speed with which

huge development in construction and growth in domestic appliance

we can deliver bonded metallic products to our customers in the

manufacturing in the region. AkzoNobel’s advanced bonding techniques

region, is just one of the ways we’re growing within the market and

can significantly improve the lustre and finish of its premium special

helping our customers stay out in front. Partnership is at the heart of

effect metallic powder coatings to deliver a uniform metallic finish with

everything we do. We exist because of and for our customers. We have

even greater colour consistency and performance.

listened to what our customers need, and with new colours, shades

“Customers can now order from a range of stunning colours and

and metallic finishes, we can help them on a journey to a new world of

textures that are always on trend with the confidence that comes with

possible.”

working with a global partner who understands the critical importance of local presence, and faster delivery,” has stated Sanal Limoncuoğlu,

© AkzoNobel

12

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

For further information: www.akzonobel.com

ADVANCEMENTS

The Plasma Technology from Plasmatreat Optimises Additive Manufacturing Edited by Plasmatreat Gmbh Steinhagen - Germany

P

lasmatreat GmbH from Steinhagen was demonstrating its

Product samples, tools, products in small batches, individualised items,

innovative Openair-Plasma processes at the world’s leading trade

spare parts and more can be produced in a very short time using 3D

fair for the plastics and rubber industry in October. In addition

printing. This makes additive manufacturing a technology in demand,

to its main booth I65 in Hall 11, the company was also represented in

e.g., to counteract supply bottlenecks. Surface treatment with plasma

the VDMA Circular Economy Forum. At both booths, the world market

can significantly improve the quality of the result.

leader for atmospheric plasma technology and various partners was demonstrating, among other things, how the quality of components

Post-processing of 3D-printed components

produced by 3D printing can be significantly improved by plasma

Plasmatreat has demonstrated the cell4_Plasmatreat automation

treatment, while at the same time reducing the carbon footprint of the

solution developed together with KUKA and the Openair-Plasma

manufacturing company.

treatment using the example of a dashboard printed in 3D technology.

© Plasmatreat Gmbh

14

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

ADVANCEMENTS

Benchmarks are set by the icon-based programming of partner FPT Robotics GmbH, which enables simple and fast commissioning, as well as program changes, without the operator having to have special robotics knowledge. The parts were produced by 3D printing specialist thinkTEC using HP Multi Jet Fusion technology, which uses a powder bed process. The individual parts are then subsequently bonded with adhesives from the manufacturer DreiBond GmbH, selectively coated with PlasmaPlus and individually digitally printed.

Improved haptics, appearance and bonding At the booth, visitors expected live how the CO2-neutral Openair-

Plasma process significantly improves the product properties of

3D-printed components as well as process efficiency: activating the surface with Openair-Plasma allows environmentally friendly printing and painting without resorting to conventional flame treatment or chemical pretreatment. The long-term durability of inks and coatings can also be further increased by a supplementary PlasmaPlus coating. When bonding products from the 3D printer, the use of plasma technology also replaces the use of chemical adhesion promoters (primers) and achieves long-term stable bonds - even when originally incompatible materials are used. Users thus benefit from an expanded choice of materials.

“3D printing alone is not enough. A strong network of manufacturers and companies that master the upstream and downstream processes is key to the breakthrough of this revolutionary technology in the industry. Plasmatreat is taking a step ahead here and shows

www.cmautomazione.com

that solutions can be implemented quickly and sustainably,” says Frank Petrolli, VP Strategic Market Development at Plasmatreat.

How plasma technology optimises industrial processes When plasma with its high energy level comes into contact with materials, it changes the surface properties, e.g., from hydrophobic to hydrophilic. Fine cleaning of metal and glass, for example, with Openair-Plasma from Plasmatreat gently and safely removes dust, grease, release agents and additives from surfaces. In the case of plastics, in addition to cleaning, an increase in surface energy is brought about by so-called activation through the introduction of hydroxyl groups into the plastic surface. In both cases, an optimized wettability of the substrate surface can be achieved and the adhesion ability significantly increased. In this way, long-term stable adhesion of adhesives and coatings is achieved. With Plasmatreat’s PlasmaPlus technology, the application (deposition) of nanocoatings can additionally produce specifically functionalized surfaces with defined properties, e.g., an adhesion promoter layer.

Opening photo: An automotive dashboard pre-treated with Openair-Plasma.

CM AUTOMAZIONE s.r.l.

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

BRAND-NEW

CISART Joins the CIE-MST Chemicals Group Following the acquisition of the CISART brand and know-how, C.I.E. can now offer a complete range of engineering and chemical solutions for the aluminium surface treatment sector.

C.

I.E. Srl, a leading company in the supply of water treatments for metal finishing processes, is continuing its expansion in the aluminium sector. Recently, it has acquired the brand

and know-how of long-standing engineering company CISART, a leader in the design of anodising and coating plants for aluminium, with approximately 200 plants built in Italy and around the world since its foundation in 1972.

The resulting “Anodising and Coating Plants” division will be headed by Claudio Cittadini, the former General Manager of the CISART GROUP as well as a skilled designer and expert technologist known and respected throughout the world of aluminium finishing.

“The acquisition of CISART,” states C.IE. General Manager Franco Falcone, “enables our parent company CIE-MST Chemicals to provide its © C.I.E.

customers with comprehensive engineering and chemical solutions for their anodising and painting processes, from water treatment systems

Franco Falcone, General Manager of C.I.E..

to process chemicals. One group, one team, one global service for all aluminium oxidisers and coaters in Italy, Europe, and the world.”

About C.I.E. Since 1980, C.I.E. (Compagnia Italiana Ecologia) has been specialising in the treatment of water from the cleaning, etching, and painting stations of metal finishing lines (CRS, HDG, EG, aluminium, and alloys). It has already installed more than 500 plants in Italy and the rest of the world (Western Europe, Eastern Europe, Middle East, America, and Australia).

C.I.E.’s systems are already successfully operating in all metal finishing fields: • steel production; • cold forming; • automotive; • household appliances; • aluminium extrusion; • aluminium cans; • coil coating; • general aluminium processing lines. © C.I.E.

For further information: www.cieeng.com

16

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

Claudio Cittadini, former General Manager of the CISART GROUP.

FILTRAZIONE PER IMPIANTI DI VERNICIATURA FILTERING FOR FINISHING LINES

rotoli, pannelli e celle in fibra di vetro

rolls, panels and cells of glass fiber

celle filtranti per alte temperature

filtering cells for high temperatures

rotoli e pannelli in fibra sintetica accumulatore vernice “Columbus” filtri “Andreae” cartucce filtranti filtri assoluti applicazioni speciali

rolls and panels of synthetic fiber paint accumulator “Columbus” “Andreae” filters filtering cartridges absolute filters special application

FILTRO ALVEOLARE MAX PAINT distributori esclusivi per l’Italia

massima efficienza massimo accumulo di vernice massima durata

=

minori costi di smaltimento minori costi di manutenzione

L’esclusivo design alveolare permette di trattenere quantità di overspray notevolmente superiori rispetto ai filtri oggi in commercio

www.defil.it

SUCCESS STORIES

Hammonds Upgrades Automatic Paint Line Hammonds, the Fitted Furniture Company, which manufactures and retails high quality tailored storage solutions upgraded panel coating line with Graco equipment.

H

ammonds, the Fitted Furniture Company, based in

to improve their manufacturing technics to the benefit of both the

Leicestershire (United Kingdom), design, manufacture and

customer and the business.

retail tailored fitted storage solutions nationwide. Through their

Hammonds automated paint plant utilises flat line multi spray gun

website customers can arrange for a designer to visit customers home

coating systems to apply Ultra Violet light curing 2-component paint

and design a tailored storage solution to meet their storage needs,

to wooden components. It wanted to improve on its existing process

whether that’s through fitted wardrobes in the bedroom, office solutions

of manually weighing and mixing the 2-component paint which is then

in study or storage for the lounge, they’ve got a solution to maximise

supplied to the spray guns from a single pump through a hopper or “hot

space throughout the home. They offer a wide range of both vinyl and

potting” in a bid to reduce wastage, improve quality and consistency

painted furniture.

as well as efficiencies which would allow them to increase production capacity.

A challenge in the paint shop

In an attempt to find a solution, Hammonds contacted Graco and asked

Hammonds is renowned for producing quality furniture and opened

for some assistance. Dave Blurton of Graco visited site to see in person

their painted factory in 2016, a first for the company. Over the years

the situation and advise what solutions Graco could offer. After the

they’ve worked extensively on their painted facility constantly looking

initial meeting an authorised Graco distributor Fluid Technologies Ltd

© Graco

Merkur pumps.

18

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

SUCCESS STORIES

located in the Midlands were introduced to Hammonds. Martin Cresswell

Immediate results

and Steve Smith from Fluidtec, provided a solution incorporating Graco

Fluid Technologies Ltd installed one Promix 2KS, four Merkur and one

Promix 2KS Electronic Mixing System and Merkur Supply Pumps. Graco’s

Merkur Bellows pumps and the necessary supply lines on a skid frame

Promix 2KS Electronic Mixing System is a tried and tested, reliable,

assembly for quick installation. The new paint system was installed and

accurate system for the on ratio mixing of 2-component paints.

commissioned together with re-instating the Air Assist function of the

The system is ideal for a wide range of solvent-borne, water-borne and

existing spray guns on the flat line machine.

high-solids materials including in this case UV curing paint. The Promix

Hammonds are very pleased with their new paint supply and mixing

2KS was installed using the non-contact Coriolis flow meter for the UV

system. “The Graco Promix 2KS system gives the mix ratio accuracy we

curing base paint, this meter has no moving parts in contact with the

need for our application, saving on time and waste. This has allowed

material.

us to increase production and improve product quality by improving

The simple integration into the automated spraying system made

paint laydown on the component and paint performance for our

possible with the EasyKey controls of the Promix 2KS. Graco’s Merkur

customers. We also saw an improved application by being able to use

Pneumatic High Pressure Supply Pumps were used to supply the paints,

the Air Assisted Airless spray guns as they should be,” explains Steve

hardener and flushing materials to the Promix 2KS at the pressure

Fitter Paint and Finishing Operations Manager. “With the Promix 2KS

and volume required for multiple spray guns on the automatic flat line

controlling the cleaning cycle for the mixed material means we use the

spraying machine.

minimum flushing material every time”.

The hardener utilised the Merkur Bellows Pump featuring a fully enclosed piston packing, this eliminates problems with the moisture curing hardener drying on the piston rod causing leaks.

For further information: www.graco.com

© Graco

The control panel of the Promix 2KS system.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2023 - N. 79

19

BRAND-NEW

New Catalyst Technology to Obtain Coating Ingredients from Renewable Materials Researchers have discovered a new catalyst technology that converts renewable materials such as trees and corn into the key chemicals for paints and coatings.

A

team led by University of Minnesota Twin Cities researchers has

improving yield and reducing waste. For the first time, this could reduce

recently invented a ground-breaking new catalyst technology

the price of renewable acrylic acid below fossil-derived chemicals. The

that converts renewable materials such as trees and corn into

economic opportunity generated by the new catalyst is being pursued

the key chemicals, acrylic acid and acrylates used in paints, coatings and

by Lakril Technologies, a startup company that aims to manufacture

superabsorbent polymers. The new catalyst technology is also highly

low-cost renewable acrylic acid and acrylates. By licensing the catalyst

efficient, which means lower costs for the manufacturing renewable

technology from the University of Minnesota, Lakril Technologies will

chemicals. The research team was supported by the U.S. National

develop the technology beyond the laboratory.

Science Foundation through the NSF Center for Sustainable Polymers,

“Chemical manufacturing has relied on a class of catalysts called ‘zeolites’

a multi-university collaborative team with the mission to transform how

for half a century,” said Dr. Chris Nicholas, CEO of Lakril Technologies.

plastics are made, unmade and remade through innovative research.

“Because the new catalyst discovery is based on a zeolite formulation

Using lactic acid derived from corn The new catalyst formulation converts lactic acid-based chemicals

already available at scale, our new process to make acrylic acid and acrylates will achieve low cost with low risk.”

derived from corn to acrylic acid and acrylates with the highest

Sustainable conversion of biomass to polymer ingredient

yield achieved to date. The technology exhibits substantially higher

At the University of Minnesota, the research team plans to continue

performance when benchmarked against other classes of leading

their basic research on catalyst design to understand the fundamental

catalysts. The public is most familiar with acrylic acid and associated

aspects of the chemistry with financial support from the Center for

acrylates through its uses in everyday items from paints and coatings

Sustainable Polymers headquartered at the University of Minnesota.

to sticky adhesives to superabsorbent materials used in diapers. These

“This is a wonderful example of how addressing important basic

chemicals and materials have been made for the last century from fossil

research questions that are at the heart of fundamental catalysis can

fuels. But in the last few decades, the corn industry has been growing

lead to innovative new processes that have true technological promise,”

to expand beyond food and livestock feed to manufacturing useful

said Marc Hillmyer, director of the Center for Sustainable Polymers and

chemicals. One such corn-derived chemical is sustainable lactic acid,

a professor in the University of Minnesota Department of Chemistry. “A

a key ingredient in the manufacturing of renewable and compostable

grand challenge in the Center for Sustainable Polymers is the efficient

plastic used in many everyday applications.

and sustainable conversion of biomass to polymer ingredients, and this

Lactic acid can also be converted to acrylic acid and acrylates using

work represents a groundbreaking solution to that challenge that will

catalysts. However, until this new catalyst discovery, traditional catalysts

have lasting impact.”

were very inefficient achieving low yields and making the overall process

Lakril Technologies, located in Chicago, already has received $1.4 million

too expensive.

in pre-seed financing to scale the process. The Iowa Corn Growers

“Our new catalyst formulation discovery achieves the highest yield to

Association led the financing with participation from the Kentucky

date of acrylic acid from lactic acid,” said Paul Dauenhauer, professor

Corn Growers Association along with grants from the Minnesota Corn

in the University of Minnesota Department of Chemical Engineering

Research and Promotion Council, Indiana Corn Marketing Council, Corn

and Materials Science. “We benchmarked the performance of our new

Marketing Council of Michigan, along with Small Business Innovation

catalyst to all prior catalysts, and the performance far exceeds previous

Research (SBIR) awards from both the U.S. Department of Agriculture

examples.”

and the U.S. Department of Energy.

The new catalyst formulation substantially reduces the cost of manufacturing renewable acrylic acid and acrylates from corn by

20

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

For further information: www.specialchem.com

THE NEW HIGH TECH ARCHITECTURAL POWDER COATINGS CLASS 1 AND CLASS 2, AVAILABLE IN ANY COLOUR, BRILLIANCE AND QUANTITY, RESULT OF DEEP KNOWLEDGE AND COLOUR ENGINEERING

WE ARE COLOURS ENGINEERS

WE ARE COLOURS ENGINEERS

BRAND-NEW

© CPCA

CPCA Announced the Annual Conference on the Canadian Paints and Coatings Industry CPCA will hold its 110th annual conference in Niagara-on-the-Lake on 25th and 26th May 2023.

C

PCA – the Canadian Paint and Coatings Association – has recently

Finally, the most important contributors will be honoured during the

announced that its annual conference and AGM will be held at

traditional Chair Awards Dinner at the Château des Charmes winery and

the Queen’s Landing hotel in Niagara-on-the-Lake from 25th to

vineyard.

16 May 2023.

“The coatings industry has become a leader in advancing more

The 110th conference of the association will describe the latest

sustainable products, which continues to help reduce the environmental

developments in the local paints and coatings industry, as well as

footprint of many end users. The attendees can expect excellent

provide a meeting place for all professionals and experts involved.

networking opportunities, engaging discussions and an evening of fine

Besides a brief introduction by the Board and Committee Chairs

dining and entertainment,” has stated Gary LeRoux, the president and

explaining the work of the association over the past year, the event

CEO of CPCA.

will focus on the evolving nature of the industry, the opportunities

The Early-Bird registration is now open, allowing to save 20% until 20th

and challenges ahead and how the industry can continue to provide

March. The rate for CPCA members is $1,080 CDN, while for the non-

essential products for a wide range of end use customers. In addition

members is $1,320 CDN.

th

to several speakers, the conference will also welcome students from several Canadian universities presenting research posters.

For further information: www.canpaint.com

international PAINT&COATING magazine - JANUARY/FEBRUARY 2023 - N. 79

21

SUCCESS STORIES

How the Contract Coater Brandt Also Successfully Coats Non-Metallic Workpieces Brandt had already many years of experience in liquid and powder coating of metal components. However, the demand for coating sensitive substrates is steadily increasing, so it decided to rely on the flexible electrostatic M-Line powder coating system from J. Wagner GmbH.

B

randt has been active in professional industrial coating for

sensitive substrates is steadily increasing. These include organic and

50 years and is today one of the leading contract coaters in

mineral materials (e.g. wood based materials or plastics), fibre cement

Denmark. The company employs around 100 people at its

panels and a variety of hybrid material composites. They are processed,

headquarters in Varde, Denmark. To be able to respond to the most

for example, into MDF kitchen fronts or window frames. Many of these

diverse customer requirements, Brandt covers the entire technology

materials have no or only very low electrical conductivity and are

spectrum - from manual coating to highly automated coating systems

sometimes very temperature-sensitive.

with liquid and powder paint. Customers include manufacturers from

Government environmental regulations and VOC guidelines in liquid

the wood and furniture, metal, construction and plastics industries.

coating are becoming increasingly restrictive. Therefore, Brandt was looking for a sustainable powder coating solution that can also be

The challenge

applied to sensitive substrates - materials that are traditionally liquid

Brandt already has many years of experience in liquid and powder

coated.

coating of metal components. However, the demand for coating

Besides the smaller ecological footprint, another advantage of powder

© J. Wagner GmbH

© J. Wagner GmbH

The M-Line powder coating system with SuperCenter EVO and monocyclone.

22

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

EPISTOLIO EPISTOLIO towards the future

coating is the significant saving of resources. The surfaces are seamlessly coated, scratch-resistant and extremely durable.

SOLUZIONI ROBOTIZZATE DI ROBOTIC PAINTING SOLUTIONS VERNICIATURA

The solution After a careful analysis with corresponding application trials, experienced specialists from WAGNER (Ursin Huwiler, Mats Rapp, Niels Ole Larsen, Janus Wemmelund), TRIAB (a Scandinavian system house provider of powder ovens) and selected powder coating manufacturers developed a flexible system concept that was installed at Brandt at the end of 2021.

With the electrostatic M-Line powder coating system, Brandt, as one of the first companies in the Scandinavian region, can also offer powder coating for non-metallic substrates. Non-conductive, temperature-sensitive materials such as plastics and even inhomogeneous natural materials such as wood are powder-coated with high efficiency in a material-friendly manner. To achieve this, the coating system can process highly reactive low-temperature powders and UV powders in addition to conventional metal powders.

The M-Line system comprises ideally matched components which ensure that different powder coatings can be applied with a high

Epistolio Srl.

Via Piemonte 120 21100 Varese (VA) ITALY Ph: +39 0332 212692 Fax: +39 0332 223666 info@epistolio.com www.epistolio.it Publierre_Milano

The powder center SuperCenter EVO.

SUCCESS STORIES

© J. Wagner GmbH

© J. Wagner GmbH

The powder coating of non-metallic workpieces in the M-Cube booth with support of Field Controllers.

degree of efficiency, even on non-conductive materials. A core element

The customer experience

here are the suction pipes arranged laterally along the coating booth

Brandt can achieve savings in many areas: With the Energy Efficiency

on both sides, which minimize the air flow in the coating zone. WAGNER

Package, the coating system requires up to 40% less energy than

Field Controllers improve the grounding of electrically low-conductive

comparable systems, as a smaller fan motor is sufficient to generate

workpieces, optimize the coating thickness distribution and prevent the

the same extraction volume in the coating booth. Brandt was able to

so-called picture frame effect. The special geometry of the piping and

significantly improve its environmental footprint with the new powder

monocyclone reduces the pressure loss in the system and the risk of

system. Moreover, in contrast to liquid coating, no solvents are used.

powder deposits. This so-called Energy Efficiency Package (EEP) from

Thanks to the recycling of overspray powder, an enormous amount of

WAGNER reduces powder friction during recovery, which generates less

material is saved. With the robust 1-layer powder technology, which

heat energy.

does not require any intermediate sanding, Brandt also significantly

This enables gentle recirculation of the highly reactive low-temperature

reduces manual processes. Compared to liquid coating, the throughput

powder. Brandt uses the SuperCenter EVO powder center with Twin

time per workpiece can be significantly reduced: About one minute

Sonic Sieve to control the complete system technology, including

of preheating, another minute of powder coating, about five minutes

automatic guns and movement units. Powder feeding and color change

of curing in the oven followed by 20 minutes of cooling - in total, the

processes are automated and very reliable.

throughput time for one circulating layer is only around 30 minutes.

Preheating and melting processes take place in infrared ovens (IR).

For Brandt, the system offers completely new possibilities: Thanks to the

Curing is then carried out using either electric infrared (IR) or ultraviolet

very flexible overall concept, the contract coater can now successfully

(UV) technology in the TRIAB “Speedoven UV”. A precise interplay of

process a wide range of non-metallic objects and materials and can

infrared radiation, convection air and ultraviolet radiation makes it

respond more flexibly to customer requests.

possible to completely cure extremely temperature-sensitive substrates already at below 120°C and within 2-3 minutes.

24

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

For further information: www.wagner-group.com

MORE innovation performance nano technology R&D ESG technical assistance

dn-chemicals.com

ASK JOE POWDER

The “Ask an Expert” Column Kevin Biller

kbiller@chemquest.com

Dear Joe, Is there any method, equation or software program to calculate powder density?

Thanking you in advance, Ali Baluli Saudi Arabia Dear Ali, I am aware of two methods used to determine powder density. Both are covered in detail in ASTM D5965 - 02(2007) Standard Test Methods for Specific Gravity of Coating Powders.

One uses the volume displacement of the powder into a fluid (kerosene or hexane) with a known density. The weight of the powder is known so the relationship between weight and volume can then be calculated.

Dear Joe, We currently use a “Midnight Black” wrinkle powder coating

Powder Specific Gravity =

supplied by a major powder producer. Can a second touchup

Weight of Powder (grams) / (Final Volume – Original Volume (millilitres))

coat be applied after first coat has cured? The first coat is being applied over cleaned HRPO (hot-rolled, pickled and oiled) steel.

This method involves introducing the fluid into a graduated

The second touchup coat does not adhere to the first coat and

cylinder. The volume and weight of the fluid is recorded. Next a given

flakes off easily. Any comments, suggestions?

weight of powder is mixed into the fluid and the displaced volume

Loyd Fields

is determined. It is essential that you eliminate all air pockets in the

Austin, Texas

mixture to obtain a reasonably accurate measurement. Please be aware that this method doesn’t easily account for the surface porosity

Dear Loyd,

common with most powder coatings and typically results is a lower than

Recoating wrinkle finishes can be a headache. This product is epoxy

true specific gravity. Nevertheless, it can be used as a decent tool to

based which makes the task even more difficult. Your best option is to

compare powders.

scuff sand the entire surface to be recoated, blow it off, then solvent

A much more accurate method is based on the Ideal Gas Law and

wipe with acetone or MEK. This should provide the adhesion you need.

utilizes a gas pyncometer instrument which measures volume of a

Using a polyester-based wrinkle is another option. These are not as

known weight of powder by gas displacement. These are relatively

hard as the epoxy wrinkle which should make recoating somewhat

expensive instruments and are available from a number of commercial

easier. However, the polyester wrinkles are more sensitive to substrate

instrument suppliers. Each instrument is slightly different; some

surface defects and pre-treatment streaking. HRPO steel can sometimes

measure volume, others can measure volume and density. You would

exhibit imperfections that will probably interfere with the development

have to consult the specific procedure provided by the instrument

of a polyester wrinkle finish.

manufacturer to successfully measure specific gravity of powders.

I would try the scuff sanding followed by solvent wiping. If this doesn’t

I recommend you use the simpler fluid method but always run a control

work, you may be relegated to stripping the defective parts, cleaning

sample of know specific gravity along with your samples to be evaluated.

them and powder coating a virgin surface.

I hope that this helps.

Good luck with sorting this out.

Best Regards,

Best Regards,

Joe

Joe

26

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

Hi Joe, I have a cleaner/phosphate that is supposed to treat magnesium but how should it be handled as far as dry-off and cure temps? I tried a couple of parts this morning, with a low gloss clear coat and they came out looking like desert storm camouflage. This was cured for 12 minutes at 180 °C. Bryan Brand Cheesequake, New Jersey Dear Bryan, Thanks for the question. Magnesium alloys are a tricky substrate to powder coat unless you know how to do it. Most magnesium fabricated products are cast resulting in a certain degree of porosity on its surface. Cleaning the substrate is a great idea however the cleaners, pre-treatment and rinses can remain harbored in the

 

pores. Indeed, even without cleaning air resides in the pores. As the powder melts and flows the cleaners and air escape from the pores. Most powders are curing at this point and can’t recover or reseal the holes caused by the volatiles. The result is pinholes, low gloss and unsightly surface disruptions. My advice is to continue cleaning as you are but run the parts through a relatively high temperature dry-off before you apply the powder coating. It’s preferable to coat the parts very soon after the dry-off, even while they are still warm so they don’t re-absorb ambient moisture. As for dry-off temperature, 200⁰C for 10 minutes is a good place to start.

You should also be aware that many powder suppliers offer product lines that are better suited for porous substrates such as magnesium. It may be best to use one of these with a well-controlled dry-off process.

Good luck.

Joe

© Kevin Biller

10X magnification of wrinkle powder coating surface.

Wrinkle finish powders require sanding to smooth the surface when recoating.





?

HOW IT’S COATED

Gold-Based Passive Heating for Eyewear Fabio Bergamin ETH Zurich - Zurich, Switzerland

Researchers from ETH Zurich have developed a new transparent gold nanocoating that harnesses sunlight to heat the lenses of glasses, thereby preventing them from fogging in humid conditions. This coating could potentially also be applied to car windshields. © ETH Zurich

In winter, face masks can lead to fogged glasses.

Here, the left lens (right from the reader’s perspective) has the new antifogging nanocoating. The other lens is uncoated.

R

Professors Dimos Poulikakos and

Absorbing a large proportion of infrared radiation

Thomas Schutzius point out that their

What is special about the new coating is that

transparent.

coating is fabricated with methods which

it absorbs solar radiation selectively. Half of

The new coating takes an approach that

are used extensively in manufacturing. In

the energy contained in sunlight resides in the

differs from conventional antifogging

a cleanroom and using vapor deposition

infrared spectrum, the other half in the visible

methods. Traditionally, surfaces are

under vacuum, minute amounts of gold are

light and UV radiation spectrum. “Our coating

coated with water-attracting (hydrophilic)

deposited onto the surface.

absorbs a large proportion of the infrared

molecules, which results in an even spread

ETH Zurich has applied for a patent on the

radiation, which causes it to heat up – by up

of condensation. This is how antifog sprays

coating.

to 8 degrees Celsius,” explains ETH doctoral

work. But the new method instead heats the

student Iwan Hächler, who was a driving force

surface, thus preventing humidity-induced

behind the development. It absorbs only a

condensation from forming there in the

28

esearchers in the group led by ETH

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

minor fraction of the radiation in the visible range, which is the reason why the coating is

© ETH Zurich

first place. It is the same principle as is used for

layers increase the efficacy of the heating effect.

a car’s rear window. But, as Hächler points out,

Moreover, the top layer of titanium oxide acts as

electric heating is inefficient and energy wasteful.

finish that protects the gold layer from wear. This

In contrast, the new coating is heated passively

whole “sandwich” is just 10 nanometres thick. By

and requires, during daytime, no additional energy

way of comparison, a common gold leaf is twelve

source.

times thicker.

Thinner, pliable and more efficient

The individual gold clusters touch each other minimally, which is what allows the gold layer to just

Poulikakos, Schutzius and their teams have been

start conducting electricity. So, in the absence of

working on passively heated surface coatings

sunlight, it would still be possible to use electricity to

for several years. Three years ago, the scientists

heat the coating.

published their first research paper on a gold

The researchers will now develop the coating further

coating that prevented transparent surfaces

for other applications. In the process, they will

from fogging up (see previous ETH News article).

investigate whether other metals work just as well

The coating they have now presented has many

as gold. In addition to eyewear and windshields, this

benefits over the first: It is made up of a single gold

antifogging method could be used wherever objects

nanolayer and is significantly thinner, which makes it

must be both heated and transparent – such as

more transparent as well as pliable. Further, it is also

windows, mirrors or optical sensors.

more transparent and efficient because it absorbs

There is no need to fear, however, that this would

infrared light more selectively.

cause a car or a building to heat up more in the

Gold might be expensive, but the researchers

summer.

emphasise that their coating requires so little

ETH doctoral student Hächler explains: “The pane

that the material costs remain low. The coating

coating absorbs infrared rays from the sun, which

comprises minuscule, extremely thin clusters of gold

specifically heats the pane and prevents the

sandwiched between two ultrathin layers of titanium

radiation from reaching the inside of the car or

oxide, an electrically insulating material.

building. As a result, the interior heats up even less

Due to their refractive properties, these two outer

than it would without the coating.”

Under the High Patronage of Mr Emmanuel MACRON, President of the French Republic

07-10 MARCH EUREXPO 2023 LYO N - F R A N C E THE INDUSTRY IS MOBILISING! Solution providers, service providers, subcontractors, manufacturers and distributors: solutions that support transitions!

• ASSEMBLY, MOUNTING, FASTENING • ELECTRONICS • ENERGIES & SUSTAINABLE MANUFACTURING • ADDITIVE MANUFACTURING & 3D PRINTING • FINISHING AND TREATMENT OF MATERIALS • FORGE & FOUNDRY • MATERIALS & SEMI-FINISHED PRODUCTS • MEASUREMENT, CONTROL, VISION, INSTRUMENTATION • PLASTICS, RUBBER, COMPOSITES • REGIONS & COUNTRIES • ROBOTICS • SERVICES AND FACTORY EQUIPMENT • SMART : DIGITALISATION, AUTOMATION, MECHATRONIC • SHEET METAL WORKING, METAL SHAPING, WELDING • MACHINING & MATERIAL REMOVAL

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global-industrie.com

WHERE WE HAVE BEEN

international PAINT&COATING magazine - JANUARY/FEBRUARY 2023 - N. 79

31

© Adobe Stock

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

34

FOCUS ON TECHNOLOGY A New Automatic Powder Coating Plant for SPRECH, a Leader in Metal and Solar Canopies: Efficiency and Quality for End Customers

40

FOCUS ON TECHNOLOGY A New Booth Water Treatment Plant for Titanium Eyewear Industry Leader Blackfin®: Reduced Maintenance, Improved Coating Quality, and Greater Process Efficiency

46

ADVANCEMENTS Independent, Continuous Quality Assurance Based on an Optimised Incentive Structure

50

FOCUS ON TECHNOLOGY Aluminium Anodizing in Ireland: AMS Architectural & Metal Systems Ltd Chooses an Italian Partner for the Installation of Its First Anodizing Line

58

BRAND NEW

international PAINT&COATING magazine - JANUARY/FEBRUARY 2023 - N. 79

33

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

A New Automatic Powder Coating Plant for SPRECH, a Leader in Metal and Solar Canopies: Efficiency and Quality for End Customers Alessia Venturi, ipcm®

Aluminium and beyond.

In the solar awning sector, especially when it comes to covering rather large spaces, using both steel and aluminium allows combining structural lightness and strength. The offer of Sprech Srl (Martano, Lecce, Italy), a company specialising in the conception, design, planning, and industrialisation of outdoor solutions, is geared towards this goal, with a particular focus on open-air public areas. Recently, the success of Sprech’s industrial philosophy has called for the installation of a new powder coating plant capable of providing the company with the finishing quality and operational flexibility required to cope with its increased production volumes.

Euroimpianti has thus developed a highly efficient, automatic plant solution in collaboration with Futura Convogliatori Aerei and Wagner Italia.

© Sprech

The Qbox Blue bioclimatic pergola by Sprech to create a dream outdoor space.

34

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

S

prech was established over forty years ago based on an idea of its current Managing Director Pasquale Rescio, who decided to combine his passion and experience in the steel and textile

awning field to start a firm whose core competence was the design of tensile structures. Today, Sprech is a family business led by its founder and his children, assisted by a highly qualified technical and professional team. The solid technological know-how acquired and constantly fine-tuned over the years allows it to offer spot-on solutions for every market need: modular covers, pergolas, gazebos, dehors, and tensile structures for commercial or residential use, with a particular focus on public spaces and coastal environments.

All Sprech products are designed to improve their users’ quality of life and foster a balanced relationship with the environment. All of its solutions can be adapted to any landscape and requirement, for both public and private use. Functionality, aesthetic refinement, and environmental sustainability are the principles that guide the design

© ipcm

of these products. “A team of architects and engineers as well as a large research & development staff enables us to launch an average of five new products every year, striving to reach performance degrees that always exceed market demands,” states Lucia Rescio, one of the founder’s daughters. “Sprech also owns a foundation that sponsors the biennial event Agora Design, which offers a rich programme of exhibitions, lectures, and thematic workshops, including a competition for the prototyping of new structures that provides an opportunity for designers to make themselves known.”

“My father Pasquale was the first to patent a pagoda-shaped outdoor cover, which is a structure with four steel poles stretching a PVC sheet,” adds Rescio. “Over the years, our business’ evolution has led Sprech to become a leader in Italy in the field of steel canopies for exteriors. We then incorporated all the technology necessary for the production of aluminium bioclimatic pergolas. Today, our main target © ipcm

market is Europe, with a 40% export share, which also includes small shares in North Africa and the Middle East. Our strength remains the manufacturing of large-sized outdoor coverings: thanks to the expertise and experience gained in metalworking, Sprech is the only company in this sector able to cover large areas with a minimum of uprights.

In this design and production context, the coating process is clearly a delicate and strategic phase, as it provides the structures with their final appearance, allows customising the proposed solutions, and guarantees excellent outdoor durability of finishes. “The powder coating plant that Euroimpianti designed by integrating Wagner’s latest application technology and a reliable Futura Convogliatori Aerei conveyor represents the end of a production line that starts from the profile cutting station and reaches directly the finishing one,” explains Alessandra Ripa, the Marketing Manager of Sprech.

“It also enables us to coat both hot-dip galvanised steel and aluminium with equal quality and durability results in compliance with the Qualicoat guidelines.”

From top: - The loading bay of the horizontal coating plant for aluminium and steel profiles and sheets supplied by Euroimpianti (Valeggio sul Mincio, Verona, Italy).

- The pre-treatment cell tunnel.

- The inside of the spray pre-treatment tunnel.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2023 - N. 79

© ipcm

35

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© ipcm

As can be seen from the type of workpieces hanging from the load bars, Sprech paints a wide range of parts in very different sizes.

© ipcm

The application area, with a focus on the switches of the power&free conveyor supplied by Futura Convogliatori Aerei (Robecco Pavese, Pavia, Italy), which create the storage buffers needed to guarantee the flexibility of the system.

Vertically integrated production

powder coating plant in use until last year could no longer meet our

At Sprech, raw materials (extrusions and sheet metal) of the highest

quality requirements nor our constantly increasing production volumes,”

quality, state-of-the-art technology, and last-generation machinery

notes Lucia Rescio. “In 2021, therefore, we started working on the

form the basis of a fully vertically integrated production process

project for a new coating system, which we wanted to be automatic and

guaranteeing certified products and high quality standards. The entire

very flexible, as well as able to process both steel and aluminium since it

manufacturing cycle is handled in-house: site surveys, design, rendering,

had to treat all Sprech’s metal components.

prototyping, production, and supervision of assembly on site. “Sprech’s

“We assessed several painting plant manufacturers and engineering

production activities are divided into two business lines, one related

firms: Euroimpianti presented us with the best performing turnkey

to steel and one to aluminium, and they take place in four plants built

solution, in terms of both coating quality and plant sturdiness. The

within a radius of 15 km from Martano, where our headquarters and

system is indeed both robust and flexible, and the fact that it is

showroom are located,” indicates Lucia Rescio. “One site performs

equipped with a power&free conveyor – for which we chose to rely

metalwork operations, from laser cutting to robotic welding. Another

on the know-how of Futura Convogliatori Aerei – allows working to

one is devoted to the processing of PVC for fabrics. The headquarters in

order without any loss of productivity. At Sprech, we coat not only our

Martano deals with aluminium processing, powder finishing, packaging,

products’ profiles, but their entire structures complete with accessories,

and shipping. Finally, we have a woodworking factory for manufacturing

coupling plates, and other components. Our customers can choose

the wood components required for some custom projects.” In fact,

from the forty colours in our catalogue, five of which are exclusive

flexibility in the production of the different components allows each

to Sprech, at no extra charge or select a customised tint, for which

part to be adapted to the specific needs of each end customer, offering

we guarantee a lead time of no more than ten to fifteen days from

extremely functional solutions that do not sacrifice aesthetics.

ordering.”

Sprech’s flagship products include canopies, which combine the and lightness of textile materials; gazebos capable of meeting all the

A flexible, automatic system performing ultra-quick colour changes

needs of the public and private sector; tensile structures and marquees

The new coating plant designed, built, and installed by Euroimpianti

for fitting out large areas; and the pergolas from the QBox line, the

was part of an investment in Industry 4.0. It is equipped with Wagner

ideal solution for creating continuity between indoor and outdoor

application technology and Futura Convogliatori Aerei power&free

environments, with steel uprights for covering large areas or minimal

conveyor. “The combination of technologies and expertise brought into

aluminium uprights for covering small spaces. “With such a variety of

play by these partners has enabled the creation of a “smart” coating

products and very often working on customised projects, the manual

plant that guarantees maximum quality and functionality. It consists

strength of steel or aluminium load-bearing structures with the flexibility

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FOCUS ON TECHNOLOGY

of high-tech machinery with automatic control even of the individual components’ maintenance process: overhead conveyor, pre-treatment tunnel, drying and curing ovens, and powder application booths. Speed and quality are guaranteed for every order. Moreover, the whole system is optimised for energy saving,” says Alessandra Ripa.

Futura’s electronic power&free overhead conveyor has a capacity of 1000 kg per load bar. The spray pre-treatment tunnel for galvanised steel and aluminium is made of stainless steel and is equipped with automatic doors to contain the heat in all hot-temperature phases, i.e. cleaning, drying, and curing, with a view to energy saving. The pre-treatment cycle includes ten stages in specific and separate cells for aluminium or galvanised steel. It starts with profile degreasing, deoxidising, acid degreasing, and rinsing with mains water to remove metal residues. It then continues with an additional rinse and the application of the nanotechnology surface conversion product based on titanium salts, which guarantees a corrosion resistance value of over 1,000 hours in compliance with the ISO 9227 standard.

After pre-treatment, the conveyor takes the load bars to the drying oven at 150 °C, followed by a visual check by the quality officers in order to verify © ipcm

the correct and uniform treatment of parts. Once they have left the drying oven, the load bars are sorted between the two Wagner booths in order to

The Wagner automatic powder application booth.

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

optimise the process. One booth is automated and equipped with a “smart” gauge reader capable of detecting the size and shape of workpieces in order to correctly trigger the eight automatic guns, which move closer or further away depending on part geometry. This booth includes a manual post-finishing platform to avoid even the smallest imperfections and a SuperCenter EVO powder centre for quick and reliable colour changes through highly automated, contamination-free operations. Equipped with sensors for data acquisition, this powder management unit sends the user statistics on various production data, such as powder consumption.

“Within one working day, we are able to change fifteen to twenty different colours in just 6 minutes and with one operator,” emphasises Lucia Rescio.

“Although it is a very quick colour change, it guarantees effective cleaning.

Since the start-up of this plant, we have already recorded significant powder savings, thanks to a 90% overspray recovery rate.” The second

© ipcm

booth is manual and it is used for primer application, should the customer require a two-coat finishing cycle, or for painting small batches or with nonstandard colours.

After coating, the parts are transported to the curing oven, where they dwell for about 25 minutes at 180 °C, depending on the type of paint applied. Then, they are placed in a cooling area before proceeding to the packaging area prior to shipping to customers.

Industry 4.0 at the service of the architecture sector Every single phase of the coating process is monitored through Industry 4.0-oriented management software for greater manufacturing efficiency. All the machines that make up the plant are interconnected, have preventive and predictive maintenance functions, and track all the working parameters of every batch loaded onto the conveyor. “Considering the parameters of efficiency, coating quality, and production flexibility, we can say we are

© ipcm

extremely pleased with the choice of installing this system and especially with the selection of the technical partners that collaborated on its implementation,” states Sprech founder Pasquale Rescio. “The new coating plant is an integral part of the evolution process that Sprech is pursuing to put customer satisfaction at the heart of all its production stages.”

From top: - The Wagner SuperCenter EVO powder management unit.

- The SuperCenter’s paint feeding system.

- Antonio Cimenes, the sales representative of Euroimpianti, Wagner, and Pulverit for the Puglia region, with Lucia Rescio from Sprech.

© ipcm

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© Blackfin®

Eyeglasses made from a single block of titanium, model Waterville

by Blackfin®in its pale yellow/ gunmetal grey version.

On the right, Pramaor Srl’s headquarters in Taibon Agordino.

FOCUS ON TECHNOLOGY

© Blackfin®

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

A New Booth Water Treatment Plant for Titanium Eyewear Industry Leader Blackfin®: Reduced Maintenance, Improved Coating Quality, and Greater Process Efficiency Alessia Venturi, ipcm®

Pramaor Srl (Taibon Agordino, Belluno, Italy) designs and manufactures titanium spectacles under the brand name Blackfin®. It recently collaborated with Water Energy (San Pietro in Casale, Bologna, Italy), a company specialising in the treatment of waste water from water-curtain coating booths, which built and installed a system enabling the efficient separation of paint overspray accumulated in the booths’ water tanks and the consequent optimisation of the eyewear production process, while also reducing maintenance costs.

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FOCUS ON TECHNOLOGY

T

he Italian eyewear sector has always been distinguished by one

© ipcm

important feature: design. This is particularly true for the province of Belluno, on one of the most beautiful mountain ranges in the

world, the Dolomitic Alps. It all began here in the 1960s with Luxottica, which specialised in the creation of metal spectacle frames and from which numerous satellite companies in the eyewear sector gradually emerged. One of these is Pramaor Srl, owner of the trademark Blackfin®. It was 1971 when Maria Luisa Pramaor, then the eighteenth

Luxottica employee, asked Cavaliere Leonardo Del Vecchio if she could open her own workshop to independently manage certain eyewear production stages. This would have gone on to become a company called Pramaor Srl, the owner of the trademark Blackfin®, now known all over the world.In the 1980s, when frames were made of common metal and acetate, it would not have occurred to anyone to use titanium.

However, in 1990, Primo Del Din and his wife Maria Pramaor started working with this material to stand out from the competition. They sent their technical managers to Japan, set up a small department devoted

© ipcm

to this metal, and began to build up the know-how that is still key to manufacturing each Blackfin® titanium frame today. This brand has since become synonymous with glasses built entirely in titanium and 100% made in Italy.

Every Blackfin® pair of glasses starts out as a concept, then it becomes a sketch, and it finally turns into a prototype. In between, there are technical trials, colour matching tests, and continuous adjustments, up until the creation of a marvellous object in terms of both technique and aesthetics. This is why the coating stage is so important for Pramaor, as it is strategic in guaranteeing the aesthetic excellence of its products, which are exceptional in terms of raw materials and design, but also of production processes.

As a leading company that is constantly evolving and striving for the best quality, Pramaor recently installed a treatment system for the water coming from the overspray collection curtains of the six liquid coating booths that make up its finishing department. After a thorough

© ipcm

assessment of different technologies, the company selected Water Energy Srl as a partner for the installation of this plant for water treatment, a very important step in guaranteeing not only the efficiency of coating systems but also the perfect quality of finishes, since water curtains are responsible for the cleanliness of the air circulating in the booths.

From top: - The precision sandblasting of frames.

- The six water-curtain manual coating booths supplied by Ultratech Srl. - A detail of the paint spraying operation. Behind the frame, you can see the booth’s water curtain, perfectly clean thanks to the treatment system installed by Water Energy Srl.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2023 - N. 79

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© ipcm

In addition to its most reliable and proven technologies, Water Energy integrated the plant with an innovative system for collecting paint-contaminated water through the “fountain effect”. Each of the six identical application booths is equipped with an overflow system that make the contaminated liquid coming from the water curtains flow into one collection tank located behind the row of booths. A single pump draws the paint-contaminated water from this tank, sending it to the purification system, while the individual booths’ pumps draw clean water from the bottom of their related water tanks, recirculating it to the vertical overspray collection curtains.

The Blackfin® eyewear production process: a true ritual Each Blackfin® frame is made only in Japanese titanium, whereas the workmanship is entirely Italian.

The manufacturing process follows several steps: it starts with the acquisition of the raw material, namely Coated titanium frames.

titanium plates, from which eyewear temples and front frames are cut. The surfaces are then cleaned in a pickling bath to remove titanium oxide and subjected to several welding and milling phases. After assembly of

© ipcm

the temples, the frames are cleaned again with a hard rubber wheel to remove all residual weld marks and harmonise their surfaces. Only for some models, some areas are then polished with a soft cloth wheel. This is followed by masking by applying a protective gel in order to prepare the frames for sandblasting, which is carried out with micro-splinters of glassy materials that roughen their surfaces to improve the adhesion of the paint film.

In preparation for coating, the frames also undergo a treatment cycle in vacuum cleaning machines using solvents. Finally, the frames are coated by means of six water-curtain coating booths, located inside a clean room to guarantee the highest quality of the circulating air and thus minimise the risk of contamination of the treated products. At that point, they are ready for the final process phases and, after the last quality check, they can be sent to opticians around the world.

The water treatment plant’s operation The major investment made by Pramaor in an ancillary The SKIMMERFLOT sludge removal device that treats the paint-contaminated water flowing from the six coating booths.

phase of its coating process, namely the treatment of the water flowing from the overspray collection curtains of its application booths, is proof of the importance it

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FOCUS ON TECHNOLOGY

Clean Efficient Superior OptiCenter® OC07

© ipcm

The tank for collecting contaminated water, which cascades here from the top of each booth by overflow.

places on air quality. Indeed, good water quality in these curtains is essential to maintain a high overspray capture rate and thus keep booth air clean.

Water Energy built and installed a customised system particularly aimed at solving a critical issue encountered by Pramaor during its eyewear coating phase: the presence of paint residues in the booths’ water collection tanks, which over time clogged nozzles and filters and compromised the frames’ surface quality.

Water Energy’s plant is a SKIMMERFLOT device with a capacity of 8000 litres/hour, an automatic flotation system for sludge removal, which manages the proportional dosing of flocculation products (also known as flocculants, chemical substances that favour the separation of paint from water) in the six booths’ water tanks as well as the continuous-flow removal of paint sludge from their water curtains.

Sludge removal takes place through the separation of paint by flotation: floating the paint sludge directly into the booth’s water

Fastest color change & stable powder output The OptiCenter OC07 powder management center combines state-of-the-art OptiSpray application pump technology with automatic fresh powder feed for fast and clean color changes. The system is the basis for constant and reproducible coating results and significant powder savings.

The OptiCenter can be equipped flexibly according to your individual demands.

tank means that the pump recirculating the water to the nozzles can draw clean liquid, while the paint-contaminated liquid overflows

Gema Europe Srl | Via Goldoni, 29 20090 Trezzano s/N | Italy T +39 02 48 400 486 gemapowdercoating.com

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

from the top of the booth and cascades into the collection tank that feeds

© ipcm

the SKIMMERFLOT system. As a result, the recirculated water in the booths’ vertical curtains and nozzles is 99% paint-free. In addition to this, the automation of the cleaning process of the overspray water curtain collection tanks keeps the nozzles clean, thus guaranteeing proper cleaning of air, which would otherwise remain polluted with paint and soil the filters above the nozzles and those protecting the recirculation units.

Problems solved with the installation of an automatic system Prior to the installation of Water Energy’s automatic system, the sludge removal and product dosing operations were done manually, leading to two problems. The first related to what is called “denaturation fluctuation”, which occurs when the amount of denaturant, namely the product used for eliminating paint stickiness, is not constant but rather fluctuates, i.e. sometimes it is too much and sometimes too little. The second problem

© ipcm

related to the manual sludge removal process itself, as over time paint could precipitate to the bottom of the tank and the recirculation pump could thus pick up old paint residues, recirculating them back into the booth and clogging the nozzles, making them unable to adequately clean the airflow.

This dirt could also clog the back-booth filters located above the nozzles, reducing the booth’s draught and creating additional overspray that risked contaminating both the eyewear frames to be painted and those already painted. Finally, in order to recover most energy, namely heat since the work takes place around 20/22 °C, the operators had to properly clean the air that was not intended for direct emission, but directed into the heat exchangers.

Benefits experienced by the user The adoption of Water Energy’s automatic system to treat a booth water flow rate of 8,000 litres/hour enabled Pramaor to achieve the following results: • high degree of water cleanliness in the coating booths;

© ipcm

• complete separation of paint overspray; • reduction of the booths’ maintenance costs; • increase in the concentration of paint sludge, which is now drained and disposed of in special containers; • reduction of booth water disposal to an annual frequency.

Scan or click the code to see NEOMADEINITALY corporate video From top: Paint sludge, partially dehydrated after passing through the SKIMMERFLOT; The SKIMMERFLOT’s four dosing systems, each with a level control device; Coated frames during the drying phase.

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ADVANCEMENTS

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Independent, Continuous Quality Assurance Based on an Optimised Incentive Structure Philipp Mader, GSB International e.V. – Düsseldorf, Germany

info@gsb-international.de

In order to implement the customer’s trust, an increasing number of companies decides to certify their systems and products in compliance with high quality standards. Starting from the end of the 1970s, GSB International defines these standards of quality for the area of aluminium and steel coating throughout Europe.

IGP Pulvertechnik AG

A

s 1977 dawned, powder coating was making its way into the

In the process, cases of damage can become extremely costly. Although

construction sector. As it is common with new technologies,

a coating typically only accounts for a low single-digit percentage of the

there were still some start-up difficulties at the beginning of the

cost of an aluminium facade, however, if there is a quality defect in this

implementation. The first complaints were observed in the window and

respect, in the worst-case scenario an entire facade must be dismantled

facade industry.

and recoated.

The storage and workshop of the Hamburg State Opera coated with the IGP-HWF classic powder coating.

ADVANCEMENTS

If this is the case, it can result in bankruptcy for

and standards, would also come up with the same

the coating company. But not only that. The

test results - for instance, in the weathering tests

building owners can also be negatively affected

for which the test sheets are drawn within the

by the situation, because delays can occur on the

scope of the company inspections. But this is a

construction site or - should the defect appear after

misconception.

the building has been put into operation - the use

This topic can be well explained by means of

can be affected.

corrosion tests. There are tolerances in the

Consequently, at the end of the 1970s, it was

international and European standards of the tests

necessary to establish a quality assurance system.

(humidity, concentrations, etc). So, it is possible that

So, a few companies joined forces to draft the first

testing institute A comes to a different result than

GSB Quality Regulations. One thing was certain.

testing institute B if they operate at opposite ends of

Regardless of the rules manifested in the Quality

the tolerances.

Regulations, concerning parameters, factory

Consequently, the laboratories must also be

production control, etc., an incentive had to be

compared with each other. It is common practice

created so that the regulations would be adhered to

to conduct round robin tests. In this process,

at any time and the quality control would be reliable.

identical sets of samples are sent to the different

Unannounced inspections of coating companies There was only one way to ensure reliable implementation of the Quality Regulations. Thus,

institutes and it is checked whether the they come to comparable results. In this way, the independent accredited testing institutes are checked again by the GSB itself.

there was no way around having unannounced

Coating material tests

company inspections. This means that the coating

During the regular process of updating the Quality

companies must be prepared for the possibility

Regulations, it became clear relatively quickly that

of an inspection at any given time. In order to

coating powders and liquid paints have a major

permanently hold one of the coveted GSB Quality

influence on the quality of the coatings. Thus, quality

Seals, the Quality Regulations must therefore be

assurance was extended to the coating materials

continuously fulfilled. For the coating companies,

and it was manifested in the Quality Regulations that

too, this is an advantage, because they are externally

GSB-certified coating companies must also use GSB-

encouraged to ensure quality and to document the

certified coating materials. In the approval process

quality assurance process. In this way, there is no

for the coating materials, test sheets are coated with

temptation to let quality control fall behind in the

the coating materials in accordance with the GSB

stressful daily business.

Quality Regulations and subjected to a wide range

Carrying out the tests of the coating companies by accredited testing institutes

Hooks & CE Hooks

From the in-stock small and thin hook to the special hook Ø30 with EU certification and loading capacity calculation, for both small and heavy parts to be coated.

HOOKS & CE HOOKS

of laboratory tests. The heart of the test, however, is the outdoor weathering. The test sheets are stored in an outdoor weathering facility in Florida.

After 1, 3, 5 or 10 years of ageing, the coating

Unannounced tests and strict quality criteria

materials must meet a residual gloss of at least 50

are of great importance, but they must also be

% and colour distances within specified tolerances.

trustworthy in order to be accepted by the market.

If the preceding laboratory tests are also positive,

For this reason, GSB inspections are carried out by

the coating materials are certified with the much-

independent accredited testing institutes. This way,

appreciated quality seal, which also displays the UV

quality monitoring by neutral third parties is always

resistance in years. Furthermore, the quality of the

guaranteed.

coating materials is continuously checked - thus test

This does not rely on just one testing institute.

sheets are constantly sent to Florida for outdoor

Several institutes test for GSB. At first glance,

weathering.

one might think that several accredited testing

Great care is also taken to ensure that the right

institutes, which test according to specified norms

incentives are in place to maintain quality when

COMPLETE SOLUTIONS FOR HANGING AND MASKING

www.rostirolla.it

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

taking samples for the prolongation tests.

to the continuous evolution of the Quality

and one for the coating of steel and galvanised

Thus, whenever possible, the samples for the

Regulations, as the experience gained over

steel. In the quality committees themselves,

tests of the coating materials are taken at

decades is of immense value. In addition to

the practical relevance could hardly be more

the coating companies within the framework

this accumulated experience, the knowledge

direct, because the committees are made up

of the company inspections and not at the

of the people who subject the Quality

of delegates from the membership. They are

material manufacturers. In this way, the

Regulations to a continuous improvement

elected every 4 years at the general assembly

material manufacturers do not know from

process is the guarantor of regulations that

and always develop the Quality Regulations

which batch the samples are taken.

are always oriented towards practice. The

above the standards. Following the democratic

group of people who continuously develop

principle of the GSB, all member companies

the Quality Regulations consists of two quality

vote on the amendments of the Quality

committees - one for the coating of aluminium

Regulations every two years within the

Testing of pre-treatment chemicals At the end of the 1990s, the use of chromium-

framework of the General Assembly.

or chromium-VI-free pre-treatment chemicals emerged and quickly expanded in the which is much talked about today. Almost

Future orientation in quality assurance

all GSB-certified coating companies now use

The art of quality assurance is to keep the

chromium- or chromium-VI-free pre-treatment

Quality Regulations constantly up to date

chemicals when coating aluminium. This

and, above all, practical. The GSB Quality

type of so-called alternative pre-treatment

Assurance System offers THE standard of

chemicals requires mandatory approval when

the architecture industry in this respect. The

used by GSB-certified coating companies. Only

mere fact that the Quality Regulations cover

in this case the chemical receives the approval.

many norms and standards gives GSB-certified

The quality of the approved pre-treatment

coating companies an enormous competitive

chemicals is continuously checked. Samples

advantage, as they cover several standards at

are also taken in this case. In the case of these

the same time through certification.

prolongation tests, this is done at the coating

The Quality Regulations are always developed

companies where the chemicals are in use. A

further using the latest versions of the

wide variety of laboratory tests is carried out

corresponding standards and guidelines.

market as a result of the REACh regulation,

– for example, the acetic acid salt spray test

Practical relevance is the top priority. It

and the filiform corrosion test. But before a chemical receives its approval, it has to pass the initial tests. For this, the same laboratory

© GSB International e.V.

Philipp Mader, Marketing Manager of GSB International e.V..

is continuously discussed whether the measuring and testing methods are practiceoriented. If there are new testing methods,

tests take place as in the prolongation test. In

they are tested and compared with the current

addition, outdoor weathering is carried out

methods. This pursuit of perfect quality has

as part of the approval test. This takes place

established the GSB Quality Assurance as a

in Hoek van Holland in a highly corrosive

permanent fixture in the market for exterior

environment characterised by a combination

coatings in architecture and industry.

of sea and industrial climate. The exposure

The interest in the GSB is so great that even in

to weathering lasts for 3 years. After 5 and 10

times of staff shortages and tightly scheduled

years, the samples are re-evaluated to gather

working days, young professionals from the

empirical values.

membership get involved in the Young GSB

Experience and continuous development exceeding the standards This is an excellent point to draw a bridge

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N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

Working Group and contribute their valuable input. In doing so, the members of the working group work independently on a wide variety of projects and also bring their input directly to the board and the quality committees.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Aluminium Anodizing in Ireland: AMS Architectural & Metal Systems Ltd Chooses an Italian Partner for the Installation of Its First Anodizing Line Alessia Venturi, ipcm®

AMS - Architectural & Metal Systems Ltd is Ireland’s only independently owned manufacturer of extruded aluminium profiles. AMS can offer a complete, turnkey solution for all aluminium products and service requirements. Beside fabrication, powder coating, and wood effect finishes, since last June AMS is also capable of providing anodizing in different colours, from light bronze to black. The anodizing line was provided by the Italian SAT, which supplied a comprehensive system that includes a user-friendly software, a conveyor technology made by four different bridge cranes to ensure production flexibility and a high throughput of the line, up to a waste water treatment system.

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FOCUS ON TECHNOLOGY

A

ccording to many different industry reports, the Irish aluminium

finish and fabrication facility bring products from conception to project

market skyrocketed in 2021, with a significant expansion in

delivery all under one roof. AMS can offer consistency in service, quality,

consumption as well.

colour and complete traceability maintaining and ensuring quality

AMS - Architectural & Metal Systems Ltd – Ireland’s only independently

standards such as ISO 9001, 14001 and 50001. Because the company

owned manufacturer of extruded aluminium profiles – was established

has total control over all the processes from start to finish, it is able to

in Cork, in 1990, by Chris Martin, President, Pat O’Hara, CEO, and the

offer its customers the best possible service to enable them to react

late Dave Rawlings, Technical Director. AMS can offer a complete,

to tight deadlines. In June last year, AMS started a new anodizing line

turnkey solution for all aluminium products and service requirements.

to round up its offer of aluminium finishes and provide its customers

It specialises in aluminium extrusion, powder coating and sheet metal

with the most complete finishing service. For this project, it relied on

fabrication as wells as providing many other services from its vast

the know-how and design skills of the Italian engineering company SAT,

450,000 sq. ft. (about 42.000 sqm) facility with 275 employees.

specialised in the supply of various kind of finishing systems for the

The company’s business divisions include standard engineering

aluminium industry.

products, architectural glazing systems, curtain walling, a bespoke aluminium design & extrusions service, and providing a wide range of thermally efficient aluminium windows, door and other commercial systems to various industries globally.

Two extrusion presses and a state-of-the-art powder coating, wood

Opening photo: General view of the anodizing line supplied by SAT. AMS new anodizing line supplied by SAT has an electro-colouring tank with the possibility to get a variety of colours, such as: champagne, bronze, brown, and black (here below).

© SAT

© SAT

© SAT

The loading area.

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Focus on investments in technology and know-how AMS understands the value of innovation, keeping ahead of the latest trends and technologies. Investments in research and development have greatly contributed to the growth of the company, which is very proud of its numerous innovative and patented products which include window, door and curtain wall systems.

“With over 180 dynamic and resourceful employees, we pride ourselves in supplying to the marketplace a professional, unrivalled high-quality service”, Chris Martin, President at AMS, states. “We have an experienced sales and design team who offer help and assistance to companies and architectural practices to bring their concepts to fruition.

Our in-house capability further complements this system for the design and production of bespoke profiles tailored to suit modern and © SAT

pioneering designs. These profiles come in an extensive range of colours and finishes,

The line is equipped with three bridge cranes which are able to handle two anodic bars at the same time.

including our in-house wood-imitation finishes.

Last but not least, we are proud to announce that we have just concluded the start-up of an anodizing line for which we have chosen an Italian engineering company, SAT in Verona.

“We are the only extrusion company in Ireland.

We put in our first press – a seven-inch press – in mid 2000s we have added a second press inch since then and we plan to put in a third press,” Pat O’Hara – AMS Chief Executive Officer, tells. “We moved to Little Island in 2001 and that’s when we started manufacturing and started powder coating. We put in a second powder coating line and eventually - as our business grew- we ordered a vertical paint line that was installed in 2008 and it’s been running very well since then. It’s been our dream, really, for many years to put in an anodizing line. When we started anodizing in the middle of May this year, we put through some scrap sections and they came up so well © SAT

Each bridge crane has a device on board to adjust the distance between the two anodic bars.

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I couldn’t believe it. And within, I’d say, the next day we went into production. All this thanks to

FOCUS ON TECHNOLOGY

SAT excellent design and manufacturing capabilities,

© SAT

to the user-friendly software developed by SAT to run the line and last but not least to the training sessions offered to our staff”.

Today, we boast processes that are nowhere else offered in the island and the anodizing plant is the last piece of the jigsaw for AMS”.

Features of the anodizing line The design of the line foresees three anodizing tanks, each equipped with a rectifier of 15.000A (for a total size of the plant of 45.000A). SAT provided also one electro-colouring tank equipped with a transformer of 8000A, with the possibility to get the variety of tonality as: champagne/bronze/brown/black.

The line is equipped with a third bridge crane; these are special bridge cranes able to handle two anodic bars at the same time and have a device on board to adjust the distance between the two anodic bars.

Immersion of the bars in a process tank.

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© SAT

© SAT

Rectifiers in the anodizing tank and the spray rinsing stage (on the right).

To eliminate the drop of productivity due to the return in counter-flow of the empty bars along the tanks line, SAT designed an extra crane with special design, operating at a higher level than the other bridge cranes.

Kevin Crowley, Plant Manager at AMS, goes on describing the anodizing line: “We have a control room run by one operator, the controller operator, who basically loads the program or the recipe. We have a loading area with six operators and an unloading area with two. The anodizing line stages are: degreasing, rinsing, E6 etching which is our strong aggressive etching, E0 etching which is a lighter etching for small hollow sections or for smaller profiles that have any channels.

Then the process features a neutralization tank, a desmut tank (which is a stripping of any residual smut after the etching). Finally, we have the anodizing tanks themselves: we have the option of a colour tank of tin sulfate or

© SAT

SAT designed an extra crane with a special design, operating at a higher level than the other bridge cranes, to eliminate the drop of productivity due to the return in counter-flow of the empty bars along the tanks line.

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straight to a hot seal tank of 98°C. The bronze colours that we are getting are very consistent.

Coatings according to GSB:

FOCUS ON TECHNOLOGY

As an example, we have just done a job with 1100 profiles and

© R. Hillebrand GmbH & Co. KG / Hueck

Long-lasting attractiveness of facades, buildings and industrial products made of aluminium, steel and galvanized steel

you probably couldn’t tell the difference between the start and

A

the end of the process. The lack of difference in colour has been

d Pre t rea rove tm p p e

nt

unbelievable!

“One of the main challenges we faced when designing the new line was the available footprint in the building” Andrea Trevisan – SAT Chief Executive Officer adds. “Outside these walls you literally have the seaside so we had to find innovative solutions to install the line within this perimeter. Each jig is loaded with two bars and the distance between these two anodic bars can be increased or decreased based on the stage where the jig is located. The line

M

Coated Aluminium & Steel.

Approved Quality. at

e ri

al

p Ap

foresees three bridge cranes that are used to move the jigs through the process. But it is also equipped with a fourth bridge crane that is used to bring jigs back to the loading area in order not to affect the productivity of the line with a counter flow movement. As SAT,

Visit us online:

we supplied the complete system including the rectifiers, the bridge cranes and an effluent treatment plant. The important thing for SAT was to provide AMS with a complete solution and I think this is exactly what we did in the end”.

Co

software is probably a lot simpler than I was expecting it to be.”

GSB International e.V. Fritz-Vomfelde-Straße 30 D-40547 Düsseldorf www.gsb-international.de

ed

how to run the line very quickly. After using it for some weeks, the

ov

trained by the SAT team on how to use the software and I learned

g in at A p p rove d C o

the software in support of the installation: it is very intuitive; we were

a te r

Another important feature to underline about this anodizing line is

r

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© SAT

© SAT

The air purification system.

On the left Andrea Trevisan, SAT’s CEO, with Pat O’Hara, AMS’ CEO.

All in-house processes

“The benefit of having an inhouse painting service means we can offer

“At AMS we have invested heavily in state-of-the-art extrusion facilities

consistency in colour, quality and efficient lead times,” Chris Martin

so, as well as extruding our own profiles, we can offer design and

adds. “Our vertical paint line has the ability to paint over 4000 profiles

extrusion of aluminium profiles to third parties, not only to the façade

up to 7.3 m in length in a shift, which is a huge improvement over the

industry, but to any industry where aluminium extrusions are being

industry standard. It can perform a colour change in only 4 minutes,

used. Imagine the flexibility of being able to have an extrusion that was

making it the most efficient method of powder coating aluminium

previously not in stock, available the next day,” Pat O’Hara enthuses.

profile systems. Our horizontal paint line is devoted to painting

“Having the full control of the extrusion process inhouse allows us

aluminium sheets and flashings, as well as section profiles with lengths

to extrude profiles of non-standard lengths to reduce optimised

up to 7.0 m and bespoke pieces. This service has proven very beneficial

wastage for large contracts. The extrusion plant has brought AMS into

to many customers as both profiles and pressings can be painted in

various new markets e.g., aerospace, engineering, renewable energies,

the one facility. The powder coating process of both lines is Qualicoat-

transportation to mention a few. It has also generated important export

approved and performs an 8-stage chrome-free pre-treatment. We

opportunities to many other markets in Europe including the UK and the

stock a wide range of standard RAL colours to suit our customers’

USA.

specific powder coating requirement and we rely on different powder

We can produce over 16,000 tonnes of extrusion per annum on our two

coatings suppliers, among which Tiger, IGP, Syntha Pulvin, AkzoNobel

extrusion presses. Once the metal has been extruded the aluminium

and Axalta.

alloy is heat treated for strength. Once aging is complete, it can then

“With over 20 years’ experience in this field, we have the dedication

be made available to the customer, or indeed, go into another process

and knowledge to cater for all our customers’ requirements. We pride

within the same building e.g. powder coating, wood-effect finishes,

ourselves in the production of quality fabricated profiles and pressings

thermal break, sheet metal fabrication or, thanks to SAT new installation,

and we ensure customers’ needs and delivery times are at the forefront

anodizing”.

of operation. The installation of an anodizing line early last year is the

AMS has capabilities, through its vertical and horizontal powder coating

fulfilment of a dream and the icing on the cake for our services,” Chris

lines, to paint extruded profiles of all shapes and sizes inhouse.

Martin concludes.

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BRAND-NEW

Interpon Focuses on Innovation in Architectural Powder Coatings At the ZAK World of Facades Conference, that took place on 24th November 2022 in Hanoi (Vietnam), AkzoNobel Powder Coatings presented its innovations in the field of sustainability, durability and metallic colours.

© AkzoNobel

T

he innovations in the field of sustainability, durability and metallic colours of Interpon powder coatings

for architects and specifiers have been the key themes surrounding the presence of AkzoNobel Powder Coatings at the ZAK World of Façade, a conference that took place in Hanoi (Vietnam) on 24th November

2022.

Hanna Nguyen, the County Sales Manager of AkzoNobel Powder Coatings who is a business leader and expert in the infrastructure and construction industry, covered the life cycle of powder coatings and how its durability can support sustainability during the ‘Powder Coating Technology for the Built Environment’ session.

In addition, she also discussed the latest colours and design collections for facades, as well as the high-quality special effect metallic finishes for both interior and exterior achieved with the breakthrough bonding technology AkzoNobel.

Finally, she presented a second powder coating plant now fast becoming operational in North Vietnam, to serve the expanding needs of the local market.

Among the new products showed there was also the Anodic range, which has the stunning look of anodized aluminium but with a minimal environmental impact.

The range is available in a wide range of colours and makes the ideal alternative to

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

anodized aluminium for windows and facades. For example, Interpon

Maximilien Schreder, Regional Commercial Director South Asia

D2000 Anodic III finish delivers superior colour and gloss retention

for AkzoNobel Powder Coatings, has explained the importance of

and better colour consistency. Also shown for the first time was the

innovation: “Our customers expect innovation not only in the products

Interpon Futura range.

we create, but also in the processes we deliver. With our superb range

Featuring a superdurable performance supported by a 25-year

of metallic effect powder coatings, supported by our investment in

warranty, the Futura range boasts 50 beautiful on-trend colours

new facilities and new manufacturing technology, we are excited about

designed to help feel closer to natural environment, safe in the

sharing our expertise with customers at the ZAK World of Facades.”

knowledge that our creations and our world are now better protected.

ZAK World of Facades also provided an opportunity for AkzoNobel to

As with the Anodic powder coatings, metallic colours within the

showcase Wild Wonder – Interpon’s newly announced Color of the

Interpon Futura range are possible thanks to AkzoNobel’s unique

Year 2023. It is one in a palette of eight new colours inspired by nature

bonding technology.

within the Interpon Futura range.

This means the metallic pigments are chemically bonded (as opposed to mechanically blended) to the base powder, to give far greater lustre, For further information: www.interpon.com

consistency, and performance.

AUTOMOTIVE

APPLIANCES

HEATING SYSTEM

ALUMINIUM SYSTEM

THE EXCELLENCE OF ITALIAN PRODUCTS

Via L. Cagnola, 29 Triuggio 20844 MB Italy Tel: +39 0362 919905 Fax +39 0362 919500 w w w.v i s a i m p i a n t i . i t v i s a @ v i s a i m p i a n t i . i t

FOCUS ON TECHNOLOGY

GPS Enhanced its Powder Coating Performance with Self-Made Plant Design and Seamless Integration of the Conveyor Monica Fumagalli, ipcm®

Experience and technology: this is the winning combination that has allowed Italian powder coating contractor GPS to design and build a new plant with a handling system supplied by CM Automazione that is efficient, has a high application performance, and is geared towards making the work environment as clean, healthy, and comfortable as possible for operators.

P

lant design is a very complex intellectual process blending indepth knowledge of mechanical engineering and production management. The further combination of these two elements

with passion and long-standing experience can then give rise to uncommon and essentially unique results – in this case, a powder coating plant in which a coater’s experience, its attention to the environment, consumption, and working comfort, and the latest technologies developed by its suppliers have led to the creation of a truly original solution. At the same time, the perfect integration of the plant with a handling system specifically designed for the special needs of this coating contractor has further improved its entire production process.

© ipcm

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GPS specialises in powder coating of components for the HVAC, agricultural, and heavy metalwork sectors.

FOCUS ON TECHNOLOGY

© ipcm

The booth of GPS’ first coating plant.

© ipcm

The loading area (left) and unloading area (right) in the new hall.

Padua, Italy), a company specialising in powder coating of components

Full service and attention to detail: the cornerstones of GPS

for the metalwork and heavy industry sectors, has always worked in the

A part of the new hall is still being completed. “The new coating line

field of surface treatments, first in an important carpentry company as

became fully operational within a short time, but we still have to finish

manager of the powder coating department and, now, as owner of GPS

setting up the 3000 m2 warehouse area. In the open area adjacent to it,

Srl and MICOLOR Srl.

we are going to build a canopy for unloading and loading materials to

“In 2002, I founded GPS Srl together with a partner, who later withdrew

optimise the traffic of trucks bringing them in and picking them up and, in

from the company. Over the last twenty years, the business has grown

the near future, we are also going to add a new cataphoresis department

a lot, going from six to forty employees and acquiring another powder

to offer a complete service to our customers, which operate mainly in

coating company, MICOLOR Srl.” Currently, GPS extends over a total

the HVAC, agricultural, and heavy metalwork sectors. In order to provide

covered area of 7,000 m2, which includes a 2,000 m2-wide hall and a

a galvanising service when required in addition to powder coating, we

Guido Borella, the owner and sole director of GPS Srl (Bagnoli di Sopra,

new 5,000 m -wide building housing a second coating line, installed

currently rely on specialist Mita (Conselve, Padua). Once galvanised, the

in August 2022 to cope with increasingly frequent production peaks.

parts reach our warehouse, where they are thoroughly cleaned to remove

The project for this new plant had started a year earlier: “I developed it

any impurities and/or oxidation traces remaining on the zinc film and thus

myself,” confirms Borella, “together with a long-standing company from

improve the adhesion of the powder layer to be applied subsequently.”

the Italian coating world, Peron Group (Officine Munari). Its integration

Such attention to detail and a team of qualified employees has enabled

with the part handling system featuring a one-rail conveyor provided by

this firm to establish itself in the northern and central Italian market and

CM Automazione Srl (Giussano, Monza e Brianza, Italy), then, was a key

become a trusted partner for some of the most important firms in the

step for introducing a number of technical measures that improved the

air conditioning and agricultural industries. “We strive to meet the high

flexibility and speed of our coating cycle.”

quality standards imposed not only by the ISO 9001, ISO 14001 and

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61

45001 standards, but also by the approval processes of the multinational

dimensions of 7 x 2.5 x 1.25 and a maximum weight of 700 kg. The

companies that contact us, so that we can present ourselves as a very

other difference relates to process management and control documents

promising choice for anyone in need of an effective service in the field of

(hardcopy in the former and digital in the latter), whereas tracking is done

industrial painting.”

by QR code scanning in both cases.” The size of the new plant is also

The coating cycle is similar in both GPS’ lines: pre-treatment with

bigger: “Whereas the first hall is 2,000 m2 wide, in the new one this is the

phosphodegreasing and passivation, drying, automatic powder coating

area occupied by the coating line alone.”

with manual pre and post-finishing operations, oven curing, quality control, and final shipment. “What does change is the size of the treated

The conveyor at the core of operations

components: in the older plant, we handle small to medium-sized parts

“Every company in this sector knows the importance of selecting the right

with dimension of 3.5 x 2 x 1.10 m and a maximum weight of 300 kg,

strategic devices during the design phase: one of them is certainly the

while, in the new one, they can reach a size of 4 x 2.20 x 1.10 m and

conveyor,” notes Borella. “It is the core of the line and the element that

a weight of 400 kg. In MICOLOR we handle the largest pieces with

determines its timing and, in some respects, its performance degree. I

© ipcm

© ipcm

© ipcm

From top left clockwise: - The control PLC’s display with the layout of the new plant.

- The entrance to the pre-treatment tunnel.

- The Morris X458 overhead conveyor is equipped with 806 two-axle trolleys.

- Top view of the one-rail conveyor installed by CM Automazione.

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© ipcm

FOCUS ON TECHNOLOGY

therefore decided to rely on CM Automazione, which proved to be an ideal partner especially in terms of the availability and flexibility with which it complied with our project, the promptness with which it solved some initial problems, and the high quality/ price ratio of its system. Compared with our old plant, the length of the chain is more than double (from 150 to 330 metres), including a 70 metre-long pre-treatment tunnel with a bend corner. My design envisaged a 4-inch chain and a maximum load capacity of 200 kg per trolley, with a continuous flow operation.

One of the most complex aspects, however, was precisely the movement of 4 metre-long parts through the bend corner of the pre-treatment tunnel. Together with Peron Group, we studied all possible solutions in detail and asked the company to create a system with such wide bends that it was possible to hang a 4 metre-long and 1.10 metre-wide workpiece at any point on the load bar while maintaining a distance of no more than 1 metre from its ends.

“Another special feature of the conveyor’s layout that I particularly insisted on was the construction of three uphill segments: one

The pitch between the hooks is 409.6 mm and the chain speed is 2.5 m/min.

© eosmarketing

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in the loading area, one in front of the drying oven, and one in the unloading area. I was aware that this could have posed a problem in a one-rail conveyor, due to the risk of a component hooked at two points of a load bar (e.g. a panel wider than 1.5 m) becoming unhooked. However, we also solved this critical issue by finding the right slope value and optimising the descent phase in the unloading area – where, if there is a defect, the component must be manipulated and sent for retouching. Moreover, in cooperation with CM Automazione, we developed a special system for locking the load bars so that they cannot tilt beyond a certain threshold during ascent. In the case of workpieces hooked at two points, this also helps prevent detachment from hooks.”

Technical characteristics of the conveyor © ipcm

The load bars’ locking system designed to ensure they do not tilt beyond a certain threshold during ascent and avoid risking the detachment of workpieces.

The one-rail overhead conveyor installed in GPS’s new hall is a Morris X458 system equipped with 806 two-axle trolleys. The pitch between the hooks is 409.6 mm, the chain speed is 2.5 m/min, and the motor power is 0.75 kW x2. “I was very doubtful about one component: the chain tensioner, which has no springs,” confesses Borella.

“I had never seen any like it and wondered how, without this technical element, it could be possible to prevent any chain elongation due to the expansion of the iron reaching high temperatures in the oven. Actually, the chain has such a tension degree that the risk of expansion is nullified. This also allows performing maintenance only once a year.

“Our partnership with CM Automazione was also very fruitful in terms of attentive advice and respected delivery times. Finally, we were not sure we could find a supplier capable of solving all the critical issues of a pioneering project that had not been devised by its own technical department and that had never been realised before, but CM Automazione did so

© ipcm

One of the electric pumps installed above the pre-treatment tanks.

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with proficiency and professionalism, actually even optimising some aspects.”

FOCUS ON TECHNOLOGY

© ipcm

The Silver Booth dense phase powder coating booth supplied by Siver and equipped with Nordson guns.

© ipcm

The entrance to the drying oven.

Other innovative technical elements

ground. In this way, the nozzles always remain clean and the noise of the

After manual loading, the parts are hung on the conveyor that leads

pumps during operation is greatly reduced.”

them to the pre-treatment tunnel, made of AISI 304 and 316 stainless steel. Here, phosphodegreasing with chemicals supplied by Kendell,

Colour change: the “pit stop” of a coating process

now part of the BASF Group, is followed by two rinses with mains water,

After drying in the air stream oven, the parts are taken to the coating

a rinse with demineralised water, passivation, and a last rinse with

booth. “The new system is equipped with a dense phase powder booth

demineralised water. The components then enter the drying oven.

from the Silver Booth series installed by Siver Srl, the exclusive dealer of

“We designed the new pre-treatment plant in such a way that, should

Nordson systems for Italy. The manufacturer had guaranteed five-minute

the need arise to replace the baths, we can only replace the first ones

colour change operations; however, since I have been doing this for over

and not all of them as is the case with our old plant, while keeping

twenty years, I trained my operators and managed to reduce this time

the parameters of the others unchanged and with constant values.

to just one minute. The secret is to consider this delicate step in the

In addition, one of the technical aspects that I personally wanted and

painting process as a car pit stop. As the conveyor is of the one-rail type,

that I had already tried first-hand on our old plant was the presence

we can carry out a colour change in the time between the passage of one

of tank doors on both sides of the pre-treatment tunnel. Cleaning

load bar and the next: in this way, we do not have to stop the chain, we

and maintenance of the structure is easier and without the risk of the

avoid leaving parts waiting in the pre-treatment tunnel with all the risks

operator getting dirty. I also chose to install the electric pumps above the

and consequences that this entails, and we optimise production times. In

tanks and not on the ground as is usually the case, so that the collectors

addition to our standard daily checks, at the customers’ request, we mark

do not draw from the bottom, but from a height of 1.5 m above the

the coated batch using special plates, which undergo the same process

international PAINT&COATING magazine - JANUARY/FEBRUARY 2023 - N. 79

65

© ipcm

A phase of manual post-finishing.

© GPS

Guido and Gaia Borella from GPS Srl.

of the material and, at the end of the treatment, are tested to guarantee

The company’s future in the hands of young people

the suitability of the coating.”

In addition to plans for the completion and improvement of its production

Afterwards, the parts reach the curing oven consisting of two combustion

structure, Guido Borella has clear ideas about what the future of his

chambers; at its exit, a conveyor chain extension allows for thorough

company should be: “I am trying to create a team of young people with

quality control of each hanging workpiece.

a few bright stars, including production manager and my daughter Gaia,

“We have an operator specifically assigned to this operation only, because

in charge of our customers’ certification and approval procedures. I

accurate quality control results cannot be achieved if the same person

hope to leave a solid and promising company in their hands, capable of

also has the task of unloading the part from the line,” emphasises Borella.

maintaining the high quality level for which it is recognised in the market

Once they have passed inspection, the parts are packed and labelled

today. I put all my experience in the project for our new coating plant,

according to the RAL code required by the customer and taken to the

but this would have never been enough on its own: the combination with

warehouse before final shipment.

the state-of-the-art systems developed by our suppliers, in particular the conveyor, was the winning mix that enabled us to obtain an efficient, flexible, fast, and high-performance line as well as a suitable and comfortable environment for all those who work there.”

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BRAND-NEW

New Pump Generation from Dürr with Contactless Changeover Valves Dürr developed a new generation of pneumatic vertical piston pumps that increases process reliability and requires less maintenance: EcoPump2 VP is designed for several media and can be used in many fields such as mechanical engineering, metal working and the furniture industry.

D

ürr has developed a new generation of pneumatic vertical

many more materials. It can also handle acidic hardeners commonly

piston pumps that increases process reliability yet requires

used in the 2K process in the North American market without any

much less maintenance.

difficulty.

The EcoPump2 VP is designed for various media typically found in

The first feedback from customers has been consistently positive. The

industry and can be used in many fields such as mechanical engineering,

pump is quieter, it pulsates less, and takes less time to clean than the

metal working and woodworking, as well as in the furniture industry.

predecessor model.

The new pump only needs one seal for most applications, which is also much quicker and easier to change than on the predecessor

About The Dürr Group

model. The fluid parts can be disconnected from the air motor with

The Dürr Group is one of the world’s leading mechanical and plant

conventional tools via a quick coupling. The new air motor can be

engineering firms with extensive expertise in automation and

operated without any oil. This significantly reduces the maintenance

digitalisation/Industry 4.0. Its products, systems and services enable

required, including in comparison with the competition. A further benefit

highly efficient and resource-saving manufacturing processes in

is that the contactless changeover valves used to regulate the air motor

different industries. The Dürr Group supplies sectors like the automotive

changeover guarantee higher process reliability. Using quick-exhaust

industry, mechanical engineering, chemical, pharmaceutical and medical

valves cuts changeover times, reduces pulsations, and increases

technology industries.

performance.

The company has around 18,100 employees and 120 business locations

With five different versions of the EcoPump2 VP covering a pressure

in 33 countries.

range from 22 to 306 bar, the pump is suitable for applying paints, highviscosity materials, and adhesives to furniture, steel constructions, and © Dürr

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For further information: www.dürr.com

BRAND-NEW

Dörken Will Be at Fastener Fair Global 2023 From 21st to 23rd March 2023 in Stuttgart, the German company Dörken will present its high-performance corrosion protection solutions during Fastener Fair Global.

T

he German company Dörken Coatings GmbH & Co. KG, an international manufacturer specialised in high-performance corrosion protection solutions, has announced that it will

showcase its latest technologies and innovations in the area of premium surface protection during Fastener Fair Global 2023, the 9th

international exhibition dedicated to the fastener and fixing industry that will take place from 21st to 23rd March at the Messe Stuttgart.

Taking place every two years in Stuttgart (Germany), Fastener Fair Global is an international event that brings together manufacturers, wholesalers, distributors and suppliers. The event covers all areas of the fastener and fixing industry and provides real insight into industry trends and key information about the latest developments in the sector. It is then an excellent opportunity to exchange knowledge and ideas, keep up to date with the latest innovations and network with professionals worldwide.

Consequently, Christos Tselebidis – the sales vice-president for the Industrial Coatings division of Dörken – and the Key Account Manager Martin Juros will welcome distributors, suppliers, engineers and other industry professionals at booth 1056 to better discuss how to protect their important assets and products.

For further information: www.doerken.com

© Dörken

?

HOW IT’S COATED

The Specialty Materials of Arkema Protect the Iconic Logo of NASA as It Blast Off to Space Kynar Aquatec® of Arkema was used in the protective clearcoat applied on the Artemis 1 Space Launch System.

A

rkema has proudly announced that it has been selected to

“We work hand-in-hand with partners like Acrymax® Technologies to

protect NASA’s iconic logo on the Artemis 1 Space Launch System

create custom solutions. Their ability to extend this partnership to NASA

(SLS). The innovative coating is powered by Arkema’s Kynar

and develop a formulation strong enough to withstand the intensity of

Aquatec® PVDF latex and provides extreme durability to keep NASA’s red

the most powerful rocket in the world is spectacular in many ways,” has

“worm” logo on the solid rocket boosters intact while soaring to space.

explained Paul Lavallee, the global market manager of Kynar® Coatings

The historic Artemis 1 SLS lifted off from Kennedy Space Center in

at Arkema. “Kynar Aquatec® PVDF latex is really unique in that it delivers

Florida on 26 November 2022. It has sent the Orion spacecraft

such world-leading performance in a user-friendly fashion. No baking or

approximately 1.3 million miles, orbiting the Moon and returning to

post-treatment is required.”

th

Earth on 11th December. The SLS boosters featuring NASA’s red logo are the largest, most powerful solid propellant boosters ever built for flight.

Watch the video.

The waterborne clearcoat protecting the logo was created by Arkema’s partner, Acrymax® Technologies Inc. Kynar Aquatec® PVDF latex enabled Acrymax® Technologies to design a water-based protective coating with exceptional durability in low VOC, air-dry systems.

Scan or click the QR code to watch the painting process of the NASA logo on SLS booster

© NASA/Ben Smegelsky

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© SMW

FOCUS ON TECHNOLOGY

A New Powder Coating Plant Installed in Europe’s Largest Bicycle Factory Ilaria Paolomelo, ipcm®

In 2021, bicycle manufacturer Sport Mechanical Workshop (Timisoara, Romania) opened an important bicycle factory in cooperation with French multinational company Decathlon. VISA Impianti (Triuggio, Monza Brianza, Italy) was among the protagonists of this ambitious project with the supply of a new powder coating line.

R

omania occupies second place on the podium of the main bike producers in Europe, only surpassed by Portugal and followed

by Italy. This is what emerges from the latest report published

by Eurostat1. Indeed, what has been defined as one of the largest bike factories in Europe was recently inaugurated in Romania, specifically in Timisoara. The protagonist of this ambitious project was Sport Mechanical Workshop. SMW was established in 2016 by three associates with solid experience in the bicycle industry and a deep understanding of their sole partner: Decathlon, the French multinational company specialising in the sale of sports goods.

“We are Laszlo Nyaradi, the owner of ALLCOLORS, a coating contractor based in Tirgu Mures (Romania) that painted the bicycles marketed by Decathlon up until the opening of SMW; Francesco Russo, a former Decathlon executive; and Vittorio Olagnero, the owner of Telai Olagnero, an Italian company specialising in the production of bicycles also on behalf of Decathlon itself,” explains Russo.

“The idea to found SMW stemmed from our willingness to assemble and paint bicycles on behalf of Decathlon while supplying it with these products within a reasonable geographic distance to limit the costs, logistical problems, and pollution related to the transport of goods.

SMW is located in a very strategic area that enables Decathlon to cover the whole of European territory: it already had a partner in the Iberian Peninsula and one in Italy, and now SMW allows is to also cover Eastern Europe.”

1

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https://bit.ly/3HdX7aD

FOCUS ON TECHNOLOGY

This is how, in 2021, what has been defined as one of the largest

© SMW

bicycle factories in Europe came into being. It occupies a total area of around 25,000 m² and it will soon produce and paint up to 2 million bicycles each year.

As for painting, SMW decided to rely on VISA Impianti, which supplied a fully automated, green powder coating plant that integrates the technologies of several leading Italian manufacturers: Futura Convogliatori Aerei (Robecco Pavese, Pavia), Ecoteam (Scandicci, Florence), Ciroldi (Ganaceto, Modena), Wagner Italia (Valmadrera, Lecco), and Chemetall (Giussano, Monza e Brianza).

The production and coating cycle Sport Mechanical Workshop manufactures a wide range of bicycles mainly in aluminium and steel: from 14’’ children’s bikes up to the most complex and structured e-bikes. “Decathlon’s catalogue includes a huge range of bicycles. SMW does not

© SMW

produce this entire portfolio for the time being, but our factory was conceived to be able to manufacture the entire range of bikes marketed by Decathlon in the near future.”

SMW’s production phase begins directly with the surface preparation and coating operations. “The customer provides us with all the required components, including tyres, frame components, and other parts. We store them in our 10,000 m2-wide warehouse and then take care of coating the frames, assembling the wheels, and preparing the products to be sent back to the customer.”

The coating cycle starts with the pre-treatment phase, which includes the following stages: • Pre-degreasing • Degreasing • 2 rinses with mains water • 1 rinse with demineralised water • Nanotechnology passivation

© SMW

• 1 rinse with demineralised water.

From top: SMW assembles and paints a wide range of bicycles mainly in aluminium and steel.

A section of the paint shop.

The components at the entrance to the pre-treatment tunnel.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2023 - N. 79

73

© SMW

© Visa Impianti

© Visa Impianti

From left to right: Overview of the pre-treatment tunnel; The booths are housed in an air-conditioned clean room; Wagner’s SuperCenter Evo booth.

Pre-treatment is performed with chemicals developed by Chemetall. It is

“The difference between these two processes lies in the type of decals

followed by a blow-off and drying phase. The frame is then transported

that the project requires. Some stickers need to be applied before

by means of a power&free conveyor to one of the two coating booths

coating, others between colour and clear coat application, and others,

for the application of powder products. “Depending on the colour to

such as phosphorescent stickers, in the final stage after clear coat,”

be applied, the operator chooses which of the two booths to use for

explains Nyaradi. “This step posed a significant technical challenge in

each product. This optimises timing and reduces the time needed for

terms of system design, because we required the greatest possible

colour changes. Both booths, of the Wagner SuperCenter Evo type,

flexibility to be able to handle all these peculiarities efficiently. At the

are air-conditioned and located inside a clean room,” explains VISA

same time, in addition to flexibility, we were also looking for a plant that

Impianti owner Paolo Massari. “As far as paint application is concerned,

guaranteed high productivity. With VISA Impianti, we have obtained both

we exclusively use polyester powders. We cooperate mainly with two

benefits,” states Laszlo Nyaradi.

suppliers, Adapta Color and Tiger Coatings. After powder application, the

“The coating plant was conceived to work in three shifts, although we

components enter the curing oven for about 24 minutes at 180 °C and

currently work in two shifts with around 70-80 operators. As many

finally reach the cooling tunnel”, states Nyaradi.

employees work on the assembly lines,” explains Russo.

The flexibility of the new coating system

A digitised and green plant

One of the manufacturing steps that truly enable to customise each

The plant was designed not only to ensure high flexibility and

bicycle is the application of stickers and decals. Therefore, SMW’s plant

productivity, but also to meet all SMW’s sustainability and energy-saving

is designed to perform two alternative processes:

requirements. “Our factory is equipped with some significant green

• The frame is unloaded, stickers are applied, and then the frame is

technologies, including a photovoltaic system on its roof. At SMW, we

reloaded onto the conveyor for the application of a second layer of clear

are very aware of environmental issues. As a consequence, it was of

coat.

paramount importance that our coating system was also in line with our

• The frame is unloaded only after colour, clear coat, and sticker

corporate values,” notes Francesco Russo. “The plant does not discharge

application.

water but rather treats it with two evaporators in order to recirculate it.

The takt-time is 37-40 minutes per load bar.

Ecoteam also installed a water purification unit.”

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FOCUS ON TECHNOLOGY

“Moreover, the system boasts a heat recovery unit that

© Visa Impianti

uses the fumes generated by the curing oven to heat the drying one. However, there remains a significant amount of residual heat, which can be recovered in future to heat the factory as much as possible. The paint stripping oven, supplied by Ciroldi, is also prearranged for the installation of a heat recovery unit to obtain even more energy,” discloses Massari.

“Our long-term goal is to recover as much heat as possible to heat our entire 10,000 m2-wide warehouse.

This will guarantee a very important benefit in terms not only of environmental protection, but also of reduction of energy-related costs.”

The coating plant and the entire production department were also designed to meet the Industry 4.0 requirements. “Through our ERP software, we are able to control every data and parameter of each production and painting stage, thus achieving a high degree of traceability. Within our paint shop, we even have an automated powder storage warehouse,” says Nyaradi.

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Find out how much you can save on your coating line at ccc.hangon.com

Powder application inside the booth.

© SMW

After powder application, the components enter the curing oven for about 24 minutes at 180 °C and finally reach the cooling tunnel.

© Visa Impianti

A detail of the coating system provided by VISA Impianti.

The valuable collaboration with VISA Impianti

is therefore the fourth plant we have designed together and we are

“For this project, VISA took care of the supply of every plant component,

already planning to install a further one.”

collaborating with numerous leading Italian companies: the conveyor was provided by Futura Convogliatori Aerei, the zero liquid discharge

Future projects

and duplex demineralisation plant was designed by ECOTEAM SpA, and

“VISA Impianti will definitely be part of SMW’s future, as we plan to

the hook paint stripping oven was supplied by Ciroldi SpA.”

install another new system, this time for liquid coating, at our Timisoara

“We opened our paint shop at the beginning of 2022 and we have only

site,” adds Laszlo Nyaradi. The opportunity to expand the factory’s

been using it at full capacity for a little over six months. However, our

capacity and production area will also be assessed in the years to

collaboration with VISA Impianti had already started in 2015. I own a

come. “Currently, our company has a production capacity of about 1.5

contract coating company located approximately 300 km away from

million units, depending on the type of bikes produced, but our plant

Timisoara, which painted bikes on behalf of Decathlon prior to the

was developed to be able to treat around 2 million frames per year. For

foundation of SMW. This is where we installed the first plant supplied

2023, we expect an increase of 4-5%; in general, it will be an important

by VISA, which enabled the treatment of around 750,000 frames

year for the bike market. We are therefore going to be ready for any

per year, as well as three other lines for coating aluminium profiles,”

increase in sales during the current year. Finally, we have an additional

states Nyaradi. “Since then, for us VISA Impianti has become a point of

15,000 m2 available to expand our production facility even further,

reference for everything painting. The powder coating line in Timisoara

according to future needs,” says Nyaradi.

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The right partner in the green transition

© Avin

HIGHLIGHT OF THE MONTH

AVIN Developed New Dialysis Cells to Reduce Energy Consumption Edited by AVIN Srl San Martino al Tagliamento (Pordenone) – Italy

info@avin.it

AVIN Srl is a company specialising in the design, construction, revamping and installation of surface treatment plants, from cataphoresis to powder and liquid spraying or immersion painting, as well as cleaning and air treatment systems.

A

VIN does not only design, manufacture, and install systems

enables us to build high-tech, energy-efficient coating and cataphoresis

based on innovative concepts, but it can also convert already

systems,” states Morgan Infanti, the General Manager of AVIN. “All our

existing machines into new, more advanced, state-of-the-art

plants are digitised, perfectly in line with the requirements of Industry

plants geared towards reaching maximum efficiency and meeting

4.0. We also offer the remote activation of our tele-assistance service to

each customer’s needs and objectives. “The experience gained to date

allow direct intervention by our technical support team.”

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HIGHLIGHT OF THE MONTH

AVIN has also developed specifically high-performance electroplating

of products: tubular, hollow and compact, or single-module membranes

cells and ultrafiltration membranes for ultrafiltration and cataphoresis

for microfiltration, ultrafiltration, nanofiltration, and reverse osmosis

plants. “From design of the smallest detail to performance and

processes.”

functionality checks, our technical staff offers a high level of flexibility and reliability, with the utmost attention paid to even the most complex

The new AUF dialysis cells

requirements of our customers. One of our latest product innovations

The new AUF membranes are obtained by extrusion and they are

are the electroplating cells of the AUF65 and AUFL80 with extruded

therefore free of bonding or welding areas. Their simple and economical

membranes series for cataphoresis and anaphoresis tanks, which we

design reduces resource consumption. Their self-supporting disposable

have developed with a view to energy savings, penetration power, ease

plastic housing elements facilitate quick installation and removal and

of operation and maintenance, and longer service life combined with

they are ideal for rinsing or recovering anodic and cathodic paint solids.

high performances.”

The membrane, based on polyvinyl fluoride (PVDF) chemistry, provides a robust and reliable solution in the harsh conditions of the electroplating

Ultrafiltration membranes

process.

“In electrophoretic coating (cataphoresis and anaphoresis), ultrafiltration

“To help our customers cut energy costs, which are increasingly

membranes are used to recover drag-out paint and to manage

weighing on all companies’ budgets,” adds Infanti, “we have studied

the bath’s chemical and physical parameters. The entire range of

these new extruded tubular dialysis cells that are more energy efficient

membranes developed by AVIN is specifically designed to achieve the

than flat membranes, thanks to their lower energy absorption and

highest performance level during the process. AVIN is thus able to

high penetrating power at a given voltage (12% to 18-20% higher).

respond to the most particular market requirements with different types

Furthermore, the AUF extruded self-supporting membranes do not

© Avin

Some AUF-80 ultrafiltration membranes.

© Avin

An application of cells in a tank.

international PAINT&COATING magazine - JANUARY/FEBRUARY 2023 - N. 79

79

need to have an anode assembled with PVC grids as is

© Avin

the case with flat membranes and they do not require internal or external support. Finally, thanks to their special construction method, they can expand freely from the dry to the wet state.”

The AUF anodes allow the anolyte to circulate under pressure (250 l/h at 0.3 bar and up to 1000 l/h at 0.6 bar); its requirements range from 3 to 5 l/h/Ampere/ m2. “These characteristics guarantee greater process safety, eliminating the risk of leaks and reducing paint sedimentation thanks to the fact that the membranes are extruded and waterproof. Indeed, their special design eliminates the risk of the anolyte/catholyte escaping from the cell into the tank. Furthermore, in the event of the rupture of a membrane, the circulation under pressure of the anolyte prevents the risk of the “siphon” effect. Finally, in the event of bacterial contamination, the AUF anodes can be cleaned and completely emptied via a screw cap at the bottom of the membrane itself.”

Other peculiarities of these dialysis cells are their ability to expand without any internal or external constraints and their roughness-free surface that does not retain paint.

Maintenance and durability “Also in terms of maintenance, the main objective was to simplify the work of operators,” notes Infanti. “It is indeed possible to dry an AUF cell after cleaning its surface with demineralised or mains water, leaving the anolyte/catholyte circulation at a lower flow rate during maintenance. The AUF membranes’ surfaces can also be brushed with a Scotch-Brite product to remove any traces of settled and/or dried paint. The anodes weigh only 15 kg each for an active membrane length of about 2.1 m, so moving or replacing them requires no special lifting equipment and only one operator, while maintenance requires a maximum of two people. Removal of the AUF anode is made easier by the PVC plastic ring nut on the top of the cell.”

The smooth surface of the AUF membranes prevents the formation of wrinkles or cracks that cause them to become clogged with paint pigments.

“Our experience confirms that the AUF anodes guarantee correct functionality even after three years The new extruded tubular dialysis cells are more energy efficient than flat membranes.

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of operation. Their service life can be extended by rotating the electrode through 90° over time (every

HIGHLIGHT OF THE MONTH

four to six months). This is why AVIN guarantees its AUF membranes

GLOBAL SOLUTIONS FOR WATER TREATMENT

with a complete service that includes system design manufacturing, installation, technical support and chemicals

for twelve months (excluding the electrode)”.

Technical data for AUF65 tubular cells • Type of membrane: - PVDF with ionic resins - Extruded (weld-free) - Extruded membrane surface: Ø 65.3 mm -> 0.2 m² active/meter - Membrane thickness: 2.95 mm - Electrical resistance: 175 Ohm/cm² - Ion exchange: 1.37 - 1.72 meq/g (dry) - No water permeability - pH resistance: 1 - 12 - Maximum pressure: 0.8 bar • Electrodes: - Materials: AISI 316 L, 316 Ti (extruded, weld-free) - Diameter: 48.3 mm x 2.77 mm - Surface: 0.153 m²/m - Maximum allowed intensity: 60 A/m² - Operating pressure: min. 0.2 bar, max. 1 bar • Anolyte/Catholyte: - Flowrate: 3 to 8 l/h/Amp/m² • Cell size: - Customisable.

Technical data for AUFL80 tubular cells • Type of membrane: - PVDF with ionic resins + Divinylbenzene - Extruded (weld-free) - Extruded membrane surface: Ø 65.3 mm -> 0.2 m² active/meter - Membrane thickness: 2.95 mm - Electrical resistance: 175 Ohm/cm² - Ion exchange: 1.37 - 1.72 meq/g (dry) - No water permeability - pH resistance: 1 - 12 - Maximum pressure: 0.8 bar

SPRAY BOOTHS WATER SLUDGE REMOVAL RESIN DEMINERALIZATION SYSTEMS REMEDIATION OF CONTAMINATED SITES BIOLOGICAL SYSTEMS BATCH TREATMENTS PHYSICAL-CHEMICAL SYSTEMS ADSORPTION FILTRATION REVERSE OSMOSIS MEMBRANE SYSTEMS EVAPORATORS BIOGAS BIOMASS SYSTEMS OIL SEPARATORS DESANDERS DESALINATION SYSTEMS PYROCHAR OTHER SYSTEMS CHEMICALS

• Electrodes: - Materials: AISI 316 L, 316 Ti (extruded, weld-free) - Diameter: 60.3 mm x 2.77 mm - Surface: 0.191 m²/m - Maximum allowed intensity: 60 A/m² - Operating pressure: min. 0.2 bar, max. 1 bar.

The new AUF-80-PLUS membrane In August 2022, AVIN launched a new model of ultrafiltration

srl

membranes on the market: the new AUF-80-PLUS series. “The new development technologies introduced in our production cycle have

Via Torricelli, 79 - Z.I. Fossatone 40059 MEDICINA (BO) - tel. (+39) 051 856263 info@hydroitalia.com - www.hydroitalia.com

enabled us to conceive a higher-performance

© Avin

filter cloth, which guarantees a 15% greater total filter surface area and an overall higher yield compared with our AUF80 membrane described above, which averages 22-25% of ultrafiltrate produced,” says Infanti. “With this product, we wanted to stabilise and maximise the durability of the membranes and the performance level of the new cataphoretic/anaphoretic coating technologies currently on the market.” The new AUF80-PLUS membranes do not require any plant modifications and fit the IN-OUT head components of the previous versions.

The technical features of these new membranes are as follows: • recirculation flow rate: 12/20 m³/h • operating pressure: 3.0-4.1 bar • maximum inlet pressure: 4.4 bar • minimum outlet pressure: 1.0 bar AVIN has specifically developed high-performance electrodeposition cells and ultrafiltration membranes for ultrafiltration and cataphoresis plants.

• maximum operating temperature (production): 50 °C (EDP temperature) • maximum operating temperature (cleaning): 50 °C (max. 30 minutes)

© Avin

• minimum storage temperature: 5 °C • prefiltration: 50 µ • membrane surface area: 30.6 m2 • weight: 29.5 kg • pH: 2÷10.

Conclusions “At a time when the cost of energy resources is rising dramatically, it is important for a company like AVIN to contribute to reducing consumption, helping its customers by all possible means. The tools we have at our disposal to do this are our expertise and experience and a vision of the future that can no longer disregard cost assessments, not only at the time of the commercial contact for the purchase/sale of our systems, but also in terms of operation, maintenance, and durability of the installed devices,” concludes Infanti.

The new membranes have a maximum length of 1200 mm.

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ADVANCEMENTS

CONDOROIL’s Low-Temperature Application Formulations Limit Energy Consumption and Protect the Environment Edited by CONDOROIL CHEMICAL S.r.l.

Casale Litta – Varese (Italy)

U

marketing@condoroil.it

sing products that allow working at 25 °C instead of 50 °C

reasons why we believe that such innovations can provide end users

guarantees significant energy savings, which translate into lower

with significant economic and technical advantages.

costs and reduced greenhouse gas emissions. Moreover, as well

Therefore, below is a brief description of our products for low-

as reducing energy costs, operating at lower temperatures also provides numerous other technical advantages, including reduced consumption

temperature application.

of water or process liquids (at low temperatures, evaporation losses

Condorcoat EC 930

are minimised), less downtime after routine maintenance (no time is

Condorcoat EC 930 is a nanotechnology passivating agent for the

lost in heating the working solution), fewer fouling problems, reduced

surface conversion of ferrous materials, galvanised iron, and aluminium.

equipment wear, and a healthier working environment (no steam is

The formulations of our Condorcoat EC 900 series can be used to

generated in the room where the plant is located). These are all the

replace outdated pre-treatment processes such as phosphodegreasing,

© Condoroil

Application of the nanotechnology passivating agent Condorcoat EC 930.

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ADVANCEMENTS

zinc phosphating, and tricationic or heavy iron

Condorine SG 515 BT

conversion.In particular, Condorcoat EC 930 replaces

Condorine SG 515 BT is a low-temperature alkaline

phosphodegreasing treatments and guarantees

degreaser, suitable for ferrous metals and galvanised

higher cost effectiveness. Its working temperature is

steel.

particularly low, between 20 and 30 °C.

Its balanced combination of surfactants and selected raw materials guarantees high degreasing power

Features and benefits

and thorough cleaning of parts, even at moderate

The product is formulated to combine a strong

temperatures. Its special composition prevents

degreasing action with the surface conversion of the

foaming even when operating at low temperatures in

substrate.

spray systems.

The nano-coating layer that is created on the treated

Sequestering agents keep the iron in solution, thus

metal surface is characterised as follows:

minimising sludge formation.

• compact, hard, and resistant;

The special feature of Condorine SG 515 BT is its

• uniform, consistent, and watertight;

effectiveness already at 20-30 °C, which is 20-25 °C

• mineral;

lower than that required by conventional products.

• protective.

It is highly appreciated by several large metalworking and industrial painting companies, which have

Its typical thickness, around 40 nm, is extremely reduced – it is more than 10 times thinner than

already been using it successfully for years.

conventional amorphous phosphates.

Condorine SG 576 N

Condorcoat EC 930 has a low environmental impact

It is a multi-metal passivating degreaser for high-

thanks to the absence of phosphates and toxic metal

pressure applications. Suitable for use on any metal

compounds, it guarantees low energy consumption,

and material (ferrous alloys, aluminium alloys, copper

it has negligible impact in terms of COD, and it emits

alloys, plastics), this neutral degreaser is used for

no VOCs.

both intermediate treatment stages in one-tank

The use of Condorcoat EC 930 brings important

plants and high-pressure operations (e.g. high-

economic and application benefits, including as

pressure deburring). It is additivated with special

follows:

corrosion inhibitors that protect the treated parts

• lower operating temperatures (20-30 °C lower than

against atmospheric corrosion. It is non-foaming and

in traditional cycles);

can be used at low temperatures.

• no sludge production;

Condorine SG 576 N is therefore a very versatile

• less equipment maintenance required;

product that can be employed in many different

• longer service life of the bath;

applications.

• lower water consumption; • more compact systems.

Condorfos K 12 L Condorfos K 12 L is a liquid phosphodegreaser suitable for ferrous components. It is an easy-to-use,

degreasing/surface conversion process, as it is

highly concentrated formulation, active from 20 °C.

enriched with surfactants that guarantee the perfect

Given the optimal pH of its working conditions, it

removal of oils and greases commonly found on

does not require neutralisation. It allows amorphous

raw parts. It is preferably diluted with demineralised

ferric phosphate salts to deposit on surfaces,

water and it can be used by either spraying or

preparing them for the subsequent coating process.

dipping.

If it is unavoidable to work at low temperatures

The workpieces’ treatment must be followed by a

(below 40 °C), Condorfos K 12 L can still perform its

rinse with demineralised water.

degreasing and passivating action, preserving the

Pre-treatment with Condorcoat EC 930 is compatible

parts against flash rusting after drying.

with all painting processes.

It can be used by dipping or spraying even in suitably

EN 1527

H

el

m

A.

Condorcoat EC 930 can also be used in a one-stage

.

Hellas S

equipped open spaces, with low-pressure nozzles or, better still, with

Condorite 796 N is also active at room temperature and it can be

high-pressure washers, on large workpieces or heavy metalwork

additivated with suitable degreasing additives. This enables to perform

structures that are difficult to treat in tank or tunnel systems.

pickling and degreasing in one operation, even at low temperatures.

Finishing can be done with traditional, water-based, or powder coatings.

The product is odourless and it does not emit harmful fumes. It is not

Condorfos K 12 L can also be used in “dry in place – no rinse” mode if

classified as dangerous under the provisions of the Regulation (EC) No.

the treated parts have no particular stagnation areas: in such cases, it is

1272/2008 (CLP) and subsequent amendments.

possible to simply allow the workpieces to dry before painting, without any rinsing.

SVA 583 paint stripper

Conclusions Economic developments and industrial needs have often collided with and sometimes upset the delicate ecological balance. The challenge

It is a universal multi-metal paint stripper suitable for ferrous metals,

is to turn this conflict into a possible alliance. CONDOROIL’s research

light alloys, galvanised steel, aluminium, etc.

laboratories and technicians have been focusing on the increasingly

Even at room temperature, this paint stripper removes solvent-based,

important issues relating to the future of our planet. Our company

water-based, and powder coatings (epoxy, polyurethane, polyvinyl, etc.)

is convinced that there will soon no longer be any room for high-

from any metal without having to resort to formulations containing

environmental impact technologies and that only environmentally

chlorinated solvents. If left to act for the necessary time, it even attacks

friendly production processes are going to be implemented in the near

and removes paint layers with a considerable thickness, up to several

future. With this in mind, we believe that investing time and resources in

millimetres, also working at room temperature, i.e. 40-50 °C lower than

optimising such processes means investing in the future. The products

conventional formulations.

we have briefly described stem precisely from this vision.

Moreover, it guarantees as follows:

CONDOROIL’s technical service is at the customers’ complete disposal

• it contains no solvents that are harmful by inhalation;

for laboratory tests and demonstrations, allowing them to assess the

• it has a limited odour;

effectiveness of its proposed solutions before their application in-line

• it does not contain methylene chloride, phenols, or other particularly

without any obligation.

hazardous solvents; • it is not classified as flammable; • it can be removed by simply washing with water; • the containers used can be made of common iron; • the treated iron parts do not rust after cleaning.

The SVA 583 paint stripper is already successfully used by several major

© Condoroil

aluminium finishing companies to restore profiles for repainting.

When paint stripping aluminium, it is essential that the product is kept anhydrous.

Condorite 796 N It is a neutral pickling agent suitable for ferrous metals, galvanised steel, and aluminium.

Condorite 796 N is recommended for metal deoxidisation even at low temperatures: it has strong deoxidising properties and it is capable of removing surface oxides or mineral residues from components.

Typical applications are as follows: removal of thermal oxides after laser cutting or welding; treatment of heavy rust/calamine layers; removal of scales and insoluble salts found in hard water.

Its balanced composition and near-neutral pH value preserve the substrates against attack, concentrating the action on the contaminants to be removed. This inherent ability not to corrode the treated parts allows for considerable variability and flexibility of working parameters.

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Paint stripping with the SVA 583 universal multi-metal product.

Zaniolo CdA-03.22

d Green Pow er

40 Years of Advanced Solutions for Metal Surfaces Treatment 40 years of targeted goals, precise choices and continuous effort developing highly performing and innovative products. For Europolveri this anniversary represents only the first step in the taken direction. Today the main challenge is to plan the future with a constantly evolving growth strategy and great care and sensitivity to the ecological-environmental context.

EUROPOLVERI S.p.A. - Sandrigo (VI) Italy - Ph. +39.0444.750643 - Fax +39.0444.750653 FILIALI/Branch Office: Cernusco sul Naviglio (MI) Ph.+39.02.92148001 - Erbusco (BS) Ph.+39.030.7704158 DEPOSITO/Depot: Iori Colori, Reggio Emilia Ph.+39.0522.327248

info@europolveri.it - www.europolveri.it

HIGHLIGHT OF THE MONTH

Meeting Each and Every Finishing Requirement: The Mission of Total Finishing Systems Interview with Ty T. Crowder, President of Total Finishing Solutions LCC & Total Finishing Systems

A US-based firm designing and constructing powder and liquid coating systems, Total Finishing Systems is part of a large family of companies whose main objective is to meet all its customers’ individual finishing needs by providing an all-round service.

O

nly by combining technical expertise, knowledge of the industry and existing technologies, and proven experience is it possible to position oneself in the

market as a one-stop-shop partner for all things painting equipment.

Total Finishing Systems, a division of Total Finishing Solutions (Riverside, California, USA), is part of a family of companies created to provide businesses in North America with a single point of contact that they can rely on for their coating systems, from design to installation and after-sales. We interviewed Total Finishing Solutions president Ty T. Crowder to find out more about his company’s history and current challenges.

Three business units to offer an all-round service: how did the Total Finishing family come about?

The Total Finishing family was founded as a group of companies aiming at bringing together the skills, knowledge, and resources needed to devise, design, and maintain finishing and painting plants and equipment for the general industry. It indeed includes three business units: • Total Finishing Solutions is the first branch of the company and it specialises in the supply of spray booths, UV and IR ovens, abrasive blasting equipment, and industrial automation solutions such as flatlines reciprocators and coating robots, with the latter being built by our partners VD Finishing Solutions, Lesta, and ABB Robotics. Our solutions group has also has been introducing Powercarts, which are battery operated autonomous carts to many finishing lines. This has been extremely useful in the door, window, and furniture coating markets.

• Total Finishing Systems was established recently for the design and integration of complex, high-quality painting © Total Finishing Systems

The pre-treatment tunnel provided by Total Finishing Systems.

systems. It supplies customised powder and liquid coating plants mainly for the automotive (Tier 1 and Tier 2), aerospace, and defence industries.

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HIGHLIGHT OF THE MONTH

• Total Finishing Supplies is the division devoted to the supply of all consumable materials and equipment necessary to maintain the operation and efficiency of plants. We have an e-commerce platform for the sale of spray guns, paint pumps, spray booth components, and so on, supplied by the partners we work with, such as Carlise FT, Wagner, Anest Iwata, and SATA Engineering. Our team of experts supports the digital shopping experience via chat.

Having these three divisions enables us to present ourselves on the market as a one-stop-shop partner that assists its customers at all stages, from the identification of the most suitable solution to aftersales services.

At the same time, our synergies and close partnerships with numerous market leaders allow us to offer proven, high-quality technologies.

It is well known that the powder sector is still rather marginal on the American continent, compared with the liquid paint market. What is your approach to powder coating?

Total Finishing Systems specialises in the design, manufacture, and assembly of turnkey systems for both powder and liquid coating operations. The type of painting process required is not a discriminating factor for us: our offer is based solely on the requirements of our customers. We propose and advise them on the most suitable and profitable investment possible based on their

BE WASTEWATER FREE

application processes and the sector in which they operate. For example, we recently proposed a cataphoresis system (E-Coat) for a manufacturer of bed frames that needed to dip coat its components, rather than a powder system. Why? Because it was the best ROI for the customers investment.

What are your plans for the near future?

Total Finishing Systems is always looking for new and profitable collaborations and synergies with other companies. Entering into exclusive agreements means being able to offer increasingly innovative, cutting-edge systems, processes, and technological solutions.

In this framework, we have recently forged new partnerships with leading firms in the surface treatment sector. In November, we announced an exclusive agreement with SFB AG, a leading manufacturer of horizontal (flatline) powder coating systems, which will enable us to provide the industry with new options for powder coating that were previously unavailable in the US market. In particular, the combination of the expertise of Total Finishing Systems and SFB has led to the development of a unique, fully automated powder coating plant that is going to especially benefit firms needing to treat small components.

ZLD SINCE 1984 www.eco-techno.it sales@eco-techno.it

© Total Finishing Systems

© Total Finishing Systems

© Total Finishing Systems

From top left clockwise: - Powercarts are extremely useful in the door, window, and furniture coating markets.

- A detail of the flatline powder coating system developed together with SFB. - A flat conveyor belt handles the workpieces, which are powder-coated on one side, cured, and then turned and painted on the other side.

A flat conveyor belt handles the workpieces, which are powder-coated

and technologies presented by leading manufacturers of plant

on one side, cured, and then turned and painted on the other side. In

components.

addition, an innovative transport and suction system allows recycling of the powder and requires no hooks or racks, meaning there is nothing

Is Europe part of your future plans?

to clean or burn off. The process also allows for perfect single sided

Currently, we do not consider Europe as a commercial target area. Our

painting of parts with no masking.

extensive sales network covers the United States, Canada, and Mexico.

Another partnership we are very proud of is the one with Erzinger,

However, Europe is a very fertile ground for leading surface treatment

a Brazilian manufacturer of equipment for surface treatments,

technologies and companies. Our goal is therefore to scour the market

pre-treatment operations, electrostatic powder application, and

in order to learn about the major technological trends and be the first to

cataphoresis (E-Coat). We have been designing and have now sold

bring these innovations to North America, thus offering our customers

several systems together with them, to be built and installed over

up-to-date, state-of-the-art products and processes.

the current year. Erzinger will also help us set up and open our new laboratory for North America, which will deal with both powder and

Total Finishing Systems is going to present its new projects in the next

liquid coating equipment, housing and analysing the latest innovations

issues of ipcm_International Paint&Coating Magazine.

Find out more about the Total Finishing Family:

Total Finishing Systems

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N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

Total Finishing Solutions

Total Finishing Supplies

www.infragas.com

INFRARED RADIANT GAS SYSTEMS FOR THERMAL TREATMENTS

© Venjakob

SUCCESS STORIES

General view of the complete coating line for plastic parts with UV, water or solvent-based coating systems.

Coating System with the Latest Control Technology. Nickname: All-rounder For a well-known contract coater of decorative components for the automotive and electrical user interface industries, Venjakob Maschinenbau developed an automatic coating solution that can coat both flat and curved 2.5D components in one spray booth. Another special feature of the system is that UV coatings can also be processed by means of a UV robot.

T

he 40-meter finishing line for plastic parts has been given the

The curves are controlled precisely

nickname “all-rounder” by the contract coater. Whether flat or

Durable, resistant to scratches, light and weathering effects – the

curved, UV, water or solvent-based coating, everything passes

requirements for the contract coater for coating quality of decorative

through here at a constant speed via the pallet conveyor system also

high-gloss surfaces are strict. Equal coating thicknesses at every point

developed by Venjakob. With brilliant results.

of the component as well as uniform curing for the UV coatings used.

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© Venjakob

The VEN DRY UV_Robot for curing the coating in seconds.

How do you get this precision work done on 2.5D components?

Gert große Deters, General Industry and Automotive Business Unit Manager at Venjakob, explains: “We went through intelligent control in this case. We adapted the spray jet parameters of the spray guns to the part geometry and stored them in the control system. At the machine infeed, a sensor measures the geometry of the workpiece and automatically generates the spray jet parameters that we previously defined in test runs.”

Thoughtful cleaning mechanisms included A coating system that uses UV coating systems in addition to wet coatings must take their special features into account during processing. For this reason, the conveyor system of the coating line was designed to avoid carryover and contamination by the UV coating material as far as possible. For cleaning during the painting process, a water-wash spray mist extraction system and a paint sludge separator for the contaminated booth water are used. The cleaning of organic solvents in the exhaust air is carried out by an exhaust air purification system developed by Venjakob Umwelttechnik.

UV robot cures coating in seconds The special feature of this system is the robot with UV lamp. It is used

SUCCESS STORIES

© Venjakob

Loading and unloading station of the automatic plastic coating line.

for hardening edges and curves of complex 2.5D components within

so that the desired treatment and holding times are achieved. The

seconds and was positioned directly in front of the 6-level dryer. In the

maximum conveying speed is two meters per minute.

higher-level controller, it is possible to select whether the robot is used

The process steps include pre-treatment with CO2 cleaning, ionization

with the UV unit or not.

Pallet conveyor guarantees uniform flow of goods

and flame treatment, painting, curing if necessary, and the drying

process. The 6-level dryer used, five of which are heated, manages to dry the components completely in 30 minutes. Afterwards, they can be

The entire system is designed for fast throughput times. The pallet

processed directly or transported through the system again for another

conveyor moves the components in a horizontal position at a constant

coating layer.

speed through all system components.

The flash-off and drying sections are matched to this conveying speed

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For further information: www.venjakob.com

FASTRIP ISP In-line system for the chemical paint stripping of hooks and frames

DELICATE

MODULAR

TIME-SAVING

POWERFUL

COST-EFFECTIVE

THE ORIGINAL

ALIT Technologies Srl - San Bonifacio, Italy +39 045.245.6638 - info@alit-tech.com

www.alit-tech.com

Fastrip ISP is a stripping machine featuring a horizontal tank above which the rail runs for the in-line handling of hooks and frames intended for electrostatic coating processes. These are immersed and flow into the stripping bath for a variable time of approximately 2 minutes. After leaving the chemical bath while still hanging onto the chain, they result perfectly clean and ready to be used in a new coating cycle. ALIT offers the complete paint stripping solution: tank and chemical paint stripping product with high performance and low environmental impact.

ADVANCEMENTS

Complete Solutions for Composites Oliver Zanner Emil Frei GmbH & Co. KG - Bräunlingen-Döggingen, Germany

o.zanner@freilacke.de

FreiLacke, the German coatings manufacturer, developed new powder technologies for composite materials production.

F

rom bucket seats and vehicle accessories to power distribution

available in various colours and reaction speeds and is highly compatible

boxes and rotor blades, the triumphant march of glass-fibre

with various fibres, filling materials, inserts and core materials.

and carbon fibre-reinforced plastics has continued unabated for

Among the applications for the new CM powder resins are the rotor

decades and their applications keep increasing.

blades of wind turbines. The best part of it: This also allows the blades

The main reason for this success are the many advantages of these

to be manufactured in a single piece. The previously required bonding

glass-fibre and carbon-fibre reinforced composites: They are very

process of two individual parts is no longer required, which also

light, extremely durable, water, heat and cold-resistant and they can

eliminates a critical predetermined breaking point.

be pressed into just about any shape. FreiLacke, the German Black Forest-based coatings manufacturer, now not only offers diverse coating

Coating of wind turbines

materials for the surfaces of parts but also the components for their

Rotor blades spin with top speeds of 300 kilometres per hour or more.

manufacture.

The aerodynamic profile at its front edges plays an important role

CM powder for component production

because it contributes significantly to the effectiveness of the turbine.

These front edges are especially prone to erosion: Environmental

One example is the new CM powder technology. Due to a special

influences, such as rain, snow, hail, sand, UV radiation as well as severe

two-stage principle, this innovative composite powder resin system

temperature and moisture fluctuation, can sharply accelerate this

stands out against conventional resin systems for composite plastics in

erosion. In the case of offshore turbines, the humidity and salinity they

that it can be melted on without starting the hardening process. That

are exposed to can add further strains.

allows them to be processed into so-called PrePregs with complete

A high-performance edge protection coating, which is also referred to as

waterproofing. “As a coatings manufacturer, we have all raw materials on

leading edge protection (LEP), is essential.

site and can use them to develop new solutions”, explains Heiko Blattert,

FreiLacke already has multiple leading edge protection systems available

FreiLacke’s head of development of PG Composites.

for its customers in the wind energy sector.

The powder-resin system contains no ingredients that have to be

“It will only work well if it is matched specifically to the substrate or

declared and it is free from solvents as well as any harmful carcinogenic

the coating materials below it”, emphasises Heiko Blattert. That is why

substances, which makes storage and transportation much easier. It is

FreiLacke is offering the complete product range for the coating of

© FreiLacke

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© FreiLacke

ADVANCEMENTS

rotor blades completely from a single source. In

cycle time is only extended by the duration of the

addition, FreiLacke also offers and uses proven

powder coating application and, depending on the

coating system structures for the production of the

component, takes about a minute. After pressing,

concrete towers of wind turbines. These systems

the finished, coated component can be demoulded.

can also be transferred to other industrial concrete

The typical fibre marking is completely levelled out

coating applications and are already being used

by the PIMC process, the parts are given a highly

successfully in these areas.

resistant and very homogeneous surface.

InMould coating with gel coats

Powder InMould Coating (PIMC) offers a wide range of colours since nearly all RAL colours can be used.

The company keeps a series of coating solutions for

That means there is no limit when it comes to the

composite materials ready – ranging from colour

colour range of the components. The material

pastes and fillers to gel coats and top coats.

is free from solvents, hazardous substances or

The family-owned business offers them for

carcinogenic raw materials.

spreading or spraying on the basis of PU/PUR or

“As an alternative, we developed a liquid coating

unsaturated polyester resins. The gel coats and top

system that can be injected into the closed mould

coats are coloured coatings that can be applied

during the production of the component”, explains

directly into tools and moulds and provide moulded

Blattert, the head of development. It features very

parts with long-term protection against moisture, UV

short pressing times as well as high resistances in

radiation and impact damage.

terms of light fastness and fastness to weathering.

After it has been manufactured and demoulded, the

The component is ready when using “finished

component is already fully coated. When comparing

casting” or can simply be coated later on. This

the PU/PUR coatings to the UP materials, the light

also allows applications at the exterior of cars, he

fastness and fastness to weathering of the former is

emphasises.

much higher.

FreiLacke have also succeeded in significantly

Finding solutions with customers

reducing the percentage of styrene in the UP gel

FreiLacke has long-established itself as a specialist

coats as the substance is deemed hazardous to

for coating systems and has now gone a step

health and problematic to the environment.

further: with the CM power resins, customers have

“Using an alternative monomer, we have

the option of directly receiving the materials as well

manufactured a reduced styrene gel coat that

as a comprehensive consultation when it comes

delivers even better results than conventional

to the project development and production of the

systems in terms of weather resistance and shelf

components. And they can count on the expertise of

life”, declares the head of development.

the coating experts from the Black Forest.

Powder InMould Coating (PIMC)

Many companies, especially those in the automotive and commercial vehicles sectors, in mechanical

FreiLacke also offers an exceptional coating

engineering, the industrial sector in general and

expertise when it comes to other composites, such

in construction are already counting on FreiLacke

as the sheet moulding compound (SMC), i.e. plate-

composites.

shaped, dough-like moulding materials made from

Heiko Blattert believes that a cornerstone of this

thermosetting reaction resins and glass fibres. In

success is the close cooperation with the customers:

a single-step production process, electrostatically

“Ever since our early days, we have been convinced

charged powder coatings that are based on UP

that true quality of service is only possible if

resins are applied onto the hot mould. During the

problems and tasks have also been viewed from the

hot-pressing process the coating creates a chemical

customer’s perspective, and are fully understood

compound with the material. This compound is

as a result” said the head of development. “We

scratch-resistant, and also extremely resistant

do not merely support them all the way to series

against chemicals, graffiti and UV radiation, which

production, but even beyond that across the entire

is particularly important for outdoor uses. The

cycle”.

ADVANCEMENTS

Spray SA DDF4 Pumps Oscar García Spray SA/RKT, Sant Boi de Llobregat, Barcelona, Spain

oscar.garcia@spray-sa.com

Ramseier Koatings Technology - Spray SA have developed the new DDF4 pump to improve on the DDF2 model.

O

ver the past twenty years, RKT has supplied more than 4,000 DDF powder pumps in various models worldwide as replacements for Venturi injectors. Based on our experience,

most old DDF2 and DDF2-DP pumps do operate smoothly and

© Spray SA

efficiently. However, the greater yield and benefits guaranteed by the DDF pumps only become truly apparent when customers and operators understand that they are different in nature from traditional Venturi injectors and recognise that their operating principles are not the same. In fact, over time, some of these customers have suggested we implemented a few improvements to our DDF pumps for different reasons. They all basically boiled down to the fact that DDF pumps are “more difficult to control” than the Venturi injectors. This is why we developed the new DDF4 powder pump.

RKT began to analyse the different causes behind these customer suggestions already about ten years ago and, as a result, decided to develop the DDF4 pumps. The research study carried out found that the fact that powder is transported “at a high density” in DDF-type pumps aggravated the issues reported. The negative impact of these factors has therefore been overcome and reduced with the development of the new DDF4 pumps. Indeed, the main difference between the DDF2 and DDF4 models lies in design. In the latter, powder is sucked into the powder chambers from the sides instead of from the bottom of the two cylinders. Higher vacuum, better powder flow consistency, improved powder management, long-term reliability, higher performance, and the ability to spray 8 g/min of powder without gushes nor blockages are only some of the improvements guaranteed by the DDF4 units.

The DDF4 pumps work best with the 600 series guns. In order to achieve good operating results, in general, these dense-flow pumps require applicators with greater operating and maintenance capabilities.

The DDF4 pumps in automatic electrostatic systems The DDF4 pumps are managed through small individual control units with one PLC for each pump. This results in greater system reliability and ease of adaptation of programmes, should they need to be modified. All changes are made via an HMI screen.

The DDF4 pumps are housed in the lower section of a control cabinet, while the PLC control units are located in the central section. Each individual PLC manages the functions of a DDF4 pump. Powder feeding is controlled through the piston speed adjustment.

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ADVANCEMENTS

The upper part of the control cabinet houses the PLC Master unit. This

• with some types of powder, colour contamination caused by

makes both maintenance and operation easier.

insufficient compressed air pressure for cleaning.

In the GCU-S600 electrostatic control module, it is possible to set the gun’s parameters, which are saved in the PLC of each pump/gun. The

The causes of these problems are linked to two main factors:

HMI screen allows selecting the programme number, the powder spray

• Powder quality: formulations containing a high percentage of particles

rate, and DDF4 pump’s flow rate. As showed in the diagram, these

smaller than 32 microns result in higher absorption of water from the

parameters are then sent to the corresponding pump. The operating

air and, in general, greater chance of clogging. Formulations with a sticky

principle is similar to that of DDF2 pumps, but with technologically

nature can create small lumps, resulting in an uneven, poor-quality flow.

updated systems. The Micro Powder Center (MPC-5Mk2) guarantees

• Operating environment: DDF pumps can also operate in high-humidity

high performance levels for fast, high-quality colour changes with the

and hot climates, and lumps may easily form if powders are not stored

DDF4 dense phase pumps; it is particularly useful for plants performing

properly. Poor compressed air quality, e.g. contaminated with oil and

more than ten colour change operations per shift.

water, makes it very difficult to transport dense powders. Although less

DDF2 pumps’ faults

severe with Venturi devices, this is a prevalent problem in many plants.

Hot compressed air may not only cause clumps of powder to clog the

The most frequent faults experienced by the DDF2 pumps, i.e. the

tubes, but, in extreme cases, also dissolve the powder around pistons

generation before DDF4, are as follows:

inside the pumps.

• inconsistent powder flow; • clogging of powder discharge tubes;

The improvement objectives of the DDF4 pumps

• contamination of vacuum control valves, leading to inconsistent

The DDF4 pumps’ design includes the following improved features:

powder delivery;

• improved seal and vacuum control to ensure reliable long-term

eosmarketing.it

ALU MIN IUM

vertical and horizontal plants

over 60 years of experience in surface finishing lines

www.trasmetal.net

pre-treatment | spray applications | electroplating | vertical & horizontal plants | enameling | aluminium | white goods | automotive | general industry

performance, especially when working with powders with poor particle

Y-tube in the DDF4 pump design has not only eliminated the cost of

size distribution;

this component, but also significantly reduced the possibility of powder

• improved power feeding, internal movement, and powder discharge.

clogging in the tubes;

The introduction of fluidised air in the lower part of the powder chamber

• improved design. The DDF4 powder pumps’ greater ease of use has

has significantly improved the flow of powder out of the chamber, a

significantly reduced their initial set-up time, but also maintenance

crucial aspect when using coating systems with reduced thicknesses. In

downtime.

addition, the horizontal powder inlet allows for much smoother entry of the powder into the chamber;

Conclusions

• better consistency and uniformity of the powder flow. Thanks to a

At the same time, some optimisation work should also be carried out by

special pulsed air unit, the dense powder flows evenly from the pump to

each customer to solve other issues, such as the presence of hot and

the guns. This is particularly useful when using powders with diversified

contaminated compressed air.

particle size distribution;

For the delivery of high-density, low-speed powder coatings to be truly

• improved pump control. The installation of a single, more user-

effective, compressed air must be dry, clean, and cool (>22 °C):

friendly, and reliable control mechanism enables DDF pumps to adapt

• Air humidity: 1.3 g/m3 (maximum)

to different types of powder;

• Oil content in the air: 0.1 g/m2 (maximum).

© Spray SA

• reduced downtime and pump operating costs. The removal of the

Guns parameters are sent to the corresponding pump.

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WELCOME TO THE INDUSTRY’S LEADING TRADE SHOW NUREMBERG // GERMANY European Coatings Show: 28 – 30 March 2023 European Coatings Show Conference: 27– 28 March 2023

ECS 2023 – innovative, modern and safe!

Accompanied by Europe’s largest and most important industry conference  Plan your visit online: european-coatings-show.com/shownavigator Organisation: NürnbergMesse european-coatings-show.com

Organiser: Vincentz Network european-coatings.com

SPECIALIZED TRAINING

ipcm® Academy Updated its 2023 Training Programme Gabriele Lazzari, ipcm®

ipcm® Academy, which has been active for over ten years in the education of surface treatment professionals, has updated its programme for the training of new Industrial Surface Finishing Process Technologists.

i

pcm® Academy, the training division of eos Mktg&Communication,

guaranteeing the expected durability, or even the improper use of

the publisher of the ipcm® magazines, has presented the 2023

the part. At the same time, all the players involved in the development

programme of its training course dedicated to the role of Industrial

and management of the finishing process, as well as in the final use of

Surface Finishing Process Technologist, recently included in Lombardy’s

the component, may be responsible for its premature deterioration:

Regional Framework of Professional Standards (QRSP).

designers, paint manufacturers, applicators, inspectors, maintainers,

It is still possible to obtain a 5% discount, when registering for either the

and users,” explains Paolo Rami, the ipcm® Academy director of studies

complete course or some individual thematic days by 28 February 2023.

and an expert in the design and approval of anti-corrosion systems

The importance of industrial surface finishing processes The quality and durability of a coating are closely related to the correct

as well as in the analysis of specific problems and defects in painting processes, also awarded a Merit for Labour.

handling of its related surface finishing processes. “The causes of

Why undertake a training course

premature degradation of a coating can be traced back to various

Knowledge and careful control of the entire finishing process can

finishing issues such as, for example, the use of defective materials,

therefore avoid or at least limit damages resulting from premature

inadequate technical specifications, a process that is not suited to

degradation of coatings.

academy 2023

CORSI DI FORMAZIONE

TECNICO DEI PROCESSI DI FINITURA INDUSTRIALE DELLE SUPERFICI Corso di formazione riconosciuto dalla Regione Lombardia con valenza nazionale ed europea

IL CORSO RIENTRA NEGLI INTERVENTI DI FORMAZIONE CONTINUA DI REGIONE LOMBARDIA ED È ACCREDITATO PER IL FINANZIAMENTO A FONDO PERDUTO ATTRAVERSO L’EROGAZIONE DI UN VOUCHER FORMATIVO

Realizzato in collaborazione con ASP G. Mazzini - Associazione Scuole Professionali

102

ente accreditato ai servizi formativi e al lavoro da

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

Scan or click the code to browse the 2023 training programme

SPECIALIZED TRAINING

“As there is no school for industrial painting and finishing technicians,

• unemployed people;

our sector has suffered from a lack of qualified personnel for many

• adult workers seeking vocational specialisation.

years. At the same time, the new technologies and constantly changing regulations make it necessary to keep up-to-date professionally.

The course’s structure

This is why, more than ten years ago, we inaugurated this course

This year, as usual, the training consists of two sessions of 100 hours

together with Paolo Rami and other industry experts, aimed at training

each: one is taking place from March 30 to June 15 and the other from

all-round professionals capable of organising and managing production

September 21 to November 16. Each session consists of 12 days in total

and process approval activities, defining protection and finishing

and it includes a theoretical part, in which specific topics are presented

processes, and performing requirement and technical reviews,” says

in depth, and a practical part with demonstrations and tests for quality

Paola Giraldo, founder of ipcm Academy. “We have already delivered

control, through the use of professional tools and the control of

over a thousand hours of theoretical and practical training, involving

samples, with the direct interaction of participants.

more than 150 companies. That is clear proof that the industry needs

Upon completion, the trainees can sit the final exam, at the end of

this.”

which, if successful, they are going to receive the Industrial Surface

®

Finishing Process Technologist certificate valid at both the national and The training course for Industrial Surface Finishing Process

European levels.

Technologists is for as follows:

In order to promote versatile training that is really close to the needs

• coating operators;

of individual participants, the courses are going to take place in hybrid

• paint shop managers;

mode, i.e. both in the classroom, at Innovhub’s headquarters in Milan,

• technical sales employees at paint manufacturers;

and online.

• quality control managers;

Say goodbye to masking Overspray-free paint application with EcoPaintJet Revolutionary precision in automatic application brings efficiency to product customization.

Dürr’s solution EcoPaintJet applies sharpedged paint lines on surfaces, pushing the limits for efficient and resource-saving coating: No overspray, no more masking of your product. www.verind.it

2023 lesson calendar

metal quality and the pre-treatment operations

• Corrosion: 30 March / 21 September

required to the type of paint to be used. In

• Pre-treatment: 13 April / 28 September

addition, a visit to the control laboratories offers

• Water treatment and purification:

the opportunity to see the characteristics of

20 April / 29 September

paint products first-hand and analyse different

• Application of powder coatings:

types of finished products.

4 May / 5 October

© ipcm

• Application of liquid paint:

Alternative attendance options

11 May / 12 October

In addition to attending the entire training

• Plastic painting: 12 May / 13 October

course, this year too ipcm® Academy offers a

• Controls: 17 May / 18 October

further option: enrolling in individual thematic

• Control methods, tools, and practical tests:

days, after which a certificate of attendance is

18 May / 19 October

issued.

• ACET test and visit to Innovhub labs:

ipcm® Academy can also organise customised

19 May / 20 October

courses to be held at the premises of

• Plants and equipment: 25 May / 26 October

interested companies with particular needs for

• Failure analysis: 8 June / 9 November

the professional training of their staff.

• Documentation, process control, and management of investments and practical

Financing options

activities: 14 and 15 June / 15 and 16 November

Thanks to its collaboration with ASP Mazzini,

• Coil coating: 22 June / 23 November

accredited by the Lombardy Region for the

© ipcm

Plastic painting and coil coating

provision of training and orientation services located in Cinisello Balsamo (Milan), the training

This edition of the ipcm® Academy course also

courses offered by ipcm® Academy can count

includes two topics that are not mandatory

on various financing options:

parts of the complete course. Since the first

• Training vouchers made available by the

session of 2022, our course has been including

Lombardy Region and activated directly by

a training day focusing on the painting of

companies;

plastics, a subject that is now very relevant in

•Training financed by the endowment system

the field of surface coatings. This additional

of the Lombardy Region for unemployed or

lesson provides an overview of the market

redundant persons;

and an in-depth look at the currently available

• Interprofessional funds, through company

thermoplastic and thermosetting coatings,

membership and participation in company and

coating cycles, main suppliers, equipment

intercompany training plans.

characteristics, cleaning operations, pre-

© ipcm

treatment, application, and curing processes,

For further information:

environmental impact, controls, and plant

https://ipcmacademy.com

solutions.

or send an e-mail to: corsi@ipcm.it

A lecture has also been added about continuous-flow coil coating, an advanced

Paolo Rami, the ipcm® Academy director of studies during a training day.

surface finishing process used for various metal

The exam sheet to become Industrial Surface Finishing Process Technologist.

an output of several million square metres per

Practical analysis of samples during the lecture dedicated to coil coating.

104

substrates such as steel and aluminium, with year. The process is presented in all its details, from the definition of the product in terms of

N. 79 - JANUARY/FEBRUARY 2023 - international PAINT&COATING magazine

4 days of intense meetings!

EXPO-SURFACE

14th Exhibition of Corrosion Protection Technology and Surface Treatment

28-31 / 03 / 2023 Kielce, Poland www.expo-surface.pl

ART WITHIN SURFACES

The Lightness of Colour in Le Rond’s Solo Exhibition Monica Fumagalli, ipcm® “He who works with his hands is a labourer. He who works with his

The poetry of wood and metal

hands and his head is a craftsman. He who works with his hands

Throughout his production, Le Rond has always had a predilection for

and his head and his heart is an artist.”

wood and metal (iron). For this exhibition, the artist transformed wood

Saint Francis of Assisi

recovered from marble quarries in the surrounding area into artistic

F

objects, emphasising his deep connection both with his roots and with

or over three years now, our magazine has been investigating the

this material, which lends itself to various poetic interpretations, be it

relationship between the surface treatment industry and art. Last

raw or treated and painted. On the other hand, metal, which evokes the

December, ipcm and eos Mktg&Communication, the publishing

craftsmanship and the industrial processes that can be observed in a

®

house of our magazines, had the opportunity to play an active role in

foundry, had a double value in this solo show: in addition to being the

a high-profile art exhibition for the first time, becoming its sponsor:

constituent material of most of the works on display, it was also chosen

“Poesia Geometrica: l’arte come atto vitale” (i.e. “Geometric Poetry: art as

for the exhibition’s display supports. Indeed, with the exception of the

a vital act”).

largest ones (about 2 m), which were placed on the ground, all the works

Held from 3 to 24 December 2022, then extended until 31st December,

of art presented were positioned on special “suspended” modular metal

in the old parish church of Urago Mella (Brescia, Italy), this solo show brought together the works realised from 2020 to 2022 by Giovanni Lamberti, AKA Le Rond, already the protagonist of several articles published on these pages1. Aimed at reflecting this Brescia-based artist’s aesthetic development over the last two years, the exhibition was part of the broad range of events connected to the appointment of BresciaBergamo as Italy’s Capital of Culture for 2023.

One of the reasons why Le Rond’s artistic world is so fascinating can be traced right in the works on display in this exhibition, characterised by the perfect balance between “concrete and exact forms, with a clear geometric and rational imprinting” – as Giovanna Galli stated in the critical comment she wrote for the show’s catalogue2 – and by the willingness to communicate through colour, “double knotted to the works’ purely aesthetic content, but also emotional and playful, thus promoting interpretative freedom within an unavoidable relational dimension.” Such a dimension was made even more evocative by the location chosen for this solo exhibition: a restored 17th-century parish church, in which Lamberti’s works were perfectly integrated through their balance between shapes and colours.

1 https://www.ipcm.it/en/open/ipcm/2020/61/148-150.aspx https://www.ipcm.it/en/open/ipcm/2021/68/142-144.aspx https://www.ipcm.it/en/open/ipcm/2022/76/116-118.aspx “Giovanni Lamberti: poesia geometrica, l’arte come atto vitale – opere e progetti 2020-2022”, Intese Grafiche Srl, November 2022.

2

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ART WITHIN SURFACES

structures in harmony with each other, designed by architect Stevan

go beyond the simple juxtaposition of geometries and colours and to

Tesic from Studio Di_archon_ass, the curator of the exhibition’s set up.

provoke visitors by playing with his interpretative skills, while keeping his

Colour as a pictorial element in sculptures

gaze focused not only on the origins of his chosen materials, but also on his surrounding environment. The continuous cross references between

One of the most significant pictorial elements of Le Rond’s artistic

ancient and modern, craft and industry, art and play, and perfection and

research is colour, as Galli pointed out in her critical comment: “[…] the

imperfection of forms make his artistic research increasingly immersed

most solid pictorial foundation of his research is colour, almost always

in a poetic and surprising vision of the world.

highlighted through monochromatic choices, which were previously restricted to primary colours but are now open to a wider range.” The

For further information: www.lerond.it

artist uses this element to enhance shapes, surfaces, and volumes and to bring out “spaces, perspectives, movement, environments, and interaction within a precise vision of art as a vital act that implies a continuous exchange of stimuli and responses, of actions and reactions, From left to right:

of rules and exceptions.”

In one of his last interviews, Lamberti emphasised that for him art is “a means of building the world, through the creation of sculptural works that look out at us every day, reminding us of the beauty and work of the human being as a builder.”3 With the works on show in this solo exhibition, Le Rond was able to 3

https://www.ipcm.it/en/open/ipcm/2022/76/116-118.aspx © ipcm

One of the works in the solo exhibition “Geometric Poetry: art as a vital act” by Le Rond.

One of the most significant elements of Le Rond’s artistic research is colour.

LR is one of the exhibited works made of recycled wood from marble quarries and coated with water-based impregnating agent.

© ipcm

© ipcm

STANDARD & LEGISLATION - UCIF Informs

The Value of Time UCIF – Italian Surface Treatment Equipment Manufacturers’ Association Milan, Italy

info@ucif.net

E

specially at this time of year, when beginning to draw up our

to ensure that its external conditions are maintained over the years,

plans for the future, we all tend to compare past and present and

if not decades. This does not apply only to cars, but also, in general,

try to learn from our experience in order to improve ourselves

to products subjected to industrial processes that involve surface

or, at least, not to make the same mistakes again. Time, understood

treatments such as shot blasting or vibratory finishing.

as the past, leaves indelible traces in our lives. This applies to every

The finishing sector, whose manufacturers are represented in Italy

human being, regardless of their characteristics, let alone their job or

by the UCIF association, is therefore driven by a focus not simply on

social background. Despite seemingly too philosophical, this concept

coatings, but rather on performance and durability. In terms of industrial

is actually applicable to our lives on a daily basis, albeit in an abstract

activities, this requires a lot of effort in research and development both

way (memories, teachings, the “hard knocks” of life...). However, there is

of materials and chemicals, a commitment to increasingly improve pre-

one particular manufacturing field that deals with the “marks of time” to

treatments, and above all the ability to analyse and understand each

ensure that they are as few as possible or even to prevent them at all. It

finished product’s intended environment, since external conditions

is the finishing sector.

are going to be the main cause of changes in its properties (exterior

Treating a surface is not just about giving it a colour or making it less

characteristics and durability). Anti-corrosion research alone is crucial to

rough. It means lending it a longer life, prolonging the freshness of a

guarantee product durability. Just think, for example, of train carriages

product while also improving its aesthetics and often its functionality.

spending most of their service lives outdoors, subjected to atmospheric

The best example of this are cars. When we buy a new car, we can

agents of all kinds.

choose its colour and the related paint, but it is actually not just about the “coating”: the body is first pre-treated to prevent future damages

However, time is not only a cause of indelible traces, but also a source

and colour fading over time. How many adverse phenomena will that

of experience that enriches today’s knowledge. UCIF is well aware of

car experience? Rain, hail, summer heat... In the course of its service

this, as it turns 50 in 2023, with a series of events already being planned

life, it will be subjected to temperature fluctuations of up to 40-50 °C (at

to celebrate. Because we can always learn from time and never stop

least in Italy) and its body, suitably pre-treated and processed, will have

improving ourselves.

© Adobe Stock

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MEETING THE INDUSTRY

EXPO-SURFACE Grows: the 2023 Edition Will Last Four Days After the success of the last edition, the Polish trade fair dedicated to corrosion protection technologies and surface treatments will come back for four days.

E

XPO-SURFACE, the most important exhibition dedicated to

of the exhibition for this year. EXPO-SURFACE 2023 will offer a wide

corrosion protection technologies and surface treatments in

scope of products and services, meeting the expectations of surface

Central and Eastern Europe, has proudly announced that it is

protection specialist. The products and services showcased will range

growing: as a matter of fact, the 2023 edition will last four days – from

to include technologies and devices for protective coatings applications,

28th to 31st March 2023 at Targi Kielce in Poland.

equipment for cleaning and preparing surfaces, specialist chemicals,

As part of the series of industrial exhibitions held under the STOM

varnishing, enamelling and plastic coating equipment, equipment for

banner, EXPO-SURFACE has become a permanent point in many

chemical and thermal surface treatment, laser and plasma technologies

calendars belonging to industry experts. The event has proven hugely

for surface coating, devices for thermal spraying, special surface

popular: even the harsh pandemic time did not diminish the expo

treatment systems, measuring and control devices and research

cycle’s importance. The 2022 expo brought together 500 exhibitors

equipment. In addition, the event will also host service providers,

who used all 7 exhibition halls. Dozens of companies from Poland, Italy,

research organisations and industry institutions presenting new

Germany, Greece and several other countries presented their offering

solutions for anti-corrosion insulation and innovative materials.

at EXPO-SURFACE.

EXPO-SURFACE is complemented and enhanced with the events

Visitors were able to hear guests speaking in many different languages

organised by the “Industrial Varnishing” portal, which offer a valuable

and virtually all corners of the world were represented.

substantive and practical dose of knowledge

The three expo days of 2022 welcomed almost 10,000 industry visitors so, according to the exhibitors’ suggestions, the management of the Kielce exhibition and congress centre resolved to extend the duration

© ExpoSurface

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For further information: www. expo-surface.com

MEETING THE INDUSTRY

Knowledge Transfer and Social Activities at the European Coatings Show 2023 After four years, the European Coatings Show will once again support the international dialogue among experts from the paints and coatings sector from 28th to 30th March 2023 in Nuremberg (Germany).

F

rom 28th to 30th March 2023, the coatings community will reunite

trade visitors can look forward to specialised suppliers from all around

at the Exhibition Centre Nuremberg (Germany) for the European

the world and a very extensive range of products. As the gathering place

Coatings Show.

for the coatings industry, the event will present ground-breaking trends

Finally, the trade fair will once again provide a platform for industry

and allow visitors to find out about the latest formulations, process and

stakeholders for whom making business contacts, face-to-face

equipment technology and reap the benefits of exchanging experiences

encounters and networking are indispensable.

with like-minded professionals. As a matter of fact, the exhibition will

Whether their focus is on paints, printing inks, laboratory, production

provide plenty of input about key topical issues like the shortage of raw

testing, measuring equipment, adhesives or construction chemicals,

materials and their rising costs.

© NuernbergMesse/Thomas Geiger

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MEETING THE INDUSTRY

Knowledge transfer and social activities In addition, with more than 140 presentations, the semi-parallel European

and build up their network with other experts from the coatings industry.

Coatings Show Conference on 27th and 28th March will offer intensive

Eight exhibition halls

knowledge transfer, as high-calibre speakers will once again offer

The European Coatings Show 2023 will occupy a total of eight exhibition

interesting insights into a wide range of topics.

halls, six of which will be dedicated to raw materials for paints, printing

The opening keynote will be by Wijnand Bruinsma from Akzo Nobel on the

inks and adhesives, construction chemical precursors and associated

topic: “The role of paints and coatings in a sustainable future.” One other

services.The Start-up Area in Hall 2 allows start-ups and young

session is devoted to the results of The Decoat Project, an international

companies from Germany and other countries to present their services

research partnership funded by the EU which is developing a solution

and product innovations to the professional audience at reduced rates.

to facilitate the use of textiles and plastic components with (multilayer)

Additional presentations in the exhibitor forum in Hall 3 will provide

coatings according to the closed loop recycling principle.

further insights into the start-up scene of the paints and coatings sector.

The nine pre-conference tutorials on the Sunday, 26th March – conducted

Furthermore, this area will allow to share expertise in more than 140

by renowned experts – will quickly bring newcomers to the field up to

product presentations combined into 24 sessions.

speed with the state-of-the-art and offer a good preparation for actively

Finally, Hall 4 will put the spotlight on laboratory and production

participating in the subsequent conference.

technology, testing and measuring systems, application technology,

Following an intensive first day at the European Coatings Show

environmental protection and occupational safety.

Conference, the after-work reception offers additional scope for personal dialogue. In a relaxed atmosphere, participants can chat to the speakers

For further information: www.european-coatings-show.com

© NuernbergMesse/Thomas Geiger

international PAINT&COATING magazine - JANUARY/FEBRUARY 2023 - N. 79

113

MEETING THE INDUSTRY

The 2022 edition of FABTECH Welcomed 30.000 Visitors The event held in Atlanta has witnessed an increase in attendance, exhibitors and show floor size.

F

ABTECH 2022, North America’s largest

“Thank you to everyone who joined us in Atlanta

pavilions covering four halls that focused

metal forming, fabricating, welding

to make FABTECH 2022 a complete success,”

on 3D/Additive Manufacturing, Forming &

and finishing event, made its return to

said John Catalano, SME senior director US

Fabricating, Finishing, METALFORM, Tube/Pipe,

Atlanta and welcomed attendees from around

events and strategic partnerships, FABTECH.

Robotics and Industrial Automation, Welding

the world for three days of ground-breaking

“FABTECH was nearly back to pre-pandemic

and Welding Automation. FABTECH also saw

innovations, inspiring keynote presentations

attendance numbers and saw increases across

the return of many exhibitors to its welding

and solution-based education sessions for the

the board over 2021 with more attendees,

pavilion, which featured approximately 350

global metal fabrication community.

more exhibitors and a bigger show floor.

companies, including industry leaders Lincoln

From November 8-10, nearly 30,000 attendees

Year after year, FABTECH continues to be our

Electric, IPG Photonics, FANUC America Corp,

– an increase of 22.6% over the 2021 event –

industry’s leading event by providing the latest

OTC DAIHEN Inc, Path Robotics, and Miller

from 70 countries and all 50 states gathered

insights and trends, attracting key decision

Electric Mfg LLC.

at the Georgia World Congress Center to meet

makers and buyers, and showcasing the most

“FABTECH 2022 was the most effective

with world-class suppliers, conduct product

innovative technologies shaping the future of

tradeshow we’ve exhibited at in close to a

evaluations, network with peers and find the

manufacturing.”

decade! Not only the volume of traffic, but

tools to improve productivity and increase

the quality of the attendees exceeded our

profits. Four expansive exhibit halls covering

Strong sales activities

610,000+ square feet of exhibit space featured

The energy at FABTECH 2022 was high, and

replicating that success in 2023 in Chicago,”

nearly 1,200 exhibitors, including 150 making

sales activity was strong each day on the busy

said Josh Dixon, COO at Beckwood Press

their debut at FABTECH, all highlighting the

exhibit floor. The show floor was 19.5% larger

Company.

emerging trends and technologies influencing

than in 2021 and welcomed over 30% more

“Abagy Robotic Systems participated for the

the future of manufacturing.

exhibitors. Attendees explored eight technology

first time in the FABTECH expo and conference,

expectations and we’re looking forward to

and we were really impressed with the quality of attendees and the level of organization.

We had a great response from hundreds of manufacturers and have already booked our booth space for the next show in Chicago”, said Kate Degai, CMO at Abagy Robotic Systems.

Successful special events FABTECH featured an inspiring line-up of special events, including keynote presentations and FABx Tech Talks that addressed the emerging trends, innovations and challenges impacting the industry today. Attendees walked away with insights into today’s pressing topics— from cutting-edge technology and the latest manufacturing processes to building successful businesses and rethinking leadership, change management, and risk. Speakers included Brad Keselowski, owner of Keselowski Advanced

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MEETING THE INDUSTRY

Manufacturing and NASCAR champion, and Jake Wood, executive

founding partner of The Franklin Partnership, provided a post-election

chairman of Team Rubicon and founder/CEO of Groundswell. The FABx

analysis and the impact of the results on tariffs, taxes, trade negations,

Tech Talks featured speakers Gillen Young, chief architect of IIOT Solutions

regulations, and workforce training. He also offered an overview of

at AT&T, Richard Boyd, CEO of Tanjo AI; and Bryce Austin, CEO of TCE

the priorities for the upcoming session and a 2023 outlook for the

Strategy, with a special appearance from Bill Carlton, owner/mastermind

manufacturing industry.

of Ekstensive Metal Worlds. Additional special events included:

FABTECH 2022 also offered over 150 carefully curated education sessions

The daily Leadership Exchange Panels included groups of subject matter

led by industry thought leaders and subject matter experts. The program

experts who will discuss the next phase of advanced manufacturing, how

spanned 16 technology tracks with sessions focused on automation,

innovation is key to outperforming the competition, tactics for cultivating

smart manufacturing, welding, cutting, lasers, workforce development,

the next generation of manufacturing talent and how to protect your

business management strategies and more.

company from a cyber security threat.

“This was my first time attending FABTECH and I was very impressed by

Wednesday’s sold-out Women of FABTECH breakfast featured three

the quality of information shared by the presenters during the conference

inspiring leaders in manufacturing—Shelly Foland, CEO of Softies, Holly

sessions. I look forward to attending FABTECH again in the future,” said

Gotfredson, president of American Metalcraft, Inc./Finishing Dynamics;

Rebeca Hernandez, a mechanical engineer at Republic Manufacturing.

and Lisa Winton, CEO and co-owner of Winton Machine—who covered

FABTECH 2023 is set to take place on September 11-14 in Chicago, with

manufacturing trends, marketing strategies and real-world examples of

registration expected to open in the spring of 2023.

their experiences as women leaders.

During Thursday’s State of the Industry session, Omar Nashashibi,

For further information: www.fabtechexpo.com

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Kevin Biller: ChemQuest Powder Coating Research

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